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Mercury Inboard 5.7L, Manual

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Mercury Inboard 5.7L Manual Download Page 79

Customer Assistance Information

90-860174050   JUNE  2005

Page  71

Section 8 - Customer Assistance Information

Table of Contents

Owner Service Assistance.................................. 72

Local Repair Service .................................... 72

Service Away From Home ........................... 72

Stolen Power Package ................................. 72

Attention Required After Submersion ........... 72

Replacement Service Parts .......................... 72

Parts And Accessories Inquiries ............ 73

Resolving A Problem .................................... 73

Mercury Marine Service Offices ................... 73

Ordering Literature.............................................. 74

United States and Canada ........................... 74

Outside The United States and Canada ...... 74

8 

  

Summary of Contents for Inboard 5.7L

Page 1: ...curring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2005 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 ar...

Page 2: ... Any Portion Contact Your Dealer For A demonstration Of Actual Starting And Operating Procedures Notice Throughout this publication and on your power package WARNINGS and CAUTIONS accompanied by the International Hazard Symbol may be used to alert the installer user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly Obs...

Page 3: ... WARNING California Proposition 65 Warning The engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm ...

Page 4: ......

Page 5: ...Responsibility 19 Star Label 19 Section 3 On The Water Safe Boating Suggestions 22 Be Alert To Carbon Monoxide Poisoning 23 Good Ventilation 24 Poor Ventilation 24 Basic Boat Operation 24 Launching and Boat Operation 24 Operation Chart 25 Starting and Stopping the Engine 25 Starting the Engine 25 Stopping the Engine 26 Throttle Only Operation 26 Freezing Temperature Operation 26 Drain Plug and Bil...

Page 6: ... Coolant 47 Checking 47 Filling 48 Changing 48 Cleaning The Flame Arrestor 49 Positive Crankcase Ventilation Valve PCV 49 Changing 49 Changing Water Separating Fuel Filter 50 Lubrication 51 Throttle Cable 51 Transmission Linkage 51 Serpentine Drive Belt 53 Checking 53 Replacing Belt and or Adjusting Tension 54 Flushing The Power Package 55 Inboards 55 Tow Sports 56 Battery 58 Section 6 Storage Col...

Page 7: ...ir Service 72 Service Away From Home 72 Stolen Power Package 72 Attention Required After Submersion 72 Replacement Service Parts 72 Parts And Accessories Inquiries 73 Resolving A Problem 73 Mercury Marine Service Offices 73 Ordering Literature 74 United States and Canada 74 Outside The United States and Canada 74 ...

Page 8: ...Page iv 90 860174050 JUNE 2005 ...

Page 9: ...tion Outside The United States And Canada 2 Mercury MerCruiser Limited Warranty United States Canada and Europe Gasoline Fueled Products Only 3 Mercury MerCruiser Limited Warranty Confederation of Independent States Middle East and Africa 5 3 Year Limited Warranty Against Corrosion Worldwide 6 Warranty Coverage And Exclusions 7 General Exclusions From Warranty 8 1 ...

Page 10: ...number to Mercury Marine s warranty registration department Your dealer can also process this change of information Mercury Marine Attn Warranty Registration Department W6250 Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 920 929 5054 Fax 920 929 5893 NOTE Registration lists must be maintained by Mercury Marine and any dealer on marine products sold in the United States should a safety recall...

Page 11: ...ld it ever be necessary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area 5 For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty Mercury MerCruiser Limited War...

Page 12: ...esented to the dealer at the time warranty service is requested in order to obtain coverage WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items tune ups adjustments normal wear and tear damage caused by abuse abnormal use use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range see the Operation and Maintenance Manual operat...

Page 13: ...ncome for any part of the warranty period even if the product is only occasionally used for such purposes The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date Unexpired warranty coverage can be transferred from one recreational use customer to a subsequent recreational use customer upon pr...

Page 14: ... or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by foreign body running the engine out of water mounting the engine too high on the transom or running the boat with the engine trimmed out too far Use of the product for racing or other competitive activity or operating with a racing type lower unit at any point even by a prior own...

Page 15: ... OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair and reasonable access to the product for warranty service Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product If purchaser cannot deliver the product to such a dealer written notice must be given to Mercury We will then arrange...

Page 16: ...authorized dealer 5 Additional service work requested by customer other than that necessary to satisfy the warranty obligation 6 Labor performed by other than an authorized dealer may be covered only under following circumstances When performed on emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out etc and prior ...

Page 17: ... section 16 Our limited warranty does not apply to any damage to our products caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered under warranty if they otherwise meet the terms of the limited warranty for that product ...

