MerCruiser 8.1 MAG Owner'S Manual Download Page 144

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Section 7 - Troubleshooting

Page 136

90-864839070 AUGUST 2007

Diagnosing EFI Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing

problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM)

on these engines has the ability to detect some problems with the system when they occur,

and store a Trouble Code in the ECM's memory. This code can then be read later by a

service technician using a special diagnostic tool.

Diagnosing DTS Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing

problems on Digital Throttle and Shift (DTS) Systems. The Electronic Control Module

(ECM)/Propulsion Control Module (PCM) on these engines has the ability to detect some

problems with the system when they occur, and store a Trouble Code in the ECM/PCM's

memory. This code can then be read later by a service technician using a special diagnostic

tool.

Engine Guardian System

The Engine 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 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 neutral.

Open circuit breaker or blown fuse.

Check and reset the circuit breaker or replace fuse.

Loose or dirty electrical connections or damaged

wiring.

Check all electrical connections and wires (especially

battery cables). Clean and tighten all faulty

connections.

Bad battery or low battery voltage.

Test the battery and charge if necessary; replace if

bad.

Lanyard stop switch activated.

Check the lanyard stop switch.

Summary of Contents for 8.1 MAG

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

Page 2: ...pecifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2008 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo Bravo Two 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: ...Bravo Transom Serial Number 17 Lanyard Stop Switch 18 Instrumentation 19 System View 19 Digital Gauges 20 Analog Gauges 21 Remote Controls Non DTS Models 21 Remote Controls 21 Panel Mount Features 22 Console Mount Features 23 Zero Effort Features 24 Remote Controls DTS Models 24 Remote Controls 24 Panel Mount Features 25 Console Mount Features Single Engine 26 Slim Binnacle Console Mount Features ...

Page 6: ...arted 53 20 Hour Break In Period 53 After Break In Period 53 End of First Season Checkup 53 Section 4 Specifications Fuel Requirements 56 Fuel Ratings 56 Using Reformulated Oxygenated Gasolines USA Only 56 Gasolines Containing Alcohol 56 Engine Oil 57 Engine Specifications 58 Fluid Specifications 59 Engine 59 Bravo Sterndrives 59 Power Assisted Steering and Power Trim Fluids 59 Approved Power Assi...

Page 7: ...of the Water 110 Draining the Sterndrive 111 Manual Drain System 8 1 Models 111 Flushing the Power Package 113 Flushing Attachments 113 Sterndrive Water Pickups 114 Alternative Water Pickups 116 SeaCore Power Package Flushing Procedure 117 Models Using The Sterndrive Water Pickup 117 Section 6 Storage Cold Weather or Extended Storage 124 Preparing Power Package for Storage 124 Engine and Fuel Syst...

Page 8: ...er Service Assistance 142 Local Repair Service 142 Service Away From Home 142 Stolen Power Package 142 Attention Required after Submersion 142 Replacement Service Parts 142 Parts and Accessories Inquiries 143 Resolving a Problem 143 Mercury Marine Service Offices 143 Ordering Literature 144 United States and Canada 144 Outside The United States and Canada 144 ...

Page 9: ...ntries please refer to the chart 4 3 Year Limited Warranty Against Corrosion USA Canada For other countries please refer to the chart 6 4 Year Limited Corrosion Warranty SeaCore Sterndrive Models with Gas Engines USA Canada For other countries please refer to the chart 7 Global Warranty Charts 8 Consumer Application Warranty Chart 9 Commercial Application Warranty Chart 10 Government Application W...

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: ...ng 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 su...

Page 12: ...lity Certified Installer or three 3 years for noncertified installations SeaCore Sterndrive Model Coverage The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Standard Model Coverage The Limited Warranty for Standard Models which do not include Horizon Sterndrive and Inboard...

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: ...noperative as a direct result of corrosion for the period of time described below Duration of Coverage This limited corrosion warranty provides coverage for three 3 years from either the date the product is first sold or the date on which the product is first put into service whichever occurs first The repair and replacement of parts or the performance of service under this warranty does not exten...

