MerCruiser Sterndrive 4.3L TKS Owner'S Manual Download

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TKS Sterndrive Models

90-860171061 1206

NOTE: The following applies to CE marked products only.

Declaration of Conformance – Mercury MerCruiser

This sterndrive or inboard engine when installed in accordance to Mercury

MerCruisers’ instructions complies with the requirements of the following directives

by meeting the associated standards, as amended:

Recreational Craft Directive 94/25/EC; 2003/44/EC

Applicable Requirement

Standards Applied

Owner’s manual (A.2.5)

ISO 10240

Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4)

ISO 8665

Inboard Engine (A.5.1.1)

ISO 15584; ISO 10088; ISO 7840; ISO 10133

Fuel System (A.5.2)

ISO 10088; ISO 7840; ISO 8469

Electrical System (A.5.3)

ISO 10133; ISO 8846

Steering system (A.5.4)

Applicable portions of: ISO 10592, ISO 8848 and

ABYC P‑17

Exhaust emission requirements (B.2)

ISO 8178

Owner’s manual (B.4)

ISO 8665

Noise emission levels (C.1)

ISO 14509

Ignition‑protected equipment (Annex II)

ISO 8846; SAE J1171; SAE J1191; SAE J 2031

Mercury MerCruiser declares that our sterndrive or inboard engines without integral

exhaust, when installed in a recreational craft, in accordance with the manufacturers

supplied instructions, will meet the exhaust emissions requirements of the directive

mentioned above. This engine must not be put into service until the recreational craft

in which it is to be installed has been declared in conformity, if so required, with the

relevant provision of the directive.

Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC

Generic emission standard

EN 50081‑1

Generic immunity standard

EN 50082‑1

Vehicles, boats and internal combustion engine

driven devices ‑ Radio disturbance characteristics SAE J551 (CISPR 12)
Electrostatic discharge testing

EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3

The notified body responsible for surveillance of the quality system under Full Quality Assurance

Module H of Directive 2003/44/EC is:
Det Norske Veritas

Norway

Notified Body Number: 0575

This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.

Patrick C. Mackey

President ‑ Mercury Marine, Fond du Lac, WI USA

Summary of Contents for Sterndrive 4.3L TKS

Page 1: ... 8846 SAE J1171 SAE J1191 SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust when installed in a recreational craft in accordance with the manufacturers supplied instructions will meet the exhaust emissions requirements of the directive mentioned above This engine must not be put into service until the recreational craft in which it is to be inst...

Page 2: ...printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2006 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...ime in order to verify and make a record of compliance with applicable standards and regulations All Mercury Marine product sold as new receives the applicable limited warranty coverage whether the engine participated in one of the test programs described above or not Read This Manual Thoroughly IMPORTANT If you don t understand any portion of this manual contact your dealer for a demonstration of...

Page 4: ...ver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used WARNING The engine exhaust from this product contains...

Page 5: ...Certification Star Label 16 Section 2 Getting to Know Your Power Package Identification 20 Engine Serial Number Decal 20 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Lanyard Stop Switch 22 Instrumentation 23 Remote Controls 24 Panel Mount Features 24 Console Mount Features 25 Power Trim 25 Single Engine Trim Trailer 26 Dual Engine Trim Trailer 27 Electrical S...

Page 6: ...s or Annually Whichever Occurs First 54 Every 200 Hours or 3 Years 55 Every 300 Hours or 3 Years 55 Every 5 Years 55 Maintenance Log 55 Sealed Carburetor Mixture Screw 56 Engine Oil 56 Checking 56 Filling 56 Changing Oil and Filter 57 Easy Engine Oil Drain System 57 Engine Oil Drain Pump 58 Changing Filter 58 Power Steering Fluid 59 Checking 59 Filling 59 Changing 59 Engine Coolant 59 Checking 59 ...

Page 7: ...at out of the Water 108 Boat in the Water 110 Draining the Sterndrive 112 Battery Storage 113 Power Package Recommissioning 113 Section 7 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks Slow 116 Engine Will Not Start Or Is Hard To Start 116 Engine Runs Rough Misses And Or Backfires 116 Poor Performance 116 Excessive Engine Temperature 117 Insufficient Engine Temperature 117 Low Engin...

Page 8: ...Page iv 90 860171061 DECEMBER 2006 ...

Page 9: ...y Charts 8 Consumer Application Warranty Chart 8 Commercial Application Warranty Chart 9 Government Application Warranty Chart 10 Mercury Installation Quality Certification Program 10 California Emissions Limited Warranty 11 What Is Covered 11 Duration Of Coverage 12 How To Obtain Warranty Coverage 12 What Mercury Will Do 13 What Is Not Covered 13 Components Of The Emission Control System 13 Discl...