Page 18: ...Warranty Notes Page 10 90 860174050 JUNE 2005 ...

Page 19: ...Lanyard Stop Switch 12 Instrumentation 13 Analog Gauges 13 Remote Controls 14 Panel Mount Features 14 Console Mount Features 15 Electrical System Overload Protection 15 Audio Warning System 17 Testing The Audio Warning System 17 Emissions Information 18 Emission Control Information Label 18 Owner Responsibility 19 Star Label 19 2 ...

Page 20: ... operator The lanyard is coiled to make its at rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects Its stretched out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If it is desired to have a shorter lanyard wrap the lanyard around t...

Page 21: ...ief explanation of the instrumentation typically found on some boats The owner operator should be familiar with all instruments and their functions Because of the large variety of instrumentation and manufacturers you should have your boat dealer explain the particular gauges and normal readings for your boat L H OIL C H TEMP 0 1 2 3 4 5 6 7 8 R P M X 1000 MPH KPH 10 20 30 40 50 60 70 80 30 40 50 ...

Page 22: ...be depressed only when the remote control handle is in the neutral position and should only be used to assist in starting the engine Lanyard Stop Switch Turns the ignition off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to Lanyard Stop Switch for information on the use of this switch Control Handle Operation of ...

Page 23: ...ion to the first detent for reverse gear and continue pushing back to increase speed Control Handle Tension Adjustment Screw not visible This screw is used to adjust the effort required to move the remote control handle Refer to instructions provided with remote control for complete adjustment instructions Electrical System Overload Protection If an electrical overload occurs a fuse will blow or t...

Page 24: ...2 2 A 90 amp fuse is located on the large post of the starter solenoid This fuse is designed to protect the engine wiring harness if an electrical overload occurs mc74907 1 3 A 20 amp fuse may be located in the ignition switch I terminal lead to protect the electrical system Check for blown fuse if the ignition key is turned to the START position and nothing happens and circuit breaker is not trip...

Page 25: ...e too low Engine temperature too hot Seawater pressure too low The audio warning system will sound with an intermittent beeping if the following occurs Transmission fluid temperature too hot CAUTION Operation of the engine after the audio warning system alarm has sounded could result in damage to the power package Do not operate engine once the alarm has sounded except to avoid a hazardous situati...

Page 26: ... of replacement decals before proceeding EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL OMXXXXXXXX FAMILY XXXXX_XXXXXX FEL XX X g kW hr D O M JAN 2003 DISP X XL 11018 Emission Control Label Non CE Marked SERIAL Engine Serial Number FAMILY Engine...

Page 27: ...alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Star Label Beginning January 1 2003 one Three Star label will be included with each factory certified 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 28: ...tboard 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 label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exha...

Page 29: ... Plug and Bilge Pump 26 Protecting People In The Water 27 While You Are Cruising 27 While Boat Is Stationary 27 High Speed And High Performance Boat Operation 27 Passenger Safety In Pontoon Boats And Deck Boats 27 Boats Having An Open Front Deck 27 Boats With Front Mounted Raised Pedestal Fishing Seats 28 Wave And Wake Jumping 28 Impact With Underwater Hazards 29 Conditions Affecting Operation 30 ...

Page 30: ...inor repairs Anchor and extra anchor line Manual bilge pump and extra drain plugs Drinking water Transistor radio Paddle or oar Spare propeller thrust hubs and an appropriate wrench First aid kit and instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board Watch for signs of ...

Page 31: ... in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier who was 61 m 200 ft in front of you in 5 seconds Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in sight ...

Page 32: ...e boat is moored in a confined space b Mooring close to another boat with its engine operating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim angle of the bow too high b Operating the boat with no forward hatches open station wagon effect Basic Boat Operation Launching and Boat Operation IMPORTANT Install bilge drain plug prior to launching b...

Page 33: ...ON position Starting and Stopping the Engine NOTE Only perform those functions applicable to your power package STARTING THE ENGINE 1 Check all items listed in the Operation Chart 2 Place the remote control handle in neutral CAUTION Overheating from insufficient cooling water will cause engine and drive system damage Ensure that there is sufficient water always available at water inlet holes durin...

Page 34: ...s section for remote control features 2 Move the control lever to the idle neutral position 3 Depress and hold the throttle only button and move the control lever to the idle forward or idle reverse position 4 Advancing the control lever beyond the idle forward or idle reverse position will cause engine speed to increase IMPORTANT Moving the control lever back to the idle neutral position will dis...

Page 35: ... near your boat High Speed And High Performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat For additional information refer to Hi Perfo...

