Page 1 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...
Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury 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 effect at the time this guide was approved for printing.
Page 3: Read This Manual Thoroughly
We suggest 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 pleasant!
Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard.
Page 5: Table Of Contents
How To Obtain Warranty Coverage....12 Mercury Product Protection Plan: United States and What Mercury Will Do........13 Canada..............3 What Is Not Covered........13 Mercury MerCruiser Limited Warranty Components Of The Emission Control System 13 (Gasoline‑Fueled Products Only) ......4 Disclaimers And Limitations......14 3‑Year Limited Warranty Against Corrosion....6 California Emission Control Warranty Statement.
Page 6 Passenger Safety in Pontoon Boats and Deck To Steer the Boat in Tight Turns at Low Boats.............39 Speeds............47 Boats Having An Open Front Deck.....39 To Spin the Boat at Low Speeds....47 Boats With Front‑Mounted, Raised Pedestal Maneuvering with the Joystick...... 47 Fishing Seats..........
Page 7 Engine Coolant............78 Engine Coupler..........92 Checking............78 Propellers..............92 Filling..............79 Propeller Repair..........92 Changing ............80 Bravo Three Propeller Removal.....92 Sterndrive Gear Lube..........80 Bravo Three Propeller Installation....94 Checking............80 Serpentine Drive Belt..........96 Filling..............81 Checking............96 Changing............82 Replacing or Adjusting........96 Power Trim Fluid...........83 Corrosion Protection..........98 Checking............83 Corrosion Information........98 Filling..............84 Maintaining Ground Circuit Continuity....98...
Page 8 Insufficient Engine Temperature....134 Steering System..........135 Low Engine Oil Pressure......134 Power Trim Does Not Operate (Motor Does Not Battery Will Not Recharge......134 Operate)............136 Joystick............134 Power Trim Does Not Operate (Motor Operates Electronic Remote Controls......135 but Sterndrive Unit Does Not Move)...136 Section 8 - Customer Assistance Information Owner Service Assistance.........138 Parts and Accessories Inquiries....139 Local Repair Service........138...
Page 9 Mercury Product Protection Plan: United States and What Is Not Covered ........13 Canada..............3 Components Of The Emission Control Mercury MerCruiser Limited Warranty (Gasoline- System ............13 Fueled Products Only) ......... 4 Disclaimers And Limitations ......14 3-Year Limited Warranty Against Corrosion..6...
Page 10: Warranty Registration: United States And Canada
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.
Page 11: Transfer Of Warranty
Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
Page 13 Section 1 - Warranty Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine is completed and documented.
Page 14: 3-Year Limited Warranty Against Corrosion
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Page 15: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
Page 16: Global Warranty Charts
Section 1 - Warranty This limited warranty does not cover the following: • Electrical system corrosion • Corrosion resulting from damage • Corrosion that causes purely cosmetic damage • Abuse or improper service • Corrosion to accessories, instruments, and steering systems •...
Page 17: Commercial Application Warranty Chart
Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...
Page 18: Government Application Warranty Chart
Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...
Page 19: Mercury Installation Quality Certification Program 10 California Emissions Limited 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 for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 20: Duration Of Coverage
Duration Of Coverage NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model...
Page 21: What Mercury Will Do
Section 1 - Warranty What Mercury Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product.
Page 22: Components Of The Emission Control System 13 Disclaimers And Limitations
Mercury Marine. 1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 23: Owner's Warranty Responsibilities
A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.
Page 24: Owner Responsibility
Beginning January 1, 2003, one Three‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating. The Three‑Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards.
Page 25 Section 1 - Warranty The Three‑Star label will be affixed on the left side of the hull as shown. XX 1234 XX mc79531 Recommended location Secondary location One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.
Page 26 Section 1 - Warranty Notes: Page 18 90-899883234 JANUARY 2008...
Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Operation ..........26 Engine Serial Number Decal MPI....20 Adjustment ..........26 Bravo Transom Serial Number......20 Joystick—Basic Operation......27 Features and Controls........
Page 28: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal MPI The serial number decal is located on the engine cover.
Page 29: Features And Controls
Section 2 - Getting to Know Your Power Package The transom serial number is also stamped on the gimbal housing. This provides a permanent reference for authorized Mercury MerCruiser dealers. 32672 Gimbal housing Transom serial number Features and Controls Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position).
Page 30: Emergency Stop (E-Stop) Switch
Section 2 - Getting to Know Your Power Package The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
Page 31: Instrumentation
Section 2 - Getting to Know Your Power Package • Occupants can be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components. •...
