Mercury 8.1S Horizon Product Applications Manual Download | Manualshive

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WARNING

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CAUTION

CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury or property damage. It may also be used to alert against unsafe
practices.

IMPORTANT: Indicates information or instructions that are necessary for a particular step
or action.
NOTE: Indicates information that helps in the understanding of a particular step or action.

Related Bulletin List

Use the following table to record any future bulletins that affect or add to the information in
this manual. List the bulletin numbers and affected sections or pages in this manual for
your reference.

Bulletin Type Bulletin Number Bulletin Description/Title

Section/Page
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Copyright and Trademark Information

Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2006, Mercury Marine
Mercury,  Mercury  Marine,  MerCruiser,  Mercury  MerCruiser,  Mercury  Racing,  Mercury
Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort,
M  with  Waves  logo,  Mercury  with  Waves  logo,  and  SmartCraft  logo  are  all  registered
trademarks  of  Brunswick  Corporation.  Mercury  Product  Protection  logo  is  a  registered
service mark of Brunswick Corporation.

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Summary of Contents for 8.1S Horizon

Page 1: ...ww mercurymarine com au Private Bag 1420 Dandenong South 3175 Victoria Australia www mercurymarine com P O Box 1939 Fond du Lac WI 54936 1939 USA www marinepower com Parc Industriel de Petit Rechain B...

Page 2: ...cturer or installing dealer is responsible for selecting the appropriate power package including correct gear ratio and propeller for a given boat Making an appropriate selection requires knowledge of...

Page 3: ...tins that affect or add to the information in this manual List the bulletin numbers and affected sections or pages in this manual for your reference Bulletin Type Bulletin Number Bulletin Description...

Page 4: ...Exhaust System A Exhaust System 7 Cooling System A Cooling System 8 Electrical System A Electrical System 9 Instrumentation and Controls A Instrumentation and Controls 10 Predelivery Preparation A Pre...

Page 5: ...Page iv...

Page 6: ...r Service Offices 1A 2 Mercury Precision Parts Quicksilver Products 1A 3 Factory Installed Options 1A 3 Serial Number Decal Placement Inboard and Tow Sports 1A 4 California Regulations for 2007 Low Pe...

Page 7: ...lity Service Support 405 743 6555 Fax 405 743 6570 Sales or Field Sales Technical Support 405 743 6505 Fax 405 743 6560 Outside the U S A Contact your Distribution Center or Distributor Mercury MerCru...

Page 8: ...r will be quickly and conveniently handled using the same warranty system as used for standard Mercury products A complete listing of all of the latest accessories can be found in the Mercury Precisio...

Page 9: ...ation California Regulations for 2007 Low Permeation Fuel Hose California Regulations for New 2007 and Later Spark Ignition Inboard Sterndrive Pleasurecraft 3 Requirements of engine manufacturers and...

Page 10: ...anization CARB California Air Resources Board EU European Union SAV Schweizer Abgas Vorschriften Swiss Gas Regulations JCI Japanese Craft Inspection Emission Control Information Label A tamper resista...

Page 11: ...Information Label on the engine the Declaration of Conformance applies NOTE The following applies to CE marked products only DECLARATION OF CONFORMANCE MERCURY MERCRUISER This sterndrive or inboard e...

Page 12: ...esponsibility of Mercury Marine and Mercury MerCruiser Patrick C Mackey President Mercury Marine Fond du Lac WI USA Regulatory contact Engineering Regulatory MerCruiser 3003 N Perkins Rd Stillwater Ok...

Page 13: ...d Mercury MerCruiser engine All Mercury MerCruiser engines 500 hp and below will have a Three Star Ultra Low Emission rating The Three Star label identifies that these engines meet the California Air...

Page 14: ...marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission A SS D mc79571 1 The three star...

Page 15: ...5000 4800 5200 Rev Limiter RPM 4950 5150 5350 Idle RPM 650 Oil Pressure 2000 RPM 207 483 kPa 30 70 psi Minimum Oil Pressure Idle 28 kPa 4 psi 41 kPa 6 psi 28 kPa 4 psi 41 kPa 6 psi Thermostat Temperat...

Page 16: ...60 F Seawater Cooled Thermostat Temperature 77 C 170 F Closed Cooled Timing 10 BTDC 8 BTDC Firing Order 1 8 4 3 6 5 7 2 Transmission Offerings Refer to SECTION 2 Transmission and Drive Line Weight 400...

