Mercury Racing HP525 EFI Bravo Sterndrive Series Operation, Maintenance & Warranty Manual Download Page 18

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WARRANTY INFORMATION

eng

WHAT MERCURY WILL DO: Mercury's sole and exclusive

obligation under this warranty is limited to, at our option,

repairing a corroded part, replacing such part or parts with new

or Mercury Marine‑certified re‑manufactured parts, or refunding

the purchase price of the Mercury product. Mercury reserves the

right to improve or modify products from time to time without

assuming an obligation to modify products previously

manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer

must provide Mercury with a reasonable opportunity to repair,

and reasonable access to the product for warranty service.

Warranty claims shall be made by delivering the product for

inspection to a Mercury dealer authorized to service the product.

If purchaser cannot deliver the product to such a dealer, written

notice must be given to Mercury. We will then arrange for the

inspection and any covered repair. Purchaser in that case shall

pay for all related transportation charges and/or travel time. If the

service provided is not covered by this warranty, purchaser shall

pay for all related labor and material, and any other expenses

associated with that service. Purchaser shall not, unless

requested by Mercury, ship the product or parts of the product

directly to Mercury. Proof of registered ownership must be

presented to the dealer at the time warranty service is requested

in order to obtain coverage.
WHAT IS NOT COVERED: This limited warranty does not cover

electrical system corrosion; corrosion resulting from damage,

corrosion which causes purely cosmetic damage, abuse or

improper service; corrosion to accessories, instruments, steering

systems; corrosion to factory installed jet drive unit; damage due

to marine growth; replacement parts (parts purchased by

customer); products used in a commercial application.

Commercial use is defined as any work or employment related

use of the product, or any use of the product which generates

income, for any part of the warranty period, even if the product is

only occasionally used for such purposes.

Summary of Contents for HP525 EFI Bravo Sterndrive Series

Page 1: ...n with the product for ready reference whenever you are on the water Again thank you for purchasing one of our Mercury Marine products We sincerely hope your boating will be pleasant Mercury Racing N7480 County Road UU Fond du Lac WI 54935 9585 7406 Warranty Message WARNING The operator driver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all ...

Page 2: ...boat operator and technician to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Observe these safety alerts carefully These safety alerts alone can not eliminate the hazards they signal Strict compliance to these special instructions when performing the service and common sense operation are major accident prevention me...

Page 3: ...ion Parts Mercury Propellers Mariner Quicksilver 1 On The Water Alpha Bravo One Bravo Two Bravo Three OptiMax Sport Jet K Planes MerCathode SmartCraft Zero Effort VesselView Zeus Axius Circle M with Waves logo Mercury with Waves logo and SmartCraft logo are all trademarks or registered trademarks of Brunswick Corporation Mercury Product Protection logo is a registered service mark of Brunswick Cor...

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Page 5: ...rcury Racing Sterndrive Products 10 E P A Emission Controls 11 General Information Before Operating Your Boat 14 Boat Horsepower Capacity 14 High Speed and High Performance Boat Operation 15 Paddle Wheel and Water Temperature Sensors 15 Lanyard Stop Switch 16 Trailering the Boat 17 Protecting People in the Water 17 Exhaust Emissions 18 Wave and Wake Jumping 20 Impact With Underwater Hazards 21 Ope...

Page 6: ...tation 36 Warning System 36 Electrical System Overload Protection 39 Remote Controls 43 Remote Controls Console Mounted Zero Effort 46 Power Trim 47 Starting Shifting and Stopping 52 Operation Chart 54 Freezing Temperature Operation 55 Drain Plug and Bilge Pump 56 Launching And Boat Operation Care 56 Conditions Affecting Operation Weight Distribution 57 Bottom Of Boat 57 Cavitation 57 Ventilation ...

Page 7: ... the Power Package 96 Seawater Pump Impeller Inspection 100 Cleaning Seawater Raw Water Section of Oil Cooler 101 Changing Positive Crankcase Ventilation Valve 102 Serpentine Drive Belt 103 Changing Fuel Filters 105 Corrosion and Corrosion Protection 108 Battery 115 Bottom of Boat 116 Inspection and Maintenance 116 Attention Required After Submersion 116 Cold Weather or Extended Storage Power Pack...

Page 8: ...0 Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move 130 Electrical Analog Trim Gauge Malfunction 131 Remote Control Operates Hard Binds Has Excessive Free Play or Makes Unusual Sounds 131 Steering Wheel Turns Hard or Jerky 131 Seawater Pressure Is Below Specification 132 Seawater Pressure Is Above Specification 132 Owner Service Assistance Local Repair Service 133 Service Away fr...

Page 9: ...eng ix Maintenance Log Maintenance Log 137 ...

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Page 11: ...y Marine and any dealer on marine products sold in the United States should a safety recall notification under the Federal Safety Act be required 2 At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration IMPORTANT Your warran...

Page 12: ...ss and engine serial number to Mercury Marine s Warranty Registration Department In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 W Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 1 920 907 6663 Upon processing the transfer of warranty Mercury Marine will send registration verification to the new owner of the product by mail Th...

Page 13: ...equent purchaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine 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 ...

Page 14: ...for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If ...

Page 15: ...ake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far The commercial use of the product defined as any work or employment related use of the product or any income generating...

Page 16: ...nt that they cannot be disclaimed the implied warranties are limited in duration to the life of the express warranty Incidental and consequential damages are excluded from coverage under this warranty Some states and countries do not allow for the disclaimers limitations and exclusions identifies above as a result they may not apply to you This warranty gives you specific legal rights and you may ...

Page 17: ... can be transferred to subsequent non commercial use purchaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified...

Page 18: ...n that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented ...

