Mercury 4.3 TKS series Operation & Maintenance Manual Download

Page: 93 / 109

Section 6 - Troubleshooting

90-8M0113857

eng

DECEMBER 2015

Page 85

Section 6 - Troubleshooting

Table of Contents

Starter Motor Will Not Crank Engine, or Cranks Slow.......... 86

Engine Will Not Start or Is Hard to Start............................... 86

Engine Runs Rough, Misses, or Backfires........................... 86

Poor Performance................................................................ 86

Excessive Engine Temperature............................................ 87

Insufficient Engine Temperature........................................... 87

Low Engine Oil Pressure...................................................... 87

Battery Will Not Recharge.................................................... 87

Remote Control Is Difficult to Move, Has Excessive Play, or

Makes Unusual Sounds........................................................ 87

Steering Wheel Jerks or Is Difficult to Turn.......................... 88

Power Trim Does Not Operate (Motor Does Not Operate)... 88

Power Trim Does Not Operate (Motor Operates but

Sterndrive Unit Does Not Move)........................................... 88

Summary of Contents for 4.3 TKS series

Page 1: ...lia www mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S...

Page 2: ......

Page 3: ...pecial instructions while performing the service plus common sense operation are major accident prevention measures WARNING Indicates a hazardous situation which if not avoided could result in death o...

Page 4: ...erCruiser Mercury Mercury with Waves Logo Mercury Marine Mercury Precision Parts Mercury Propellers Mercury Racing MotorGuide OptiMax Quicksilver SeaCore Skyhook SmartCraft Sport Jet Verado VesselView...

Page 5: ...r It Has Been Stopped While In Gear 17 Throttle Only Operation 17 Trailering the Boat 18 Freezing Temperature Operation 18 Drain Plug and Bilge Pump 18 Protecting People in the Water 18 While You Are...

Page 6: ...n 55 Flushing the Power Package 55 Flushing Attachments 55 Sterndrive Water Pickups 56 Alternative Water Pickups 57 SeaCore Power Package Flushing Procedure 58 Models Using The Sterndrive Water Pickup...

Page 7: ...er Assistance Information Owner Service Assistance 90 Local Repair Service 90 Service Away From Home 90 Stolen Power Package 90 Attention Required After Submersion 90 Replacement Service Parts 90 Part...

Page 8: ...Page iv 90 8M0113857 eng DECEMBER 2015...

Page 9: ...tification 3 Bravo Transom Serial Number 4 Lanyard Stop Switch 4 Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition 5 Instrumentation 5 VesselView 5 SmartCraft Digital Instrumen...

Page 10: ...nd serial numbers Engine Serial Number Decal The serial number decal is located on the engine cover 26301 Serial numbers and maintenance color codes decal The engine serial number is also stamped in t...

Page 11: ...mber location on gimbal housing Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number gear ratio model number and bar code are embedded in the ground plate on the port s...

Page 12: ...ping a Transom assembly serial number Lanyard Stop Switch A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm as may happen in an accid...

Page 13: ...operator to the stop switch using a lanyard Accidental or unintended activation of the switch during normal operation is also a possibility This could cause any or all of the following potentially haz...

Page 14: ...ng fault codes associated with the engine audio warning system The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display For basic operation...

Page 15: ...thout shifting the engine This is done by disengaging the shift mechanism from the control handle The throttle only button can be depressed only when the remote control handle is in the neutral positi...

Page 16: ...l for complete adjustment instructions Power trim switch See Power Trim section for detailed power trim operating procedures Trailer switch Used to raise drive unit for trailering launching beaching o...

Page 17: ...he sterndrive to a position suitable for trailer purposes only Dual Engine Trim Trailer NOTICE If using external tie bars raising or lowering the drives independently of each other can damage the driv...

Page 18: ...d Reset the breaker by pushing the red button 51185 Engine wiring harness and instrumentation circuit breaker 2 A 20 amp fuse is located near the carburetor body This fuse protects the fuel pump and i...

