Mercury/Mariner 25 MARATHON Manual Download

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Section 1 - Warranty

90-8M0074347

eng

OCTOBER 2012

Page 13

Global Warranty Application Charts (3.0 TKS)

TKS Sterndrive Series Non‑Emissions Control (Recreational Use)

Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer

All Engines (TKS)

Region

Non

‑

Installation Quality Certified Boat

Manufacturer

Installation Quality Certified Boat

Manufacturer

Americas

(Excluding Brazil)

1 Year

2 Years

Latin America

1 Year

2 Years

Brazil

2 Years

Europe, CIS, South Africa

2 Years

3 Years

Middle East, Africa

1 Year

2 Years

Australia, New Zealand

2 Years

Japan

2 Years

Starting 01/01/2013

2 Years

Starting 01/01/2013

South Pacific

2 Years

Other Asian Regions

1 Year

TKS Sterndrive Series Non‑Emissions Control (Commercial Use)

Commercial Application: Standard Limited Warranty by Region and Boat Manufacturer

All Engines (TKS)

Region

Non

‑

Installation Quality Certified Boat

Manufacturer

Installation Quality Certified Boat

Manufacturer

Americas

(Excluding Brazil)

1 Year

Latin America

1 Year or 500 Hours

Brazil

1 Year or 500 Hours

Europe, CIS, South Africa

1 Year or 500 Hours

Middle East, Africa

1 Year or 500 Hours

Australia, New Zealand

1 Year or 500 Hours

Japan

1 Year or 500 Hours

South Pacific

1 Year or 500 Hours

Other Asian Regions

1 Year or 500 Hours

Summary of Contents for 25 MARATHON

Page 1: ...Code 1322 Country Norway ID Number 0575 Conformity assessment module used for exhaust emissions B C B D B E B F G H Conformity assessment module used for noise emissions A Aa G H Other Community Directives applied Electromagnetic Compatibility Directive 2004 108 EC Description of Engines and Essential Requirements Engine Type Fuel Type Combustion Cycle z or sterndrive with integral exhaust Petrol ...

Page 2: ...tive document method Technical file Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 engine identification B 2 exhaust emission requirements EN ISO 8178 1 1996 B 3 durability B 4 owner s manual ISO 8665 1995 Annex 1 C Noise Emissions C 1 Noise emission levels EN ISO 14509 C 2 Owner s manual Owner s manual This declaration of conformity is issued under the sole respo...

Page 3: ...njoy using this product for many boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation Maintenance and Warranty Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Mercur...

Page 4: ...in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury NOTICE Indicates a situation which if not avoided could result in engine or major component failure IMPORTANT Identifies information essential to the successful completion of the task NOTE Indicates information that helps in the understanding of a particular step or acti...

Page 5: ... Government Use 14 TKS Sterndrive Series Non Emissions Control Recreational Use Corrosion 14 TKS Sterndrive Series Non Emissions Control Commercial Use Corrosion 15 TKS Sterndrive Series Non Emissions Control Government Use Corrosion 15 Global Warranty Application Charts 3 0 MPI ECT 16 MPI Sterndrive Series with Emissions Control Technology Recreational Use 16 MPI Sterndrive Series with Emissions ...

Page 6: ... Cavitation 46 Ventilation 46 Elevation and Climate 46 Propeller Selection 46 Getting Started 3 0 MPI ECT 47 20 Hour Break In Period 47 After Break In Period 47 End of First Season Checkup 47 Getting Started 3 0 TKS 47 20 Hour Break In Period 47 After Break In Period 47 End of First Season Checkup 48 Section 4 Specifications Specifications 3 0 MPI ECT 50 Engine Specifications 3 0 MPI ECT 50 Fuel R...

Page 7: ...Steering System 82 Manual Steering System 83 Throttle Cable 3 0 MPI ECT 84 Throttle Cable 3 0 TKS 84 Shift Cable Typical 85 Sterndrive U joint Shaft Splines and O rings Sterndrive Unit Removed 85 Engine Coupler 85 Driveshaft Extension Models 86 Propellers 86 Propeller Repair 86 Alpha Propeller Removal 86 Alpha Propeller Installation 87 Flushing the Power Package 87 Flushing Attachments 88 Sterndri...

Page 8: ...erate Motor Operates but Sterndrive Unit Does Not Move 114 Section 8 Customer Assistance Information Owner Service Assistance 116 Local Repair Service 116 Service Away From Home 116 Stolen Power Package 116 Attention Required After Submersion 116 Replacement Service Parts 116 Parts and Accessories Inquiries 116 Resolving a Problem 116 Contact Information for Mercury Marine Customer Service 117 Cus...

Page 9: ...to Obtain Warranty Coverage 11 What Mercury Will Do 11 How to Obtain Warranty Coverage Under This Limited Warranty 11 What is Not Covered 11 Expense of Claiming This Limited Warranty 12 Transfer of Warranty Australia and New Zealand Policy 12 Global Warranty Application Charts 3 0 TKS 13 TKS Sterndrive Series Non Emissions Control Recreational Use 13 TKS Sterndrive Series Non Emissions Control Com...

