MerCruiser Black Scorpion User Manual Download Page 100

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Section 7 - Troubleshooting

Page 92

90-865253070 JUNE 2007

Diagnosing EFI Problems

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

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

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

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

service technician using a special diagnostic tool.

Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early

indications of problems. The system will respond to a problem by emitting a continuous

beep and/or reducing engine power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The horn will turn off when

throttle speed is within the allowable limit. Consult an authorized Mercury MerCruiser

dealer for assistance.

Starter Motor Will Not Crank Engine, Or Cranks Slow

Possible Cause

Remedy

Battery switch turned off.

Turn the switch on.

Remote control not in neutral position.

Position the control lever in neutral.

Open circuit breaker or blown fuse.

Check and reset the circuit breaker or replace fuse.

Loose or dirty electrical connections or damaged

wiring.

Check all electrical connections and wires (especially

battery cables). Clean and tighten all faulty

connections.

Bad battery or low battery voltage.

Test the battery and charge if necessary; replace if

bad.

Lanyard stop switch activated.

Check the lanyard stop switch.

Engine Will Not Start Or Is Hard To Start

Possible Cause

Remedy

Lanyard stop switch activated.

Check the lanyard stop switch.

Improper starting procedure.

Read the starting procedure.

Insufficient fuel supply.

Fill fuel tank or open valve.

Faulty ignition system component.

Service the ignition system.

Clogged fuel filter.

Replace fuel filter.

Stale or contaminated fuel.

Drain fuel tank. Fill with fresh fuel.

Fuel line or tank vent line kinked or clogged. Replace kinked lines or blow out lines with compressed air to

remove obstruction.

Faulty wire connections.

Check wire connections.

EFI system fault.

Have EFI System checked by an authorized Mercury

MerCruiser dealer.

Engine Runs Rough, Misses And/Or Backfires

Possible Cause

Remedy

Clogged fuel filter.

Replace filter.

Stale or contaminated fuel.

If contaminated, drain tank. Fill with fresh fuel.

Summary of Contents for Black Scorpion

Page 1: ...uipment 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 wh...

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: ...7 Emission Certification Star Label 17 Section 2 Getting to Know Your Power Package Lanyard Stop Switch 20 Instrumentation 21 System View 21 Digital Gauges 22 Analog Gauges 22 Remote Controls 22 Panel Mount Features 23 Console Mount Features 24 Zero Effort Features 24 Electrical System Overload Protection 25 Audio Warning System 26 Testing The Audio Warning System 27 Engine Guardian Strategy 27 Wa...

Page 6: ...Engine Oil Drain System 53 Engine Oil Drain Pump 54 Changing Filter 55 Transmission Fluid 56 Checking While the Engine is Warm 56 Checking While Engine is Cold 56 Changing 56 IAC Muffler 56 Changing 56 Cleaning The Flame Arrestor 56 Positive Crankcase Ventilation Valve PCV 57 Changing 57 Changing Water Separating Fuel Filter 58 In line Fuel Filter 59 Lubrication 61 Throttle Cable 61 Transmission L...

Page 7: ...oor Performance 93 Excessive Engine Temperature 93 Insufficient Engine Temperature 93 Low Engine Oil Pressure 93 Battery Will Not Come Up On Charge 94 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 94 Steering Wheel Turns Hard Or Jerky 94 Section 8 Customer Assistance Information Owner Service Assistance 96 Local Repair Service 96 Service Away From Home 96 Stole...

Page 8: ...Page iv 90 865253070 JUNE 2007 ...

Page 9: ...harts 8 Consumer Application Warranty Chart 9 Commercial Application Warranty Chart 10 Government Application Warranty Chart 11 Mercury Installation Quality Certification Program 11 California Emissions Limited Warranty 12 What Is Covered 12 Duration Of Coverage 13 How To Obtain Warranty Coverage 13 What Mercury Will Do 14 What Is Not Covered 14 Components Of The Emission Control System 14 Disclai...

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

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

Page 12: ...2 Black Scorpion Tow Sport Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations SeaCore Sterndrive Model Coverage The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Standard Model Coverage The L...

Page 13: ...per maintenance What Mercury Marine Will Do Mercury Marine s sole and exclusive obligation under this warranty is limited to at our option repairing a defective part replacing such part or parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury Marine product Mercury Marine reserves the right to improve or modify products from time to time wit...

Page 14: ...wing 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 associated with the removal or replacement of boat partitions or other material in order to gain access to the product are not covered by this warranty No individual or entity inclu...

