MerCruiser Sterndrive 350 MAG MPI User Manual Download Page 89

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Section 5 - Maintenance

90-864195061 NOVEMBER 2006

Page 81

10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve

cover.

11. Install the engine cover.

Positive Crankcase Ventilation Valve (PCV)

CHANGING

IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with

emission regulations.

NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of

the valve cover.

1. Remove the PCV valve from the port valve cover.

mc71925-1

a -

PCV valve

b -

Hose

2. Disconnect the PCV valve from the hose and discard the valve.
3. Install a new PCV valve in the valve cover and reconnect the hose.
4. Ensure the PCV valve is tightly seated in the valve cover.

Water‑Separating Fuel Filter (MPI)

Water‑Separating Fuel Filter

WARNING

Avoid serious injury or death from a gasoline fire or explosion; gasoline is extremely

flammable and highly explosive under certain conditions. When servicing the fuel system

components ensure that the engine is cool, the ignition switch is in the off position, and

that the lanyard stop switch, if equipped, is in the off position. Do not smoke or allow

spark or open flame in the area. Wipe up any spilled fuel immediately. Ensure that no

fuel leaks exist before closing the engine hatch.

WARNING

Avoid serious injury or death caused by fire or explosion. The fuel system is pressurized

during operation. Use care when removing the fuel filter. Fuel could spray on the hot

engine causing fire or explosion. Allow the engine to cool down and relieve fuel system

pressure before attempting to remove the fuel filter.

Summary of Contents for Sterndrive 350 MAG MPI

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

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 2006 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...0 hours of engine run time 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...

Page 4: ... 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 chemicals known to the state of California to cause cancer birth defects or other reproductive harm ...

Page 5: ...ion Star Label 16 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal MPI 20 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Lanyard Stop Switch 22 Instrumentation 23 System View 23 Digital Gauges 24 Analog Gauges 25 Remote Controls Non DTS Models 25 Remote Controls 25 Panel Mount Features 26 Console Mount Features 27 Remote...

Page 6: ...20 Hour Break In Period 55 After Break In Period 56 End of First Season Checkup 56 Section 4 Specifications Fuel Requirements 58 Fuel Ratings 58 Using Reformulated Oxygenated Gasolines USA Only 58 Gasolines Containing Alcohol 58 Engine Oil 59 Engine Specifications MPI 59 Engine Specifications 59 Fluid Specifications MPI 60 Fluid Specifications 60 Engine 60 Alpha Sterndrive 61 Bravo Sterndrives 61 ...

Page 7: ...n 97 Corrosion Protection 98 Corrosion Information 98 Maintaining Ground Circuit Continuity 99 Anodes and MerCathode System Locations 99 Checking the Quicksilver MerCathode System 100 Power Package Exterior Surfaces 101 Boat Bottom Care 101 Anti fouling Paint 101 Sterndrive Surface Care 103 Flushing the Power Package 104 Flushing Attachments 104 Sterndrive Water Pickups 105 Alternative Water Picku...

Page 8: ...ree play Or Makes Unusual Sounds 134 Steering Wheel Turns Hard Or Jerky 134 Power Trim Does Not Operate Motor Does Not Operate 135 Power Trim Does Not Operate Motor Operates But Sterndrive Unit Does Not Move 135 Section 8 Customer Assistance Information Owner Service Assistance 138 Local Repair Service 138 Service Away From Home 138 Stolen Power Package 138 Attention Required After Submersion 138 ...

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

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: ...Non Certified Boat Brand Certified Boat Brand All Boat Brands Region Standard SeaCore Horizon 6 2 Scorpion Standard SeaCore Horizon 6 2 Scorpion Standard and Horizon 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 Mexico 1 year 3 years 1 year 1 year 1 yea...

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

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

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

Page 21: ...er 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 associa...

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

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

Page 24: ...ification 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 envir...

Page 25: ...es 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 emissio...

Page 26: ...Section 1 Warranty Notes Page 18 90 864195061 NOVEMBER 2006 ...