Page 19: ...etween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Man...

Page 20: ...e not covered Warranty is limited to defects in material or workmanship but only to retail customers that purchase from a dealer authorized by Mercury Marine 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 Should you have any questions concerning warranty coverage contac...

Page 21: ... is considered a marine hazard 9 Water in the starter motor 10 Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commutator because of excess cranking 11 Valve or valve seat grinding required because of wear E P A Emission Controls INTRODUCTION Consistent with the obligations created by 40 CFR Part 1045 Subpart B Mercury Marine provides an emiss...

Page 22: ...ol 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 Turbocharger 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 internal parts b ...

Page 23: ... b Fuel tanks c Purge valve s 9 Miscellaneous items used in above systems a Hoses clamps fittings tubing sealing gaskets or devices and mounting hardware b Pulleys belts and idlers c Vacuum temperature check and time sensitive valves and switches d Electronic controls NOTE The EPA emission related warranty does not cover components whose failure would not increase an engine s emissions on any regu...

Page 24: ...azardous situation which if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation which if not avoided could result in minor or moderate injury IMPORTANT Indicates information or instructions that are necessary for proper operation and or maintenance NOTE Indicates information that helps in the understanding of a step or action Boat Horsepower Capacity WARNING...

Page 25: ...re unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat power package combination For additional information obtain a copy of our High Performance Boat Operation booklet from your dealer distributor or Mercury Marine Paddle Whee...

Page 26: ...ding upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power a Lanyard cord b Lanyard stop switch We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to ope...

Page 27: ... particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller Loss of power and directional control in heavy seas strong current or high winds Loss of control when docking Trailering the Boat The boat can be trailered with the drive unit in up or down position Adequate road clearance is required between road and gear...

Page 28: ...hift into neutral and shut off the engine before allowing people to swim or be in the water near your boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines This includes the outboards sterndrives and inboard engines that propel boats as well as the generators that power various boat accessories Carbon monoxid...

Page 29: ...on a very calm day swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide While Boat Is Stationary a Running the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine running While Boat is Moving a Running the boat with the trim angle of the bo...

Page 30: ...mpletely out of the water certain hazards arise particularly when the boat enters the water 5450 The primary concern is the boat changing direction while in the midst of the jump In such case the landing may cause the boat to veer violently in a new direction Such a sharp change in direction can cause occupants to be thrown out of their seats or out of the boat WARNING Wave or wake jumping can cau...

Page 31: ...and proceed with caution whenever you drive a boat in shallow water areas or in areas where you suspect underwater obstacles may exist which could be struck by the sterndrive or the boat bottom The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed Under these conditions boat speed should be kept to a mi...

Page 32: ...e vessel or power package After striking a submerged object stop the engine as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the sterndrive should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures or water leaks Operating a damaged sterndrive coul...

Page 33: ...ble to clogging when operated in shallow or weedy water Low Water Inlet Gearcase a Low water inlets The design of the dual water inlet gear case reduces the risk of restricting or shutting off the water supply to the engine but caution should still be used when operating in shallow or weedy water CLEARING A DUAL WATER INLET GEAR CASE 1 Idle the boat out to deep water 2 Bring the boat up on plane b...

Page 34: ...tion device of suitable size for each person aboard it is the law and have it readily accessible Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate If in doubt contact your dealer or the boats manufacturer Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly m...

Page 35: ...nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squadron 3 The Red Cross 4 Your state boating law enforcement agency Direct all inquiries to the Boat U S Foundation information number 1 800 336 BOAT 2626 We strongly recommend that all powerboat operators attend one of the...

Page 36: ...are boarding unloading or are near the back stern of the boat Just shifting the power package into neutral is not sufficient Be alert The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passengers load or fishing seats should block the operators view when operating the boat above i...

Page 37: ... loss of the boat IMPORTANT Seek further assistance from local law enforcement for a complete list of rules and regulations Stolen Power Package If your power package is stolen immediately advise the local authorities and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Power Package information is placed into a file at Mercury Marine to aid au...

Page 38: ...al Number ________________________ Propeller Number Pitch _________________________ Sterndrive Serial Number Gear Ratio ________________________ Model Displacement Max WOT RPM Spark Plugs Spark Plug Gap Spark Timing Fuel Octane Engine Oil Engine Coolant see owner s manual HP525 EFI 502 C I D 4800 5200 NGK BPR6ES 0 035 Inch non adjustable 87 R M 2 or 92 RON International Quicksilver 25W40 Dex Cool ...

Page 39: ...RNING Fuel leakage is a fire or explosion hazard which can cause serious injury or death Periodically inspect all fuel system components for leaks softening hardening swelling or corrosion particularly after storage Any sign of leakage or deterioration requires replacement before further engine operation NOTICE The use of improper fuel can cause serious damage to the engine Damage resulting from t...

Page 40: ...ects 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 fuel 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 engine will withstand up to 10 alcohol content ...

Page 41: ...ining alcohol is available or if the presence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required Low Permeation Fuel Hose Requirement Low permeation fuel hose must be installed on all sterndrive engine packages that are manufactured for sale sold or offered for sale in the United States The Environmental Protection Agency EPA requires that any sterndrive e...

Page 42: ...ls other than the ones recommended Low quality oils Do Not Mix Different brands of oils straight weight or multi viscosity Different weights of straight weight or different weights of multi viscosity oils TEMPERATURE OIL VISCOSITY CHART Multi viscosity Oil 20 0 20 40 60 80 100 F C SJ CF 2 CF 4 20 30 10 20 0 30 40 10 Mercury Quicksilver 25W 40 7760 ...

