MerCruiser 8.1 H.O. User Manual Download Page 3

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Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your

boating will be pleasant!
Mercury MerCruiser

Warranty Message

The product you have purchased comes with a

limited warranty

from Mercury Marine;

the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty

statement contains a description of what is covered, what is not covered, the duration of

coverage, how to best obtain warranty coverage,

important disclaimers and limitations

of damages

and other related information. Please review this important information.

Mercury Marine products are designed and manufactured to comply with our own high

quality standards, applicable industry standards and regulations, as well as certain

emissions regulations. At Mercury Marine every engine is operated and tested before it is

boxed for shipment to make sure that the product is ready for use. In addition, certain

Mercury Marine products are tested in a controlled and monitored environment, for up to

10 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 for a

demonstration of actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, dangers, warnings, cautions, and

notices, accompanied by the International Hazard Symbol

, may be used to alert the

installer/user to special instructions concerning a particular service or operation that may

be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI

standard Z535.6‑2006 for product safety information in product manuals, instructions, and

other collateral materials.

Observe them carefully.

These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance

with these special instructions while performing the service, plus common sense operation,

are major accident prevention measures.

DANGER

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious

injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate

injury.

Summary of Contents for 8.1 H.O.

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

Page 2: ...to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2007 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Pro Max OptiMax Sport Jet K Planes MerCathode RideGuide SmartCraft Zero Effort...

Page 3: ...Marine product sold as new receives the applicable limited warranty coverage whether the engine participated in one of the test programs described above or not Read This Manual Thoroughly IMPORTANT If you don t understand any portion of this manual contact your dealer for a demonstration of actual starting and operating procedures Notice Throughout this publication and on your power package danger...

Page 4: ...ver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used WARNING The engine exhaust from this product contains...

Page 5: ...ication Star Label 16 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal 20 Lanyard Stop Switch 20 Instrumentation 21 System View 21 Digital Gauges 22 Analog Gauges 23 Remote Controls Non DTS Models 23 Remote Controls 23 Panel Mount Features 24 Console Mount Features 25 Zero Effort Features 25 Remote Controls DTS Models 26 Remote Controls 26 Panel Mount Featu...

Page 6: ...rmulated Oxygenated Gasoline USA Only 52 Gasoline Containing Alcohol 52 Engine Oil 53 Engine Specifications 54 Fluid Specifications 54 Engine 54 Transmission 55 Section 5 Maintenance Owner Operator Responsibilities 58 Dealer Responsibilities 58 Maintenance 58 Do It Yourself Maintenance Suggestions 59 Inspection 59 Maintenance Schedule Inboard Models 60 Routine Maintenance 60 Scheduled Maintenance ...

Page 7: ...ng Charts 90 Starter Motor Will Not Crank Engine or Cranks Slowly 90 Engine Will Not Start or Is Hard to Start 91 Engine Runs Rough Misses or Backfires 91 Poor Performance 91 Excessive Engine Temperature 91 Insufficient Engine Temperature 92 Low Engine Oil Pressure 92 Battery Will Not Recharge 92 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 92 Steering Wheel Jerks...

Page 8: ...Page iv 90 899883273 MARCH 2008 ...

Page 9: ... Chart 7 Commercial Application Warranty Chart 8 Government Application Warranty Chart 9 Mercury Installation Quality Certification Program 9 California Emissions Limited Warranty 10 What Is Covered 10 Duration Of Coverage 11 How To Obtain Warranty Coverage 12 What Mercury Will Do 12 What Is Not Covered 12 Components Of The Emission Control System 12 Disclaimers And Limitations 14 California Emiss...

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

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

Page 12: ...ed installations Coverage for SeaCore Sterndrive Models 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 Coverage for Standard Models The Limited Warranty for Standard Models which do not include Sterndrive Models with Closed Cooling Inboard Models Scorpion 377 Models Vaz...

Page 13: ... 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 ex...

Page 14: ...t 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 cus...

Page 15: ...nds Region Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Vazer Standard Models and and Models with Closed Cooling 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 Mexic...

Page 16: ...year 1 year 1 year Europe 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 ...

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

Page 18: ...rtification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and fo...

