Mercury Racing HP565 Manual Download Page 1

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eng

Declaration of Conformity for Recreational Craft

Propulsion Engines with the Requirements of Directive

94/25/EC as Amended by 2003/44/EC

Manufacturer:

Mercury Racing

N7480 County Road UU

Fond du Lac, WI 54937–9385

USA

Authorized Representative:

Brunswick Marine EMEA, Inc.

Parc Industriel de Petit-Rechain

Verviers, 4800,

Belgium

Notified Body for Exhaust Emission Assessment:

Det Norske Veritas AS

Veritasveien 1

Hovik, 1322,

Norway

ID Number: 0575
Conformity Assessment Module used for Exhaust

Emissions: H
Other Community Directives Applied: Electromagnetic

Compatibility Directive 2004/108/EC

Description of Engine(s) and Essential Requirements

Engine Type:

Fuel Type: Combustion Cycle

z or sterndrive without integral

exhaust

Petrol

4‑Stroke

520 Bravo Sterndrive Models

90-8M0083289 713

Summary of Contents for HP565

Page 1: ...chain Verviers 4800 Belgium Notified Body for Exhaust Emission Assessment Det Norske Veritas AS Veritasveien 1 Hovik 1322 Norway ID Number 0575 Conformity Assessment Module used for Exhaust Emissions...

Page 2: ...Number 0M968960 RCD H 2 Stds Other Normative Document Method Technic al File Please specify in more detail mandatory standard Annex 1 B Exhaust Emissions B 1 Engine Identification X B 2 Exhaust Emiss...

Page 3: ...ring Systems B 3 Durability X B 4 Owner s Manual X This declaration of conformity is issued under the sole responsibility of the manufacturer I declare on behalf of the engine manufacturer that the en...

Page 4: ...y 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...

Page 5: ...red the duration of coverage how to best obtain warranty coverage important disclaimers and limitations of damages and other related information Please review this important information Safety Alerts...

Page 6: ...xhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm Copyright and Trademark Information Mercury Marine Fond du Lac Wis...

Page 7: ...Control Warranty Statement 12 California Emission Control Warranty Rights and Obligations 16 E P A Emission Controls 18 General Information Before Operating Your Boat 21 Boat Horsepower Capacity 21 Hi...

Page 8: ...ration Instrumentation 43 Warning System 43 Electrical System Overload Protection 45 Remote Controls Console Mounted Zero Effort 51 Starting Shifting and Stopping 51 Operation Chart 52 Freezing Temper...

Page 9: ...Section of Oil Cooler 95 Changing Positive Crankcase Ventilation Valve 96 Cleaning the Flame Arrester 97 Serpentine Drive Belt 99 Water Separating Fuel Filter 102 Corrosion and Corrosion Protection 1...

Page 10: ...Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move 132 Electrical Analog Trim Gauge Malfunction 133 Remote Control Operates Hard Binds Has Excessive Free Play or Makes Unusual Sounds...

Page 11: ...eng xi Maintenance Log Maintenance Log 139...

Page 12: ...xii eng...

Page 13: ...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 wa...

Page 14: ...s 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 Bo...

Page 15: ...creational 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 purcha...

Page 16: ...product for inspection to a Mercury dealer authorized to service the product If the purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange...

Page 17: ...on the transom or running the boat with the engine trimmed out too far Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss...

Page 18: ...u This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state and country to country Products Sold to Government Agencies Contact the Mercury...

Page 19: ...spection 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 Operatio...

Page 20: ...ssociated 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 a...

Page 21: ...tween 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...

Page 22: ...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...

Page 23: ...or Quicksilver parts when making warranty repairs 7 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in...

Page 24: ...nformation regarding the limited warranty for the non emissions related components of the inboard or sterndrive engine please see the limited warranty statement for your engine WHAT IS COVERED Mercury...