Page 43: ...CA 950 MCA 180 Amp Hrs Electrical System 12 Volt Negative Ground Ignition type PCM Distributorless Wasted Spark Control Spark plug type 810883 NGK BPR6ES Spark plug gap 0 9 mm 0 035 in Fuel system Sequential Port Electronic Fuel Injection Emission Control System Electronic Engine Control EC Length of Bravo Engine Package transom mount to front of engine 869 mm 34 19 in Width 838 mm 33 0 in Height ...

Page 44: ... thermostat is at maximum open at temperature 71 C 160 F Minimum water pressure supplied to the engine at WOT 207 kPa 30 psi Maximum water pressure supplied to the engine at WOT 296 kPa 43 psi Minimum oil pressure at idle Hot 138 kPa 20 psi Minimum oil pressure at WOT Hot 331 kPa 48 psi Maximum oil temperature 121 C 250 F a Front of engine and boat b Firing order 1 8 4 3 6 5 7 2 1 2 3 4 5 6 7 8 69...

Page 45: ...tly check engine oil level Add oil if needed It is normal for oil consumption to be high during break in period After Break In Period To help extend the life of your power package Mercury Marine recommends the following After 5 hr Break in Use a propeller that allows the engine to operate at or near the top of the maximum RPM range See Specifications section when at full throttle with a normal boa...

Page 46: ...e the warning system in any way NOTICE A continuous horn indicates a critical fault Operating the engine during a critical fault can damage components If the warning horn emits a continuous beep do not operate the engine unless avoiding a hazardous situation ENGINE GUARDIAN SYSTEM The Engine Guardian system monitors sensors on the engine for any early indications of problems If a sensor indicates ...

Page 47: ...nal DDT or Computer Diagnostic System CDS is required to extract specific problem codes from the PCM WARNING SYSTEM TABLE The following table is divided into four columns The Possible Cause column lists items that could be initiating the fault The Horn column lists the type of audible alert that will be given if a fault is detected If the boat is equipped with System View the Monitor Display colum...

Page 48: ...No Oil Temperature Sensor Failure 3 Beeps 1 5 Sec Long Yes No Charge Temperature High Steady Horn Yes No Charge Temperature Sensor Failure 3 Beeps 1 5 Sec Long Yes No Crankshaft Position Sensor Rationale Steady Horn Yes Yes MAP Sensor Error 5 Beeps 3 Sec Long Yes No Coil Pack Failure 5 Beeps 3 Sec Long Yes No Fuel Injector Failure 5 Beeps 3 Sec Long Yes No Fuel Pump Failure 5 Beeps 3 Sec Long Yes ...

Page 49: ...ker protects the engine wiring harness and instrumentation power lead Reset by pushing the reset button In an emergency if you cannot locate and correct the cause of the high current draw and you must operate the engine perform the following 1 Turn off or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker 2 If the breaker remains open an ele...

Page 50: ...OPERATION 40 eng 4 The power trim system is protected from overload by a 110 amp fuse and a 20 amp in line fuse on power trim pump a 20 AMP Fuse b 110 AMP fuse 10121 a b ...

Page 51: ... line fuse in the wire which connects to the positive terminal on the controller If fuse is blown the MerCathode system will not operate and a loss of corrosion protection will result a 20 amp in line fuse 6 A 110 amp fuse is located on the starter MERCATHODE A R 7775 a ...

Page 52: ...tions 7 Eight fuses are located at the upper rear of the engine in two fuse holders four fuses in each holder Fuse Holder C24 Fuse Holder C25 1 5 amp YEL PPL to YEL CAN 1 20 amp RED GRN to RED WHT Fuel injectors 2 5 amp RED to RED WHT MPR 2 25 amp RED PNK to RED BLK Fuel pump Alternator 3 2 amp RED to RED ORN Diagnostics 3 20 amp RED YEL to RED GRN Ignition coils 4 15 amp RED PPL to RED Key switch...

Page 53: ...ll controls feature an integral safety switch that allows starting the engine in neutral only If the boat is equipped with a remote control other than that shown consult your dealer for a description and or demonstration of the control ...

Page 54: ...OPERATION 44 eng 1 7 3 5 4 6 2 1 4 2 3 6 4 2 8 6 7820 3 7 ...

Page 55: ...witch section at the front of this manual for operation and safety warning on the use of this switch 6 Control Handle Tension Adjustment Screw This screw can be adjusted to increase or decrease the tension on the control handle This will help prevent Creep of the remote control handle Turn the screw clockwise to increase tension and Counter clockwise to decrease tension Adjust to the tension desir...

Page 56: ...ne is operating at idle If you must shift while the engine is not operating rotate the propeller shaft in the appropriate direction during shifting 2 Control shifting by moving the shorter control lever s This control shifts the unit into gear with full lever movement Move the lever forward to engage the forward gear Move lever backward to engage reverse gear Place the lever in the center position...

Page 57: ...power trim will function on their particular boat The boat owner operator must be aware of how the power trim functions before operating the boat In most cases best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the water a Boat bottom at 3 to 5 angle with water Trimming Drive Unit Up Out Can Generally increase top speed Increase clear...

Page 58: ...ed If in excess lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steering or over steering If any turn is attempted or if a significant wave is encountered Power Trim Sender Conversion Module If Installed Trim limit is determined by the sender Trailer position is achiev...

Page 59: ...port flanges while the boat is underway or at engine speeds above 1200 RPM NOTICE If using external tie bars raising or lowering the drives independently of each other can damage the drive and steering systems If using an external tie bar raise and lower all drives together as a unit IMPORTANT Holding the trailer button depressed after the drive unit reaches the end of its travel will cause an int...

