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8.1S and 8.1S Horizon Inboard Models

90-864841062 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

Содержание 8.1S HO

Страница 1: ... 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 5: ...y 16 Emission Certification Star Label 16 Section 2 Getting to Know Your Power Package Lanyard Stop Switch 20 Instrumentation 21 System View 21 Digital Gauges 22 Analog Gauges 22 Remote Controls Non DTS Models 23 Remote Controls 23 Panel Mount Features 23 Console Mount Features 24 Zero Effort Features 24 Remote Controls DTS Models 25 Remote Controls 25 Panel Mount Features 25 Console Mount Feature...

Страница 6: ...Containing Alcohol 50 Engine Oil 51 Engine Specifications 52 Fluid Specifications 53 Transmission 53 Engine 53 Section 5 Maintenance Owner Operator Responsibilities 56 Dealer Responsibilities 56 Maintenance 56 Do It Yourself Maintenance Suggestions 57 Inspection 57 Maintenance Schedule Inboard Models 58 Routine Maintenance 58 Each Day Start 58 Each Day End 58 Weekly 58 Every Two Months or 50 Hours...

Страница 7: ...tarter Motor Will Not Crank Engine Or Cranks Slow 86 Engine Will Not Start Or Is Hard To Start 86 Engine Runs Rough Misses And Or Backfires 87 Poor Performance 87 Excessive Engine Temperature 87 Insufficient Engine Temperature 88 Low Engine Oil Pressure 88 Battery Will Not Come Up On Charge 88 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 88 Steering Wheel Turn...

Страница 8: ...Page iv 90 864841062 DECEMBER 2006 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 26: ...Section 1 Warranty Notes Page 18 90 864841062 DECEMBER 2006 ...

Страница 27: ...ort Features 24 Remote Controls DTS Models 25 Remote Controls 25 Panel Mount Features 25 Console Mount Features Single Engine 26 Slim Binnacle Console Mount Features Single Engine 27 Console Mount Features Dual Engine 28 Synchronizing Dual Engines 28 Dual Helm Station Transfer 29 Synchronizing Dual Helms Prior To Station Transfer 30 Zero Effort Features 30 Electrical System Overload Protection 30 ...

Страница 28: ... 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...

Страница 29: ...ormation ranging from basic operating data to engine alarm data The SC5000 System View Display is a comprehensive boat information center System View allows the boat operator to receive a wealth of critical operational information displayed clearly and instantly at the helm on the LCD display The System View continuously monitors and reports information ranging from basic operating data to detaile...

Страница 30: ...ner 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 16 BATT 0 4 4 4 FUEL CRUISELOG 0 0 0 0 0 a b c d...

Страница 31: ...rottle only button can 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 Contr...

Страница 32: ...n to the first detent for forward gear and continue pushing forward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Control Handle Tension Adjustment Screw not visible This screw is used to adjust the effort required to move the remote control handle Refer to instructions provided ...

Страница 33: ...rks with specialized helm components such as a command module kit and electronic remote control Consult your dealer for a description and or demonstration of your remote control Panel Mount Features 17358 c d e b a f g a Lanyard stop switch b Control handle c Shift lock d Trim tilt switch e Throttle only button f Start stop button g Detent tension adjustment screw h Control handle friction adjustm...

Страница 34: ... Control handle b Active light c Neutral light d Select key e Arrow trackpad f Throttle only station select key g Detent tension adjustment h Control handle friction adjustment screw Control Handle Operation of the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear Contin...

Страница 35: ...ward to increase speed Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue pushing back to increase speed Active Light The active light is illuminated to show the remote control is active and ready for use Neutral Light The neutral light is illuminated when the engine is in neutral gear position Start Stop Button Allows the boat oper...

Страница 36: ...tion messages Sync Light The sync light is illuminated when the RPM of the two engines are being synchronized by the DTS system Throttle Only Station Select Key Allows engine throttle advancement without shifting the engine The throttle only station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms Re...

