Page 1 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. Kevin Grodzki President ‑ Mercury MerCruiser, Stillwater, OK, USA...
Page 2 Length 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
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant! Mercury MerCruiser Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty...
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
Mercury Product Protection Plan: United States and Commercial Application Warranty Chart...10 Canada..............3 Government Application Warranty Chart..11 Mercury MerCruiser Limited Warranty Mercury Installation Quality Certification Program 11 (Gasoline‑Fueled Products Only) ‑ USA & Canada Emission Control Information Label.......12 (For other countries please refer to the chart) ..4 Owner Responsibility........13...
Page 6 Freezing Temperature Operation....44 Boats With Front‑Mounted, Raised Pedestal Drain Plug and Bilge Pump......45 Fishing Seats...........49 Basic Boat Operation (DTS Models)....45 Wave and Wake Jumping........49 Launching and Boat Operation..... 45 Impact with Underwater Hazards......50 Operation Chart.......... 45 Drive Unit Impact Protection......51 Starting and Stopping the Engine....
Page 7 GEN III Models..........80 Maintaining Ground Circuit Continuity....99 Removal............80 Anodes and MerCathode System Locations. .99 Installation............81 Checking the Quicksilver MerCathode Lubrication.............81 System............100 Steering System..........81 Power Package Exterior Surfaces....101 Throttle Cable..........83 Boat Bottom Care.........101 Shift Cable ‑ Typical........84 Anti‑fouling Paint..........101 Sterndrive Unit and Transom Assembly..84 Sterndrive Surface Care.......103 Sterndrive U‑joint Shaft Splines And O‑rings Draining the Seawater System......104...
Page 8 Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move)......139 Section 8 - Customer Assistance Information Owner Service Assistance.........142 Parts and Accessories Inquiries....143 Local Repair Service........142 Resolving a Problem........143 Service Away From Home......142 Mercury Marine Service Offices.....143 Stolen Power Package........142 Ordering Literature..........144 Attention Required after Submersion....142...
Page 9: Section 1 - Warranty
Mercury Product Protection Plan: United States and Consumer Application Warranty Chart ... 9 Canada..............3 Commercial Application Warranty Chart ..10 Mercury MerCruiser Limited Warranty (Gasoline- Government Application Warranty Chart ..11 Fueled Products Only) - USA & Canada (For other Mercury Installation Quality Certification Program countries please refer to the chart) ......
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) - Usa & Canada (For Other Countries Please Refer To The Chart)
Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only) ‑ USA & Canada (For other countries please refer to the chart) MERCURY MERCRUISER LIMITED WARRANTY (GASOLINE-FUELED PRODUCTS ONLY) - USA & Canada (For other countries please refer to the chart) What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following.
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 - Usa & Canada (For Other Countries Please Refer To The Chart)
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 - Usa & Canada (For Other Countries Please Refer To The Chart)
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 The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine.
Page 17: Consumer Application Warranty Chart
Section 1 - Warranty Consumer Application Warranty Chart Limited Corrosion Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion and Horizon...
Page 18: 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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...
Page 19: 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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...
Page 20: Mercury Installation Quality Certification Program 11 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. In addition to the required emissions statement, the label lists the engine serial number, family, FEL (emission level), date of manufacture (month, year), and the engine displacement.
Page 21: 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 22 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 23: 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............16 Slim Binnacle Console Mount Features - Single Engine Serial Number Decal......16 Engine............27 Bravo Sterndrive Serial Number and Console Mount Features- Dual Engine..28 Identification..........16 Synchronizing Dual Engines......29...
Page 24: 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 The serial number decal is located on top of the engine.
Page 25: Bravo Transom Serial Number
Section 2 - Getting to Know Your Power Package The serial number is also stamped as a permanent reference on the sterndrive casting inside the back cover. 33534 Bravo sterndrive serial number stamping Bravo Transom Serial Number The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.
Page 26: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. 25905 Gimbal housing with serial number stamping Transom assembly serial Number...
