MerCruiser Scorpion 350 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 Scorpion 350

Page 1: ...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 it 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: ... to Know Your Power Package Identification 20 Engine Serial Number Decal 20 Lanyard Stop Switch 20 Instrumentation 21 VesselView 21 Digital Gauges 22 Analog Gauges 23 Remote Controls 23 Tow Sport Panel Mount Features 24 Electrical System Overload Protection 25 Audio Warning System 27 Caution 27 Severe 27 OBDM 28 Testing The Audio Warning System 28 Guardian Strategy 28 Section 3 On the Water Safe B...

Page 6: ...he Engine is Warm 56 Checking While Engine is Cold 56 Changing 56 IAC Muffler 56 Changing 56 Battery 56 Multiple EFI Engine Battery Precautions 57 Cleaning The Flame Arrestor 57 Positive Crankcase Ventilation Valve PCV 58 Changing 58 Water Separating Fuel Filter 59 GEN III Models 60 Removal 60 Installation 61 Serpentine Drive Belt 61 Checking 62 Replacing Belt and or Adjusting Tension 62 Flushing ...

Page 7: ...ery Will Not Recharge 86 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 86 Steering Wheel Jerks or Is Difficult to Turn 87 Section 8 Customer Assistance Information Owner Service Assistance 90 Local Repair Service 90 Service Away From Home 90 Stolen Power Package 90 Attention Required after Submersion 90 Replacement Service Parts 90 Parts and Accessories Inquiries 9...

Page 8: ...Page iv 90 899883175 DECEMBER 2007 ...

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

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: ...rands Region Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Vazer Standard Models and and Models with Closed Cooling SeaCore USA and Canada 1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years Latin America 1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years Mex...

Page 16: ...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 17: ...or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 h...

Page 18: ...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 19: ...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 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 25: ... 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 26: ...Section 1 Warranty Notes Page 18 90 899883175 DECEMBER 2007 ...

Page 27: ...Identification 20 Engine Serial Number Decal 20 Lanyard Stop Switch 20 Instrumentation 21 VesselView 21 Digital Gauges 22 Analog Gauges 23 Remote Controls 23 Tow Sport Panel Mount Features 24 Electrical System Overload Protection 25 Audio Warning System 27 Caution 27 Severe 27 OBDM 28 Testing The Audio Warning System 28 Guardian Strategy 28 2 ...

Page 28: ...ated on the engine cover plenum a b 33054 a Engine serial number b Specifications label The engine serial number is also stamped in the engine block Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator s position as in accidental ejection from the operator s position 74608 RUN a b c a Stop switch b Lanyard c Clips to the op...

Page 29: ...ot complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e g if the operator is accidentally ejected WARNING If the operator falls out of the bo...

Page 30: ...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 31: ...peedometer Indicates boat speed b Tachometer Indicates engine RPM c Oil pressure gauge Indicates engine oil pressure d Voltmeter Indicates battery voltage e Coolant temperature gauge Indicates engine operating temperature f Fuel gauge Indicates quantity of fuel in tank g Hour meter Records engine operating time h Bilge blower switch Operates the bilge blower i Ignition switch Allows the operator t...

Page 32: ...lows the engine to shift The shift lock must always be pressed when moving the control handle out of the neutral position Throttle only button optional The throttle only button allows engine throttle advancement without shifting the engine The throttle only button can be pressed only when the remote control is in the neutral position and should only be used to assist in starting or warming up the ...

Page 33: ... 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 A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead Test the circuit breaker by pushing the red button If the circuit breake...

Page 34: ...fuel pump ignition and accessory circuits 33211 Two 10 amp fuses protect the O2 oxygen sensors These are located at the top of the engine 33190 Oxygen sensor fuses 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 a b c 32206 a Fuse cover b 5 amp fuse c Power harness ...

Page 35: ...r power package 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 O...

Page 36: ... 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 37: ...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 38: ...Section 2 Getting to Know Your Power Package Notes Page 30 90 899883175 DECEMBER 2007 ...