Страница 37: ...lm transfer should only be performed while engine is in neutral NOTE Idle position is preferred when doing a station transfer If conditions do not allow the remote control to be placed at idle position a station transfer can be done while in gear NOTE Pressing and releasing station select button at new station allows the engine control to be transferred to the new station The control will automati...

Страница 38: ...on Shift into neutral by moving the shift lever to its center position Shift into forward by moving the shift lever to its forward position Throttle Lever Throttle functions are controlled by the movement of the throttle lever Increase the RPM by moving the throttle lever forward Achieve Wide Open Throttle WOT by placing the throttle lever in its full forward position Decrease RPM by moving the th...

Страница 39: ...ll appear Reset after testing or if tripped by pushing the yellow lever back into the housing b a 22529 Yellow lever style circuit breaker typical a Yellow lever shown tripped b Red test button 2 A 90 amp fuse is located on the large post of the starter solenoid This fuse protects the engine wiring harness if an electrical overload occurs mc74907 1 3 Four fuses are located on the port side of the ...

Страница 40: ...smission fluid temperature too hot Transmission pressure too low NOTICE A continuous horn indicates a critical fault Operating the engine during a critical fault can damage components 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 ca...

Страница 41: ... Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage Transmission Guardian monitors the clutch pack pressure in forward and reverse gears If the transmission fluid pressure drops below a predetermined level Transmission Guardian lowers the engine torque and speed to prevent clutch slippage To avoid possible recurrence of the problem you should contact a...

Страница 42: ...Section 2 Getting to Know Your Power Package Notes Page 34 90 864841062 DECEMBER 2006 ...

Страница 43: ... Stopping the Engine 41 Starting the Engine 41 Stopping the Engine 42 Throttle Only Operation 42 Freezing Temperature Operation 43 Drain Plug and Bilge Pump 43 Protecting People In The Water 43 While You Are Cruising 43 While Boat Is Stationary 44 High Speed And High Performance Boat Operation 44 Passenger Safety In Pontoon Boats And Deck Boats 44 Boats Having An Open Front Deck 44 Boats With Fron...

Страница 44: ...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...

Страница 45: ...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...

Страница 46: ...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 Non DTS Models Launching and Boat Operation IMPORTANT Install bilge drain plug pri...

Страница 47: ...ore 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 START Release key when engine starts and allow switch to return to ON position Allow engine to warm up 6 10 minutes on first start...

Страница 48: ...forward or idle reverse position without pressing the throttle only button will shift the unit into the chosen gear Freezing Temperature Operation IMPORTANT If the boat is operated during periods of freezing temperature precautions must be taken to prevent freeze damage to the power package Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty Drain Plug and Bilge Pump Th...

Страница 49: ... 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 NOTE MerCruiser DTS models are equipped with SmartStart The SmartStart feature incorporates push button sta...

Страница 50: ...ystem will be deactivated b Depress the start stop button if equipped The engine will stop and the control system will remain active c Momentarily move the ignition key switch to the START position then release immediately The control system will recognize that the engine is running and will stop the engine The control system will remain active Moving the ignition key switch to the START position ...

Страница 51: ...tle only button will shift the unit into the chosen gear Freezing Temperature Operation IMPORTANT If the boat is operated during periods of freezing temperature precautions must be taken to prevent freeze damage to the power package Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for wa...

Страница 52: ...ion observe the location of all passengers Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed A sudden reduction in boat speed such as plunging into a large wave or wake a sudden throttle reduction or a sharp change of boat direction could throw them over the front of boat Falling over the front of the boat between the two pontoons wi...

Страница 53: ...er 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 violently veer in a new direction Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat There is another less common hazardous result from allowing your boat to launch off of a wave or wake If the bow of your ...

Страница 54: ... or suspected the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair The boat should be checked for hull fractures transom fractures and water leaks Operating with damaged underwater drive components rudder or boat bottom could cause additional damage to other parts of the power package or could affect control of the boat If cont...