Page 27: ...25 Panel Mount Features 26 Console Mount Features 27 Remote Controls DTS Models 27 Remote Controls 27 Panel Mount Features 28 Console Mount Features Single Engine 29 Slim Binnacle Console Mount Features Single Engine 30 Console Mount Features Dual Engine 31 Synchronizing Dual Engines 32 Dual Helm Station Transfer 32 Synchronizing Dual Helms Prior To Station Transfer 33 Zero Effort Features 33 Powe...

Page 28: ...d serial 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 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 B...

Page 29: ...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 30: ...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 31: ... 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 Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connec...

Page 32: ...peed and fuel to destination information When a problem is detected with the engine or system the System View will alert the operator to the potential problem by displaying the alarm message in the information window located at the bottom of the view screen If the problem can cause immediate engine damage the Engine Guardian System will respond to the problem by limiting engine power Immediately r...

Page 33: ...uge d Voltmeter e Water temperature gauge f Fuel gauge g Hour meter h Bilge blower switch i Ignition switch j Power trim gauge Speedometer Indicates boat speed Tachometer Indicates engine RPM Oil Pressure Gauge Indicates engine oil pressure Voltmeter Indicates battery voltage Water Temperature Gauge Indicates engine operating temperature Fuel Gauge Indicates quantity of fuel in tank Hour meter Rec...

Page 34: ...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 35: ... 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 36: ...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 37: ... 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 38: ... 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 39: ...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 40: ...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 41: ...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 42: ...terndrive unit raised Severe damage to the sterndrive unit may result if unit is raised beyond the gimbal ring support flanges 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 C...

Page 43: ...n engine speed is above 3500 RPM Dual Engine Trim Trailer CAUTION Avoid twisting or binding dual engine tie bars Damage to the tie bar and sterndrives could occur Always raise or lower the sterndrive units evenly 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 ...

Page 44: ...ear Reset the yellow lever after testing or if tripped by pushing the yellow lever back into the housing b a 22529 Yellow lever style circuit breaker typical a Yellow lever shown tripped b Red test button 2 A 90 amp fuse is located on the large post of the starter solenoid This fuse is designed to protect the engine wiring harness if an electrical overload occurs mc74907 1 3 Four fuses are located...

Page 45: ... happens and circuit breaker is not tripped mc70525 1 5 The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump The trim pump may also have an in line circuit protection device in the power trim positive lead near the battery switch or battery connection a b 9208 a 20 amp spade fuse b 110 amp fuse 6 The Quicksilver Three Button Power Trim C...

Page 46: ...il level too low CAUTION Operation of the engine after the audio warning system alarm has sounded could result in damage to the power package When the alarm has sounded do not operate engine except to avoid a hazardous situation If the alarm sounds stop the engine immediately Investigate cause and correct it if possible If the cause cannot be determined contact your authorized Mercury MerCruiser d...

Page 47: ... 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 diagnose problems Warning Horn Signals Most faults will cause the warning horn circuit to activate How the warning horn activates depends on how serious the problem is There are four warning horn states Caution horn signal varies with pro...

Page 48: ...Section 2 Getting to Know Your Power Package Notes Page 40 90 864195061 NOVEMBER 2006 ...

Page 49: ...ng the Engine 48 Stopping the Engine 49 Throttle Only Operation 49 Trailering the Boat 50 Freezing Temperature Operation 50 Drain Plug and Bilge Pump 50 Protecting People In The Water 50 While You Are Cruising 50 While Boat Is Stationary 50 High Speed And High Performance Boat Operation 51 Passenger Safety In Pontoon Boats And Deck Boats 51 Boats Having An Open Front Deck 51 Boats With Front Mount...

Page 50: ...y 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 si...

Page 51: ...r 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 in...

Page 52: ... 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 launching boat ...

Page 53: ...r boat builder Listen for Audio Warning Alarm to sound when the ignition switch is in the ON position Starting and Stopping the Engine NOTE Only perform those functions applicable to your power package STARTING THE ENGINE 1 Check all items listed in the Operation Chart 2 Place the remote control handle in neutral CAUTION Overheating from insufficient cooling water will cause engine and drive syste...

Page 54: ...nd pull repeatedly on the remote control handle until handle returns to the neutral idle position This may take several tries if the power package was operating above idle RPM when the engine stopped 2 After the handle returns to the neutral idle position resume normal starting procedures Throttle Only Operation 1 Refer to Remote Controls section for remote control features 2 Move the control leve...

