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Mercury TowSport Inboards Manual

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Tow Sports / Inboard MPI Models
2002, Mercury Marine
90 864197020 302

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  • Page 1 INDEX Tow Sports / Inboard MPI Models  2002, Mercury Marine 90 864197020 302...
  • Page 2 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 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: Read This Manual Thoroughly

    0004 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, 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.

  • Page 5: Table Of Contents

    ....Direct Sale By Owner ... . . Mercury MerCruiser One Year Mercury Product Protection Plan ..
  • Page 6 ....Otros idiomas ....Mercury Marine Service Offices ..Andra språk .
  • Page 7 ....Direct Sale By Owner ....Mercury MerCruiser One Year Mercury Product Protection Plan ..

  • Page 8: Warranty Information

    WARRANTY 0005 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. •...

  • Page 9: International Owner Registration

    WARRANTY International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. •...

  • Page 10: Warranty Policies

    Mercury MerCruiser One Year Limited Warranty (Gasoline Fueled Products Only) WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for either one (1) year from the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first.
  • Page 11 If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 12: Year Limited Warranty Against Corrosion (Worldwide)

    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 Mercury Marine specified pre-delivery inspection process is completed and documented.
  • Page 13 If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service.

  • Page 14: Transferable Warranty

    The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty. The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. Two, three or four - year term plans can be purchased up to 12 months after the original engine registration date.
  • Page 15 WARRANTY THIS PAGE IS INTENTIONALLY BLANK 90-864197020 MARCH 2002 Page 9...
  • Page 16 WARRANTY THIS PAGE IS INTENTIONALLY BLANK Page 10 90-864197020 MARCH 2002...
  • Page 17 GETTING TO KNOW YOUR POWER PACKAGE GETTING TO KNOW YOUR POWER PACKAGE Table of Contents Features And Controls ....Lanyard Stop Switch ....Instrumentation .

  • Page 18: Getting To Know Your Power Package

    GETTING TO KNOW YOUR POWER PACKAGE 0010 Features And Controls 0011 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). 74608 Stop Switch Lanyard...
  • Page 19 GETTING TO KNOW YOUR POWER PACKAGE Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat’s path as seriously as the boat would when under power.

  • Page 20: Instrumentation

    0013 SMARTCRAFT PRODUCT 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, water pressure, battery voltage, fuel consumption and engine operating hours.

  • Page 21: Remote Controls

    GETTING TO KNOW YOUR POWER PACKAGE 0014 Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.
  • Page 22 GETTING TO KNOW YOUR POWER PACKAGE 0016 CONSOLE MOUNTED CAUTION Avoid possible boat and power package damage. Never shift unit into or out of gear unless throttle lever is at idle rpm. IMPORTANT: Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control.
  • Page 23 GETTING TO KNOW YOUR POWER PACKAGE 0017 CONSOLE MOUNTED 77971 1. 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, and should only be used to assist in starting the engine.

  • Page 24: Electrical System Overload Protection

    Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical system. Contact your authorized Mercury MerCruiser dealer. 0019 74907...

  • Page 25: Audio Warning System

    0020 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 26: Engine Guardian Strategy

    If the debris passes through and full water flow is restored, engine power levels are restored to normal. To avoid a possible recurrence of the problem you should contact an authorized Mercury MerCruiser dealer. The ECM stores the fault and with this information the technician will be able to more rapidly diagnose problems.
  • Page 27 GETTING TO KNOW YOUR POWER PACKAGE THIS PAGE IS INTENTIONALLY BLANK 90-864197020 MARCH 2002 Page 21...
  • Page 28 GETTING TO KNOW YOUR POWER PACKAGE THIS PAGE IS INTENTIONALLY BLANK Page 22 90-864197020 MARCH 2002...
  • Page 29 ON THE WATER ON THE WATER Table of Contents Safe Boating Suggestions ... . Impact With Underwater Hazards ..Be Alert To Carbon Monoxide Conditions Affecting Operation .

  • Page 30: Safe Boating Suggestions

    • Know and obey all nautical rules and laws of the waterways. Mercury MerCruiser strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency.
  • Page 31 (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. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use.