Page 17: ...hermostat Temperature 71 C 160 F Seawater Cooled N A Thermostat Temperature 77 C 170 F Closed Cooling 71 C 160 F Closed Cooling Timing 8 BTDC N A Firing Order 1 8 4 3 6 5 7 2 1 8 7 2 6 5 4 3 Transmiss...

Page 18: ...rews 64 47 Trunnion clamping screws and nuts 68 50 Thermostat housing attaching screws 41 30 Propeller shaft coupling screws and nuts 68 50 Shift and throttle cable fasteners Tighten securely then loo...

Page 19: ...Important Information Notes Page 1A 14 90 863758060 AUGUST 2006...

Page 20: ...and Propeller Shaft Installation Angle 2A 2 Propeller Shaft Rotation and Spacing on Dual Installations 2A 2 Propeller Blade Tip Clearance 2A 3 Propeller Shaft Coupling 2A 3 Propeller Shaft 2A 4 Prope...

Page 21: ...front end too high can cause aeration of the transmission fluid and engine oil Special care must be taken on 350 cid 5 7L and 377 cid 6 2L V drive applications with propeller shaft angles of less than...

Page 22: ...igid propeller shaft coupling can be used Rigid propeller shaft couplings can be ordered with the engine or purchased through Mercury Precision Parts and Accessories Alignment with these couplings is...

Page 23: ...esponsible for engine damage caused by improper cooling system connections for the propeller shaft log seal The propeller shaft log seal hose should be routed so that a portion of the hose extends abo...

Page 24: ...r port on the port exhaust elbow a 7641 Propeller shaft log seal connection 5 7L and 6 2L models a Shaft log seal fitting SCORPION MODELS A brass plug is installed at the factory into the proper port...

Page 25: ...0 1 2 5 1 350 MAG MPI Horizon 1 0 1 1 0 1 1 25 1 1 5 1 2 0 1 2 5 1 2 8 1 1 5 1 2 0 1 2 5 1 1 5 1 2 0 1 2 5 1 2 7 1 1 5 1 2 0 1 2 5 1 6 2L MX MPI 1 0 1 1 25 1 1 5 1 2 0 1 2 5 1 2 8 1 1 5 1 2 0 1 2 5 1...

Page 26: ...ation in FORWARD gear is indicated on a decal on the transmission case Transmission rotation is described when viewed from the rear of transmission c a b 7424 Velvet Drive 71C and 72C transmissions a...

Page 27: ...06 7370 a a Identification plate ZF MARINE 630 AND 800 SERIES TRANSMISSIONS On the ZF Marine Down Angle and V Drive transmissions the identification plate indicates gear ratio serial number and model...

Page 28: ...ntification plate is located on the top rear of the transmission 14913 a ZF Marine Hurth 45C a Identification plate WALTER V DRIVE TRANSMISSIONS On the Walter V Drive transmissions the identification...

Page 29: ...attachment at the remote control b c b d e 7648 a Velvet Drive 5000A 8 down angle a b b g d f 7649 Velvet Drive 5000V V Drive a Direction of shift lever engagement toward flywheel b Engine transmissi...

Page 30: ...tion direction RH as viewed at propeller d Direction of shift lever engagement away from flywheel e Transmission output propeller shaft rotation direction LH as viewed at propeller f Transmission outp...

Page 31: ...Information 3A 2 Engine Rotation 3A 2 Engine Lifting Provisions 3A 3 Engine Oil Dipstick Relocation 3A 3 Engine Compartment Construction 3A 4 Engine Compartment Ventilation 3A 4 Engine Compartment Se...

Page 32: ...ignment hook 91 863375A 1 9190 Assists during engine alignment General Information Engine Rotation Engine rotation is described when observed from the rear of the engine transmission end looking forwa...

Page 33: ...t hook 91 863375A 1 Engine Oil Dipstick Relocation Some models are equipped with an oil dipstick in the port and starboard dipstick tubes If only one dipstick is present and the engine is equipped wit...

Page 34: ...d i e stringers must be designed to support the G forces imposed by the engine during the most severe duty The bed must also handle the torque produced by the engine and the thrust generated by the pr...

Page 35: ...life of the product Considering serviceability when designing the engine compartment could have a major impact on customer and dealer satisfaction In addition to customer and dealer satisfaction cons...