Page 10: ...urned to him for warranty service The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required You may change your address at any time including at time of warranty clai...

Page 11: ...ing the warranty registration card and its relationship to warranty claim processing refer to the International Warranty See Table of Contents NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event of a safety recall notification under the Federal Boat Safety Act Transfer of Warranty The limited warranty is transferable to a s...

Page 12: ...ed installations SeaCore Sterndrive Model Coverage The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Standard Model Coverage The Limited Warranty for Standard Models which do not include Horizon Sterndrive and Inboard Models MX 6 2 Black Scorpion Tow Sport Models or SeaCor...

Page 13: ...e purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any covered repair The purchaser in that case shall pay for all related transportation charges and travel time If the service provided is not covered by this warranty the purchaser shall pay for all related labor and material and any other e...

Page 14: ...nt noncommercial use purchaser upon proper re registration of the product Warranty coverage is terminated for used product repossessed from a retail customer purchased at auction from a salvage yard or from an insurance company that obtained the product as a result of an insurance claim Condition That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail cu...

Page 15: ... to distribute the product in the country in which the sale occurred and then only after the pre delivery inspection process specified by Mercury Marine is completed and documented Warranty coverage becomes available upon proper registration of the product by the authorized dealer Corrosion prevention devices specified in the Operation Maintenance Warranty manual must be in use on the boat and rou...

Page 16: ...Non Certified Boat Brand Certified Boat Brand All Boat Brands Region Standard SeaCore Horizon 6 2 Scorpion Standard SeaCore Horizon 6 2 Scorpion Standard and Horizon SeaCore USA and Canada 1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years Latin America 1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years Mexico 1 year 3 years 1 year 1 year 1 yea...

Page 17: ... 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year ...

Page 18: ... hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1...

Page 19: ...Certification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and ...

Page 20: ...ted warranty provides coverage for the components of the emissions control systems of new 2003 2008 model year inboard and sterndrive engines for 2 years from either the date the product is first sold or first put into service whichever occurs first Emission related normal maintenance items such as spark plugs and filters that are on the warranted parts list see following are warranted up to their...

Page 21: ...er competitive activity or operating with a racing type lower unit at any point even by a prior owner of the product voids the warranty Expenses related to haul out launch towing storage telephone rental inconvenience slip fees insurance coverage loan payments loss of time loss of income or any other type of incidental or consequential damages are not covered by this warranty Also expenses associa...

Page 22: ...d to explain the emission control system warranty on your 2003 model year1 and later inboard or sterndrive engine In California new inboard and sterndrive engines must be designed built and equipped to meet the State s stringent anti smog standards Mercury Marine must warrant the emission control system on your inboard or sterndrive engine for the periods of time listed below provided there has be...

Page 23: ...nty repairs will be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding your warranty rights and responsibilities refer to Owner Service Assistance for contact information Emission Control Information Label A tamper resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser ...

Page 24: ...ification standards The owner operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications Emission Certification Star Label Your boat is labeled on the hull with one of the following star labels The Symbol for Cleaner Marine Engines Means 1 Cleaner Air and Water for a healthier lifestyle and envir...

Page 25: ...es that meet the Air Resources Board s Personal Watercraft and Outboard 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 emissio...

Page 26: ...Section 1 Warranty Notes Page 18 90 860171061 DECEMBER 2006 ...

Page 27: ...0 Bravo Sterndrive Serial Number and Identification 20 Bravo Transom Serial Number 21 Lanyard Stop Switch 22 Instrumentation 23 Remote Controls 24 Panel Mount Features 24 Console Mount Features 25 Power Trim 25 Single Engine Trim Trailer 26 Dual Engine Trim Trailer 27 Electrical System Overload Protection Carbureted Engines 27 Audio Warning System 29 Testing The Audio Warning System 30 2 ...

Page 28: ...numbers and maintenance color codes decal The engine serial number is also stamped in the engine block Bravo Sterndrive Serial Number and Identification The sterndrive serial number gear ratio model number and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive c b a d 25906 a Bar code b Serial Number c Gear ratio d Model number The serial number is also stamp...

Page 29: ...tamped in the U bolt plate of the Bravo transom assembly 25904 a Bravo transom assembly U bolt plate a Transom assembly serial Number The serial number is also stamped on the gimbal housing This is used as a permanent reference for authorized MerCruiser Dealers 25905 a Gimbal housing with serial number stamping a Transom assembly serial Number ...