Page 19: ...endar year As an example 2003 model year products refers to products manufactured during calendar year 2003 This limited warranty provides coverage for the components of the emissions control systems Select emission control parts from model year 2003 2005 inboard or sterndrive engines are warranted for 2 years from either the date the product is first sold or first put into service whichever occur...

Page 20: ...sistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the p...

Page 21: ...tion System a Oil pump and internal parts b Oil injector s c Oil meter 5 Positive Crankcase Ventilation PCV System a PCV Valve b Oil filler cap 6 Exhaust System a Exhaust manifold b Exhaust elbow c Intermediate exhaust elbow d Lower exhaust pipe e Tailpipe 7 Catalysts or Thermal Reactor System a Catalytic converter b Thermal reactor c Exhaust manifold d Exhaust valve s 8 Miscellaneous Items Used i...

Page 22: ...r improper maintenance of your inboard or sterndrive engine Your emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine will repair your inboard or sterndrive engine at no cost to you inc...

Page 23: ...on to the engine at time of manufacture by Mercury MerCruiser In addition to the required emissions statement the label lists the engine serial number family STD emission standard level date of manufacture month year and the engine displacement Please note that the low emissions certification will not affect the fit function or performance of the engines Boatbuilders and dealers may not remove the...

Page 24: ... 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 environment 2 Better Fuel Economy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources 3 Longer Emission Warranty Protects consumer...

Page 25: ...t meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission A SS D mc79571 1 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission stan...

Page 26: ...Section 1 Warranty Notes Page 18 90 899883273 MARCH 2008 ...

Page 27: ...25 Zero Effort Features 25 Remote Controls DTS Models 26 Remote Controls 26 Panel Mount Features 26 Console Mount Features Single Engine 27 Slim Binnacle Console Mount Features Single Engine 28 Console Mount Features Dual Engine 29 Synchronizing Dual Engines 29 Dual Helm Station Transfer 30 Synchronizing Dual Helms Prior To Station Transfer 31 Zero Effort Features 31 Electrical System Overload Pro...

Page 28: ...tch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator s position as in accidental ejection from the operator s position 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 al...

Page 29: ...serious injury or death from being struck by the boat Always properly connect the operator to the stop switch using a lanyard Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward due to unexpected loss of forward motion a particular concern for ...

Page 30: ...A Mercury SmartCraft System instrument package can be purchased for this product A few of the functions the instrument package will display are engine RPM coolant temperature oil pressure requires a SmartCraft oil pressure sender kit battery voltage fuel consumption and engine operating hours SmartCraft digital gauges also feature troll control This allows a vessel to maintain a constant speed wit...

Page 31: ...L CRUISELOG 0 0 0 0 0 a b c d e f g h i 17352 Reference Gauge Function a Speedometer Indicates boat speed b Tachometer Indicates engine RPM c Oil pressure gauge Indicates engine oil pressure d Voltmeter Indicates battery voltage e Coolant temperature gauge Indicates engine operating temperature f Fuel gauge Indicates quantity of fuel in tank g Hour meter Records engine operating time h Bilge blowe...

Page 32: ...in starting the engine Lanyard Stop Switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to 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 fr...

Page 33: ...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 required to move the remote control handle Refer to instructions provided wi...

Page 34: ...system works with specialized helm components such as a command module kit and electronic remote control Consult your dealer for a description and or demonstration of your remote control Panel Mount Features 17358 c d e b a f g a Lanyard stop switch b Control handle c Shift lock d Trim tilt switch e Throttle only button f Detent tension adjustment screw g Control handle friction adjustment screw L...

Page 35: ...ontrol handle b Active light c Neutral light d Select key e Arrow trackpad f Throttle only station select key g Detent tension adjustment h Control handle friction adjustment screw Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear Continue...

Page 36: ...rd 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 Active Light The active light is illuminated to show the remote control is active and ready for use Neutral Light The neutral light is illuminated when the engine is in neutral gear position Start Stop Button Allows the boat operat...

Page 37: ...on messages Sync Light The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system Throttle Only Station Select Key Allows engine throttle advancement without shifting the engine The throttle only station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms Refe...

Page 38: ...m transfer should only be performed while engine is in neutral NOTE Idle position is preferred when doing a station transfer If conditions do not allow the remote control to be placed at idle position a station transfer can be done while in gear NOTE Pressing and releasing station select button at new station allows the engine control to be transferred to the new station The control will automatic...

