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Mercury TowSport Inboards, Manual

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Mercury TowSport Inboards Manual Download Page 1

2002, Mercury Marine

Tow Sports / Inboard MPI Models

90Ć864197020   302

Summary of Contents for TowSport Inboards

Page 1: ...2002 Mercury Marine Tow Sports Inboard MPI Models 90 864197020 302...

Page 2: ...y MerCruiser power package When contacting your Authorized Mercury MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in e...

Page 3: ...that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our Mercury MerCruiser products We sincerely hope your boating will be pleas...

Page 4: ...ons while performing the service plus common sense operation are major accident prevention measures WARNING WARNING Hazards or unsafe practices which could result in severe personal injury or death CA...

Page 5: ...Warning System 19 Engine Guardian Strategy 20 ON THE WATER Safe Boating Suggestions 24 Be Alert To Carbon Monoxide Poisoning 26 Basic Boat Operation 28 Launching And Boat Operation Care 28 Starting An...

Page 6: ...79 Tow Sports 81 Power Package Recommissioning 83 Emissions Europe Only 84 Emissions Testing 84 Installing Test Probes 84 TROUBLESHOOTING Diagnosing EFI Problems 88 Troubleshooting Charts 88 Starter...

Page 7: ...istration 2 International Owner Registration 3 Warranty Policies 4 Mercury MerCruiser One Year Limited Warranty Gasoline Fueled Products Only 4 3 Year Limited Warranty Against Corrosion Worldwide 6 Tr...

Page 8: ...be required Warranty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only...

Page 9: ...is product your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marin...

Page 10: ...the product Unexpired warranty coverage cannot be transferred either to or from a commercial use customer CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is availab...

Page 11: ...eration with fuels oils or lubricants which are not suitable for use with the product see the Operation and Maintenance Manual alteration or removal of parts water entering the engine through the fuel...

Page 12: ...urchase 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...

Page 13: ...ess requested by Mercury ship the product or parts of the product directly to Mercury The warranty registration card is the only valid registration identification and must be presented to the dealer a...

Page 14: ...e and address Registration records will be changed on the factory computer registration file There is no charge for this service Outside the United States and Canada please contact the distributor in...

Page 15: ...WARRANTY 90 864197020 MARCH 2002 Page 9 THIS PAGE IS INTENTIONALLY BLANK...

Page 16: ...WARRANTY Page 10 90 864197020 MARCH 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 17: ...MARCH 2002 Page 11 GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls 12 Lanyard Stop Switch 12 Instrumentation 14 Remote Controls 15 Electrical System Overload Protection 18 A...

Page 18: ...ng your grip on the steering wheel that is pulling in one direction consuming alcohol or drugs high speed boating maneuvers Some remote control units are equipped with a lanyard stop switch if your re...

Page 19: ...he boat hull and propeller from accidental ejection Personal injury or death could occur Always properly connect both ends of the lanyard stop switch Accidental or unintended activation of the switch...

Page 20: ...r Temperature Gauge Indicates engine operating temperature 6 Fuel Gauge Indicates quantity of fuel in tank 7 Hour Meter Records engine running time 8 Bilge Blower Switch Operates bilge blower 9 Igniti...

Page 21: ...starting the engine 3 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 L...

Page 22: ...full lever movement Move lever forward to shift to FORWARD gear Move lever backward to shift to REVERSE gear Lever in full vertical position shifts to NEUTRAL 2 Throttle Lever allows engine rpm to be...

Page 23: ...be adjusted to increase or decrease the tension on the control handle cover must be removed to adjust This will help prevent slipping of the remote control handle Turn screw clockwise to increase tens...

Page 24: ...Contact your authorized Mercury MerCruiser dealer 0019 77602 70525 74907 77906 1 2 4 3 5 1 A red circuit breaker provides protection for engine wiring harness and the instrumenta tion power lead Reset...

Page 25: ...ng system will sound with an intermittent horn if the following occurs 3 Transmission Fluid Temperature Too Hot CAUTION Operation of the engine after the audio warning system alarm has sounded could r...

Page 26: ...Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails For example if the water inlet becomes partially blocked Engine Guardian Strategy w...

Page 27: ...GETTING TO KNOW YOUR POWER PACKAGE 90 864197020 MARCH 2002 Page 21 THIS PAGE IS INTENTIONALLY BLANK...

Page 28: ...GETTING TO KNOW YOUR POWER PACKAGE Page 22 90 864197020 MARCH 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 29: ...and Bilge Pump 29 Protecting People In The Water 30 While You Are Cruising 30 While Boat Is Stationary 30 High Speed And High Performance Boat Operation 30 Wave And Wake Jumping 31 Impact With Underwa...

