Mercury Racing Sterndrive 600SCi User Manual Download

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TABLE OF CONTENTS

Cleaning the Seawater (Raw Water) Section of the Engine Oil,

Power Steering, and Fuel Coolers...........................................100

Serpentine and Supercharger Drive Belts...............................102

Fuel Filters...............................................................................107

Corrosion and Corrosion Protection........................................109

Battery.....................................................................................114

Bottom of Boat.........................................................................115

Inspection and Maintenance....................................................115

Attention Required After Submersion......................................116

Cold Weather or Extended Storage

Power Package Lay-up............................................................117

Draining Instructions................................................................119

Battery Winter Storage............................................................123

Power Package Recommissioning..........................................123

Troubleshooting

Engine Will Not Crank .............................................................127

Engine Cranks But Will Not Start.............................................128

Engine Hard to Start, Runs Rough, Misses, and/or Backfires. 128

Poor Performance....................................................................129

Engine Coolant Temperature Too Low....................................129

Engine Coolant Temperature Too High...................................130

Low Engine Oil Pressure.........................................................130

Power Trim Does Not Operate (Motor Doesn't Run)...............131

Battery Will Not Come Up On Charge.....................................131

Power Trim Does Not Operate (Motor Runs But Drive Unit Does

Not Move)................................................................................131

Electrical Analog Trim Gauge Malfunction...............................132

Remote Control Operates Hard, Binds, Has Excessive Free-Play

or Makes Unusual Sounds.......................................................132

Steering Wheel Turns Hard or Jerky.......................................132

Seawater Pressure Is Below Specification..............................133

Seawater Pressure Is Above Specification..............................133

Summary of Contents for Racing Sterndrive 600SCi

Page 1: ...65 Inboard Engine A 5 1 1 ISO 15584 ISO 7840 ISO 10133 Fuel System A 5 2 ISO 7840 ISO 8469 Electrical System A 5 3 ISO 10133 ISO 8846 General Steering System A 5 4 1 Applicable portions of ABYC P 21 EN ISO 10592 Exhaust emission requirements B 2 ISO 8178 1 Owner s manual B 4 ISO 8665 Module used for exhaust emission assessment Modules B C EC Type Examination Certificate No EXMERC001 The notified b...

Page 2: ...1000 4 3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe Patrick C Mackey President Mercury Marine Fond du Lac WI USA Regulatory contact Engineering Regulations Mercury Racing N7480 County Road UU Fond du Lac WI 54935 9585 USA Thank You for your purchase of one of the finest marine power packages available It incorporates numerous design features ...

Page 3: ...e warranty are set forth in the Warranty Information section of this manual The warranty statement contains a description of what is covered what is not covered the duration of coverage how to best obtain warranty coverage important disclaimers and limitations of damages and other related information Please review this important information WARNING The operator driver is responsible for the correc...

Page 4: ...ict compliance to these special instructions when performing the service and common sense operation are major accident prevention measures WARNING WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage It ...

Page 5: ... 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 ...

Page 6: ...vi ...

Page 7: ...apacity 12 High Speed and High Performance Boat Operation 13 Paddle Wheel and Water Temperature Sensors 13 Lanyard Stop Switch 13 Trailering Boat 15 Protecting People In The Water 15 Exhaust Emissions 16 Wave And Wake Jumping 18 Impact With Underwater Hazards 19 Operating in Shallow Water 20 Safe Boating Suggestions 22 Stolen Power Package 25 Specifications Engine Identification 26 General Engine ...

Page 8: ...e 57 Conditions Affecting Operation Weight Distribution 58 Bottom Of Boat 58 Cavitation 58 Ventilation 59 Propeller Selection 59 Conditions That Lower Engine Performance 60 Maintenance Special Tools 61 Servicing High Horsepower Engines 62 Service Responsibilities 62 Replacement Service Parts 63 Do It Yourself Maintenance Suggestions 64 Engine Maintenance Charts 65 Bravo Drive Maintenance Charts 67...

Page 9: ...ing Engine Will Not Crank 127 Engine Cranks But Will Not Start 128 Engine Hard to Start Runs Rough Misses and or Backfires 128 Poor Performance 129 Engine Coolant Temperature Too Low 129 Engine Coolant Temperature Too High 130 Low Engine Oil Pressure 130 Power Trim Does Not Operate Motor Doesn t Run 131 Battery Will Not Come Up On Charge 131 Power Trim Does Not Operate Motor Runs But Drive Unit Do...

Page 10: ...ervice 134 Service Away From Home 134 Parts And Accessories Inquiries 134 Service Assistance 134 Mercury Mercruiser Service Offices 135 Ordering Literature United States and Canada 137 Outside The United States and Canada 137 Maintenance Log Maintenance Log 138 ...

Page 11: ...eral Safety Act be required 2 At the time of sale the dealer should complete the warranty registration and immediately submit it to Mercury Marine via MercNET E mail or mail Upon receipt of this warranty registration Mercury Marine will record the registration IMPORTANT Your warranty coverage begins at the time of sale but warranty claims cannot be processed until the product is registered with Me...

Page 12: ...he distributor in your country or the Marine Power Service Center closest to you Mercury Racing Division One Year Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products and remanufactured products sold under the trade name Pacemaker to be free of defects in material and workmanship during the period described below DURATION OF COVERAGE This Limited Warranty provides coverage for...

Page 13: ...nge of use from recreational to commercial may void the warranty at the sole discretion of Mercury Marine Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to maintain warranty coverage Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance WHAT MERCURY WILL DO Mercury s sole and exclusive obligat...

Page 14: ...e must be given to Mercury We will then arrange for the inspection and any covered repair Purchaser in that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the...

Page 15: ...ing the engine through the fuel intake air intake or exhaust system or damage to the product from insufficient cooling water caused by blockage of the cooling system by a 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 The commercial use of the product defined as any work or employment related use of t...

Page 16: ...ED TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY SOME STATES COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE AS A RESULT THEY MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AN...