Page 30: ... 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 the operator s wrist or leg or tie a knot in...

Page 31: ...trumentation 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 60 70 80 90 100 120 110 10...

Page 32: ... 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 33: ...stment 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 Power Trim Switch See Power Trim section for detailed power trim operating procedures Trailer Switch Used to raise drive unit for trailering launching beaching or shallow water operation See Power Trim fo...

Page 34: ...sterndrive unit down in can 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...

Page 35: ...ircuit breaker will trip open The cause must be found and corrected before replacing the fuse or resetting the circuit breaker NOTE In an emergency when the engine must be operated and the cause for the high current draw cannot be located and corrected turn off or disconnect all accessories connected to the engine and instrumentation wiring Reset the circuit breaker If the breaker remains open the...

Page 36: ...harness if an electrical overload occurs mc74907 1 3 A 15 amp accessory fuse is located on the rear of the engine This fuse protects the accessory circuits 7524 4 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 tripped mc70525 ...

Page 37: ...im Control Panel is further protected by a 20 amp in line fuse mc70527 1 7 The Quicksilver MerCathode System has a 20 amp in line fuse in the wire which connects to the positive terminal on controller If the fuse is blown the system will not operate resulting in a loss of corrosion protection mc79977 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning S...

Page 38: ...s If the warning horn emits a continuous beep do not operate the engine unless avoiding a hazardous situation If the alarm sounds stop the engine immediately Investigate cause and correct it if possible If the cause cannot be determined contact your authorized Mercury MerCruiser dealer Testing The Audio Warning System 1 Turn the ignition switch to the ON position without cranking the engine 2 List...

Page 39: ...p 37 Protecting People In The Water 37 While You Are Cruising 37 While Boat Is Stationary 37 High Speed And High Performance Boat Operation 37 Passenger Safety In Pontoon Boats And Deck Boats 38 Boats Having An Open Front Deck 38 Boats With Front Mounted Raised Pedestal Fishing Seats 38 Wave And Wake Jumping 39 Impact With Underwater Hazards 39 Drive Unit Impact Protection 40 Operating With Low Wa...

Page 40: ...y for minor 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 si...

Page 41: ...r skier 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...

Page 42: ...ne when the 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 l...

Page 43: ...Ensure that there is sufficient water always available at water inlet holes during operation WARNING Avoid fire or explosion Before starting the engine operate the bilge blower for at least five minutes to remove any explosive fumes from the engine compartment If the boat is not equipped with a bilge blower open the engine hatch and leave it open while starting the engine 3 Turn ignition key to ST...

Page 44: ...ition resume normal starting procedures Throttle Only Operation 1 Refer to Remote Controls 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 ...

Page 45: ...ven coasting and the gear shift is in neutral there is sufficient force by the water on the propeller to cause the propeller to rotate This neutral propeller rotation can cause serious injury While Boat Is Stationary WARNING Stop your engine immediately 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 b...

Page 46: ...nt of the fence while the boat is in motion Keep all passengers behind the front fence or enclosure Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water mc79555 1 WARNING Avoid serious injury or death from falling over the front end of a pontoon or deck boat and being run over S...

Page 47: ...oat to launch off of a wave or wake If the bow of your boat pitches down far enough while airborne upon water contact it may penetrate under the water surface and submarine for an instant This will bring the boat nearly to a stop in an instant and can send the occupants flying forward The boat may also veer sharply to one side Impact With Underwater Hazards Reduce speed and proceed with caution wh...

Page 48: ...is necessary do so at greatly reduced speeds WARNING Avoid serious injury or death from loss of boat control Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts Have the power package thoroughly inspected and any necessary repairs made Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protecti...

Page 49: ...ion nearly flat where it contacts the water Straight and smooth fore and aft Marine vegetation may accumulate when the boat is docked This growth must be removed before operation it may clog the water inlets and cause 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 perm...

Page 50: ...opeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating RPM range will cause higher than normal...

Page 51: ...sure 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 normal boat load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at WOT RPM Change the engine oil and oil filter Refer to Maintenance Change the transmission oil and filter Refer to Mainten...

Page 52: ...Section 3 On The Water Notes Page 44 90 860171061 DECEMBER 2006 ...

Page 53: ... 45 Section 4 Specifications Table of Contents Fuel Requirements 46 Fuel Ratings 46 Using Reformulated Oxygenated Gasolines USA Only 46 Gasolines Containing Alcohol 46 Engine Oil 47 Engine Specifications 48 Fluid Specifications 48 Sterndrives 48 Engine 48 4 ...