Page 10: ...f the warranty registration card designated as the purchaser s copy must be given to you immediately after the card has been completely filled out by the selling distributor or dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty service on this product your dealer may ask you for the warran...

Page 11: ...icient installation processes Industry standard end of line test procedures Boatbuilders that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one 1 year of Mercury limited factory warranty coverage on all MerCruiser powered boats that are registered on and after the boatbuilder s cert...

Page 12: ...for Commercial Use The warranty period begins on the date the product is first sold to a commercial use retail purchaser or the date on which the product is first put into service whichever occurs first Commercial users of these products receive warranty coverage for either one 1 year from the date of first retail sale or the accumulation of 500 hours of operation whichever occurs first Commercial...

Page 13: ...its recommended RPM range see the Operation Maintenance Warranty manual Operation of the product in a manner inconsistent with the recommended operation and duty cycle section of the Operation Maintenance Warranty manual Neglect Accident Submersion Improper installation proper installation specifications and techniques are set forth in the installation instructions for the product Improper service...

Page 14: ...ine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process 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 15: ...abel or the part it is affixed to before sale If modifications are necessary contact Mercury MerCruiser about the availability of replacement decals before proceeding In addition to the required emissions statement the label lists the engine serial number family applicable emission standard date of manufacture month year and engine displacement a Applicable standard b Engine serial number c Engine...

Page 16: ...ine exempt under 40 CFR 1068 255 from United States EPA exhaust emission regulations for 2010 This marine engine is not for sale in California EMISSION CONTROLINFORMATION XXXXXXXX SERIAL DOM MMM YYYY DISP X XL ECICARBX 0575 43522 THIS ENGINE CONFORMS TO 2010 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES THIS ENGINE IS EXEMPT UNDER 40 CFR 1068 255 FROM EMISSION STANDARDS AND REL...

Page 17: ...back and control system c Cold start enrichment system d Intake valves 2 Air induction system a Controlled hot air intake system b Intake manifold c Air filter d Turbo charger systems e Heat riser valve and assembly 3 Ignition system a Spark plugs b Magneto or electronic ignition system c Spark control system d Ignition coil or control module e Ignition wires 4 Lubrication system a Oil pump and in...

Page 18: ...ight commercial MerCruiser Tow Sport Engines 3 year product warranty 3 year corrosion warranty 1 year 500 hours product warranty light commercial Warranty Period for Recreational Use The warranty period begins on the date the product is first sold to a recreational use retail purchaser or the date on which the product is first put into service whichever occurs first The repair or replacement of pa...

Page 19: ...ercury Marine dealer authorized to service the product A list of dealers and their contact details is available at http www mercurymarine com au home aspx If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine at the address shown above Mercury Marine will then arrange for the inspection and any covered repair This Limited Warranty will not cove...

Page 20: ...the warranty DISCLAIMERS AND LIMITATIONS EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED...

Page 21: ... 01 01 2013 South Pacific 2 Years 2 Years Other Asian Regions 1 Year 1 Year TKS Sterndrive Series Non Emissions Control Commercial Use Commercial Application Standard Limited Warranty by Region and Boat Manufacturer All Engines TKS Region Non Installation Quality Certified Boat Manufacturer Installation Quality Certified Boat Manufacturer Americas Excluding Brazil 1 Year 1 Year Latin America 1 Yea...

Page 22: ... Hours Middle East Africa 1 Year or 500 Hours 1 Year or 500 Hours Australia New Zealand 1 Year or 500 Hours 1 Year or 500 Hours Japan 1 Year or 500 Hours 1 Year or 500 Hours South Pacific 1 Year or 500 Hours 1 Year or 500 Hours Other Asian Regions 1 Year or 500 Hours 1 Year or 500 Hours TKS Sterndrive Series Non Emissions Control Recreational Use Corrosion Recreational Application Standard Limited...

Page 23: ...ustralia New Zealand 1 Year or 500 Hours Japan 1 Year or 500 Hours South Pacific 1 Year or 500 Hours Other Asian Regions 1 Year or 500 Hours TKS Sterndrive Series Non Emissions Control Government Use Corrosion Government Application Standard Limited Corrosion Warranty by Region for All Boat Manufacturers Region All Engines TKS Americas Excluding Brazil 3 Years Latin America 1 Year or 500 Hours Bra...

Page 24: ...ng 01 01 2013 South Pacific 2 Years 2 Years Other Asian Regions 1 Year 1 Year MPI Sterndrive Series with Emissions Control Technology Commercial Use Commercial Application Standard Limited Warranty by Region and Boat Manufacturer All Engines MPI Region Non Installation Quality Certified Boat Manufacturer Installation Quality Certified Boat Manufacturer Americas Excluding Brazil 1 Year 1 Year Latin...

Page 25: ... Hours Middle East Africa 1 Year or 500 Hours 1 Year or 500 Hours Australia New Zealand 1 Year or 500 Hours 1 Year or 500 Hours Japan 1 Year or 500 Hours 1 Year or 500 Hours South Pacific 1 Year or 500 Hours 1 Year or 500 Hours Other Asian Regions 1 Year or 500 Hours 1 Year or 500 Hours MPI Sterndrive Series with Emissions Control Technology Recreational Use Corrosion Recreational Application Stan...