Page 17: ... be transferred to subsequent non commercial use purchaser upon proper re registration of the product CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre...

Page 18: ...that case shall pay for all related transportation charges and or travel time If the service provided is not covered by this warranty purchaser shall pay for all related labor and material and any other expenses associated with that service Purchaser shall not unless requested by Mercury ship the product or parts of the product directly to Mercury Proof of registered ownership must be presented to...

Page 19: ...ween the warranted product and the paint For MerCruiser product an unpainted gap of at least 38 mm 1 5 in should be left around the transom assembly Refer to the Operation and Maintenance Manual for additional details For additional information regarding events and circumstances covered by this warranty and those that are not see the Warranty Coverage section of the Operation and Maintenance Manua...

Page 20: ...ot covered Warranty is limited to defects 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 occurred and then only after the Mercury Marine specified pre delivery inspection process is completed and documented Should you have any questions concerning warranty coverage contact y...

Page 21: ... Quicksilver parts when making warranty repairs 7 Engine noise does not necessarily indicate a serious engine problem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty 8 Lower unit and or propeller damage caused by striking a submerged object is considered a marine hazard 9 Water in the ...

Page 22: ...G Avoid serious injury death or property damage from overpowering a boat Using a power package that exceeds the maximum horsepower limit of a boat can Cause loss of boat control Place too much weight at the transom altering the designed flotation characteristics of the boat Cause the boat to break apart particularly around the transom area Do not overpower or overload your boat Most boats will car...

Page 23: ...r Mercury Marine Paddle Wheel and Water Temperature Sensors Paddle wheels cannot be utilized on vessels that are capable of speeds in excess of 50 mph Water temperature sensors cannot be connected to Race Sterndrive engines that are equipped with a Propulsion Control Module PCM The water temperatue sensor connection is utilized by the PCM for monitoring engine oil temperature Lanyard Stop Switch T...

Page 24: ...ngine in an emergency e g if the operator is accidentally ejected WARNING Should the operator fall out of the boat the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately Always properly connect both ends of the stop switch lanyard to the stop switch and the operator WARNING Avoid serious injury or death from deceleration...

Page 25: ...d and gear housing skeg when trailering with the drive unit in down position If adequate road clearance is a problem place drive unit in full up position Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction even at slow speeds 21604 Always slow down and exercise extreme caution any time ...

Page 26: ...ous boat accessories Carbon monoxide is a deadly gas that is odorless colorless and tasteless Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication include headache dizziness drowsiness and nausea WARNING Avoid the combination of a running engine and poor ventilation Prolonged exposure to carbon monoxide in sufficient concentration can lead to un...

Page 27: ...ce b Mooring close to another boat that has its engine running While Boat is Moving 5449 a b a Running the boat with the trim angle of the bow too high b Running the boat with no forward hatches open station wagon effect GOOD VENTILATION Ventilate passenger area open side curtains or forward hatches to remove fumes 5448 ...

Page 28: ...e occupants to be thrown out of their seats or out of the boat 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 any boat hand hold There is another less common hazardous result from allowing your boat...

Page 29: ...floating or underwater object is to control the boat speed Under these conditions boat speed should be kept to a minimum planing speed 24 to 40 km h 15 to 25 MPH 7462 Striking a floating or underwater object could result in an infinite number of situations Some of these situations could result in the following Part of the sterndrive or the entire sterndrive could break loose and fly into the boat ...

Page 30: ...ne as soon as possible and inspect it for any broken or loose parts If damage is present or suspected the sterndrive should be taken to an authorized dealer for a thorough inspection and necessary repair The boat should also be checked for any hull fractures transom fractures or water leaks Operating a damaged sterndrive could cause additional damage to other parts of the sterndrive or could affec...

Page 31: ...ed in shallow or weedy water a b 23755 Low Water Inlet and Sportmaster Gearcase a Low water pick up gearcase b Sportmaster gearcase The design of the dual water inlet gear case reduces the risk of restricting or shutting off the water supply to the engine but caution should still be used when operating in shallow or weedy water CLEARING A DUAL WATER INLET GEAR CASE 1 Idle the boat out to deep wate...

Page 32: ...ard it is the law and have it readily accessible Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate If in doubt contact your dealer or the boats manufacturer Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made Check safety equipment on board Here are sug...

Page 33: ...800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT We strongly recommend that all powerboat operators attend one of these courses You should also review the NMMA Sources of Waterway 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 Ass...

Page 34: ...oat above idle speed Never drive your boat directly behind a water skier in case the skier falls As an example your boat traveling at 40 km h 25 MPH will overtake a fallen skier 61 m 200 ft in front of you in five 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 assist th...

Page 35: ...n immediately advise the local authorities and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines ...

Page 36: ...oolant see owner s manual HP600 SCi 502 C I D 4800 5200 NGK BPR6ES 0 035 Inch non adjustable 91 R M 2 or 98 RON International Kendall GT 1 Dex Cool SERIAL NUMBERS ENGINE DRIVE TRANSOM SAE 20W50 10013 a Engine identification placard Record the serial numbers from the engine placard in the space provided below Serial Numbers Engine Drive Transom ...

Page 37: ...sion ratio 7 5 1 Supercharger 3 3 L Screw type compressor Altenator 65 amp 917 watt Battery requirements 750 CCA 950 MCA Ignition type PCM 03 Distributorless Spark plug type NGK BPR6ES Spark plug gap 0 889 mm 0 035 in Fuel system Sequential Fuel Injection Length transom mount to front of engine 907 mm 35 7 in Width 838 mm 33 0 in Height 691 mm 27 2 in Weight 575 kg 1267 lbs ...

Page 38: ...ine 290 kPa 42 psi at 5200 RPM from oil cooler sensor Minimum oil pressure at idle Hot 138 kPa 20 psi Minimum oil pressure at 5200 RPM Hot 331 kPa 48 psi Maxiumum oil temperature 85 C 185 F Fuel Requirements Use a major brand of unleaded gasoline preferably without alcohol Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness WARNING FIRE AND EXPLOSION H...