Page 54: ...se adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank The fuel system components on your Mercury MerCruiser engine will withst...

Page 55: ... protection we strongly recommend the use of the following oils listed in the order of recommendation 1 MerCruiser Quicksilver Synthetic Blend NMMA FC W rated 4 cycle oil 2 MerCruiser Quicksilver 25W40 NMMA FC W rated oil 3 A NMMA FC W rated oil 4 MerCruiser Quicksilver 4 cycle 25W40 non FC W rated oil 5 A good grade straight weight detergent automotive oil per the operating chart below NOTE The u...

Page 56: ...ications Sterndrives NOTE Oil capacity includes gear lube monitor Model Capacity Fluid Type Alpha One 1892 ml 64 oz High Performance Gear Lubricant Bravo One 2736 ml 92 1 2 oz Bravo Two 3209 ml 108 1 2 oz Bravo Three 2972 ml 100 1 2 oz Engine IMPORTANT All capacities are approximate fluid measures IMPORTANT It may be necessary to adjust oil levels depending on installation angle and cooling system...

Page 57: ...rcury Extended Life Coolant Antifreeze or Extended Life Ethylene Glycol 5 100 Coolant Antifreeze mixed 50 50 with Purified Water 5 0L 305 CID and 5 7L 350 CID Models Capacity Fluid Type Engine Oil With Filter 1 4 25 liters 4 5 U S qt Mercury Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 Seawater Cooling System 2 20 liters 21 U S qt Propylene Glycol and Purified Water 1 Always use the di...

Page 58: ...Section 4 Specifications Notes Page 50 90 860171061 DECEMBER 2006 ...

Page 59: ...59 Filling 60 Changing 61 Drive Unit Oil 61 Checking 61 Filling 62 Changing 63 Power Trim Fluid 65 Checking 65 Filling 65 Changing 66 Cleaning The Flame Arrestor 66 Positive Crankcase Ventilation Valve PCV 66 Changing 66 Changing Water Separating Fuel Filter 67 Lubrication 68 Steering System 68 Throttle Cable 70 Shift Cable Typical 70 Sterndrive Unit and Transom Assembly 71 Sterndrive U joint Shaf...

Page 60: ...e 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 ...

Page 61: ...e 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 proc...

Page 62: ...s and the wiring connections are secure Clean the gauges 1 Scheduled Maintenance NOTE Only perform maintenance which applies to your particular power package AFTER THE INITIAL 20 HOUR BREAK IN PERIOD To help extend the life of your Mercury MerCruiser power package we reccommend the following Change the engine oil and filter Change the sterndrive lube EVERY 100 HOURS OR ANNUALLY WHICHEVER OCCURS FI...

Page 63: ... damaged or corroded fasteners Check the cooling system and the exhaust system hose clamps for tightness Inspect both systems for damage or leaks Disassemble and inspect the seawater pump and replace worn components Clean the seawater section of the closed cooling system Clean inspect and test the pressure cap Inspect the exhaust system components and verify that the flapper valves are not missing...

Page 64: ...dispose of oil or oil waste as directed by local authorities Checking 1 Stop the engine Allow approximately 5 minutes for the oil to drain into the oil pan The boat must be at rest in the water 2 Remove the dipstick Wipe clean and reinstall fully into the dipstick tube Wait 60 seconds to allow trapped air to vent NOTE Ensure that dipstick is installed with oil level indication marks facing the rea...

Page 65: ...lver Synthetic Blend MerCruiser Engine Oil 25W 40 5 0L 305 cid 4 25 liters 4 5 U S qt 5 7L 350 cid Changing Oil and Filter Refer to the Maintenance schedule for the change interval Engine oil should be changed before placing the boat in storage IMPORTANT Change engine oil when the engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended engine oil...

Page 66: ... Coat sealing ring on new filter with engine oil and install 3 Tighten oil filter securely following filter manufacturer s instructions 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 the bottom of the OK range on the dipstick 6 With the boat at rest in the water check the oil lev...

Page 67: ...nd observe the level 2 Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid ATF to bring the fluid level up to the proper level Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power steering system 92 858074K01 3 Reinstall the fill cap dipstick Changing Power steering fluid does not require changing unless it becomes contaminated wit...

Page 68: ...th the engine at normal operating temperature check the coolant level in the coolant recovery bottle 5 The coolant level should be between the ADD and FULL marks 6102 6 Add the specified fluid as necessary Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 Filling CAUTION Alcohol or Methanol based antifreeze or plain water are not reco...

