MerCruiser Axius SeaCore 350 MAG User Manual Download Page 2 | Manualshive

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Regulatory contact:

Engineering - Regulatory

MerCruiser

3003 N. Perkins Rd

Stillwater, Oklahoma 74075

USA

(405) 377-1200

Identification Record

Please record the following information:

Engine Model and Horsepower

Engine Serial Number

Transom Assembly Serial Number (Sterndrive)

Gear Ratio

Sterndrive Unit Serial Number

Transmission Model (Inboard)

Gear Ratio

Transmission Serial Number

Propeller Number

Pitch

Diameter

Hull Identification Number (HIN)

Purchase Date

Boat Manufacturer

Boat Model

Length

Exhaust Gas Emissions Certification Number

The serial numbers are the manufacturer’s keys to numerous engineering details that apply

to your Mercury MerCruiser® power package. When contacting your Authorized Mercury

MerCruiser Dealer about service,

always specify model and serial numbers.

The description and specifications contained herein were in effect at the time this guide

was approved for 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, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,

Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort,

M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered

trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered

service mark of Brunswick Corporation.

Welcome

You have selected one of the finest marine power packages available. It incorporates

numerous design features to assure operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many

boating seasons. To ensure maximum performance and carefree use, we ask that you

thoroughly read this manual.

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Summary of Contents for Axius SeaCore 350 MAG

Page 1: ...nt 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 which i...

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: ... Owner Responsibility 17 Emission Certification Star Label 17 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal MPI 20 Alpha Sterndrive Decal Identification 20 Alpha Transom Serial Number 21 Bravo Sterndrive Serial Number and Identification 21 Bravo Transom Serial Number 22 Lanyard Stop Switch 23 Instrumentation 24 VesselView 24 Digital Gauges 25 Analog Gaug...

Page 6: ...ion 55 Weight Distribution Passengers and Gear Inside the Boat 55 The Bottom of the Boat 55 Cavitation 56 Ventilation 56 Elevation and Climate 56 Propeller Selection 56 Getting Started 57 20 Hour Break In Period 57 After the Break In Period 57 End of First Season Checkup 57 Section 4 Specifications Fuel Requirements 60 Fuel Ratings 60 Using Reformulated Oxygenated Gasoline USA Only 60 Gasoline Con...

Page 7: ...ing the Quicksilver MerCathode System 102 Power Package Exterior Surfaces 103 Boat Bottom Care 103 Anti fouling Paint 103 Sterndrive Surface Care 105 Flushing the Power Package Alpha 106 Flushing Attachments 106 Sterndrive Water Pickups 107 Flushing the Power Package Bravo 108 General Information 108 Flushing the Power Package 108 Flushing Attachments 109 Sterndrive Water Pickups 110 Alternative W...

Page 8: ...ks or Is Difficult to Turn 137 Power Trim Does Not Operate Motor Does Not Operate 137 Power Trim Does Not Operate Motor Operates but Sterndrive Unit Does Not Move 137 Section 8 Customer Assistance Information Owner Service Assistance 140 Local Repair Service 140 Service Away From Home 140 Stolen Power Package 140 Attention Required after Submersion 140 Replacement Service Parts 140 Parts and Acces...

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

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

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

Page 12: ...fied installations Coverage for SeaCore Sterndrive Models The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Coverage for Standard Models The Limited Warranty for Standard Models which do not include Sterndrive Models with Closed Cooling Inboard Models Scorpion 377 Models V...

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: ...1 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 ...

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 ...

Page 19: ...Certification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and ...

Page 20: ...alendar year As an example 2003 model year products refers to products manufactured during calendar year 2003 This limited warranty provides coverage for the components of the emissions control systems Select emission control parts from model year 2003 2005 inboard or sterndrive engines are warranted for 2 years from either the date the product is first sold or first put into service whichever occ...

Page 21: ...nsistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impellers and liners operation with fuels oils or lubricants which are not suitable for use with the ...