Page 39: ... S The two types of oxygenates used in these fuels are alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to the Fuel Containing Alcohol section These reformulated fuels are acceptable for use in your Mercury engine FUEL CONTAINING ALCOHOL If the fuel in your area contains either methanol methyl alcohol or ethanol ethyl alcohol you sho...

Page 40: ... fuel lines Starting and operating difficulties CAUTION When operating a Mercury engine with fuel containing alcohol avoid storing the fuel in the fuel tank for long periods of time Long storage periods common to boats create unique problems In cars alcohol blend fuels are normally consumed before they can absorb enough moisture to cause trouble However boats often sit idle long enough for phase s...

Page 41: ... 50 SL SJ CF IMPORTANT OIL PRACTICES Do Not Use Straight weight oils Non detergent oils Oils containing solid additives Multi viscosity oils other than the ones recommended Low quality oils Do Not Mix Different brands of oils straight weight or multi viscosity Different weights of straight weight or different weights of multi viscosity oils TEMPERATURE OIL VISCOSITY CHART Multi viscosity Oil 20 0 ...

Page 42: ...and engine specifications directly related to emissions is placed on the engine at the time of manufacture EMISSION CONTROL INFORMATION THIS ENGINE IS RATED AT GREATER THAN 500 HP CRANKSHAFT AND IS THEREFORE EXEMPT FROM CALIFORNIA EMISSIONS REGULATIONS FOR SPARK IGNITION MARINE ENGINES 6104 Engine Break in CAUTION Severe damage to the engine can result by not complying with the engine break in pro...

Page 43: ...n period After Break In Period To help extend the life of your power package Mercury Marine recommends the following After 5 hr Break in Use a propeller that allows the engine to operate at or near the top of the maximum RPM range See Specifications section when at full throttle with a normal boat load Do not advance the throttle until the engine runs smoothly at idle and water temperature reaches...

Page 44: ...tem voltage Guardian fault messages SmartCraft instruments display all of the above critical engine functions as well as others not listed SmartCraft instruments also display information about power train sensor faults and Guardian activation Warning System The engine s warning system includes an audible alert consisting of a horn located in the helm harness and the Engine Guardian system Do not a...

Page 45: ...ne dealer to correct the problem as soon as possible If on restart the beeping stops the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault If the Propulsion Control Module PCM detects a fault signal from an engine sensor it records a fault code A Digital Diagnostic Terminal DDT or Computer Diagnostic System C...

Page 46: ...o Oil Temperature High Steady Horn Yes No Coil Pack Failure 5 Beeps 3 Sec Long Yes No Fuel Injector Failure 5 Beeps 3 Sec Long Yes No Fuel Pump Failure 5 Beeps 3 Sec Long Yes No Idle Air Control Failure 5 Beeps 3 Sec Long Yes No Guardian Envoked 3 Beeps 1 5 Sec Long Yes No Coolant Overheat 3 Beeps 1 5 Sec Long Yes Yes Knock Sensor 3 Beeps 1 5 Sec Long Yes Yes Charge Temperature Sensor Failure 3 Be...

Page 47: ...ensor Failure 3 Beeps 1 5 Sec Long Yes No Coolant Temperature Sensor 3 Beeps 1 5 Sec Long Yes No Throttle Position Sensor 3 Beeps 1 5 Sec Long Yes Yes Low Battery Voltage 2 Beeps 1 Sec Long Yes No Low Drive Lube 2 Beeps 1 Sec Long Yes No Electrical System Overload Protection If an electrical overload occurs a fuse or circuit breaker opens Locate and correct the problem before replacing the fuse or...

Page 48: ...rform the following 1 Turn off or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker 2 If the breaker remains open electrical overload is still present Inspect the electrical system 3 A 15 amp fuse located on the engine s electrical panel protects the keyswitch power Check for an open fuse if the key is turned to START and nothing happens an...

Page 49: ...OPERATION 39 4 The power trim system is protected from overload by a 110 amp fuse and a 20 amp in line fuse on the power trim pump 10121 a b a 20 amp fuse holder b 110 amp fuse ...

Page 50: ... the positive terminal on the controller If the fuse is open the MerCathode system will not operate and a loss of corrosion protection will result MERCATHODE A R 7775 a a 20 amp in line fuse 6 A 90 amp fuse is located on the starter 10309 b a c a Positive battery cable b 90 amp fuse c Starter ...

Page 51: ...OPERATION 41 7 Eight fuses are located at the upper rear of the engine in two fuse holders four fuses in each holder 1 5 2 6 4 8 3 7 a a 10310 a Fuse holders 2 ...

Page 52: ... RED PPL key switch CAN power 8 20 amp RED GRN to RED BLU driver power Remote Controls Console Mounted Zero Effort 1 Control the throttle by moving the longer control lever s or to increase speed push the control lever forward Detents give the movement of the lever a notched precise feel The detents also help hold the lever at the desired engine RPM to reduce operator fatigue CAUTION Avoid possibl...

Page 53: ...ear position with a quick firm motion The control handle should be adjusted by your dealer to engage forward reverse and neutral when the lever is at the appropriate detent a b c 4090 a Throttle control lever b Power trim switch c Shift control lever 3 See Power Trim section for detailed power trim operating procedures Remote Controls All controls feature an integral safety switch that allows star...

Page 54: ...OPERATION 44 1 7 3 5 4 6 2 1 4 2 3 6 4 2 8 6 7820 3 7 ...

Page 55: ...tch section at the front of this manual for operation and safety warning on the use of this switch 6 Control Handle Tension Adjustment Screw This screw can be adjusted to increase or decrease the tension on the control handle This will help prevent Creep of the remote control handle Turn the screw clockwise to increase tension and Counter clockwise to decrease tension Adjust to the tension desired...

Page 56: ...erating the engine over 1200 RPM a maximum trim angle of 12 beyond vertical is considered to be within mechanical limitations to prevent damage to the drive unit It is recommended that the boat is equipped with a trim indicator s in the dash so the operator is aware the drive unit s trim angle IMPORTANT Each boat manufacturer has the option as to how the power trim will function on their particula...