Page 36: ...lt in the elevated passenger falling over the front of the boat mc79557 1 Wave And Wake Jumping WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake Avoid wave or wake jumping whenever possible Instruct all occupants that if a wake or wave jump occurs get low and hang on to a boat hand hold mc79680 1 Operating recreational boats...

Page 37: ...nge in direction or turn can cause occupants to be thrown out of their seats or out of the boat A rapid reduction in speed This will cause occupants to be thrown forward even out of the boat Impact damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed...

Page 38: ...se the engine to overheat Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object such as a gear housing or a propeller Cavitation permits the propeller to speed up but the boat speed to reduce Cavitation can seriously erode the surface of the gear housing or the propeller Common causes of cavitation are Weeds or other debris snagged on the propell...

Page 39: ...vel Add oil as needed It is normal for oil consumption to be high during the break in period After Break In Period To help extend the life of your Mercury MerCruiser power package the following recommendations should be considered Ensure that propeller allows the engine to operate at or near the top of the specified WOT RPM range Refer to Specifications and Maintenance when at full throttle with a...

Page 40: ...On The Water Notes Page 32 90 860174050 JUNE 2005 ...

Page 41: ...pecifications Table of Contents Cruising RPM 34 Fuel Requirements 34 Fuel Ratings 34 Using Reformulated Oxygenated Gasolines USA Only 34 Gasolines Containing Alcohol 34 Engine Oil 35 Engine Specifications 36 Fluid Specifications 37 Engine 37 Transmission 37 4 ...

Page 42: ...Canada having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a major brand of leaded gasoline Using Reformulated Oxygenated Gasolines USA Only This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels is Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygen...

Page 43: ...and abnormalities is required IMPORTANT When operating a Mercury MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of storage common to boats create unique problems In cars alcohol blend fuels normally are consumed before they can absorb enough moisture to cause trouble but boats often sit idle long enough for phas...

Page 44: ...e 2000 RPM4 124 kPa 18 psi Thermostat 71 C 160 F Timing Idle3 10 BTDC Firing Order 1 8 4 3 6 5 7 2 Electrical System 12 Volt Negative Ground Alternator Rating Hot Operating Amps 65 amp Alternator Rating Cold Operating Amps 72 amp Recommended Battery Rating Minimum 375 CCA 475 MCA or 90 Ah 1 Performance obtained and corrected in accordance with SAE J1228 ISO 8665 Crankshaft Power 2 Measured using a...

Page 45: ...000A 2 84L 3 qt Dexron III Automatic Transmission Fluid or Equivalent 5000V 3 30L 3 1 2 qt 71C In Line 1 66L 1 3 4 qt Mobil 424 or Dexron III Automatic Transmission Fluid Do Not Mix 71C Gear Reduction 2 84L 3 qt 71C Remote V Drive 1 66L 1 3 4 qt 72C In Line 1 66L 1 3 4 qt Mobil 424 or Universal Tractor Mobil Hydraulic Oil Do Not Mix 72C Gear Reduction 1 66L 1 3 4 qt 72C Remote V Drive 1 66L 1 3 4 ...

Page 46: ...Specifications Notes Page 38 90 860174050 JUNE 2005 ...

Page 47: ...aintenance Log 43 Sealed Carburetor Mixture Screw 43 Engine Oil 43 Checking 44 Filling 44 Changing Oil and Filter 45 Easy Engine Oil Drain System 45 Engine Oil Drain Pump 45 Changing Filter 46 Transmission Fluid 46 Checking While the Engine is Warm 46 Checking While Engine is Cold 47 Changing 47 Engine Coolant 47 Checking 47 Filling 48 Changing 48 Cleaning The Flame Arrestor 49 Positive Crankcase ...

Page 48: ... all necessary adjustments for maximum efficiency Familiarize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Predelivery Inspection Checklist Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product Maintenance WARNING A...

Page 49: ...ive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may be a very simple adjustment to correct the problem Do not telephone the dealer service office or the factory to attempt for them to diagnose a problem or to request the repair pr...

Page 50: ...ackage Change the crankcase oil and filter Change the transmission fluid ZF Transmission Models 2 Replace the water separating fuel filter element Check the steering system and the remote control for loose missing or damaged parts Lubricate the cables and the linkages Inspect the condition of the belts Clean the flame arrestor IAC muffler MPI engines and the crankcase ventilation hoses Inspect the...

Page 51: ...move mixture screw seals and or attempt to adjust fuel mixture setting Tampering with the mixture setting on this engine could affect the exhaust emissions level thus voiding the emissions certification These seals should only be removed by an authorized dealer or emissions testing agency Engine Oil CAUTION ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restricted by la...