Page 26: ...t Africa 1 Year or 500 Hours Australia New Zealand 1 Year or 500 Hours Japan 1 Year or 500 Hours South Pacific 1 Year or 500 Hours Other Asian Regions 1 Year or 500 Hours 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 environment 2 Better fuel ...

Page 27: ...ngines Three Stars Ultra Low emission 42538 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 emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission engines Four Stars Super Ultra Low emissio...

Page 28: ... 1 Warranty Page 20 90 8M0074347 eng OCTOBER 2012 If in California the dealer must place the hang tag in a visible location in the boat prior to displaying the boat 43291 Hang tag front side Hang tag back side ...

Page 29: ...uges 25 System Link Digital Gauges 25 Remote Controls 26 Panel Mount Features 26 Console Mount Features 26 Power Trim 27 Single Engine Trim Trailer 28 Dual Engine Trim Trailer 28 Electrical System Overload Protection 3 0 MPI ECT 28 Electrical System Overload Protection 3 0 TKS 31 Audio Visual and Engine Warning Systems 3 0 MPI ECT 33 Audio Warning System 33 Caution 34 Severe 34 Testing the Audio W...

Page 30: ...er about service always specify model and serial numbers Alpha Sterndrive Decal Identification The drive serial number is located on the port side of the Alpha sterndrive The drive ratio is located on the starboard side of the Alpha sterndrive Alpha sterndrive a Drive gear ratio decal starboard b Serial number decal port Alpha Transom Serial Number The transom serial number is located on the top o...

Page 31: ...op 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 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 ...

Page 32: ...e boat stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat Always properly connect the operator to the stop switch using a lanyard Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially hazardous situations Occupants could be thrown forward du...

Page 33: ...otential problems on its LCD display For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the system refer to the manual provided with your gauge package System Link Digital Gauges Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft tachometer and speedometer The ow...

Page 34: ...ld only be used to assist in starting the engine Lanyard stop switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to Lanyard Stop Switch for information on the use of this switch Control handle Operation of the shift and throttle are controlled by the movement of the control handle Push the...

Page 35: ...ng launching beaching or shallow water operation See Power Trim for detailed trailer switch operation Power Trim Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and water conditions Also the trailering feature allows the operator to raise and lower the sterndrive unit for trailering beaching launching low speed below 120...

Page 36: ...xternal tie bar raise and lower all drives together as a unit Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only Electrical System Overload Protection 3 0 MPI ECT An electri...

Page 37: ... the engine underneath the engine information plate Fuse locations a O2 sensor fuses b Main power fuel pump ignition and accessory fuses A 90 amp fuse located on the large post of the starter solenoid protects the engine wiring harness if an electrical overload occurs mc74907 1 Engine wiring harness fuse A 15 amp accessory fuse is located on the rear of the engine This fuse protects the accessory ...

Page 38: ... 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 Power trim fuses a 20 amp spade fuse b 110 amp fuse A dedicated power harness supplies continuous power to the PCM to ensure uninterrupted operation This harness is pr...

Page 39: ...ou must find and repair the source of the overload before replacing the fuse or resetting the circuit breaker NOTE In an emergency when the engine must be operated and the cause for the high current draw cannot be located and corrected turn off or disconnect all accessories connected to the engine and instrumentation wiring Reset the circuit breaker If the breaker remains open the electrical overl...

Page 40: ...15 amp accessory fuse is located on the rear of the engine This fuse protects the accessory circuits A 20 amp fuse is located on the top of the engine to protect the TKS circuit 7524 Accessory fuse A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical system Check for an open fuse or open circuit breaker if the ignition key is turned to the start position an...

Page 41: ...p fuse The three button power trim control panel is further protected by a 20 amp in line fuse mc70527 1 Power trim control panel fuse The MerCathode system has a 5 amp fuse which connects to the positive terminal on the controller If the fuse is open the system will not operate resulting in a loss of corrosion protection a MerCathode b Red purple wire c 5 amp fuse Audio Visual and Engine Warning ...

Page 42: ...ounds for two half second intervals every sixty seconds a Horn on or off b Time in seconds Below are some examples of a severe state Transmission fluid temperature is too hot inboard models only Engine oil pressure is too low Engine temperature is too hot Seawater pressure is too low Transmission pressure is low inboard models only Testing the Audio Warning System 1 Turn the ignition switch to the...

Page 43: ...of the problem contact an authorized Mercury MerCruiser dealer As another example Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage Transmission Guardian 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...

Page 44: ...Section 2 Getting to Know Your Power Package Page 36 90 8M0074347 eng OCTOBER 2012 2 Listen for the audio alarm The alarm will sound if the system is functioning correctly ...

Page 45: ...tle Only Operation 43 Trailering the Boat 43 Freezing Temperature Operation 43 Drain Plug and Bilge Pump 43 Protecting People in the Water 43 While You Are Cruising 43 While Boat Is Stationary 43 High Speed and High Performance Operation 43 Passenger Safety in Pontoon Boats and Deck Boats 44 Boats Having an Open Front Deck 44 Boats With Front Mounted Raised Pedestal Fishing Seats 44 Wave and Wake ...