Page 57: ...wn In Can 7420 Help the boat accelerate and plane off quicker Generally improve 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 an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant ...

Page 58: ...sition beyond the gimbal ring side support at engine speeds above 1200 RPM On boats equipped with multiple drives each drive unit may be trimmed independently There may be individual remote trim or trailer switches for each drive unit on the dash It is important to equalize the units trim position by monitoring the trim position gauges or indicators Or if gauges indicators are not available trim t...

Page 59: ...s raise or lower the sterndrive units evenly 1 2 7868 1 Trailering and trimming up out position Press the top up out portion of the switch until drive unit reaches desired trim trailering position 2 Trim drive unit in down position Press the bottom in down portion of the switch until drive unit reaches desired trim position ...

Page 60: ...ped with multiple drives each drive unit may be trimmed independently There may be individual remote trim or trailer switches for each drive unit It is important to equalize the units trim position by monitoring the trim position gauges or indicators Or if gauges indicators are not available trim the units fully down in to equalize the units Then by operating the power trim with the integral trim ...

Page 61: ...OPERATION 51 ...

Page 62: ...OPERATION 52 1 2 2 1 2 3 7867 1 ...

Page 63: ...une the trim adjustment of each drive unit Press the switches to set each drive unit to the desired trim angle Then use the integral trim switch in the handle to control the trim of both drive units simultaneously Freezing Temperature Operation IMPORTANT If operating the boat in freezing temperatures ensure that closed coolant is rated for the temperature range in which it is to be used The seawat...

Page 64: ...hat have not been started for extended periods or have had fuel filter changes may not stay running on the first few initial attempts to start Do not advance the throttle to keep the engine running Continue to restart the engine until it idles smoothly which means the fuel system is primed Allow the engine to warm up to 54 C 130 F before advancing the throttle Do not operate at full throttle until...

Page 65: ...he key to the START position momentarily to release the clutch from gear 3 Resume the normal starting procedure SHIFTING 1 To shift the drive unit into gear move the control shift lever with a firm quick motion forward to shift to forward gear or backward to shift to reverse 2 After shifting the drive unit advance the throttle to the desired setting STOPPING 1 To shift the drive unit out of gear t...

Page 66: ...ttery switch OFF if equipped Close fuel valve Close seacock Flush cooling system if in saltwater area Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect For this reason boats are normally equipped with a drain plug and or a bilge pump It is very important to check these items on a regular basis to ensure that the water level does not rise to come ...

Page 67: ...tem which could cause engine component failure Unloading a boat from a trailer Slowing down rapidly or stopping suddenly Backing up rapidly In any of the situations described in the preceding caution water entering the engine could cause severe damage to internal parts Refer to Attention Required After Submersion in the General Information section of this manual ...

Page 68: ...of barnacles and marine growth Free of distortion and nearly flat where it contacts the water Straight and smooth both fore and aft Marine vegetation may accumulate when the boat is docked clogging water inlets and causing the engine to overheat This growth must be removed before operation Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object suc...

Page 69: ...erating RPM range are listed in Specifications IMPORTANT All Mercury Racing engines have a RPM rev limiter that is set to an upper or limited RPM This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM Once the RPM drops into the recommended operating RPM range normal engine operation resumes Select a propeller that all...

Page 70: ...ssion EXAMPLE An engine running at an elevation of 2 438 m 8 000 ft will have over a 30 power loss while engine power on a hot and humid day can be reduced by as much as 14 These losses apply to both normally aspirated and supercharged engines To compensate for power robbing conditions Switch to a lower pitch propeller Change the gear ratio Some boat performance can be regained by dropping to a lo...

Page 71: ...2 Description Attaches to the drive unit water intakes provides a fresh water connection when flushing the cooling system or operating the engine 4730 Flushing Kit 91 849996T1 Description Use for flushing drives with low water inlet gearcases 5324 Flushing Attachment 91 843122A01 14565 Attaches to the water intakes provides a fresh water connection when flushing the cooling system or operating the...

Page 72: ...eckup Perform normal maintenance service using authorized replacement parts Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your overall operating expenses at a minimum See your authorized Mercury Marine dealer for service aids DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include pre delivery inspec...

Page 73: ...hey existed Marine engines are expected to operate at or near 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 marine engine parts as specifications are quite different from those of the standard automotive engine For example one of the most important an...

Page 74: ... procedures you don t understand Do not attempt repairs if you do not understand the procedures Special tools and equipment may be required to perform some repairs Do not attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you for the repair If you partially disassemble an engine or drive assembl...

Page 75: ...manual Mercury Marine recommends purchasing a Mercury Marine Service Manual Engine Maintenance Charts NOTE Only perform maintenance which applies to your particular power package Interval Task Check prior to every use and every 3 hours of operation Engine crankcase oil Check level Engine Inspect Seawater filter Check for debris or leakage Power steering fluid Check level After every use in salty b...

Page 76: ...for tightness Electrical system Check for loose or damaged wiring Continuity circuit Check components for loose connections broken or frayed wires Throttle cable and linkage Lubricate and inspect for loose damaged or missing parts Engine exhaust system Inspect for damage deterioration and restrictions Check clamps for tightness Water separator filter Inspect If Installed on boat Freshwater use Twi...

Page 77: ...spect Engine output shaft bearing and pilot bushing Inspect and lubricate Rear bearing support block Check alignment MerCathode system Test output Every 100 hours of operation or recommissioning after storage Fuel filters Replace Every 100 hours of operation or once a season and whenever insufficient seawater flow is suspected if the operating temperature exceeds normal Seawater pick up pump Disas...

Page 78: ...age Lubricate and inspect for loose damaged or missing parts Water separator filter Inspect If Installed on boat Engine coupling universal joint shaft spline Lubricate Sterndrive unit Oil change Every 50 hours or once a year whichever occurs first Sterndrive unit universal joint cross bearings Inspect and lubricate Gimbal ring clamping screws Re torque to 67 74 Nm 50 55 lb ft Gimbal bearing Lubric...