Page 69: ...covery bottle 2 Fill to the FULL line with the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooling System 92 877770K1 3 Install the fill cap onto the coolant recovery bottle Changing Contact your authorized Mercury MerCruiser dealer Drive Unit Oil CAUTION ENVIRONMENTAL HAZARD Discharge of oil or oil waste into the environment is restrict...

Page 70: ...Closed cooled models a Gear lube monitor Filling IMPORTANT If more than 59 ml 2 fl oz of High Performance Gear Lubricant is required to fill the monitor a seal may be leaking Damage to the sterndrive unit may occur due to lack of lubrication Contact your authorized Mercury MerCruiser dealer 1 Remove the gear lube monitor cap 2 Fill the monitor with the specified fluid so that the oil level is in t...

Page 71: ...ar lube monitor 2 Empty the contents into a suitable container 3 Install the gear lube monitor in the bracket 4 Bravo One Models Remove the propeller lower the sterndrive unit to the full down in position remove the oil fill drain screw and sealing washer and drain the oil a mc79506 1 b a Oil fill drain screw b Sealing washer ...

Page 72: ...wer the sterndrive unit so that the propeller shaft is level Fill the sterndrive unit through the oil fill drain hole with specified gear lubricant until an air free stream of lubricant flows from oil vent hole Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Sterndrive unit 92 802854A1 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndriv...

Page 73: ...s cool and the engine is shut down Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive unit in the full down in position only 1 Place the sterndrive unit in full down in position 2 Remove the fill cap from the reservoir b c a 5573 a Fill cap b Reservoir fill neck c MIN and MAX lines 3 Observe the oil level Level must be between the MIN and MAX lines on the reservoir NOTE Fi...

Page 74: ... Sealing washer c Typical carburetor d Crankcase ventilation hose e Flame arrestor 3 Clean the flame arrestor with warm water and a mild detergent 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 ...

Page 75: ... components ensure that the engine is cool the ignition switch 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 ...

Page 76: ...ventilate the engine compartment If leaks continue stop engine immediately and contact your authorized Mercury MerCruiser dealer Lubrication Steering System WARNING Do not grease the steering cable while it is extended Hydraulic lock could occur and cause loss of steering control NOTE If steering cable does not have grease fitting inner wire of cable cannot be greased 1 If Steering Cable Has Greas...

Page 77: ...teering pin mc71904 1 a a Steering pin Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Steering pin 92 883725K01 4 On dual engine boats Lubricate the tie bar pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie bar pivot points 92 883725K01 5 Upon first starting engine turn steering wheel several time...

Page 78: ...e Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 Shift Cable Typical 1 Lubricate the pivot points and the guide contact surfaces mc79736 a b a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cable pivot points guide contact surfaces 92...

Page 79: ...shaft lubrication refer to Propellers Sterndrive U joint Shaft Splines And O rings Sterndrive Unit Removed 1 Coat sterndrive U joint O rings and driveshaft splines with grease b a 8591 a Driveshaft splines b U joint O rings 3 Tube Ref No Description Where Used Part No 91 Engine Coupler Spline Grease Driveshaft splines and U joint O rings 92 802869A1 2 For propeller shaft lubrication refer to Prope...

Page 80: ...dels The coupler and shaft splines can be lubricated without removing the sterndrive unit Apply lubricant from a typical hand operated grease gun until a small amount of grease begins to push out The Perm a Lube U joints do not require lubrication Driveshaft Extension Models 1 Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10 12 pumps of grease fro...

Page 81: ... plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer drive sleeve propeller and thrust hub off propeller shaft Alpha Propeller Installation CAUTION Avoid injury and propeller damage or sterndrive damage or both caused by a loose propeller or propellers The propeller may become loose during normal operation Period...

Page 82: ...t least after 20 hours of operation Do not operate with loose propeller Bravo One Propeller Removal WARNING Avoid Injury Remote Control must be in neutral and ignition key removed from switch before removing and or installing propeller WARNING A rotating propeller can cause injury Place a block of wood between the anti ventilation plate and the propeller to protect hands from the propeller blades ...

Page 83: ...ller shaft 92 802859A1 3 Install Flo Torq II Drive Hub into propeller NOTE The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued 4 Align splines and place propeller on propeller shaft 5 Install drive sleeve and locking tab washer 6 Install and torque the propeller nut Description Nm lb in lb ft Propeller nut1 75 55 7 Bend three tabs on the...