Page 15: ...escribed below Duration of Coverage This limited corrosion warranty provides coverage for four 4 years from either the date on which the MerCruiser SeaCore engine transom and sterndrive package is first sold or the date on which it is first put into service whichever occurs first The repair or replacement of parts or the performance of service under this warranty does not extend the life of this w...

Page 16: ...product or parts of the product directly to Mercury Marine Proof of registered ownership must be presented to the dealer at the time warranty service is requested in order to obtain coverage What Is Not Covered This limited warranty does not cover the following Electrical system corrosion Corrosion resulting from damage Corrosion that causes purely cosmetic damage Abuse or improper service Corrosi...

Page 17: ...ear 1 year 1 year 4 years EMEA 2 years 3 years 2 years 2 years 3 years 4 years 3 years 3 years 3 years 4 years Japan 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year Australia and New Zealand 2 years 3 years 3 years 3 years all Tow Sports 2 years 3 years 3 years 3 years all Tow Sports 3 years 4 years South Pacific 1 year 3 years 1 year 1 year 1 year 3 years 1 year 1 year 3 yea...

Page 18: ... year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year or...

Page 19: ...ours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 y...

Page 20: ... an additional one 1 year of Mercury limited factory warranty coverage on all MerCruiser powered boats that are registered on and after the boat builder s certification date for all worldwide registrations Mercury has designated a section of our Website to promote the Installation Quality Certification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat ...

Page 21: ...o maintain emission levels within prescribed certification 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 ...

Page 22: ...s that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission A SS D mc79571 1 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission...

Page 23: ...le Mount Features 23 Zero Effort Features 24 Remote Controls DTS Models 24 Remote Controls 24 Panel Mount Features 25 Console Mount Features Single Engine 26 Slim Binnacle Console Mount Features Single Engine 27 Console Mount Features Dual Engine 28 Synchronizing Dual Engines 29 Dual Helm Station Transfer 29 Synchronizing Dual Helms Prior To Station Transfer 30 Zero Effort Features 30 Power Trim 3...

Page 24: ...cify model and 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 Bravo sterndrive serial number gear ratio model number and bar code are embedded in the ground plate on the port side...

Page 25: ...s a permanent reference on the sterndrive casting inside the back cover 33534 Bravo sterndrive 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 26: ... 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 pl...

Page 27: ...nder power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected WARNING If the operator falls out of the boat stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat Always properly connect t...

Page 28: ...eed 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 re...

Page 29: ...ge 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 Reco...

Page 30: ...rting 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 neu...

Page 31: ...andle 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 32: ...ng 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 i...

Page 33: ...ushing 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 t...

Page 34: ...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 the...

Page 35: ...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 thro...

Page 36: ...ition 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 Thr...

Page 37: ...ontrol 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 engi...

Page 38: ... 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 o...

Page 39: ...r trim out beyond the gimbal ring support flanges while the boat is underway or at engine speeds above 1200 RPM For best performance trim the sterndrive unit so that the boat bottom is at a 3 5 angle to the water 3 5 mc79528 Trimming sterndrive unit up out can Generally increase top speed Increase clearance over submerged objects or a shallow bottom Cause boat to accelerate and plane off slower In...

Page 40: ...mage the drive and steering systems If using an external tie bar raise and lower all drives together as a unit Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only Trim withou...

Page 41: ...d 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 che...

Page 42: ...ide 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 turne...

Page 43: ...m 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 Sy...

Page 44: ...e by reducing 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 ...

Page 45: ...Section 2 Getting to Know Your Power Package 90 864839070 AUGUST 2007 Page 37 In addition depending on the gauge package there will be warning icons and fault messages on the dash mounted gauges ...

Page 46: ...Section 2 Getting to Know Your Power Package Notes Page 38 90 864839070 AUGUST 2007 ...

Page 47: ...tarting the Engine 45 Stopping the Engine 46 Throttle Only Operation 47 Trailering the Boat 47 Freezing Temperature Operation 47 Drain Plug and Bilge Pump 48 Protecting People in the Water 48 While You Are Cruising 48 While Boat Is Stationary 48 High Speed and High Performance Operation 48 Passenger Safety in Pontoon Boats and Deck Boats 48 Boats Having An Open Front Deck 49 Boats With Front Mount...