Page 79: ... Check Exhaust Check for signs of water leakage Exhaust system internal and external shutters Inspect Engine output shaft bearing and pilot bushing Inspect and lubricate Rear bearing support block Check alignment MerCathode system Test output Steering head and remote control Inspect and lubricate Drive unit bellows and clamps Inspect Propeller shaft bearing Inspect by measuring shaft deflection Dr...

Page 80: ...drain into the oil pan The boat must be at rest in the water or at the approximate angle that it would be if setting in the water 3 Remove the dipstick wipe it clean and re install it all the way into the dipstick tube 4 Remove the dipstick and check the oil level The oil level must be between the OK RANGE and the ADD marks 5 If the oil level is below the ADD mark remove the oil filler cap port or...

Page 81: ... abnormal color it would indicate that there is an internal problem with the supercharger Contact your authorized Mercury Marine dealer 1 Stop the engine 2 Allow approximately 5 minutes for the oil in the supercharger case to settle and the sight glass to clear 3 Visually inspect the level and quality of the oil in the sight glass gauge The oil should be covering approximately half of the sight gl...

Page 82: ... the cap dipstick b c 21834 a a Power steering reservoir fill dipstick cap b Add fluid mark c Full fluid mark Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steering pump 92 858074K0 1 4 Re install the cap dipstick SEAWATER FUEL PUMP OIL IMPORTANT Oil must be changed at specified intervals Refer to the Maintenance Chart for specific requirements Use only High Pe...

Page 83: ...is oil level is low a 87 10073 a Oil level screw Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Seawater fuel pump 92 802854A1 ENGINE COOLANT WARNING Avoid personal injury and burns from hot engine coolant 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 IMPORTANT ...

Page 84: ...ape slowly then push down and turn the cap all the way off COLD FILL b a 10140 122 c a Coolant reservoir cap b Cold full decal on the front of the reservoir c Cold full raised bosses on the back of the reservoir Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed cooling system 92 877770K1 2 If coolant is low inspect coolant recovery system for leaks 3 Inspect th...

Page 85: ...nditions indicate a water leak somewhere in the drive unit IMPORTANT If more than 59ml 2 fl oz of High Performance Gear Lube is required to fill the monitor a seal may be leaking Damage to the drive unit may occur due to lack of lubrication Contact your authorized Mercury Marine dealer for service 87 7333 a a Gear lube monitor Tube Ref No Description Where Used Part No 87 High Performance Gear Lub...

Page 86: ...e fill cap vent slots to ensure that they are clean Re install the fill cap Changing Fluids See the Maintenance Chart for lubricant change frequency Lubricant should be changed before placing the boat in storage Power trim or power steering fluids do not require changing CRANKCASE OIL AND FILTER BOAT IN THE WATER CAUTION ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is re...

Page 87: ...h to break the internal vacuum approximately 1 4 turn Then turn the filter back clockwise until the oil filter seal makes light contact with the housing approximately an 1 8 turn to prevent unwanted oil leakage Let the oil drain back into the system for 15 minutes prior to complete removal of the filter a 10449 a Crankcase oil filter 1 With the engine at normal operating temperature remove the dip...

Page 88: ...nkcase is empty a b 10460 a Crankcase oil pump b Crankcase oil pump hose 4 Remove the crankcase oil pump 5 Place a container below the oil filter 6 Remove the oil filter from the adaptor and discard the old oil filter and old sealing ring 7 Coat the sealing ring on the new filter with motor oil and install the new sealing ring and filter ...

Page 89: ...n a 9998 a Oil filter sealing ring 9 Remove the oil filler cap port or starboard 10 Add oil to bring level up to but not over the OK RANGE mark on the dipstick IMPORTANT Always use the dipstick to determine exactly how much oil is required a 10152 a Crankcase oil fill cap ...

Page 90: ... is to be tested with boat out of the water the propeller must be removed to avoid injury CAUTION Avoid engine damage from overheating If the engine is operated above 1500 RPM during flushing suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat CAUTION ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restricted by...

Page 91: ...e c Flushing attachment for dual water inlet drives d Nose cone water pickup cover for dual water inlet drives 2 With the drive unit in normal operating position partially open the water tap about 1 2 maximum 3 Place the remote control in neutral position and start the engine Operate the engine at idle speed in neutral until the engine reaches normal operating temperature 4 Stop the engine and shu...

Page 92: ...m for 15 minutes prior to complete removal of the filter a 10449 a Crankcase oil filter 5 Remove the bilge plug The oil drain hose is tethered to the plug 6150 e d c b a a Bilge drain plug b Tether c Oil drain plug d Bilge drain flange e Oil drain hose 6 Pull the oil drain hose through the bilge drain flange 7 Place an appropriate container directly under the oil drain hose 8 Using two wrenches se...

Page 93: ...he sealing ring and filter Tighten the filter securely by hand Do not overtighten a 9998 a Oil filter sealing ring 12 Using two wrenches connect the oil drain hose plug to the oil drain hose and place it back into the boat 13 Tighten the bilge drain plug 14 Remove the oil filler cap port or starboard Add oil to bring level up to but not over the FULL mark on the dipstick ...

Page 94: ...il to bring the level up to but not over the OK range mark on the dipstick NOTE It is normal for the oil level to be low after changing the oil and filter because the filter is empty and gets filled at start up 17 Remove the flushing attachment s SUPERCHARGER GEARCASE OIL IMPORTANT Change the supercharger oil when the engine and supercharger are warm from operation Warm oil flows more freely carry...

Page 95: ... the plug threads 5 Install the drain plug in the gearcase and torque to specifications 6 Fill the gearcase through the top fill hole with approximately 177 milliliters 6 oz of oil The oil should cover half of the sight glass in the gearcase 7 Install the fill plug and torque to specifications a c b 10567 a Drain plug b Sight glass c Fill plug Description Nm lb in lb ft Fill and drain plugs superc...