Page 84: ...ating season and at the maintenance intervals specified the propeller nut or nuts must be checked for tightness Torque the propeller nut or nuts to specification IMPORTANT If reusing tab washer carefully inspect tabs for cracks or other damage Replace tab washer if condition is questionable a b c d e f 14946 a Propeller shaft b Thrust hub c Propeller d Propeller nut e Spline washer f Tab washer 1 ...

Page 85: ...tween the anti ventilation plate and the propeller to protect hands from the propeller blades and to prevent the propeller from rotating when removing or installing the propeller nut 1 Place wood block between propeller blades and anti ventilation plate to prevent rotation 2 Remove the bolt and washers securing the propeller shaft anode 3 Remove the propeller shaft anode a b d c f e 5303 a Propell...

Page 86: ...ge or sterndrive damage or both caused by a loose propeller or propellers The propeller may become loose during normal operation Periodically throughout the boating season and at the maintenance intervals specified the propeller nut or nuts must be checked for tightness Torque the propeller nut or nuts to specification e f a b c d 5304 g h i j a Rear propeller nut b Rear propeller c Rear propeller...

Page 87: ...n splines and place propeller on propeller shaft 7 Install and torque the propeller nut Check propeller at least every 20 hours of operation and retorque as needed Description Nm lb in lb ft Aft propeller nut 81 60 8 Install the propeller shaft anode over the propeller shaft nut 9 Place the flat washer onto the propeller shaft anode screw 10 Place the star washer onto the propeller shaft anode scr...

Page 88: ...ternator pulley e Seawater pump pulley f Power steering 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 Longitudinal cracks in the direction of belt length that join transverse cracks are NOT acceptable Fraying Glazed surfaces Proper tension 13 mm 1 2 in deflection with...

Page 89: ...lection is 13 mm 1 2 in b Attach the Kent Moore Belt Tension Gauge to the belt The gauge has different ranges for new and used belts CO LO R GU ID E fo r PA TE N T 2 83 91 8 NEWTONE N E W T O N E b a 14980 a Kent Moore Tension Gauge b Serpentine belt 7 While holding the adjustment stud at the correct belt tension tighten the 16 mm 5 8 in locking nut a b 6119 a 16 mm 5 8 in locking nut b 8 mm 5 8 i...

Page 90: ...2 9192 Attaches to the water intakes provides a fresh water 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 Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives dual water and side pickups Dual...

Page 91: ...t a hose running to the transom refer to Alternative Water Pickups 4 If flushing the cooling system with the boat in the water a Raise sterndrive unit to trailer position b Install the appropriate flushing attachment over the water inlet holes in the gear housing c Lower sterndrive unit to full down in position 5 If flushing the cooling system with the boat out of the water a Lower sterndrive unit...

Page 92: ...ications Flushing is recommended after each outing for best results IMPORTANT Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive unit and to the engine during operation 1 If flushing the cooling system with the boat in the water a Raise sterndrive unit to trailer position...

Page 93: ...e causing the engine to overheat 9 Slowly advance throttle until engine reaches 1300 RPM 100 RPM CAUTION Engine overheating can cause engine damage To avoid observe the water temperature gauge and ensure that the engine is operating in the normal range 10 Observe the water temperature gauge to ensure that the engine is operating in the normal range 11 Operate engine with sterndrive in neutral for ...

Page 94: ...age Washing the MerCathode assembly especially with a brush or high pressure washer will damage the MerCathode assembly making it unable to inhibit galvanic corrosion When cleaning the boat do not use a brush or a high pressure washer to wash the MerCathode assembly found on the bottom of the transom assembly 6211 c b a a MerCathode reference electrode b Do not paint c Do not pressure wash Wheneve...

Page 95: ...some models have a MerCathode System as standard equipment 8716 5 6 1 7 8 2 4 3 1 2 2 3 4 5 6 7 8 1 Gearcase anodic plate 2 Ventilation plate anode 3 Gimbal mounted anodic block 4 MerCathode System 5 Anode kit 6 Trim cylinder anodes 7 Bearing carrier anodes Alpha only 8 Propshaft Anode Bravo III standard IMPORTANT Replace sacrificial anodes if eroded 50 percent or more The following sacrificial an...

Page 96: ...ate Anode Mounted on the front of the gearcase a 6122 a 5639 a Anode Drive Mounted Anodic Block if equipped Mounted to underside of gimbal housing 5640 MerCathode System Electrode assembly replaces Anodic block System should be tested to ensure adequate output The test should be performed where boat is moored using Quicksilver Reference Electrode and Test Meter Contact your authorized Mercury MerC...

