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Mercury HP 500 EFI Bravo XR/XZ/III, User Manual, Page: 116 / 148

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Mercury HP 500 EFI Bravo XR/XZ/III User Manual Download Page 116

 112

500 EFI Bravo

 MAINTENANCE

70573

1

CB172

Fuel Filters

WARNING

Avoid Fire or Explosion: Be careful when changing fuel filters.
Gasoline is extremely flammable and highly explosive under
certain conditions. Be sure ignition key is OFF. Do not smoke
or allow spark or open flame in area when changing fuel filter.
Wipe up any spilled fuel immediately.

1

Remove water separating fuel filter (by turning counterclock-
wise) and sealing ring from mounting bracket and discard. Coat
sealing ring on new filter with motor oil. Thread filter clockwise
onto bracket and tighten securely by hand. Do not use a filter
wrench.

2

Start and run engine ( See Starting, Shifting and Stopping in the
Operation Section of this manual). Check filter connection for
gasoline leaks. If leaks exist, recheck filter installation. lf leaks
continue, stop engine immediately and contact your Authorized
MerCruiser Dealer.

WARNING

Avoid Fire or Explosion: Make sure no fuel leaks exist before
closing engine hatch.

Summary of Contents for HP 500 EFI Bravo XR/XZ/III

Page 1: ...onal in structions for the power package and all related acces sories before the boat is used WARNING The engine exhaust from this product contains chemi cals known to the state of California to cause...

Page 2: ...2 500 EFI Bravo...

Page 3: ...ensure maxi mum performance and carefree use we ask that you thor oughly read this manual The Operation and Maintenance Manual contains specific in structions for using and maintaining your product W...

Page 4: ...N 4 Stern Drive S N Gear Ratio 5 Propeller Number Pitch 6 Hull ID Number 7 Boat Model Length SERIAL NUMBERS The serial numbers are the manufacturer s keys to numerous engineering details which apply...

Page 5: ...1 500 EFI Bravo 4 3 2 1 2 3 4 5 7 6...

Page 6: ...and High Performance Boat Operation 18 Lanyard Stop Switch 19 Trailering Boat 20 Protecting People In The Water 21 Carbon Monoxide Risk 23 Wave And Wake Jumping 24 Impact With Underwater Hazards 25 Op...

Page 7: ...nditions That Lower Engine Performance 71 Maintenance Operation And Maintenance 72 Replacement Service Parts 73 Do It Yourself Maintenance Suggestions 74 Maintenance Charts 77 Checking Fluid Levels 83...

Page 8: ...gine Oil Pressure 132 Battery Will Not Come Up On Charge 132 Power Trim Does Not Operate Motor Doesn t Run 133 Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move 133 Remote Control Op...

Page 9: ...y claims will not be accepted without presentation of this card 4 A temporary Owner Warranty Registration Card will be pres ented to you when you purchase the product It is valid only for 30 days from...

Page 10: ...vice on this product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to pre pare the warranty claim form s 4 In some countr...

Page 11: ...r s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine W6250 W Pioneer Road P O Box 1939 Fond du...

Page 12: ...is tration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that pur chase from a Dealer authorized by Mercury Ma...

Page 13: ...duct for warranty service Warranty claims shall be made by delivering the product for inspec tion to a Mercury dealer authorized to service the product If purchas er cannot deliver the product to such...

Page 14: ...ce Warranty Manual alteration or removal of parts water entering the engine through the fuel intake air intake or exhaust system or damage to the product from insufficient cooling water caused by bloc...

Page 15: ...PURPOSE ARE EXPRESSLY DIS CLAIMED TO THE EXTENT THAT THEY CANNOT BE DIS CLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCI DENTAL AND CONSEQUENTIAL DAMAGES...

Page 16: ...uent noncommercial use purchaser upon proper re regis tration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers th...

Page 17: ...r all related transporta tion charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and materi al and any other expenses associat...

Page 18: ...cal interconnection between the warranted product and the paint For MerCruiser product an un painted gap of at least 1 5 inches 38 mm should be left around the transom assembly Refer to the Operation...

Page 19: ...in material or workmanship but only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale oc curred and then only afte...

Page 20: ...ision or Quicksilver parts when making warranty repairs 8 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condi tion which could re...

Page 21: ...g Your Boat Read this manual carefully Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage If you have any questio...