Page 96: ...1 Remove the propeller and place the drive unit in the full down position 2 Place a suitable container below the drive fill drain screw 3 Remove the fill drain screw and sealing washer and drain the oil IMPORTANT If any water drained from the oil fill drain hole or if oil appears milky the drive unit is leaking and should be checked immediately by your authorized Mercury Marine dealer a 7986 a Oil...

Page 97: ...ust the drive unit so that the propeller shaft is level 6 Fill the drive unit through the oil fill drain hole with High Performance Gear Lube until an air free stream of lubricant flows from the oil vent hole a 87 7988 a Oil fill drain screw Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Drive unit 92 802854A1 ...

Page 98: ...en securely 87 7333 a a Gear lube monitor bottle Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Gear lube monitor 92 802854A1 10 Continue adding gear lube to the monitor bottle until the oil level is at the FULL line mark on the bottle 11 Lubricate the O ring on the bottle neck with sterndrive oil to ensure ease of installation and removal of the cap 12 Install the f...

Page 99: ... shaft 92 802867A1 Description Nm lb in lb ft Propeller nut 75 55 IMPORTANT Oil level in the gear lube monitor will rise and fall during drive operation Always check the oil level when the drive is cool and the engine is shut down Lubrication SHIFT CABLE Lubricate the pivot points with 4 Cycle 25W40 motor oil 79 7997 Tube Ref No Description Where Used Part No 79 MerCruiser 4 cycle 25W40 Engine Oil...

Page 100: ...edometer hose fitting damage Disconnect the speedometer hose fitting from the driveshaft housing before removing the sterndrive unit IMPORTANT The sterndrive must be removed to lubricate the U joints Contact your authorized Mercury Marine dealer for this service NOTE The engine coupling and shaft splines are greased with engine coupler spline grease Universal joints are greased with 2 4 C with Tef...

Page 101: ...n Where Used Part No 95 2 4 C Marine Lubricant with Teflon Gimbal bearing 92 802859A1 ENGINE COUPLER Lubricate the engine coupler and shaft splines with engine coupler spline grease 91 8014 Tube Ref No Description Where Used Part No 91 Engine Coupler Spline Grease Engine coupler and shaft splines 92 802869A1 ...

Page 102: ...eflon Drive shaft grease fittings 92 802859A1 Propellers XR MODEL PROPELLERS WARNING Avoid serious injury or death Place the remote control in neutral and remove the ignition key from the switch before removing and or installing the propeller Place a block of wood between the anti ventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating ...

Page 103: ...s during boating season A minimum of 75 Nm 55 lb ft torque is required Removal 1 Place a wood block between the propeller blade and the anti ventilation plate to prevent rotation a b 7448 a Wood block b Propeller nut 2 Turn the propeller shaft nut counter clockwise to remove the nut ...

Page 104: ... the washers propeller and prop hub assembly a b c d e f g 8018 a Propshaft b Prop hub assembly c Propeller assembly d Washer e Belleville washer f Washer g Locknut NOTE Some damaged propellers can be repaired See your dealer ...

Page 105: ...n Where Used Part No 94 Anti Corrosion Grease Exposed surfaces of propeller shaft 92 802867A1 2 Apply the following lubricants to the entire exposed surface of the propshaft Salt Water Anti Corrosion Grease Fresh Water Anti Corrosion Grease or Optimal Paste White T Grease 3 After first use Re tighten propeller nut Check propeller at least every 20 hours of operation Do not operate with a loose pro...

Page 106: ...er connection when flushing the cooling system or operating the engine Dual Water Pick up Flush Gearcase Seal Kit 91 881150K 1 9194 Blocks off the front water inlet holes on the dual water inlet gearcases Flushing Kit 91 849996T 1 9195 Use for flushing gearcases with low water inlets Flushing Attachment 91 843122A01 14565 Attaches to the water intakes provides a fresh water connection when flushin...

Page 107: ...l water pickups require the flushing attachment 91 44357Q 2 and the flush seal kit 91 881150K 1 The Hi Performance low water pickup drive requires the flushing attachment 91 849996T 1 while the SportMaster low water pickup drive requires flushing attachment 91 843122A01 5752 5771 19310 Dual Water Pickup SportMaster Low Water Pickup Hi Performance Low Water Pickup ...

Page 108: ...c Lower sterndrive unit to full down in position 3 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 If flushing the cooling system with the boat out of the water a Lower sterndrive unit to full down in position b Remove...

Page 109: ...r temperature gauge and ensure that the engine is operating in the normal range 8 Observe the water temperature gauge to ensure that the engine is operating in the normal range 9 Stop the engine 10 Shut off the water and remove the flushing attachment Seawater Pump Impeller Inspection NOTE The seawater pump is located at the lower front on the starboard side of the engine 1 Inspect the seawater pu...

Page 110: ... at least once a year or whenever decreased cooling efficiency is noticed ENGINE OIL COOLER NOTE The engine oil cooler is located on the top rear portion of the engine 1 Remove the end plates and gaskets a a 8030 a End plates 2 2 Clean the oil cooler with a suitable brush 3 Flush the passages with fresh water 4 Inspect the gaskets for deterioration and replace if necessary 5 Install the gaskets an...

Page 111: ... a 10518 a Hose clamps 2 2 Re install the cooler and tighten the hose clamps securely 3 Check the power steering fluid level 4 Start the engine and inspect the cooling system for leaks FUEL COOLER NOTE The fuel cooler is located on the lower starboard side of the engine 1 Loosen the water hose clamps and remove the water hoses to inspect or clean the cooler ...

Page 112: ...he cooler and tighten the hose clamps securely 4 Start the engine and inspect the cooling system for leaks Serpentine and Supercharger Drive Belts SERPENTINE DRIVE BELT ROUTING AND TENSION WARNING Avoid possible serious injury Make sure that the engine is turned off and the ignition key is removed before inspecting belts IMPORTANT The drive belt must be routed as shown or damage may result ...