Page 15: ...Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dea...

Page 16: ...t our option repairing a corroded part replacing such part or parts with new or Mercury Marine certified remanufactured parts or refunding the purchase price of the Mercury product Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured How to Obtain Warranty Coverage The customer must provide Mercury Mari...

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

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

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

Page 20: ...rtification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and fo...

Page 21: ...d 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 f...

Page 22: ...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 a...

Page 23: ... Owner Service Assistance for contact information California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board is 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 str...

Page 24: ...m You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine dealer authorized to service the product as soon as a problem exists The warranty 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 Con...

Page 25: ...ication 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 environ...

Page 26: ... 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 27: ... Lanyard Stop Switch 20 Instrumentation 21 System View 21 Digital Gauges 22 Analog Gauges 22 Remote Controls 22 Panel Mount Features 23 Console Mount Features 24 Zero Effort Features 24 Electrical System Overload Protection 25 Audio Warning System 26 Testing The Audio Warning System 27 Engine Guardian Strategy 27 Warning Horn Signals 27 2 ...

Page 28: ...d 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 close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around the operator s wrist ...

Page 29: ...mation ranging from basic operating data to engine alarm data The SC5000 System View Display is a comprehensive boat information center System View allows the boat operator to receive a wealth of critical operational information displayed clearly and instantly at the helm on the LCD display The System View continuously monitors and reports information ranging from basic operating data to detailed ...

Page 30: ...ion and manufacturers you should have your boat dealer explain the particular gauges and normal readings for your boat L H OIL C H TEMP 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 a b c d e f g h i 17352 a Speedometer b Tachometer c Oil pressure gauge d Voltmeter e Water temperature gauge f Fuel gauge g...

Page 31: ...in starting the engine Lanyard Stop Switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to Lanyard Stop Switch for information on the use of this switch Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward fr...

Page 32: ...to the first detent for forward gear and continue pushing forward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Control Handle Tension Adjustment Screw not visible This screw is used to adjust the effort required to move the remote control handle Refer to instructions provided wi...

Page 33: ...d the cause for the high current draw cannot be located and corrected turn off or disconnect all accessories connected to the engine and instrumentation wiring Reset the circuit breaker If the breaker remains open the electrical overload has not been eliminated Further checks must be made on the electrical system Contact your authorized dealer 1 A circuit breaker protects the engine wiring harness...

Page 34: ... 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 if one of the following occurs Engine oil pressure too low Engine temperature too hot Seawater pressure too low The audio warning system will sound with an intermittent beep...

Page 35: ...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 water flow to the engine If the debris passes through and full water flow is restored engine power levels are restored to normal To avoid a possible recurre...

Page 36: ...Section 2 Getting to Know Your Power Package Notes Page 28 90 865253070 JUNE 2007 ...

Page 37: ...Bilge Pump 34 Protecting People In The Water 35 While You Are Cruising 35 While Boat Is Stationary 35 High Speed And High Performance Boat Operation 35 Passenger Safety In Pontoon Boats And Deck Boats 35 Boats Having An Open Front Deck 35 Boats With Front Mounted Raised Pedestal Fishing Seats 36 Wave And Wake Jumping 36 Impact With Underwater Hazards 37 Conditions Affecting Operation 37 Weight Dis...

Page 38: ...for minor repairs Anchor and extra anchor line Manual bilge pump and extra drain plugs Drinking water Transistor radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board Watch for sign...

Page 39: ...er skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier who was 61 m 200 ft in front of you in 5 seconds Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier i...

Page 40: ... 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 high b Operating the boat with no forward hatches open station wagon effect Basic Boat Operation Launching and Boat Operation IMPORTANT Install bilge drain plug prior to lau...

Page 41: ... 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 minutes 3 Turn ignition key to START Release key when engine starts and allow switch to return to ON position Allow engine to warm up 6 10 minutes on first start of the day The engi...

Page 42: ... 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 the idle neutral position will disengage the throttle only button and allow the engine to shift into gear 5 Throttle only mode is deactivated by moving the control lever to ...

Page 43: ...d High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat For additional information refer to Hi Performance Boat Operation booklet...

Page 44: ...ling at faster speeds Any unexpected sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat mc79557 1 Wave And Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible mc79680 1 Operating recreational boats over waves and wakes is a...

Page 45: ...to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward even out of the boat Impact damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed Boat speed should be kept to a minimum plani...