Page 36: ...ign work MAJOR SERVICE POINTS LIST Oil filter Engine oil dipstick Crankcase oil fill cap Water separating fuel filter Transmission fluid dipstick Transmission propeller shaft coupler Engine mounts Ign...

Page 37: ...ical 8 1L inboard side view a Transmission output flange b Engine mounts 4 c Transmission dipstick d Starter inboard style e Transmission fluid cooler f Ignition components g Dipstick h Engine cover i...

Page 38: ...Heat exchanger c Coolant reservoir d Pressure cap e Flame arrestor f Electrical bracket g Thermostat housing h Alternator i Circulating pump OIL FILTERS 14333 a Typical tow sports engine oil filter a...

Page 39: ...ONS 14851 a a Models with boost pump Models without boost pump a Fuel inlet fitting a 8269 Gen III Cool Fuel Module Inboard models a Fuel inlet fitting Tube Ref No Description Where Used Part No 9 Loc...

Page 40: ...e 3A 10 90 863758060 AUGUST 2006 ELECTRICAL 14957 Typical electrical components bracket THROTTLE a b c 7926 Typical throttle cable and linkages a Flat washer and locknut b Cable barrel c Flat washer a...

Page 41: ...58060 AUGUST 2006 Page 3A 11 11527 a b c Typical quick connect throttle cable a Jam nut b Cable barrel c Throttle body bracket SHIFT a c b 11531 Typical quick connect shift cable a Jam nut b Cable bar...

Page 42: ...6 a 7670 Typical transmission a Shift cable 7657 a c b d f g e Typical dual station transmission a Cable end guide b Cable barrel c Cable barrel stud d Elastic stop nut and washer e Spacer f Cable end...

Page 43: ...on DTS transmissions 20418 ZF Marine Hurth transmission with electric shift DTS models FLUSH a 6090 Typical flush connector models so equipped a Flush connector COOLANT a b c d 8295 Typical heat exch...

Page 44: ...A 14 90 863758060 AUGUST 2006 b d b a c 7804 Coolant recovery bottle closed cooled engines except 8 1S a Coolant recovery bottle b Mounting holes c Hose d Hose clamp SEA STRAINER 7533 Typical sea stra...

Page 45: ...Engine 90 863758060 AUGUST 2006 Page 3A 15 STARTER c b a 7766 Typical starter a Rubber boot b Starter solenoid c 90 amp fuse THERMOSTAT a 8219 Typical thermostat housing a Housing...

Page 46: ...63758060 AUGUST 2006 FUEL AND AIR INDUCTION 14339 Typical Fuel Air Induction System FUEL SYSTEMS a b 14931 Typical fuel filter a Water separating fuel filter cover MPI tow sports models only b Water s...

Page 47: ...cooler Gen II a Fuel cooler d a b c e f g h 8837 Gen III Cool Fuel Module a Cool Fuel Module b Cool Fuel Module harness c Filter cap d Filter assembly retaining screw e Fuel filter element f Filter cu...

Page 48: ...hull On applications with a rigid propeller shaft coupler the coupler should be disconnected from the transmission for shipment The alignment should then be rechecked with the boat in the water The re...

Page 49: ...c Transmission output flange Specification mm in Transmission output flange to propeller shaft coupler alignment tolerance 0 0 0 07 0 0 0 003 The slot on the front mounts should face forward The adju...

Page 50: ...t d Tab washer Tighten mount locknuts securely Bend the tab washer tab that is closest to the adjacent flat on the locknut against the flat to prevent it from loosening Torque trunnion clamping screws...

Page 51: ...he rotation is established by the gear box The transmission can only be operated under full power when in the FORWARD gear position 14917 b a Velvet Drive 71C and 72C transmission a Output flange rota...

Page 52: ...temperature sensor Connect the wire connections of the harness to the oil temperature sensor b a 12122 ZF Marine transmission DTS oil temperature sensor installed a Oil temperature sensor b Oil tempe...

Page 53: ...Transmission and Drive Line Notes Page 2A 14 90 863758060 AUGUST 2006...

Page 54: ...A Air Intake System Section 4A Air Intake System Table of Contents Engine Compartment Ventilation 4A 2 Engine Compartment and Fuel System Pressure and Temperature Test 4A 3 Connections 4A 3 Running T...