  • Page 32: Be Alert To Carbon Monoxide Poisoning

    ON THE WATER • Know your boating area and avoid hazardous locations. • 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.
  • Page 33 ON THE WATER 0024 GOOD VENTILATION Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. Courtesy of ABYC 0025 POOR VENTILATION Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 34: Basic Boat Operation

    ON THE WATER 0026 Basic Boat Operation 0027 Launching And Boat Operation Care CAUTION To avoid possible ingestion of water that can damage engine components: • Do NOT turn the ignition key off when the engine is above idle speed. w When launching your boat from a steep ramp, enter the water slowly.

  • Page 35: Starting And Stopping The Engine

    Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

  • Page 36: Protecting People In The Water

    For additional information, refer to Hi-Performance Boat Operation booklet (90-849250--1) from your dealer, distributor or Mercury Marine. Page 30 90-864197020 MARCH 2002...

  • Page 37: Wave And Wake Jumping

    ON THE WATER 0034 Wave And Wake Jumping WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.

  • Page 38: 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 39: Conditions Affecting Operation

    ON THE WATER 0036 Conditions Affecting Operation Weight Distribution (Passengers And Gear) Inside The Boat Shifting weight to rear (stern): • Generally increases speed and engine rpm • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane •...

  • Page 40: Elevation And Climate

    ON THE WATER 0039 Elevation And Climate Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by: • Higher elevations • Higher temperatures • Low barometric pressures • High humidity For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum rpm range with a normal boat load during your normal boating weather conditions.

  • Page 41: Getting Started

    0044 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 42 ON THE WATER THIS PAGE IS INTENTIONALLY BLANK Page 36 90-864197020 MARCH 2002...
  • Page 43 SPECIFICATIONS AND MAINTENANCE SPECIFICATIONS AND MAINTENANCE Table of Contents Specifications ..... . . Flame Arrestor and Fuel Recommendations ... Related Components .

  • Page 44: Specifications

    FUEL RATINGS Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following specifications: USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline [92 (R+M)/2 Octane] is also acceptable.
  • Page 45 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 46: Engine Oil

    SPECIFICATIONS AND MAINTENANCE 0048 Engine Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil. This oil is a special blend of 25-weight and 40-weight oils for marine engines. If not available, a good grade, straight weight, detergent automotive oil of correct viscosity, with an API classification of SJ, CF-2, CH-4 may be used.

  • Page 47: Engine Specifications

    SPECIFICATIONS AND MAINTENANCE 0049 Engine Specifications 0050 350 MAG MX 6.2 MPI Tow MX 6.2 Models Sports Horizon Horizon Propshaft Horsepower Propshaft Kilowatts Displacement 350 cid (5.7 liter) 377 cid (6.2 liter) Specified WOT rpm 4600-5000 4400-4800 4600-5000 Range Idle rpm in NEUTRAL Minimum Oil Pressure @ 124 kPa (18 psi) 2000 rpm...

  • Page 48: Fluid Specifications

    Quicksilver 4-Cycle 25W-40 Marine 5.20 (5-1/2) Filter) Engine Oil Seawater Cooling 20 (21) Propylene Glycol and Purified Water System Mercury Extended Life Coolant/Antifreeze or Extended Life Closed Cooling 19 (20) Ethylene Glycol 5/100 System Antifreeze/Coolant mixed 50/50 with Purified Water Always use the dipstick to determine the exact quantity of oil or fluid required.

  • Page 49: 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 50: Maintenance

    IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed. Some listings can be done by owner/operator, while others should be performed by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, it is recommended that a Mercury MerCruiser Service Manual be purchased and read thoroughly.

  • Page 51: Do-It-Yourself Maintenance Suggestions

    0057 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 52: Inspection

    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. 0059 Inboard Maintenance Chart Routine Maintenance *...
  • Page 53 SPECIFICATIONS AND MAINTENANCE 0060 Inboard Maintenance Chart (continued) Scheduled Maintenance * Every Every Every Every Every hours hours Annually hours or or 3 or 3 Annually years years years years Touch-up paint power package and spray with corrosion guard. Change the engine oil and the filter.
  • Page 54 SPECIFICATIONS AND MAINTENANCE Inboard Maintenance Chart (continued) Scheduled Maintenance * Every Every Every Every Every hours hours Annually hours or or 3 or 3 Annually years years years years Check the cooling system and the exhaust system hose clamps for tightness.