Page 46: ...ing Stop the engine whenever passengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal Law requires that there be a U S Coast Guard approved life jacket personal flotation device correctly sized and readily accessible for every person onboard plus a throwable cushion or ring We strongly adv...

Page 47: ... the boat Seek further assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal combustion engines including the engines that propel boats and the generators that power boat accessories By itself CO is odorless colorless and tasteless but if you can smell or taste eng...

Page 48: ...n a confined space b Mooring close to another boat that has its engine operating 2 Examples of poor ventilation while the boat is moving 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 Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat Operation Chart Operation Chart BEFORE STAR...

Page 49: ...ing operation WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion Before starting the engine operate the bilge blower or vent the engine compartment for at least five minutes 3 Turn ignition key to START Release key when engine starts and allow switch to return to ON position Allow engine to warm up 6 10 minutes on first start of the...

Page 50: ... the remote control handle throttle lever to the 1 4 throttle position b Turn ignition key to START Release key when engine starts and allow switch to return to ON position 5 If engine does not start after step 4 a Move the remote control handle throttle lever to full throttle position then return to 1 4 throttle b Turn ignition key to START Release key when engine starts and allow switch to retur...

Page 51: ... 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 by submersion is not covered by the Mercury MerCruiser Limited Wa...

Page 52: ...can cause serious injury or death Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion Boats With Front Mounted Raised Pedestal Fishing Seats Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed Sit only in seats designated for traveling at faster speeds Any unexpected sudden reduction ...

Page 53: ...derwater obstacles After striking a submerged object stop the engine as soon as possible and inspect the drive system for any broken or loose parts If damage is present or suspected the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair The boat should be checked for hull fractures transom fractures and water leaks Operating with...

Page 54: ...sing propeller diffuser ring A damaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing Drive unit installed too high on transom Elevation and Climate Elevation and climate changes will affect the performance of your power package Loss of performance can be caused by Higher elevations Higher temperatures Low barometric pressures High humidity For yo...

Page 55: ...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 End of First Season Checkup At the end of the first season of operation contact an authorized Mercury MerCruiser dealer to discuss and or perform scheduled maintenance items If you are in an area where the product is operated continuou...

Page 56: ... season of operation contact an authorized Mercury MerCruiser dealer to discuss and or perform scheduled maintenance items If you are in an area where the product is operated continuously year round you should contact your dealer at the end of the first 100 hours of operation or once yearly whichever occurs first ...

Page 57: ...Ratings 50 Using Reformulated Oxygenated Gasoline USA Only 50 Gasoline Containing Alcohol 51 Engine Oil 51 Fluid Specifications 52 Sterndrives 52 Engine 52 Specifications 3 0 TKS 52 Engine Specifications 3 0 TKS 52 Fuel Requirements 53 Fuel Ratings 53 Using Reformulated Oxygenated Gasolines USA Only 53 Gasolines Containing Alcohol 53 Engine Oil 54 Fluid Specifications 54 Sterndrives 54 Engine 54 4...

Page 58: ...ol system Electronic control EC heated oxygen sensor HO2S catalyst Fuel Requirements NOTICE Running out of fuel can damage catalyst components Do not allow the fuel tanks to become empty during operation IMPORTANT Use of improper gasoline can damage your engine Engine damage resulting from the use of improper gasoline is considered misuse of the engine and will not be covered under the limited war...

Page 59: ...ties IMPORTANT When operating a Mercury MerCruiser engine on gasoline containing alcohol do not store the gasoline in the fuel tank for long periods Cars normally consume alcohol blend fuels before they can absorb enough moisture to cause trouble boats often sit idle long enough for phase separation to take place Internal corrosion may take place during storage if alcohol has washed protective oil...

Page 60: ...asures 3 0 MPI Capacity Fluid Type Engine oil with filter 3 8 L 4 US qt Mercury Full Synthetic MerCruiser 20W 40 NMMA FC W rated oil Seawater cooling system 9 L 8 5 US qt Propylene glycol and purified water Closed cooling system 9 L 8 5 US qt Mercury Extended Life Coolant Antifreeze or extended life ethylene glycol 5 100 antifreeze mixed 50 50 with purified water Specifications 3 0 TKS Engine Spec...

Page 61: ...ines are acceptable for use in your Mercury MerCruiser engine Gasolines Containing Alcohol If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you should be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these ...

Page 62: ...ized brands of NMMA FC W rated 4 cycle oils 4 A good grade straight weight detergent automotive oil per the operating chart below NOTE We do not recommend nondetergent oils multi viscosity oils other than as specified non FC W rated synthetic oils low quality oils or oils that contain solid additives Mercury Full Synthetic MerCruiser Engine Oil 20W 40 NMMA FC W rated MerCruiser Quicksilver 25W 40 ...

Page 63: ...Checking 73 Filling 73 Changing 74 Scheduled Maintenance Procedures Specifically for 3 0 MPI ECT 74 Cleaning the Flame Arrestor 74 Cleaning the IAC Muffler 74 Changing the Water Separating Fuel Filter 75 Inspecting the Fuel Pump Sight Tube 76 Drive Belts 76 Checking 76 Replacing Belts on Front Mount Models 77 Power Steering Pump Drive Belt 77 Alternator Belt 77 Replacing Belts on Side Mount Models...