Page 55: ...r boat from a steep ramp enter the water slowly Do not use the lanyard stop switch to shut off the engine above idle speed When coming off plane if a large following wave may roll over the boat s transom apply a short light burst of throttle to minimize the wave action against the stern of the boat Do not come off plane quickly and then shut off the engine Also avoid shifting into reverse while on...

Page 56: ...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 starting process times out after a few seconds or when the engine reaches 400 RPM Attempting to start the engine with the engine already running will turn the engine off 3 Turn ignition key to RUN position 4 Turn the ignition key switch to the START position t...

Page 57: ...ral mode the DTS Control System will not allow the engine speed to increase above 3500 RPM Zero effort remote controls Zero effort remote controls have seperate throttle control and shift control levers Advancing the throttle control lever beyond the idle position while the shift control lever is in the neutral position will cause engine speed to increase but only up to the maximum neutral engine ...

Page 58: ...on 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 by submersion is not covered by the Mercury MerCruiser Limited Warranty Protecting People In The Water While You Are Cr...

Page 59: ...sharp change of boat direction 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 p...

Page 60: ...oat to launch off of a wave or wake If the bow of your boat pitches down far enough while airborne upon water contact it may penetrate 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 wh...

Page 61: ...is necessary do so at greatly reduced speeds WARNING Avoid serious injury or death from loss of boat control Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts Have the power package thoroughly inspected and any necessary repairs made Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protecti...

Page 62: ...ere it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when the boat is docked This growth must be removed before operation it may clog the water inlets and cause the engine to overheat Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object such as a gear housing or a propeller Cavitation permits the propeller ...

Page 63: ...opeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal...

Page 64: ...sure that propeller allows the engine to operate at or near the top of the specified WOT RPM range Refer to Specifications and Maintenance when at full throttle with a normal boat load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at WOT RPM Change the engine oil and oil filter Refer to Maintenance Change the transmission oil and filter Refer to Mainten...

Page 65: ... Oxygenated Gasolines USA Only 58 Gasolines Containing Alcohol 58 Engine Oil 59 Engine Specifications MPI 59 Engine Specifications 59 Fluid Specifications MPI 60 Fluid Specifications 60 Engine 60 Alpha Sterndrive 61 Bravo Sterndrives 61 Power Assisted Steering and Power Trim Fluids 61 Approved Power Assisted Steering Fluids 61 Approved Power Trim Fluids 61 4 ...

Page 66: ...se 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 system components on your Mercury MerCruiser engine will withst...

Page 67: ...icksilver Synthetic Blend NMMA FC W rated 4 cycle oil 2 MerCruiser Quicksilver 25W40 NMMA FC W rated oil 3 A NMMA FC W rated oil 4 MerCruiser Quicksilver 4 cycle 25W40 non FC W rated oil 5 A good grade straight weight detergent automotive oil per the operating chart below NOTE The use of non detergent oils multi viscosity oils other than as specified non FC W rated synthetic oils low quality oils ...

Page 68: ...und Alternator rating 65 amp Recommended battery rating Non DTS models minimum 750 CCA 950 MCA or 180 Ah Recommended battery rating DTS models minimum 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 MPI Fluid Specifications IMPORTANT All capacities are approximate fluid measures Engine IMPORTANT It may be necessary to adjust oil ...

Page 69: ...ater Alpha Sterndrive NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Alpha One 1892 ml 64 oz High Performance Gear Lubricant Bravo Sterndrives NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Bravo One 2736 ml 92 1 2 oz High Performance Gear Lubricant Bravo Two 3209 ml 108 1 2 oz Bravo Three 2972 ml 100 1 2 oz Power Assisted Steering and Power Trim Flu...

Page 70: ...Section 4 Specifications Notes Page 62 90 864195061 NOVEMBER 2006 ...

Page 71: ... Flame Arrestor 80 Positive Crankcase Ventilation Valve PCV 81 Changing 81 Water Separating Fuel Filter MPI 81 Water Separating Fuel Filter 81 GEN II Models 82 Removal 82 Installation 82 GEN III Models 83 Removal 83 Installation 84 Lubrication 84 Steering System 84 Throttle Cable 86 Shift Cable Typical 87 Sterndrive Unit and Transom Assembly 87 Sterndrive U joint Shaft Splines And O rings Sterndri...