Page 22: ...boat manufacturer WARNING Overpowering a Boat Can Cause Serious injury death or boat damage Loss of Boat Control Flotation Characteristics of Boat to be Altered from Placing Too Much Weight on Transom...

Page 23: ...far enough away from the operator s position as in accidental ejection from the operator s position to activate the switch A lanyard stop switch can be installed as an accessory generally on the dashb...

Page 24: ...ts could be thrown forward due to unexpected loss of forward motion a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case...

Page 25: ...g even with the drive unit in neutral position there is sufficient force by the water to rotate the propeller This neutral propeller rotation can cause serious injury WHILE BOAT IS STATIONARY Shift th...

Page 26: ...22 500 EFI Bravo GENERAL INFORMATION Courtesy of ABYC 1 2 3 4 5...

Page 27: ...ed cabins or cockpits with insufficient ventilation may draw in carbon monoxide Install one or more carbon monoxide detectors in your boat Although rare on a very calm day swimmers and passengers in a...

Page 28: ...cause occupants to be thrown out of their seats or out of the boat There is another less common hazardous result from allowing your boat to launch off a wave or wake If the bow of your boat pitches do...

Page 29: ...E The hydraulic system will cushion the kickup of the drive unit as it clears the object reducing damage to unit After drive unit has cleared object the drive will return to the original operating pos...

Page 30: ...soon as possible and inspect the sterndrive unit for any broken or loose parts If dam age is present or suspected the power package should be taken to an authorized dealer for a thorough inspection an...

Page 31: ...re is high suction at the water inlets These inlets will easily clog with bottom contact and are susceptible to clog ging when operated in shallow or weedy water 2 Dual Water Inlet Gear Cases The desi...

Page 32: ...way Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Asso...

Page 33: ...board in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maxi...

Page 34: ...tor s side of the boat while returning to attend the skier The opera tor should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operato...

Page 35: ...s replacement before further engine operation CAUTION Use of improper gasoline can damage your engine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and...

Page 36: ...ethyl alcohol you should 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...

Page 37: ...the pres ence of alcohol is unknown increased inspection frequency for leaks and abnormalities is required IMPORTANT When operating a MerCruiser engine on gasoline containing alcohol storage of gasol...

Page 38: ...utomo tive oil SH SG CF CF 2 Straight weight detergent automotive oil of correct viscosity See Chart Below SH SG CF CF 2 Oil filter should always be changed with oil IMPORTANT OIL PRACTICES Do Not Use...

Page 39: ...cksilver 25W 40 20W 50 Capacities MODEL 500 EFI Crankcase Oil Ca pacity w New Filter 1 8 US qts 7 6 L Bravo XR XZ Drive Unit Oil Capacity w Monitor 2 8 US qts 2 65 L Bravo III Drive Unit Oil Capacity...

Page 40: ...Horsepower 470 Propshaft Kilowatts 350 Bore 4 47 in 113 5 mm Stroke 4 00 in 101 6 mm Compression Ratio 8 75 1 Compression Pressure 175 psi 1207 kPa Maximum rpm WOT 1 4800 5200 Idle rpm in or out of Ge...

Page 41: ...ion system that have a built in 5400 rpm rev limiter Engine is performing normally if it will not exceed this rpm Tune Up Specifications MODEL 500 EFI Spark Plug Type AC MR43T NGK BR6FS P N 33 59571 o...

Page 42: ...ifications cont MODEL 500 EFI Electrical System 12 Volt Negative Ground Alternator 50 Amps Valve Lash 1 turn down from zero lash Recommended Battery Rating Minimum 550 CCA or 700 mca or 120 Amp Hrs FR...

Page 43: ...al for oil consumption to be high during break in period CA211hp After Break In Period To help extend the life of your MerCruiser power package the following recommendations should be considered AFTER...

Page 44: ...40 500 EFI Bravo CA26 OPERATION 70514 70515 70516 70523 70517 70522 70518 70521 70519 1 2 3 7 5 6 8 9 10 4 70518 100 300...

Page 45: ...engine rpm 3 Oil Pressure Gauge indicates engine oil pressure 4 Oil Temperature Gauge indicates engine oil operating tempera ture 5 Water Temperature Gauge indicates engine operating temper ature 6 F...

Page 46: ...42 500 EFI Bravo OPERATION CB218 70516 1 2 70518 70517 4 3...