Page 60: ...OPERATION 50 eng 1 2 2 1 2 3 7867 1 ...

Page 61: ...andle to control the trim of both drive units simultaneously Zero Effort Control with Integral Trim Switch Some bravo heavy duty transom assemblies do not have an electrical trim limit switch or trim position sender Therefore the following precautions must be observed WARNING Excessive trim can cause serious injury or death at high speeds and single ram trim systems do not provide a trim out limit...

Page 62: ...ive unit in down position Press bottom in down portion of switch until drive unit reaches desired trim position Starting Shifting and Stopping 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 NEW ENGINES OR ENGINES COMING O...

Page 63: ...as started and is idling smoothly IMPORTANT If the engine has not been operated for more than 24 hours Mercury Marine recommends priming the engine oil system NOTE Engines that have not been started for extended periods or have had fuel filter changes may not stay running on the first few initial attempts to start Do not advance the throttle to keep the engine running Continue to restart the engin...

Page 64: ...ove the control shift lever with a firm quick motion forward to shift to forward gear or backward to shift to reverse After shifting the drive unit advance the throttle to the desired setting STOPPING To shift the drive unit out of gear move the control shift lever to neutral and allow the engine to drop to idle speed If the engine has been operating at high speed for a long period of time allow t...

Page 65: ...trol operation Check steering operation 3 While Underway Observe all gauges to monitor engine condition 4 After Stopping Shift to neutral Turn ignition key OFF Turn battery switch OFF if equipped Close fuel valve Close seacock Flush cooling system if in saltwater area Freezing Temperature Operation IMPORTANT If boat is operated in freezing temperatures ensure that closed coolant is rated for the t...

Page 66: ...f submerged Damage caused by submersion is not covered by the Mercury Racing Limited Warranty Launching And Boat Operation Care NOTICE Some boating maneuvers can introduce water into the engine through the exhaust system causing severe engine damage Be careful when unloading a boat from its trailer slowing down rapidly backing up rapidly and stopping suddenly In any of the situations described in ...

Page 67: ...e of barnacles and marine growth Free of distortion and nearly flat where it contacts the water Straight and smooth both fore and aft Marine vegetation may accumulate when the boat is docked clogging water inlets and causing the engine to overheat This growth must be removed before operation Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object s...

Page 68: ...d in Specifications IMPORTANT All Mercury Racing engines have an RPM rev limiter that is set to an upper or limited RPM This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM Once the RPM drops into the recommended operating RPM range normal engine operation resumes Select a propeller that allows the engine to operate ...

Page 69: ...st pressure on supercharged engines Horsepower and torque throughout the RPM range Peak RPM Cranking compression EXAMPLE An engine running at an elevation of 2 438 m 8 000 ft will have over a 30 power loss while engine power on a hot and humid day can be reduced by as much as 14 These losses apply to both normally aspirated and supercharged engines Compensating for power robbing conditions Switch ...

Page 70: ...EALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation These include Completing a Warranty Registration Card and mailing it to the factory immediately upon sale of the new product Properly equipping the boat Making certain that the Mercury Marine power package and other equipment are in proper operating condition prior to delive...

Page 71: ...e parts as specifications are quite different from those of the standard automotive engine For example one of the most important and probably the least suspected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket uses special materials to resist corrosive action Since marine engin...

Page 72: ...nderstand the procedures Special tools and equipment may be required to perform some repairs Do not attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you for the repair If you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must re assemble th...

Page 73: ...manual Mercury Marine recommends purchasing a Mercury Marine Service Manual Servicing High Horsepower Engines All high performance engines require frequent maintenance and inspection schedules due to the extreme duty cycles and related stress these products endure Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastrophic en...

Page 74: ...ndition and check tension Cooling system hoses and clamps Inspect for damage and deterioration Check clamps for tightness Electrical system Check for loose or damaged wiring Continuity circuit Check components for loose connections broken or frayed wires Throttle cable and linkage Lubricate and inspect for loose damaged or missing parts Engine exhaust system Inspect for damage deterioration and re...

Page 75: ...ommissioning after storage Fuel filters Replace Every 100 hours of operation or once a season and whenever insufficient seawater flow is suspected if the operating temperature exceeds normal Seawater pick up pump Disassemble and inspect Every 150 hours of operation Replace positive crankcase ventilation PCV valve Every 200 hours of operation Ignition system Clean and inspect condition Adjust or re...

Page 76: ...Lubricate and inspect for loose damaged or missing parts Engine coupler and universal joint shaft splines and O rings Lubricate Sterndrive unit Oil change Sterndrive unit universal joint cross bearings Inspect and lubricate Gimbal ring clamping screws Re torque to 67 74 Nm 50 55 lb ft Gimbal bearing Lubricate Transom gimbal housing assembly swivel shaft and gimbal bearing Lubricate Engine drivesha...

Page 77: ...odels Checking Fluid Levels CRANKCASE OIL The engine crankcase oil must be checked at the intervals specified in the Maintenance Chart NOTE Oil consumption is greatly dependant on engine speed consumption is highest at wide open throttle and decreases substantially as engine speed is reduced It is common for big block high performance engines to use up to one quart of oil in one to five hours if t...

Page 78: ... Do not overfill crankcase oil 3 If the oil level is below the ADD mark remove the oil filler cap port or starboard Add the specified oil to bring the level up to but not over the OK range mark on the dipstick a Filler cap Tube Ref No Description Where Used Part No 25W50 Synthetic Blend 4 Stroke Racing Engine Oil Crankcase 8M0078013 ADD FULL a a 19674 a 7899 79 ...