Страница 55: ...ear housing Drive unit installed too high on transom Elevation And Climate Elevation and climate changes will affect the performance of your power package Loss of performance can be caused by Higher elevations Higher temperatures Low barometric pressures High humidity For you to have optimum engine performance under changing weather conditions it is essential that the engine be propped to allow th...

Страница 56: ...nce 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 Maintenance ZF Transmission models 1 End of First Season Checkup At the end of the first season of operation contact an authorized Mercury Mer...

Страница 57: ...ion 4 Specifications Table of Contents Cruising RPM 50 Fuel Requirements 50 Fuel Ratings 50 Using Reformulated Oxygenated Gasolines USA Only 50 Gasolines Containing Alcohol 50 Engine Oil 51 Engine Specifications 52 Fluid Specifications 53 Transmission 53 Engine 53 4 ...

Страница 58: ...not use leaded gasoline Outside USA and Canada having a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also acceptable If unleaded gasoline is not available use a major brand of leaded gasoline Using Reformulated Oxygenated Gasolines USA Only This type of gasoline is required in certain areas of the USA The 2 types of oxygenates used in these fuels is Alcohol Ethanol or Eth...

Страница 59: ...pection frequency for leaks and abnormalities is required IMPORTANT When operating a Mercury MerCruiser engine on gasoline containing alcohol storage of gasoline in the fuel tank for long periods should be avoided Long periods of storage common to boats create unique problems In cars alcohol blend fuels normally are consumed before they can absorb enough moisture to cause trouble but boats often s...

Страница 60: ...splacement 8 1 L 496 cid Specified WOT RPM Range2 4200 4600 4400 4800 Idle RPM in Neutral2 6503 Minimum Oil Pressure Idle4 103 kPa 15 psi Thermostat 71 C 160 F Timing Idle3 Not adjustable Firing Order 1 8 7 2 6 5 4 3 Electrical System 12 volt negative ground Alternator Rating 65 amp Recommended Battery Rating Non DTS Models Minimum 750 CCA 950 MCA or 180 Ah Recommended Battery Rating DTS Models Mi...

Страница 61: ...g on installation angle and cooling systems heat exchanger and fluid lines All Models Capacity Fluid Type Engine Oil With Filter 1 8 5 liters 9 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 Closed Cooling System 18 liters 19 U S qt Mercury Extended Life Coolant Antifreeze or Extended Life Et...

Страница 62: ...Section 4 Specifications Notes Page 54 90 864841062 DECEMBER 2006 ...

Страница 63: ...ichever Occurs First 58 Every 300 Hours or 3 Years 58 Every 5 Years 59 Maintenance Log 59 Engine Oil 59 Checking 60 Filling 60 Changing Oil and Filter 61 Engine Oil Drain Pump 61 Changing Filter 62 Transmission Fluid 62 Checking While the Engine is Warm 62 Checking While Engine is Cold 63 Changing 63 Engine Coolant 63 Checking 63 Filling 64 Changing 64 Cleaning The Flame Arrestor 64 Changing Water...

Страница 64: ...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 ...

Страница 65: ...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...

Страница 66: ...d the life of your Mercury MerCruiser power package the following is recommended 1 Change the engine oil and filter 2 Change the transmission fluid and filter on inboard models NOTE ZF Marine requires the transmission fluid and filter be changed to preserve the warranty EVERY 100 HOURS OR ANNUALLY WHICHEVER OCCURS FIRST Touch up the paint on the power package Change the crankcase oil and filter Ch...

Страница 67: ...t system components and verify that the flapper valves are not missing or worn if equipped EVERY 5 YEARS Replace the coolant every two years if extended life antifreeze coolant is not being used Inboard and sterndrive models only Maintenance Log Record all maintenance performed on your power package here Be sure to save all work orders and receipts Date Maintenance Performed Engine Hours Engine Oi...

Страница 68: ...that dipstick is installed with oil level indication marks facing the rear of the engine flywheel end 8480 a a Dipstick tube IMPORTANT Add the specified engine oil to bring the level up to but not over the full or OK range mark on the dipstick 3 Remove the dipstick and observe the oil level Oil level must be between full or OK range and add Reinstall dipstick into dipstick tube Filling IMPORTANT D...

