MerCruiser Axius 496 MAG H.O. Owner'S Manual Download

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Section 8 - Customer Assistance Information

90-899883154 JANUARY 2008

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Section 8 - Customer Assistance Information

Table of Contents

Owner Service Assistance................................ 138

Local Repair Service .................................. 138

Service Away From Home ......................... 138

Stolen Power Package ............................... 138

Attention Required after Submersion ......... 138

Replacement Service Parts ........................ 138

Parts and Accessories Inquiries ........... 139

Resolving a Problem .................................. 139

Mercury Marine Service Offices ................. 139

Ordering Literature............................................ 140

United States and Canada ......................... 140

Outside The United States and Canada .... 140

Summary of Contents for Axius 496 MAG H.O.

Page 1: ...quipment 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 w...

Page 2: ...printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2007 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...ime 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...

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: ...ion Label 15 Owner Responsibility 16 Emission Certification Star Label 16 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal 20 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Features and Controls 22 Lanyard Stop Switch 22 Emergency Stop E Stop Switch 23 Instrumentation 23 VesselView If Equipped 23 SC1000 and SC100 Digital...

Page 6: ...s Plus CAN Control Pad If Equipped 55 General Information 55 Heading Adjustment and Override 55 Standby 55 Standby and Active Lights 56 Power Icon 56 Auto Heading 56 Disengage Auto Heading 59 To Resume to a Heading 60 Changing VesselView Mode Display Times 60 Cruise Control 60 After Break In Period 60 End of First Season Checkup 60 Contingent Operations 61 Port Engine Only Operation 61 Axius Shift...

Page 7: ... Point Drain System 101 Manual Drain System 102 Air Actuated Single Point Drain System 102 Boat in the Water 102 Boat out of the Water 104 Manual Drain System 106 Boat in the Water 106 Boat out of the Water 107 Draining the Sterndrive 108 Manual Drain System 496 MAG and 496 MAG H O Models 108 Flushing the Power Package 110 General Information 110 Flushing Attachments 111 Sterndrive Water Pickups 1...

Page 8: ...e Motor Does Not Operate 136 Power Trim Does Not Operate Motor Operates but Sterndrive Unit Does Not Move 136 Section 8 Customer Assistance Information Owner Service Assistance 138 Local Repair Service 138 Service Away From Home 138 Stolen Power Package 138 Attention Required after Submersion 138 Replacement Service Parts 138 Parts and Accessories Inquiries 139 Resolving a Problem 139 Mercury Mari...

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

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

Page 11: ...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: ...d installations SeaCore Sterndrive Model Coverage The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Standard Model Coverage The Limited Warranty for Standard Models which do not include Horizon Sterndrive and Inboard Models MX 6 2 Black Scorpion Tow Sport Models or SeaCore...

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

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

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

Page 16: ...ll Boat Brands 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 ...

Page 17: ... 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 18: ...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 500 hours 1 year or 500 h...

Page 19: ...ertification 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 f...

Page 20: ...ed warranty provides coverage for the components of the emissions control systems of new 2003 2008 model year inboard and sterndrive engines for 2 years from either the date the product is first sold or first put into service whichever occurs first Emission related normal maintenance items such as spark plugs and filters that are on the warranted parts list see following are warranted up to their ...

Page 21: ...g or other competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses...

Page 22: ...s pleased to explain the emission control system warranty on your 2003 model year1 and later inboard or sterndrive engine In California new inboard and sterndrive engines must be designed built and equipped to meet the State s stringent anti smog standards Mercury Marine must warrant the emission control system on your inboard or sterndrive engine for the periods of time listed below provided ther...

Page 23: ...ty repairs will be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities refer to Owner Service Assistance for contact information Emission Control Information Label A tamper resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser I...

Page 24: ...fication standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Emission Certification Star Label Your boat is labeled on the hull with one of the following star labels The Symbol for Cleaner Marine Engines Means 1 Cleaner Air and Water for a healthier lifestyle and enviro...

Page 25: ...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 26: ...Section 1 Warranty Notes Page 18 90 899883154 JANUARY 2008 ...