Page 52: ...lywheel end a a 6076 a Dipstick tube IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dipstick 3 Remove the dipstick and observe the oil level Oil level must be between full or OK range and add Reinstall dipstick into dipstick tube Filling IMPORTANT Do not overfill the engine with oil IMPORTANT Always use the dipstick to determine the ex...

Page 53: ...n Warm oil flows more freely carrying away more impurities Use only recommended engine oil refer to Specifications EASY ENGINE OIL DRAIN SYSTEM NOTE Boat must be out of water to perform this procedure 1 Loosen the oil filter to vent the system 2 Remove the bilge drain plug 3 Pull tether through the bilge drain f e d c b a 7284 a Binge drain plug b Tether c Clip d Oil drain hose plug e Oil drain ho...

Page 54: ...o bring the oil level up to but not over the full or OK range NOTE Adding 0 95 liters 1 quart of engine oil will raise the level from the add mark to the top of the OK range Models Capacity Fluid Type Engine Oil With Filter 4 7 liters 5 U S Quart Mercury Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 7 Start the engine run the engine for three minutes and check for leaks Stop the engine ...

Page 55: ... 4 Reinstall the dipstick tighten the T handle securely Do not overtighten Changing Contact your authorized Mercury MerCruiser dealer Engine Coolant Checking WARNING Allow the engine to cool down before removing the coolant pressure cap A sudden loss of pressure could cause hot coolant to boil and discharge violently After the engine has cooled turn the cap 1 4 turn to allow any pressure to escape...

Page 56: ...lable at water inlet holes during operation CAUTION Air trapped in the closed cooling section of an engine cooling system can cause the engine to overheat resulting in engine damage To minimize the possibility of trapping air when initially filling the closed cooling system position the boat so that the front of the engine is higher than the rear of the engine NOTE Add coolant only when engine is ...

Page 57: ...ent 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 warm water and a mild detergent Dry with compressed air or allow to air dry completely 7 Inspect the crankcase ventilation hose for cracks or deterioration Replace if necessary 8 Install the flame arrestor se...

Page 58: ...witch is in the off position and that the lanyard stop switch if equipped is in the off position Do not smoke or allow spark or open flame in the area Wipe up any spilled fuel immediately Ensure that no fuel leaks exist before closing the engine hatch 1 Allow the engine to cool down NOTE Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal 2 Close fuel sup...

Page 59: ...eck the filter installation clean spilled fuel and properly ventilate the engine compartment If leaks continue stop engine immediately and contact your authorized Mercury MerCruiser dealer Lubrication Throttle Cable 1 Lubricate the pivot points and the guide contact surfaces b a 6208 a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engin...

Page 60: ... Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Detent ball and shift lever holes 92 883725K01 2 Lubricate the shift cable pivot points a a 5935 a Pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cable pivot points 92 883725K01 ...

Page 61: ...NING Avoid possible serious injury Make sure engine is shut off and ignition key is removed before inspecting belt b a c d e 6089 a Idler pulley b Circulating pump pulley c Crankshaft pulley d Alternator pulley e Seawater pump pulley Checking 1 Inspect the drive belt for proper tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the belt width may be acceptable ...

Page 62: ... adjustment stud 2 Turn the adjustment stud and loosen the belt 3 If a new serpentine drive belt is required remove the old belt and install a new belt 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 adjusting the stud to adjust the belt deflection 6 Using one of the 2 methods following check for correct deflection a Push down...

Page 63: ...is recommended after each outing for best results 1 Close the seacock if equipped or remove the water inlet hose and plug the inlet 2 Drain the seawater from the engine 3 Attach the quick connect fitting to a water hose 4 Open the water source completely 5 Remove the blue cap from the flush socket on the engine CAUTION Overheating from insufficient cooling water will cause engine and drive system ...

Page 64: ...t let water run more than 15 seconds with engine not operating or too much flushing water will collect in the muffler 12 Within 15 seconds disconnect the quick connect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket 13 Attach to the next engine if equipped and repeat procedure 14 Turn off the water source 15 Remove the quick connect fit...

Page 65: ... seawater pickup pump Proceed to Step 3 6092 WARNING Contact with moving drive components and the propeller can cause personal injury or death To avoid possible injury remove the propeller and ensure that no people or animals are in the area of the drive unit while flushing 2 If flushing the engine with the boat out of the water remove the propeller Refer to boat manufacturers instructions a Model...