Page 55: ...and temperature at top of engine compartment as defined under the engine compartment and fuel system pressure and temperature test following 2 The minimum air vent cross sectional area shown in the fo...

Page 56: ...ed in the boat audit tool kit to measure the RVP if this information cannot be obtained from your fuel distributor This test should be performed under the highest ambient air temperatures that the boa...

Page 57: ...f room and no danger to other boaters 8 Do not close the throttle if a hesitation stumble bog or stall occurs Allow the engine to recover if possible on its own 9 Observe operating characteristics and...

Page 58: ...temperature or pressure differential Insufficient cross sectional area of air vents and related hardware Inlet and exhaust vents improperly located on boat too close to one another both in high press...

Page 59: ...Air Intake System Notes Page 4A 6 90 863758060 AUGUST 2006...

Page 60: ...ystem Section 5A Fuel Delivery System Table of Contents Fuel Delivery System 5A 2 Fuel Tank 5A 3 Anti Siphon Valve 5A 4 Fuel Lines and Fittings 5A 5 Fuel Inlet Connection 5A 5 Inline Fuel Filter 5A 7...

Page 61: ...l system cannot handle this vapor and therefore fuel starvation results when the boater attempts to resume operation Depending upon the degree of vapor locking this can range from a hesitation or bog...

Page 62: ...delines The fuel pickup should be at least 25 mm 1 in from the bottom of fuel tank to prevent picking up impurities The maximum measured vacuum at the engine s fuel inlet must not exceed 6 9 kPa 1 psi...

Page 63: ...amount of fuel tank surface area that is exposed to the engine compartment can have a significant affect on fuel temperature It may be necessary to insulate the tank if fuel inlet temperature is exces...

Page 64: ...ngs can increase the fuel inlet temperature to the engine by absorbing heat from the engine compartment Use the Fuel System Pressure and Temperature Test to determine if fuel pressure and temperature...

Page 65: ...Model Size All models including 8 1S with standard fitting 3 8 in 18 NPSF 8 1S models with special order fitting Compression fitting in SAE b a 14354 V 8 carbureted models a Fuel inlet b Water separa...

Page 66: ...line from the tank to the engine 3 With the engine installed locate a section of the fuel line in a serviceable location leaving enough room for filter connections and bracket mounting 4 Remove 76 mm...

Page 67: ...insert the barbs into the hose Torque the hose clamps 12 Inspect the fuel line mounting clips to ensure that the recommended length between clips has not been exceeded The maximum allowable length is...

Page 68: ...r added resistance to vapor locking On tow sports models this includes insulator covers on the water separating fuel filter which act as a barrier to heat transfer during a heat soak condition engine...

Page 69: ...Fuel Delivery System Page 5A 10 90 863758060 AUGUST 2006 a 14340 Fuel cooler a Gen II fuel cooler...

Page 70: ...In Line Muffler 6A 10 V Pipe and In Line Muffler 6A 11 Water Lift Exhaust System 6A 11 Collector and Water Lift Muffler 6A 14 S pipe Used With Water Lift Muffler 6A 14 Measuring Exhaust Elbow Height...

Page 71: ...egulations NMMA ABYC SAE USGC EUs RCD ISO for the markets where the boat will be sold must be adhered to when designing and installing exhaust system Exhaust system design and installation can affect...

Page 72: ...is near an operating engine may be exposed to a hazardous level of carbon monoxide 1 Examples of poor ventilation while a boat is stationary mc79554 1 a b a Operating the engine when the boat is moor...

Page 73: ...must be installed at the angle shown following 18576 18577 Correct Incorrect e a b c d 18578 a Maximum misalignment 5 degrees b Exhaust outlet centerline 14 vs crankshaft centerline c Exhaust hose cen...

Page 74: ...roblems This is a requirement on all applications except water lift mufflers where it is still recommended A variety of fittings is available through Mercury Precision Parts and Accessories 13377 NOTE...

Page 75: ...Precision Parts and Accessories Resonators are installed as shown Because of the critical nature of the placement of the resonator Mercury MerCruiser will free license this technology to allow the res...

Page 76: ...use of heat resistant rubber hose on the outlet side of the system These specifications must be observed by the OEM and muffler manufacturer when designing manufacturing and installing the exhaust sys...