Page 27: ...elView If Equipped 23 SC1000 and SC100 Digital Gauges If Equipped 24 SmartCraft Partner Digital Gauges 24 Analog Gauges If Equipped 24 Electronic Helm Steering 25 Dual Handle Electronic Remote Control ERC with DTS Trackpad Features and Operation 25 Operation 25 Adjustment 26 Joystick Basic Operation 27 Power Trim 27 ERC Trim Control 27 Joystick and Trim Control 29 Trailer and Trailer Limit Positio...

Page 28: ...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 29: ...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 a Transom serial number The transom serial number is also stamped on the gimbal housing This provides a permanent reference for authorized Mercury MerCruiser dealers 0W750000 32672 a b a Gimbal housing b Transom serial number ...

Page 30: ...an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area cl...

Page 31: ...verboard or tangled propeller When activated the E stop switch interrupts the power supply to the main power relay including power to the gauges steering and accessories Activation of the E stop switch stops the engines immediately but the boat continues to coast for some distance depending upon the velocity and degree of any turn at shutdown However the boat does not complete a full circle While ...

Page 32: ... Typical SmartCraft gauges a Tachometer b Speedometer c LCD System View display SMARTCRAFT PARTNER DIGITAL GAUGES For other gauge manufacturers and other SmartCraft compatible products visit www smartcraftnetworked com See the specific manufacturer s operation manual for more information ANALOG GAUGES IF EQUIPPED Instrumentation packages may vary and may contain additional gauges The owner and ope...

Page 33: ...otorsimulates the resistance feedback found in hydraulic steering systems We recommend that you drive carefully until you have a chance to explore the Axius system s handling characteristics and boat s responses in an open area clear of obstructions or other boat traffic The initial steering setting of two turns lock to lock provids a fast steering response Maneuvers at speed can be more abrupt th...

Page 34: ...stable to help prevent unwanted motion of the handle in rough water To adjust ERC handle tension 1 Remove the port side cover for port lever adjustment and starboard side cover for starboard lever adjustment 2 Turn the screw clockwise to increase tension on the control handle and counter clockwise to decrease tension 3 Adjust to tension desired To adjust ERC handle detent tension 1 Remove the port...

Page 35: ...in open water Thereafter you should occaisionallly practice operating without the joystick in case the joystick becomes inoperable Power Trim Power trim allows the operator to adjust the sterndrive angle while underway to achieve the ideal boat angle for varying load and water conditions The trailering feature allows the operator to raise and lower the sterndrive unit for trailering beaching launc...

Page 36: ...boat to accelerate and plane off slower In excess cause boat porpoising bouncing or propeller ventilation Cause engine overheating if trimmed up out to a point where any cooling water intake holes are above the water line mc78529 Trimming the sterndrive unit down in can Causes the boat to accelerate and plane off quicker Generally improve the ride in choppy water In most cases reduce boat speed In...

Page 37: ...ut Key CAUTION The Trim Without Key mode allows trim operation after the ignition key switch is turned off To avoid injury or product damage do not attempt any engine or sterndrive related repairs or maintenance until performing the Wide Open Throttle Reverse operation to end the Trim Without Key mode Trim without key is a method of allowing trim operation after the ignition key switch is turned o...

Page 38: ... the electrical system Contact your authorized dealer 1 A circuit breaker protects the engine wiring harness and the instrumentation power lead Test the circuit breaker by pushing the red button To reset the breaker push the yellow lever back into the housing b a 22529 a Yellow lever shown tripped b Red test button 2 A 90 amp fuse is located on the large post of the starter solenoid This fuse prot...

Page 39: ...pade fuse on the power trim pump The trim pump may also have an in line circuit protection device in the power trim positive lead near the battery switch or battery connection a b 9208 a 20 amp spade fuse b 110 amp fuse 5 The electronic control unit of each engine has a separate power harness to minimize voltage drop The power harness connects to the engine starting battery and is protected by a 1...

