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Mercury 4.3 TKS series Operation & Maintenance Manual

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4.3 TKS Models
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O P ERA T I O N &
M AI N T E N AN C E
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Summary of Contents for Mercury 4.3 TKS series

  • Page 1 4.3 TKS Models ( Non-ECT ) O P ERA T I O N & M AI N T E N AN C E M AN U AL...

  • Page 3: Read This Manual Thoroughly

    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.
  • Page 4 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.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Identification................2 System Link Digital Instruments........... 6 Engine Serial Number Decal ..........2 Remote Controls................ 7 Alpha Sterndrive Serial Number......... 2 Panel Mount Features............7 Alpha Transom Serial Number........... 2 Console Mount Features............
  • Page 6 Inspection................31 Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit Maintenance Schedule–Sterndrive Models......31 Removed)................ 45 Routine Maintenance............31 Engine Coupler..............45 Scheduled Maintenance..........31 Driveshaft Extension Models........... 46 Sealed Carburetor Mixture Screw.......... 32 Propellers................46 Engine Oil................32 Propeller Repair.............. 46 Checking................
  • Page 7 Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds............87 Section 7 - Customer Assistance Information Owner Service Assistance............90 Contact Information for Mercury Marine Customer Service Local Repair Service............90 ................... 91 Service Away From Home..........90 Customer Service Literature............
  • Page 8 Page iv 90-8M0113857 DECEMBER 2015...
  • Page 9 Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Identification................2 System Link Digital Instruments ........6 Engine Serial Number Decal .......... 2 Remote Controls..............7 Alpha Sterndrive Serial Number........2 Panel Mount Features ............

  • Page 10: Section 1 - Getting To Know Your Power Package

    Section 1 - Getting to Know Your Power Package Identification The serial numbers are the manufacturer's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal The serial number decal is located on the engine cover.

  • Page 11: Bravo Sterndrive Serial Number And Identification

    Section 1 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers. 44425 Serial number location on gimbal housing Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive.

  • Page 12: Bravo Transom Serial Number

    Section 1 - Getting to Know Your Power Package Bravo Transom Serial Number The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly. Bravo transom assembly U-bolt plate Transom assembly serial number 25904 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers.

  • Page 13: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Section 1 - Getting to Know Your Power Package • High‑performance boats Accidental ejections can also occur from: • Poor operating practices • Sitting on the seat or gunwale at planing speeds • Standing at planing speeds • Operating at planing speeds in shallow or obstacle‑infested waters •...

  • Page 14: Smartcraft Digital Instruments

    Section 1 - Getting to Know Your Power Package Refer to the VesselView operator's manual for more information. 56038 VesselView 7 SmartCraft Digital Instruments The SmartCraft instrument package augments the VesselView display. The instrument package may include: • Tachometer • Speedometer •...

  • Page 15: Remote Controls

    Quantity of fuel in tank Remote Controls Your boat may be equipped with 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 16: Console Mount Features

    Section 1 - Getting to Know Your Power Package Console Mount Features Throttle only button Control handle Power trim switch Trailer switch mc79503-1 Throttle only button ‑ Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle.

  • Page 17: Single Engine Trim/Trailer

    Section 1 - Getting to Know Your Power Package • Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the waterline mc78529 Trimming sterndrive unit down/in can: • Help the boat accelerate and plane off quicker •...
  • Page 18 Section 1 - Getting to Know Your Power Package A circuit breaker protects the engine wiring harness and the instrumentation power lead. Reset the breaker by pushing the red button. 51185 Engine wiring harness and instrumentation circuit breaker A 20‑amp fuse is located near the carburetor body. This fuse protects the fuel pump and ignition system circuits. 7524 A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
  • Page 19 Section 1 - Getting to Know Your Power Package A 15‑amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits. 7524 A 20‑amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for an open fuse or an open circuit breaker if the ignition key is turned to the "START"...

  • Page 20: Audio Warning System

    50534 Audio Warning System The 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 21 Section 2 - On the Water Section 2 - On the Water Table of Contents Safe Boating Recommendations.......... 14 High‑Speed and High‑Performance Operation..... 18 Carbon Monoxide Exposure..........15 Passenger Safety in Pontoon Boats and Deck Boats..18 Be Alert To Carbon Monoxide Poisoning ..... 15 Boats Having an Open Front Deck .......

  • Page 22: Safe Boating Recommendations

    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.

  • Page 23: Carbon Monoxide Exposure

    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.

  • Page 24: Poor Ventilation

    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.

  • Page 25: Starting And Stopping The Engine

    Section 2 - On the Water Starting and Stopping the Engine NOTE: Only perform those functions applicable to your power package. Starting the Engine Check all items listed in the Operation Chart. Place the remote control handle in neutral. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 26: Trailering The Boat

    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 27: Section 2 - On The Water

    Section 2 - On the Water Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. mc79555-1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 28: 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 29: Operating With Low Water Inlets In Shallow Water

    Section 2 - On the Water Operating with Low Water Inlets in Shallow Water Low water inlets mc75827-1 NOTICE Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling water supply to the engine.

  • Page 30: Elevation And Climate

    Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, follow these recommendations: •...

