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Owner's Manual
NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury MerCruisers' instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4)
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a
recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions
requirements of the directive mentioned above. This engine must not be put into service until the recreational craft in which
it is to be installed has been declared in conformity, if so required, with the relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine driven
devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
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.
President ‑ Mercury MerCruiser, Stillwater, OK, USA
Regulatory contact:
Regulations and Product Safety Department
Mercury Marine
W6250 W. Pioneer Road
Fond du Lac, WI 54936
USA
Identification Record
Please record the following information:
ISO 10240
ISO 9093‑1; ISO 9093‑2
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and ABYC
P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
Kevin Grodzki
Standards Applied
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Table of Contents
Related Manuals for MerCruiser 350 MAG MPI Tow Sports
Summary of Contents for MerCruiser 350 MAG MPI Tow Sports
- Page 1 Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when installed in a recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust emissions requirements of the directive mentioned above.
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Page 2: Read This Manual Thoroughly
Boat Model 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. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation. - Page 3 Notice Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. These Safety Alerts alone cannot eliminate the hazards that they signal.
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Page 5: Table Of Contents
Transfer of Warranty..............2 Duration of Coverage............11 Mercury Product Protection Plan: United States and Canada... 3 How to Obtain Warranty Coverage........12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Mercury Will Do............12 Products Only) ................3 What Is Not Covered............12 3‑Year Limited Warranty Against Corrosion......5 Disclaimers and Limitations..........12... - Page 6 After Break‑In Period............39 End of First Season Checkup.......... 39 Section 4 - Specifications Cruising RPM................. 42 Engine Specifications............. 43 Fuel Requirements..............42 Tow Sports Models............43 Fuel Ratings..............42 Inboard Models..............44 Using Reformulated (Oxygenated) Gasolines (USA Only) 42 Fluid Specifications..............44 Gasolines Containing Alcohol...........
- Page 7 Section 7 - Troubleshooting Diagnosing EFI Problems............84 Excessive Engine Temperature..........85 Diagnosing DTS Problems............. 84 Insufficient Engine Temperature..........85 Engine Guardian System............84 Low Engine Oil Pressure............86 Starter Motor Will Not Crank Engine, Or Cranks Slow... 84 Battery Will Not Recharge............86 Engine Will Not Start or Is Hard to Start.........
- Page 8 Page iv 90-8M0053272 NOVEMBER 2010...
- Page 9 Mercury Product Protection Plan: United States and Canada How to Obtain Warranty Coverage ....... 12 ....................3 What Mercury Will Do ........... 12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Is Not Covered ............ 12 Products Only) ............... 3 Disclaimers and Limitations .......... 12 3‑Year Limited Warranty Against Corrosion......
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Page 10: Warranty Registration: United States And Canada
Federal Boat Safety Act is required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number. -
Page 11: Mercury Product Protection Plan: United States And Canada
The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. 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 12 Section 1 - Warranty Transfer of Coverage Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use customer.
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Page 13: 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 14: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
4-YEAR LIMITED CORROSION WARRANTY: SEACORE STERNDRIVE MODELS WITH GAS ENGINES What Is Covered Mercury Marine warrants that each new MerCruiser SeaCore engine, transom, and sterndrive package will not be rendered inoperative as a direct result of corrosion for the period of time described below. -
Page 15: Global Warranty Charts
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: 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 Horizon... -
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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon... -
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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon... -
Page 19: California Emissions Limited Warranty
California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003. -
Page 20: How To Obtain Warranty Coverage
Your Warranty Rights and Obligations NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003. -
Page 21: Manufacturer's Warranty Coverage
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 22: 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 23 Section 1 - Warranty 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. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
- Page 24 Section 1 - Warranty Notes: Page 16 90-8M0053272 NOVEMBER 2010...
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Page 25: 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 Lanyard Stop Switch............. 18 Slim Binnacle Console Mount Features ‑ Single Engine Instrumentation..............19 ..................23 System View ..............19 Console Mount Features‑... -
Page 26: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position). Stop switch Lanyard Clips to the operator... -
Page 27: Instrumentation
Section 2 - Getting to Know Your Power Package Instrumentation System View Smart Craft SELEC T System View H O M E 5650 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. -
Page 28: Remote Controls (Non-Dts Models)
Section 2 - Getting to Know Your Power Package Speedometer: Indicates boat speed. Tachometer: Indicates engine RPM. Oil Pressure Gauge: Indicates engine oil pressure. Voltmeter: Indicates battery voltage. Water Temperature Gauge: Indicates engine operating temperature. Fuel Gauge: Indicates quantity of fuel in tank. Hour meter: Records engine operating time. -
Page 29: Console Mount Features
Section 2 - Getting to Know Your Power Package Console Mount Features Throttle Only Button Control Handle 17356 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 30: Panel Mount Features
Section 2 - Getting to Know Your Power Package The Digital Throttle and Shift System (DTS) required to operate this engine package provides start and stop functions, throttle control, shift control, start in gear protection, and emergency lanyard stop functions. The DTS system works with specialized helm components such as a command module kit and electronic remote control. -
Page 31: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 17359 Control handle 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. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. -
Page 32: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed. -
Page 33: Dual Helm Station Transfer
Section 2 - Getting to Know Your Power Package Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the engines are synchronized. SYNC ACTIVE THROTTLE ONLY STAT ION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%. -
Page 34: Zero Effort Features
Section 2 - Getting to Know Your Power Package Zero Effort Features Shift ever Throttle lever 17357 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. -
Page 35: 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 36: Testing The Audio Warning System
IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle. Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears. If the transmission fluid pressure drops below a predetermined level, Transmission Guardian lowers the engine torque and speed to prevent clutch slippage. - Page 37 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions............ 30 Protecting People in the Water..........36 Be Alert to Carbon Monoxide Poisoning....... 31 While You Are Cruising ..........36 Good Ventilation ............31 While Boat Is Stationary ..........