Page 40: ...ur Mercury MerCruiser power package may be equipped with an Audio Warning System The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred The audio warning system will sound with a continuous horn Engine oil pressure is too low Engine temperature is too hot Seawater pressure is too low The audio warning system will sound with ...

Page 41: ...ature Seawater pressure Engine overspeed Exhaust Manifold Temperature 8 1 liter 496 cid engines only Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails For example if the water inlet becomes partially blocked Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage from decreased wa...

Page 42: ...Section 2 Getting to Know Your Power Package Notes Page 34 90 899883154 JANUARY 2008 ...

Page 43: ... 42 Ventilation 42 Elevation and Climate 43 Propeller Selection 43 Getting Started 44 20 Hour Break In Period 44 Launching and Boat Operation 44 Operation Chart 44 Starting and Stopping the Engine 44 Starting the Engine 45 Stopping the Engine 46 Throttle Only Operation 46 Traditional Maneuvering with Steering and Thrust 46 To Maneuver the Boat in Forward 47 To Steer the Boat in Tight Turns at Low ...

Page 44: ...ular schedule and ensure that all repairs are properly made Check for onboard safety equipment We suggest the following Approved fire extinguishers Signal devices flashlight rockets or flares flag and a whistle or horn Spare operating equipment batteries bulbs fuses etc Tools necessary for minor repairs An anchor and extra anchor line A manual bilge pump and extra drain plugs A supply of drinking ...

Page 45: ...ward view should not be obstructed by passengers cargo or removable seats Be aware of others the water and your wake Never follow a water skier Your boat will quickly overtake a fallen skier If a skier falls a boat following 61 m 200 ft behind at 40 km h 25 mph will overtake the skier in five seconds Watch fallen skiers Never back up to anyone including skiers in the water The operator should alwa...

Page 46: ... an operating engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while a boat is stationary mc79554 1 a b a Operating the engine when the boat 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 hig...

Page 47: ... 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 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 ...

Page 48: ...umping 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 natural part of boating However when this activity is done with enough speed to force the boat hull partially or completely out of the water certain hazards arise particularly when the boat re en...

Page 49: ...imum planing speed when driving in waters known to have underwater obstacles After striking a submerged object stop the engine as soon as possible and inspect the drive system for any broken or loose parts If damage is present or suspected the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair The boat should be checked for hull ...

Page 50: ...wave splashing into the boat when coming off plane At extremes can cause the boat to porpoise Shifting weight to front bow Improves ease of planing Improves rough water ride At extremes can cause the boat to veer back and forth bow steer The Bottom of the Boat To maintain maximum speed the boat bottom should be Clean free of barnacles and marine growth Free of distortion nearly flat where it conta...

Page 51: ... Once the RPM returns to the recommended operating RPM range normal engine operation resumes The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller Refer to Mercury Marine s web page http www mercurymarine com everything_you_need_to_know_about_propellers6 Select a propeller that will allow the engine power package to operate at or ne...

Page 52: ...on to be high during the break in period Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat OPERATION CHART Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Install bilge drain plug Observe all gauges to check condition of engine If not normal stop engine Observe all gauges to check condition of engine If not normal stop engine Turn ...

Page 53: ...y to the RUN position WARNING 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 4 Turn the ignition key switch to the START position then release or depress the start stop button and release If the engine is cold allow the engine to operate at idle for ...

Page 54: ... 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 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 th...

Page 55: ...each drive the throttle level and the proper gear to push or rotate the boat in a direction corresponding to a joystick movement or twist For example if you move the joystick sideways the computer control system applies a thrust to the boat in the sideways direction Rotating the joystick prompts the computer to create forces that rotate the boat around its center You can move and rotate the joysti...

Page 56: ... JANUARY 2008 Joystick Input Boat Response Movement shown from light gray to dark gray 24705 Boat moves forward 25928 24706 Boat moves aft 25927 24707 Boat moves to starboard without rotating 25929 24708 Boat moves to port without rotating 25931 ...