Page 46: ...f cavitation are Weeds or other debris snagged on the propeller Bent propeller blade Raised burrs or sharp edges on the propeller Ventilation Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed up and a reduction in boat speed Air bubbles strike the propeller blade and cause erosion of the blade surface If allowed to continue ...

Page 47: ...perating in a higher elevation causes a loss of RPM Operating with a dirty boat bottom causes a loss of RPM Operating with increased load additional passengers pulling skiers causes a loss of RPM For better acceleration such as is needed for water skiing use the next lower pitch propeller When not pulling skiers do not operate at full throttle when using the lower pitch propeller Getting Started 2...

Page 48: ...d oil filter Refer to Maintenance Change the transmission oil and filter Refer to Maintenance ZF Transmission models 1 End of First Season Checkup At the end of the first season of operation contact an authorized Mercury MerCruiser dealer to discuss and or perform scheduled maintenance items If you are in an area where the product is operated continuously year round you should contact your dealer ...

Page 49: ...tion 4 Specifications Table of Contents Fuel Requirements 42 Fuel Ratings 42 Using Reformulated Oxygenated Gasolines USA Only 42 Gasolines Containing Alcohol 42 Engine Oil 43 Engine Specifications Scorpion 44 Fluid Specifications 44 Engine 44 Transmission 45 4 ...

Page 50: ... 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 tank The fuel s...

Page 51: ...rotection we strongly recommend the use of the following oils listed in the order of recommendation 1 MerCruiser Quicksilver Synthetic Blend NMMA FC W rated 4 cycle oil 2 MerCruiser Quicksilver 25W40 NMMA FC W rated oil 3 A NMMA FC W rated oil 4 MerCruiser Quicksilver 4 cycle 25W40 non FC W rated oil 5 A good grade straight weight detergent automotive oil per the operating chart below NOTE The use...

Page 52: ...e with SAE J1228 ISO 8665 Crankshaft Power All measurements were obtained using an accurate service tachometer with the engine at normal operating temperatures The oil pressure must be checked with the engine at normal operating temperature The idle speed on EFI models is not adjustable Fluid Specifications Engine IMPORTANT All capacities are approximate fluid measures IMPORTANT It may be necessar...

Page 53: ...n Line3 1 94 Liter 66 oz Dexron lll Automatic Transmission Fluid RV 36 V drive gear box only 4 0 5 Liter 0 75 U S Quart SAE 30 Heavy Duty Motor Exxon Spartan EP 68 Gear Oil APG 80 Gear Oil 3 Refer to manufacturers owners manual for information concerning remote V drive fluid capacities 4 Walters V drive Applications have 2 fluid service points the transmission and the gear box ...

Page 54: ...Section 4 Specifications Notes Page 46 90 865253070 JUNE 2007 ...

Page 55: ... Maintenance Log 51 Engine Oil 51 Checking 52 Filling 52 Changing Oil and Filter 53 Easy Engine Oil Drain System 53 Engine Oil Drain Pump 54 Changing Filter 55 Transmission Fluid 56 Checking While the Engine is Warm 56 Checking While Engine is Cold 56 Changing 56 IAC Muffler 56 Changing 56 Cleaning The Flame Arrestor 56 Positive Crankcase Ventilation Valve PCV 57 Changing 57 Changing Water Separat...

Page 56: ...arize 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 disconnec...

Page 57: ...engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or to request t...

Page 58: ...the life of your Mercury MerCruiser power package the following is recommended 1 Change the engine oil and filter 2 Change the transmission fluid and filter on inboard models NOTE ZF Marine requires the transmission fluid and filter be changed to preserve the warranty EVERY 100 HOURS OR ANNUALLY WHICHEVER OCCURS FIRST Touch up the paint on the power package Change the crankcase oil and filter Chan...

Page 59: ...lapper valves are not missing or worn if equipped EVERY 5 YEARS Replace the coolant every two years if extended life antifreeze coolant is not being used Inboard and sterndrive models only Maintenance Log Record all maintenance performed on your power package here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours Engine Oil NOTICE Discharge of oil coolant or othe...

Page 60: ...t dipstick is installed with oil level indication marks facing the rear of the engine flywheel end a 10718 a Dipstick tube IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dipstick 3 Remove the dipstick and observe the oil level Oil level must be between full or OK range and add Reinstall dipstick into dipstick tube Filling IMPORTANT Do ...

Page 61: ...Engine Oil With Filter 4 25 liters 4 5 U S Quart Mercury Quicksilver Synthetic 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 recomme...

Page 62: ...ter oil has drained completely install the drain plug in the oil drain hose 7 Push the hose through bilge drain 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 appropriat...