Page 48: ...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 49: ...r 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 involve...

Page 50: ...t is moored in a confined space b Mooring close to another boat with its engine operating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim angle of the bow too high b Operating the boat with no forward hatches open station wagon effect Basic Boat Operation Non DTS Models Launching and Boat Operation IMPORTANT Install bilge drain plug prior to l...

Page 51: ... sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five min...

Page 52: ...ration 1 Refer to Remote Controls section for remote control features 2 Move the control lever to the idle neutral position 3 Depress and hold the throttle only button and move the control lever to the idle forward or idle reverse position 4 Advancing the control lever beyond the idle forward or idle reverse position will cause engine speed to increase IMPORTANT Moving the control lever back to th...

Page 53: ... engine If not normal stop engine Observe all gauges to check condition of engine If not normal stop engine Turn ignition key to the OFF position Open engine hatch Check for fuel oil water fluid and exhaust leaks Listen for the audio alarm Turn battery switch to the OFF position Turn battery switch on Check shift and throttle control operation Close fuel shut off valve Operate bilge blowers Check ...

Page 54: ...ure reaches 60 C 140 F 5 If the engine does not start after three attempts a Push the throttle only button and position the remote control handle or throttle lever to the 1 4 throttle position b Turn the ignition key to START Release key when the engine starts and allow the switch to return to the ON position 6 If the engine does not start after step 5 a Move the remote control handle throttle lev...

Page 55: ...le Mount Remote Controls Panel mount and console mount remote controls are equipped with a throttle only button To activate throttle only mode 1 Refer to Remote Controls section for remote control features 2 Move the control lever to the idle neutral position 3 Depress the throttle only button and move the control lever to the idle forward or idle reverse position The DTS control system will sound...

Page 56: ...NING A spinning propeller a moving boat or any solid device attached to the boat can cause serious injury or death to swimmers Stop the engine immediately whenever anyone in the water is near your boat Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat High Speed and High Performance Operation If your boat is considered a high speed or high ...

Page 57: ... is traveling faster than idle or trolling speed Sit only in seats designated for traveling 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 jum...

Page 58: ... Such a sharp change in direction or turn can cause occupants 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 contr...

Page 59: ...ion from impact damage under all conditions Operating with Low Water Inlets in Shallow Water mc75827 1 a a Low Water Inlets NOTICE Operating in shallow water can cause severe engine damage due to clogged water inlets Ensure that the water inlets on the gearcase do not ingest sand silt or other debris which can restrict or stop cooling water supply to the engine Extreme care should be exercised whe...

Page 60: ... housing which allows exhaust gases to escape between propeller and gear housing Drive unit installed too high on transom 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 have optimum engine performance under changing weat...

Page 61: ...dvance the throttle above 1500 rpm if conditions permit safe operation Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during the first 10 hours During the next 10 hours occasional operation at full throttle is permissible 5 minutes at a time maximum Avoid full throttle acceleration from idle speed Do not operate at full throttle until the engine reaches no...

Page 62: ...Section 3 On The Water Notes Page 54 90 864839070 AUGUST 2007 ...

Page 63: ...56 Fuel Ratings 56 Using Reformulated Oxygenated Gasolines USA Only 56 Gasolines Containing Alcohol 56 Engine Oil 57 Engine Specifications 58 Fluid Specifications 59 Engine 59 Bravo Sterndrives 59 Power Assisted Steering and Power Trim Fluids 59 Approved Power Assisted Steering Fluids 59 Approved Power Trim Fluids 59 4 ...

Page 64: ... alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tan...

Page 65: ...e of the following oils listed in the order of recommendation 1 MerCruiser Quicksilver 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...

Page 66: ...PM in neutral 650 Measured using an accurate service tachometer with the engine at normal operating temperatures Idle speed and timing on EFI models are not adjustable Minimum oil pressure at idle 103 kPa 15 psi Oil pressure must be checked with the engine at normal operating temperature Thermostat 71 C 160 F Timing at idle Not adjustable Idle speed and timing on EFI models are not adjustable Firi...