Page 22: ...cation System a Oil pump and internal parts b Oil injector s c Oil meter 5 Positive Crankcase Ventilation PCV System a PCV Valve b Oil filler cap 6 Exhaust System a Exhaust manifold b Exhaust elbow c Intermediate exhaust elbow d Lower exhaust pipe e Tailpipe 7 Catalysts or Thermal Reactor System a Catalytic converter b Thermal reactor c Exhaust manifold d Exhaust valve s 8 Miscellaneous Items Used...

Page 23: ...so included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine will repair your inboard or sterndrive engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage For 2003 2008 spark ignition inboard and sterndrive marine engines Select emission control parts from model year1 2003 2008 inboard and...

Page 24: ...he label or the part it is affixed to before sale If modifications are necessary contact Mercury MerCruiser about the availability of replacement decals before proceeding NOTE When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine the Declaration of Conformance applies Refer to the front page of this manual for further information EMISSION CON...

Page 25: ...nomy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources 3 Longer Emission Warranty Protects consumer for worry free operation Beginning January 1 2003 one Three Star or Four Star label will be included with each factory certified Mercury MerCruiser engine All Mercury MerCruiser engines 500 hp and below will have a Three Star Ultra ...

Page 26: ... 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 standards or the Sterndrive and Inboard marine engine 2003 exhaust em...

Page 27: ...ls Non DTS Models 26 Remote Controls 26 Panel Mount Features 27 Console Mount Features 28 Remote Controls DTS Models 28 Remote Controls 28 Panel Mount Features 29 Console Mount Features Single Engine 30 Slim Binnacle Console Mount Features Single Engine 31 Console Mount Features Dual Engine 32 Synchronizing Dual Engines 33 Dual Helm Station Transfer 33 Synchronizing Dual Helms Prior To Station Tra...

Page 28: ...erial numbers Engine Serial Number Decal MPI The serial number decal is located on the engine cover 25903 Serial numbers and maintenance color codes decal The engine serial number is also stamped in the engine block Alpha Sterndrive Decal Identification The Drive Serial No is located on the port side of the alpha sterndrive The Drive Ratio is located on the starboard side of the alpha sterndrive b...

Page 29: ...d on the top of the transom assembly 25619 Alpha transom assembly serial number Bravo Sterndrive Serial Number and Identification The sterndrive serial number gear ratio model number and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive c b a d 25906 a Bar code b Serial Number c Gear ratio d Model number ...

Page 30: ...back cover This is used as a permanent reference for authorized MerCruiser Dealers 25907 a Bravo sterndrive serial number stamping a Serial number stamping Bravo Transom Serial Number The Bravo transom serial number is stamped in the U bolt plate of the Bravo transom assembly 25904 a Bravo transom assembly U bolt plate a Transom assembly serial Number ...

Page 31: ...e operator s position as in accidental ejection from the operator s position 74608 RUN a b c a Stop switch b Lanyard c Clips to the operator Accidental ejections such as falling overboard are more likely to occur in low sided sport boats bass boats high performance boats Accidental ejections can also occur from poor operating practices sitting on the seat or gunwale at planing speeds standing at p...

Page 32: ...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 the operator...

Page 33: ...n VesselView may also be connected to other vessel systems such as GPS generators and cabin environmental controls This comprehensive vessel integration allows the operator to monitor and control a wide range of vessel systems from a single convenient display Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product A few of the functions the instrument packag...

Page 34: ... 0 1 2 3 4 5 6 7 8 R P M X 1000 MPH KPH 10 20 30 40 50 60 70 80 30 40 50 60 70 80 90 100 120 110 10 16 BATT 0 4 4 4 FUEL CRUISELOG 0 0 0 0 0 TRIM a b c d e f g h i j 14671 Reference Gauge Function a Speedometer Indicates boat speed b Tachometer Indicates engine RPM c Oil pressure gauge Indicates engine oil pressure d Voltmeter Indicates battery voltage e Coolant temperature gauge Indicates engine ...

Page 35: ...arting the engine Lanyard Stop Switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to Lanyard Stop Switch for information on the use of this switch Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from ne...

Page 36: ... used to adjust the effort required to move the remote control handle Refer to instructions provided with remote control for complete adjustment instructions Power Trim Switch See Power Trim section for detailed power trim operating procedures Trailer Switch Used to raise drive unit for trailering launching beaching or shallow water operation See Power Trim for detailed trailer switch operation Re...