Page 32: Smartcraft Partner Digital Gauges
Section 2 - Getting to Know Your Power Package SC1000 AND SC100 DIGITAL GAUGES (IF EQUIPPED) The SmartCraft SC1000 and SC100 digital gauges complement VesselView. Refer to the SC1000 and SC100 Digital Gauge Operator's Manual for more information. 24575 Typical SmartCraft gauges Tachometer Speedometer LCD System View display...
Page 33: Bravo Sterndrive Serial Number And Identification
Section 2 - Getting to Know Your Power Package Item Gauge Function Speedometer Indicates boat speed. Tachometer Indicates engine RPM. Oil pressure gauge Indicates engine oil pressure. Voltmeter Indicates battery voltage. Water temperature gauge Indicates engine operating temperature. Fuel gauge Indicates the quantity of fuel in tank.
Page 34: Dual-Handle Electronic Remote Control (Erc)
Section 2 - Getting to Know Your Power Package We recommend that you drive carefully until you have a chance to explore the Axius system's handling characteristics and boat's responses in an open area clear of obstructions or other boat traffic. The initial steering setting of two turns lock‑to‑lock provids a fast steering response.
Page 35: Joystick-Basic Operation
Section 2 - Getting to Know Your Power Package 2. Turn the screw clockwise to increase tension on the control handle and counter‑clockwise to decrease tension. 3. Adjust to desired tension. 28087 Starboard side with side cover removed. ERC handle tension adjustment screw, labeled "De" ERC handle detent tension adjustment screw, labeled "Fr"...
Page 36 Section 2 - Getting to Know Your Power Package For best performance trim the sterndrive unit so that the boat bottom is at a 3‑5° angle to the water. 3 - 5 mc79528 Trimming the sterndrive unit up (out) can: •...
Page 37: Joystick And Trim Control
Section 2 - Getting to Know Your Power Package JOYSTICK AND TRIM CONTROL 24704 Typical joystick While using the Axius joystick, the best boat control is achieved when the sterndrives are in the full down (in) position. Full down (in) trim maximizes propeller efficiency allowing the boat to move parallel with the joystick command.
Page 38 Section 2 - Getting to Know Your Power Package NOTE: In an emergency, when the engine must be operated and the cause for the high current draw (overload) 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 electrical overload has not been eliminated.
Page 39 Section 2 - Getting to Know Your Power Package NOTE: The main power and fuel pump relays are located next to the fuses and control voltage to the engine with the ignition key in the on position. mc77602-2 4. The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump.
Page 40: Warning Horn Signals
Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
Page 41: Engine Guardian Strategy
Section 2 - Getting to Know Your Power Package 2. Listen for the audio alarm. One short beep will sound for each engine upon key‑up, indicating the system is functioning correctly. Engine Guardian Strategy IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle. Engine Guardian Strategy is designed to help reduce the potential for engine damage by reducing engine power when a potential problem is sensed by the ECM.
Page 42 Section 2 - Getting to Know Your Power Package Notes: Page 34 90-899883234 JANUARY 2008...
Page 43: Section 3 - On The Water
Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........36 Stopping the Engine ....... 46 Be Alert to Carbon Monoxide Poisoning..... 37 Throttle Only Operation.........46 Good Ventilation ........... 38 Traditional Maneuvering with Steering and Poor Ventilation ...........
Page 44: Safe Boating Suggestions
Section 3 - On The Water Safe Boating Suggestions To enjoy the water safely, you should know and understand all boating regulations and restrictions that pertain to your activity. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.
Page 45: Be Alert To Carbon Monoxide Poisoning
Section 3 - On The Water Most boats are rated and certified for a maximum load capacity. Know your boat’s loading limitations (refer to the boat capacity plate). If in doubt, contact your dealer or the boat's manufacturer. Never boat under the influence of alcohol or drugs. It is illegal to operate a boat under the influence of drugs or alcohol.
Page 46: Good Ventilation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 47: 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. Protecting People in the Water...
Page 48: Boats With Front-Mounted, Raised Pedestal Fishing Seats
Section 3 - On The Water 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 Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Page 49: Impact With Underwater Hazards
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 50: Trailering The Boat
If you require additional clearance, place the sterndrive unit in full trailer position and support it with an optional trailer kit, which is available from your authorized Mercury MerCruiser dealer. Conditions Affecting Operation...