  • Page 55: Maintenance Record

    SPECIFICATIONS AND MAINTENANCE 0166 Maintenance Record Hour Meter Maintenance Per- Date Serviced By Reading formed 90-864197020 MARCH 2002 Page 49...

  • Page 56: Engine Oil

    SPECIFICATIONS AND MAINTENANCE 0062 Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as defined by local authorities.

  • Page 57: Filling

    SPECIFICATIONS AND MAINTENANCE 0064 Filling IMPORTANT: Do not overfill the engine with oil. 1. Remove oil fill cap. 77842 2. Add the specified engine oil to bring the level up to, but not over, the FULL or OK RANGE mark on the dipstick. Refer to Specifications. Capacity All Models Fluid Type...

  • Page 58: Changing Oil And Filter

    SPECIFICATIONS AND MAINTENANCE 0065 Changing Oil and Filter Refer to the 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.
  • Page 59 SPECIFICATIONS AND MAINTENANCE 0068 ALL MODELS 1. Remove and discard oil filter. 77808 2. Coat sealing ring on new filter with engine oil and install. 3. Tighten oil filter securely (following filter manufacturer’s instructions). Do NOT overtighten. 4. Remove oil fill cap. IMPORTANT: Always use dipstick to determine exactly how much oil is required.

  • Page 60: Transmission Fluid

    2. Remove the dipstick, wipe clean and reinsert. 3. Remove the dipstick, observe the fluid level and mark the cold fluid level. 4. Reinstall the dipstick, tighten the T-handle securely. Do NOT overtighten. 0070 CHANGING Contact your authorized Mercury MerCruiser dealer. Page 54 90-864197020 MARCH 2002...

  • Page 61: Lubrication

    SPECIFICATIONS AND MAINTENANCE 0078 Lubrication 0079 Throttle Cable 1. Lubricate the pivot points and the guide contact surfaces. 78033 Pivot Points Guide Contact Surfaces Description Where Used Part Number Pivot points, guide contact Engine Oil Obtain Locally surfaces 0196 Transmission Linkage - Typical 1.

  • Page 62: Engine Coolant - Closed Cooled Models Only

    SPECIFICATIONS AND MAINTENANCE 0071 Engine Coolant - Closed Cooled Models Only Checking CAUTION Allow the engine to cool down before removing the pressure cap. A sudden loss of pressure could cause hot coolant to boil and discharge violently. After the engine has cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.

  • Page 63: Filling

    Antifreeze or Extended Life Eth- Closed Cooling System 92-877770K1 ylene Glycol 5/100 Antifreeze/ Coolant mixed 50/50 with Puri- fied Water 3. Install the fill cap onto the coolant recovery bottle. 0073 Changing Contact your authorized Mercury MerCruiser dealer. 90-864197020 MARCH 2002 Page 57...

  • Page 64: Flame Arrestor And Related Components

    SPECIFICATIONS AND MAINTENANCE 0074 Flame Arrestor and Related Components Cleaning 1. Remove the engine cover. 2. Remove the crankcase ventilation hose from the fitting on the side of the flame arrestor housing. 3. Remove the flame arrestor. 77946 78480 Engine Cover Knob Engine Cover Nuts, Flame Arrestor Cover Mount Bracket...

  • Page 65: Positive Crankcase Ventilation Valve (Pcv)

    Flame Arrestor Bracket Nuts 9. Install the engine cover. 0167 Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. 1. Remove PCV valve from port valve cover. 71925 PCV Valve Hose 2.

  • Page 66: Water Separating Fuel Filter

    Ensure that no fuel leaks exist before closing the engine hatch. 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. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray.
  • Page 67 6. Supply cooling water to the engine. 7. Start engine. Check the filter connection for gasoline leaks. If leaks exist, recheck filter installation. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. 90-864197020 MARCH 2002 Page 61...

  • Page 68: In-Line Fuel Filter

    SPECIFICATIONS AND MAINTENANCE 0168 In-line Fuel Filter Changing WARNING Be careful when changing the fuel filter. Gasoline is extremely flammable and highly explosive under certain conditions. Ensure that the ignition key is OFF. Do not smoke or allow spark or open flame in the area when changing the fuel filter. Wipe up any spilled fuel immediately.
  • Page 69 SPECIFICATIONS AND MAINTENANCE 7. Install and torque screw and washer through the mounting clip into the stringer. Description lb-in. lb-ft Screw, Mounting Clip 12.2 8. Install and torque hose clamps over hose and insert barbs into hose. 78289 Fuel Line Stringer Clips Fuel Line Description lb-in.