Page 77: ...ations when designing the collector Collector Inlet and Outlet Specifications 1 The inlet hose for the collector must be placed above and within 180 of the horizontal centerline of the collector 2 The...

Page 78: ...s The muffler collector and exhaust hoses must be adequately supported for proper orientation and to prevent overstressing the exhaust manifolds and elbows The support requirements will vary with exha...

Page 79: ...uals drawings or orientation marks on production assemblies It is strongly recommended that orientation marks be used on all production exhaust system assemblies In line mufflers collectors and hoses...

Page 80: ...tem in which exhaust is mixed with water in the exhaust elbows This cools the exhaust and allows the use of heat resistant rubber hose on the outlet side of the system These specifications must be obs...

Page 81: ...pot does not exist at any point Exhaust resonators can be used on any models except 3 0L models that may experience a water intrusion problem Refer to Exhaust Resonators Through the hull exhaust fitti...

Page 82: ...needed to obtain the specified distance The muffler riser must also exceed both Mercury s and the exhaust system manufacturer s specified distance above the waterline to prevent the muffler from filli...

Page 83: ...break vacuum valve Must be installed in cooling water circuit if exhaust elbows are at or below water level Refer to muffler manufacturing recommendations c Exhaust back pressure check point d Resonat...

Page 84: ...stribution conditions that will affect the exhaust system must be clearly communicated to the operator in the owner s manual For example the number of people that can be located on the swim platform s...

Page 85: ...quirements a b c 18582 Typical exhaust except 8 1L 496 cid a Inclinometer b Exhaust hose or tube c Minimum 457 mm 18 in a b 8235 c Typical exhaust 8 1L 496 cid a Inclinometer b Exhaust hose or tube c...

Page 86: ...74 84 kg 165 lb Cargo per person is equivalent to 11 34 kg 25 lb 4 Add weight for any additional boat options extra battery battery charger tower arch generator ballast tanks ballast sacks television...

Page 87: ...4 If applicable load cargo leftover persons weight onto the boat Distribute cargo as described below IMPORTANT If the boat configuration does not allow for aft center and bow storage choose the storag...

Page 88: ...eight to be placed in the boat 1100 lb 400 lb 700 lb 2 Remaining weight to be placed in the boat MerCruiser person weight number of persons to load onto the boat 700 lb 165 lb 4 24 persons 3 Total num...

Page 89: ...ber of 165 lb persons to load onto the boat Round up to next whole number See Example 3 IMPORTANT To account for cargo add a weight of 25 lb per person to the boat before loading passenger weight onto...

Page 90: ...aximum cargo weight per passenger 9 passengers 25 lb 225 lb 2 To determine the preferred cargo distribution for aft center and bow storage a To determine the maximum aft storage cargo weight multiply...

Page 91: ...i j 24864 Cargo swim platform and passenger weight loading diagram a Swim platform load b MerCruiser person weight one c MerCruiser person weight two d MerCruiser person weight three e MerCruiser per...

Page 92: ...of exhaust elbow c Clear hose d Weight e Measurement waterline to top of exhaust elbow Clear Hose Measurement Method From Seacock or Muffler Drain IMPORTANT Measure the exhaust elbow height to the wa...

Page 93: ...r height is 20 3 cm 8 in on 496 models 15 2 cm 6 in on all other models 24866 a b Typical vertical water lift muffler a Minimum exhaust elbow height with maximum load b Clear hose for measuring waterl...

Page 94: ...hould be designed and tested for the highest horsepower engine to be offered in that boat Ensure that both cylinder banks of any engine are tested Record the highest and lowest back pressure readings...

Page 95: ...haust manifold tap method provides a more accurate means to measure the water but requires that a hole be drilled in each manifold The manifolds must be replaced after performing this check so the pro...

Page 96: ...ot water jacketed a 13414 b 13415 a Number 4 exhaust manifold runner b Number 5 exhaust manifold runner 2 Insert brass drain plugs into the holes Qty Description Part Number 2 Brass drain plugs 22 818...

Page 97: ...Leaking exhaust elbows or risers i e loose screws damaged gasket Improperly designed collector or Y pipe See Exhaust System Design Exhaust system causing a tuning effect See Exhaust Resonators Imprope...

Page 98: ...7A 8 Seawater Inlet Restriction Test 7A 8 Seawater Pressure Test for MPI Models 7A 9 Seawater Aeration Test 7A 9 Closed Cooling 7A 10 Description 7A 10 Antifreeze Recommendations 7A 10 Coolant Recover...