Page 51: Elevation And Climate
Section 3 - On The Water • Drive unit trimmed out too far. • A missing propeller diffuser ring. • A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing. • Drive unit installed too high on transom. Elevation and Climate Elevation and climate changes will affect the performance of your power package.
Page 52: Getting Started
Section 3 - On The Water Getting Started 20‑Hour Break‑In Period IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil consumption and maximum engine performance. During this break‑in period, the following rules must be observed: •...
Page 53: Starting The Engine
Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push‑button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 54: Stopping The Engine
Section 3 - On The Water STOPPING THE ENGINE 1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If the engine has been operated at high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes.
Page 55: To Maneuver The Boat In Forward
Section 3 - On The Water TO MANEUVER THE BOAT IN FORWARD Place one or both engines in forward gear and steer with the steering wheel as you would any comparable boat. TO STEER THE BOAT IN TIGHT TURNS AT LOW SPEEDS •...
Page 56 Section 3 - On The Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves forward 25928 24705 Boat moves aft 25927 24706 Boat moves to starboard without rotating 25929 24707 Boat moves to port without rotating 25931 24708...
Page 57 Section 3 - On The Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves diagonally forward and to the starboard without rotating 25926 24709 Boat moves diagonally aft and to the starboard without rotating 25924 24710 Boat moves diagonally aft...
Page 58 Section 3 - On The Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat rotates clockwise 25921 24713 Boat rotates counter clockwise 25920 24714 Boat moves diagonally forward and to the starboard while rotating clockwise 25916 24715 Boat moves diagonally...
Page 59: Special Digital Throttle And Shift (Dts) Features
Section 3 - On The Water Movement Joystick Input Boat Response (shown from light gray to dark gray) Boat moves diagonally forward and to the port while rotating counterclockwise 25917 24719 Boat moves to the port while rotating clockwise 25930 24720 Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the Electronic Remote...
Page 60: Dock
Section 3 - On The Water Item Control Function Illuminate when the transmission is in the neutral gear position. The "NEUTRAL" lights lights flash when the engine is in throttle only mode. Not used None Allows boat control to be transferred to a different helm. Refer to Helm "TRANSFER"...
Page 61: Throttle Only
Section 3 - On The Water THROTTLE ONLY 31465 "THROTTLE ONLY" button To engage Throttle Only mode: 1. Place both ERC levers in neutral. 2. Press the "THROTTLE ONLY" button, located on the DTS trackpad. 3. The "THROTTLE ONLY" button light illuminates and the neutral lights blink. 4.
Page 62: Single) Lever
Section 3 - On The Water 1 (SINGLE) LEVER The Axius system features the ability to command both engines with a single lever. This feature simplifies engine management during rough sea conditions by allowing you to grasp a single lever to command both engines simultaneously. 31466 "1 LEVER"...
Page 63: Axius Plus Can Control Pad (If Equipped)
Section 3 - On The Water VesselView shows an orange icon if the engines exceed a 10% difference in RPM of each other, and the icon turns red when they synchronize. The icon turns off when Sync is off. 31467 "SYNC"...
Page 64: Standby And Active Lights
Section 3 - On The Water STANDBY AND ACTIVE LIGHTS Axius Plus CAN Control Pad is disengaged (off) when the "STANDBY" light is illuminated. You must press a button to engage a mode. When the "ACTIVE" light is illuminated one mode of Axius is engaged (on). STANDBY ACTIVE TURN...
Page 65 Section 3 - On The Water 2. Press the "AUTO HEADING" button to engage Axius. The button illuminates and a single beep sounds. A double beep sounds if auto heading does not engage. STANDBY ACTIVE TURN TURN RESUME AUTO HEADING 32507 "AUTO HEADING"...
Page 66 Section 3 - On The Water • Press one of the "TURN" buttons in the direction you want to turn. Each press of the button changes the desired heading by 10°. STANDBY ACTIVE TURN TURN RESUME AUTO HEADING 32508 Port "TURN" button Starboard "TURN"...
Page 67: Disengage Auto Heading
Section 3 - On The Water 7. If the ERC Handles are moved to neutral, Auto Heading turns off, a single beep sounds, and the "STANDBY" light turns on. You cannot resume your course by pressing the "RESUME" button. 31408 "OFF"...
Page 68: To Resume To A Heading
Change the engine oil and oil filter. Refer to Maintenance. End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of...
Page 69: Contingent Operations
Section 3 - On The Water Contingent Operations Port Engine Only Operation The force feedback feature of the steering wheel is only available when the starboard key switch is in the on position. If the starboard key switch is off or there has been damage to the starboard electrical system, the port control system monitors the steering wheel.