Page 72: ...Section 5 Maintenance Page 64 90 864195061 NOVEMBER 2006 Alternative Water Pickups 107 The SeaCore Power Package Flushing Procedure 108 Models Using The Sterndrive Water Pickup 108 ...

Page 73: ...e all necessary adjustments for maximum efficiency 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 ...

Page 74: ...e 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 the repair proc...

Page 75: ...s and the wiring connections are secure Clean the gauges 1 Scheduled Maintenance NOTE Only perform maintenance which applies to your particular power package AFTER THE INITIAL 20 HOUR BREAK IN PERIOD To help extend the life of your Mercury MerCruiser power package we reccommend the following Change the engine oil and filter Change the sterndrive lube EVERY 100 HOURS OR ANNUALLY WHICHEVER OCCURS FI...

Page 76: ... damaged or corroded fasteners Check the cooling system and the exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn components Clean the seawater section of the closed cooling system Clean inspect and test the pressure cap Inspect the exhaust system components and verify that the flapper valves are not missing...

Page 77: ... at rest in the water 2 Remove the dipstick Wipe clean and reinstall fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NOTE Ensure that dipstick is installed with oil level indication marks facing the rear of the engine flywheel end a 6095 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...

Page 78: ...thetic Blend MerCruiser Engine Oil 25W 40 5 0L 305 cid 4 25 liters 4 5 U S qt 5 7L 350 cid Changing Oil and Filter Refer to the Maintenance schedule for the change interval Engine oil should be changed before placing the boat in storage IMPORTANT Change engine oil when the engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended engine oil refer t...

Page 79: ...n the oil filter to vent the system 2 Remove the dipstick 3 Install the oil pump onto the dipstick tube mc70571 1 a c b a Typical oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the crankcase oil pump onto an appropriate container and using the handle pump until the crankcase is empty 5 Remove the pump 6 Install the dipstick CHANGING FILTER 1 Remove and discard oil filter 6068 a...

Page 80: ...7 Start the engine run the engine for three minutes and check for leaks Stop the engine Allow approximately 5 minutes for the oil to drain into the oil pan The boat must be at rest in the water Power Steering Fluid Checking 1 Stop the engine and center the sterndrive unit 2 Remove the fill cap dipstick and observe the level a Proper fluid level with engine at normal operating temperature should be...

Page 81: ...d cause hot coolant to boil and discharge violently After the engine has cooled turn the cap 1 4 turn to allow any pressure to escape slowly then push down and turn the cap all the way off 1 Remove the cap from the heat exchanger and observe the fluid level a 6101 a Heat exchanger cap 2 The coolant level in the heat exchanger should be at the bottom of the filler neck If the coolant level is low c...

Page 82: ...ys available at water inlet holes during operation CAUTION Air trapped in the closed cooling section of an engine cooling system can cause the engine to overheat resulting in engine damage To minimize the possibility of trapping air when initially filling the closed cooling system position the boat so that the front of the engine is higher than the rear of the engine NOTE Add coolant only when eng...

Page 83: ... oil appears discolored contact your authorized Mercury MerCruiser dealer immediately Both conditions may indicate a water leak somewhere in the sterndrive unit a 6107 a 6105 Seawater cooled models Closed cooled models a Gear lube monitor Filling IMPORTANT If more than 59 ml 2 fl oz of High Performance Gear Lubricant is required to fill the monitor a seal may be leaking Damage to the sterndrive un...

Page 84: ...ar lube monitor 2 Empty the contents into a suitable container 3 Install the gear lube monitor in the bracket 4 Bravo One Models Remove the propeller lower the sterndrive unit to the full down in position remove the oil fill drain screw and sealing washer and drain the oil a mc79506 1 b a Oil fill drain screw b Sealing washer ...

Page 85: ...wer the sterndrive unit so that the propeller shaft is level Fill the sterndrive unit through the oil fill drain hole with specified gear lubricant until an air free stream of lubricant flows from oil vent hole Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Sterndrive unit 92 802854A1 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndriv...