Page 39: ... Throttle Lever Throttle functions are controlled by the movement of the throttle lever Increase the RPM by moving the throttle lever forward Achieve Wide Open Throttle WOT by placing the throttle lever in its full forward position Decrease RPM by moving the throttle lever back Achieve minimum RPM idle by placing the throttle lever in its full aft position Electrical System Overload Protection An ...

Page 40: ... A 90 amp fuse located on the large post of the starter solenoid protects the engine wiring harness if an electrical overload occurs mc74907 1 Four fuses protect the main power fuel pump ignition and accessory circuits These are located on the top of the engine near the PCM Four 10 amp fuses protect the O2 sensors These are located near the 14 pin harness connector a b 32646 a main power fuel pump...

Page 41: ...sition and nothing happens assuming the circuit breaker is not tripped mc70525 1 The clean power harness connected to the engine starting battery minimizes voltage drop to the electrical system and is protected by a 5 amp fuse 32777 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System The Audio Warning System will not protect the engine from damag...

Page 42: ...e engine 2 Listen for the audio alarm The alarm will sound if the system is functioning correctly Audio Warning System IMPORTANT The audio warning system alerts the operator that a problem has occurred It does not protect the engine from damage Your Mercury MerCruiser power package may be equipped with an audio warning system Most faults cause the warning horn circuit to activate How the warning h...

Page 43: ...Warning System 1 Turn the ignition switch to the ON position without cranking the engine 2 Listen for the audio alarm The alarm will sound if the system is functioning correctly Guardian Strategy Engine Guardian reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem Below are some examples of what Engine Guardian monitors Oil pressure Engine ov...

Page 44: ...n monitors the clutch pack pressure in forward and reverse gears If the transmission fluid pressure drops below a predetermined level Transmission Guardian lowers the engine torque and speed to prevent clutch slippage To avoid possible recurrence of the problem you should contact an authorized dealer The ECM stores the fault and with this information the technician will be able to more rapidly dia...

Page 45: ... and Stopping the Engine 43 Starting the Engine 43 Stopping the Engine 44 Throttle Only Operation 45 Freezing Temperature Operation 45 Drain Plug and Bilge Pump 45 Protecting People in the Water 46 While You Are Cruising 46 While Boat Is Stationary 46 High Speed and High Performance Operation 46 Passenger Safety in Pontoon Boats and Deck Boats 46 Boats Having An Open Front Deck 46 Boats With Front...

Page 46: ...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 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 unloading...

Page 47: ... 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 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...

Page 48: ...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 Follow these guidelines when operating your b...

Page 49: ...und 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 NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a suffici...

Page 50: ...ver beyond the idle forward or idle reverse position will cause engine speed to increase IMPORTANT Moving the control lever back to the idle neutral position will disengage the throttle only button and allow the engine to shift into gear 5 Throttle only mode is deactivated by moving the control lever to the idle neutral position Moving the control lever from the idle neutral position to the idle f...

Page 51: ...battery switch to the OFF position Turn battery switch on Check shift and throttle control operation Close fuel shut off valve Operate bilge blowers Check steering operation Close seacock if equipped Open fuel shut off valve Flush cooling system if in saltwater Open seacock if equipped Drain bilge Close the drain system Check the engine oil Perform all other checks specified by your dealer and or ...

Page 52: ...ey when the engine starts and allow the switch to return to the ON position 7 Inspect the power package for fuel oil water and exhaust leaks 8 Move the control handle with a firm quick motion forward to shift to forward gear or backward to shift to reverse After shifting advance throttle to desired setting NOTICE Shifting into gear at engine speeds above idle will damage the drive system Shift the...

Page 53: ...ward or idle reverse position The DTS control system will sound two beeps on the audio warning horn to indicate throttle only mode is active On console mount remote controls the neutral light will begin to blink 4 Advancing the control lever beyond the idle forward or idle reverse position will cause engine speed to increase IMPORTANT Moving the control lever back to the idle neutral position will...

Page 54: ... and High Performance Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat For additional information refer to Hi Performance Boat Operation booklet 9...

Page 55: ...ling at faster speeds Any unexpected sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat mc79557 1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible mc79680 1 Operating recreational boats over waves and wakes is a...