Page 57: ...y to dark gray 24709 Boat moves diagonally forward and to the starboard without rotating 25926 24710 Boat moves diagonally aft and to the starboard without rotating 25924 24711 Boat moves diagonally aft and to the port without rotating 25923 24712 Boat moves diagonally forward and to the port without rotating 25925 ...

Page 58: ... shown from light gray to dark gray 24713 Boat rotates clockwise 25921 24714 Boat rotates counter clockwise 25920 24715 Boat moves diagonally forward and to the starboard while rotating clockwise 25916 24718 Boat moves diagonally forward and to the starboard while rotating counterclockwise 25918 ...

Page 59: ...e rotating clockwise 25930 Special Digital Throttle and Shift DTS Features The DTS system features several alternate operational modes for the Electronic Remote Control ERC levers Any of the listed features can operate simultaneously and can help you with Warming the engines Synchronizing the engines Accessing the slow speed trolling features of the integrated transmission system 28090 c d e f g b...

Page 60: ...fer to Synchronizing Engines h increase and decrease Increases and decreases settings for various functions like cruise control speed NOTE Not all functions may be active DOCK Dock mode reduces the RPM throughout the range by 50 Dock mode also reduces available power when the joystick is enabled allowing finer control of engine power in close quarter situations 31464 DOCK button To engage Dock mod...

Page 61: ...er into gear 5 The RPM of the engines can be increased while the transmissions remains in Neutral NOTE Pressing the THROTTLE ONLY button while the ERC levers are in gear turns off the button light but the boat remains in throttle only mode until you place the levers in neutral To disengage throttle only mode 1 Bring both ERC levers to neutral Throttle only will not disengage unless the ERC levers ...

Page 62: ...rboard ERC lever into gear 5 The engine RPM raises and lowers simultaneously while the transmissions remain in the same gear To disengage 1 single lever mode 1 Place both ERC levers in neutral 2 Press the 1 LEVER button The 1 LEVER button light turns off SYNC The Axius system features Sync an automatic engine synchronization feature which engages automatically at key up Sync monitors the position ...

Page 63: ...OTE Not all of the functions of the Axius system work when DTS functions are engaged Disengage the DTS functions to use the functions of Axius track pad The following information shows the location and explains the function of the Axius track pad lights and buttons HEADING ADJUSTMENT AND OVERRIDE When Auto Heading is engaged the steering wheel feels locked into a detent Approximately 3 4 4 5 kg 8 ...

Page 64: ... a button that engages or disengages an Axius Plus CAN Control Pad function indicated on the button If you press a button that has the power icon when that button light is on the light turns off for that button and the STANDBY light illuminates If you press a button with the power icon when that button light is off the light turns on for that button a single beep sounds and the ACTIVE light illumi...

Page 65: ... engage RESUME STANDBY ACTIVE AUTO HEADING TURN TURN 32507 a b a AUTO HEADING button b Power icon 3 Axius holds the compass heading the boat is following when the AUTO HEADING button is pressed 31409 4 To make adjustments in the default heading while auto heading is active and the button light is on press the respective TURN button on the trackpad or tap quickly move the joystick 5 To make a turn ...

Page 66: ...ft port or right starboard adjusts your course by 1 for each movement 24707 Adjusting the heading to starboard port opposite 6 Turn the wheel or press the AUTO HEADING button to disengage Auto Heading and a single beep sounds If the steering wheel is used to disengage Auto Heading the resume button LED turns on and a single beep sounds While the LED is lit you can press the RESUME button to resume...

Page 67: ... not appear the AUTO HEADING screen needs to be activated in VesselView calibration Axius CAN still engages whether the screen appears or not NOTE If you press the AUTO HEADING button a second time the Axius CAN goes to Standby mode and all lights other than STANDBY turn off DISENGAGE AUTO HEADING 1 Disengage the Auto Heading mode by any of the following actions Place the ERC levers for both engin...

Page 68: ... Wide Open Throttle WOT This feature requires VesselView Refer to the owner s manual provided with your VesselView for operation instructions These additional notes are exclusive to your package You can change or disengage cruise through the screen at any time Cruise resets when the key is turned off If the cruise limit is changed while the levers are at WOT cruise gradually changes to the new spe...