Page 86: ... sterndrive is cool and the engine is shut down Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive unit in full down in position 2 Observe the oil level Level must be between the MIN and MAX lines on the reservoir a b 7876 a Reservoir b MIN and MAX lines 3 Fill as necessary with the specified fluid Tube Ref No D...

Page 87: ...rmally the other engine s alternator will not be required to supply any charging current EFI Electronic Control Module ECM The ECM requires a stable voltage source During multiple engine operation an onboard electrical device may cause a sudden drain of voltage at the engine s battery The voltage may go below the ECM s minimum required voltage Also the alternator on the other engine may now start ...

Page 88: ...ghly explosive under certain conditions Never use gasoline as a cleaning solvent 6110 a b c d e f a Engine cover knob b Engine cover c Nuts flame arrestor d Cover mount bracket e Flame arrestor f Crankcase ventilation hose 4 Clean the flame arrestor with warm water and a mild detergent 5 Inspect the flame arrestor for holes cracks or deterioration Replace if necessary 6 Allow the flame arrestor to...

Page 89: ...n the valve cover Water Separating Fuel Filter MPI Water Separating Fuel Filter WARNING Avoid serious injury or death from a gasoline fire or explosion gasoline is extremely flammable and highly explosive under certain conditions When servicing the fuel system components ensure that the engine is cool the ignition switch is in the off position and that the lanyard stop switch if equipped is in the...

Page 90: ...t INSTALLATION 1 Coat the sealing ring on the new filter with engine oil Tube Ref No Description Where Used Part No 80 SAE Engine Oil 30W Water separating fuel filter sealing ring Obtain Locally 2 Thread filter onto the mounting bracket and tighten securely by hand Do not use a filter wrench 3 Open fuel supply valve if equipped 4 Ensure that engine compartment is properly ventilated CAUTION Overhe...

Page 91: ...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 92: ...ing screw Description Nm lb in lb ft Filter assembly retaining screw 6 53 6 Open fuel supply valve if equipped 7 Reconnect the Cool Fuel Module harness to the engine wiring harness 8 Properly ventilate the engine compartment CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes durin...

Page 93: ...rom 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 802865A1 2 Turn steering wheel until steering cable fully extended Lightly lubricate the exposed part of cable a 6222 a Extended steering cable Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Steering ...

Page 94: ...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 95: ... 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 96: ...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 97: ...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 Avoid Injury Remote Control must be in neutral and ignition key removed from switch before...

Page 98: ...b d Propeller e Drive sleeve f Locking tab washer g Propeller nut 1 Apply a liberal coat of one of the following lubricants to the propeller shaft Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft 92 802865A1 94 Anti Corrosion Grease Propeller shaft 92 802867A1 95 2 4 C Marine Lubricant with Teflon Propeller shaft 92 802859A1 2 Slide thrust hub onto propeller shaf...

Page 99: ...etween propeller blade and anti ventilation plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer drive sleeve propeller and thrust hub off propeller shaft Bravo One Propeller Installation CAUTION Avoid injury and propeller damage or sterndrive damage or both caused by a loose propeller or propellers The propeller ...

Page 100: ...must be in neutral and ignition key removed from switch before removing and or installing propeller WARNING A rotating propeller can cause injury Place a block of wood between the anti ventilation plate and the propeller to protect hands from the propeller blades and to prevent the propeller from rotating when removing or installing the propeller nut 1 Place wood block between propeller blade and ...

Page 101: ... torque the propeller nut Description Nm lb in lb ft Propeller nut1 81 60 6 Bend 3 tabs on the tab washer down into the grooves in spline washer After the first use bend the 3 tabs straight and retorque the propeller nut 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 Avoid Injury ...

Page 102: ...propeller and thrust hub off propeller shaft 6 Turn front propeller shaft nut 70 mm 2 3 4 in counterclockwise to remove nut 7 Slide propeller and thrust hub off propeller shaft NOTE Some damaged propellers can be repaired Contact your authorized Mercury MerCruiser dealer e f a b c d 5304 g h i j a Rear propeller nut b Rear propeller c Rear propeller thrust hub d Front propeller nut e Front propell...