Page 79: ...MPORTANT If fluid is not visible in the reservoir contact your authorized Mercury MerCruiser dealer 1 Remove the fill cap dipstick and observe the level The oil level must be at the lower mark when the engine is cold and at the upper mark when the engine is warm a Cap Dipstick b Power steering pump reservoir Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steerin...

Page 80: ...pecified intervals Refer to Maintenance Chart for specific requirements Use only High Performance Gear Lube in pump 1 Remove fill screw top and check oil level 2 Oil must come up to fill hole If oil level is low contact your authorized Mercury MerCruiser dealer for appropriate service Do not operate engine if this oil level is low a Fill screw a 7901 ...

Page 81: ...harge violently resulting in serious injury from burns Allow the engine to cool down before removing the coolant pressure cap IMPORTANT Check engine coolant before starting engine 1 Check coolant level in coolant reservoir Coolant should be at the full line marked on the reservoir with the engine cold Add specified coolant as required a Reservoir 2 If coolant is low inspect coolant recovery system...

Page 82: ...ury MerCruiser dealer immediately both conditions indicate a water leak somewhere in the drive unit IMPORTANT See the where used information in Lubricants Sealants Adhesives before adding fluid If more than 59ml 2 fl oz of lubricant is required to fill monitor a seal may be leaking Damage to drive unit may occur due to lack of lubrication Contact your authorized Mercury MerCruiser dealer for servi...

Page 83: ...ut not over bottom of filler neck NOTE Ensure that the cap plug has been removed and discarded from filler neck a Cap plug Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump reservoir 92 858074K01 3 Add power trim and steering fluid if required to bring the level to bottom of filler neck 4 Re install fill cap NOTE Fill cap is vented frequently ensure that ...

Page 84: ...ature remove the dipstick 2 Install the crankcase oil pump onto the dipstick tube 3 Insert the hose end of crankcase oil pump into an appropriate container and using the pump handle pump until the crankcase is empty a Crankcase oil pump b Crankcase oil pump hose 4 Remove the crankcase oil pump 5 Place a container below the oil filter NOTE To allow the oil to drain from the filter loosen the filter...

Page 85: ...uired a Crankcase oil filler cap Tube Ref No Description Where Used Part No 25W50 Synthetic Blend 4 Stroke Racing Engine Oil Crankcase 8M0078013 152 25W 50 Verado FourStroke Outboard Oil Crankcase 92 858084K01 79 MerCruiser 4 cycle 25W40 Engine Oil Engine crankcase 92 858048K01 CRANKCASE OIL AND FILTER BOAT OUT OF THE WATER WARNING Performing tests with the engine running may cause the propeller t...

Page 86: ...ater intake holes and attach a water hose Use only recommended motor oil see Specifications 1 Provide cooling water to the engine see Flushing the Cooling System in this section 2 Place the remote control in the neutral position and start the engine Operate the engine at idle speed in neutral until the engine reaches normal operating temperature 3 Stop the engine shut off the water and remove the ...

Page 87: ...ptor and discard old oil filter and the old sealing ring 10 Coat the sealing ring on new the filter with motor oil Install the new sealing ring and filter Tighten the filter securely Do not overtighten 11 Using two wrenches connect the oil drain hose plug to the oil drain hose and place back into the boat 12 Tighten the bilge drain plug 13 Remove oil filler cap port or starboard Add oil to bring t...

Page 88: ...48K01 DRIVE UNIT OIL BRAVO ONE XR MODELS IMPORTANT Use only High Performance Gear Lube in the drive unit 1 Remove the propeller place the drive unit in full down position remove the oil fill drain screw and sealing washer and drain the oil a Oil fill drain plug 2 Remove the oil vent screw and sealing washer Allow the oil to drain completely a 7986 ...

Page 89: ...d should be checked immediately by your authorized Mercury MerCruiser dealer a Sealing washer b Oil vent screw 3 Adjust the drive unit so the propeller shaft is level 4 Fill the drive unit through the oil fill drain hole until an air free stream of lubricant flows from the oil vent hole a Oil fill drain screw a b 7987 a 87 7988 ...

Page 90: ...e oil starts to run out the the oil vent hole reinstall the drive oil vent screw and seal Tighten securely a Gear lube monitor bottle Tube Ref No Description Where Used Part No SAE 85W90 Mercury Racing Gear Oil Gear lube monitor bottle 8M0078015 8 Continue adding gear lube until the oil level is at the top line marked OPERATING RANGE on the bottle 9 Lubricate the O ring on the neck to ensure ease ...

Page 91: ...e install the propeller and torque the nut to specifications 94 7990 Tube Ref No Description Where Used Part No Extreme Grease 8M0071842 Description Nm lb in lb ft Propeller nut 75 55 IMPORTANT Oil level in the gear lube monitor will rise and fall during drive operation Always check the oil level when the drive is cool and the engine is shut down ...

Page 92: ...e bracket a Gear lube monitor bottle Tube Ref No Description Where Used Part No SAE 85W90 Mercury Racing Gear Oil Gear lube monitor bottle 8M0078015 2 Empty the contents into suitable container 3 Install the monitor in the bracket 4 Place the drive unit in the full trim out position 87 7333 a ...

Page 93: ...screw and sealing washer Allow the oil to drain completely IMPORTANT If any water drains from the oil fill drain hole or if the oil appears milky the drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer a Sealing washer b Oil vent screw 7 Lower drive unit so propeller shaft is level b a mc79507 1 a b 7991 ...

Page 94: ...he gear lube monitor circuit until oil appears in the monitor 11 Fill the monitor to the top line of the OPERATING RANGE 12 Lubricate O ring on the neck Install the filler cap being careful to not overtighten 13 Remove the pump from the oil fill drain hole 14 Quickly install the sealing washer and the oil fill drain screw Tighten securely 15 Re check the oil level after first use IMPORTANT Oil lev...