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Page 38: 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. Ensure that everyone in the boat is properly seated. -
Page 39: Be Alert To Carbon Monoxide Poisoning
Section 3 - On The Water • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when the boat is above idle or planing transition speed. -
Page 40: Basic Boat Operation (Non-Dts Models)
Section 3 - On The Water Examples of poor ventilation while a boat is moving: Operating the boat with the trim angle of the bow too high Operating the boat with no mc79556-1 forward hatches open (station wagon effect) Basic Boat Operation (Non‑DTS Models) Launching and Boat Operation IMPORTANT: Install bilge drain plug prior to launching boat. -
Page 41: 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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect. -
Page 42: Starting And Stopping The Engine
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 43: 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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect. -
Page 44: Protecting People In The Water
Section 3 - On The Water Protecting People in the Water While You Are Cruising It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. -
Page 45: Wave And Wake Jumping
Section 3 - On The Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible. -
Page 46: Conditions Affecting Operation
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 47: 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 48 Section 3 - On The Water Notes: Page 40 90-8M0053272 NOVEMBER 2010...
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Page 49: Section 4 - Specifications
Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............... 42 Engine Specifications............43 Fuel Requirements............... 42 Tow Sports Models ............43 Fuel Ratings ..............42 Inboard Models ............. 44 Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............... 44 .................. -
Page 50: Cruising Rpm
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. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). -
Page 51: Engine Oil
Section 4 - Specifications IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, do not store the gasoline in the fuel tank for long periods. Whereas cars normally consume alcohol‑blend fuels before they can absorb enough moisture to cause trouble, boats often sit idle long enough for phase separation to take place. -
Page 52: Inboard Models
Section 4 - Specifications Models 350 MAG MPI Tow Sports MX 6.2 MPI Tow Sports 41 kPa (6 psi) Minimum Oil Pressure @ Idle Thermostat, seawater cooled models 71° C (160° F) Thermostat, closed cooled models 77° C (170° F) -
Page 53: Transmission
Section 4 - Specifications All Models Capacity Fluid Type 4.25 liters (4.5 U.S qts) Quicksilver Synthetic Blend, NMMA FC‑W rated, 4 cycle oil Engine Oil (With Filter) 20 liters (21 U.S. qts) Propylene Glycol and Purified Water Seawater Cooling System Mercury Extended Life Coolant/Antifreeze or Extended Life Ethylene Closed Cooling System 19 liters (20 U.S. - Page 54 Section 4 - Specifications Notes: Page 46 90-8M0053272 NOVEMBER 2010...
- Page 55 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 48 Checking While the Engine is Warm ......53 Dealer Responsibilities............48 Checking While Engine is Cold ........53 Maintenance................. 48 Changing ..............53 Do‑It‑Yourself Maintenance Suggestions......48 Engine Coolant..............
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Page 56: Owner/Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty. -
Page 57: Inspection
Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer. -
Page 58: Every 100 Hours Or Annually (Whichever Occurs First)
Record all maintenance performed on your power package here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours 2. Require fluid and filter change after the first 25 hours and then every 100 hours. 3. Contact your authorized Mercury MerCruiser dealer to replace the IAC muffler. Page 50 90-8M0053272 NOVEMBER 2010... -
Page 59: 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 60: Changing Oil And Filter
Fluid Type 4.25 liters Engine Oil (With Filter) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 (4.5 U.S. Quart) 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 61: Changing Filter
Fluid Type 4.25 liters Engine Oil (With Filter) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 (4.5 U.S. Quart) Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water. -
Page 62: Engine Coolant
6101 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. Install the cap onto the heat exchanger. IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck. -
Page 63: Changing
Coolant Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. -
Page 64: Positive Crankcase Ventilation Valve (Pcv)
Positive Crankcase Ventilation Valve (PCV) Changing NOTE: We recommend the use of 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 65: Changing Water Separating Fuel Filter
GEN II Models Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray. -
Page 66: Gen Iii Models
GEN III Models Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness. -
Page 67: In-Line Fuel Filter
Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray. -
Page 68: Lubrication
14. 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 Throttle Cable Lubricate the pivot points and the guide contact surfaces. - Page 69 Lubricate the detent ball and the holes in the shift lever. 5934 In-Line Transmission Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Detent ball and shift lever 92‑883725K01 SAE25W‑40 holes Lubricate the shift cable pivot points. Pivot points 5935 Tube Ref.