Page 56: ...to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward even out of the boat Impact damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed Boat speed should be kept to a minimum plani...

Page 57: ...ear housing or the propeller Common causes of cavitation are Weeds or other debris snagged on the propeller Bent propeller blade Raised burrs or sharp edges on the propeller Elevation and Climate Elevation and climate changes will affect the performance of your power package Loss of performance can be caused by Higher elevations Higher temperatures Low barometric pressures High humidity For you to...

Page 58: ...dations Ensure that propeller allows the engine to operate at or near the top of the specified WOT RPM range Refer to Specifications and Maintenance Operate the engine at 3 4 throttle or lower Refrain from prolonged operation at wide open throttle RPM Change the engine oil and oil filter Refer to Maintenance Change the transmission oil and filter Refer to Maintenance ZF Transmission models 1 End o...

Page 59: ...on 4 Specifications Table of Contents Cruising RPM 52 Fuel Requirements 52 Fuel Ratings 52 Using Reformulated Oxygenated Gasoline USA Only 52 Gasoline Containing Alcohol 52 Engine Oil 53 Engine Specifications 54 Fluid Specifications 54 Engine 54 Transmission 55 4 ...

Page 60: ...pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable Do not use leaded gasoline Outside USA and Canada A posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a major brand of leaded gasoline Using Reformulated Oxygenated Gasoline USA Only Reformulated gasoline is required in certain ar...

Page 61: ...rnal corrosion may take place during storage if alcohol has washed protective oil films from internal components Engine Oil For optimum engine performance and maximum protection use the following oil Application Recommended Oil All MerCruiser engines Mercury MerCruiser Full Synthetic Engine Oil 20W 40 NMMA FC W rated IMPORTANT Lubrication requirements for catalyzed engines differ from the requirem...

Page 62: ...cksilver 25W 40 NMMA FC W rated 4 cycle MerCruiser oil Engine Specifications Models 8 1 H O Horizon 8 1 Power 313 kW 420 hp 276 kW 370 hp Displacement 8 1 L 496 cid Specified WOT RPM range 4400 4800 4200 4600 Idle RPM in neutral 650 Minimum oil pressure at idle 103 kPa 15 psi Thermostat 71 C 160 F Timing at Idle Not adjustable Firing order 1 8 7 2 6 5 4 3 Electrical system 12 V negative ground Alt...

Page 63: ...zation use only 20 L 21 US qt Propylene glycol and purified water Closed cooling system 18 L 19 US qt Mercury Extended Life Coolant Antifreeze or extended life ethylene glycol 5 100 antifreeze mixed 50 50 with purified water Transmission Model Capacity Fluid Type 500A 2 84 L 3 00 US qt Dexron III Automatic Transmission Fluid 5000V 3 30 L 3 5 US qt 63A 4 00 L 4 5 US qt 63V 4 00 L 4 5 US qt 80A 5 50...

Page 64: ...Section 4 Specifications Notes Page 56 90 899883273 MARCH 2008 ...

Page 65: ...on Fluid 64 Checking While the Engine is Warm 64 Checking While Engine is Cold 64 Changing 65 Engine Coolant 65 Checking 65 Filling 65 Changing 66 Battery 66 Multiple EFI Engine Battery Precautions 66 Cleaning the Flame Arrestor 67 Cleaning the IAC Muffler Non DTS Models Only 68 Water Separating Fuel Filter 69 GEN III Models 69 Removal 69 Installation 70 Lubrication 71 Throttle Cable 71 Shift Cabl...

Page 66: ... 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 Performing service or maintenance without first di...

Page 67: ...engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or to request t...

Page 68: ...aintenance NOTE Only perform maintenance that applies to your particular power package Task Interval Maintenance to Be Performed After the initial 20 hour break in period Change the engine oil and filter Change the engine oil and filter Change the transmission fluid and filter ZF Marine requires changing the transmission fluid and filter maintain warranty Every 100 hours or annually whichever occu...

Page 69: ... 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 If the package was equipped with water shutters fl...

Page 70: ...an for approximately five minutes with the boat 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 Install the dipstick with oil level indication marks facing the rear of the engine flywheel end a b 32560 a Dipstick option 1 b Dipstick option 2 3 Inspect the dipstick reading which should indicate a leve...