Page 95: ...9 7997 Tube Ref No Description Where Used Part No 79 MerCruiser 4 cycle 25W40 Engine Oil Pivot points 92 858048K01 THROTTLE CABLE 1 Lubricate pivot points with 4 Cycle 25W40 motor oil 79 8008 Tube Ref No Description Where Used Part No 79 MerCruiser 4 cycle 25W40 Engine Oil Pivot points 92 858048K01 ...

Page 96: ...thorized Mercury MerCruiser dealer for this service NOTE The engine coupling and shaft splines are greased with engine coupler spline grease Universal joints are greased with 2 4 C with PTFE lubricant Contact your authorized Mercury MerCruiser dealer for this service 1 Lubricate gimbal bearing with 2 4 C with PTFE lubricant a Gimbal bearing grease fitting Tube Ref No Description Where Used Part No...

Page 97: ...ith engine coupler spline grease 91 8014 Tube Ref No Description Where Used Part No 91 Engine Coupler Spline Grease Engine coupler and shaft splines 8M0071842 DRIVE SHAFT EXTENSION MODELS 1 Lubricate drive shaft grease fittings at the transom end with 2 4 C with PTFE lubricant 95 8015 ...

Page 98: ...ler place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate NOTICE Operating the engine with a loose propeller can damage the propeller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the ...

Page 99: ... the order shown a Propshaft b Prop hub assembly c Propeller assembly d Washer e Belleville washer f Washer g Locknut Tube Ref No Description Where Used Part No 94 Anti Corrosion Grease Exposed surfaces of propeller shaft Obtain Locally 3 After first use Re tighten propeller nut Description Nm lb in lb ft Propeller nut 75 55 b c d e f g a 8020 94 ...

Page 100: ... 90 eng Removal 1 Place a wood block between the propeller blade and the anti ventilation plate to prevent rotation a Wood block b Propeller nut 2 Turn the propeller shaft nut counter clockwise to remove a b 7448 ...

Page 101: ...horized Mercury Marine dealer BRAVO III XR MODEL PROPELLERS Removal WARNING Rotating propellers can cause serious injury or death Never operate the boat out of the water with a propeller installed Before installing or removing a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the ...

Page 102: ...ode a Propeller b Propeller shaft nut c Propeller shaft anode d Propeller shaft anode screw e Flat washer f Star washer 4 Turn the aft propeller shaft nut 37 mm 1 7 16 in counter clockwise to remove 5 Slide the propeller and thrust hub off the propeller shaft 6 Turn the front propeller shaft nut 70 mm 2 3 4 in counter clockwise to remove 7 Slide the propeller and thrust hub off the propeller shaft...

Page 103: ...Front propeller f Front propeller thrust hub g Propeller shaft anode screw h Flat washer i Star washer j Propeller shaft anode Installation NOTICE Operating the engine with a loose propeller can damage the propeller the drive or drive components Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval e f a b c d 5304 g...

Page 104: ...o XR drive Doing so voids the product warranty a Rear propeller nut b Rear propeller c Rear propeller thrust hub d Front propeller nut e Front propeller f Front propeller thrust hub g Propeller shaft anode screw h Flat washer i Star washer j Propeller shaft anode 1 Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub 2 Apply a liberal coat of one of ...

Page 105: ...eller nut to the specified torque Description Nm lb in lb ft Forward propeller nut 136 100 5 Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub toward the end of the shaft 6 Align splines and place the propeller on the propeller shaft 7 Install and tighten the propeller nut to the specified torque Description Nm lb in lb ft Aft propeller nut 81 60 8 In...

Page 106: ...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 shaft anode screw and washers Tighten the screw to the specified torque Description Nm lb in lb ft Propeller shaft anode screw 38 mm 0 3125 18 x 1 5 in long 27 20 Flushing the Power Package The following procedure explains flushi...

Page 107: ...the engine Dual Water Pick up Flush Gearcase Seal Kit 91 881150K 1 9194 Blocks off the front water inlet holes on the dual water inlet gearcases Flushing Kit 91 849996T 1 9195 Use for flushing gearcases with low water inlets Flushing Attachment 91 843122A01 14565 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the engine ...

Page 108: ...ckups Dual water pickups require the flushing attachment 91 44357Q 2 and the flush seal kit 91 881150K 1 The High Performance low water pickup drive requires the flushing attachment 91 849996T 1 while the SportMaster low water pickup drive requires flushing attachment 91 843122A01 Side pickups require the flushing attachment 91 44357Q 2 5752 Dual water pickup ...

Page 109: ...e seawater to flow into the engine resulting in engine damage Close the seacock before flushing the engine Keep the seacock closed until starting the engine 1 Drain the seawater section of the cooling system 2 If flushing the cooling system with the boat in the water a Raise sterndrive unit to trailer position b Install the appropriate flushing attachment over the water inlet holes in the gear hou...

Page 110: ...attachment and the water source 5 With the sterndrive unit in normal operating position partially open the water source about 1 2 maximum 6 Place the remote control in the neutral idle speed position and start the engine NOTICE Operating the engine out of the water at high speeds creates suction which can collapse the water supply hose and overheat the engine Do not operate the engine above 1400 R...

Page 111: ...r into the boat causing damage or sinking the boat Always close the water supply from the seawater pump water inlet or seacock when performing service or maintenance on the cooling system The seawater section of oil cooler should be cleaned at least once a year or whenever decreased cooling efficiency is noticed ENGINE OIL COOLER NOTE The engine oil cooler is located on the top rear portion of the...