Page 69: ...uring single engine operation Axius Shift Override Emergency Procedure If the VesselView display shows the error message GEAR POS DIFF and an engine will not start or will not shift into gear there is a problem with the Electronic Shift Control ESC system If one drive is working you may operate on one engine and drive CAUTION Using the emergency procedure to manually shift the drive disengages shi...

Page 70: ...lanyard WARNING 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 6 Ensure that no one is in the water near the boat then start the engine 7 With the engine running at idle speed the drive can be shifted into gear and out of gear by manually moving the ...

Page 71: ...ecifications Table of Contents Fuel Requirements 64 Fuel Ratings 64 Using Reformulated Oxygenated Gasolines USA Only 64 Gasolines Containing Alcohol 64 Engine Oil 65 Engine Specifications 65 Fluid Specifications 66 Engine 66 Sterndrive Bravo 66 Steering 67 Power Trim 67 4 ...

Page 72: ... 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 73: ...MMA FC W rated 4 cycle oil 2 MerCruiser Quicksilver 25W40 NMMA FC W rated oil 3 A NMMA FC W rated oil 4 MerCruiser Quicksilver 4 cycle 25W40 non FC W rated oil 5 A good grade straight weight detergent automotive oil per the operating chart below NOTE The use of non detergent oils multi viscosity oils other than as specified non FC W rated synthetic oils low quality oils or oils that contain solid ...

Page 74: ...5 mm 0 060 in Fluid Specifications IMPORTANT All capacities are approximate fluid measures Engine IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines Always use the dipstick to determine the exact quantity of oil or fluid required All Models Capacity Fluid Type Engine oil with filter 8 5 liters 9 U S qt Mercury Quick...

Page 75: ...ARY 2008 Page 67 Steering Axius All Models Capacity Fluid Type Steering system 2914 mL 98 1 2 oz Dexron III Power Trim Description Part Number Power Trim and Steering Fluid 92 858074K01 SAE Engine Oil 10W 30 Obtain locally SAE Engine Oil 10W 40 ...

Page 76: ...Section 4 Specifications Notes Page 68 90 899883154 JANUARY 2008 ...

Page 77: ...Cable 88 Sterndrive Unit and Transom Assembly 89 Sterndrive U joint Shaft Splines And O rings Sterndrive Unit Removed 89 Engine Coupler 90 Propellers 90 Propeller Repair 90 Bravo Three Propeller Removal 90 Bravo Three Propeller Installation 92 Serpentine Drive Belt 94 Checking 94 Replacing 94 Corrosion Protection 96 Corrosion Information 96 Maintaining Ground Circuit Continuity 96 Anodes and MerCa...

Page 78: ...y 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 d...

Page 79: ... 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 80: ... to 25 hours or 30 days whichever occurs first Scheduled Maintenance Axius Models NOTE Only perform maintenance that applies to your particular power package Task Interval Maintenance to Be Performed After the first 20 hours and not to exceed 25 hours Change the engine oil and filter Check and adjust the serpentine belt tension Every 100 hours or annually whichever occurs first Touch up the paint ...

Page 81: ...ition of these components is satisfactory at inspection repeat inspection every 100 hours or once a year whichever occurs first Check 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 ...

Page 82: ...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 83: ...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 84: ...rain and install the plug ENGINE OIL DRAIN PUMP 1 Loosen the oil filter to vent the system 2 Remove the dipstick 3 Install the oil pump onto the dipstick tube mc70571 1 a c b a Typical oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the crankcase oil pump onto an appropriate container and using the handle pump until the crankcase is empty 5 Remove the pump 6 Install the dipstick...

Page 85: ...erCruiser 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 Steering Fluid Checking and Filling Steering Fluid IMPORTANT Use only specified lubricant IMPORTANT Running the pump dry will damage the pump Always check steering fluid levels b...

Page 86: ...the fluid level was low or you are installing or performing service to the system be prepared to stop the engine and add fluid after the first operation Changing Steering Fluid You do not need to change the steering fluid 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 cool...