Page 63: ...ill cap IMPORTANT Always use dipstick to determine exactly how much oil is required 5 Add recommended 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 liters 1 quart of engine oil will raise the level from the add...

Page 64: ...Engine is Cold NOTE Cold fluid level check To ease checking the fluid level the dipstick can be marked or scribed with a cold level mark 1 Follow the procedure for the warm fluid level check then allow the boat to sit overnight IMPORTANT Be sure to push the dipstick all the way down into the dipstick tube when checking the fluid level 2 Remove the dipstick wipe clean and reinsert 3 Remove the dips...

Page 65: ...ect the crankcase ventilation hose for cracks or deterioration Replace if necessary 7 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 8 Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover 9 Install the engine cover Positive Crankcase Ventilation Valve PC...

Page 66: ... 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 1 Allow the engine to cool down NOTE Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal 2 Close fuel supply valve if equipped 3 Wrap the water separati...

Page 67: ...ury MerCruiser dealer In line 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 to start the engine and wipe up...

Page 68: ... fitting nearest to the connector a b 9132 a Connector b Hex fitting Description Nm lb in lb ft Connectors 19 27 14 20 8 Insert filter into mounting clip 9136 a b c a Connectors b In line filter c Mounting clip 9 Install and torque screw and washer through the mounting clip into the stringer Description Nm lb in lb ft Mounting clip screw 12 2 9 10 Insert the hoses onto the barb fittings and fasten...

Page 69: ...er installation clean spilled fuel and properly ventilate the engine compartment If leaks continue stop engine immediately and contact your authorized Mercury MerCruiser dealer Lubrication Throttle Cable 1 Lubricate the pivot points and the guide contact surfaces 10723 a b b a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE...

Page 70: ...a 10724 In Line Transmission Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Detent ball and shift lever holes 92 883725K01 2 Lubricate the shift cable pivot points a a 5935 a Pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cable pivot points 92 883725K01 ...

Page 71: ... of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys mc75130 1 Replacing Belt and or Adjusting Tension IMPORTANT If a belt is to be reused it should be installed in the same direction of rotation as before NOTE Belt defl...

Page 72: ...b 6119 a 8 mm 1 16 in adjusting stud b 16 mm 5 8 in locking nut 8 Operate the engine for a short period of time and recheck the belt adjustment Flushing The Power Package Tow Sports The Boat Out of the Water IMPORTANT Flushing the power package is most effective when performed with the boat out of the water IMPORTANT Flushing is needed If the engine package has been operated in salty brackish mine...

Page 73: ...ed and then disconnect the seawater inlet hose from the seawater pump inlet fitting b If not equipped with a seacock disconnect the seawater inlet hose from the seawater pump and plug the hose 10839 c Using a suitable adapter connect the flushing hose from the water source to the water inlet of the seawater pump d Proceed to step 3 NOTICE Flushing the engine when it is not operating will result in...

Page 74: ...t off the supply water and remove the flushing attachment 13 Install the water inlet hose to the seawater inlet of the seawater pump or V Drive water inlet 14 Tighten hose clamp securely 15 Attach to the next engine if equipped and repeat procedure The Boat In the Water IMPORTANT Flushing the power package is most effective when performed with the boat out of the water IMPORTANT Flushing is needed...

Page 75: ...ngine damage Close the seacock before disconnecting the seawater inlet hose Plug the seawater inlet hose immediately after disconnecting it b If not equipped with a seacock disconnect the seawater inlet hose from the seawater pump inlet fitting and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat 10839 c Using a suitable adapter connect the flushing ...

Page 76: ... connector from the water inlet 14 Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose to be reconnected prior to operating the engine 15 Repeat the flushing procedure on the next engine if equipped Battery Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precau...

Page 77: ...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 its own battery Do not operate engines with switches in both or all p...

Page 78: ...Section 5 Maintenance Notes Page 70 90 865253070 JUNE 2007 ...

Page 79: ...System 74 Manual Single Point Drain System 75 Three Point Manual Drain System 75 Multi Point Drain MPD System 76 Air Actuated Single Point Drain System 76 Boat in the Water 76 Boat out of the Water 79 Manual Single Point Drain System 81 Boat in the Water 81 Boat out of the Water 82 Three Point Manual Drain System 83 Boat in the Water 83 Boat out of the Water 84 Multi Point Drain MPD System 85 Boat...

Page 80: ...ne glycol manufacturer s recommendations Preparing Power Package for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not...