Page 71: ...nge 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 the Specifications section 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 tub...

Page 72: ...gine oil with filter 8 5 L 9 US qt Mercury Full Synthetic MerCruiser Engine Oil 20W 40 8 Start the engine and operate for three minutes checking for leaks 9 Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water Transmission Fluid Checking While the Engine is Warm 1 Velvet Drive Transmissions Stop engine and quickly check fluid...

Page 73: ...ng CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns Allow the engine to cool down before removing the coolant pressure cap 1 With the engine at normal operating temperature check the coolant level in the coolant recovery bottle 32566 2 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Ex...

Page 74: ...ntifreeze concentration for adequate freeze protection and correct if necessary Refer to the Specifications section 4 Install the fill cap to the coolant recovery bottle Changing Contact your authorized Mercury MerCruiser dealer Battery Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precautions when handling a batter...

Page 75: ...d always be positioned so each engine is operating off of its own battery Do not operate engines with switches in both or all position In an emergency another engine s battery can be used to start an engine with a dead battery Battery Isolators Isolators can be used to charge an auxiliary battery used for powering accessories in the boat They should not be used to charge the battery of another eng...

Page 76: ...tilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately 1 Locate the idle air control valve IAC on the rear of the engine 2 Remove the IAC muffler from the slot in the air valve plate using needle nosed pliers a b c 32564 a a IAC b Air valve plate c IAC muffler location 3 Inspect the muffler for holes crac...

Page 77: ...e fuel system will result in fuel spraying out which can cause a fire or explosion Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system Always protect eyes and skin from pressurized fuel and vapors GEN III Models d a b c e f g h 8837 a Cool Fuel Module b Cool Fuel Module harness c Filter cap d Filter assembly retaining screw e Fuel filter e...

Page 78: ...ing on the filter cup 3 Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter clockwise direction while holding the filter cup stationary until the filter cap locks securely into place 4 Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel and align the screws retained in the filter cap with the screw holes in the Cool...

Page 79: ...vot points guide contact surfaces 92 883725K01 Shift Cable Typical 1 Lubricate the pivot points and the guide contact surfaces mc79736 a b a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cable pivot points guide contact surfaces 92 883725K01 Engine Coupler 1 Lubricate engine coupler splines through grease fitt...

Page 80: ...se gun until a small amount of grease begins to push out Driveshaft Extension Models 1 Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10 12 pumps of grease from a typical hand operated grease gun 2 Lubricate the driveshaft grease fittings by applying approximately 3 4 pumps of grease from a typical hand operated grease gun a b a c 17014 a Driveshaf...

Page 81: ...Crankshaft pulley d Alternator pulley e Seawater pump pulley f Tensioner pulley Checking Inspect the drive belt for Proper belt tension deflection Excessive wear Cracks Fraying Glazed surfaces Proper tension Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys Description Deflection 13 mm 1 2 in NOTE Minor transverse cracks across the belt width may...

Page 82: ...tops 2 Remove the belt from the idler pulley and slowly relieve the tension on the breaker bar 32565 3 Remove the belt and route the replacement belt according to the belt routing diagram 4 Carefully release the tensioner and ensure that the belt stays properly positioned 5 Use moderate thumb pressure on the belt at the location that has the longest distance between two pulleys Description Deflect...

Page 83: ...ne is operating in the normal range 9 Operate the engine with the transmission in neutral for a minimum of 10 minutes 10 For power packages operated in salty brackish mineral laden or polluted water Continue to operate the engine until the discharge water is clear 11 Slowly return the throttle to idle speed position 12 Stop the engine 13 Immediately shut off the supply water and remove the flushin...

Page 84: ...heat the engine Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply 7 Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM 100 RPM 8 Observe the water temperature gauge to ensure that the engine is operating in the normal range 9 Operate the engine with the transmission in neutral for a minimum of 10 mi...

Page 85: ...and Fuel System Preparation 79 Draining the Seawater System 80 Drain System Identification 80 Air Actuated Single Point Drain System 80 Manual Drain System 81 Air Actuated Single Point Drain System 81 Boat in the Water 81 Boat out of the Water 83 Manual Drain System 85 Boat in the Water 85 Boat out of the Water 86 Battery Storage 87 Power Package Recommissioning 87 6 ...