Page 67: ... 20 liters 21 U S qt Propylene Glycol and Purified Water Closed cooling system 18 liters 19 U S qt Mercury Extended Life Coolant Antifreeze or Extended Life Ethylene Glycol 5 100 Coolant Antifreeze mixed 50 50 with Purified Water Bravo Sterndrives NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Bravo One 2736 mL 92 1 2 oz High Performance Gear Lubricant Bravo Two 3209 mL 108...

Page 68: ...Section 4 Specifications Notes Page 60 90 864839070 AUGUST 2007 ...

Page 69: ...haft Splines And O rings Sterndrive Unit Removed 85 Engine Coupler 85 Engine Coupler 86 Driveshaft Extension Models 86 Propellers 87 Propeller Repair 87 Bravo Sterndrive Propeller Removal 87 Bravo One Models 87 Bravo Two Models 89 Bravo Three Models 90 Bravo Sterndrive Propeller Installation 92 Bravo One Models 92 Bravo Two Models 94 Bravo Three 95 Serpentine Drive Belt 97 Checking 97 Replacing 97...

Page 70: ...Section 5 Maintenance Page 62 90 864839070 AUGUST 2007 Models Using The Sterndrive Water Pickup 117 ...

Page 71: ... 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 72: ... 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 ...

Page 73: ... secure Clean the gauges If operating in saltwater reduce this interval to every 25 hours or 30 days whichever occurs first Scheduled Maintenance 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 Every 100 hours or annually whichever occurs first Touch up t...

Page 74: ...k the electrical system for loose 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 wa...

Page 75: ...n The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reinstall fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NOTE Ensure that dipstick is installed with oil level indication marks facing the rear of the engine flywheel end 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...

Page 76: ...etic 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 77: ...ain 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 78: ...ise 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 Power...

Page 79: ...74K01 3 Reinstall the fill cap dipstick Changing Power steering fluid does not require changing unless it becomes contaminated with water or debris Contact your authorized Mercury MerCruiser dealer Engine Coolant Checking 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 c...

Page 80: ...ill 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 ...

Page 81: ... 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 o...

Page 82: ...r 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 83: ... sterndrive unit so that the propeller shaft is level Fill the sterndrive unit through the oil fill drain hole with specified gear lubricant until an air free stream of lubricant flows from oil vent hole Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Sterndrive unit 92 858064K01 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndrive unit...

Page 84: ...s cool and the engine is shut down Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive unit in full down in position 2 Observe the oil level Level must be between the MIN and MAX lines on the reservoir a b 7876 a Reservoir b MIN and MAX lines 3 Fill as necessary with the specified fluid Tube Ref No Description Wh...

Page 85: ...ired to supply any charging current EFI Electronic Control Module ECM The ECM requires a stable voltage source During multiple engine operation an onboard electrical device may cause a sudden drain of voltage at the engine s battery The voltage may go below the ECM s minimum required voltage Also the alternator on the other engine may now start charging This could cause a voltage spike in the engi...

Page 86: ...osen the flame arrestor clamp and remove the flame arrestor 3 Clean the flame arrestor with solvent Dry with compressed air or allow to air dry completely 8482 a a Flame arrestor 4 Install flame arrestor Tighten the flame arrestor clamp 5 Install the engine cover Cleaning The IAC Muffler WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so that the ...

Page 87: ...dry before use 7 Reinstall the IAC muffler Water Separating Fuel Filter WARNING Fuel is flammable and explosive Ensure the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting t...

Page 88: ...ff 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 89: ...ter assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness to the engine wiring harness 8 Properly ventilate the engine compartment NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 9 Supply cooling water...

Page 90: ...m a typical hand operated grease gun 6221 a a Steering cable grease fitting Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Steering cable grease fitting 92 802865Q02 2 Turn steering wheel until steering cable fully extended Lightly lubricate the exposed part of cable a 6222 a Extended steering cable Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Steering c...

Page 91: ... 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 92: ...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 For...

Page 93: ...ine 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 Used...

Page 94: ...y 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 802869A 1 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 Lubricate...

Page 95: ...NG Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate BRAVO ONE MODELS NOTE Bravo One XR models do not u...