Page 112: ... or clean cooler IMPORTANT If the oil hoses need to be removed from the cooler be prepared to cap or plug them to avoid draining the power steering reservoir a Hose clamps 2 2 Re install cooler and tighten hose clamps securely 3 Check power steering fluid level 4 Start engine and inspect cooling system for leaks Changing Positive Crankcase Ventilation Valve This engine is equipped with a positive ...

Page 113: ...h Turn off the engine and remove the ignition key before adjusting tension or inspecting belts IMPORTANT Drive belt must be routed as shown or damage may result 1 Loosen the 5 8 in locking nut on adjustment stud Leave the wrench on the adjustment nut 2 Install the belt tension gauge onto the belt 3 Use a 5 16 in socket and tighten adjusting stud until the belt tension conforms to the correct setti...

Page 114: ...eck tension a Crankshaft pulley b Circulating pump pulley c Alternator pulley d Power steering pulley Non power steering models have an idler pulley e Idler pump f Seawater pump pulley g Belt tension gauge Description N lb New Belt 489 110 Used Belt 400 90 c b a g f e d 6163 ...

Page 115: ...faces a Fraying b Transverse cracks c Longitudinal cracks Changing Fuel Filters WATER SEPARATING FUEL FILTER WARNING Fuel is flammable and explosive Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start Do not smoke or allow sources of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors ...

Page 116: ...er 3 Thread the filter onto the bracket and tighten securely by hand 4 Start and run engine If the engine stops or will not start it may be necessary to prime the fuel system see Priming the Fuel System Prior to Starting in the Cold Weather or Extended Storage section of this manual 5 Check the filter connection for fuel leaks If leaks exist recheck the filter installation 6 If leaks continue stop...

Page 117: ...he filter head a Fuel filter head b Fuel line c Fuel filter element 2 Turn the filter head and remove 3 Remove the internal filter element 4 Insert the new filter element 5 Install the filter head 6 Install the fuel line 7 Start the engine and check for leaks 18962 a b c ...

Page 118: ...etal surface of the drive resulting in corrosion damage from the paint blistering and peeling off the drive Use magnesium anodes in fresh water only IMPORTANT Mercury Marine recommends installing a MerCathode System or Anti Corrosion Kit be installed whenever using a stainless steel propeller or if the boat is equipped with stainless steel components immersed below the waterline that are connected...

Page 119: ... Sacrificial anodes help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package These anodes are installed at different location on your power package 1 Ventilation plate anode serves as a sacrificial anode Unscrew both attaching screws and remove Install a new anodic plate and tighten securely a Anodic...

Page 120: ...ted in the splash plate just above the propellers XR Bravo One XR Bravo III a Gear housing anode 3 SportMaster splash plate anode is located on the splash plate that is attached to the gear housing just above the propeller SportMaster Gearcase a Splash plate anode a 6205 9329 a ...

Page 121: ...the trim cylinder anodes a Remove the two screws from each anode b Install the new anodes and tighten securely a Screws 2 b Trim cylinder anodes 2 6 Bearing Carrier Anode XR Bravo One is located in front of the propeller between the front side of the propeller and the gear housing Refer to Propellers in this manual for propeller removal and installation To replace the bearing carrier anode a 8033 ...

Page 122: ...pshaft Anode XR Bravo III is located behind the aft propeller To replace the propshaft anode a Place a block of wood between the propeller blades and the anti ventilation plate to prevent propeller rotation b Remove the bolt and washers securing the propshaft anode and remove the anode c Install the new propshaft anode over the propeller nut d Place the flat washer then the star washer onto the pr...

Page 123: ...ft anode screw e Flat washer f Star washer Tube Ref No Description Where Used Part No 7 Loctite 271 Threadlocker Bravo III propshaft anode screw 92 809819 Description Nm lb in lb ft Propshaft anode screw 27 20 PAINTING THE BOAT HULL OR TRANSOM 1 If anti fouling protection is required for boat hull or boat transom copper or tin base paints can be used unless otherwise prohibited by law a b d c f e ...

Page 124: ...m 1 5 in unpainted area on the transom of the boat around these items a Anti fouling paint b Unpainted area IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the limited warranty NOTE Do not paint anodes or the MerCathode System reference electrode and anode as this will render them ineffective as galvanic corrosion inhibitors a b 61...

Page 125: ...on Where Used Part No 120 Corrosion Guard Power package 92 802878 55 2 All lubrication points especially the steering system and shift and throttle linkages should be kept well lubricated 3 Flush the seawater system after each use in salty brackish or mineral laden water Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below batt...

Page 126: ...e engine to overheat Inspection and Maintenance Inspect the power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts 1 Check for loose damaged or missing parts hoses and clamps tighten or replace as required 2 Check plug lead...

Page 127: ...e and change oil and oil filter 2 Flush cooling system Refer to Flushing Cooling System shown earlier in this manual WARNING Fuel vapors trapped in the engine compartment may be an irritant cause difficulty breathing or may ignite resulting in a fire or explosion Always ventilate the engine compartment before servicing the power package 3 Close the fuel shut off valve if equipped 4 Prepare fuel sy...

Page 128: ...mon to a boat Cars normally consume alcohol blend fuels before they absorb enough moisture to cause problems however boats often sit idle long enough for phase separation to occur In addition alcohol can wash protective oil films from internal components causing corrosion IMPORTANT Do not run the engine s fuel system dry of this fogging mixture in the 23 liter 6 U S gal remote outboard fuel tank N...

Page 129: ...rom flowing back into the cooling system If the boat is not fitted with a seacock leave the water inlet 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 IMPORTANT The boat must be as level as possible to ensure ...