Page 64: ...ct Maintenance WARNING Performing service or maintenance without first disconnecting the battery can cause product damage personal injury or death due to fire explosion electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components WARNING Fuel vapors trapped in the engine compartme...

Page 65: ...loose damaged or missing parts hoses and clamps tighten or replace as necessary Check plug leads and electrical leads for damage Remove and inspect the propeller If badly nicked bent or cracked contact your authorized Mercury MerCruiser dealer Repair nicks and corrosion damage on power package exterior finish Contact your authorized Mercury MerCruiser dealer Sealed Carburetor Mixture Screw IMPORTA...

Page 66: ...or annually whichever occurs first Touch up the paint on the power package Change the engine oil and filter Change the sterndrive gear lube If the condition of the spark plugs spark plug wires and the distributor cap and rotor was satisfactory at the initial inspection as listed in Every 300 hours or 3 years inspect the condition of these components Replace as necessary On models with closed cooli...

Page 67: ...Lubricate the engine coupler Every 5 years Replace the coolant anitifreeze Replace every two years if not using extended life coolant antifreeze Maintenance Schedules 3 0 TKS Routine Maintenance NOTE Only perform maintenance that applies to your particular power package New Bravo sterndrive installations may require as much as 470 mL 16 fl oz of gear lube added to the monitor bottle during the bre...

Page 68: ...upler every 50 hours if operated at idle for prolonged periods of time Every 100 hours of operation or annually whichever occurs first Touch up the paint on the power package Change the engine oil and filter Change the sterndrive gear lube On models with closed cooling check the coolant level and antifreeze concentration for adequate freeze protection Correct if necessary Refer to the Specificatio...

Page 69: ...tion of the closed cooling system Clean inspect and test the pressure cap Inspect the exhaust system components If the package was equipped with water shutters flapper valves verify that they are not missing or worn Check the engine alignment Inspect the U joints the splines the bellows and check the clamps Lubricate the U joint splines and cross bearing if equipped with a grease fitting Inspect t...

Page 70: ...minutes with the boat at rest in the water 2 Remove the dipstick wipe clean and install fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NOTE Install the dipstick with the oil level indication marks facing the rear of the engine 32550 3 Remove the dipstick and observe the oil level 4 If the level is below the add mark remove the oil fill cap and add the specified oil to br...

Page 71: ...ick Recheck the oil level as you fill the system IMPORTANT Do not overfill the engine with oil NOTE Adding 0 95 L 1 qt of engine oil will raise the level from the add mark to the top of the OK range Engine Model Capacity Fluid Type 3 0 MPI 3 8 L 4 US qt Mercury Full Synthetic MerCruiser Oil 20W 40 5 Start and operate the engine for three minutes checking for leaks 6 Stop the engine and allow the o...

Page 72: ... add the specified oil to bring the level up to the OK range on the dipstick Check the oil level as you fill the system 5 IMPORTANT Do not overfill the engine with oil a Oil fill cap Engine Model Capacity Fluid Type 3 0 TKS 3 8 L 4 US qt Mercury Full Synthetic MerCruiser Oil 20W 40 6 Install dipstick into dipstick tube 7 Install the oil fill cap Changing Refer to Maintenance Schedules for the engi...

Page 73: ...rocedure may be performed with the boat at rest in the water or with the boat out of the water 1 Loosen the oil filter to vent the system 2 Remove the dipstick 3 Install the oil pump onto the dipstick tube a Typical oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the crankcase oil pump into an appropriate container and using the handle pump until the crankcase is empty 5 Remove ...

Page 74: ...l level must be at the lower mark when the engine is cold and at the upper mark when the engine is warm a Power steering pump reservoir cap b Warm full mark c Cold full mark 3 Add the specified fluid if required Refer to Filling IMPORTANT If fluid is not visible in pump contact your authorized Mercury MerCruiser dealer Filling 1 Remove the fill cap and dipstick and observe the fluid level 2 Add th...

Page 75: ... Dexron III Automatic Transmission Fluid ATF to bring the fluid level up to the proper level Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steering system 92 858074K01 3 Reinstall the fill cap dipstick Changing Power steering fluid does not require changing unless it becomes contaminated with water or debris Contact your authorized Mercury MerCruiser dealer Eng...

Page 76: ...With the engine at normal operating temperature check that the coolant level in the coolant recovery bottle is between the ADD and FULL marks 6102 6 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling...

Page 77: ...ife Antifreeze Coolant Closed cooling system 92 877770K1 3 Check the antifreeze concentration for adequate freeze protection and correct if necessary Refer to the Specifications section 4 Install the fill cap to the coolant recovery bottle Changing Contact your authorized Mercury MerCruiser dealer Engine Coolant 3 0 TKS Checking CAUTION A sudden loss of pressure can cause hot coolant to boil and d...

Page 78: ...he engine to overheat resulting in engine damage Minimize the possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine is higher than the rear of the engine NOTE Add coolant only when engine is at normal operating temperature 1 Remove the fill cap from the coolant recovery bottle 2 Fill to the FULL line with the specified ...