Page 37: ...pushing back to increase speed Shift Lock Pressing the shift lock allows the engine to shift The shift lock must always be pressed when moving the control handle out of the neutral position Trim Tilt Switch if equipped Refer to Power Trim Throttle Only Button Allows engine throttle advancement without shifting the engine The throttle only button can be depressed only when the remote control is in ...

Page 38: ... engine is in neutral gear position NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the gear switch Select Key Selects System View on screen options and confirms data entries Arrow Trackpad Navigates through System View on screen function messages Throttle Only Station Select Key Allows engine throttle advancement without shifting th...

Page 39: ... light is illuminated when the engine is in neutral gear position NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the gear switch Stop Start Button Allows the boat operator to start or stop the engine without using the ignition key Throttle Only Station Select Key Allows engine throttle advancement without shifting the engine The thr...

Page 40: ...sition NOTE Gear position is determined by sensing the position of the shift actuator on the engine not the position of the gear switch Select Key Selects System View on screen options and confirms data entries Arrow Trackpad Navigates through System View on screen function messages Sync Light The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system Th...

Page 41: ...control of the engine operation The active light is illuminated at the remote control station that is in control of the engine WARNING Avoid serious injury or death from loss of boat control The boat operator should never leave the active station while engine is in gear Helm transfer should only be attempted while both stations are manned One person helm transfer should only be performed while eng...

Page 42: ...e nearing match position Once the light stays on continuously the handles are matched and the button can be released Transfer process is complete and the new station is now in control If the button is held for over 10 seconds the station transfer is cancelled Zero Effort Features c a b 5656 a Shift ever b Throttle lever c Trim tilt switch Shift Lever Shift functions are controlled by the movement ...

Page 43: ...er 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 I...

Page 44: ...dependently of each other can damage 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 t...

Page 45: ...ing b a 22529 Yellow lever style circuit breaker a Yellow lever b Red test button A 90 amp fuse located on the large post of the starter solenoid protects the engine wiring harness if an electrical overload occurs mc74907 1 Four fuses located on the port side of the engine protect various electronic fuel injection EFI circuits 33214 Engine fuses ...

Page 46: ...14 pin connector 33177 A 15 amp accessory fuse protects the accessory circuits This fuse is located on the rear of the engine a b c 32206 a Cover b 15 amp fuse c Accessory harness A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical system Check for an open fuse if the engine does not start and the circuit breaker is not tripped mc70525 1 ...

Page 47: ...power trim positive lead near the battery switch or battery connection a b 9208 a 20 amp spade fuse b 110 amp fuse A power harness connected to the engine starting battery minimizes voltage drop to the electrical system This harness is protected by a 5 amp fuse This connection is located at the rear of the engine near the 14 pin connector 33179 Power harness connection The Quicksilver Three Button...

Page 48: ...ge may be equipped with an audio warning system Most faults cause the warning horn circuit to activate How the warning horn activates depends on the severity of the problem There are three warning horn states Caution Severe Onboard Diagnostic Marine OBDM fault Caution If a caution is detected the audio warning system will sound for six one second intervals ON ON OFF ON OFF ON OFF ON OFF ON OFF 1 1...

Page 49: ... Warning System 1 Turn the ignition switch to the ON position without cranking the engine 2 Listen for the audio alarm The alarm will sound if the system is functioning correctly Guardian Strategy Engine Guardian reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem Below are some examples of what Engine Guardian monitors Oil pressure Engine o...

Page 50: ...ian monitors the clutch pack pressure in forward and reverse gears If the transmission fluid pressure drops below a predetermined level Transmission Guardian lowers the engine torque and speed to prevent clutch slippage To avoid possible recurrence of the problem you should contact an authorized dealer The ECM stores the fault and with this information the technician will be able to more rapidly d...

Page 51: ...arting the Engine 49 Stopping the Engine 50 Throttle Only Operation 51 Trailering the Boat 51 Freezing Temperature Operation 51 Drain Plug and Bilge Pump 52 Protecting People in the Water 52 While You Are Cruising 52 While Boat Is Stationary 52 High Speed and High Performance Operation 52 Passenger Safety in Pontoon Boats and Deck Boats 52 Boats Having An Open Front Deck 53 Boats With Front Mounte...

