Mercury 350 MAG MPI Horizon Service Manual Download | Manualshive

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Summary of Contents for 350 MAG MPI Horizon

Page 1: ...Horizon Inboard Models 2001 Mercury Marine 90 861357002 101...

Page 2: ...MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Mar...

Page 3: ...oating will be pleasant Consumer Affairs Department CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine the terms of the warranty are set forth in t...

Page 4: ...eration 18 Important Information 20 Operation And Maintenance 20 Freezing Temperature Operation 21 Drain Plug and Bilge Pump 21 Attention Required After Submersion 21 Launching And Boat Operation Care...

Page 5: ...g Flame Arrestor and Related Components 49 Lubrication 51 Flushing Cooling System 350 MAG MPI Only 53 Flushing Cooling System 8 1 S Horizon Only 54 Serpentine Drive Belt 55 Battery 56 Cold Weather or...

Page 6: ...nty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from...

Page 7: ...ler may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Cen...

Page 8: ...s to the Product V Claim shall be made under this warranty by delivering the Product for inspection to a Mercury MerCruiser dealer authorized to service the Purchaser s product If purchaser cannot del...

Page 9: ...rine Power Service Center or distributor shall then arrange for the inspection and repair provided such ser vice is covered under this warranty Purchaser shall pay for all related transportation charg...

Page 10: ...EXCLUSION MAY NOT APPLY TO YOU V This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state or country to country VI Other details of this w...

Page 11: ...no Authorized Dealers in area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work performed at this facility All incident...

Page 12: ...gistration records will be changed on the factory computer registration file There is no charge for this service Outside the United States and Canada please contact the distributor in your country or...

Page 13: ...11 CA961 THIS PAGE IS INTENTIONALLY BLANK...

Page 14: ...tions while performing the service plus common sense operation are major accident prevention measures WARNING WARNING Hazards or unsafe practices which could result in severe personal injury or death...

Page 15: ...f the seat or gunwale at planing speeds standing at planing speeds sitting on elevated fishing boat decks operating at planing speeds in shallow or obstacle infested waters releasing your grip on a st...

Page 16: ...14 CC670 Courtesy of ABYC 2A 2B 3A 3B 1...

Page 17: ...senger area open side curtains or forward hatches to remove fumes 1 Example of desired air flow through the boat CA643 POOR VENTILATION Under certain running and or wind conditions permanently enclose...

Page 18: ...or flares flag and whistle or horn 3 Spare propeller thrust hubs and an appropriate wrench 4 Tools for necessary minor repairs first aid kit and book 5 Anchor and extra anchor line water proof storage...

Page 19: ...rning to attend the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Bo...

Page 20: ...t Distribution Passengers And Gear Inside The Boat Shifting weight to rear stern Generally increases speed and engine rpm At extremes can cause boat to porpoise Causes bow to bounce in choppy water In...

Page 21: ...t will allow the engine power package to operate at or near the top end of the recommended WOT operating rpm range with a normal load If full throttle operation is below the recommended range the prop...

Page 22: ...ed rpm This will result in further loss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be somewhat regained by switching to a lower pitch propeller...

Page 23: ...emperature Operation IMPORTANT If boat is operated during periods of freezing temperature precautions must be taken to prevent freezing damage to power package Damage caused by freezing IS NOT covered...

Page 24: ...re or explosion Use of replacement electrical ignition or fuel system components which do not comply to these rules and regulations could result in a fire or explosion hazard and should be avoided Whe...

Page 25: ...t are 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...

Page 26: ...s should always be positioned so each engine is running off its own battery DO NOT operate engines with switches in BOTH or ALL position In an emergency another engine s battery can be used to start a...

Page 27: ...ormal operating temperature Frequently check crankcase oil level Add oil if needed It is normal for oil consumption to be high during break in period CA874 After Break In Period To help extend the lif...

Page 28: ...ns on the boat 1 Speedometer indicates boat speed 2 Tachometer indicates engine rpm 3 Oil Pressure Gauge indicates engine oil pressure 4 Battery Meter indicates battery voltage 5 Water Temperature Gau...

Page 29: ...tch to the ON position without cranking the engine The alarm will sound if the system is work ing correctly CAUTION Avoid engine damage Do not operate engine once the alarm has sounded EXCEPT TO AVOID...

Page 30: ...28 CC882 70525 4 3A 3B 3C 71585 2 72852 1 74898 77001 2 3 77602 77498 1...

Page 31: ...ies connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 2 A 90 Amp...

Page 32: ...ull back for REVERSE Then push the throttle control forward to increase speed 2 Neutral Release Lever Prevents accidental shift and throttle engagement Neutral lock button must be pushed IN to move th...

Page 33: ...have separate control handles for each engine The operation of the dual engine control handles is the same as the single engine control handle 2 Throttle Control Handle Push the control handle forward...

Page 34: ...to ON position Push the throttle only button and place the throttle lever in the 50 position Attempt to start engine As soon as engine starts return throttle to the IDLE position 5 Turn ignition key...

Page 35: ...ed could be reduced to idle and may not respond to throttle Engine Guardian Strategy is designed to help reduce the potential for engine damage by reducing engine power when a potential problem is sen...

Page 36: ...level Listen for audio warning horn signifying Guardian Mode if equipped Close fuel shutoff valve if equipped Check coolant level Close seacock if equipped Check transmission fluid Flush cooling syste...

Page 37: ...ould be aware of certain adverse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some...

Page 38: ...CC16 Sea Strainer Recommendation Strainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling engine A minimum of 30 gallons per minute 114 liters...