Page 39: ...d Bilge Pump 37 Protecting People in the Water 37 While You Are Cruising 37 While Boat Is Stationary 37 High Speed and High Performance Operation 38 Passenger Safety in Pontoon Boats and Deck Boats 38 Boats Having An Open Front Deck 38 Boats With Front Mounted Raised Pedestal Fishing Seats 38 Wave and Wake Jumping 39 Impact with Underwater Hazards 39 Conditions Affecting Operation 40 Weight Distri...

Page 40: ... 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 41: ...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 42: ... 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 DTS Models Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat OPERATION CHART Operation Chart BEFORE STARTING AFTER STARTING WHILE ...

Page 43: ...Cruiser DTS models are equipped with SmartStart The SmartStart feature incorporates push button starting Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts SmartStart completely controls the starting process When the start button is pushed the DTS system signals the engine PCM to start the engine If the engine does not start the star...

Page 44: ...Moving the ignition key switch to the START position again will issue a start request to the control system and the control system will start the engine if appropriate d Activate the lanyard stop switch if equipped The engine will stop but the control system will remain active The control system will not allow the engine to start if the lanyard stop switch is activated Throttle Only Operation NOTE...

Page 45: ...ty Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normally equipped with a drain plug and or a bilge pump It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package Components on your engine will be damaged if submerged Damage caused b...

Page 46: ...rection could throw them over the front of boat Falling over the front of the boat between the two pontoons will position them to be run over Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their f...

Page 47: ...te under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occupants flying forward The boat may also veer sharply to one side Impact with Underwater Hazards Reduce speed and proceed with caution whenever you re driving a boat in shallow water or in areas where the waters are suspected of having underwater obstacles that could b...

Page 48: ... inspect and repair the vessel or power package Conditions Affecting Operation Weight Distribution Passengers and Gear Inside the Boat Shifting weight to rear stern Generally increases speed and engine RPM Causes bow to bounce in choppy water Increases danger of following wave splashing into the boat when coming off plane At extremes can cause the boat to porpoise Shifting weight to front bow Impr...

Page 49: ...th an RPM rev limiter that is set to an upper RPM limit This limit which is slightly above the normal operating range of the engine helps prevent damage from excessive engine RPM Once the RPM returns to the recommended operating RPM range normal engine operation resumes The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller Refer to ...

Page 50: ...emperature Frequently check engine oil level Add oil as needed It is normal for oil consumption to be high during the break in period After Break In Period To help extend the life of your Mercury MerCruiser power package follow these recommendations Ensure that propeller allows the engine to operate at or near the top of the specified WOT RPM range Refer to Specifications and Maintenance Operate t...

Page 51: ...Specifications Table of Contents Fuel Requirements 44 US and Canada 44 Outside the US and Canada 44 Using Reformulated Oxygenated Gasoline USA Only 44 Gasoline Containing Alcohol 44 Engine Oil 45 Engine Specifications 46 Fluid Specifications 46 Engine 46 Transmission 46 4 ...

Page 52: ...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 from the gasoline in the fuel tank IMPORTANT The fuel system components on your Mercury MerCruiser engine will withstand up to 10 alcohol content in the gasoline We do not...

Page 53: ...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 54: ...operating temperature Fluid Specifications Engine IMPORTANT Always use the dipstick to determine the exact quantity of oil or fluid required IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling systems heat exchanger and fluid lines NOTE All capacities are approximate fluid measures Seawater cooling system capacity information is for winterization use only...

Page 55: ...y Engine Oil Drain System 53 Engine Oil Drain Pump 53 Changing the Oil 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 Battery 56 Multiple EFI Engine Battery Precautions 57 Cleaning The Flame Arrestor 57 Positive Crankcase Ventilation Valve PCV 58 Changing 58 Water Separating Fuel Filter 59 GEN III Models ...

Page 56: ...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 57: ...re 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 diff...