Page 52: ... 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 unloadin...

Page 53: ...or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in 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 involv...

Page 54: ...at 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 ...

Page 55: ...t 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 mi...

Page 56: ...eration 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 t...

Page 57: ...f 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 58: ...ture 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 le...

Page 59: ...ole 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 soun...

Page 60: ...RNING 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 61: ...t 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 ju...

Page 62: ...n 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 cont...

Page 63: ...tion 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 wh...

Page 64: ...r 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 wea...

Page 65: ...me for the first 10 hours Shift into gear as soon as possible after starting and advance 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 accele...

Page 66: ...Section 3 On the Water Notes Page 58 90 899883169 DECEMBER 2007 ...

Page 67: ...Ratings 60 Using Reformulated Oxygenated Gasoline USA Only 60 Gasoline Containing Alcohol 60 Engine Oil 61 Engine Specifications 62 Fluid Specifications 62 Engine 62 Alpha Sterndrive 62 Bravo Sterndrives 63 Power Assisted Steering and Power Trim Fluids 63 Approved Power Assisted Steering Fluids 63 Approved Power Trim Fluids 63 4 ...

Page 68: ...Gasoline Containing Alcohol Gasoline Containing Alcohol If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol be aware of possible adverse effects These adverse effects are more severe with methanol and worsen according to the percentage of alcohol in the fuel Alcohol in gasoline can absorb moisture from the air causing the water and the alcohol to separate ...

Page 69: ...or non catalyzed engines Some marine grade lubricants contain high levels of phosphorus which can damage the catalyst system on MerCruiser engines Although these high phosphorus lubricants may allow for acceptable engine performance exposure over time will damage the catalyst Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty ...

Page 70: ...dle Not adjustable Firing order 1 8 4 3 6 5 7 2 Electrical system 12 V negative ground Alternator rating 65 A Recommended minimum battery rating non DTS models 750 CCA 950 MCA or 180 Ah Recommended minimum battery rating DTS models 800 CCA 1000 MCA or 190 Ah Spark plug type AC Platinum AC 41 993 Spark plug gap 1 5 mm 0 060 in Fluid Specifications IMPORTANT All capacities are approximate fluid meas...

Page 71: ... mL 108 1 2 oz Bravo Three single seawater pickup 2972 mL 100 1 2 oz Bravo Three dual seawater pickup 2736 mL 92 1 2 oz Power Assisted Steering and Power Trim Fluids APPROVED POWER ASSISTED STEERING FLUIDS Description Part Number Power Trim and Steering Fluid 92 858074K01 APPROVED POWER TRIM FLUIDS Description Part Number Power Trim and Steering Fluid 92 858074K01 SAE Engine Oil 10W 30 Obtain loca...

Page 72: ...Section 4 Specifications Notes Page 64 90 899883169 DECEMBER 2007 ...

Page 73: ...ering System 88 Throttle Cable 89 Shift Cable Typical 90 Sterndrive Unit and Transom Assembly 90 Sterndrive U joint Shaft Splines And O rings Sterndrive Unit Removed 91 Engine Coupler 91 Driveshaft Extension Models 92 Propellers 92 Propeller Repair 92 Alpha Propeller Removal 92 Alpha Propeller Installation 93 Bravo One Propeller Removal 94 Bravo One Propeller Installation 94 Bravo Two Propeller Re...

Page 74: ...Section 5 Maintenance Page 66 90 899883169 DECEMBER 2007 ...

Page 75: ...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 76: ...are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or to request the repair procedure It is dif...

Page 77: ...awater section of the cooling system after each use Weekly Check the water inlets for debris or marine growth Check and clean the seawater strainer if equipped Check the coolant level Inspect the sterndrive anodes and replace if 50 eroded Every two months or 50 hours Lubricate the propeller shaft and retorque the nut If operating only in freshwater you can extend the interval to every four months ...