Page 97: ...e that the MerCathode reference electrode is not damaged do not paint or pressure wash 6206 a b a MerCathode controller b MerCathode assembly Anode Kit if equipped Mounted to the boat transom 5642 Trim Cylinder Anodes Mounted on each trim cylinder a 5643 a Trim cylinder anodes ...

Page 98: ...o be sprayed 3 All lubrication points especially steering system shift and throttle linkages should be kept well lubricated 4 Flush cooling system periodically preferably after each use Painting Your Power Package IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the limited warranty 1 Painting Boat Hull or Boat Transom Anti fouling ...

Page 99: ...transom of the boat around these items b a 5578 a Painted boat transom b Unpainted Area on Transom 2 Painting Sterndrive Unit or Transom Assembly Sterndrive unit and transom assembly should be painted with a good quality marine paint or an anti fouling paint that does not contain copper tin or any other material that could conduct electrical current Do not paint drain holes anodes MerCathode syste...

Page 100: ...Section 5 Maintenance Notes Page 92 90 860171061 DECEMBER 2006 ...

Page 101: ...ingle Point Drain System 97 Three Point Manual Drain System 98 Multi Point Drain MPD System 98 Air Actuated Single Point Drain System 99 Boat in the Water 99 Boat out of the Water 101 Manual Single Point Drain System 104 Boat in the Water 104 Boat out of the Water 105 Three Point Manual Drain System 106 Boat in the Water 106 Boat out of the Water 107 Multi Point Drain MPD System 108 Boat out of th...

Page 102: ...extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations Preparing Power Package for Storage 1 Fill the fuel tanks with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to tre...

Page 103: ...wn in position 12 Store the battery according to the manufacturer s instructions ENGINE AND FUEL SYSTEM PREPARATION WARNING Avoid serious injury or death from a gasoline fire or explosion gasoline is extremely flammable and highly explosive under certain conditions When servicing the fuel system components ensure that the engine is cool the ignition switch is in the off position and that the lanya...

Page 104: ...lter Draining the Seawater System CAUTION Excess water in the bilge can damage the engine or cause the boat to sink Ensure that the boat is out of the water the seacock is closed if equipped or the seawater inlet hose is disconnected and plugged on both ends and the bilge pump is operating before beginning the draining procedure CAUTION Excess water in the bilge can damage the engine or cause the ...

Page 105: ...6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators 21125 a b c d d Black Scorpion Models a Blue air pump b Air manifold c Green indicators d Blue drain plug locations MANUAL SINGLE POINT DRAIN SYSTEM b a b 6128 a Blue handle b Blue drain plug location ...

Page 106: ...THREE POINT MANUAL DRAIN SYSTEM a a 6126 a Blue drain plug MULTI POINT DRAIN MPD SYSTEM 10226 M110050 932356 72 b a a b 6129 a Side of cylinder block b Bottom of exhaust manifolds a b 6130 a Water circulating pump hose b Fuel cooler to thermostat housing ...

Page 107: ...water inlet hose 2 Remove the air pump from the engine 3 Ensure that the lever on top of the pump is flush with the handle horizontal 4 Install the air pump on the actuator fitting 5 Pull lever on air pump vertical to lock pump on the fitting 8293 b d e a c a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators...

Page 108: ... exchanger This must be removed within 30 seconds to properly vent the cooling system 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c Air manifold d Green indicators 21125 a b c d d Black Scorpion Models a Blue air pump b Air manifold c Green indicators d Blue drain plug locations ...

Page 109: ...er 12 Remove the air pump from the air manifold and 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 drained 14 Before launching the boat pull up on the manual release valve Verify that the green indicators are no longer extended a 6135 a Green indic...

Page 110: ... the fitting 8293 b d e a c a Actuator fitting b Green indicators c Manual release valve d Air pump e Lever locking 6 Pump air into the system until both green indicators extend and water drains from both sides of the engine The port side will begin draining before the starboard side 6124 a b c d 6125 a b c d Closed Cooled Models Seawater Cooled Models a Blue drain plug location b Blue air pump c ...

Page 111: ...ard side drain location 8 Allow the system to drain for a minimum of five minutes Pump air as necessary to keep the green indicators extended 9 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump Do not allow engine to start 10 Remove the air pump from the air manifold and return it to the mounting bracket 11 Mercury MerCruiser recommends leaving the d...