Page 87: ... sufficient supply of water to the water inlets during operation NOTICE Air trapped in the closed cooling system can cause the engine to overheat resulting in engine damage Minimize the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine is higher than the rear of the engine NOTE Add coolant only when engine is at nor...

Page 88: ...gine cold before starting 1 Check the gear lube oil level Keep the oil level within the recommended operating range If any water is visible at the bottom of the monitor or appears at the oil fill drain plug or if oil appears discolored contact your authorized Mercury MerCruiser dealer immediately Both conditions may indicate a water leak somewhere in the sterndrive unit a 8530 a Gear lube monitor ...

Page 89: ...nit refer to Changing instructions following Changing 1 Remove the gear lube monitor from the bracket a 8530 a Gear lube monitor 2 Empty the contents into a suitable container 3 Install the gear lube monitor in the bracket 4 Place the sterndrive unit in full up out position 5 Remove the oil fill drain screw and sealing washer and drain the oil into a suitable container b a mc79507 1 a Oil fill dra...

Page 90: ...er 9 Continue to pump gear lubricant into the drive through the oil fill drain hole until the gear lubricant appears in the gear lube monitor NOTE Oil capacity includes gear lube monitor 10 Fill the monitor so that the oil level is in the operating range Do not overfill Model Capacity Fluid Type Bravo Three Single seawater pickup 2972 ml 100 1 2 oz High performance gear lubricant Bravo Three Dual ...

Page 91: ...e reservoir Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074K01 3 Install the cap Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris Contact your authorized Mercury MerCruiser dealer Battery Refer to specific instructions and warnings accompanying your battery If this information is not avail...

Page 92: ...he engine will operate normally The ECM shuts off and resets itself so quickly that the engine may only seem to have an ignition miss Batteries Boats with multi engine EFI power packages require each engine be connected to its own battery This ensures that the engine s ECM has a stable voltage source Battery Switches Battery switches should always be positioned so each engine is operating off of i...

Page 93: ...ngine 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 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 to start the engine and wipe up any ...

Page 94: ...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 95: ...off position 6 Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module Do not remove the filter assembly retaining screws from the filter cap 7 Unseat the filter assembly by grasping the filter assembly handle and pulling upward Do not remove the filter assembly from the Cool Fuel Module at this time 8 Allow any fuel that may be in the filter assembly to...

Page 96: ...ter assembly retaining screw Description Nm lb in lb ft Filter assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness to the engine wiring harness 8 Properly ventilate the engine compartment NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water ...

Page 97: ...8 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 propeller shaft lubrication refer to Propellers Sterndrive U joint Shaft Splines And O rings Sterndrive Unit Removed 1 Coat sterndrive U joint O rings and driveshaft splines with grease b a 8591 a Driveshaft splines b U joint O rings 3 Tube Ref No D...

Page 98: ...t removing the sterndrive unit Apply lubricant from a typical hand operated grease gun until a small amount of grease begins to push out Propellers Propeller Repair Some damaged propellers can be repaired Contact your authorized Mercury MerCruiser dealer Bravo Three Propeller Removal WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propel...

Page 99: ...ropeller and thrust hub off propeller shaft 6 Turn front propeller shaft nut 70 mm 2 3 4 in counterclockwise to remove nut 7 Slide propeller and thrust hub off propeller shaft NOTE Some damaged propellers can be repaired Contact your authorized Mercury MerCruiser dealer e f a b c d 5304 g h i j a Rear propeller nut b Rear propeller c Rear propeller thrust hub d Front propeller nut e Front propelle...

Page 100: ...ard end of shaft 2 Apply a liberal coat of one of the following lubricants to the propeller shaft Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft 92 802865Q02 94 Anti Corrosion Grease Propeller shaft 92 802867Q 1 95 2 4 C Marine Lubricant with Teflon Propeller shaft 92 802859A 1 3 Align splines and place propeller on propeller shaft 4 Install and torque the prop...