Page 78: ...ns section On driveshaft extension models lubricate the driveshaft U joints and tailstock input and output bearings Every 200 hours or 3 years Inspect the U joints the splines and the bellows Check the clamps Check the engine alignment Lubricate the U joint splines and cross bearing if equipped with grease fittings Lubricate the gimbal bearing and the engine coupler NOTE Lubricate the engine coupl...

Page 79: ... other fluids into the environment when using or servicing your boat Be aware of the local restrictions governing the disposal or recycling of waste and contain and dispose of fluids as required Checking 1 Stop the engine Allow approximately five minutes for the oil to drain into the oil pan The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reinstall fully into the dipstic...

Page 80: ...ll dipstick into dipstick tube Filling IMPORTANT Do not overfill the engine with oil IMPORTANT Always use the dipstick to determine the exact quantity of oil or fluid required 1 Remove oil fill cap 33210 Oil fill cap IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dipstick 2 Add the specified engine oil to bring the level up to but not ...

Page 81: ...edure 1 Loosen the oil filter to vent the system f e d c b a 7284 a Bilge drain plug b Tether c Clip d Oil drain hose plug e Oil drain hose f Bilge drain flange 2 Remove the bilge drain plug 3 Pull tether through the bilge drain 4 Place the oil drain hose in a suitable container 5 Remove the drain plug from the oil drain hose 6 After oil has drained completely install the drain plug in the oil dra...

Page 82: ...ecommended engine oil to bring level up to the bottom of the OK range on the dipstick 6 With the boat at rest in the water check the oil level and add specified fluid to bring the oil level up to but not over the full or OK range NOTE Adding 0 95 L 1 qt of engine oil will raise the level from the add mark to the top of the OK range 7 Start the engine run the engine for three minutes and check for ...

Page 83: ...luid or Dexron III Automatic Transmission Fluid ATF to bring the fluid level up to the proper level Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steering system 92 858074K01 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 dea...

Page 84: ...until it seats on the filler neck 4 With the engine at normal operating temperature check the coolant level in the coolant recovery bottle 5 The coolant level should be between the ADD and FULL marks 6102 6 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol anti...

Page 85: ...eeds can trap air in the system and make purge procedures more difficult Operate at idle when filling the system or purging air 2 Fill to the full mark with the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed cooling system 92 877770K1 3 Check the antifreeze concentration for adequate freeze protection and correct if necessary Refer to the S...

Page 86: ...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 overfill Tube Ref No Description Where Used Part No 87 High ...

Page 87: ...drain the oil b a mc79507 1 a Oil fill drain screw b Sealing washer 6 Remove the oil vent screw and sealing washer Allow the oil to drain completely mc77106 1 b a a Oil vent screw b Sealing washer IMPORTANT If any water drained from the oil fill drain hole or if the oil appears milky the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer 7 Low...

Page 88: ... Do not overtighten NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Alpha One 1892 mL 64 oz High Performance Gear Lubricant Bravo One 2736 mL 92 1 2 oz Bravo Two 3209 mL 108 1 2 oz Bravo Three single seawater pickup 2972 mL 100 1 2 oz Bravo Three dual seawater pickup 2736 ml 92 1 2 oz 11 Remove the pump from the oil fill drain hole Quickly install the sealing washer and oil ...

Page 89: ...er 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 available observe the following precautions when handling a battery WARNING Recharging a weak battery in the boat or using jumper cables and a booster ba...

Page 90: ...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 its own battery Do not operate engines with switches in both or all position In an emergency another engine s battery can be used to start an eng...

Page 91: ... the crankcase ventilation hose with warm water and a mild detergent Dry with compressed air or allow to air dry completely 8 Inspect the crankcase ventilation hose for cracks or deterioration Replace if necessary 9 Install the flame arrestor and flame arrestor bracket Torque the flame arrestor bracket nuts Description Nm lb in lb ft Flame arrestor bracket nut 12 106 10 Connect the crankcase venti...

Page 92: ... 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 spilled fuel immediately NOTE The IAC muffler may be installed in the throttle body or in the IAC adapter Locate ...