Page 30: ...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 Associa...

Page 31: ...driver becomes disabled or falls overboard Do not overload your boat Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate Know your boat s operating...

Page 32: ...tors are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported...

Page 33: ...our boat Although the occurrence is rare on a very calm day swimmers and passengers in an open area of a stationary boat that contains or is near an operating engine may be exposed to a hazardous leve...

Page 34: ...ne 0028 OPERATION CHART Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Open engine hatch Observe all gauges to check condition of engine If not normal stop engine Observe...

Page 35: ...position 5 If engine is cold operate engine for 1 or 2 minutes at fast IDLE 1000 1500 rpm or until engine temperature reaches 140 160 degrees F 60 71 degrees C 6 Inspect the power package for fuel oi...

Page 36: ...ly whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a gear case or any solid device rigidly attache...

Page 37: ...tain hazards arise particularly when the boat re enters the water The primary concern is the boat changing direction while in the midst of the jump In such cases the landing may cause the boat to viol...

Page 38: ...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 spe...

Page 39: ...at bottom should be Clean free of barnacles and marine growth Free of distortion nearly flat where it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when the boat...

Page 40: ...resumes It is the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller Refer to Everything You Need To Know About Propellers 90 8614...

Page 41: ...the engine reaches normal operating temperature Frequently check engine oil level Add oil as needed It is normal for oil consumption to be high during the break in period 0043 After Break In Period To...

Page 42: ...ON THE WATER Page 36 90 864197020 MARCH 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 43: ...le Cable 55 Transmission Linkage 55 Engine Coolant Closed Cooled Models Only 56 Checking 56 Filling 57 Changing 57 Flame Arrestor and Related Components 58 Cleaning 58 Positive Crankcase Ventilation V...

Page 44: ...pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable DO NOT use leaded gasoline Outside USA and Canada having a posted pump Octane Rating of 90 RON minimum Premiu...

Page 45: ...and operating difficulties WARNING FIRE AND EXPLOSION HAZARD Fuel leakage from any part of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death Care ful p...

Page 46: ...CH 4 may be used In those areas where Quicksilver 4 Cycle 25W 40 Marine Engine Oil or a recommended straight weight oil are not available a multi viscosity 20W 40 or a less preferable choice 20W 50 w...

Page 47: ...dle4 41 kPa 6 psi Thermostat 71 degrees C 160 degrees F Timing Idle3 0 degrees Firing Order 1 8 4 3 6 5 7 2 Electrical System 12 Volt Negative Ground Alternator Rating Hot Operating Amps 65 amp Altern...

Page 48: ...with Purified Water 1 Always use the dipstick to determine the exact quantity of oil or fluid required 2 Seawater Cooling System capacity information is for winterization use only 0053 TRANSMISSION M...

Page 49: ...package will ensure optimum performance and dependability and will keep your overall operating expenses at a minimum See your authorized Mercury MerCruiser dealer for service aids 0055 Dealer Responsi...

Page 50: ...gine compartment prior to servicing the power package IMPORTANT Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed Some listings can be done by owner operator...

Page 51: ...t are 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...

Page 52: ...n damage on power package exterior finish Contact your authorized Mercury MerCruiser dealer 0059 Inboard Maintenance Chart Routine Maintenance Each Day Start Each Day End Weekly Every Two Months Check...

Page 53: ...ange the transmission fluid Replace the fuel filters Check the steering system and the remote control for loose missing or damaged parts Lubricate the cables and the linkages Retorque the engine mount...

Page 54: ...the exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace the worn components Clean the seawater section of the closed...

Page 55: ...SPECIFICATIONS AND MAINTENANCE 90 864197020 MARCH 2002 Page 49 0166 Maintenance Record Date Hour Meter Reading Serviced By Maintenance Per formed...

Page 56: ...he engine Allow approximately five minutes for the oil to drain into the oil pan The boat must be at rest in the water a a a a 77808 78027 a Dipstick Tubes 2 Remove the dipstick Wipe clean and reinsta...

Page 57: ...dd the specified engine oil to bring the level up to but not over the FULL or OK RANGE mark on the dipstick Refer to Specifications All Models Capacity Liters U S qts Fluid Type Engine Oil With Filter...

Page 58: ...Pull tether through the bilge drain 3 Place the oil drain hose in a suitable container 4 Remove the drain plug from the oil drain hose 5 After oil has drained completely install the drain plug in the...

Page 59: ...tions Do NOT overtighten 4 Remove oil fill cap IMPORTANT Always use dipstick to determine exactly how much oil is required 5 Add recommended engine oil to bring level up to but not over FULL or OK RAN...