Page 19: ...protect the electrical system Check for an open fuse or an open circuit breaker if the ignition key is turned to the START position and nothing happens mc70525 1 6 The power trim system is protected...

Page 20: ...of the following occurs Engine oil pressure too low Engine temperature too hot Sterndrive oil level too low if equipped with a drive reservoir having low oil level switch Transmission temperature is t...

Page 21: ...e Operation 18 Drain Plug and Bilge Pump 18 Protecting People in the Water 18 While You Are Cruising 18 While Boat Is Stationary 18 High Speed and High Performance Operation 18 Passenger Safety in Pon...

Page 22: ...passengers are boarding unloading or are near the back stern of the boat Shifting the drive unit into neutral is not sufficient Use personal flotation devices Federal law requires that there be a U S...

Page 23: ...urther assistance from local law enforcement Carbon Monoxide Exposure Be Alert To Carbon Monoxide Poisoning Carbon monoxide CO is a deadly gas that is present in the exhaust fumes of all internal comb...

Page 24: ...Basic Boat Operation Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching boat Operation Chart Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPIN...

Page 25: ...ICE Shifting into gear at engine speeds above idle will damage the gearcase Shifting into gear when the engine is not running can misalign the clutch preventing proper shifting Always shift the gearca...

Page 26: ...oving even coasting and the gear shift is in neutral there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury W...

Page 27: ...jumping can cause serious injury or death from occupants being thrown within or out of the boat Avoid wave or wake jumping whenever possible mc79680 1 Operating recreational boats over waves and wake...

Page 28: ...or any broken or loose parts If damage is present or suspected the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair The boat shou...

Page 29: ...he Boat To maintain maximum speed the boat bottom should be Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts the water Straight and smooth fore and aft Marine...

Page 30: ...may require that the propeller be changed to a lower pitch Warmer weather and greater humidity cause a loss of RPM Operating in a higher elevation causes a loss of RPM Operating with a dirty boat bott...

Page 31: ...season of operation contact an authorized Mercury MerCruiser dealer to discuss and or perform scheduled maintenance items If you are in an area where the product is operated continuously year round yo...

Page 32: ...Section 2 On the Water Notes Page 24 90 8M0113857 eng DECEMBER 2015...

Page 33: ...of Contents Fuel Requirements 26 Fuel Ratings 26 Using Reformulated Oxygenated Gasoline USA Only 26 Gasoline Containing Alcohol 26 Bu16 Butanol Fuel Blends 26 Methanol and Ethanol Fuel Blends 26 Engin...

Page 34: ...tact your boat manufacturer for specific recommendations on your boat s fuel system components fuel tanks fuel lines and fittings Be aware that gasoline containing methanol or ethanol may cause increa...

Page 35: ...Catalyst Compatible rated 4 cycle oil SAE 20W SAE30W SAE40W AIR TEMPERATURE ORDER OF PREFERENCE 32 F 0 C 50 F 10 C Mercury Quicksilver 25W 40 Mineral NMMA FC W Catalyst Compatible rated 4 cycle oil 53...

Page 36: ...with filter 3 8 L 4 US qt Mercury Quicksilver 25W 40 Synthetic Blend Engine Oil NMMA FC W Catalyst Compatible rated Seawater cooling system 14 1 L 15 US qt Propylene glycol and purified water Closed...

Page 37: ...cation 45 Driveshaft U joint Splines and O Rings Sterndrive Unit Removed 45 Engine Coupler 45 Driveshaft Extension Models 46 Propellers 46 Propeller Repair 46 Alpha Propeller Removal 47 Alpha Propelle...

Page 38: ...n electrical shock or unexpected engine starting Always disconnect the battery cables from the battery before maintaining servicing installing or removing engine or drive components WARNING Fuel vapor...

Page 39: ...t your authorized Mercury MerCruiser dealer Maintenance Schedule Sterndrive Models Routine Maintenance NOTE Only perform maintenance that applies to your particular power package New sterndrive instal...