  • Page 70: Battery

    SPECIFICATIONS AND MAINTENANCE 0076 Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. WARNING Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine.

  • Page 71: Serpentine Drive Belt

    SPECIFICATIONS AND MAINTENANCE 0081 Serpentine Drive Belt WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt. 76503 Idler Pulley Circulating Pump Pulley Crankshaft Pulley Alternator Pulley Seawater Pump Pulley 0082 CHECKING 1.
  • Page 72 SPECIFICATIONS AND MAINTENANCE 0083 REPLACING AND / OR ADJUSTING TENSION IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation as before. NOTE: The upper, left (port) idler pulley is the belt adjustment pulley. NOTE: Belt deflection is to be measured on the belt at the location that has the longest dis- tance between two (2) pulleys.
  • Page 73 SPECIFICATIONS AND MAINTENANCE b. Attach the Kent Moore Belt Tension Gauge to the belt. The gauge has different ranges for new and used belts. 77574 77573 Kent Moore Tension Gauge Serpentine Belt 8. While holding the adjustment stud at the correct belt tension, tighten the 5/8 in. locking nut.

  • Page 74: Cold Weather Or Extended Storage

    0084 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 IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist.
  • Page 75 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System Treatment and Stabilizer Concentrate. Description Where Used Part Number Mercury Fuel System Treatment Fuel System 92-802875A1 and Stabilizer Mercury Fuel System Treatment Fuel System...

  • Page 76: Draining Instructions

    SPECIFICATIONS AND MAINTENANCE IMPORTANT: Supply cooling water to the engine. 5. Start and operate the engine at 1300 rpm for 5 minutes. 6. After specified operating time is complete, slowly return throttle to idle rpm and shut engine off. IMPORTANT: Ensure that some fogging mixture remains in the engine. Do NOT allow the engine’s fuel system to become completely dry.

  • Page 77: Identification

    SPECIFICATIONS AND MAINTENANCE 0179 Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM 77955 77955 Closed Cooled Models Seawater Cooled Models Blue Drain Plug Location Blue Air Pump Air Manifold Green Indicators 0180 3 POINT MANUAL DRAIN SYSTEM 77908 77917 Blue Drain Plug 90-864197020 MARCH 2002 Page 71...

  • Page 78: Boat In Water

    SPECIFICATIONS AND MAINTENANCE 0182 Boat In Water AIR ACTUATED SINGLE POINT DRAIN SYSTEM NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Close the seacock. 2. Remove the blue air pump from the engine. 3.
  • Page 79 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 80 SPECIFICATIONS AND MAINTENANCE 0183 3 POINT MANUAL DRAIN SYSTEM 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. 1. Close the seacock. 2. Remove the blue drain plug from the distribution housing (lower front, port side). 77917 Blue Drain Plug 3.
  • Page 81 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 77908 5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance.

  • Page 82: Boat Out Of The Water

    SPECIFICATIONS AND MAINTENANCE 0184 Boat Out Of The Water AIR ACTUATED SINGLE POINT DRAIN SYSTEM NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Remove the blue air pump from the engine. 2.
  • Page 83 9. Remove the air pump from the air manifold and return it to the mounting bracket. 10. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained.

  • Page 84: All Models

    Blue Drain Plug 2. Verify that water is draining from each opening. 3. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained.

  • Page 85: Flushing The Power Package

    SPECIFICATIONS AND MAINTENANCE 0098 Flushing The Power Package CAUTION Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at the water inlet during engine operation. CAUTION If flushing with the boat in the water, seawater can flow into the engine causing engine damage.
  • Page 86 SPECIFICATIONS AND MAINTENANCE 6. Snap the quick connect fitting and the water hose into the flush socket on the engine. 75423 Quick Connect Fitting 7. Start the engine within 15 seconds. 8. Operate the engine between 600 rpm and 800 rpm. Do NOT exceed 800 rpm. 9.