Page 47: ...ngine immediately Investigate cause and correct it if possible If cause cannot be determined consult your Authorized MerCruiser Dealer The audio warning system buzzer will sound continuously if any of...

Page 48: ...44 500 EFI Bravo OPERATION 70525 70528 70526 2 4 3 1 40671 6 5...

Page 49: ...ted Further checks must be made on electrical system 2 A 20 amp fuse may be located in ignition switch I terminal lead to protect electrical system Check for blown fuse if key is turned to START and n...

Page 50: ...46 500 EFI Bravo OPERATION CB181 4 5 3 1 7 6 2...

Page 51: ...tarting the engine 3 Power Trim Switch See Power Trim for detailed power trim operating procedures 4 Trailer Switch Not used with Bravo Heavy Duty Transoms See Power Trim for detailed trailer switch o...

Page 52: ...48 500 EFI Bravo OPERATION CB183 6 5 5 2 2 1 4 4 6 1 3 3...

Page 53: ...The throttle only button can be depressed only when the remote control handle is in the Neu tral position and should only be used to assist in starting the engine 3 Control Handle Tension Adjustment S...

Page 54: ...50 500 EFI Bravo OPERATION 1 3 1 2 3...

Page 55: ...gear unless the engine is at idle rpm 2 Shift Control Lever s Shifting is controlled by the shorter con trol lever s This control shifts unit into gear with full lever move ment Move lever forward to...

Page 56: ...52 500 EFI Bravo OPERATION CA34 1 2 3 5...

Page 57: ...rottle setting CAUTION Use extreme caution when operating with drive unit raised Severe damage to the drive unit may result if unit is raised be yond the gimbal ring support flanges at engine speeds a...

Page 58: ...e the ride in choppy water In most cases reduce boat speed If in excess lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane This can result in...

Page 59: ...55 500 EFI Bravo NOTES...

Page 60: ...56 500 EFI Bravo OPERATION CB187 73976 73977 6 5 4 3 2 1...

Page 61: ...g at a preset trim limit Manual indicators are recommended to help keep the operator aware of the drive positioning 1 Trailer Button Not used with Bravo Heavy Duty Transoms Press button until drive un...

Page 62: ...58 500 EFI Bravo OPERATION CB190 73979 1 b a 2...

Page 63: ...stern drives evenly may result in tie bar or stern drive s damage CAUTION The Bravo heavy duty gimbal does not have a trim limit switch Depressing the trim and or trailer buttons will allow the drive...

Page 64: ...60 500 EFI Bravo OPERATION CB190 73978 1 2 3...

Page 65: ...trim limit switch Depressing the trim and or trailer buttons will allow the drive to be tilted to its full extension without stopping at a preset trim limit Manual indicators are recommended to help...

Page 66: ...62 500 EFI Bravo OPERATION 1 2 1 2...

Page 67: ...mechanical cable actuated Trim Position Indi cator be used to provide important drive unit trim angle infor mation to the operator and that the Trim Indicator be marked to clearly indicate the maximum...

Page 68: ...cks as indicated by your dealer or specified in your boat owner s manual Place drive unit in full down in position Place control handle in NEUTRAL Position throttle setting as follows COLD OR WARM ENG...

Page 69: ...rve power package for fuel oil water and exhaust leaks To shift drive unit into gear move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shift to REVERSE...

Page 70: ...n battery switch OFF if so equipped Operate bilge blowers if so equipped Check shift and throttle control opera tion Close fuel valve Open fuel shutoff valve Check steer ing operation Close sea cock i...

Page 71: ...AUTION During launching from a trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rapidly and at a steep angle This may force water through the exhau...

Page 72: ...t when coming off plane Shifting weight to front bow will Improve ease of planing Improve rough water ride At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain ma...

Page 73: ...e Weeds or other debris snagged on propeller or gear housing Bent propeller blade or damaged gear housing skeg Raised burrs or sharp edges on propeller or gear housing Ventilation Ventilation is cause...

Page 74: ...ct a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded Refer to specifications If full throttle operation is below...

Page 75: ...et will have over a 30 power loss while a loss of engine power on a hot and humid day could be as much as 14 These losses apply to normally aspi rated and supercharged engines Compensating for power r...

Page 76: ...horized MerCruiser Dealer for service aids CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation such as Your selling deale...

Page 77: ...ear full throttle for most of their life They are also expected to operate in fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing m...