Page 70 Section 3 - On The Water 3. Move the shift lever into the neutral position. The shift actuator is in the neutral position when the shift lever is straight up and the shift interrupt switch is fully engaged. 32243 Harness Shift lever Shift lever in neutral position Shift lever in forward position...
Page 71 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........64 Engine Specifications......... 65 Fuel Ratings ..........64 Fluid Specifications..........66 Using Reformulated (Oxygenated) Gasolines Engine............66 (USA Only) ........... 64 Sterndrive—Bravo.........66 Gasolines Containing Alcohol ...... 64 Steering............67 Engine Oil............
Page 72: Fuel Requirements
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand.
Page 73: Engine Oil
To help obtain optimum engine performance and to provide maximum 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.
Page 74: Fluid Specifications
All Models Capacity Fluid Type Mercury/Quicksilver Synthetic Blend Engine oil (with filter) 4.25 liters (4.5 U.S. qt.) MerCruiser Engine Oil 25W‑40 Seawater cooling system (winterization 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water use only) Mercury Extended Life Coolant/...
Page 75: Steering
Section 4 - Specifications Steering Axius—All Models Capacity Fluid Type Steering system 2914 mL (98‑1/2 oz) Dexron III Power Trim Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 90-899883234 JANUARY 2008 Page 67...
Page 76 Section 4 - Specifications Notes: Page 68 90-899883234 JANUARY 2008...
Page 77 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......70 Water-Separating Fuel Filter......88 Dealer Responsibilities........70 GEN III Models..........89 Maintenance............70 Removal ..........89 Do-It-Yourself Maintenance Suggestions... 71 Installation ..........90 Inspection............71 Lubrication............90 Maintenance Schedules—Axius Models.... 72 Electronic Shift Control (ESC) Shift Cable..90 Routine Maintenance—Axius Models...72 Sterndrive Unit and Transom Assembly..
Page 78: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...
Page 79: Do-It-Yourself Maintenance Suggestions
Transmission (inboard models only) Do‑It‑Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 80: Maintenance Schedules-Axius Models
Section 5 - Maintenance Maintenance Schedules—Axius Models Routine Maintenance—Axius Models NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) •...
Page 81: Maintenance Log
Section 5 - Maintenance Task Interval Maintenance to Be Performed • Inspect the U‑joints, the splines, and the bellows. Check the clamps. • Check the engine alignment. • Lubricate the U‑joint splines and cross bearing, if equipped with grease Every 200 hours or 3 fittings.
Page 82: Engine Oil
Section 5 - Maintenance Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
Page 83: Changing Oil And Filter
Fluid type 4.3L (262 cid) 3.8 liters (4 U.S. qt.) 5.0L (305 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 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.
Page 84: Engine Oil Drain Pump
Section 5 - Maintenance 1. Loosen the oil filter to vent the system. 7284 Bilge drain plug Oil drain hose plug Tether Oil drain hose Clip Bilge drain flange 2. Remove the bilge drain plug. 3. Pull tether through the bilge drain. 4.
Page 85: Changing Filter
Mercury/Quicksilver Synthetic Blend 4.25 liters (4.5 U.S. qt.) MerCruiser Engine Oil 25W‑40 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan.
Page 86: Changing Steering Fluid
Changing Steering Fluid You do not need to change the steering fluid unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Engine Coolant Checking...
Page 87: Filling
Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger.
Page 88: Changing
Closed Cooling System 92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Sterndrive Gear Lube Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law.
Page 89: Filling
2. Inspect the lubricant condition. If any water is visible at the bottom of the gear lube monitor, if water appears at the fill and drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately. These conditions can indicate a water leak in the sterndrive.
Page 90: Changing
Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 32539 Gear lube monitor Typical closed cooled model Typical seawater cooled model 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4.
Page 91: Power Trim Fluid
IMPORTANT: If any water drained from the gear lube fill and drain hole, or if the gear lube appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 6. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the fill and drain hole, with specified gear lubricant until an air‑free stream of...
Page 92: Filling
3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 93: Multiple Efi Engine Battery Precautions
Section 5 - Maintenance Multiple EFI Engine Battery Precautions Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for 2 different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine's alternator will not be required to supply any charging current.
Page 94: Positive Crankcase Ventilation Valve (Pcv)
Section 5 - Maintenance 3. Remove the flame arrestor. 6110 Engine cover knob Cover mount bracket Engine cover Flame arrestor Nuts, flame arrestor Crankcase ventilation hose 4. Clean the flame arrestor with warm water and a mild detergent. 5. Inspect the flame arrestor for holes, cracks or deterioration. Replace if necessary. 6.