Page 103: ...lide forward thrust hub onto propeller shaft with tapered side toward propeller hub toward end of shaft 2 Apply a liberal coat of one of the following lubricants to the propeller shaft Tube Ref No Description Where Used Part No 34 Special Lubricant 101 Propeller shaft 92 802865A1 94 Anti Corrosion Grease Propeller shaft 92 802867A1 95 2 4 C Marine Lubricant with Teflon Propeller shaft 92 802859A1 ...

Page 104: ...led apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw a b d c f e 5303 a Propeller b Propeller shaft nut c Propeller shaft anode d Propeller shaft anode screw e Flat washer f Star washer Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Propeller shaft threads 92 809819 12 Secure the propeller shaft anode to the propeller shaft using the propeller...

Page 105: ...ollowing Excessive wear Cracks NOTE Minor transverse cracks across the belt width may be acceptable Longitudinal cracks in the direction of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys mc75130 1 Replacing Belt and or...

Page 106: ... NEWTONE N E W T O N E b a 14980 a Kent Moore Tension Gauge b Serpentine belt 7 While holding the adjustment stud at the correct belt tension tighten the 16 mm 5 8 in locking nut a b 6119 a 16 mm 5 8 in locking nut b 8 mm 5 8 in adjusting stud 8 Operate the engine for a short period of time and recheck the belt adjustment Corrosion Protection Corrosion Information Whenever two or more dissimilar m...

Page 107: ... and MerCathode System Locations IMPORTANT Replace sacrificial anodes if eroded 50 percent or more The following sacrificial anodes are installed at different locations on your power package These anodes help protect against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package MerCathode System Electrode assembly replaces the Anode bl...

Page 108: ...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 109: ...m 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 110: ...ransom 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 system or items specified by the boat manufacturer CAUTION Improper boat cleaning procedure...

Page 111: ...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 112: ...hing the Power Package Your boat could come equipped with a combination of any of three different types of water pickups through the hull through the transom and through the sterndrive The flushing procedures for these systems are separated into two categories sterndrive water pickups and alternative water pickups Consult your authorized Mercury MerCruiser dealer for further explanation IMPORTANT ...

Page 113: ... flushing attachment 44357Q 2 and the flush seal kit 881150K 1 and side pickups require the flushing attachment 44357Q 2 5752 5773 Dual Water Pickup Side Pickup NOTE Flushing is needed only for salty brackish mineral laden or polluted water applications Flushing is recommended after each outing for best results CAUTION If flushing the engine with the boat in the water seawater can flow into the en...

Page 114: ...ause personal injury or death To avoid possible injury remove the propeller and ensure that no people or animals are in the area of the drive unit while flushing b Remove propeller c Install the appropriate flushing attachment over the water inlet holes in the gear housing 6 Connect hose between flushing attachment and water source 7 With sterndrive in normal operating position open the water sour...

Page 115: ...a Raise sterndrive to trailer position b Install the appropriate flushing attachment over the water inlet holes in the gear housing c Lower sterndrive unit to full down in position 2 If flushing the cooling system with the boat out of the water a Lower sterndrive to full down in position WARNING Contact with moving drive components and the propeller can cause personal injury or death To avoid poss...

Page 116: ...e flushing attachments 15 If the boat is out of the water Install the water inlet hose to the aft side of the seawater pump Tighten the hose clamp securely 16 If the boat is in the water Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine The SeaCore Power Package Flushing Procedure NOTE Flushing is needed only for salt brac...

Page 117: ...own is not installed a Hose fitting to engine b Seacock c Handle closed position d To water source pickup attachment 3 If equipped with an alternative water pickup and not equipped with a seacock disconnect the water hose from the alternative water pickup and plug both ends excluding the Bravo sterndrive 4 Ensure that the inlet water hose from the sterndrive to the engine is connected 5 Remove the...

Page 118: ...control in neutral idle speed position and start engine CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes during operation 11 Operate the engine at idle speed in neutral gear Do not exceed 1200 RPM 12 Monitor the engine temperature while operating the engine 13 Flush the engine f...