Page 39: ...8 4 3 6 5 7 2 1 8 7 2 6 5 4 3 Electrical System 12 Volt Negative Ground Alternator Rating Hot Operating Amps 65 Amps Alternator Rating Cold Operating Amps 72 Amps Recommended Battery Rating Min 550 cc...

Page 40: ...Transmission Dexron III Automatic Transmission Fluid 2 Crankcase Oil Quicksilver 4 Cycle Marine Engine Oil Refer to Specifications for alternatives and oil recommendations for varying ambient temperat...

Page 41: ...4 0 6 5 5 Dexron III Automatic Transmission Fluid 1 Fluid should be circulated and then rechecked Add additional fluid as necessary CH46 Gas Inboard Routine Maintenance Each Day Start Each Day End We...

Page 42: ...nd linkages L Retorque engine mounts L Check spark plugs wires distribu tor cap and ignition timing Check and adjust idle speed L Clean flame arrestor L Check electrical system for loose damaged or co...

Page 43: ...41 THIS PAGE IS INTENTIONALLY BLANK...

Page 44: ...42 CH37 75540 2 76385 5 71419 7 70547 77631 2 2 2 4 8 7...

Page 45: ...r FULL or OK RANGE mark on dipstick IMPORTANT DO NOT overfill crankcase oil CHECKING TRANSMISSION FLUID IMPORTANT Engine must be operated at 1500 rpm for 2 minutes immediately prior to checking level...

Page 46: ...44 CA514 1 3 70571 74767 74766 5 5 77631 3...

Page 47: ...all Quicksilver Crankcase Oil Pump onto dipstick tube 2 Insert hose end of crankcase oil pump into an appropriate container and using handle pump until crankcase is empty Remove crankcase oil pump NOT...

Page 48: ...46 CC1011 77629 3 70573 1...

Page 49: ...in the following procedure Also hold a clean shop towel over the water separating fuel filter when removing it to help avoid fuel spraying on the engine The installation of additional fuel filters an...

Page 50: ...48 CH40 76360 76365 1 2 70573 2...

Page 51: ...ove flame arrestor and related components 3 Clean flame arrestor in solvent Dry with compressed air or allow to air dry completely WARNING Avoid gasoline fire or explosion Gasoline is extremely flamma...

Page 52: ...50 CH42 3 4 71457 2 50946 1A 74941 1B 77597...

Page 53: ...mote control shift cable and linkages must position transmission shift lever so that it is fully in the FORWARD and REVERSE gear detent positions with the lever over the letter F on transmission case...

Page 54: ...52 CC886 3 4 74073 1 75637 7 2 75423...

Page 55: ...on the engine IMPORTANT Run bilge pump during flushing to pump flushing water overboard 6 Flush engine for 10 minutes 7 Disconnect the quick connect and water hose from the flush socket on the engine...

Page 56: ...d to prevent water from flowing into boat CAUTION If boat is in the water do not open water inlet valve until engine is to be restarted to prevent contami nated water from flowing back into engine NOT...

Page 57: ...pected for condition and tension NOTE Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys 1 Check the tension of the serpentine drive belt I...

Page 58: ...d could cause blindness or other serious injury Safety glasses and rubber gloves are recommended when handling batteries or filling with electrolyte Hydrogen gases that escape from the battery during...

Page 59: ...damage to engine may result IMPORTANT Before starting engine a water source must be attached to the seawater pickup pump Follow all warnings and flushing attachments procedures stated in FLUSHING COO...

Page 60: ...and engine stops G Remove and discard water separating fuel filter H Install a new water separating fuel filter I Reconnect harness connections at both fuel pumps 8 Clean flame arrestor Refer to Clea...

Page 61: ...mited Warranty CAUTION If engine will be exposed to freezing temperatures ensure closed cooling section is filled with an ethyl ene glycol antifreeze and water solution properly mixed to protect engin...

Page 62: ...60 CC1017 77516 71515 77512 8 5 3 10 A 77638 3...

Page 63: ...ve system pressurized while transporting boat or during other maintenance items to allow the remaining water to drain IMPORTANT Before launching boat pull up on manual release valve A Verify that gree...

Page 64: ...serpentine drive belt condition and tension Refer to Serpentine Drive Belt 5 Perform all lubrication and maintenance specified for completion Annually in maintenance schedule except items which were p...

Page 65: ...starting procedure Read starting procedure Empty fuel tank or fuel shutoff valve closed Fill tank or open valve Engine flooded Do not attempt to start engine for at least 5 minutes Refer to Starting...

Page 66: ...EFI System checked by an Authorized Mercury MerCruiser Dealer Low on fuel Fill tank Engine timing off Check timing CH47 Poor Performance Possible Cause Remedy Throttle not fully open Inspect throttle...

Page 67: ...nsmission fluid cooler and or engine oil cooler plugged with foreign material Disconnect hoses from coolers and flush out with a water hose in direction opposite normal water flow CA448 Insufficient E...

Page 68: ...ted electrical connections and wires especially battery cables Clean and tighten faulty connections Repair or replace damaged wiring Alternator drive belt loose or in poor condition Replace and or adj...

Page 69: ...nearest Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Ca...

Page 70: ...this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Off...

Page 71: ...3 791 5822 61 3 793 5880 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Europe Middle East Africa 32 87 32 32 11 32 87 31 19 65 Marine Power Europe Inc Parc Industri...

Page 72: ...nternational servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual p et andet sprog En liste med reservedelsnumre for andre sprog leveres sammen med din powe...

Page 73: ...m outro idioma contate o Centro de Servi o Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informa es Uma lista de n meros de refer ncia para outros idiomas...

Page 74: ...ealer 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 Con...

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