Page 40: ...rk plug wires and the distributor cap and rotor if equipped Replace as necessary If the condition of these components is satisfactory at inspection repeat inspection every 100 hours or once a year whi...

Page 41: ...l IMPORTANT Always use the dipstick to determine the exact quantity of oil or fluid required 1 Remove the oil fill cap a Oil fill cap IMPORTANT Add the specified engine oil to bring the level up to bu...

Page 42: ...mp onto the dipstick tube a Typical oil pump b Dipstick tube c Oil drain hose 4 Insert the hose end of the crankcase oil pump onto an appropriate container and using the handle pump until the crankcas...

Page 43: ...ngine cold should be within the cold range a Power steering pump b Cold range c Warm range 3 Fill to full line with specified fluid IMPORTANT If fluid is not visible in pump contact your authorized Me...

Page 44: ...freeze Coolant Closed Cooling System 92 877770K1 Filling NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine Fill the closed cooling syste...

Page 45: ...he gear lube level in the monitor bottle Keep the gear lube level within the recommended operating range a Seawater cooled models b Closed cooling models 2 Inspect the gear lube condition If any water...

Page 46: ...he propeller shaft is level Fill the sterndrive unit through the oil fill and drain hole with the specified gear lubricant until an air free stream of lubricant flows from the oil vent hole Tube Ref N...

Page 47: ...These conditions can indicate a water leak in the sterndrive 43200 Gear lube monitor Filling New installations may require as much as 470 mL 16 fl oz of gear lube added to the monitor bottle during th...

Page 48: ...dealer 7 Lower the sterndrive unit so the propeller shaft is level IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in the sterndrive unit 8 Fill the sterndrive unit through the...

Page 49: ...Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive unit in full down in position 2 Remove the fill cap from the reservoir a Fill c...

Page 50: ...etergent 4 Inspect the flame arrestor for holes cracks or deterioration Replace if necessary 5 Allow the flame arrestor to air dry completely before use 6 Clean the crankcase ventilation hose with war...

Page 51: ...ter separating fuel filter and sealing ring from the mounting bracket 5 Coat the sealing ring on the new filter with engine oil Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser En...

Page 52: ...d Part No Extreme Grease Steering cable grease fitting 8M0071842 2 Turn the steering wheel until the steering cable is fully extended Lightly lubricate the exposed part of the cable a Extended steerin...

Page 53: ...the product is operated in saltwater Alpha shift plate shown Bravo shift plate similar a Remote control shift cable b Shift assist assembly c Intermediate shift cable Driveshaft U joint Splines and O...

Page 54: ...ation Driveshaft Extension Models 1 Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10 12 pumps of grease from a typical hand operated grease gun 2 Lub...

Page 55: ...ly inspect tabs for cracks or other damage Replace the tab washer if condition is questionable a Propeller shaft b Thrust hub c Flo Torq II drive hub d Propeller e Drive sleeve f Locking tab washer g...

Page 56: ...aft rotation 1 Liberally lubricate the propeller shaft spline with one of the following Quicksilver lubricants Tube Ref No Description Where Used Part No 95 2 4 C with PTFE Propeller shaft splines 92...

Page 57: ...forward gear direction of propeller shaft rotation 1 Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants Tube Ref No Description Where Used Part No 95 2 4 C with...

Page 58: ...shaft anode 3 Remove the propeller shaft anode a Propeller b Rear propeller nut c Propeller shaft anode d Propeller shaft anode screw e Flat washer f Star washer 4 Turn the rear propeller nut 37 mm 1...

Page 59: ...o Extreme Grease Propeller shaft 8M0071842 95 2 4 C with PTFE Propeller shaft 92 802859A 1 3 Align the splines and install the front propeller onto the propeller shaft 4 Install the front propeller nu...

Page 60: ...washers Tighten the anode 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 Serpentine Drive Belt WARNING Inspecting the belts wi...

Page 61: ...elt onto the pulleys 4 Put a wrench on the adjustment stud 16 mm 5 8 in locking nut 5 Use a 8 mm 5 16 in socket and tighten the adjusting stud to adjust the belt deflection 6 Use one of the two follow...