Page 66: ... the seacock should remain closed until time of usage If unit is to be stored out of the water open the seacock 12 Replace the propeller if removed Refer to the boat manufacturers instructions Battery Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precautions when handling a battery WARNING Avoid serious injury from ...

Page 67: ...r Extended Storage 60 Preparing Power Package for Storage 60 Engine and Fuel System Preparation 61 Draining the Seawater System 62 Drain System Identification 62 Multi Point Drain MPD System 62 Multi Point Drain MPD System 63 Battery Storage 64 Power Package Recommissioning 64 Seacock 65 6 ...

Page 68: ...lcohol in fuel tanks if fuel without alcohol is not available Fuel tanks should be drained as low as possible and Mercury Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to Fuel Requirements for additional information 3 Flush the cooling system Refer to the Maintenance section 4 Operate the engine sufficiently to bring it up to normal operating temp...

Page 69: ...st idle 1300 RPM fog internal surfaces of induction system and combustion chambers by spraying approximately 227 g 8 oz of Mercury Quicksilver Storage Seal or SAE 20W engine oil into carburetor bores e Spray the remaining 57 g 2 oz of Storage Seal or oil rapidly into carburetor just as the engine begins to stall due to lack of fuel Allow engine to stop Tube Ref No Description Where Used Part No 11...

Page 70: ...n excess water can enter the bilge Do not operate the engine with the drain system open IMPORTANT Only drain the seawater section of the closed cooling system IMPORTANT The boat must be as level as possible to ensure complete draining of the cooling system Your power package is equipped with a drain system Refer to Drain System Identification to determine which instructions apply to your power pac...

Page 71: ...e the blue drain plugs from the following locations It may be necessary to clean out the drain holes using a stiff piece of wire Do no until the entire system is drained a Port and starboard side of cylinder block b Bottom of exhaust manifolds 10226 M110050 932356 72 b a a b 6129 a Cylinder block drain plug b Exhaust manifold drain plug c Water circulating pump hose a 6143 a Drain plug ...

Page 72: ...ll hose clamps securely Battery Storage Whenever the battery will be stored for an extended period of time be sure the cells are full of water and the battery is fully charged and in good operating condition It should be clean and free of leaks Follow the battery manufacturer s instructions for storage Power Package Recommissioning 1 Ensure that all cooling system hoses are connected properly and ...

Page 73: ...ation Seacock The ABYC and other industry standards regulations require the use of a seacock on certain types of applications to stop the entry of water in the event of a leak in the cooling system Refer to applicable standards regulations for specific requirements The seacock also allows the water to be shut off when servicing the engine Seacock must provide minimum restriction to wter flow refer...

Page 74: ...Storage Notes Page 66 90 860174050 JUNE 2005 ...

Page 75: ...l Not Start Or Is Hard To Start 68 Engine Runs Rough Misses And Or Backfires 68 Poor Performance 68 Excessive Engine Temperature 69 Insufficient Engine Temperature 69 Low Engine Oil Pressure 69 Battery Will Not Come Up On Charge 69 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 70 Steering Wheel Turns Hard Or Jerky 70 7 ...

Page 76: ...the 1 4 throttle position and attempt to restart Faulty ignition system component Service the ignition 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 with compressed air to remove obstruction Faulty wire connections Check wire connections TKS fuse blo...

Page 77: ...test pressure cap Faulty seawater pickup pump Repair Seawater discharge restricted or plugged Clean exhaust elbows Insufficient Engine Temperature Possible Cause Remedy Faulty thermostat Replace Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase Check and add oil Excessive oil in crankcase causing it to become aerated Check and remove required amount of oil Check for cause...

Page 78: ...er immediately Shift or throttle cable kinked Straighten cable or have authorized Mercury MerCruiser dealer replace cable if damaged beyond repair Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level Check for leak Refill system with fluid Drive belt loose or in poor condition Replace and or adjust Insufficient lubrication on steering components Lubricate Lo...

Page 79: ...ssistance 72 Local Repair Service 72 Service Away From Home 72 Stolen Power Package 72 Attention Required After Submersion 72 Replacement Service Parts 72 Parts And Accessories Inquiries 73 Resolving A Problem 73 Mercury Marine Service Offices 73 Ordering Literature 74 United States and Canada 74 Outside The United States and Canada 74 8 ...

Page 80: ...nufactured or installed To minimize risks of fire or explosion electrical ignition and fuel system components on Mercury Marine power products are designed and manufactured to comply with numerous international directives federal regulations voluntary standards and product installation instructions Use or installation of replacement electrical ignition or fuel system components which do not comply...

Page 81: ...ger 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 contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the service office Your name and ...

Page 82: ...tes and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for info...

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