Page 27: Instrumentation
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 28: Digital Gauges
Section 2 - Getting to Know Your Power Package Your power package may be connected to the Mercury SC5000 SmartCraft System View display. The display monitors and reports information 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.
Page 29: Analog Gauges
Section 2 - Getting to Know Your Power Package Analog Gauges The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.
Page 30: Panel Mount Features
Section 2 - Getting to Know Your Power Package PANEL MOUNT FEATURES mc77019-1 Neutral lock button Control handle tension adjustment screw Throttle only button Control handle Lanyard stop switch Trim/tilt button Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.
Page 31: Console Mount Features
Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.
Page 32: Zero Effort Features
Section 2 - Getting to Know Your Power Package Zero Effort Features 5656 Shift ever Trim/tilt switch Throttle lever Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position.
Page 33: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features 3409 Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw 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.
Page 34: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 3410 Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 35: Engine
Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features ‑ Single Engine START STOP 14637 Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 36: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch Arrow trackpad Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw...
Page 37: Synchronizing Dual Engines
Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine. Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5°...
Page 38: Synchronizing Dual Helms Prior To Station
Section 2 - Getting to Know Your Power Package 3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STAT ION SELECT STATION SELECT 3433...
Page 39: Power Trim
Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
Page 40: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
Page 41: Trim Delta
Section 2 - Getting to Know Your Power Package Trim Delta Trim delta controls the distance between the individual adjacent drive angles when trimming. The trim delta limit is preset, and will not allow extreme drive angle differences that could damage tie bars. If the maximum trim delta limit is met, the drive furthest in the trim process "up or down", will stop trimming until the adjacent drive is back within the delta limit.
Page 42 Section 2 - Getting to Know Your Power Package 2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs. mc74907-1 3.
Page 43: Audio Warning System
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 44: Testing The Audio Warning System
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 you cannot determine the cause, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System 1.
Page 45 Section 2 - Getting to Know Your Power Package In addition, depending on the gauge package, there will be warning icons and fault messages on the dash mounted gauges. 90-864839070 AUGUST 2007 Page 37...
Page 46 Section 2 - Getting to Know Your Power Package Notes: Page 38 90-864839070 AUGUST 2007...
Page 47: Section 3 - On The Water
Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........40 While You Are Cruising ........ 48 Be Alert to Carbon Monoxide Poisoning..... 41 While Boat Is Stationary ....... 48 Good Ventilation ........... 41 High-Speed and High-Performance Operation Poor Ventilation ...........
Page 48: Safe Boating Suggestions
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.
Page 49: Be Alert To Carbon Monoxide Poisoning
Section 3 - On The Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...
Page 50: Poor Ventilation
Section 3 - On The Water 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Page 51: Starting And Stopping The Engine
Section 3 - On The Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Check shift and Turn battery switch on. throttle control Close fuel shut off valve. operation. Check steering Close seacock, if Operate bilge blowers. operation. equipped.
Page 52: Stopping The Engine
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. Page 44 90-864839070 AUGUST 2007...
Page 53: Drain Plug And Bilge Pump
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 54: Stopping 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 55: Throttle-Only 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. 90-864839070 AUGUST 2007 Page 47...
Page 56: Drain Plug And Bilge Pump
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 57: Boats Having An Open Front Deck
Section 3 - On The Water Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.
Page 58: 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 59: Drive Unit Impact Protection
Section 3 - On The Water Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit.
Page 60: Cavitation
Section 3 - On The Water • 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 is docked. This growth must be removed before operation;...
Page 61: Getting Started
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 the first 100 hours of operation or once yearly, whichever occurs first.
Page 62 Section 3 - On The Water Notes: Page 54 90-864839070 AUGUST 2007...
Page 63 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........56 Engine............59 Fuel Ratings ..........56 Bravo Sterndrives..........59 Using Reformulated (Oxygenated) Gasolines Power-Assisted Steering and Power Trim Fluids (USA Only) ........... 56 ..............59 Gasolines Containing Alcohol ...... 56 Approved Power-Assisted Steering Fluids Engine Oil............