Page 93: ...g to start the engine and wipe up any spilled fuel immediately CAUTION Failure to release pressure from the fuel system will result in fuel spraying out which can cause a fire or explosion Allow the engine to cool completely and release all fuel pressure before servicing any part of the fuel system Always protect eyes and skin from pressurized fuel and vapors GEN II Models a b c 6527 a Fuel filter...

Page 94: ... water inlets during operation 5 Supply cooling water to the engine 6 Start the engine Check for gasoline leaks around the fuel filter assembly If leaks exist stop the engine immediately Recheck the filter installation wipe up any spilled fuel and properly ventilate the engine compartment If leaks continue stop the engine immediately and contact your authorized Mercury MerCruiser dealer GEN III Mo...

Page 95: ...nt into the cup until completely seated 2 Install new O ring on the filter cup 3 Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter clockwise direction while holding the filter cup stationary until the filter cap locks securely into place 4 Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel and align the screws re...

Page 96: ...If Steering Cable Has Grease Fittings Turn steering wheel until steering cable is fully retracted into cable housing Apply approximately 3 pumps of grease from 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 extend...

Page 97: ...o Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie bar pivot points 92 883725K01 5 Upon first starting engine turn steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway Throttle Cable 1 Lubricate the pivot points and the guide contact surfaces a b a 5577 a Pivot points b Guide contact surfaces Tube Ref No Description...

Page 98: ... MerCruiser Engine Oil SAE25W 40 Shift cable pivot points guide contact surfaces 92 883725K01 Sterndrive Unit and Transom Assembly 1 Lubricate gimbal bearing by applying approximately 8 10 pumps of grease from a typical hand operated grease gun mc77068 1 a a Gimbal bearing grease fitting Tube Ref No Description Where Used Part No 42 U joint and Gimbal Bearing Grease Gimbal bearing 92 802870A1 2 Fo...

Page 99: ...gh 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 Part No 91 Engine Couple...

Page 100: ...ting Tube Ref No Description Where Used Part No 42 U joint and Gimbal Bearing Grease Transom end grease fitting engine end grease fitting driveshaft grease fittings 92 802870A1 Propellers Propeller Repair Some damaged propellers can be repaired Contact your authorized Mercury MerCruiser dealer Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death Never operate the b...

Page 101: ...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 2 Slide thrust hub onto propeller shaft with stepped side toward propeller hub 3 Install Flo Torq II Drive Hub into propeller NOTE The drive sleeve is tapered and will slide fully into the propeller as the nut is...

Page 102: ...NOTICE Operating the engine with a loose propeller can damage the propeller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval IMPORTANT If reusing tab washer carefully inspect tabs for cracks or other damage Replace tab washer if condition is questionable a b c d e g 6215 f a Propell...

Page 103: ...emoval 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 propeller blade and the anti ventilation plate 1 Place wood block between propeller b...

Page 104: ... Bend tabs back down into spline washer Check propeller at least after 20 hours of operation Do not operate with loose propeller Bravo Three Propeller Removal 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 ...

Page 105: ... Flat washer i Star washer j Propeller shaft anode Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval e f a b c d 5304 g h i j a Rear propeller nut b Rear propeller c Rear pr...

Page 106: ...gn splines and place propeller on propeller shaft 7 Install and torque the propeller nut Check propeller at least every 20 hours of operation and retorque as needed Description Nm lb in lb ft Aft propeller nut 81 60 8 Install the propeller shaft anode over the propeller shaft nut 9 Place the flat washer onto the propeller shaft anode screw 10 Place the star washer onto the propeller shaft anode sc...

Page 107: ...c Crankshaft pulley d Alternator pulley e Seawater pump pulley f Power steering pump 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 m...

Page 108: ...djusting the stud to adjust the belt deflection 6 Using one of the 2 methods following check for correct deflection a Push down with moderate thumb pressure on the longest stretch of belt Proper deflection is 13 mm 1 2 in b Attach the Kent Moore Belt Tension Gauge to the belt The gauge has different ranges for new and used belts CO LO R GU ID E fo r PA TE N T 2 83 91 8 NEWTONE N E W T O N E b a 14...