Page 99: ...fresh water antifreeze and water and seawater for cooling Both types of systems are designed to keep the engine operating temperature at approximately 71 degrees C 160 degrees F for optimum performanc...

Page 100: ...te Minimum kPa psi 350 Mag MPI Closed Cooling System Through Hull 4000 106 liter 28 GPM 138 kPa 20 psi 350 Mag MPI Horizon MX 6 2 MPI MX 6 2 MPI Horizon 8 1S Horizon 76 liter 20 GPM 75 kPa 11 psi 8 1S...

Page 101: ...e should be oil and seawater resistant Use the shortest hose length possible with the least number of bends to minimize restriction All connections must be secured with a hose clamp Fasten hose as app...

Page 102: ...seawater flow to engine seawater pickup pump for adequate engine cooling The seawater pickup also must supply a positive head while underway The seawater pickup should be located as close to the seaw...

Page 103: ...iven the hull material being used and the composition of the surrounding components Some industry standards and regulations also require that the pickup be connected into the boat s bonding system to...

Page 104: ...oling system Refer to applicable standards and regulations for specific requirements The seacock also allows the seawater to be shut off when servicing the engine The seacock must provide minimum rest...

Page 105: ...hen servicing The strainer must have provision to allow draining in freezing temperature periods 7533 Typical Sea Strainer Seawater Supply Test Seawater Inlet Restriction Test Maximum seawater inlet r...

Page 106: ...air free flow of seawater Excessive bends in seawater inlet hose Seawater inlet hose collapsing wire reinforced hose not used Seawater Pressure Test for MPI Models IMPORTANT MPI models must use the fl...

Page 107: ...ystems are developed by the same people who design our engines to ensure compatibility and the same high quality standards Our systems employ several exclusive features to provide unsurpassed cooling...

Page 108: ...Life Dex Cool Prestone also offers a version of this antifreeze called Extended Life 5 100 Only coolants that state that they are compatible with Dex Cool should be used Extended life coolants can be...

Page 109: ...ply and return hoses are too large Maximum ID of heater supply and return hose 16 mm 5 8 in Make heater connections only at locations specified Do not reposition the temperature senders or switches fo...

Page 110: ...ed from the system IMPORTANT Closed cooling system capacity will be different than shown in Operation Maintenance and Warranty manual Be sure to advise owner of the proper capacity for your applicatio...

Page 111: ...6 a 7564 Water circulating pump housing a Location for return hose connection WATER HEATER CONNECTIONS CARBURETED MODELS 7562 a a a Location for hot water supply connection a 7564 Water circulating pu...

Page 112: ...ELS NOTE Some models may be equiped with additional fittings a b 11478 b a 11479 Port side intake manifold plug Starboard side intake manifold plug a Location for hot water supply connection b Thermos...

Page 113: ...ng a cabin shower Supply hose Must Not Exceed 16 mm 5 8 in inside diameter ID Do not reposition shaft log seal a 11460 a Hose for cold water supply WATER HEATER CONNECTIONS 8 1S MODELS a b 8238 a Loca...

Page 114: ...er Flow Diagram SEAWATER COOLING SYSTEM a b c d e f g h i 7567 a Seawater inlet b Seawater pump c Transmission cooler d Thermostat housing and cover assembly e Engine water circulating pump f Engine b...

Page 115: ...ar power package but the water flow paths remain similar on all engines a b c d e f g h i j k l m c n o 8182 a Seawater inlet b Transmission cooler c Gen III Cool Fuel module d Exhaust and seawater ou...

Page 116: ...8183 a Seawater inlet b Transmission cooler c Gen III Cool Fuel module d Exhaust and seawater outlet e Exhaust manifold f Distribution housing g Water circulating pump h Thermostat housing i Exhaust...

Page 117: ...a Seawater inlet b Transmission cooler c Gen III Cool Fuel module d Exhaust and seawater outlet e Exhaust manifold f Distribution housing g Water circulating pump h Thermostat housing i Exhaust elbow...

Page 118: ...wer package but the water and coolant flow paths remain similar on all engines 1 2 3 4 5 6 7 8 9 10 11 12 13 15 8227 14 1 Seawater pump Air actuator 2 Air actuator 3 Transmission cooler 4 Oil cooler 5...