Page 64: 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 65: 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 66: Engine Specifications
Section 4 - Specifications Engine Specifications Models 8.1 MAG 8.1 MAG H.O. Notes Performance obtained and corrected in Horsepower accordance with SAE J1228/ISO 8665 Crankshaft Power. Performance obtained and corrected in Kilowatts accordance with SAE J1228/ISO 8665 Crankshaft Power. Displacement 8.1 L (496 cid)
Page 67: Fluid Specifications
Capacity Fluid Type Mercury/Quicksilver Synthetic Blend Engine oil (with filter) 8.5 liters (9 U.S. qt.) MerCruiser Engine Oil 25W‑40 Seawater cooling system (winterization use 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water only) Mercury Extended Life Coolant/ Antifreeze or Extended Life Ethylene Closed cooling system 18 liters (19 U.S.
Page 68 Section 4 - Specifications Notes: Page 60 90-864839070 AUGUST 2007...
Page 69 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......63 Engine Coupler..........85 Dealer Responsibilities........63 Engine Coupler..........86 Maintenance............63 Driveshaft Extension Models......86 Do-It-Yourself Maintenance Suggestions... 64 Propellers............87 Inspection............64 Propeller Repair..........87 Maintenance Schedules........65 Bravo Sterndrive Propeller Removal.....87 Routine Maintenance........65 Bravo One Models .........
Page 70 Section 5 - Maintenance Models Using The Sterndrive Water Pickup ............. 117 Page 62 90-864839070 AUGUST 2007...
Page 71: 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 72: 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 73: Maintenance Schedules
• Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts.
Page 74: 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 75: 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 76: Changing Oil And Filter
3. Replace the fill cap. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 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.
Page 77: Engine Oil Drain Pump
Section 5 - Maintenance 4. Place the oil drain hose in a suitable container. 5. Remove the drain plug from the oil drain hose. 6. After oil has drained completely, install the drain plug in the oil drain hose. 7. Push the hose through bilge drain and install the plug. ENGINE OIL DRAIN PUMP 1.
Page 78: Power Steering Fluid
OK range. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W‑40 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.
Page 79: Filling
Section 5 - Maintenance 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add the specified fluid to bring the fluid level up to the proper range.
Page 80: Filling
92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit 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.
Page 81: Filling
If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Page 82: Changing
Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 8530 Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
Page 83 IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of...
Page 84: Power Trim Fluid
Section 5 - Maintenance Model Capacity Fluid Type Bravo One 2736 ml (92‑1/2 oz.) Bravo Two 3209 ml (108‑1/2 oz.) High Performance Gear Lubricant Bravo Three 2972 ml (100‑1/2 oz.) 11. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and oil fill/drain screw.
Page 85: Changing
Section 5 - Maintenance 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 86: Cleaning The Flame Arrestor
Section 5 - Maintenance Cleaning The Flame Arrestor WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.
Page 87: Water-Separating Fuel Filter
Section 5 - Maintenance 2. Remove the IAC muffler. 18495 IAC muffler installed in the throttle body IAC muffler 3. Inspect the IAC muffler for damage such as, holes, cracks or deterioration. Replace the IAC muffler if damaged. IMPORTANT: Do not use cleaner containing methyl ethyl ketone. IMPORTANT: Do not get cleaner on electrical connections.
Page 88: 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 89: 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 Steering System...
Page 90 Section 5 - Maintenance 1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand‑operated grease gun. 6221 Steering cable grease fitting Tube Ref No.
Page 91: Throttle Cable
3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 92: Shift Cable - Typical
Pivot points Guide contact surfaces 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 93: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)
Section 5 - Maintenance Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Unit Removed) 1. Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. 8591 Driveshaft splines U‑joint O‑rings (3) Tube Ref No. Description Where Used Part No. Driveshaft splines and U-joint Engine Coupler Spline Grease 92-802869A 1 O-rings...
Page 94: Engine Coupler
Section 5 - Maintenance NOTE: Bravo Models ‑ The coupler and shaft splines can be lubricated without removing the sterndrive unit. Apply lubricant from a typical hand‑operated grease gun until a small amount of grease begins to push out. Engine Coupler 1.