Page 62: ...ter can cause 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 On seawater cooled models pro...

Page 63: ...ed remove the seawater inlet hose from the thermostat housing and plug the hose to prevent water from siphoning into the boat This prevents seawater from contaminating the engine flush 14 Tag the igni...

Page 64: ...ns Flushing is recommended after each outing for best results NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine resulting in engine damage Close the seac...

Page 65: ...in neutral for about 10 minutes or until discharge water is clear 12 Slowly return the throttle to the idle speed position 13 Stop the engine 14 Shut off the water and remove flushing attachment 15 R...

Page 66: ...top the engine 14 Shut off the water and remove flushing attachments 15 If the boat is out of the water install the water inlet hose to the aft side of the seawater pump Tighten the hose clamp securel...

Page 67: ...let water hose from the sterndrive to the engine is connected 5 Remove the quick connect fitting from the parts bag supplied with the engine 6 Attach the quick connect fitting to a water hose a Quick...

Page 68: ...se end b Flush socket release button 18 Remove the quick connect fitting from the water hose a Quick connect fitting water hose end b Water hose 19 Retain the quick connect fitting with the water hose...

Page 69: ...ventilated area away from sparks or flames WARNING An operating or charging battery produces gas that can ignite and explode spraying out sulfuric acid which can cause severe burns Ventilate the area...

Page 70: ...lpha models MerCathode Bravo models b Ventilation plate anode c Trim cylinder anodes d Bearing carrier anodes e Gearcase anodic plate f Anode kit on hull if equipped Dual sterndrive a Anode Alpha mode...

Page 71: ...be slowly eroded instead of the metal components on the power package MerCathode system The electrode assembly if equipped replaces the anode block The system should be monitored to ensure adequate ou...

Page 72: ...ray external power package components 3 Keep all lubrication points especially the steering system shift and throttle linkages well lubricated 4 Flush the cooling system periodically preferably after...

Page 73: ...wire harness If further assistance is required contact your local Mercury Service dealer Power Package Exterior Surfaces 1 Spray the entire power package at recommended intervals with Corrosion Guard...

Page 74: ...s to clean the MerCathode assembly 3 Do not power wash a sterndrive that has a MerCathode assembly Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosi...

Page 75: ...d at regular intervals and replace it before it is half gone If a stainless steel propeller is installed additional anodes or a MerCathode system will be required Inspect the propeller shaft for fishi...

Page 76: ...Section 4 Maintenance Notes Page 68 90 8M0113857 eng DECEMBER 2015...

Page 77: ...72 Manual Single Point Drain System Seawater cooled models 73 4 3 ECT Single Point Drain System with Plug 73 Three Point Manual Drain System Seawater cooled 73 Multipoint Drain MPD System 74 Air Actua...

Page 78: ...deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline only alcohol free gasoline should be used If only fuel containing alcohol...

Page 79: ...nance section 6 Start the engine 7 Run the engine at 1300 RPM for five minutes This is usually enough time for the engine to reach a normal operating temperature and for the treated gasoline to circul...

Page 80: ...ating at any point during the draining procedure IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to the manufacturer s instructions be used in the seawater section of the...

Page 81: ...System Seawater cooled models Non ECT shown ECT similar a Blue handle b Blue drain plug location 4 3 ECT Single Point Drain System with Plug 45951 Blue drain plug Three Point Manual Drain System Seaw...

Page 82: ...uated Single Point Drain System Boat in the Water NOTE This procedure is written for the air pump that is included with the engine However any air source can be used 1 Close the seacock if equipped or...

Page 83: ...rom both sides of the engine The port side will begin draining before the starboard side 7 Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger This mus...

Page 84: ...e mounting bracket 13 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is drained 14 Befor...

Page 85: ...r locking 6 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 Closed cooling models...

Page 86: ...start 10 Remove the air pump from the air manifold and return it to the mounting bracket 11 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing...