Page 25: ...nes mechanical emission related components including but not limited to the engine block crankshaft camshaft connecting rods valves manifolds rotating parts pistons and turbo superchargers are warrant...

Page 26: ...ges and or travel time If the service provided is not covered by this warranty the purchaser shall pay for all related labor and material and any other expenses associated with that service The purcha...

Page 27: ...telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also ex...

Page 28: ...r contact information California Emission Control Warranty Rights and Obligations YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board is pleased to explain the emission control sys...

Page 29: ...ercury Racing OWNER S WARRANTY RESPONSIBILITIES As the sterndrive engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Mercury Racing recommen...

Page 30: ...n 213 of the Clean Air Act and the engine is free from defects in materials and workmanship that cause the engine to fail to conform with applicable regulations EMISSION CONTROL SYSTEM COMPONENTS The...

Page 31: ...aust elbow c Intermediate exhaust elbow d Lower exhaust pipe e Tailpipe 7 Catalysts or thermal reactor system a Catalytic converter b Thermal reactor c Exhaust manifold d Exhaust valves 8 Evaporative...

Page 32: ...WARRANTY INFORMATION 20 eng NOTE The EPA emission related warranty does not cover components whose failure would not increase an engine s emissions on any regulated pollutant...

Page 33: ...zardous 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...

Page 34: ...e 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...

Page 35: ...ing 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 t...

Page 36: ...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 stron...

Page 37: ...wing people to swim or be in the water near your boat Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal co...

Page 38: ...ging teak body surfing This dangerous practice not only places a person in an area of high engine exhaust concentration but also subjects them to the possibility of injury from the boat propeller GOOD...

Page 39: ...of carbon monoxide 1 Examples of poor ventilation while the boat is stationary a Operating the engine when the boat is moored in a confined space b Mooring close to another boat that has its engine o...

Page 40: ...w 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 cause serious injury or death from occupants being...

Page 41: ...pt to a minimum planing speed 24 to 40 km h 15 to 25 MPH 45914 Striking a floating or underwater object could result in an infinite number of situations Some of these situations could result in the fo...

Page 42: ...uld 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 sterndri...

Page 43: ...le 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 wate...

Page 44: ...ion 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...

Page 45: ...autical 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...

Page 46: ...re 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...

Page 47: ...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 l...

Page 48: ...erial Number ________________________ Propeller Number Pitch _________________________ Sterndrive Serial Number Gear Ratio ________________________ Running Rotation _________________________ Hull Iden...

Page 49: ...use of improper fuel can cause serious damage to the engine Damage resulting from the use of improper fuel is considered engine misuse and is not covered under the limited warranty Use only the recom...

Page 50: ...re 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 in the gasol...

Page 51: ...fuel hose connecting the fuel tank to the engine Low permeation hose is USCG Type B1 15 or Type A1 15 defined as not exceeding 15 gm 24 h with CE 10 fuel at 23 C as specified in SAE J 1527 marine fue...

Page 52: ...Group 31M 1150 CCA minimum Electrical system 12 volt negative ground Ignition type PCM distributorless wasted spark Spark plug type NGK BKR6ES Spark plug gap 0 9 mm 0 035 in Fuel system Sequential por...

Page 53: ...ially opens at 62 C 143 F Coolant thermostat is wide open at 70 C 158 F Minimum water pressure supplied to the engine at WOT 172 kPa 25 psi Maximum water pressure supplied to the engine at WOT 345 kPa...

Page 54: ...ly 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 recomm...

Page 55: ...ARDIAN SYSTEM The Engine Guardian system monitors sensors on the engine for early indications of problems If a sensor indicates a fault the system responds to the problem by sounding the horn and depe...

Page 56: ...e attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault If the propulsion control module PCM detects a fault signal from an engine sensor it recor...

Page 57: ...s a fuse will blow or the circuit breaker will trip open The cause must be found and corrected before replacing the fuse or resetting the circuit breaker NOTE In an emergency when you must operate the...