Страница 69: ... 25W 40 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 refer to Specifications ENGINE OIL DRAIN PUMP 1 Loosen the oil filter to vent the system 2...

Страница 70: ...el up to but not over the full or OK range NOTE Adding 0 95 liters 1 quart of engine oil will raise the level from the add mark to the top of the OK range All Models Capacity Fluid Type Engine Oil With Filter 8 5 liters 9 U S Quart Mercury Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 7 Start the engine run the engine for three minutes and check for leaks Stop the engine Allow approxima...

Страница 71: ... clean and reinsert 3 Remove the dipstick observe the fluid level and mark the cold fluid level 4 Reinstall the dipstick tighten the T handle securely Do not overtighten Changing Contact your authorized Mercury MerCruiser dealer Engine Coolant Checking WARNING Allow the engine to cool down before removing the coolant pressure cap A sudden loss of pressure could cause hot coolant to boil and discha...

Страница 72: ...if necessary IMPORTANT This closed cooling system flows coolant at a high rate Higher idle speeds increase dispersion of trapped air into the system making it more difficult to purge trapped air Operate at idle during filling and air purging when specified 2 Fill to the full mark with the specified coolant Tube Ref No Description Where Used Part No 122 Extended Life Antifreeze Coolant Closed Cooli...

Страница 73: ...em 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 shu...

Страница 74: ...p and rotating it in a clockwise direction while holding the filter cup stationary 10 Remove the used water separating fuel filter element from the filter cup place it in a clean approved container 11 Dispose of any water or debris that may be in the filter cup 12 Install a new water separating fuel filter element into the filter cup Push the element into the cup until completely seated 13 Install...

Страница 75: ...the engine compartment If leaks continue stop engine immediately and contact your authorized Mercury MerCruiser dealer Serpentine Drive Belt WARNING Avoid possible serious injury Make sure that the engine is turned off and the ignition key is removed before inspecting belts b a c d e 8119 f a Idler pulley b Water circulating pump pulley c Crankshaft pulley d Alternator pulley e Seawater pump pulle...

Страница 76: ...kets bracket failure accessory drive component movement incorrect belt length or belt failure can cause the tensioner to contact the limits See your authorized MerCruiser dealer for service if these conditions exist CAUTION The belt tensioner assembly contains a high tension spring Rapid release of the tensioner or allowing the tensioner to snap back quickly could injure the operator or cause prod...

Страница 77: ... effective when performed with the boat out of the water IMPORTANT We recommend flushing after each outing in salty brackish mineral laden or polluted water and before cold weather and extended storage 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 o...

Страница 78: ...utes 10 For power packages operated in salty brackish mineral laden or polluted water Continue to operate the engine until the discharge water is clear 11 Slowly return the throttle to idle speed position CAUTION Flush water will collect in the exhaust system when the engine is not operating resulting in engine damage Do not supply flush water for more than 15 seconds without the engine operating ...

Страница 79: ...ted above 1400 RPM during flushing suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat 7 Depress the throttle only button and slowly advance the throttle until the 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 n...

Страница 80: ...ing 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 battery The voltage may go below the ECM s minimum required voltage Also the alternator on the other engine may now start charging This could cause a voltage spike in the engine s electrical system I...

Страница 81: ...e and Fuel System Preparation 75 Draining the Seawater System 76 Drain System Identification 76 Air Actuated Single Point Drain System 76 Manual Drain System 77 Air Actuated Single Point Drain System 77 Boat in the Water 77 Boat out of the Water 79 Manual Drain System 81 Boat in the Water 81 Boat out of the Water 82 Battery Storage 83 Power Package Recommissioning 83 6 ...

Страница 82: ...mendations 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 treat the gasoline Follow instructions on the container 2 If the boat is to be placed in storage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Fuel tanks should b...

