The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
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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 Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information.
TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Identification................2 Operation................ 9 Information Decal..............2 Adjustment..............9 Quick Response (QR) Code..........2 Special Digital Throttle and Shift (DTS) Features..... 10 Engine Serial Number ............3 Dock................11 Lanyard Stop Switch..............
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Section 7 - Customer Assistance Information Owner Service Assistance............64 Contact Information for Mercury Marine Customer Service Local Repair Service............64 ................... 65 Service Away From Home..........64 Customer Service Literature............ 65 Stolen Power Package............64 English Language.............. 65 Attention Required After Submersion......... 64 Other Languages..............
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Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Identification................2 Adjustment .............. 9 Information Decal............. 2 Special Digital Throttle and Shift (DTS) Features..10 Quick Response (QR) Code..........2 Dock ..............
Section 1 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's key to numerous details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Information Decal The information decal is located on the coolant reservoir.
Section 1 - Getting to Know Your Power Package Engine Serial Number The engine serial number stamp is located on the starboard side of the engine block next to the flywheel housing cover. Flywheel housing cover Engine serial number stamp Engine block 43554 Lanyard Stop Switch...
Section 1 - Getting to Know Your Power Package Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an emergency. WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat.
650–1200 Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.
Section 1 - Getting to Know Your Power Package SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between the specified RPM range. SmartCraft gauges Tachometer Speedometer LCD system view display 26238 The SmartCraft instrument package also aids in Engine Guardian diagnostics.
Remote Controls IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.
Section 1 - Getting to Know Your Power Package Trim Switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The PCM closes the ground circuit to the up or down trim relay.
Section 1 - Getting to Know Your Power Package Item Control Function Raises and lowers the engine for best efficiency, or for conditions such as shallow water, Trim control (handle) trailering, etc. Allows the operator to start or stop the engine without the use of the key switch. The key switch "Stop/Start"...
Section 1 - Getting to Know Your Power Package Adjust to the tension desired. Detent tension adjustment screw Handle tension adjustment screw 51901 Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously.
Section 1 - Getting to Know Your Power Package Item Control Function "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges. Allows the boat operator to increase engine RPM for warm‑up without shifting the "THROTTLE ONLY" transmission into gear. "–"...
Section 1 - Getting to Know Your Power Package Press the "THROTTLE ONLY" button. The button light will turn off. The neutral lights stop flashing and remain illuminated. The joystick can now be used. 1 Lever The outboard joystick system features the ability to command both engines with a single lever on a dual‑engine application. This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both engines simultaneously.
Section 1 - Getting to Know Your Power Package Transfer (Boats equipped with dual helms) The "TRANSFER" button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer. 51858 "TRANSFER"...
Section 1 - Getting to Know Your Power Package 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. Shift into forward by moving the shift lever to its forward position.
Section 1 - Getting to Know Your Power Package Four fuses protect the main power, fuel pump, ignition, and accessory circuits. These are located on the top of the engine near the PCM. Fuses protect the O sensors. These are located near the 14‑pin harness connector. 43553 A 15‑amp accessory fuse protects the accessory circuits.
Section 1 - Getting to Know Your Power Package The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and will remain illuminated while the OBD‑M fault is active. 47594 SC 1000 gauge and service engine light Testing the OBD-M Malfunction Indicator Lamp (MIL) Turn the ignition switch to the on position without cranking the engine.
Section 1 - Getting to Know Your Power Package Testing the Audio Warning System Turn the key switch to the on position without cranking the engine. Listen for the audio alarm. The alarm will sound if the system is functioning correctly. Guardian Strategy The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM detects a potential problem.
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Section 1 - Getting to Know Your Power Package Notes: Page 18 90-8M0113925 DECEMBER 2015...
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Section 2 - On the Water Section 2 - On the Water Table of Contents Safe Boating Recommendations.......... 20 High‑Speed and High‑Performance Operation..... 25 Carbon Monoxide Exposure..........21 Passenger Safety in Pontoon Boats and Deck Boats..25 Be Alert To Carbon Monoxide Poisoning ..... 21 Boats Having an Open Front Deck .......
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.
Section 2 - On the Water Be alert. • 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 operator's view when the boat is above idle or planing transition speed.
Section 2 - On the Water Poor Ventilation Under certain running or wind 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. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
Section 2 - On the Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Check the engine oil. Perform all other checks specified by your dealer and/or boat builder. Listen for Audio Warning Alarm to sound when the ignition switch is in the "ON" position.
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.