Page 79: ...lube condition If any water is visible in the bottom of the gear lube monitor if water appears at the fill and drain plug hole or if the gear lube appears discolored these conditions can indicate a water leak in the sterndrive Contact your authorized Mercury MerCruiser dealer Filling IMPORTANT If more than 59 ml 2 fl oz of gear lubricant is required to fill the monitor a seal may be leaking Damage...

Page 80: ...ly a Oil vent screw b Sealing washer IMPORTANT If any water drained from the oil fill drain hole or if the oil appears milky the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer 6 Lower the sterndrive unit so that the propeller shaft is level Fill the sterndrive unit through the oil fill and drain hole with the specified gear lubricant until...

Page 81: ...l fluctuates during operation Check when the engine is cold 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 Remove the fill cap from the reservoir a Fill cap b Reservoir fill neck c MIN and MAX lines 3 Observe the oil level Level must be between the MIN and MAX lines on the res...

Page 82: ...ely 1 Loosen the flame arrestor clamp 2 Remove the flame arrestor a Flame arrestor b Clamp IMPORTANT Do not use an acid based cleaner as it can deteriorate portions of the flame arrestor 3 Clean the flame arrestor with warm soapy water 4 Inspect the flame arrestor for holes cracks or deterioration Replace if necessary 5 Allow the flame arrestor to air dry completely before use 6 Install the flame ...

Page 83: ...ys check for leaks before attempting to start the engine and wipe up any spilled fuel immediately 1 Shut off the engine and allow to cool for 12 hours 2 Close the fuel supply valve if equipped 3 Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray 4 Remove and discard the water separating fuel filter and sealing ring from the mounting bracket 5 Coat the sealing...

Page 84: ...he engine and remove the ignition key before adjusting tension or inspecting belts a Power steering pump pulley b Water circulating pump pulley c Crankshaft pulley d Alternator pulley Checking 1 Check the drive belt for excessive wear fraying glazed surfaces or cracks NOTE Minor transverse cracks across the belt width may be acceptable Longitudinal cracks in the direction of belt length that join ...

Page 85: ...racket assembly and the engine block Install the two screws using the washers removed previously 6 Adjust the crank position sensor so the gap between the sensor and the flywheel meets the following specification Description Specification Crankshaft position sensor air gap 0 040 in 7 Tighten the two spacer block bolts If necessary you can loosen the crankshaft position sensor bolts to move the sen...

Page 86: ...tempting to start the engine and wipe up any spilled fuel immediately 1 Disconnect and remove the crankcase ventilation hose from the fitting on the flame arrestor and valve cover 2 Remove the flame arrestor a Flame arrestor b Flame arrestor nut and washer c Crankcase ventilation hose 3 Clean the flame arrestor with warm water and a mild detergent 4 Inspect the flame arrestor for holes cracks or d...

Page 87: ...ea while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately 1 Allow the engine to cool down NOTE Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal 2 Close the fuel supply valve if equipped 3 Wrap the water separating fue...

Page 88: ... the belts with the engine running may cause serious injury or death Turn off the engine and remove the ignition key before adjusting tension or inspecting belts a Power steering pump pulley b Water circulating pump pulley c Crankshaft pulley d Alternator pulley Checking 1 Inspect the drive belt for proper tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the ...

Page 89: ...e alternator belt 5 Replace the spacer block between the bracket assembly and the engine block Install the two screws using the flat and lockwashers removed previously Torque the two spacer block screws Description Nm lb in lb ft Spacer block screws 28 21 6 Install power steering belt if equipped Adjust tension of both drive belts Description Deflection 6 mm 1 4 inches Replacing Side Mount Models ...

Page 90: ... death from loss of boat control Completely retract the end of the steering cable before applying lubricant NOTE If the steering cable does not have a grease fitting the inner wire of the cable cannot be greased 1 If the steering cable has grease fittings Turn the steering wheel until the steering cable is fully retracted into the cable housing Apply approximately three pumps of grease from a typi...

Page 91: ...e the tie bar pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie bar pivot points 92 883725K01 5 Upon first starting the engine turn the steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway Manual Steering System 1 Inspect the bushings for debris and lubricate th...

Page 92: ...tact surfaces with oil a Pivot points b Guide contact surfaces Throttle Cable 3 0 TKS 1 Lubricate the pivot points and the guide contact surfaces a Pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 32586 a a b a 7169 ...

Page 93: ...and driveshaft splines with grease a U joint O rings 3 b Driveshaft splines Tube Ref No Description Where Used Part No 91 Engine Coupler Spline Grease Driveshaft splines and U joint O rings 8M0071842 2 For propeller shaft lubrication refer to Propellers Engine Coupler 1 Lubricate engine coupler splines through grease fittings on coupler by applying approximately 8 10 pumps of grease from a typical...

Page 94: ... end grease fitting Tube Ref No Description Where Used Part No 42 U Joint and Gimbal Bearing Grease Transom end grease fitting engine end grease fitting driveshaft grease fittings 8M0071842 Propellers Propeller Repair Some damaged propellers can be repaired Contact your authorized Mercury MerCruiser dealer Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death Never ...