Page 58: ... saltwater reduce this interval to every 25 hours or 30 days whichever occurs first Scheduled Maintenance NOTE Only perform maintenance that applies to your particular power package Task Interval Maintenance to Be Performed After the initial 20 hour break in period Change the engine oil and filter Change the engine oil and filter Change the transmission fluid and filter ZF Marine requires changing...

Page 59: ... system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn components Inspect the exhaust system components If the package was equipped with water shutters flapper valves verify that they are not missing or worn Maintenance Log Record all maintenance performed on your power package here Be sure to save all work orders and r...

Page 60: ...the dipstick reading which should indicate a level between the full or OK mark and the ADD mark Reinstall the dipstick into the dipstick tube If the oil level is low refer to Filling Filling IMPORTANT Do not overfill the engine with oil Always use the dipstick to determine the exact quantity of oil or fluid required 1 Remove the oil fill cap 33192 IMPORTANT Add the specified engine oil to bring th...

Page 61: ...e boat must be out of water to perform this procedure 1 Loosen the oil filter to vent the system 2 Allow sufficient time for the oil to drain from the filter down into the engine block 3 Remove the bilge drain plug 4 Pull tether through the bilge drain 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 5 Place the oil drain hose in a sui...

Page 62: ...he oil pump onto the dipstick tube mc70571 1 a c b a Oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the crankcase oil pump onto an appropriate container and usie the handle to pump until the crankcase is empty 5 Remove the pump 6 Install the dipstick ...

Page 63: ...hten 4 Remove the oil fill cap 5 Use the dipstick to determine the amount of engine oil required Replace the dipstick 6 Add the required amount of the recommended oil to bring the level up to the bottom of the OK range on the dipstick 7 With the boat at rest in the water repeat steps 5 and 6 if necessary NOTE Adding 0 95 L 1 US qt of engine oil raises the level from the add mark to the top of the ...

Page 64: ...w 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 dipstick observe the fluid level and mark the cold fluid level 4 Reinstall the dipstick tighten the T handle securely Do not overtighten Changing Co...

Page 65: ...ss 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 position In an emergency another engine s battery can be used to...

Page 66: ...ressed air or allow to air dry completely 5 Inspect the crankcase ventilation hose for cracks or deterioration Replace if necessary 6 Install the flame arrestor and flame arrestor bracket Tighten the flame arrestor clamp to specifications Description Nm lb in lb ft Flame arrestor clamp 5 6 50 7 Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover Positive Cra...

Page 67: ...ch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately CAUTION Failure to release pressure from the fuel system will result in...

Page 68: ...off position 6 Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module Do not remove the filter assembly retaining screws from the filter cap 7 Unseat the filter assembly by grasping the filter assembly handle and pulling upward Do not remove the filter assembly from the Cool Fuel Module at this time 8 Allow any fuel that may be in the filter assembly to...

Page 69: ...r assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness to the engine wiring harness 8 Properly ventilate the engine compartment NOTICE Without sufficient cooling water the engine the water pump and other components will overheat and suffer damage Provide a sufficient supply of water to the water inlets during operation 9 Supply cooling water t...

Page 70: ...on is to be measured on the belt at the location that has the longest distance between two pulleys 1 Loosen the 16 mm 5 8 in locking nut on the adjustment stud 2 Turn the adjustment stud and loosen the belt 3 If a new serpentine drive belt is required remove the old belt and install a new belt onto the pulleys 4 Put a wrench on the adjustment stud 16 mm 5 8 in locking nut 5 Use a 8 mm 5 16 in sock...

Page 71: ...er each outing and before cold weather and extended storage 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 ven...

Page 72: ...tion 5 Immediately start the engine NOTICE Operating the engine out of the water at high speeds creates suction which can collapse the water supply hose and overheat the engine Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply 6 Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM 100 RPM 7 Observe th...

Page 73: ...e seacock before disconnecting the seawater inlet hose Plug the seawater inlet hose immediately after disconnecting it 1 Models with Walter V Drive Transmissions a Close the seacock if equipped and then disconnect the seawater inlet hose from the transmission seawater inlet fitting NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage Close the...