Page 60: ...lly seated 3 Walter V Drive Transmissions Stop engine and remove dipstick to check level If fluid is below top full line add specified fluid through breather elbow Do not overfill Reinstall dipstick w...

Page 61: ...ivot Points b Guide Contact Surfaces Description Where Used Part Number Engine Oil Pivot points guide contact surfaces Obtain Locally 0196 Transmission Linkage Typical 1 Lubricate the detent ball and...

Page 62: ...rn the cap 1 4 turn to allow any pressure to escape slowly then push down and turn the cap all the way off 1 Remove the cap from the heat exchanger and observe the fluid level a 77955 a Heat Exchanger...

Page 63: ...xed 50 50 with Purified Water Closed Cooling System 92 877770K1 0072 Filling 1 Remove the fill cap from the coolant recovery bottle 2 Fill to the FULL line with the specified coolant Description Where...

Page 64: ...flame arrestor 77946 a b c d e f 78480 a Engine Cover Knob b Engine Cover c Nuts Flame Arrestor d Cover Mount Bracket e Flame Arrestor f Crankcase Ventilation Hose 4 Clean the flame arrestor in water...

Page 65: ...Nuts 12 9 9 Install the engine cover 0167 Positive Crankcase Ventilation Valve PCV CHANGING IMPORTANT Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations 1 Rem...

Page 66: ...e water separating fuel filter Gasoline is extremely flammable and highly explosive under certain conditions Ensure the ignition key is OFF Do not smoke or allow spark or open flame in the area when c...

Page 67: ...T use a filter wrench 70573 77933 a b c a Fuel Filter Base b Sealing Ring c Fuel Filter 6 Supply cooling water to the engine 7 Start engine Check the filter connection for gasoline leaks If leaks exis...

Page 68: ...el immediately 1 Verify the presence of an anti siphon valve If no anti siphon valve is present plug fuel line from the fuel tank 2 Remove the existing in line fuel filter 3 Select appropriate size co...

Page 69: ...crew and washer through the mounting clip into the stringer Description Nm lb in lb ft Screw Mounting Clip 12 2 9 8 Install and torque hose clamps over hose and insert barbs into hose 78289 b a a Fuel...

Page 70: ...g current EFI Electronic Control Module ECM The ECM requires a stable voltage source During multiple engine operation an onboard electrical device may cause a sudden drain of voltage at the engine s b...

Page 71: ...Alternator Pulley e Seawater Pump Pulley 0082 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 b...

Page 72: ...s the longest dis tance between two 2 pulleys 1 Loosen the 5 8 in locking nut on the adjustment stud 2 Turn the adjustment stud and loosen the belt 3 Remove the serpentine drive belt 4 Install the ser...

Page 73: ...different ranges for new and used belts 77573 a b 77574 a Kent Moore Tension Gauge b Serpentine Belt 8 While holding the adjustment stud at the correct belt tension tighten the 5 8 in locking nut 7782...

Page 74: ...inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 0085 Preparing Your Power Package For Storage 1 Fill the fuel tanks wit...

Page 75: ...23 liter 6 U S gal remote fuel tank mix a 19 liter 5 U S gal regular unleaded 87 octane 90 RON gasoline b 1 89 liter 2 U S qts Premium Plus 2 Cycle TC W3 Outboard Oil c 150 ml 5 ounces Fuel System Tr...

Page 76: ...88 Draining Instructions CAUTION Ensure that boat is out of the water or seacock is closed and bilge pump is operating before beginning procedure Excess water in bilge can damage engine or cause boat...

Page 77: ...dentification AIR ACTUATED SINGLE POINT DRAIN SYSTEM b a d c 77955 77955 a b c d Closed Cooled Models Seawater Cooled Models a Blue Drain Plug Location b Blue Air Pump c Air Manifold d Green Indicator...

Page 78: ...the air manifold 77638 a a Green Indicators 5 Pull lever on air pump up vertical to lock pump on the fitting 6 Pump air into the system until both green indicators extend and water drains from both s...

Page 79: ...d return it to the mounting bracket 13 Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance This helps ensure that all water is...

Page 80: ...point drain system or if the single point drain system fails 1 Close the seacock 2 Remove the blue drain plug from the distribution housing lower front port side 77917 a a Blue Drain Plug 3 Immediatel...

Page 81: ...or to purge any water trapped in seawater pickup pump Do NOT allow engine to start 8 Prior to launching boat or starting the engine close the drain system by installing the 4 blue drain plugs IMPORTAN...