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Page 70: 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. Idler pulley Circulating pump pulley Crankshaft pulley Alternator pulley Seawater pump pulley... -
Page 71: Flushing The Power Package-Tow Sports
Section 5 - Maintenance Attach the Kent Moore© Belt Tension Gauge to the belt. The gauge has different ranges for new and used belts. Kent Moore© Tension Gauge Serpentine belt 14980 While holding the adjustment stud at the correct belt tension, tighten the 16 mm (5/8 in.) locking nut. 8 mm (1/16 in.) adjusting stud 16 mm (5/8 in.) locking nut 6119... -
Page 72: The Boat In The Water
Section 5 - Maintenance All other models: Close the seacock, if equipped, and then disconnect the seawater inlet hose from the seawater pump inlet fitting.. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump and plug the hose. 10839 Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump. - Page 73 Section 5 - Maintenance Models with Walter V-Drive Transmissions: Close the seacock, if equipped, and then disconnect the seawater inlet hose from the transmission seawater inlet fitting. NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the seacock before disconnecting the seawater inlet hose.
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Page 74: Battery
Section 5 - Maintenance NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (±... -
Page 75: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........68 Manual Single‑Point Drain System........ 75 Preparing Power Package for Storage......68 Boat in the Water ........... 75 Engine and Fuel System Preparation ....68 Boat out of the Water .......... -
Page 76: Cold Weather Or Extended 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. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. -
Page 77: Draining The Seawater System
IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. -
Page 78: Drain System Identification
Section 6 - Storage Drain System Identification Air Actuated Single Point Drain System 6124 6125 Closed Cooled Models Seawater Cooled Models Blue drain plug location Blue air pump Air manifold Green indicators Black Scorpion Models Blue air pump Air manifold Green indicators Blue drain plug locations 21125... -
Page 79: Three Point Manual Drain System
Section 6 - Storage Three Point Manual Drain System Blue drain plug 6126 Multi-Point Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 6130 Water circulating pump hose Fuel cooler to thermostat housing Check valve (if equipped) 6131 90-8M0053272 NOVEMBER 2010... -
Page 80: Air Actuated Single Point Drain System
Section 6 - Storage 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. Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the air pump from the engine. -
Page 81: Boat Out Of The Water
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 82 Section 6 - Storage Install the air pump on the actuator fitting. Pull lever on air pump (vertical) to lock pump on the fitting. Actuator fitting Green indicators Manual release valve Air pump Lever (locking) 8293 Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side.
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Page 83: Manual Single-Point Drain System
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 84: Boat Out Of The Water
Section 6 - Storage Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually. Drain location ‑ orange or red Blue drain plug 6137 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 85: Three-Point Manual Drain System
Section 6 - Storage 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. Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug. The handle is fully seated when no red is visible. -
Page 86: Boat Out Of The Water
Section 6 - Storage Boat out of the Water NOTE: Use this procedure if your engine is not equipped with an air‑actuated single‑point drain system or if the single‑point drain system fails. Place the boat on a level surface to ensure complete draining of the system. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). - Page 87 Section 6 - Storage Water‑circulating pump hose Drain plug 6143 Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 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.
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Page 88: Boat In The Water
Section 6 - Storage Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. After the cooling system has been drained completely, install the drain plugs, reconnect the hoses, and tighten all hose clamps securely. -
Page 89: Battery Storage
Section 6 - Storage Check valve Drain plug (if equipped) 6131 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 90 Section 6 - Storage Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks. Inspect the steering system, shift and throttle control for proper operation. Page 82 90-8M0053272 NOVEMBER 2010...
- Page 91 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems............. 84 Excessive Engine Temperature..........85 Diagnosing DTS Problems........... 84 Insufficient Engine Temperature........... 85 Engine Guardian System............84 Low Engine Oil Pressure............86 Starter Motor Will Not Crank Engine, Or Cranks Slow..84 Battery Will Not Recharge............
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Page 92: Diagnosing Efi Problems
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 93: Engine Runs Rough, Misses, Or Backfires
Clean Flame Arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI System fault. Have EFI System checked by an authorized Mercury MerCruiser dealer. Poor Performance Possible Cause Remedy Throttle not fully open. -
Page 94: Low Engine Oil Pressure
Check all throttle linkages. If any are loose or missing, see authorized Loose or missing shift and throttle linkages. Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair. -
Page 95: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 88 Parts and Accessories Inquiries ......88 Local Repair Service ............ 88 Resolving a Problem ............ 88 Service Away From Home ..........88 Mercury Marine Service Offices ........ -
Page 96: Owner Service Assistance
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. If you need additional assistance: Talk with the dealership's sales manager or service manager. -
Page 97: Mercury Marine Service Offices
• 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 us at: Mercury Marine Publications P.O. Box 1939... -
Page 98: Outside The United States And Canada
Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Print or type your mailing address, which be used as your shipping label, and include your order and payment. Mail to:...