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TROUBLESHOOTING

90-864197020 MARCH 2002

Page 87

TROUBLESHOOTING

Table of Contents

Diagnosing EFI Problems

. . . . . . . . . . . .

Troubleshooting Charts

. . . . . . . . . . . . . .

Starter Motor Will Not Crank
Engine Or Cranks Slow

. . . . . . . . . . .

Engine Will Not Start,
Or Is Hard To Start

. . . . . . . . . . . . . . . .

Engine Runs Rough, Misses
And/Or Backfires

. . . . . . . . . . . . . . . . .

Poor Performance

. . . . . . . . . . . . . . . .

Excessive Engine Temperature

. . . . .

Insufficient Engine Temperature

. . . .

Low Engine Oil Pressure

. . . . . . . . . .

Excessive Transmission Fluid
Temperature or Slipping Transmission

Battery Will Not Come
Up On Charge

. . . . . . . . . . . . . . . . . . .

Remote Control Operates Hard,
Binds, Has Excessive Free-play
Or Makes Unusual Sounds

. . . . . . . .

Содержание TowSport Inboards

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

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

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

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

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

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

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

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

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

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

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

Страница 12: ...urchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred and then only after the Mercury Marine specified pre delivery inspection process...

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

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

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

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

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

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

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

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

Страница 21: ...starting the engine 3 Lanyard Stop Switch Turns the ignition OFF whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch Refer to L...

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

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

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

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

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

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

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

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

Страница 30: ...Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Associa...

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

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

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

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

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

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

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

Страница 38: ...damage to the underwater drive components rudder and or boat Keep in mind one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat spe...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 51: ...t are required to perform some repairs Do not attempt these repairs unless you have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 71: ...Alternator Pulley e Seawater Pump Pulley 0082 CHECKING 1 Inspect the drive belt for proper tension and for the following Excessive wear Cracks NOTE Minor transverse cracks across the belt width may b...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 102: ...anager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please conta...

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

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

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

Страница 106: ...act your nearest dealer or contact Mercury Marine Telephone Fax Mail 920 929 5110 920 929 4894 Mercury Marine Attn Publications Department P O Box 1939 Fond du Lac WI 54935 1939 Outside The United Sta...

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

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

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