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
Commercial Application Warranty Chart.....9 Mercury Product Protection Plan: United States and Government Application Warranty Chart..10 Canada..............3 Mercury Installation Quality Certification Program 10 Mercury MerCruiser Limited Warranty Emission Control Information Label.......11 (Gasoline‑Fueled Products Only) ......4 Owner Responsibility........12 3‑Year Limited Warranty Against Corrosion....6 Section 2 - Getting to Know Your Power Package Identification............14...
Page 6 Freezing Temperature Operation....41 Operating with Low Water Inlets in Shallow Drain Plug and Bilge Pump......42 Water..............45 Protecting People in the Water......42 Conditions Affecting Operation......45 While You Are Cruising........42 Weight Distribution (Passengers and Gear) While Boat Is Stationary........42 Inside the Boat..........
Page 7 Steering System..........75 Replacing Belt and/or Adjusting Tension..87 Throttle Cable..........77 Corrosion Protection..........89 Shift Cable ‑ Typical........78 Corrosion Information........89 Sterndrive Unit and Transom Assembly..78 Maintaining Ground Circuit Continuity....89 Sterndrive U‑joint Shaft Splines And O‑rings Anodes and MerCathode System Locations. .89 (Sterndrive Unit Removed)......79 Checking the Quicksilver MerCathode Engine Coupler..........
Page 8 Section 8 - Customer Assistance Information Owner Service Assistance.........128 Parts and Accessories Inquiries....129 Local Repair Service........128 Resolving a Problem........129 Service Away From Home......128 Mercury Marine Service Offices.....129 Stolen Power Package........128 Ordering Literature..........130 Attention Required after Submersion....128 United States and Canada......130 Replacement Service Parts......128 Outside The United States and Canada..130 Page iv...
Page 9: Section 1 - Warranty
Mercury Product Protection Plan: United States and Government Application Warranty Chart ..10 Canada..............3 Mercury Installation Quality Certification Program Mercury MerCruiser Limited Warranty (Gasoline- ................10 Fueled Products Only) ......... 4 Emission Control Information Label....11 3-Year Limited Warranty Against Corrosion..6 Owner Responsibility ........
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 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, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.
Page 20: Owner Responsibility
Section 1 - Warranty NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION...
Page 21: 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............14 Slim Binnacle Console Mount Features - Single Engine Serial Number Decal MPI....14 Engine............23 Bravo Sterndrive Serial Number and Console Mount Features- Dual Engine..24 Identification..........14 Synchronizing Dual Engines......25...
Page 22: 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 23: Bravo Transom Serial Number
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers. 25907 Bravo sterndrive serial number stamping...
Page 24: 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 25: 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 26: 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. As the owner or operator, you 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 27: 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 28: 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 29: 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 30: 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 31: Slim Binnacle Console Mount Features - Single 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 32: 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 33: 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 34: Synchronizing Dual Helms Prior To Station Transfer
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 35: 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 36: 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 37 Section 2 - Getting to Know Your Power Package 1. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
Page 38 Section 2 - Getting to Know Your Power Package 4. A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped).
Page 39: 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 40: Warning Horn Signals
Section 2 - Getting to Know Your Power Package Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails. For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage from decreased water flow to the engine.
Page 41 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........34 While You Are Cruising ........ 42 Be Alert to Carbon Monoxide Poisoning..... 35 While Boat Is Stationary ....... 42 Good Ventilation ........... 35 High-Speed and High-Performance Operation Poor Ventilation ...........
Page 42: 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 43: 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 44: 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 45: 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 46: 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 38 90-864195072 OCTOBER 2007...
Page 47: 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 48: 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 49: 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. 90-864195072 OCTOBER 2007 Page 41...
Page 50: 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 51: 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 52: 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 53: 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 54: 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 55: Getting Started
Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered; •...
Page 56: End Of First Season Checkup
Section 3 - On The Water 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 57 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........50 Engine............52 Fuel Ratings ..........50 Alpha Sterndrive..........52 Using Reformulated (Oxygenated) Gasolines Bravo Sterndrives..........52 (USA Only) ........... 50 Power-Assisted Steering and Power Trim Fluids Gasolines Containing Alcohol ...... 50 ..............53 Engine Oil............
Page 58: 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 59: Engine Oil
All MerCruiser engines Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation: 1. Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W–rated 4‑cycle MerCruiser 2.
Page 60: Fluid Specifications
Section 4 - Specifications Models 350 MAG and SeaCore 350 MAG 377 MAG and SeaCore 377 MAG Power 224 kW (300 hp) 238 kW (320 hp) Number of cylinders Displacement 5.7 L (350 cid) 6.2 L (377 cid) Bore and stroke 101.6 ×...
Page 61: Power-Assisted Steering And Power Trim Fluids
Section 4 - Specifications 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 (single seawater pickup) 2972 mL (100‑1/2 oz) Bravo Three (dual seawater pickup) 2736 mL (92‑1/2 oz) Power‑Assisted Steering and Power Trim Fluids APPROVED POWER-ASSISTED STEERING FLUIDS Description...
Page 62 Section 4 - Specifications Notes: Page 54 90-864195072 OCTOBER 2007...
Page 63 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......56 Removal ..........74 Dealer Responsibilities........56 Installation ..........75 Maintenance............56 Lubrication............75 Do-It-Yourself Maintenance Suggestions... 57 Steering System..........75 Inspection............57 Throttle Cable..........77 Maintenance Schedule—Sterndrive Models..58 Shift Cable - Typical........78 Routine Maintenance........58 Sterndrive Unit and Transom Assembly..