Page 96: ...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 97: ...ls 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 98: ...peller 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 securin...

Page 99: ...eller 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 nut...

Page 100: ... 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 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 splines 92 802865Q02 95 2 ...

Page 101: ...e f g 19816 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 NOTE Bravo One XR models do not use the tab washer 4 Models equipped with the tab washer Continue to tighten the propeller nut until the...

Page 102: ...silver lubricants Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft splines 92 802865Q02 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A 1 94 Anti Corrosion Grease Propeller shaft splines 92 802867Q 1 NOTE Anti corrosion grease is for salt water applications only 2 Install the propeller with the attaching hardware as shown 3 Torque the pro...

Page 103: ...splines 92 802865Q02 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A 1 95 2 4 C Marine Lubricant with Teflon Propeller shaft splines 92 802859A 1 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 on propeller shaft 4 Install front pr...

Page 104: ...all 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 anode screw 19 168 ...

Page 105: ...ive belt for proper tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the belt width may be acceptable Longitudinal cracks in the direction of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressure on the belt at the location that has the longest distance between tw...

Page 106: ...tions exist CAUTION Rapid release of the belt tensioner or allowing the tensioner to snap back quickly could cause injury or product damage Relieve the spring tension slowly 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 idler pulley and slowly relieve the tension on the ...

Page 107: ... 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 engi...

Page 108: ...sing 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 Propsh...

Page 109: ...Care To achieve maximum performance and fuel economy the boat bottom must be kept clean Accumulation of marine growth or other foreign matter can greatly reduce boat speed and increase fuel consumption To ensure best performance and efficiency periodically clean the boat bottom in accordance with manufacturer s recommendations In some areas it may be advisable to paint the bottom to help prevent m...

Page 110: ...2 in UNPAINTED area on transom of the boat around these items 8107 b a a Painted boat transom b Minimum 40 mm 1 1 2 in unpainted area around transom assembly NOTE Sterndrive and transom assembly can be painted with a good marine paint or an anti fouling paint that DOES NOT contain copper or any other material that could conduct electrical current Do not paint drain holes anodes the MerCathode syst...

Page 111: ...ever 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 nic...

Page 112: ...stem CAUTION Water can enter the bilge when the drain system is open damaging the engine or causing the boat to sink Remove the boat from the water or close the seacock disconnect and plug the seawater inlet hose and ensure the bilge pump is operational before draining Do not operate the engine with the drain system open IMPORTANT Only drain the seawater section of the closed cooling system IMPORT...

Page 113: ...a b 17254 a Port side drain location b Starboard side drain location MANUAL DRAIN SYSTEM a 17255 a a Blue drain plug locations Air Actuated Single Point Drain System BOAT IN THE WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Close the seacock if equipped or remove and plug the water inlet hose ...

Page 114: ...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 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 ...

Page 115: ...d 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 no longer extended a 6135 a Green indicators 14 Open the seacock if equipped or unplu...

Page 116: ... c a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side b c a 8294 a Actuator fitting b Green indicators c Manual release valve ...

Page 117: ...e seawater 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 a...

Page 118: ...se 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 ...

Page 119: ...causing the bellows to fail when returned to service and allowing water to enter the boat Store the sterndrive in the full down position 2 Lower the sterndrive unit to the full down in position 3 For additional assurance against freezing and rust after draining fill the cooling system with propylene glycol mixed to the manufacturer s recommendation to protect engine to the lowest temperature to wh...

Page 120: ... heat exchangers a b c d 8295 a Heat exchanger b Gaskets c Sealing washer d End cap 3 Repeatedly clean out drain holes using a stiff wire Do this until entire system is drained 4 Remove both hoses from seawater pump a b c a c b 8578 a Seawater pump b Seawater inlet hose fitting c Seawater out hose to cooler ...

Page 121: ...ould come equipped with a combination of any of three different types of water pickups through the hull through the transom and through the sterndrive The flushing procedures for these systems are separated into two categories sterndrive water pickups and alternative water pickups Consult your authorized Mercury MerCruiser dealer for further explanation IMPORTANT Bravo models equipped with closed ...