Page 78: ...t may be required to perform some re pairs 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 ch...

Page 79: ...l it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly Maintenance Aids Power Steering System Mercury Precision Power Trim and Steering Fluid or Dexron III automatic t...

Page 80: ...5hp MAINTENANCE Maintenance Aids cont Gasoline Stabilizer Gasoline Stabilizer and Conditioner Engine Coupler and Splined Shaft Engine Coupler Spline Grease P N 92 816391A4 Thread Sealant Loctite Pipe...

Page 81: ...ousing Water Pick ups Check for marine growth or debris Serpentine Belt Inspect condition and check tension Every 100 Hours of Operation or 120 Days Whichever Occurs First Propeller Shaft Lubricate Sa...

Page 82: ...If Operating Temperature Exceeds Normal Range Crankcase Oil and Filter Change Every 25 Hours of Operation or Once Every 30 Days Whichever Occurs First Stern Drive Unit Oil Change Universal Joint Cross...

Page 83: ...case Ventilation PCV valve Transom Gimbal Housing Assembly Swivel Shaft and Gimbal Bearing Lubricate Saltwater use Every 50 Hours of Engine Drive Shaft Lubri cate if so equipped Saltwater use Every 5...

Page 84: ...or missing parts y Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Which Engine Exhaust System Inspect for damage deteri oration and restrictions C...

Page 85: ...81 500 EFI Bravo NOTES...

Page 86: ...82 500 EFI Bravo MAINTENANCE 2 3 70543 40556 1 4 115 Quicksilver Power Trim and Steering Fluid 92 90100A12 115...

Page 87: ...hest at wi de open throttle and decreasing substantially as engine speed is re duced It is not uncommon for big block high performance engines to use up to 1 quart of oil in 1 5 hours if the engine is...

Page 88: ...changed at specified intervals Refer to Maintenance Chart for specific requirements Use only Quicksilver High Performance Gear Lube in pump 5 Remove fill screw top and check oil level Oil must come up...

Page 89: ...85 500 EFI Bravo NOTES...

Page 90: ...86 500 EFI Bravo MAINTENANCE 1 70979 70551 2 115 Quicksilver Power Trim and Steering Fluid 92 90100A12 115 87 Quicksilver High Performance Gear Lube 92 816026A2 87 a b 2 71987...

Page 91: ...Quicksilver High Performance Gear Lube is required to fill monitor a seal may be leaking Damage to drive unit may occur due to lack of lubrica tion Contact your Authorized MerCruiser Dealer for servi...

Page 92: ...88 500 EFI Bravo MAINTENANCE HP 1 2 3 70571...

Page 93: ...and using pump handle pump until crankcase is empty Remove crankcase oil pump 2 Place a container below the oil filter Filter removal tip To allow the oil to drain from the filter loosen the filter j...

Page 94: ...90 500 EFI Bravo MAINTENANCE XR and XZ Models 50132 3 70568 4 5 87 87 6 Quicksilver High Performance Gear Lube 92 816026A2 87 Anti Corrosion Grease 92 78376A6 94 94 2 1...

Page 95: ...rom OIL VENT hole Remove tube from OIL FILL DRAIN hole Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 4 Add Specified Gear Lube to the monitor bottle When oil starts to run o...

Page 96: ...92 500 EFI Bravo MAINTENANCE Bravo III CB688 72522 77106 87 1 3 4 5 Quicksilver High Performance Gear Lube 92 816026A2 87 Anti Corrosion Grease 92 78376A6 94 71987...

Page 97: ...h Specified Gear Lube until an air free stream of lubricant flows from OIL VENT hole IMPORTANT Use only Quicksilver High Performance Gear Lube in drive unit 7 Install OIL VENT screw and sealing washer...

Page 98: ...EFI Bravo MAINTENANCE 1 70556 25W40 Motor Oil 92 90024 79 2 79 79 Lubrication SHIFT CABLE 1 Lubricate pivot points with SAE 25W40 motor oil THROTTLE CABLE 2 Lubricate pivot points with SAE 25W40 moto...

Page 99: ...95 500 EFI Bravo NOTES...

Page 100: ...96 500 EFI Bravo MAINTENANCE 1 2 4 70558 71346 71347 70559 3 95 Quicksilver Spline Grease 92 816391A4 2 4 C With Teflon 92 825407A12 95 91 95 91 95...