Page 119: ...Cooling System Notes Page 7A 22 90 863758060 AUGUST 2006...

Page 120: ...y Standards and Regulations 8A 3 Battery and Battery Cables Requirements 8A 4 Battery 8A 4 Battery Cables 8A 5 Battery Cable Connections 8A 6 Electrical Connections 8A 8 SmartCraft Product 8A 8 Engine...

Page 121: ...rds and regulations to prevent the ignition of combustible fumes in the engine compartment should they exist These components should not be confused with standard automotive components which typically...

Page 122: ...ard USCG European Union Recreational Craft Directive EU RCD etc and the standards they reference American Boat and Yacht Council ABYC Society of Automotive Engineers SAE International Standards Organi...

Page 123: ...andards with the proper overcurrent protection being used Battery and Battery Cables Requirements CAUTION Electrical system is negative ground Do not reverse battery cables or alternator and other ele...

Page 124: ...ttery is not installed above or below a fuel tank fuel filter or fitting in a fuel line ABYC Standard The battery is installed so that the metallic objects cannot come in contact with the ungrounded p...

Page 125: ...ve battery cable must be routed to avoid contact with any portion of the engine or drive train Cables that are exposed to physical damage should be protected by conduit raceways tape etc Cables that p...

Page 126: ...s to the boat using industry approved fasteners to prevent stressing the cable and terminals Apply liquid neoprene on the connections at the engine to prevent corrosion Tube Ref No Description Where U...

Page 127: ...tage fuel consumption and engine operating hours The SmartCraft Instrument package will also aid in Engine Guardian diagnostics The SmartCraft Instrument package will display critical engine alarm dat...

Page 128: ...sure that the harness does not rub or get pinched If an extension harness is required be sure to secure the connection properly 2 Fasten the harnesses to the boat at least every 45 7 cm 18 in using ap...

Page 129: ...HE DASHBOARD OR OTHER APPROPRIATE LOCATION AUDIO WARNING HORN WILL SOUND WHEN 1 ENGINE OIL PRESSURE IS TOO LOW 2 ENGINE TEMP IS TOO HIGH OR 3 DRIVE OIL LEVEL IS TOO LOW TO TEST AUDIO WARNING HORN TURN...

Page 130: ...Model 32023A battery isolator is connected to 2 banks of batteries 3 Each bank contains 2 batteries with the cranking battery for 1 engine in each bank 4 The second battery in each bank is connected i...

Page 131: ...A battery isolator can be installed to allow the charging of an auxiliary battery for use in operating accessories The battery isolator will allow the alternator to charge both the cranking battery a...

Page 132: ...round stud e Auxiliary battery f Isolator CAUTION Avoid wiring damage Do not cut the orange wire flush with the wiring loom Doing so will damage other wires in the loom 1 Disconnect the orange wire fr...

Page 133: ...Electrical System Notes Page 8A 14 90 863758060 AUGUST 2006...

Page 134: ...Connections 9A 3 Dual Station Instrumentation 9A 3 Audio Warning System 9A 4 Engine Guardian 9A 5 Lanyard Stop Switch Information 9A 6 Instrumentation Harness Receptacle 9A 7 10 Pin Instrument Harness...

Page 135: ...r engines and engineered to the same high quality and performance standards Refer to the Mercury Precision Parts Accessories Guide for a complete list Wiring diagrams of some of the basic instrumentat...

Page 136: ...anel with up to a 40 amp current draw can be connected to the helm harness On dual station applications the combined current draw for both stations must not exceed 40 amps If optional accessory power...

Page 137: ...of the system WARNING Fire or explosion hazard The horn is not external ignition proof therefore do not mount the horn in the engine or fuel tank compartments Select mounting location where alarm is o...

Page 138: ...ser MPI models are equipped with an Engine Guardian to provide additional protection against engine damage The system is designed to help reduce the potential for engine damage by reducing engine powe...

Page 139: ...tch If your remote control is not equipped with a lanyard stop switch one can be installed on the dashboard or side adjacent to the operator s position The lanyard is a cord usually 1 2 1 5 m 4 5 ft l...

Page 140: ...power and directional control in heavy seas strong current or high winds Loss of control when docking Instrumentation Harness Receptacle A receptacle is provided on the engine for connecting Quicksil...