Page 112: ...acock if equipped or remove and plug the water inlet hose 2 Rotate the blue handle counterclockwise until it stops approximately two turns The red on the handle shaft indicates that the drain system is open Do not force the handle as this will create new threads 3 Immediately remove the blue drain plug from the side of the thermostat housing This must be removed within 30 seconds to properly vent ...

Page 113: ...mostat housing 7 Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug if removed The handle is fully seated when no red is visible Do not overtighten the handle as this will create new threads 8 Open the seacock if equipped or unplug and reconnect the water inlet hose prior to operating the engine BOAT OUT OF THE WATER 1 Place the boat on a le...

Page 114: ...sure that all water is drained 5 Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug The handle is fully seated when no red is visible Do not overtighten handle as this will create new threads Three Point Manual Drain System BOAT IN THE WATER NOTE Use this procedure if your engine is not equipped with an air actuated single point drain syst...

Page 115: ...ansporting the boat or while performing other maintenance to ensure that all water is drained 7 Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 8 Prior to launching the boat or starting the engine close the drain system by installing the four blue drain plugs 9 Open the seacock if equipped or unplug and recon...

Page 116: ... engine over slightly with starter motor to purge any water trapped in the seawater pickup pump Do not allow the engine to start 6 Prior to launching the boat or starting the engine close the drain system by installing the three blue drain plugs Multi Point Drain MPD System BOAT OUT OF THE WATER 1 Place the boat on a level surface to ensure complete draining of the system 2 Remove the blue drain p...

Page 117: ...ion 6 Storage 90 860171061 DECEMBER 2006 Page 109 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 118: ...kup pump Do not allow the engine to start 5 After the cooling system has been drained completely install the drain plugs reconnect the hoses and tighten all hose clamps securely BOAT IN THE WATER 1 Close the seacock if equipped or remove and plug the water inlet hose 2 Remove the blue drain plugs from the following locations If necessary clean out the drain holes using a stiff piece of wire Do so ...

Page 119: ...ion 6 Storage 90 860171061 DECEMBER 2006 Page 111 c Water circulating pump hose a 6143 a Drain plug d Fuel cooler to thermostat housing hose a 6144 a Drain plug e Check valve a 6131 a Drain plug if equipped ...

Page 120: ...e drain system by installing the blue drain plugs 6 Open the seacock if equipped or unplug and reconnect the water inlet hose before operating the engine Draining the Sterndrive NOTE This procedure is needed only for salty brackish mineral laden or polluted water applications and for freezing temperatures or extended storage 1 Insert a small wire repeatedly to make sure that vent holes water drain...

Page 121: ...ioning 1 Ensure that all cooling system hoses are connected properly and hose clamps are tight CAUTION Reversing the battery cables or connection order will damage the electrical system When installing the battery be sure to connect the positive battery cable to the positive battery terminal first and the negative battery cable to the negative battery terminal second 2 Install a fully charged batt...

Page 122: ...Section 6 Storage Notes Page 114 90 860171061 DECEMBER 2006 ...

Page 123: ...Or Backfires 116 Poor Performance 116 Excessive Engine Temperature 117 Insufficient Engine Temperature 117 Low Engine Oil Pressure 117 Battery Will Not Come Up On Charge 117 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 118 Steering Wheel Turns Hard Or Jerky 118 Power Trim Does Not Operate Motor Does Not Operate 118 Power Trim Does Not Operate Motor Operates Bu...

Page 124: ...ver to 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 f...

Page 125: ...ect and 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 f...

Page 126: ... Replace and or adjust Insufficient lubrication on steering components Lubricate Loose or missing steering fasteners or parts Check all parts and fasteners if any are loose or missing see authorized Mercury MerCruiser dealer immediately Contaminated power steering fluid See authorized Mercury MerCruiser dealer Power Trim Does Not Operate Motor Does Not Operate Possible Cause Remedy Blown fuse Repl...

Page 127: ... Assistance 120 Local Repair Service 120 Service Away From Home 120 Stolen Power Package 120 Attention Required After Submersion 120 Replacement Service Parts 120 Parts And Accessories Inquiries 121 Resolving A Problem 121 Mercury Marine Service Offices 121 Ordering Literature 122 United States and Canada 122 Outside The United States and Canada 122 8 ...

Page 128: ...mage Replacement Service Parts WARNING Avoid fire or explosion hazard Electrical ignition and fuel system components on Mercury Marine products comply with U S Coast Guard rules to minimize risk of fire or explosion Do not use replacement electrical or fuel system components that do not comply with these rules When servicing the electrical and fuel systems properly install and tighten all componen...

Page 129: ...es manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please 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 na...

Page 130: ...ited States 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 ...

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