Page 95: Replacement
5. Install the PCV valve in the valve cover and reconnect the hose, if not connected already. 6. Ensure that the PCV valve is tightly seated in the valve cover. Replacement IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. 90-899883234 JANUARY 2008 Page 87...
Page 96: Water-Separating Fuel Filter (Mpi)
Section 5 - Maintenance 1. Remove the PCV valve from the port valve cover. mc71925-1 PCV valve Hose 2. Disconnect the PCV valve from the hose and discard the valve. 3. Install a new PCV valve in the valve cover and reconnect the hose. 4.
Page 97: Gen Iii Models
O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness.
Page 98: Installation
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Electronic Shift Control (ESC) Shift Cable 1.
Page 99: Sterndrive Unit And Transom Assembly
Section 5 - Maintenance Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Shift cable pivot points & guide 92‑883725K01 Oil SAE25W‑40 contact surfaces Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
Page 100: Engine Coupler
Apply lubricant from a typical hand‑operated grease gun until a small amount of grease begins to push out. Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo Three Propeller Removal WARNING Rotating propellers can cause serious injury or death.
Page 101 6. Turn front propeller shaft nut 70 mm (2‑3/4 in.) counterclockwise to remove nut. 7. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304 Rear propeller nut...
Page 102: Bravo Three Propeller Installation
Section 5 - Maintenance Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. 5304 Rear propeller nut Front propeller thrust hub...
Page 103 Section 5 - Maintenance 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 screw. 11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw.
Page 104: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt Checking WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. 33283 Alternator pulley Steering pump pulley Water circulating pump pulley Crankshaft pulley...
Page 105 Section 5 - Maintenance 3. Attach the Kent Moore belt tension gauge, or equivalent, to the belt. 4. Put a wrench on the adjustment stud 16 mm (5/8 in.) locking nut. 5. Use a 8 mm (5/16 in.) socket and tighten the adjusting stud to adjust the belt tension. 6.
Page 106: Corrosion Protection
The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90‑881813003).
Page 107: Checking The Quicksilver Mercathode System
Checking the Quicksilver MerCathode System The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information . Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system.
Page 108: Boat Bottom Care
• If using copper based anti‑fouling paint, avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.
Page 109 Section 5 - Maintenance NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly. Do not wash the sterndrive unit with a power washer. High pressures can damage the coating on the reference wire of the MerCathode assembly, if equipped, and increase corrosion.
Page 110: Sterndrive Surface Care
Section 5 - Maintenance Sterndrive Surface Care 21083 Standard Bravo sterndrive Sacrificial trim cylinder anode Stainless steel hoses Sacrificial anodic plate Ground wire between the gimbal housing and trim cylinder Steering lever ground wire Ground wire between the gimbal Ground wire between the gimbal ring and gimbal housing ring and bell housing We recommend the following maintenance items to help keep your sterndrive...
Page 111: Flushing The Power Package
Section 5 - Maintenance Flushing the Power Package General Information Your authorized Mercury MerCruiser dealer can explain how to properly flush your power package. The boat can be equipped with a combination of any of three different types of water pickups: through the hull, through the transom, and through the sterndrive.
Page 112: Sterndrive Water Pickups
9194 STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).
Page 113: Alternative Water Pickups
Section 5 - Maintenance If there is not a hose running to the transom, refer to Alternative Water Pickups. 4. If flushing the cooling system with the boat in the water: Raise sterndrive to trailer position. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
Page 114 Section 5 - Maintenance 1. If flushing the cooling system with the boat in the water: Raise sterndrive to trailer position. Install the appropriate flushing attachment over the water inlet holes in the gear housing. Lower sterndrive unit to full down (in) position. 2.
Page 115: Seacore Power Package Flushing Procedure
Section 5 - Maintenance 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 about 10 minutes or until discharge water is clear. 12. Slowly return throttle to idle speed position. 13.
Page 116 Section 5 - Maintenance 2. Close the seacock, if equipped. 18510 For visual clarity, the secock shown is not installed Hose fitting to engine Handle (closed position) Seacock To water source pickup attachment 3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive.
Page 117 Section 5 - Maintenance 7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine. 18489 Water hose Flush socket Quick‑connect fitting (water hose end) 8. Open the water source of the water hose to a full flow. 9.
Page 118 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 25900 Quick‑connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 119 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. 18490 Dust cover installed in the flush socket Dust cover Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage.