Page 101: ...e removed to lubricate U joints Contact your authorized MerCruiser dealer for this ser vice CAUTION Speedometer water hose must be disconnected from drive unit BEFORE removing drive unit Failure to do...

Page 102: ...98 500 EFI Bravo MAINTENANCE XR XZ Models 1 2 1 2 3...

Page 103: ...from propeller blades and to prevent propeller from rotating when removing propeller nut CAUTION Avoid Injury Periodically check propeller nut for tightness during boating season A minimum of 55 lb ft...

Page 104: ...100 500 EFI Bravo MAINTENANCE XR XZ Models Anti Corrosion Grease 92 78376A6 94 4 94 a b e f c d g...

Page 105: ...ion Grease 92 78376A 6 Fresh Water Anti Corrosion Grease or Optimal Paste White T Grease 92 847206 b Install prop hub assembly into propeller if removed c Propeller Assembly d Washer e Belleville Wash...

Page 106: ...102 500 EFI Bravo NOTES...

Page 107: ...peller nut CAUTION Avoid Injury Periodically check propeller nut for tightness during boating season A minimum of 55 lb ft 75 Nm torque is required REMOVAL 1 Place wood block between propeller blades...

Page 108: ...104 500 EFI Bravo MAINTENANCE CB150 Bravo III Models 77107 1 2 3 4 5 6 7...

Page 109: ...ign splines and place propeller on propeller shaft 4 Install propeller nut Tighten nut securely A minimum of 100 lb ft 136 Nm torque is required Check propeller at least after 20 hours of operation Do...

Page 110: ...106 500 EFI Bravo MAINTENANCE 1 2 3 1 2 a b...

Page 111: ...sition On dual water inlet drives cover the low water inlets with suitable tape a or a water pickup cap b is also available for the torpedo water pickup 1 Install Quicksilver flushing attachments or e...

Page 112: ...108 500 EFI Bravo MAINTENANCE 1 2...

Page 113: ...tes Tighten screws securely 2 Power Steering Cooler Loosen water hose clamps and re move hoses if it is necessary to inspect or clean cooler If the oil hoses need to be removed from the cooler be prep...

Page 114: ...ley b Water Circulating Pulley c Alternator Pulley d Power Steering Pump Pulley e Idler Pulley Adjustment Pulley f Seawater Pump Pulley g Belt Tension Gauge Check for belt tension here New Belt 120 lb...

Page 115: ...ptable Longitudinal cracks in direction of belt length that join transverse cracks are NOT acceptable If drive belt needs replacement see your Authorized MerCruiser Dealer Drive Belt Routing and Tensi...

Page 116: ...by turning counterclock wise and sealing ring from mounting bracket and discard Coat sealing ring on new filter with motor oil Thread filter clockwise onto bracket and tighten securely by hand Do not...

Page 117: ...rrosion information available through your Mer cury MerCruiser Dealer WARNING DO NOT ATTEMPT TO USE MAGNESIUM ANODES IN SALT WATER They will provide overprotection resulting in a differ ent electroche...

Page 118: ...114 500 EFI Bravo MAINTENANCE 5 6 70578 70577 70575 2 3 4 1 72032 71966 72029...

Page 119: ...Dealer to arrange for this test 4 Anodic Block Kit Optional Mounted to boat transom Acts as a sacrificial anode Replace as required 5 Trim Cylinder Anodes are mounted on each trim cylinder To replace...

Page 120: ...116 500 EFI Bravo MAINTENANCE CB170 1 3 71176 1 2 3...

Page 121: ...per or tin based antifouling paints observe the following 2 Avoid any electrical interconnection between the MerCruis er Product Anodic Blocks or MerCathode System and the paint by allowing a minimum...

Page 122: ...s sparks or flames Hydrogen gases that escape from the battery during charg ing are explosive Batteries contain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries pr...

Page 123: ...ain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts 1 Check for loose damaged...

Page 124: ...500 EFI Bravo ok MAINTENANCE LOG oka1 Record here all maintenance performed on your Mercruiser Hi Per formance package Be sure to save all work orders and receipts Date Maintenance Performed Engine Ho...

Page 125: ...121 500 EFI Bravo ok MAINTENANCE LOG Date Maintenance Performed Engine Hours...