Page 74: ...ter source to provide maximum water supply 4 Place the remote control in the neutral idle speed position 5 Immediately start the engine NOTICE Operating the engine out of the water at high speeds creates suction which can collapse the water supply hose and overheat the engine Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply 6 Depress the throttl...

Page 75: ...ly and remove the flushing attachment 13 Remove the flushing 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 ...

Page 76: ...Section 5 Maintenance Notes Page 68 90 899883175 DECEMBER 2007 ...

Page 77: ...l System Preparation 71 Draining the Seawater System 72 Drain System Identification 72 Air Actuated Single Point Drain System 72 Multi Point Drain MPD System 73 Air Actuated Single Point Drain System 73 Boat in the Water 73 Boat out of the Water 75 Multi Point Drain MPD System 77 Boat out of the Water 77 Boat in the Water 79 Battery Storage 81 Power Package Recommissioning 81 6 ...

Page 78: ...ecommendations Preparing Power Package for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline Follow instructions on the container 2 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Fuel tanks shou...

Page 79: ...g 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 N...

Page 80: ... drain system Refer to Drain System Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturer s instructions be used in the seawater section of the cooling system for freezing temperatures or extended...

Page 81: ...ck 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 Install the air p...

Page 82: ...6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 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 a b 33151 c a Air manifold b Green indicators c Blue ...

Page 83: ...anifold and return it to the mounting bracket 13 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 14 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 15 Open the seacock if equipped or...

Page 84: ... 8293 b d e a c a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side a b 33151 c Scorpion models a Air manifold b Green indicators c Blue drain plug locations ...

Page 85: ... air manifold and return it to the mounting bracket 11 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 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 Multi Point Drain MPD System...

Page 86: ...CEMBER 2007 b Bottom of exhaust manifolds 10226 M110050 932356 72 b a a b 6129 a Cylinder block drain plug b Exhaust manifold drain plug c Fuel cooler to thermostat housing hose a 6144 a Drain plug d Check valve a 6131 a Drain plug if equipped ...

Page 87: ...kup 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 ...

Page 88: ...ion 6 Storage Page 80 90 899883175 DECEMBER 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 89: ...ctions 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 Clean...

Page 90: ...Section 6 Storage Notes Page 82 90 899883175 DECEMBER 2007 ...

Page 91: ...arter Motor Will Not Crank Engine or Cranks Slowly 84 Engine Will Not Start or Is Hard to Start 85 Engine Runs Rough Misses or Backfires 85 Poor Performance 85 Excessive Engine Temperature 85 Insufficient Engine Temperature 86 Low Engine Oil Pressure 86 Battery Will Not Recharge 86 Remote Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds 86 Steering Wheel Jerks or Is Difficul...

Page 92: ...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 93: ...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 94: ...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 95: ...eak Refill system with fluid Drive belt loose or in poor condition Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all parts and fasteners if any are loose or missing see authorized Mercury MerCruiser dealer immediately Contaminated power steering fluid See authorized Mercury MerCruiser dealer ...

Page 96: ...Section 7 Troubleshooting Notes Page 88 90 899883175 DECEMBER 2007 ...

Page 97: ...rvice Assistance 90 Local Repair Service 90 Service Away From Home 90 Stolen Power Package 90 Attention Required after Submersion 90 Replacement Service Parts 90 Parts and Accessories Inquiries 91 Resolving a Problem 91 Mercury Marine Service Offices 91 Ordering Literature 92 United States and Canada 92 Outside The United States and Canada 92 8 ...

Page 98: ...ct an authorized Mercury MerCruiser dealer 2 After recovery immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage Replacement Service Parts WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or e...

Page 99: ...t the owner of the dealership if the sales manager and service manager have been unable to resolve the problem 2 If your question concern or problem cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the Service Office Your name an...

Page 100: ...ted States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center f...

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