Страница 83: ...n Always ventilate the engine compartment prior to servicing the power package 1 In a 23 liter 6 U S gal remote fuel tank mix a 19 liter 5 U S gal regular unleaded 87 octain 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 Treatment and Stabilizer or 30 ml 1 ounce Fuel System Treatment and Stabilizer Concentrate Tube Ref No Description Wh...

Страница 84: ...e boat must be as level as possible to ensure complete draining of the cooling system Your power package is equipped with a drain system Refer to Drain System Identification to determine which instructions apply to your power package IMPORTANT The engine must not be operating at any point during the draining procedure IMPORTANT Mercury MerCruiser requires that propylene glycol antifreeze mixed to ...

Страница 85: ... Single Point Drain System BOAT IN THE WATER NOTE This procedure is written for the air pump that is attached to the engine However any air source can be used 1 Close the seacock if equipped or remove and plug the 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 ...

Страница 86: ...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 b c a 8294 a Actuator fitting b Green indicators c Manual release valve ...

Страница 87: ... and return it to the mounting bracket 12 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 13 Before launching the boat pull up on the manual release valve Verify that the green indicators are no longer extended a 6135 a Green indicators 14 Open the seacock if equipped or unplug...

Страница 88: ...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 b c a 8294 a Actuator fitting b Green indicators c Manual release valve ...

Страница 89: ...seawater pump Do not allow engine to start 11 Remove the air pump from the air manifold and return it to the mounting bracket 12 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 13 Before launching the boat pull up on the manual release valve Verify that the green indicators are...

Страница 90: ...e the drain system by installing the four blue drain plugs 8 Open the seacock if equipped or unplug and reconnect the water inlet hose prior to operating the engine BOAT OUT OF THE WATER NOTE Use this procedure if the air actuated single point drain system fails NOTE It may be necessary to lift bend or lower hoses to allow water to completely drain when hoses are disconnected 1 Place the boat on a...

Страница 91: ...ll 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 battery Clean the battery cable clamps and terminals and reconnect cables Tighten each cable clamp securely when connecting 3 Coat the terminal connections wi...

Страница 92: ...Section 6 Storage Notes Page 84 90 864841062 DECEMBER 2006 ...

Страница 93: ...l Not Crank Engine Or Cranks Slow 86 Engine Will Not Start Or Is Hard To Start 86 Engine Runs Rough Misses And Or Backfires 87 Poor Performance 87 Excessive Engine Temperature 87 Insufficient Engine Temperature 88 Low Engine Oil Pressure 88 Battery Will Not Come Up On Charge 88 Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds 88 Steering Wheel Turns Hard Or Jerky ...

Страница 94: ...ine protection If Guardian System has been activated reduce throttle speed The horn will turn off when throttle speed is within the allowable limit Consult an authorized Mercury MerCruiser dealer for assistance Starter Motor Will Not Crank Engine Or Cranks Slow Possible Cause Remedy Battery switch turned off Turn the switch on Remote control not in neutral position Position the control lever in ne...

Страница 95: ... Drain and check for cause of entry Boat overloaded or load improperly distributed Reduce load or redistribute load more evenly Flame arrestor dirty Clean the flame arrestor Boat bottom fouled or damaged Clean or repair as necessary Ignition problem See Engine Runs Rough Misses or Backfires Engine overheating See Excessive Engine Temperature EFI System fault Have EFI System checked by an authorize...

Страница 96: ...nd tighten faulty connections Repair or replace damaged wiring Faulty alternator Test alternator output replace if necessary Remote Control Operates Hard Binds Has Excessive Free play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fasteners Lubricate Obstruction in shift or throttle linkages Remove obstruction Loose or missing shift and throttl...

Страница 97: ...rvice Assistance 90 Local Repair Service 90 Service Away From Home 90 Stolen Power Package 90 Attention Required After Submersion 90 Replacement Service Parts 90 Parts And Accessories Inquiries 91 Resolving A Problem 91 Mercury Marine Service Offices 91 Ordering Literature 92 United States and Canada 92 Outside The United States and Canada 92 8 ...

Страница 98: ...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...

Страница 99: ...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...

Страница 100: ...ted 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 f...

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