Page 109: ...nd Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine transom assembly and sterndrive components Good continuity is essential for the MerCathode System to function effectively Anodes and MerCathode System Locations IMPORTANT Replace sacrificial anodes if eroded 50 percent or more The following sacri...

Page 110: ...ts 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 Propshaft anode Bravo Three Located behind the aft propeller 20344 Checking the Quicksilver MerCathode System Th...

Page 111: ... Care To achieve maximum performance and fuel economy the boat bottom must be kept clean Accumulation of marine growth or other foreign matter can greatly reduce boat speed and increase fuel consumption To ensure best performance and efficiency periodically clean the boat bottom in accordance with manufacturer s recommendations In some areas it may be advisable to paint the bottom to help prevent ...

Page 112: ... 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 sys...

Page 113: ...lever ground wire d Ground wire between the gimbal ring and bell housing e Stainless steel hoses f Ground wire between the gimbal housing and trim cylinder g Ground wire between the gimbal ring and gimbal housing We recommend the following maintenance items to help keep your sterndrive corrosion free Maintain a complete paint covering on the sterndrive Check the finish regularly Prime and paint ni...

Page 114: ...t least every 60 days and lubricate the propeller shaft Do not use lubricants containing graphite on or near the aluminum in saltwater Do not paint trim tabs or the mounting surface Flushing the Power Package Alpha Your boat comes equipped with through the sterndrive water pickups See Sterndrive Water Pickups following for the flushing procedure Consult your authorized Mercury MerCruiser dealer fo...

Page 115: ... in the water a Raise the sterndrive to trailer position b Install the appropriate flushing attachment over the water inlet holes in the gear housing c Lower sterndrive to full down in position 3 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 wa...

Page 116: ... the hose to prevent water from siphoning into the boat This prevents seawater from contaminating the engine flush 14 Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine Flushing the Power Package Bravo General Information Your authorized Mercury MerCruiser dealer can explain how to properly flush your power package Flushing...

Page 117: ...ter 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 118: ...n models with the sterndrive seawater inlet blocked supply water to the sterndrive and to the engine See Alternative Water Pickups 3 On models using the sterndrive seawater inlet and a through hull or through transom alternative water pickup supply water 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 ...

Page 119: ...e to ensure that the engine is operating in the normal range 11 Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear 12 Slowly return throttle to idle speed position 13 Stop engine 14 Shut off water and remove flushing attachment 15 Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine 16 ...

Page 120: ... hose connection 6 Using a suitable adapter connect the 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 ...

Page 121: ... water hose from the sterndrive to the engine NOTE Engines with the 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...

Page 122: ... to a full flow 9 Allow the water to flush 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...

Page 123: ...onnect fitting water hose end b Water hose 19 Retain the quick connect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access IMPORTANT Do not store the quick connect fitting in the flush socket on the engine Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem Damages due t...

Page 124: ...over installed in the flush socket a Dust cover b Flush socket IMPORTANT If the unit is to be stored in the water the seacock should remain closed until time of usage If unit is to be stored out of the water open the seacock 21 Open the seacock if equipped or reconnect the alternative water inlet source prior to operating the engine ...

Page 125: ...r Actuated Single Point Drain System 120 Manual Single Point Drain System Alpha 121 Three Point Manual Drain System 121 Multi Point Drain MPD System 121 Air Actuated Single Point Drain System 122 Boat in the Water 122 Boat out of the Water 124 Manual Single Point Drain System Alpha 126 Boat in the Water 126 Boat out of the Water 127 Three Point Manual Drain System 128 Boat in the Water 128 Boat ou...

Page 126: ...ge for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 Check the antifreeze concentration Refer to the Specifications section 3 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alc...

Page 127: ...ng out of fuel can damage catalyst components Do not allow the fuel tanks to become empty during operation 1 In a 23 liter 6 US gal remote fuel tank mix a 19 liter 5 US gal regular unleaded 87 octane 90 RON gasoline b 1 89 liter 2 US qt Premium Plus 2 Cycle TC W3 Outboard Oil c 150 ml 5 oz Fuel System Treatment and Stabilizer or 30 ml 1 oz Fuel System Treatment and Stabilizer Concentrate Tube Ref ...