Page 95: ...hub 3 Install the Flo Torq II drive hub into the propeller NOTE The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued 4 Align the splines and place the propeller on the propeller shaft 5 Install the drive sleeve and locking tab washer 6 Install and torque the propeller nut Description Nm lb in lb ft Propeller nut minimum 75 55 7 Bend three...

Page 96: ...engine NOTE Closed cooled models are equipped with a heat exchanger on the side of the engine 1 If flushing the cooling system with the boat in the water a Raise the sterndrive to trailer position b Install the appropriate flushing attachment over the water inlet holes in the gear housing c Lower sterndrive to full down in position 2 If flushing the cooling system with the boat out of the water a ...

Page 97: ...using and plug the hose to prevent water from siphoning into the boat This prevents seawater from contaminating the engine flush 13 Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine Battery Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following preca...

Page 98: ...o the Marine Corrosion Protection Guide 90 88181301 Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions However for severe conditions i e when using a stainless steel propeller docking mooring in areas with rapid water flow etc it is recommended that a Quicksilver Anti Corrosion Anode Kit and or a MerCathode System be in...

Page 99: ...Gearcase Anodic Plate Mounted on the underside of the lower gearcase a Anode Ventilation Plate Anode Mounted on the front of the gearcase a Anode Drive Mounted Anodic Block if equipped Mounted to underside of gimbal housing 5640 MerCathode System Electrode assembly replaces Anodic block System should be tested to ensure adequate output The test should be performed where boat is moored using Quicks...

Page 100: ... wash a MerCathode controller b MerCathode assembly Anode Kit if equipped Mounted to the boat transom 5642 Trim Cylinder Anodes Mounted on each trim cylinder a Trim cylinder anodes Bearing Carrier Anode Alpha Located in front of the propeller between the front side of the propeller and the gear housing a Bearing carrier anode b Screws 6206 a b a 7460 a b 7461 ...

Page 101: ...oat transom but you must observe the following IMPORTANT Do NOT paint anodes or MerCathode System reference electrode and anode as this will render them ineffective as galvanic corrosion inhibitors IMPORTANT If anti fouling protection is required for boat hull or boat transom copper or tin base paints if not prohibited by law can be used If using copper or tin based anti fouling paints observe the...

Page 102: ...Section 5 Maintenance Notes Page 94 90 8M0074347 eng OCTOBER 2012 ...

Page 103: ...ngine and Fuel System Preparation 98 Draining the Seawater System 99 Draining the 3 0 MPI ECT Seawater System 99 Single Point Drain System 99 Draining the Seawater Section of Models with Closed Cooling 100 Draining the 3 0 TKS Seawater System 102 Single Point Drain System 102 Draining the Seawater Section of Models With Closed Cooling 103 Clearing Clogged Blue Drain Hoses 105 Draining the Sterndri...

Page 104: ...soline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to Fuel Requirements for additional information 4 Flush the cooling system Refer to the Maintenance section 5 Supply cooling water to engine Refer to the Maintenance section 6 Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel with Mercury Quicksilver Gasoline Stabilizer to...

Page 105: ...lcohol in fuel tanks 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 IMPORTANT In order to run the engine as required in the remainder of the ...

Page 106: ...itting if not equipped with a fuel shut off valve e While operating engine at fast idle 1300 RPM fog internal surfaces of induction system and combustion changers by spraying approximately 227 g 8 oz of Mercury Quicksilver Storage Seal or SAE 20W engine oil into carburetor bores f Spray the remaining 57 g 2 oz of Storage Seal or oil rapidly into carburetor just as the engine begins to stall due to...

Page 107: ...to inform others of the water inlet connection IMPORTANT Do not start or operate the engine at any point in this procedure 1 If draining with the boat in the water close the seacock if equipped or remove and plug the water inlet hose If draining with the boat out of the water place it on a level surface to drain completely 2 Turn on the bilge pump 3 Push the quick connect fitting release buttons a...

Page 108: ...nlet hose disconnected and plugged NOTE As a precautionary measure attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine 1 If draining with the boat in the water close the seacock if equipped or remove and plug the water inlet hose If draining with the boat out of the water pla...

Page 109: ... to the heat exchanger a Power steering cooler b Water inlet to heat exchanger hose 5 Ensure that the speedometer pitot hole gear housing water vent and drain holes and trim tab cavity vent and drain holes are open and unobstructed a Gear housing vent holes b Trim tab cavity drain holes c Gear housing drain hole d Speedometer pitot hole 32651 a b a c d b 7329 ...

Page 110: ...ses can cause serious burns due to hot water Check all hose connections before operating the engine and never disconnect the hoses until the engine has had suffient time to cool NOTICE If the boat is at rest in the water with the engine off an open seacock or water inlet hose could introduce water into the engine s cooling system or the boat Keep the seacock or water inlet hose plugged until ready...

Page 111: ...inspect that the blue drain hoses are connected and not leaking Draining the Seawater Section of Models With Closed Cooling NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures If the boat is in the water keep the s...

Page 112: ...iff piece of wire until the entire system is drained NOTE It may be necessary to lift or bend hoses to allow water to drain completely 4 Remove and lower the hose from the water inlet to the power steering cooler if equipped or the water inlet to the heat exchanger a Power steering cooler if equipped b Water inlet to heat exchanger hose 7186 a a 48856 b ...