For additional information, refer to Hi‑Performance Boat Operation booklet (90‑849250‑R03) from your dealer, distributor, or Mercury Marine. Passenger Safety in Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.
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.
Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. Conditions Affecting Operation...
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.
Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Section 3 - Specifications IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause trouble;...
Fluid Specifications Engine IMPORTANT: All capacities are approximate fluid measures. All Models Capacity Fluid Type Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA Engine oil (with filter) 6.5 L (7 US qt) FC‑W Seawater cooling system 20 L (21 US qt)
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.
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.
Section 4 - Maintenance • Inspect the condition of the accessory drive belt—dealer item • Replace the PCV valve • Spray the power package with Corrosion Guard • Inspect anodes, if equipped Three Years or 300 Hours • Inspect the spark plugs and spark plug wires •...
Add the specified engine oil to bring the level up to, but not over, the operating range cross markings on the dipstick. All Models Capacity Fluid Type Engine oil (with filter) 6.5 L (7 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Check the oil level and replace the fill cap. 90-8M0113925 DECEMBER 2015 Page 37...
Section 4 - Maintenance Changing Oil and Filter Refer to Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
Engine oil (with filter) 6.5 L (7 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil Start the engine and operate for three minutes, checking for leaks. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.
Section 4 - Maintenance Closed Cooling System Coolant Requirement NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.
"FULL" mark, repeat the warm‑up/cool‑down cycle, and check the coolant level again. Maintain the coolant level in the reservoir at or near the "FULL" mark with the engine cold. Draining Contact your authorized Mercury MerCruiser dealer. Cleaning Contact your authorized Mercury MerCruiser dealer.
Section 4 - Maintenance In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself, and the engine will operate normally. The ECM shuts off and resets itself so quickly that the engine may only seem to have an ignition miss.
Inspect the PCV valve and replace if necessary. Install the PCV valve into the intake manifold. Ensure that the PCV valve is tightly seated into the intake manifold. We recommend the use of Mercury MerCruiser replacement parts. Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive.
Removal 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.
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Check 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. Serpentine Drive Belt...
Section 4 - Maintenance NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable. 21062 Replacing IMPORTANT: If reusing a belt, install it in the same direction of rotation as before. The belt tensioner operates within the limits of movement provided by the cast stops when the belt length and geometry are correct.
Section 4 - Maintenance NOTE: Proper tension is a measurement of deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys. 50920 Deflection measurement point Description Deflection 13 mm (½ in.) Flushing the Seawater System—Inboard Models The Boat Out of the Water—Inboard Models IMPORTANT: Flushing the power package is most effective when performed with the boat out of the water.
Section 4 - Maintenance 10. For power packages operated in salty, brackish, mineral‑laden, or polluted water: Continue to operate the engine until the discharge water is clear. 11. Slowly return the throttle to idle speed position. 12. Stop the engine. 13.
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Section 5 - Storage Section 5 - Storage Table of Contents Cold Weather or Extended Storage........50 Air‑Actuated Single‑Point Drain System......53 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 50 Boat in the Water ........... 53 Fuel Containing Alcohol..........50 Boat Out of the Water ..........54 Preparing Power Package for Storage—MPI Models..
(phase) of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury Marine 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).
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. Check the antifreeze concentration where applicable. Refer to the Specifications section. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following: Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add...
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. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Section 5 - Storage Manual Drain System Starboard side blue drain plugs Port side blue drain plug 50412 Air‑Actuated Single‑Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that was shipped with the engine from the factory. However, any air source can be used.
12. Remove the air pump from the air connection 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.
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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.
Verify that water is draining from each opening. 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.
Draining Water from the Cool Fuel Module Mercury MerCruiser recommends draining the Gen 3 Cool Fuel Module if it is equipped with a drain plug. Remove the drain plug from the Gen 3 Cool Fuel Module and allow the water to completely drain from the module.
Diagnosing DTS Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory.
Clean the 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...
Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners. If any are loose or missing, see authorized Loose or missing steering fasteners or parts. Mercury MerCruiser dealer immediately. Contaminated power steering fluid. See authorized Mercury MerCruiser dealer. Page 62 90-8M0113925 DECEMBER 2015...
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Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............ 64 Contact Information for Mercury Marine Customer Local Repair Service ............ 64 Service ................. 65 Service Away From Home ..........64 Customer Service Literature..........65 Stolen Power Package ..........
If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.
Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...
Enclose full remittance in check or money order (NO COD). Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
Section 8 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...
Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
Section 9 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...
Section 9 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0113925 DECEMBER 2015 Page 73...