Page 58: ...cuit breaker is located at the starboard rear of the engine in the electrical center 53508 A 90 amp fuse located on the large post of the starter solenoid protects the engine wiring harness if an elec...

Page 59: ...ocated near the 14 pin harness connector a Good fuse b Bad fuse c Alternator and fuel pump circuit 20 amp fuse d Power to 14 pin helm harness 20 amp fuse e ECM driver power fuel pump relay coils and s...

Page 60: ...d by a 5 amp fuse a Paddle wheel and tank level connector b Diagnostic connector c 14 pin harness connector d Clean power harness connector e Transom harness connector A 15 amp accessory fuse protects...

Page 61: ...s a 5 amp fuse b Positive battery terminal harness lead with fuse c Negative battery terminal A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical system Check...

Page 62: ...on the power trim pump The trim pump may also have an in line circuit protection device in the power trim positive lead near the battery switch or battery connection a 20 amp spade fuse b 110 amp fus...

Page 63: ...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 t...

Page 64: ...tart check for full battery voltage 13 8 14 2 volts Move control throttle lever to full throttle Be prepared to decrease the engine speed to idle as soon as the engine starts STARTING PROCEDURE 1 Turn...

Page 65: ...on 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...

Page 66: ...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...

Page 67: ...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 w...

Page 68: ...ottle WOT and operating RPM range are listed 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 norm...

Page 69: ...uel or electronic management systems Above sea level elevations High temperature Low barometric pressure High humidity The conditions listed above reduce air density to the engine which in turn reduce...

Page 70: ...ower pitch propeller but engine performance will remain lower In some cases a gear ratio reduction may be more beneficial To optimize engine performance prop the engine to allow operation at or near t...

Page 71: ...ALER 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...

Page 72: ...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 cylinde...

Page 73: ...s 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...

Page 74: ...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...

Page 75: ...ll 25 hour maintenance items Serpentine and drive belts All Inspect condition and check tension Cooling system hoses and clamps Inspect for damage and deterioration Check clamps for tightness Electric...

Page 76: ...age Exhaust system internal and external shutters Inspect MerCathode system Test output Every 100 hours of operation or recommissioning after storage Fuel filters Replace Every 100 hours of operation...

Page 77: ...t Every 25 hours of operation or once every 30 days whichever occurs first Gear housing water pickups Check for marine growth or debris Anodes Inspect for erosion Sterndrive unit oil Check level Trim...

Page 78: ...ive 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 gi...

Page 79: ...Checking Fluid Levels CRANKCASE OIL The engine crankcase oil level must be checked at the intervals specified in the Maintenance Chart NOTE Oil consumption is greatly dependant on engine speed Consum...

Page 80: ...must be between the FULL and ADD mark ADD FULL 53509 IMPORTANT Do not overfill crankcase oil 3 If the oil level is below the ADD mark remove the oil filler cap Add the specified oil to bring the level...

Page 81: ...ine Oil Engine crankcase 92 858048K01 POWER STEERING PUMP Stop the engine and position the drive unit straight back IMPORTANT If fluid is not visible in the reservoir contact your authorized Mercury M...

Page 82: ...LL line 2 If there is water at bottom of the monitor and or if the oil appears a milky tan contact your authorized Mercury MerCruiser dealer immediately both conditions indicate a water leak somewhere...

Page 83: ...fill cap from reservoir and observe the fluid level The level must be up to but not over the bottom of the filler neck NOTE Ensure that the cap plug has been removed and discarded from the filler nec...

Page 84: ...n ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed NOTE All factory installed closed cooling systems come filled with Extended Life Coolant Th...

Page 85: ...ne to cool down before removing the coolant pressure cap IMPORTANT When reinstalling the coolant reservoir cap ensure that it is tightened securely The coolant level should be at the full mark on the...

Page 86: ...ife Antifreeze Coolant Closed cooling system 92 877770K1 NOTE Coolant section capacity is approximate 8 2 Models Capacity Fluid Type Closed cooling system 17 4L 18 4 US qt Extended Life Antifreeze Coo...