Page 141: ...60 AUGUST 2006 a b c d e 12118 Typical 14 pin DTS harness a Engine harness connector b Transmission harness connector c Paddle wheel tank level connector d DLC depth transducer connector e Power harne...

Page 142: ...2 i See Note 3 j To engine wiring harness Refer to gauge manufacturer s instructions for specific connections Note 1 Connect wires together with screw and hex nut apply liquid neoprene to connection a...

Page 143: ...3 4 5 6 NOTE 4 NOTE 4 NOTE 1 NOTE 1 BRN WHT NOTE 3 NOTE 3 NOTE 3 NOTE 3 NOTE 2 A B 14925 A Primary Station B Secondary Station 1 Start stop panel 1 Ignition switch 2 Tachometer 2 Tachometer 3 Oil pres...

Page 144: ...el may be connected at this location The combined current draw of the primary station and secondary station must not exceed 40 amperes Note 3 Connect the wires together using a screw nut and sleeve Ap...

Page 145: ...e levers can be used on single station applications Two lever controls are required on dual station helm applications Remote control must provide a cable travel at engine end Remote Control Cable Trav...

Page 146: ...bles to the boat or any other objects within 92 cm 3 ft of the remote control and engine attaching points Keep bends to a minimum Route cables so that they do not have less than an 20 cm 8 in radius a...

Page 147: ...e then connected to the engine using the single cable attachment procedure On some applications it may be preferable to connect both sets of cable directly to the engine using a parallel connection Me...

Page 148: ...d f e b g h 7672 Typical single cable forward entry a Cable end guide b Locknut and washer c Spacer fits over bushings d Bushings e Cable barrel location f Spacer fits over stud g Cable barrel stud h...

Page 149: ...nd guides b Locknut and washer c Spacer fits over stud d Bushings e Cable barrel locations f Cable barrel stud g Cable end guide stud e a b c d e b f g 7675 Typical dual cable rear entry a Cable end g...

Page 150: ...in any manner or if remote control and shift cable do not position shift lever exactly as shown The shift and throttle cable must be installed and adjusted exactly as stated in the installation instr...

Page 151: ...t hand propeller shaft rotation is desired c Poppet ball must be centered in this detent hole when right hand propeller shaft rotation is desired d Poppet ball must be centered in this detent hole for...

Page 152: ...REVERSE with the wrong rotation propeller under full power F N R F R a b c d e 7653 Velvet Drive 71C and 72C Transmission a Transmission shift lever b Shift lever must be over this letter when propel...

Page 153: ...Instrumentation and Controls Notes Page 9A 20 90 863758060 AUGUST 2006...

Page 154: ...out of the Water 10A 2 Propeller Selection 10A 3 Selection Procedure 10A 3 Cruising RPM 10A 5 How Elevation and Climate Affect Performance 10A 5 Power Package Preparation for Shipment 10A 6 Extended...

Page 155: ...If for some reason it is not possible to perform some of the checks at your facility i e performance checks arrangements should be made with the dealer to ensure that these checks are completed before...

Page 156: ...provides the latest in propellers how they work types design and manufacturing how to select the proper propeller for a given application and answers to many commonly asked questions about boating per...

Page 157: ...s 1 US gallon gasoline 0 72 kg 6 lbs 1 US Gallon Water 1 kg 8 3 lbs Select model and initial pitch propeller to begin testing with using information provided in the Mercury Precision Parts and Accesso...

Page 158: ...r optimum boat performance and engine life Cruising RPM Modern inboard engines operate at higher engine speeds than those produced just a few years ago This increased RPM along with better breathing i...

Page 159: ...so be operating in an RPM range that discourages detonation This enhances overall reliability and durability of the engine Power Package Preparation for Shipment Extended Storage If the boat will not...

Page 160: ...ed in our draining instructions IMPORTANT The boat must be as level as possible to ensure complete draining of the cooling system IMPORTANT Mercury MerCruiser recommends that propylene glycol a nontox...

Page 161: ...n applications with a rigid propeller shaft coupling the coupling must be disconnected from the transmission flange before boat is removed from the water for shipment Coupling should not be reconnecte...

Page 162: ...rotation propeller installed and torqued Forward Neutral Reverse gear operation Throttle shift and steering system fasteners tightened properly Steering operation throughout range Throttle plates ope...

Page 163: ...Predelivery Preparation Notes Page 10A 10 90 863758060 AUGUST 2006...

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