Page 119: ...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 120: ...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 121: ...Drain System 116 Manual Single Point Drain System 116 Three Point Manual Drain System 117 Multi Point Drain MPD System 117 Air Actuated Single Point Drain System 118 Boat in the Water 118 Boat out of the Water 120 Manual Single Point Drain System 122 Boat in the Water 122 Boat out of the Water 123 Three Point Manual Drain System 124 Boat in the Water 124 Boat out of the Water 125 Multi Point Drain...

Page 122: ... if fuel without alcohol is not available Fuel tanks should be drained as low as possible and Mercury Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to Fuel Requirements for additional information 3 Flush the cooling system Refer to the Maintenance section 4 For additional assurance against freezing and rust after draining fill the seawater cooling...

Page 123: ...eatment and Stabilizer Concentrate Tube Ref No Description Where Used Part No 115 Premium Plus 2 cycle TC W3 Outboard Oil Fuel system 92 802824A1 124 Fuel System Treatment Stabilizer Fuel system 802875A1 2 Allow the engine to cool down IMPORTANT Immediately wipe up any fuel spills or sprays 3 Close the fuel shut off valve if equipped Disconnect and plug the fuel inlet fitting if not equipped with ...

Page 124: ...sure complete draining of the cooling system Your power package is equipped with a drain system Refer to Drain System Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure Drain System Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM 6124 a b c d 6125 a b c d Closed Cooled Models Seawate...

Page 125: ... 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 a b 6130 a Water circulating pump hose b Fuel cooler to thermostat housing ...

Page 126: ...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 Air pump e Lever locking 6 Pump air into the system until both green indicators...

Page 127: ...ystem instructions a 6133 b 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 128: ...E WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Place the boat on a lever surface to ensure complete draining of system 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to loc...

Page 129: ...ot use the Three Point Manual Drain System instructions a 6133 b 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 130: ...acock 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 vent ...

Page 131: ...mostat 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 le...

Page 132: ...sure 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 syst...

Page 133: ...ansporting 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 recon...

Page 134: ...nk the engine 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 1 Place the boat on a level surface to ensure complete draining of the system 2 Remove the blue drain plugs from the fo...

Page 135: ...ion 6 Storage 90 864195061 NOVEMBER 2006 Page 127 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 136: ...edure is needed only for salty brackish mineral laden or polluted water applications and for freezing temperatures or extended storage 1 Insert a small wire repeatedly to make sure that vent holes water drain holes and passages are unobstructed and open b a d e f c 6146 Sterndrive Water Drain Holes a Speedometer pitot tube b Trim tab cavity vent hole c Trim tab cavity drain passage d Gear housing ...

Page 137: ...facturer s instructions for storage Power Package Recommissioning 1 Ensure that all cooling system hoses are connected properly and hose clamps are tight CAUTION Reversing the battery cables or connection order will damage the electrical system When installing the battery be sure to connect the positive battery cable to the positive battery terminal first and the negative battery cable to the nega...

Page 138: ...Section 6 Storage Notes Page 130 90 864195061 NOVEMBER 2006 ...

Page 139: ...To Start 132 Engine Runs Rough Misses And Or Backfires 133 Poor Performance 133 Excessive Engine Temperature 133 Insufficient Engine Temperature 134 Low Engine Oil Pressure 134 Battery Will Not Come Up On Charge 134 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 134 Steering Wheel Turns Hard Or Jerky 134 Power Trim Does Not Operate Motor Does Not Operate 135 Pow...

Page 140: ...gine 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 n...

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

Page 142: ...and tighten faulty connections Repair or replace damaged wiring Faulty alternator 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 thrott...

Page 143: ...attery lead near the battery switch or a combination of these Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not Operate Motor Operates But Sterndrive Unit Does Not Move Possible Cause Remedy Trim pump oil level low Fill pump with oil...

Page 144: ...Section 7 Troubleshooting Notes Page 136 90 864195061 NOVEMBER 2006 ...

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

Page 146: ...gned manufactured or installed To minimize risks of fire or explosion electrical ignition and fuel system components on Mercury Marine power products are designed and manufactured to comply with numerous international directives federal regulations voluntary standards and product installation instructions Use or installation of replacement electrical ignition or fuel system components which do not...

Page 147: ...es 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 na...

Page 148: ...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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MerCruiser Sterndrive 350 MAG MPI, User Manual

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