Page 126: ...d change oil and oil filter 2 Flush cooling system Refer to Flushing Cooling System proce dure shown earlier in this manual WARNING Avoid Fire or Explosion Be sure engine compartment is well ventilate...

Page 127: ...silver Gaso line Stabilizer and Conditioner added to any fuel remaining in the tank Refer to FUEL REQUIREMENTS for additional information 5 Close fuel shut off valve if so equipped CAUTION Avoid Damag...

Page 128: ...124 500 EFI Bravo COLD WEATHER OR EXTENDED STORAGE 2 4 a c e f d b...

Page 129: ...and or cor rosion damage to engine 1 Level engine to ensure complete draining of cooling system 2 Remove the following drain plugs a Cylinder Block port and starboard b Bottom of exhaust manifolds c F...

Page 130: ...6 500 EFI Bravo COLD WEATHER OR EXTENDED STORAGE 5 a b c 5 Make sure the following passages are open and unobstructed a Speedometer Pilot Tube b Trim Tab Cavity Vent Hole c Trim Tab Cavity Drain Passa...

Page 131: ...s recommendations a Remove Hoses b Remove T Fitting 6 For additional assurance against freezing and rust remove the hoses from the T fitting of the thermostat cover and then re move the T fitting Fill...

Page 132: ...POSITIVE battery cable to POSITIVE battery terminal If battery cables are reversed electrical system damage will result 2 Install fully charged battery Clean battery cable clamps and ter minals and re...

Page 133: ...k all electrical connections and wires especially battery cables Clean and tighten faulty connection Bad battery Test and replace if bad Engine Will Not Start or Is Hard to Start Possible Cause Remedy...

Page 134: ...isses and or Backfires Possible Cause Remedy Idle speed too low Have adjustments checked by an Authorized MerCruiser Dealer Faulty ignition system component Service ignition system Clogged fuel filter...

Page 135: ...aged Clean or repair as necessary Flame Arrestor dirty Clean Flame Arrestor Excessive Engine Temperature Possible Cause Remedy Seacock closed Open Drive belt loose or in poor condition Replace or adju...

Page 136: ...sive oil improper filling etc Diluted or improper viscosity oil Change oil and oil filter using correct grade and viscosity oil Determine cause for dilution excessive idling etc Faulty Oil Pressure Ga...

Page 137: ...Run Possible Cause Remedy Blown fuse Replace fuse Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tigh...

Page 138: ...Remove obstruction Shift or throttle cable kinked Straighten cable or have dealer replace cable if damaged beyond repair Friction adjustment excessive Adjust Steering Wheel Turns Hard or Jerky Possib...

Page 139: ...k Water Pressure Is Below Specification LOW WATER INLET GEARCASE Possible Cause Remedy Lower the X dimension Insufficient water supply Change propeller that reduces pp y Change propeller that reduces...

Page 140: ...p Pump c Fuel Cooler d Engine Oil Cooler e Power Steering Cooler f Thermostat Housing g Engine Circulating Pump h To Exhaust Elbows i To Exhaust Manifold j To Engine Circulating Pump k Coolant From En...

Page 141: ...ngle Engine BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark 22252 b a c d e a 20 Amp Fuse b Ground Bolt Floor Mou...

Page 142: ...ple RED Red WHT White LIT Light c a b d f e g h i j k g h i j k a Port Trim Pump b Starboard Trim Pump c To 12V Power Source d Console Mounted Port Trim Switch e Console Mounted Starboard Trim Switch...

Page 143: ...ning Buzzer f Ignition Switch b Tachometer g Oil Temperature c Oil Pressure h Electrical Connections d Water Temperature i To Engine Wiring Harness e Battery Meter j See Note NOTE Power for a Fused Ac...

Page 144: ...nd the need arises for service contact the nearest authorized dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Mercury Marine...

Page 145: ...s manager or service manager If 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 co...

Page 146: ...480 County Rd UU Fond du Lac WI 54935 9585 Canada 905 567 6372 905 567 8515 Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario Canada L5N 7W6 Australia Pacific 61 3 9791 5822 61 3 9793 5880 M...

Page 147: ...ry Marine Service Offices cont Telephone Fax Mail Japan 81 53 423 2500 81 53 423 2510 Mercury Marine Japan 283 1 Anshin cho Hamamatsu Shizuoka 435 0005 Japan Asia Singapore 65 546 6160 65 546 7789 Mer...

Page 148: ...lable for your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine At...

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