Page 95: Propellers
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo Sterndrive Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
Page 96 Section 5 - Maintenance 2. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate. 4826 Wood block Propeller nut under socket Propeller 3. Turn the propeller shaft nut counterclockwise and remove the nut. 4. Slide the propeller and the attaching hardware from the propeller shaft. 5301 Bravo One models Propeller shaft splines...
Page 97: Bravo Two Models
Section 5 - Maintenance 19816 Bravo One XR models Propeller shaft Washer Propeller hub insert with snubbers Washer Propeller Propeller nut Thrust washer BRAVO TWO MODELS 1. Straighten the bent tabs of the tab washer on the propeller shaft. 4750 Prop Tab bent down Tab washer...
Page 98: Bravo Three Models
Section 5 - Maintenance 2. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate. 4826 Wood block Propeller nut under socket Propeller 3. Turn propeller shaft nut counterclockwise to remove nut. 4. Slide the propeller and attaching hardware from the propeller shaft. 8566 Bravo Two Propeller shaft splines...
Page 99 Section 5 - Maintenance 3. Remove the propeller shaft anode. 19058 Propeller Propeller shaft anode screw Propeller shaft nut Flat washer Propeller shaft anode Star washer 4. Turn aft propeller shaft nut counterclockwise to remove nut. 5. Slide propeller and thrust hub off propeller shaft. 6.
Page 100: Bravo Sterndrive Propeller Installation
Section 5 - Maintenance Bravo Sterndrive Propeller Installation WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
Page 101 Section 5 - Maintenance 3. Torque the propeller nut. 5301 Typical Bravo One models Propeller shaft splines Drive sleeve adapter Forward thrust hub Tab washer Flo‑Torque II drive hub Propeller nut Propeller 19816 Bravo One XR models Propeller shaft Washer Propeller hub insert with snubbers Washer Propeller...
Page 102: Bravo Two Models
Section 5 - Maintenance 5. Bend the three tabs down into the grooves. 4750 Prop Tab bent down Tab washer Propeller nut Drive sleeve adapter BRAVO TWO MODELS IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller shaft.
Page 103: Bravo Three
Section 5 - Maintenance Description lb. in. lb. ft. Bravo Two propeller nut – 4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer. 5. Bend the three tabs down into the grooves. 4750 Prop Tab bent down...
Page 104 Section 5 - Maintenance 7. Install propeller nut and torque. Description lb. in. lb. ft. Bravo Three rear propeller nut – 8. Install propeller shaft anode and screw and torque. 5304 Bravo Three Rear propeller nut Front propeller thrust hub Rear propeller Propeller shaft anode screw Rear propeller thrust hub...
Page 105: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt 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. 8118 Belt Routing Diagram Idler pulley Seawater pump pulley Water circulating pump pulley...
Page 106 Loose brackets, 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 Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.
Page 107: 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 108: 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 . Page 100 90-864839070 AUGUST 2007...
Page 109: Power Package Exterior Surfaces
Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Power Package Exterior Surfaces 1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
Page 110 • 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 111: Sterndrive Surface Care
Section 5 - Maintenance Do not power‑wash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosion. 21563 Reference electrode Anode plate Sterndrive Surface Care 21083 Standard Bravo sterndrive Sacrificial trim cylinder anode Stainless steel hoses...
Page 112: Draining The Seawater System
This power package comes with one of several available seawater drain systems. See the following information to identify the specific drain system on your power package. You are responsible for identifying your drain system. Mercury MerCruiser is not responsible for freeze damage.
Page 113: Air-Actuated Single-Point Drain System
Section 5 - Maintenance AIR-ACTUATED SINGLE-POINT DRAIN SYSTEM 8294 Actuator fitting Manual release valve Green indicators 17254 Port side drain location Starboard side drain location MANUAL DRAIN SYSTEM 17255 Blue drain plug locations 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.