Page 130: ...nut b Fuel cooler wingnut c Power steering cooler wingnut 2 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 3 Loosen hose clamp and remove the hose from inlet fitting of seawater pickup pump NOTE Lift or bend hoses to allow water to drain completely a Hose clamp a b c 8039 a 8040 ...

Page 131: ... and rust in the engine seawater cooling system when storing for winter or long periods of non use perform the following steps IMPORTANT A nontoxic and environmentally safe ethylene glycol antifreeze containing a rust inhibitor must be used when preparing the seawater section of the cooling system for cold weather or extended storage Be certain to follow the manufacturer s recommendations NOTE If ...

Page 132: ...r of antifreeze c Sea strainer d To the seawater pump e Boat hull f Seawater pickup b Operate engine at idle until antifreeze is expelled from the exhaust manifolds of the engine c Stop the engine and reconnect the pickup hose 7 Perform all checks inspections lubrication and fluid changes outlined in the Maintenance Chart under at least once a year Battery Winter Storage Follow the battery manufac...

Page 133: ...lushing Cooling System before starting engine 6 Supply water to engine cooling system STARTING WITHOUT PRIMING THE FUEL SYSTEM IMPORTANT The throttle must not be advanced until the engine idles and runs smoothly and the water temperature reaches a minimum of 54 C 130 F Advancing the throttle prematurely while the PCM is in its rich running mode will result in poor engine starting and performance 1...

Page 134: ... to vapors Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately 1 Remove the plug from the water separating fuel filter as shown following and install a barbed fitting into the water separating fuel filter a Water seperating fuel filter plug b Barbed fitting 2 Attach an outboard type portable fuel tank with primer bulb to the barbed fitting with a h...

Page 135: ...oving the remote fuel tank line from the engine connection ensure that the primer bulb is soft 7 Re install the plug in the water separating fuel filter using Loctite Pipe Sealant with PTFE on the threads 8 Attempt to start the engine by turning the key switch to the START position for a maximum of 15 seconds or until the engine starts and runs smoothly Do not advance the throttle until the water ...

Page 136: ...agnostic and replace flywheel Engine is seized Check to see if engine can be rotated by hand with the spark plugs removed If not then determine cause Faulty ignition switch Test wire with a remote starter switch at the starter motor Engine Cranks But Will Not Start Possible Cause Remedy Improper starting procedure Read starting procedure Low battery voltage Charge the battery Empty fuel tank or fu...

Page 137: ...Hard to Start Runs Rough Misses and or Backfires Possible Cause Remedy Faulty ignition system component Service ignition system Clogged fuel filter Replace filters Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Kinked or clogged fuel line or fuel tank vent line Replace kinked lines or blow out lines with compressed air to remove obstruction Flame arrestor plugged Clean ...

Page 138: ...nd check for cause of entry Boat overloaded or load improperly distributed Reduce load or redistribute load more evenly Boat bottom fouled or damaged Clean or repair as necessary Flame arrestor dirty Change or clean flame arrestor Insufficient Engine Temperature Possible Cause Remedy Faulty water thermostat Replace water thermostat Faulty gauge or sender Test with shop gauge test sender Faulty oil...

Page 139: ...th shop gauges test senders Aerated water supply to water pick up Place water pick up in a non aerated water supply Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in system Check and add oil Excessive oil in system causing it to become aerated Check and bring oil to required level Check for cause of excessive oil improper filling defective fuel pump etc Diluted or improper viscosit...

Page 140: ...drive belt loose or in poor condition Replace and or adjust Defective battery Test battery Power Trim Does Not Operate Motor Doesn t Run Possible Cause Remedy Open fuse Replace fuse Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connections Repair or replace damaged wiring Power Trim D...

Page 141: ... If any are loose or missing see authorized Mercury Marine dealer immediately Shift or throttle cable kinked Replace cable Friction adjustment excessive Adjust friction Steering Wheel Turns Hard or Jerky Possible Cause Remedy Low power steering pump fluid level Refill system with fluid and check for leaks Sepentine belt loose or damaged Replace and or adjust Insufficient lubrication on steering sy...

Page 142: ...seacock is completely open Check supply hoses for obstruction Check for external water pick up obstruction Check for sea strainer obstruction Check condition of sea pump Seawater Pressure Is Above Specification Possible Cause Remedy High boat speed causing high ram pressure Install a sea strainer with a bypass relief valve ...

Page 143: ...horized dealer The dealer has the necessary information to order parts and accessories for you When inquiring about parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Satisfaction with your Sterndrive or Inboard product is very important to your dealer and to us If you ever have a problem question or concern about your Sterndrive or ...

Page 144: ...de your daytime telephone number with mail and fax correspondence United States Mercury Racing Telephone Fax Mercury Racing N7480 County Rd UU Fond du Lac WI 54935 9585 920 924 2088 920 924 2096 Canada Telephone Fax Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada 905 567 6372 905 567 8515 Australia Pacific Telephone Fax Mercury Marine Australia 132 140 Frankston Road Dan...

Page 145: ... 65 Mexico Central America South America Caribbean Telephone Fax Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A 954 744 3500 954 744 3535 Japan Telephone Fax Mercury Marine Japan 283 1 Anshin cho Hamamatsu Shizuoka 435 0005 Japan 81 53 423 2500 81 53 423 2510 Asia Singapore Telephone Fax Mercury Marine Singapore 72 Loyang Way Singapore 508762 5466160 5467789 ...

Page 146: ...r nearest dealer or contact MERCURY MARINE Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 Outside The United States and Canada Before ordering literature please have the following information about your power package available Engine Model Horsepower Serial Number Model year Contact your nearest dealer or Marine Power...

Page 147: ...MAINTENANCE LOG eng 137 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

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