Page 87: ...engine operating temperature is normal If the gauge indicates excessive temperature stop the engine immediately and determine the cause CAUTION A sudden loss of pressure can cause hot coolant to boil...

Page 88: ...When changing the oil make sure that the engine is near operating temperature Use only the recommended motor oil refer to Specifications 1 With the engine off but at normal operating temperature remov...

Page 89: ...he sealing ring on the new filter with motor oil and install a new sealing ring and filter 8 Tighten the filter securely Do not over tighten 9 Remove the oil filler cap Add oil to bring the level up t...

Page 90: ...uction which can collapse the water supply hose and overheat the engine Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply IMPORTANT Change the oil o...

Page 91: ...oil to drain from the filter loosen the filter enough to break the internal vacuum Let the oil drain back into the system for 15 minutes prior to complete removal of the filter 9 Remove the oil filter...

Page 92: ...hetic Blend 4 Stroke Racing Engine Oil Crankcase 8M0078013 152 25W 50 Verado FourStroke Outboard Oil Crankcase 92 858084K01 79 MerCruiser 4 Cycle 25W 40 Engine Oil Crankcase 92 858048K01 DRIVE UNIT OI...

Page 93: ...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...

Page 94: ...hecked 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 dra...

Page 95: ...dd the specified gear lube to the monitor bottle 7 When the oil starts to run out the oil vent hole reinstall the drive oil vent screw and seal Securely tighten the screw a Gear lube monitor bottle b...

Page 96: ...er the first use 11 Heavily grease the propeller shaft with Extreme Grease Reinstall the propeller and tighten the nut to the specified torque 7990 Tube Ref No Description Where Used Part No Extreme G...

Page 97: ...der to lubricate the U joints Contact your authorized Mercury MerCruiser dealer for this service NOTE The engine coupling and shaft splines are greased with engine coupler spline grease Universal join...

Page 98: ...th 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 d...

Page 99: ...ving a propeller place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting Place a block of wood between the propeller blade and the anti ventilation plate...

Page 100: ...8M0071842 2 Install the Bravo XR replaceable hub propeller components in the order shown a Propeller shaft b Prop hub assembly c Propeller assembly d Washer e Belleville washer f Washer g Locknut 3 Af...

Page 101: ...MAINTENANCE eng 89 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 Remove the propeller nut a b 7448...

Page 102: ...hub assembly c Propeller assembly d Washer e Belleville washer f Washer g Locknut NOTE Some damaged propellers can be repaired See your authorized Mercury Marine dealer Flushing the Power Package The...

Page 103: ...he 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 gearcase...

Page 104: ...kups 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...

Page 105: ...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...

Page 106: ...gear housing 4 Connect a hose between the flushing 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...

Page 107: ...eaned 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 engine 1 Remove end plates and gas...

Page 108: ...d level 4 Start engine and inspect cooling system for leaks Changing Positive Crankcase Ventilation Valve This engine is equipped with a positive crankcase ventilation valve PCV Change the valve every...

Page 109: ...e 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 Loosen the flame arrester cla...

Page 110: ...MAINTENANCE 98 eng Description Nm lb in lb ft Flame arrester clamp 6 2 55 4 Install the silencer...

Page 111: ...elts with the engine running may cause serious injury or death Turn off the engine and remove the ignition key before inspecting the belts a Alternator pulley b Idler pulley c Power steering pump pull...

Page 112: ...ion Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys Description Deflection 13 mm 1 2 in NOTE Minor transverse cracks across the belt width may be...

Page 113: ...ensioner to contact the cast stops See your authorized MerCruiser dealer for service if these conditions exist CAUTION Rapid release of the belt tensioner or allowing the tensioner to snap back quickl...