Page 113: ...culating pump pulley d Crankshaft pulley e Belt tension gauge f Power steering pulley non power steering models have an idler pulley g Alternator pulley 2 Loosen the 5 8 in locking nut on the adjusting screw Leave the wrench on the adjustment nut 3 Use a 5 16 in socket and tighten the adjusting screw until the belt tension conforms to the correct setting on the gauge ...

Page 114: ...AINTENANCE 104 4 Hold the adjustment stud and tighten the 5 8 in locking nut a c 10287 b a Belt tensioner pulley b Adjustment locking nut c Adjustment screw 5 Remove the belt tension gauge from the belt ...

Page 115: ...g B E L T T E N S I O N GAUGE e 10286 a Seawater pump pulley b Belt adjustment pulley c Re circulating pump pulley d Crankshaft pulley e Belt tension gauge f Power steering pulley non power steering models have an idler pulley g Alternator pulley Description N lb New Belt 489 110 Used Belt 400 90 ...

Page 116: ... BELT ROUTING AND TENSION a b c e d 10289 c a Supercharger pulley b Self adjusting belt tensioner c Idler pulley d Supercharger belt e Crankshaft pulley The supercharger belt uses a self tensioner and does not require tension adjustment ...

Page 117: ... be replaced for the following conditions Excessive wear Cracks as explained previously Fraying Glazed surfaces Fuel Filters WARNING Avoid serious injury or death from a gasoline fire or explosion When changing fuel system components be sure that the ignition key is OFF that the lanyard stop switch is positioned so that the engine cannot start and that there are no sources of high heat spark open ...

Page 118: ...use a filter wrench when installing the water separating fuel filter 3 Thread the filter clockwise onto the housing and tighten securely by hand Do not over tighten 4 Start and run the engine If the engine stops or will not start it may be necessary to prime the fuel system see Priming the Fuel System Prior to Starting in the Cold Weather or Extended Storage section of this manual 5 Check the filt...

Page 119: ...ting in a different electrochemical reaction that will create hydrogen on the metal surface of the drive under the paint This causes the paint to blister and peel completely from the surface of the overprotected drive CAUTION Avoid corrosion damage Mercury Marine recommends using anodes sold through Mercury Precision Parts only Some other manufacturers of aluminum anodes use alloys that are insuff...

Page 120: ...e system should be tested to ensure adequate output The test should be made where boat is moored using a reference electrode and test meter Contact your authorized Mercury Marine dealer to arrange for this test 9322 a b a MerCathode b Electrode assembly ...

Page 121: ... half gone Inspect the propeller shaft for fishing line which can cause corrosion on the stainless steel propeller shaft Remove the propeller at least every 60 days and lubricate the propeller shaft with anti corrosion grease Do not use lubricants containing graphite on or near aluminum in saltwater Refer to the drive unit service manual for complete information on anode mainteinance and replaceme...

Page 122: ...om Black paint Use only tin based anti fouling paint or equivalent on or near aluminum surfaces below the waterline If the surface is showing bare metal apply 2 coats of paint Do not paint the anodes This will prevent them from functioning properly Do not paint the trim tabs or the mounting surfaces ...

Page 123: ...r or tin based anti fouling paints avoid any electrical interconnection between the Mercury Marine Product anodic blocks and the paint by allowing a minimum of 40 mm 1 5 in unpainted area on the transom of the boat around these items a b 6118 a Anti fouling paint b Unpainted area IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the ...

Page 124: ...s on the inside of the boat every two to three weeks with Corrosion Guard to protect the finish from dulling and corrosion External power package components may also be sprayed Tube Ref No Description Where Used Part No 120 Corrosion Guard Power package 92 802878 5 5 2 All lubrication points especially the steering system and shift and throttle linkages should be kept well lubricated 3 Flush seawa...

Page 125: ...us injury or death Batteries contain acid that can cause severe burns Avoid contact with skin eyes and clothing Bottom of Boat To maintain maximum speed ensure that the boat bottom is Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts water Straight and smooth fore and aft Marine vegetation may accumulate when the boat is docked This growth must be removed b...

Page 126: ...sion damage on the power package s exterior finish Use Quicksilver spray paints see your authorized Mercury Marine dealer Attention Required After Submersion Before recovery contact an authorized Mercury Marine dealer After recovery immediate service by an authorized Mercury Marine dealer is required to prevent serious damage to power package ...

Page 127: ...and change oil and oil filter 2 Flush cooling system Refer to Flushing Cooling System shown earlier in this manual WARNING Avoid Fire or Explosion Ensure that the engine compartment is well ventilated and no gasoline vapors are present during the following operation 3 Close the fuel shut off valve if equipped 4 Prepare fuel system for extended storage by mixing the following in a 23 liter 6 U S ga...

Page 128: ...s are normally consumed before they can absorb enough moisture to cause trouble However boats often sit idle long enough for phase separation to take place In addition internal corrosion may take place during storage if alcohol has washed protective oil films from internal components IMPORTANT Do not run the engine s fuel system dry of this fogging mixture in the 23 liter 6 U S gal remote outboard...

Page 129: ...weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freezing and or corrosion damage to the engine IMPORTANT The boat must be as level as possible to ensure complete draining of cooling system 1 Remove the following drain plugs NOTE Removing the drain plugs from the following locations will ensure that the charge cooler is drained End...

Page 130: ...header balance rail plastic wing nut plugs 2 Starboard side b Fuel cooler plastic wing nut plug c Exhaust header balance rail plastic wing nut plugs 2 Port side one plug is hidden d Power steering cooler plastic wing nut plug 2 Repeatedly clean out drain holes using a stiff piece of wire Do this until the entire system is drained ...

Page 131: ...nstall the drain plugs Perfect Seal is not required on wing nut type plugs reconnect the hoses and tighten all hose clamps securely 5 Make sure the following passages are open and unobstructed a b c 8042 a Speedometer pitot tube b Trim tab cavity vent hole c Trim tab cavity drain passage 6 For additional assurance against freezing and rust in the engine seawater cooling system when storing for win...