Page 101: ...cker 271 to the threads of the propeller shaft anode screw a b d c f e 5303 a Propeller b Propeller shaft nut c Propeller shaft anode d Propeller shaft anode screw e Flat washer f Star washer Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Propeller shaft threads 92 809819 12 Secure the propeller shaft anode to the propeller shaft using the propeller shaft anode screw and was...

Page 102: ...ulley g Crankshaft pulley h Seawater pump pulley i Tensioner pulley Checking 1 Inspect the drive 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...

Page 103: ...the limits See your authorized MerCruiser dealer for service if these conditions 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 R...

Page 104: ...al that is most 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 b...

Page 105: ...e 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 The boat transom 20341 Trim cylinder anodes Mounted on each of the trim cylinders 20342 Propshaft anode Bravo Three Bbehind the aft propeller 20344 Checking the Quicksilver MerCathode System The MerCathode system should be tested to ensure adequ...

Page 106: ...n the boat bottom in accordance with manufacturer s recommendations In some areas it may be advisable to paint the bottom to help prevent marine growth Refer to the following information for special notes about the use of anti fouling paints Anti fouling Paint IMPORTANT Corrosion damage that results from an improper type or application of anti fouling paint will not be covered by the limited warra...

Page 107: ... any cleaning equipment such as brushes or high pressure washers to clean the MerCathode assembly Do not wash the sterndrive unit with a power washer High pressures can damage the coating on the reference wire of the MerCathode assembly if equipped and increase corrosion 32671 c b a a a MerCathode reference electrode b Do not paint c Do not pressure wash ...

Page 108: ...d anti fouling paint or its equivalent on or near aluminum surfaces below the waterline If bare metal is showing apply 2 coats paint Description Where used Part number Mercury Phantom Black Bare metal 92 802878 1 Spray all electrical connections with sealant Tube Ref No Description Where Used Part No 25 Liquid Neoprene All electrical connections 92 25711 3 Inspect the sacrificial trim tab or anode...

Page 109: ...as possible to ensure complete draining of the cooling system Your power package is equipped with a drain system Refer to Drain System Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure Drain System Identification This power package comes with one of several available seawater drain system...

Page 110: ...ed 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 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 111: ...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 release valve ...

Page 112: ...ld 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 unpl...

Page 113: ...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 release valve ...

Page 114: ...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 115: ...ose 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 116: ... 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 which it ...

Page 117: ...he heat exchangers a b c d 8295 a Heat exchanger b Gaskets c Sealing washer d End cap 3 Use a stiff wire to clean out the drain holes Repeat until the entire system is drained 4 Remove both hoses from the seawater pump a b c a c b 8578 a Seawater pump b Seawater inlet hose fitting c Seawater out hose to cooler ...

Page 118: ...rndrive unit in full down in position Flushing the Power Package General Information Your authorized Mercury MerCruiser dealer can explain how to properly flush your power package Your boat could come equipped with a combination of any of three different types of water pickups through the hull through the transom and through the sterndrive The flushing procedures for these systems are separated in...

Page 119: ...er pickup a Flushing device b Hose attachment c Dual water pickup flush gearcase seal kit Flushing Device 91 44357Q 2 9192 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the engine Dual Water Pick up Flush Gearcase Seal Kit 91 881150K 1 9194 Blocks off the front water inlet holes on the dual water inlet gearcases ...

Page 120: ...ls Proceed to Step 3 or Step 4 2 On Bravo closed cooled models using the sterndrive seawater inlet and a through hull or through transom alternative water pickup Flushing water will need to be supplied to only the sterndrive by taking the following steps to block or disconnect and block the hose from the alternative seawater pickup pump inlet Y fitting a If equipped with a seacock close the seacoc...

Page 121: ...gauge to ensure that the engine is operating in the normal range 10 Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear 11 Slowly return throttle to idle speed position 12 Stop the engine 13 Shut off water and remove flushing attachment 14 Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the en...

Page 122: ...he flushing hose from the water source to the water inlet of the seawater pump 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 7 With sterndrive in normal operating position open the water source fully 8 Place the remote control in neutral idle speed posi...