Page 128: ... System Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturer s instructions be used in the seawater section of the cooling system for freezing temperatures or extended storage Make sure that the ...

Page 129: ...SINGLE POINT DRAIN SYSTEM ALPHA b a b 6128 a Blue handle b Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM a a 6126 a Blue drain plug MULTI POINT DRAIN MPD SYSTEM 10226 M110050 932356 72 b a a b 6129 a Side of cylinder block b Bottom of exhaust manifolds ...

Page 130: ...move 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 release valve d Blue air pump e Lever locking 6 Pump air into the system unti...

Page 131: ...ystem instructions a b 6133 a Port side drain location b Starboard side drain location 9 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 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 Reinstall the blue drain plug in the thermostat housing or...

Page 132: ...ATER 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 p...

Page 133: ...ot use the Three Point Manual Drain System instructions a b 6133 a Port side drain location b Starboard side drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump Do not allow engine to start 10 Remove the air pump from t...

Page 134: ... seacock if equipped or remove and plug the water inlet hose 2 Rotate the blue handle counterclockwise until it stops approximately two turns The red on the handle shaft indicates that the drain system is open Do not force the handle as this will create new threads 3 Immediately remove the blue drain plug from the side of the thermostat housing This must be removed within 30 seconds to properly ve...

Page 135: ...Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug if removed The handle is fully seated when no red is visible Do not overtighten the handle as this action will create new threads 8 Open the seacock if equipped or unplug and reconnect the water inlet hose before operating the engine BOAT OUT OF THE WATER 1 Place the boat on a level surface ...

Page 136: ...water is drained 5 Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug The handle is fully seated when no red is visible Do not overtighten handle as this action will create new threads Three Point Manual Drain System BOAT IN THE WATER NOTE Use this procedure if your engine is not equipped with an air actuated single point drain system or i...

Page 137: ...orting the boat or performing other maintenance to ensure that all water is drained 7 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 8 Before launching the boat or starting the engine close the drain system by installing the four blue drain plugs 9 Open the seacock if equipped or unplug and reconnect the wat...

Page 138: ...t should be clean and free of leaks Follow the battery manufacturer s instructions for storage Power Package Recommissioning 1 Ensure that all cooling system hoses are connected properly and hose clamps are tight CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system Always disconnect the negative bat...

Page 139: ...Section 6 Storage 90 899883169 DECEMBER 2007 Page 131 7 Inspect the steering system shift and throttle control for proper operation ...

Page 140: ...Section 6 Storage Notes Page 132 90 899883169 DECEMBER 2007 ...

Page 141: ... Start or Is Hard to Start 135 Engine Runs Rough Misses or Backfires 135 Poor Performance 135 Excessive Engine Temperature 135 Insufficient Engine Temperature 136 Low Engine Oil Pressure 136 Battery Will Not Recharge 136 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 136 Steering Wheel Jerks or Is Difficult to Turn 137 Power Trim Does Not Operate Motor Does Not Oper...

Page 142: ...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 Mercur...

Page 143: ...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 Performance Possible Cause Remedy T...

Page 144: ...r improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling Battery Will Not Recharge Possible Cause Remedy Excessive current draw from battery Turn off non essential accessories Alternator drive belt loose or in poor condition Replace and or adjust Unacceptable battery condition Test battery replace if necessary Loose or d...

Page 145: ...ering fluid See authorized Mercury MerCruiser dealer Power Trim Does Not Operate Motor Does Not Operate Possible Cause Remedy Blown fuse Replace fuse Fuses may be located 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 conn...

Page 146: ...Section 7 Troubleshooting Notes Page 138 90 899883169 DECEMBER 2007 ...

Page 147: ... Assistance 140 Local Repair Service 140 Service Away From Home 140 Stolen Power Package 140 Attention Required after Submersion 140 Replacement Service Parts 140 Parts and Accessories Inquiries 141 Resolving a Problem 141 Mercury Marine Service Offices 141 Ordering Literature 142 United States and Canada 142 Outside The United States and Canada 142 8 ...

Page 148: ...act 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 ...

Page 149: ...ct 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 a...

Page 150: ...ited States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center ...

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