Page 86: ... for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 Check the antifreeze concentration Refer to the Specifications section 3 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcoh...

Page 87: ... out of fuel can damage catalyst components Do not allow the fuel tanks to become empty during operation 1 In a 23 liter 6 US gal remote fuel tank mix a 19 liter 5 US gal regular unleaded 87 octane 90 RON gasoline b 1 89 liter 2 US qt Premium Plus 2 Cycle TC W3 Outboard Oil c 150 ml 5 oz Fuel System Treatment and Stabilizer or 30 ml 1 oz Fuel System Treatment and Stabilizer Concentrate Tube Ref No...

Page 88: ... 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 IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturer s instructions be used in the seawater section of the cooling system for ...

Page 89: ...ingle Point Drain System BOAT IN THE WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting ...

Page 90: ...a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side b c a 8294 a Actuator fitting b Green indicators c Manual release valve ...

Page 91: ...nd return it to the mounting bracket 12 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 13 Before launching the boat pull up on the manual release valve Verify that the green indicators are no longer extended a 6135 a Green indicators 14 Open the seacock if equipped or unplug a...

Page 92: ...a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side b c a 8294 a Actuator fitting b Green indicators c Manual release valve ...

Page 93: ...eawater pump Do not allow engine to start 11 Remove the air pump from the air manifold and return it to the mounting bracket 12 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 13 Before launching the boat pull up on the manual release valve Verify that the green indicators are ...

Page 94: ...the drain system by installing the four blue drain plugs 8 Open the seacock if equipped or unplug and reconnect the water inlet hose prior to operating the engine BOAT OUT OF THE WATER NOTE Use this procedure if the air actuated single point drain system fails NOTE It may be necessary to lift bend or lower hoses to allow water to completely drain when hoses are disconnected 1 Place the boat on a l...

Page 95: ...e battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last 2 Install a fully charged battery Clean the battery cable clamps and terminals and reconnect cables Tighten each cable clamp securely when connecting 3 Coat the terminal connections with a battery terminal anti cor...

Page 96: ...Section 6 Storage Notes Page 88 90 899883273 MARCH 2008 ...

Page 97: ...rter Motor Will Not Crank Engine or Cranks Slowly 90 Engine Will Not Start or Is Hard to Start 91 Engine Runs Rough Misses or Backfires 91 Poor Performance 91 Excessive Engine Temperature 91 Insufficient Engine Temperature 92 Low Engine Oil Pressure 92 Battery Will Not Recharge 92 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 92 Steering Wheel Jerks or Is Difficult...

Page 98: ...gine Guardian System monitors the critical sensors on the engine for any early indications of problems The system will respond to a problem by emitting a continuous beep and or reducing engine power in order to provide engine 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 ...

Page 99: ...nt line Replace kinked lines or blow out lines with compressed air to remove obstruction Flame Arrestor dirty Clean Flame Arrestor Faulty ignition system component Service ignition system Idle speed too low Have EFI system checked by an authorized Mercury MerCruiser dealer EFI System fault Have EFI System checked by an authorized Mercury MerCruiser dealer Poor Performance Possible Cause Remedy Thr...

Page 100: ...improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling Battery Will Not Recharge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Alternator drive belt loose or in poor condition Replace and or adjust Unacceptable battery condition Test battery replace if necessary Loose or dir...

Page 101: ...k Refill system with fluid Drive belt loose or in poor condition Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all parts and fasteners if any are loose or missing see authorized Mercury MerCruiser dealer immediately Contaminated power steering fluid See authorized Mercury MerCruiser dealer ...

Page 102: ...Section 7 Troubleshooting Notes Page 94 90 899883273 MARCH 2008 ...

Page 103: ...vice Assistance 96 Local Repair Service 96 Service Away From Home 96 Stolen Power Package 96 Attention Required after Submersion 96 Replacement Service Parts 96 Parts and Accessories Inquiries 97 Resolving a Problem 97 Mercury Marine Service Offices 97 Ordering Literature 98 United States and Canada 98 Outside The United States and Canada 98 8 ...

Page 104: ...t an authorized Mercury MerCruiser dealer 2 After recovery immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage Replacement Service Parts WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or ex...

Page 105: ... the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the Service Office Your name and...

Page 106: ...ed States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center fo...

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