Page 113: ...eat exchanger plug 92 34227Q02 8 Prior to launching the boat or starting the engine install the drain plugs reconnect the hoses and tighten all hose clamps securely 9 If the boat was drained in the water open the seacock if equipped or unplug and reconnect the water inlet hose prior to operating the engine Clearing Clogged Blue Drain Hoses CAUTION Disconnecting the blue drain hoses can cause serio...

Page 114: ...the water source if connected to a flush device 8 Attach the female end of the water hose adapter fitting to a water supply 7252 Hose Adapter Fitting 22 863840 9 Attach the clogged blue drain hose to the male end of the water hose adapter fitting 10 Fully open the water supply and allow it to run for 1 minute 11 Turn off the water supply Disconnect the water hose adapter from the blue drain hose a...

Page 115: ...inst freezing and rust after draining fill the cooling system with propylene glycol mixed to the manufacturer s recommendation to protect the engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage Battery Storage Whenever the battery will be stored for an extended period of time be sure the cells are full of water and the battery is fully char...

Page 116: ...eat and suffer damage Provide a sufficient supply of water to the water inlets during operation 5 Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly 6 Carefully inspect the engine for fuel oil fluid water and exhaust leaks 7 Inspect the steering system shift and throttle control for proper operation ...

Page 117: ...lly for 3 0 TKS 111 Starter Motor Will Not Crank Engine or Cranks Slow 111 Engine Will Not Start or Is Hard to Start 111 Engine Runs Rough Misses or Backfires 112 Poor Performance 112 Troubleshooting Charts for 3 0 MPI ECT and 3 0 TKS 112 Excessive Engine Temperature 112 Insufficient Engine Temperature 113 Low Engine Oil Pressure 113 Battery Will Not Recharge 113 Remote Control Is Difficult to Mov...

Page 118: ...y Battery switch turned off Turn the switch on Remote control not in neutral position Position the control lever in neutral Open circuit breaker or fuse Check and reset the main power circuit breaker or replace the fuse Check the 5 amp fuse on the power harness connected to the battery and replace if necessary Loose or dirty electrical connections or damaged wiring Check all electrical connections...

Page 119: ...ires Engine overheating See Excessive Engine Temperature EFI system fault Have EFI system checked by an authorized Mercury MerCruiser dealer Troubleshooting Charts Specifically for 3 0 TKS Starter Motor Will Not Crank Engine or Cranks Slow Possible Cause Remedy Battery switch turned off Turn the switch on Remote control not in the neutral position Position the control lever in neutral Open circuit...

Page 120: ...n 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 Running rich Have authorized Mercury MerCruiser dealer check ...

Page 121: ...te Control Is Difficult to Move Has Excessive Play or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fasteners Lubricate Obstruction in shift or throttle linkages Remove obstruction Loose or missing shift and throttle linkages Check all linkages If any are loose or missing see authorized Mercury MerCruiser dealer immediately Shift or throttle cabl...

Page 122: ...ng 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 Drive unit binding in gimbal ring Check for obstruction ...

Page 123: ... Away From Home 116 Stolen Power Package 116 Attention Required After Submersion 116 Replacement Service Parts 116 Parts and Accessories Inquiries 116 Resolving a Problem 116 Contact Information for Mercury Marine Customer Service 117 Customer Service Literature 117 English Language 117 Other Languages 118 Ordering Literature 118 United States and Canada 118 Outside the United States and Canada 11...

Page 124: ... their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standard automotive engine For example one of the most important special replacement parts is the cylinder head gasket Marine engines cannot use steel type autom...

Page 125: ...Europe Middle East Africa Telephone 32 87 32 32 11 Brunswick Marine Europe Parc Industriel de Petit Rechain B 4800 Verviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan Telephone 072 233 8888 Kisaka Co Ltd 4 130 Kannabecho Sakai shi Sakai ku 5900984 Os...

Page 126: ...rsepower Year United States and Canada For additional literature for your Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54935 1939 Outside the United States and Canada Contact your nearest Mercury Marine authorize...

Page 127: ...Section 9 Checklists 90 8M0074347 eng OCTOBER 2012 Page 119 Section 9 Checklists Table of Contents Predelivery Inspection PDI 120 Customer Delivery Inspection CDI 121 9 ...

Page 128: ...ners tight Battery of proper rating fully charged secured with protective covers in place All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct propeller selected installed and tightened to specifications Throttle shift and steering system fasteners tightened to specifications Test OBDM warning system and MIL light operation EC models only Steering op...

Page 129: ... Resident of California CARB hang tag in boat CARB decal properly affixed to boat hull Customer Delivery Inspection CDI IMPORTANT This checklist is for packages that are not equipped with Axius For engine packages equipped with Axius use the Axius specific checklist which appears in Section 5 of the Axius Operation Manual Perform these tasks after the Predelivery Inspection PDI This inspection mus...

Page 130: ...f SmartCraft accessories if applicable Off season storage and maintenance schedule Engine starting stopping shifting using throttle Boat lights battery switch location fuses breakers Trailer if applicable Registration Complete and submit warranty registration provide the customer with a copy ...

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