  • Page 87: Tow Sports

    SPECIFICATIONS AND MAINTENANCE 0100 Tow Sports 1. If flushing the engine with the boat in the water, close the water inlet valve or remove and plug the water inlet hose. a. Models with Walter V-Drive Transmissions: Disconnect water inlet hose from the transmission fitting.
  • Page 88 SPECIFICATIONS AND MAINTENANCE 2. If flushing the engine with the boat out of the water, remove the propeller. Refer to boat manufacturers’ instructions. a. Models with Walter V-Drive Transmissions: Disconnect water inlet hose from transmission fitting. Using appropriate connector, connect the flushing hose. Proceed to Step 3.

  • Page 89: Power Package Recommissioning

    SPECIFICATIONS AND MAINTENANCE 0101 Power Package Recommissioning 1. Ensure that all cooling system hoses are connected properly and hose clamps are tight. CAUTION When installing the battery, be sure to connect the NEGATIVE (–) battery cable to the NEGATIVE (–) battery terminal and the POSITIVE (+) battery cable to the POSITIVE (+) battery terminal.

  • Page 90: Emissions (Europe Only)

    Proper engine tuning procedures to ensure these features remain in good operating order. • Proper steps to maintain the engine within specifications. Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. 0165 Installing Test Probes IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine.
  • Page 91 SPECIFICATIONS AND MAINTENANCE 2. Apply sealant to the adapter fitting threads that go into the exhaust elbow. 3. Install fittings into elbows. Tighten fittings securely. 71926 Adapter Fitting Elbow Side Probe Description Where Used Part Number Pipe Sealant with Teflon Adapter fitting threads 92-809822 4.
  • Page 92 SPECIFICATIONS AND MAINTENANCE THIS PAGE IS INTENTIONALLY BLANK Page 86 90-864197020 MARCH 2002...

  • Page 93: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Table of Contents Diagnosing EFI Problems ... . Insufficient Engine Temperature ..Troubleshooting Charts ....Low Engine Oil Pressure .

  • Page 94: Diagnosing Efi Problems

    0102 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 95: Engine Runs Rough, Misses And/Or Backfires

    Clean Flame Arrestor. Faulty ignition system component. Service ignition system. Have EFI system checked by an Idle speed too low. authorized Mercury MerCruiser dealer. EFI System fault. Have EFI System checked by an authorized Mercury MerCruiser dealer. 0106 Poor Performance...

  • Page 96: Excessive Engine Temperature

    TROUBLESHOOTING 0107 Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups obstructed. Remove obstruction. Faulty thermostat. Replace. Check for cause of low coolant level and Coolant level low in closed cooling repair.

  • Page 97: Excessive Transmission Fluid Temperature Or Slipping Transmission 91 Battery Will Not Come Up On Charge

    Check all throttle linkages. If any are loose Loose or missing shift and throttle or missing, see authorized Mercury linkages. MerCruiser dealer immediately. Straighten cable or have authorized Shift or throttle cable kinked. Mercury MerCruiser dealer replace cable if damaged beyond repair. 90-864197020 MARCH 2002 Page 91...
  • Page 98 TROUBLESHOOTING THIS PAGE IS INTENTIONALLY BLANK Page 92 90-864197020 MARCH 2002...

  • Page 99: Customer Assistance Information

    ....Otros idiomas ....Mercury Marine Service Offices ..Andra språk .

  • Page 100: Owner Service Assistance

    If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 101: Replacement Service Parts

    These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance.

  • Page 102: Resolving A Problem

    0119 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 additional assistance is required, take these steps: 1.

  • Page 103: Mercury Marine Service Offices

    (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America & Caribbean 9010 S.W. 137th Ave. (305) 385-9585 (305) 385-5507 Suite 226 Miami, FL 33186 U.S.A.

  • Page 104: Customer Service Literature

    Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 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: •...

  • Page 105: Andere Sprachen

    Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los números de pieza para los otros idiomas.

  • Page 106: Ordering Literature

    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. Please return with payment to:...

  • Page 107: March

    CUSTOMER ASSISTANCE INFORMATION THIS PAGE IS INTENTIONALLY BLANK 90-864197020 MARCH 2002 Page 101...
  • Page 108 CUSTOMER ASSISTANCE INFORMATION THIS PAGE IS INTENTIONALLY BLANK Page 102 90-864197020 MARCH 2002...

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