Page 87: ...s not drain remove the blue drain plug from the distribution housing and drain manually 5 0 MPI ECT a Blue drain plug b Drain location orange or red 4 Allow the system to drain for a minimum of ten mi...

Page 88: ...y vent the cooling system a Blue handle b Blue drain plug location 3 Visually verify that water is draining On the 5 0 MPI ECT if water does not drain remove the blue drain plug from the distribution...

Page 89: ...pickup pump front starboard side a Two blue drain plugs starboard side 5 Verify that water is draining from each opening 6 Allow the system to drain for a minimum of five minutes We recommend leaving...

Page 90: ...the engine to start 6 Before launching the boat or starting the engine close the drain system by installing the three blue drain plugs Draining Water from the Gen III Cool Fuel Module Mercury MerCrui...

Page 91: ...ells are full of water and the battery is fully charged and in good operating condition It should be clean and free of leaks Follow the battery manufacturer s instructions for storage Recommissioning...

Page 92: ...Section 5 Storage Notes Page 84 90 8M0113857 eng DECEMBER 2015...

Page 93: ...ses or Backfires 86 Poor Performance 86 Excessive Engine Temperature 87 Insufficient Engine Temperature 87 Low Engine Oil Pressure 87 Battery Will Not Recharge 87 Remote Control Is Difficult to Move H...

Page 94: ...system Clogged fuel filter Replace fuel filter Stale or contaminated fuel Drain fuel tank Fill with fresh fuel Fuel line or tank vent line kinked or clogged Replace kinked lines or blow out lines wit...

Page 95: ...t of oil Check for cause of excessive oil improper filling Diluted or improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idli...

Page 96: ...eering fluid See authorized Mercury MerCruiser dealer Power Trim Does Not Operate Motor Does Not Operate Possible Cause Remedy Blown fuse Replace fuse Fuses may be located near the dash trim switch at...

Page 97: ...rvice Away From Home 90 Stolen Power Package 90 Attention Required After Submersion 90 Replacement Service Parts 90 Parts and Accessories Inquiries 90 Resolving a Problem 90 Contact Information for Me...

Page 98: ...in both fresh and saltwater environments These conditions require numerous special parts Exercise care when replacing marine engine parts because specifications are different from those of the standa...

Page 99: ...rviers Belgium Fax 32 87 31 19 65 Mexico Central America South America Caribbean Telephone 1 954 744 3500 Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A Fax 1 954 744 3535 Japan...

Page 100: ...Mercury Marine power package contact your nearest Mercury Marine dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 USA only 920 929 4894 USA only Mercury Marine Attn Publications Depar...

Page 101: ...Section 8 Checklists 90 8M0113857 eng DECEMBER 2015 Page 93 Section 8 Checklists Table of Contents Predelivery Inspection PDI 94 Customer Delivery Inspection CDI 95 8...

Page 102: ...ers tight Battery of proper rating fully charged secured with protective covers in place All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct propeller...

Page 103: ...CDI IMPORTANT This checklist is for packages that are not equipped with Axius For engine packages equipped with Axius use the Axius specific checklist which appears in Section 5 of the Axius Operation...

Page 104: ...Section 8 Checklists Page 96 90 8M0113857 eng DECEMBER 2015 N A Completed Item Complete and submit warranty registration provide the customer with a copy...

Page 105: ...Section 9 Maintenance Log 90 8M0113857 eng DECEMBER 2015 Page 97 Section 9 Maintenance Log Table of Contents Scheduled Maintenance Log 98 Vessel Maintenance Notes 99 9...

Page 106: ...me Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name Signa...

Page 107: ...g 90 8M0113857 eng DECEMBER 2015 Page 99 Vessel Maintenance Notes Record all general maintenance performed on your power package here Save all work orders and receipts Date Engine Hours Maintenance Co...

Page 108: ......

Page 109: ...lia www mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www brunswick marine com Parc Industriel de Petit Rechain B 4800 Verviers Belgium Mercury Marine All rights reserved Printed in U S...

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