Page 120 Section 5 - Maintenance Notes: Page 112 90-899883234 JANUARY 2008...
Page 121 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....114 Boat out of the Water ......120 Preparing Power Package for Storage..114 Manual Single-Point Drain System.....122 Engine and Fuel System Preparation . . 115 Boat in the Water .........
Page 122: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.
Page 123: Engine And Fuel System Preparation
Section 6 - Storage 9. After draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation for the lowest temperature to which the engine will be exposed during freezing temperatures or extended storage. 10. Store the battery according to the manufacturer's instructions. ENGINE AND FUEL SYSTEM PREPARATION WARNING Fuel is flammable and explosive.
Page 124: Draining The Seawater System
Section 6 - Storage Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining.
Page 125: Three Point Manual Drain System
Section 6 - Storage THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 6130 Water circulating pump hose Fuel cooler to thermostat housing 90-899883234 JANUARY 2008 Page 117...
Page 126: Air Actuated Single Point Drain System
Section 6 - Storage 6131 Check valve (if equipped) Air Actuated 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.
Page 127 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.
Page 128: Boat Out Of The Water
Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 129 10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. 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.
Page 130: Manual Single-Point Drain System
Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators Manual Single‑Point Drain System BOAT IN THE WATER 1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2.
Page 131: Boat Out Of The Water
Section 6 - Storage 4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. 6137 Drain location ‑ orange or red Blue drain plug 5. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance.
Page 132: Three-Point Manual Drain System
Section 6 - Storage 3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. 6137 Drain location ‑ orange or red Blue drain plug 4. Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained.
Page 133: Boat Out Of The Water
Section 6 - Storage 3. To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. 6139 Blue drain plug location 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 6140 Blue drain plugs 5.
Page 134: Multi-Point Drain (Mpd) System
Section 6 - Storage 2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug 3. Verify that water is draining from each opening. 4.
Page 135 Section 6 - Storage Water circulating pump hose 6143 Drain plug Fuel cooler to thermostat housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) 90-899883234 JANUARY 2008 Page 127...
Page 136: Section 6 - Storage
Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
Page 137: Battery Storage
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.
Page 138 Section 6 - Storage Notes: Page 130 90-899883234 JANUARY 2008...
Page 139: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Check VesselView First........132 Insufficient Engine Temperature....134 Diagnosing EFI Problems......... 132 Low Engine Oil Pressure......134 Diagnosing DTS Problems....... 132 Battery Will Not Recharge......134 Engine Guardian System........132 Joystick............134 Troubleshooting Charts........132 Electronic Remote Controls......135 Starter Motor Will Not Crank Engine, Or Cranks Steering System..........135...
Page 140: Check Vesselview First
Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 141: Engine Will Not Start Or Is Hard To Start
Clean or repair as necessary. See Engine Runs Rough, Misses or Backfires. Ignition problem. Engine overheating. See Excessive Engine Temperature. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Engine Runs Rough, Misses, or Backfires Possible Cause Remedy Clogged fuel filter.
Page 142: Insufficient Engine Temperature
The joystick does not function properly and a fault indicate reduced engine power. If found, have the code is set. system checked by your authorized Mercury MerCruiser dealer. The joystick does not work; No fault code is set and Disengage cruise control. cruise control engaged.
Page 143: Electronic Remote Controls
If found, contact your authorized Mercury MerCruiser dealer to ask if the propellers need to be changed. The ERC lever controls the Check the "TROLL" button on the DTS track pad. Put the handles in Neutral and engine and drive, but does push the "TROLL"...
Page 144: Power Trim Does Not Operate (Motor Does Not Operate)
Section 7 - Troubleshooting Symptom Remedy The steering wheel turned past Key off and key on to restore steering wheel self‑centering, cruise control, end stop. and to eliminate the fault code. Power Trim Does Not Operate (Motor Does Not Operate) Possible Cause Remedy Replace fuse.
Page 145: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 138 Parts and Accessories Inquiries ... 139 Local Repair Service ........138 Resolving a Problem ........139 Service Away From Home ......138 Mercury Marine Service Offices ....
Page 146: Owner Service Assistance
Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.
Page 147: Parts And Accessories Inquiries
Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership.
Page 148: Ordering Literature
• Year built United 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...

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MerCruiser Axius 350 MAG User Manual

Section 3 - on the Water

Section 4 - Specifications

Section 5 - Maintenance

Section 7 - Troubleshooting

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Troubleshooting

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