Page 64: 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 65: 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 66: Maintenance Schedule-Sterndrive Models
• 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 67: 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 68: 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 69: Changing Oil And Filter
Recheck oil level. 3. Replace the fill cap. Engine Model Engine Oil Capacity Fluid type 350 MAG and SeaCore 350 MAG Mercury MerCruiser Full‑Synthetic Engine Oil, 4.25 L (4.5 US qt) 20W‑40 377 MAG and SeaCore 377 MAG Changing Oil and Filter Refer to the Maintenance schedule for the change interval.
Page 70: Engine Oil Drain Pump
Section 5 - Maintenance 2. Remove the bilge drain plug. 3. Pull tether through the bilge drain. 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.
Page 71: Power Steering Fluid
Power steering pump Warm range Cold range 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 Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.
Page 72: Changing
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 73: Filling
2. Fill to the "FULL" line with the specified coolant. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. 90-864195072 OCTOBER 2007 Page 65...
Page 74: Drive Unit Oil
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 75: Changing
Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 6109 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 76 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 77: Power Trim Fluid
Section 5 - Maintenance Model Capacity Fluid Type Alpha One 1892 mL (64 oz) Bravo One 2736 mL (92‑1/2 oz) High Performance Gear Lubricant Bravo Two 3209 mL (108‑1/2 oz) 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 78: 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 79: 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 80: Positive Crankcase Ventilation Valve (Pcv)
Section 5 - Maintenance Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover.
Page 81: Gen Ii Models
Sealing 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 the fuel supply valve, if equipped. 3. Wrap the water‑separating fuel filter with a cloth to help catch any fuel spills or spray.
Page 82: 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 83: 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 84: October
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 85: 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 86: 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 87: 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 92-802869A1 O-rings...
Page 88: Driveshaft Extension Models
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal 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.
Page 89: Alpha Propeller Installation
Section 5 - Maintenance Alpha 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. IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage.
Page 90: Bravo One Propeller Removal
Section 5 - Maintenance Bravo One Propeller Removal 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 91: Bravo Two Propeller Removal
Section 5 - Maintenance NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued. 4. Align splines and place propeller on propeller shaft. 5. Install drive sleeve and locking tab washer. 6.
Page 92: Bravo Three Propeller Removal
Section 5 - Maintenance 1. Slide thrust hub into propeller hub with stepped side toward propeller hub. 2. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865Q02...
Page 93: Bravo Three Propeller Installation
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 94 Section 5 - Maintenance 2. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865Q02 Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon...
Page 95: Serpentine Drive Belt
Section 5 - Maintenance Description llb‑in. lb‑ft Propeller shaft anode screw 38 mm (0.3125‑18 x 1.5 in.) long – 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. 6117 6116 With a seawater pump...
Page 96 Section 5 - Maintenance NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys. 1. Loosen the 16 mm (5/8 in.) locking nut on the adjustment stud. 2. Turn the adjustment stud and loosen the belt. 3.
Page 97: 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 98: 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 90 90-864195072 OCTOBER 2007...
Page 99: 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 100 • 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 101: 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 102: Flushing The Power Package
Do not paint trim tabs or the mounting surface. 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 103: 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 104 Section 5 - Maintenance 3. On models using the sterndrive seawater inlet and a through‑hull or through‑transom alternative water pickup, supply water 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 105: Alternative Water Pickups
Section 5 - Maintenance 16. 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 106: 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 107 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 108 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 109 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 110 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 111: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....104 Boat out of the Water ......110 Preparing Power Package for Storage..104 Manual Single-Point Drain System.....112 Engine and Fuel System Preparation . . 105 Boat in the Water .........
Page 112: 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 113: Engine And Fuel System Preparation
Section 6 - Storage NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
Page 114: Draining The Seawater System
Section 6 - Storage 3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off valve. 4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting. IMPORTANT: Supply cooling water to the engine.
Page 115: Manual Single Point Drain System
Section 6 - Storage MANUAL SINGLE POINT DRAIN SYSTEM 6128 Blue handle Blue drain plug location THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 90-864195072 OCTOBER 2007 Page 107...
Page 116: Air Actuated Single Point Drain System
Section 6 - Storage 6130 Water circulating pump hose Fuel cooler to thermostat housing 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.
Page 117 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 118: 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 119 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 120: 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 121: 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 122: 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 123: Boat Out Of The Water
Blue drain plugs 5. Verify that water is draining from each opening. 6. 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 124: Multi-Point Drain (Mpd) System
Blue drain plug 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 125 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) 90-864195072 OCTOBER 2007 Page 117...
Page 126: Draining The Sterndrive
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 127: 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 128 Section 6 - Storage Notes: Page 120 90-864195072 OCTOBER 2007...
Page 129 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 122 Low Engine Oil Pressure........124 Diagnosing DTS Problems....... 122 Battery Will Not Recharge........ 124 Engine Guardian System........122 Remote Control Is Difficult to Move, Has Excessive Starter Motor Will Not Crank Engine, Or Cranks Play, or Makes Unusual Sounds.......
Page 130: 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 131: 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 132: 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 133: 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 134 Section 7 - Troubleshooting Notes: Page 126 90-864195072 OCTOBER 2007...
Page 135 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 128 Parts and Accessories Inquiries ... 129 Local Repair Service ........128 Resolving a Problem ........129 Service Away From Home ......128 Mercury Marine Service Offices ....
Page 136: 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 137: 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 138: 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 377 mag

MerCruiser 350 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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