Page 132: ...eading to the seawater pump and place the hose into a container of ethylene glycol antifreeze and water The antifreeze mixture should be at the correct concentration level to protect the engine to the lowest temperature to which it will be exposed during cold weather or extended storage a b c d 13180 e f a Seawater shut off valve b Disconnect hose here and place into container of antifreeze c Sea ...

Page 133: ...first and the negative battery cable to the negative battery terminal second 2 Install a fully charged battery Clean the battery cable clamps and terminals and reconnect cables Tighten each cable clamp securely when connecting 3 Coat battery terminal connections with an anti corrosion agent 4 Perform all checks in Operation Chart in the Before Starting column 5 Refer to Flushing Cooling System bef...

Page 134: ... Observe the instrumentation to ensure all systems are functioning 5 Inspect engine for fuel oil fluid water and exhaust leaks 6 Check the steering system 7 Check shifting and throttle control for proper operation PRIMING THE FUEL SYSTEM PRIOR TO STARTING WARNING Avoid fire or explosion Gasoline is extremely flammable and highly explosive Ensure key switch is OFF Do not smoke or allow a spark or o...

Page 135: ...e barbed fitting with a hose clamp 3 Squeeze the primer bulb until the bulb becomes firm NOTE Do not turn the key switch to the START position during the following priming procedure 4 Cycle the ignition key switch to the RUN position for three seconds and then OFF 5 Repeat steps 3 and 4 one or two more times The object of this procedure is to prime the fuel system but not to the point of having th...

Page 136: ...essure regulator housing 92 809822 8 Attempt to start the engine by turning the key switch to the START position for a maximum of 15 seconds or until the engine starts and runs smoothly Do not advance the throttle until the water temperature has reached a minimum of 54 C 130 F IMPORTANT The throttle must not be advanced until the engine idles and runs smoothly and the water temperature has reached...

Page 137: ... or replace fuse Master or starter solenoid defective Replace Loose or dirty electrical connections or damaged wiring battery cable diameter gauge too small for the application Check all electrical connections and wires especially battery cables Clean and tighten faulty connection Low battery charge or defective battery Test and replace if defective Defective starter Test and replace if defective ...

Page 138: ...d Replace kinked lines or blow out lines with compressed air to remove obstruction Crankshaft position sensor faulty Test and replace if faulty Faulty fuel pressure regulator diaphragm Test and replace if faulty Do not attempt to start the engine if the fuel pressure regulator diaphragm is ruptured Engine Hard to Start Runs Rough Misses and or Backfires Possible Cause Remedy Faulty ignition system...

Page 139: ...load improperly distributed Reduce load or redistribute load more evenly Boat bottom fouled or damaged Clean or repair as necessary Flame arrestor dirty or restricted Change or clean flame arrestor Stale or contaminated fuel If contaminated drain tank Fill with fresh fuel Engine Coolant Temperature Too Low Possible Cause Remedy Faulty coolant thermostat Replace water thermostat Faulty gauge or sen...

Page 140: ...st senders Aerated water supply to water pick up Place water pick up in a non aerated water supply Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in system Check and add oil Excessive oil in system causing it to become aerated Check and bring oil to required level Check for cause of excessive oil improper filling defective fuel pump etc Diluted or improper viscosity oil Change oil ...

Page 141: ...Remedy Excessive current draw from battery Turn off non essential accessories Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten faulty connections Repair or replace damaged wiring Alternator drive belt loose or in poor condition Replace and or adjust Defective battery Test battery Power Trim Doe...

Page 142: ...f any are loose or missing see authorized Mercury Marine dealer immediately Shift or throttle cable kinked Replace cable Friction adjustment excessive Adjust friction Steering Wheel Turns Hard or Jerky Possible Cause Remedy Low power steering pump fluid level Refill system with fluid and check for leaks Sepentine belt loose or damaged Replace and or adjust Insufficient lubrication on steering syst...

Page 143: ...acock is completely open Check supply hoses for obstruction Check for external water pick up obstruction Check for sea strainer obstruction Check condition of sea pump Seawater Pressure Is Above Specification Possible Cause Remedy High boat speed causing high ram pressure Install a sea strainer with a bypass relief valve ...

Page 144: ...r has the necessary information to order parts and accessories for you When inquiring on parts and accessories the dealer requires the model and serial number to order the correct parts Service Assistance Satisfaction with your Sterndrive or Inboard product is very important to your dealer and to us If you ever have a problem question or concern about your Sterndrive or Inboard product contact you...

Page 145: ...lephone Fax Mercury MerCruiser 3003 N Perkins Road Stillwater OK 74075 405 743 6566 405 743 6570 United States Mercury Racing Telephone Fax Mercury Racing N7480 County Rd UU Fond du Lac WI 54935 9585 920 924 2088 920 924 2096 Canada Telephone Fax Mercury Marine Ltd 2395 Meadowpine Blvd Mississauga Ontario L5N 7W6 Canada 905 567 6372 905 567 8515 Australia Pacific Telephone Fax Mercury Marine Austr...

Page 146: ...5 Mexico Central America South America Caribbean Telephone Fax Mercury Marine 11650 Interchange Circle North Miramar FL 33025 U S A 954 744 3500 954 744 3535 Japan Telephone Fax Mercury Marine Japan 283 1 Anshin cho Hamamatsu Shizuoka 435 0005 Japan 81 53 423 2500 81 53 423 2510 Asia Singapore Telephone Fax Mercury Marine Singapore 72 Loyang Way Singapore 508762 5466160 5467789 ...

Page 147: ...nearest dealer or contact MERCURY MARINE Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54936 1939 Outside The United States and Canada Before ordering literature please have the following information about your power package available Engine Model Horsepower Serial Number Model year Contact your nearest dealer or Marine Power S...

Page 148: ...MAINTENANCE LOG 138 Maintenance Log Record all maintenance performed on your outboard here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours ...

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Mercury Racing Sterndrive 600SCi, User Manual

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