Page 114 Section 5 - Maintenance 2. Remove the air pump from the engine. 3. Ensure that the lever on top of the pump is flush with the handle (horizontal). 4. Install the air pump on the actuator fitting. 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump...
Page 115: Boat Out Of The Water
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.
Page 116 Section 5 - Maintenance 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump Green indicators Lever (locking) Manual release valve 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine.
Page 117: Manual Drain System
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.
Page 118: Boat Out Of The Water
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 119: Draining The Sterndrive
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 120 Section 5 - Maintenance 2. Remove end caps, sealing washers and gaskets from heat exchangers. 8295 Heat exchanger Sealing washer Gaskets End cap 3. Repeatedly clean out drain holes using a stiff wire. Do this until entire system is drained. 4.
Page 121: Flushing The Power Package
The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Bravo models equipped with closed cooling require dual water pickups and must be equipped with a through‑hull or through‑transom pickup in addition to the...
Page 122: Sterndrive Water Pickups
9194 STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
Page 123 Section 5 - Maintenance 2. On Bravo closed cooled models using the sterndrive seawater inlet and a through-hull or through-transom alternative water pickup: Flushing water will need to be supplied to only the sterndrive by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet Y‑fitting.
Page 124: Alternative Water Pickups
Section 5 - Maintenance 15. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine. ALTERNATIVE WATER PICKUPS IMPORTANT: Two water sources are needed for this procedure. NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications.
Page 125: Seacore Power Package Flushing Procedure
Section 5 - Maintenance NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 7. With sterndrive in normal operating position, open the water source fully. 8.
Page 126 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 127 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 128 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 129 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 130 Section 5 - Maintenance Notes: Page 122 90-864839070 AUGUST 2007...
Page 131: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....124 Boat in the Water ......... 127 Preparing Power Package for Storage..124 Boat out of the Water ......129 Engine and Fuel System Preparation . . 125 Manual Drain System........131 Draining the Seawater System......
Page 132: 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 133: Engine And Fuel System Preparation
Section 6 - Storage 9. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.
Page 134: 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 135: Manual Drain System
Section 6 - Storage MANUAL DRAIN SYSTEM 17255 Blue drain plug locations 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 136 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.
Page 137: Boat Out Of The Water
Section 6 - Storage 13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 138 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.
Page 139: Manual Drain System
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 140: Boat Out Of The Water
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 141: 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 142 Section 6 - Storage 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 with a battery terminal anti‑corrosion agent. 4. Perform all the checks in the before starting column of the Operation Chart. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
Page 143 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 136 Low Engine Oil Pressure........138 Diagnosing DTS Problems....... 136 Battery Will Not Recharge........ 138 Engine Guardian System........136 Remote Control Is Difficult to Move, Has Excessive Starter Motor Will Not Crank Engine, Or Cranks Play, or Makes Unusual Sounds.......
Page 144: Diagnosing Efi Problems
Section 7 - Troubleshooting 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 145: Engine Will Not Start Or Is Hard To Start
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. Have EFI System checked by an authorized Mercury MerCruiser EFI System fault dealer. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed.
Page 146: Insufficient Engine Temperature
Section 7 - Troubleshooting Possible Cause Remedy Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups or sea strainer obstructed. Remove obstruction. Faulty thermostat. Replace. Coolant level (if equipped) low in closed cooling Check for cause of low coolant level and repair. Fill section.
Page 147: Remote Control Is Difficult To Move, Has Excessive Play, Or Makes Unusual Sounds
Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Low power steering pump fluid level.
Page 148 Section 7 - Troubleshooting Notes: Page 140 90-864839070 AUGUST 2007...
Page 149: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 142 Parts and Accessories Inquiries ... 143 Local Repair Service ........142 Resolving a Problem ........143 Service Away From Home ......142 Mercury Marine Service Offices ....
Page 150: 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 151: 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 152: 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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Seacore 8.1

MerCruiser 8.1 MAG Owner's Manual

Section 1 - Warranty

Section 3 - on the Water

Section 4 - Specifications

Section 5 - Maintenance

Section 7 - Troubleshooting

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