Page 122: ...es dual water and side pickups Dual water pickups require the flushing attachment 44357Q 2 and the flush seal kit 881150K 1 and side pickups require the flushing attachment 44357Q 2 5752 5773 Dual Water Pickup Side Pickup NOTE Flushing is needed only for salty brackish mineral laden or polluted water applications Flushing is recommended after each outing for best results NOTICE Flushing the engine...

Page 123: ...installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate b Remove propeller c Install the appropriate flushing attachment over the water inlet holes in the gear housing 5 Connect a hose between the flushing attachment and water source 6 W...

Page 124: ... housing c Lower sterndrive to full down in position 2 If flushing the cooling system with the boat out of the water a Lower sterndrive to full down in position WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch t...

Page 125: ...g the seawater inlet hose to be reconnected prior to operating engine 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 packag...

Page 126: ...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 1848...

Page 127: ...rol in neutral idle speed position and start engine NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 11 Operate the engine at idle speed in neutral gear Do not exceed 1200 RPM 12 Monitor the engine temperature while operating the engine 13 Flush the engine...

Page 128: ...nnect fitting water hose end b Water hose 19 Retain the quick connect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access IMPORTANT Do not store the quick connect fitting in the flush socket on the engine Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem Damages due to...

Page 129: ...ver 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 130: ...Section 5 Maintenance Notes Page 122 90 864839070 AUGUST 2007 ...

Page 131: ...eparation 125 Draining the Seawater System 126 Drain System Identification 126 Air Actuated Single Point Drain System 126 Manual Drain System 127 Air Actuated Single Point Drain System 127 Boat in the Water 127 Boat out of the Water 129 Manual Drain System 131 Boat in the Water 131 Boat out of the Water 132 Draining the Sterndrive 132 Battery Storage 133 Power Package Recommissioning 133 6 ...

Page 132: ...endations Preparing Power Package for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Fuel tanks should be...

Page 133: ...ent before servicing the power package 1 In a 23 liter 6 US gal remote fuel tank mix a 19 liter 5 US gal regular unleaded 87 octain 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 Description Where Used Part No 115 Premium Plus 2 cycle TC W3 Out...

Page 134: ...TANT Only drain the seawater section of the closed cooling system IMPORTANT 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 Dr...

Page 135: ...ngine 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 Manual...

Page 136: ...e 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 137: ... 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 lock...

Page 138: ...ide 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 th...

Page 139: ... 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 by...

Page 140: ... 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 141: ...rature 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 extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in ma...

Page 142: ...in the before starting column of the Operation Chart NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 5 Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly 6 Carefully inspect the engine for fuel oil fl...

Page 143: ...d to Start 137 Engine Runs Rough Misses or Backfires 137 Poor Performance 137 Excessive Engine Temperature 137 Insufficient Engine Temperature 138 Low Engine Oil Pressure 138 Battery Will Not Recharge 138 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 139 Steering Wheel Jerks or Is Difficult to Turn 139 Power Trim Does Not Operate Motor Does Not Operate 139 Power Tr...

Page 144: ...an using a special diagnostic tool Engine Guardian System The Engine 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 sp...

Page 145: ...logged fuel line or fuel tank vent 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 Perfo...

Page 146: ...le Cause Remedy Faulty thermostat Replace Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase Check and add oil Excessive oil in crankcase causing it to become aerated Check and remove required amount of oil Check for cause of excessive oil improper filling Diluted or improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for ...

Page 147: ...on 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 Power Trim Does Not Operate Motor Does Not Operate Possible Cause Remedy Blown fuse Re...

Page 148: ...Section 7 Troubleshooting Notes Page 140 90 864839070 AUGUST 2007 ...

Page 149: ...Assistance 142 Local Repair Service 142 Service Away From Home 142 Stolen Power Package 142 Attention Required after Submersion 142 Replacement Service Parts 142 Parts and Accessories Inquiries 143 Resolving a Problem 143 Mercury Marine Service Offices 143 Ordering Literature 144 United States and Canada 144 Outside The United States and Canada 144 8 ...

Page 150: ...ct 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 e...

Page 151: ...t 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 an...

Page 152: ...ted 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 f...

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