Page 114: ...urces of spark or open flame in the area while servicing Keep the work area well ventilated and avoid prolonged exposure to vapors Always check for leaks before attempting to start the engine and wipe...

Page 115: ...gine be shut off for 12 hours prior to filter removal 2 Close fuel supply valve if equipped 3 Disconnect the Cool Fuel Module harness from the engine wiring harness 4 Turn the key switch to the start...

Page 116: ...ilter element into the filter cup Push the element into the cup until completely seated 2 Install new O ring on the filter cup 3 Attach the filter cap to the filter cup by grasping the filter cap and...

Page 117: ...imilar metals such as those found on the sterndrive are submerged in a conductive solution such as saltwater polluted water or water with a high mineral content a chemical reaction takes place causing...

Page 118: ...ic corrosion potential Replace the sacrificial anodes if eroded 50 or more Mercury Marine recommends using anodes sold through Mercury Precision Parts only Some other manufacturers of aluminum anodes...

Page 119: ...etal 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 a...

Page 120: ...ed 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 jus...

Page 121: ...he 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 fro...

Page 122: ...e and tighten securely d Reinstall the propeller See Propeller Installation for proper torque a Bearing carrier anode PAINTING THE BOAT HULL OR TRANSOM 1 If anti fouling protection is required for boa...

Page 123: ...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 w...

Page 124: ...n 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 s...

Page 125: ...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...

Page 126: ...ystem open IMPORTANT Only drain the seawater section of the closed cooling system IMPORTANT The boat must be as level as possible to ensure complete draining of the cooling system Your power package i...

Page 127: ...COLD WEATHER OR EXTENDED STORAGE eng 115 a Starboard side air actuated drain location b Port side air actuated drain location a b a 53834...

Page 128: ...re is written for the air pump that was shipped with the engine from the factory However any air source can be used 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Obtain the...

Page 129: ...the connection 7 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side a Manual release...

Page 130: ...ended 10 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit by pulling the fuse marked CD 11 Crank the engine over slightly with the starter motor to purge any wa...

Page 131: ...ect the water inlet hose prior to operating the engine BOAT OUT OF THE WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Place t...

Page 132: ...tem until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side a Manual release valve b Air pump lever locked c Air p...

Page 133: ...xtended 9 For DTS engines pull the lanyard stop switch if equipped or disable the ignition circuit by pulling the fuse marked CD 10 Crank the engine over slightly with the starter motor to purge any w...

Page 134: ...release valve b Threaded cap for air connection c Green indicators Manual Drain System BOAT IN THE WATER NOTE Use this procedure if the air actuated single point drain system fails NOTE It may be nece...

Page 135: ...leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained 5 For DTS engines pull the lanyard stop switch if equipped or disab...

Page 136: ...ils NOTE It may be necessary to lift bend or lower hoses to allow water to completely drain when hoses are disconnected 1 Place the boat on a level surface to ensure complete draining of the system 2...

Page 137: ...7 Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 8 Prior to launching the boat or starting the engine clo...

Page 138: ...re Used Part No 19 Perfect Seal Drain plug threads 92 34227Q02 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...

Page 139: ...cting 3 Coat the terminal connections with a battery terminal anticorrosion agent 4 Perform all the checks in the Before Starting column of the Operation Chart NOTICE Without sufficient cooling water...

Page 140: ...gnostic 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 star...

Page 141: ...ard 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 contami...

Page 142: ...d 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 C...

Page 143: ...h 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 ad...

Page 144: ...rive 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 elec...

Page 145: ...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 Jer...

Page 146: ...eacock 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 Spec...

Page 147: ...orized 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 co...

Page 148: ...spondence United States Telephone Fax Mercury MerCruiser W6250 W Pioneer Road Fond du Lac WI 54936 1939 920 929 5040 N A United States Mercury Racing Telephone Fax Mercury Racing N7480 County Rd UU Fo...

Page 149: ...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...

Page 150: ...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...

Page 151: ...MAINTENANCE LOG eng 139 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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