Page 123: ... sterndrive water inlet blocked off at the gimbal housing Refer to Alternative Water Pickups 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 to prevent the engine from starting Place a block of wood between the...

Page 124: ...sh the sterndrive for 30 seconds 10 Place the remote control 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 t...

Page 125: ...onnect fitting water hose end b Water hose 19 Retain the quick connect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access IMPORTANT Do not store the quick connect fitting in the flush socket on the engine Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem Damages due t...

Page 126: ...over installed in the flush socket a Dust cover b Flush socket IMPORTANT If the unit is to be stored in the water the seacock should remain closed until time of usage If unit is to be stored out of the water open the seacock 21 Open the seacock if equipped or reconnect the alternative water inlet source prior to operating the engine ...

Page 127: ...eparation 121 Draining the Seawater System 122 Drain System Identification 122 Air Actuated Single Point Drain System 122 Manual Drain System 123 Air Actuated Single Point Drain System 123 Boat in the Water 123 Boat out of the Water 125 Manual Drain System 127 Boat in the Water 127 Boat out of the Water 128 Draining the Sterndrive 128 Battery Storage 129 Power Package Recommissioning 129 6 ...

Page 128: ...mmendations 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 following the instructions on the container 2 If fuel without alcohol is not available and the boat will be stored with gasoline that contains alcohol in the tanks drain the fuel t...

Page 129: ...a 23 L 6 US gal remote fuel tank mix a 19 L 5 US gal regular unleaded 87 octane 90 RON gasoline b 1 89 L 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 Outboard Oil Fuel system 92 858026K01 124 Fuel System Treat...

Page 130: ...RTANT 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 D...

Page 131: ...engine However any air source can be used 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lock pump on the fitting 8293 b d e a c a Actuator fitting b Green indicators c Manua...

Page 132: ...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 133: ... 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 134: ...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 135: ... 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 136: ...n for a minimum of five minutes Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained 5 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit by pulling the fuse marked CD 6 Crank the engine over slightly with starter motor to purge any water trapped in the...

Page 137: ...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 138: ... 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 f...

Page 139: ...rank Engine Or Cranks Slow 132 Engine Will Not Start or Is Hard to Start 133 Poor Performance 133 Engine Runs Rough Misses or Backfires 133 Excessive Engine Temperature 133 Insufficient Engine Temperature 134 Low Engine Oil Pressure 134 Battery Will Not Recharge 134 Joystick 134 Electronic Remote Controls 135 Steering System 135 Power Trim Does Not Operate Motor Does Not Operate 136 Power Trim Doe...

Page 140: ... 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 contin...

Page 141: ...ck for cause of entry Boat overloaded or load improperly distributed Reduce load or redistribute load more evenly Flame arrestor dirty Clean the flame arrestor Boat bottom fouled or damaged Clean or repair as necessary Ignition problem See Engine Runs Rough Misses or Backfires Engine overheating See Excessive Engine Temperature EFI System fault Have EFI System checked by an authorized Mercury MerC...

Page 142: ...ne 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 dirty electrical connections or damaged wiring Check all associated electrical connections and wi...

Page 143: ...d engine power If found contact your authorized Mercury MerCruiser dealer to ask if the propellers need to be changed The ERC lever controls the engine and drive but does not respond in a linear manner Check the TROLL button on the DTS track pad Put the handles in Neutral and push the TROLL button to disengage if light is on Check whether dock mode or cruise control are on If on turn off or diseng...

Page 144: ...cated near the dash trim switch at the trim pump in the positive red power trim battery lead near the battery switch or a combination of these Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not Operate Motor Operates but Sterndrive Un...

Page 145: ...Assistance 138 Local Repair Service 138 Service Away From Home 138 Stolen Power Package 138 Attention Required after Submersion 138 Replacement Service Parts 138 Parts and Accessories Inquiries 139 Resolving a Problem 139 Mercury Marine Service Offices 139 Ordering Literature 140 United States and Canada 140 Outside The United States and Canada 140 8 ...

Page 146: ...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 147: ...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 148: ...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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MerCruiser Axius 496 MAG H.O., Owner'S Manual

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