Page 82: ...op of pump is flush with the handle horizontal 3 Install air pump on the fitting in the air manifold 77638 a a Green Indicators 4 Pull lever on air pump up vertical to lock pump on the fitting 5 Pump...

Page 83: ...it to the mounting bracket 10 Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained IMPORTANT Mercu...

Page 84: ...tart IMPORTANT Mercury MerCruiser recommends that propylene glycol a nontoxic and environmentally safe antifreeze be used in the seawater section of the cooling system for cold weather or extended sto...

Page 85: ...rom flowing back into engine CAUTION Engine overheating can cause engine damage To avoid observe the water temperature gauge and ensure the engine is operating in the normal ranges 0099 Inboards NOTE...

Page 86: ...eat 10 Flush the engine for 10 minutes or until discharge water is clear 11 Shut off the engine CAUTION Do not let water run more than 15 seconds with engine not operating or too much flushing water w...

Page 87: ...fitting Using appropriate connector connect water hose to water source Proceed to Step 3 75191 b All other models Using appropriate connector connect the flushing hose from the water to the water inle...

Page 88: ...e upper hose of the seawater pickup pump Proceed to Step 3 77908 3 Open the water source 4 Place remote control in NEUTRAL idle speed position and start engine Operate engine at idle speed in NEUTRAL...

Page 89: ...erminals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat the terminal connections with a battery terminal anti corrosion agent 4 Perform all the...

Page 90: ...hould follow Recommended maintenance schedules particularly as to the ignition system Proper engine tuning procedures to ensure these features remain in good operating order Proper steps to maintain t...

Page 91: ...Description Where Used Part Number A Pipe Sealant with Teflon Adapter fitting threads 92 809822 4 Insert exhaust probes into fittings and tighten securely 75324 a a Test Probes Installed The testing a...

Page 92: ...SPECIFICATIONS AND MAINTENANCE Page 86 90 864197020 MARCH 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 93: ...ine Will Not Start Or Is Hard To Start 88 Engine Runs Rough Misses And Or Backfires 89 Poor Performance 89 Excessive Engine Temperature 90 Insufficient Engine Temperature 90 Low Engine Oil Pressure 90...

Page 94: ...ace fuse Loose or dirty electrical connections or damaged wiring Check all electrical connections and wires especially battery cables Clean and tighten faulty connection Bad battery Test and replace i...

Page 95: ...ry MerCruiser dealer EFI System fault Have EFI System checked by an authorized Mercury MerCruiser dealer 0106 Poor Performance Possible Cause Remedy Throttle not fully open Inspect throttle cable and...

Page 96: ...anger Loss of pressure in closed cooling section Check for leaks Clean inspect and test pressure cap Faulty seawater pickup pump Repair Seawater discharge restricted or plugged Clean exhaust elbows 01...

Page 97: ...cceptable battery condition Test battery Loose or dirty electrical connections or damaged wiring Check all associated electrical connections and wires especially battery cables Clean and tighten fault...

Page 98: ...TROUBLESHOOTING Page 92 90 864197020 MARCH 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 99: ...ubmersion 94 Replacement Service Parts 95 Resolving A Problem 96 Mercury Marine Service Offices 97 Customer Service Literature 98 English Language 98 Other Languages 98 Andre sprog 98 Andere talen 98...

Page 100: ...arises for service contact the nearest authorized dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Ou...

Page 101: ...those of the standard automotive engine For example one of the most important and probably the least suspected special replacement part is the cylinder head gasket Since saltwater is highly corrosive...

Page 102: ...anager 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 conta...

Page 103: ...L5N 7W6 Australia Pacific 61 3 791 5822 61 3 793 5880 Mercury Marine Australia 132 140 Frankston Road Dandenong Victoria 3164 Australia Europe Middle East Africa 32 87 32 32 11 32 87 31 19 65 Marine...

Page 104: ...y Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe en Betjenings og vedligeholdelsesmanual p et andet sprog En liste med reservedelsnumre for andre spro...

Page 105: ...al de Opera o e Manuten o em outro idioma contate o Centro de Servi o Internacional de Marine Power Pot ncia Marinha ou a Mercury Marine mais pr xima para obter informa es Uma lista de n meros de refe...

Page 106: ...act your 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 54935 1939 Outside The United Sta...

Page 107: ...CUSTOMER ASSISTANCE INFORMATION 90 864197020 MARCH 2002 Page 101 THIS PAGE IS INTENTIONALLY BLANK...

Page 108: ...CUSTOMER ASSISTANCE INFORMATION Page 102 90 864197020 MARCH 2002 THIS PAGE IS INTENTIONALLY BLANK...

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