Page 81: ...ore servicing the power package 1 In a 23 liter 6 U S gal remote fuel tank mix a 19 liter 5 U S gal regular unleaded 87 octain 90 RON gasoline b 1 89 liter 2 U S qts Premium Plus 2 Cycle TC W3 Outboard Oil c 150 ml 5 ounces Fuel System Treatment and Stabilizer or 30 ml 1 ounce Fuel System Treatment and Stabilizer Concentrate Tube Ref No Description Where Used Part No 115 Premium Plus 2 cycle TC W3...

Page 82: ...d 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 IMPORTANT Mercury MerCruiser requires that propylen...

Page 83: ...5 a b c d d Black Scorpion Models a Blue air pump b Air manifold c Green indicators d Blue drain plug locations MANUAL SINGLE POINT DRAIN SYSTEM b a b 6128 a Blue handle b Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM a a 6126 a Blue drain plug ...

Page 84: ...ing a 6131 a Check valve if equipped Air Actuated Single Point Drain System BOAT IN THE WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Close the seacock if equipped or remove and plug the water inlet hose 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 I...

Page 85: ...reen indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 7 Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger This must be removed within 30 seconds to properly vent the cooling system 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug loca...

Page 86: ...o 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 heat exchanger 12 Remove the air pump from the air manifold and return it to the mounting bracket 13 Mercu...

Page 87: ...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 88: ... d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators 21125 a b c d d Black Scorpion Models a Blue air pump b Air manifold c Green indicators d Blue drain plug locations 7 Verify that water is draining from each opening If not use the Three Point Manual Drain System instructions a 6133 b a Port side drain location b...

Page 89: ...lps ensure that all water is drained 12 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 Manual Single Point Drain System BOAT IN THE WATER 1 Close the 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 t...

Page 90: ...stat housing 7 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 will create new threads 8 Open the seacock if equipped or unplug and reconnect the water inlet hose prior to operating the engine BOAT OUT OF THE WATER 1 Place the boat on a leve...

Page 91: ...re that all 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 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...

Page 92: ...sporting the boat or while 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 Prior to 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 reconne...

Page 93: ...ngine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 6 Prior to launching the boat or starting the engine close the drain system by installing the three blue drain plugs Multi Point Drain MPD System BOAT OUT OF THE WATER 1 Place the boat on a level surface to ensure complete draining of the system 2 Remove the blue drain plu...

Page 94: ...ction 6 Storage Page 86 90 865253070 JUNE 2007 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 95: ...p pump Do not allow the engine to start 5 After the cooling system has been drained completely install the drain plugs reconnect the hoses and tighten all hose clamps securely BOAT IN THE WATER 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the blue drain plugs from the following locations If necessary clean out the drain holes using a stiff piece of wire Do so un...

Page 96: ...ction 6 Storage Page 88 90 865253070 JUNE 2007 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 97: ...ructions 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 battery cable first and connect it last 2 Install a fully charged battery Cle...

Page 98: ...Section 6 Storage Notes Page 90 90 865253070 JUNE 2007 ...

Page 99: ...ne Or Cranks Slow 92 Engine Will Not Start Or Is Hard To Start 92 Engine Runs Rough Misses And Or Backfires 92 Poor Performance 93 Excessive Engine Temperature 93 Insufficient Engine Temperature 93 Low Engine Oil Pressure 93 Battery Will Not Come Up On Charge 94 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 94 Steering Wheel Turns Hard Or Jerky 94 7 ...

Page 100: ...l position Position the control lever in neutral Open circuit breaker or blown fuse Check and reset the circuit breaker or replace fuse Loose or dirty electrical connections or damaged wiring Check all electrical connections and wires especially battery cables Clean and tighten all faulty connections Bad battery or low battery voltage Test the battery and charge if necessary replace if bad Lanyard...

Page 101: ...r 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 MerCruiser dealer Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed Open Drive belt loose or in poor condition Replace or adjust belt Seawater pickups or sea strainer obstructed...

Page 102: ...or Test alternator output replace if necessary Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fasteners Lubricate Obstruction in shift or throttle linkages Remove obstruction Loose or missing shift and throttle linkages Check all throttle linkages If any are loose or missing see authori...

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

Page 104: ...ge Replacement Service Parts WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with U S Coast Guard rules to minimize risk of fire or explosion Do not use replacement electrical or fuel system components that do not comply with these rules When servicing the electrical and fuel systems properly install and tighten all components...

Page 105: ... manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the service office Your name...

Page 106: ...d 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 for...

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