  • Page 31: End Of First Season Checkup

    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 32 Section 2 - On the Water Notes: Page 24 90-8M0113857 DECEMBER 2015...

  • Page 33: Section 3 - Specifications

    Section 3 - Specifications Section 3 - Specifications Table of Contents Fuel Requirements............... 26 Engine Oil................26 Fuel Ratings ..............26 Engine Specifications............27 Using Reformulated (Oxygenated) Gasoline (USA Only) 4.3 TKS................27 ..................26 Fluid Specifications............... 28 Gasoline Containing Alcohol ........26 Engine ................

  • Page 34: Fuel Requirements

    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).

  • Page 35: Engine Specifications

    Section 3 - Specifications If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation. 1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible. IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.

  • Page 36: Fluid Specifications

    Listed capacities are approximate. 4.3 TKS Models Capacity Fluid Type Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst Engine oil (with filter) 3.8 L (4 US qt) Compatible rated Seawater cooling system 14.1 L (15 US qt) Propylene glycol and purified water...

  • Page 37: Section 4 - Maintenance

    Section 4 - Maintenance Section 4 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 30 Steering System............43 Dealer Responsibilities............30 Shift Plate Control Cable Lubrication......45 Maintenance................. 30 Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit Do‑It‑Yourself Maintenance Suggestions......30 Removed)..............45 Inspection................

  • Page 38: 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 39: 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 40: Sealed Carburetor Mixture Screw

    IMPORTANT: Changing the mixture setting on this engine can affect the exhaust emissions level and void the emissions certification. Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury dealer or emissions testing agency.

  • Page 41: Checking

    Fluid type 3.8 Liter (4 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst Compatible rated 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 42: Engine Oil Drain Pump

    Section 4 - Maintenance Loosen the oil filter to vent the system. 7284 Bilge drain plug Tether Clip Oil drain hose plug Oil drain hose Bilge drain flange Remove the bilge drain plug. Pull the tether through the bilge drain. Place the oil drain hose in a suitable container.

  • Page 43: Power Steering Fluid

    Warm range 6631 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.

  • Page 44: Filling

    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 45: Changing

    IMPORTANT: If more than 59 ml (2 fl oz) of gear lubricant is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer.

  • Page 46: Changing

    Sterndrive unit 92-858064K01 IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Install the oil vent screw and sealing washer. Continue to pump gear lubricant into the drive through the oil fill and drain plug hole until gear lubricant appears in the gear lube monitor.

  • Page 47: Sterndrive Gear Lube

    Inspect the lubricant condition. If any water is visible at the bottom of the gear lube monitor, if water appears at the fill and drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately.
  • Page 48 Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant flows from the oil vent hole.

  • Page 49: Power Trim Fluid

    Part No. Power Trim and Steering Fluid Power trim pump 92-858074K01 Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. 90-8M0113857 DECEMBER 2015 Page 41...

  • Page 50: Cleaning The Flame Arrestor

    Positive Crankcase Ventilation (PCV) Valve 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 nonserviceable and is an internal component of the valve cover.

  • Page 51: Changing The Water-Separating 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 the fuel supply valve, if equipped. Wrap the water‑separating fuel filter with a cloth to help catch any fuel spills or spray.
  • Page 52 Lubricate the steering pin. Steering pin mc71904-1 Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Steering pin 92-8M0078629 4-Stroke Engine Oil On dual engine boats: Lubricate the tie bar pivot points. Page 44 90-8M0113857 DECEMBER 2015...

  • Page 53: Shift Plate Control Cable Lubrication

    Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Tie bar pivot points 92-8M0078629 4-Stroke Engine Oil After starting the engine, turn the steering wheel several times to port and starboard to ensure that the steering system operates properly before getting underway.

  • Page 54: Driveshaft Extension Models

    Tube Ref No. Description Where Used Part No. Transom end grease fitting, engine end grease fitting, driveshaft grease Extreme Grease 8M0071842 fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Page 46 90-8M0113857 DECEMBER 2015...

  • Page 55: Alpha Propeller Removal

    Section 4 - Maintenance Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 56: Bravo One Propeller Removal

    Section 4 - Maintenance Bravo One Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 57: Bravo Two Propeller Removal

    Section 4 - Maintenance Bravo Two Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 58: Bravo Three Propeller Removal

    Turn the front propeller nut 70 mm (2‑3/4 in.) counterclockwise to remove the nut. Slide the propeller and thrust hub off the propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut...

  • Page 59: Bravo Three Propeller Installation

    Section 4 - Maintenance Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. Rear propeller nut Rear propeller Rear propeller thrust hub...

  • Page 60: Serpentine Drive Belt

    Section 4 - Maintenance 11. Apply Loctite 271 Threadlocker onto the propeller shaft anode screw threads. Propeller Rear propeller nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 5303 Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Propeller shaft anode screw threads 92-809819...

  • Page 61: Replacing Belt And/Or Adjusting Tension

    Operate the engine for a short period of time and recheck the belt adjustment. Flushing the Power Package (Alpha) Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. 90-8M0113857 DECEMBER 2015...

  • Page 62: Flushing Attachments

    9192 Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 5773 Side pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications. Flushing is recommended after each outing for best results.

  • Page 63: Flushing The Power Package (Bravo)

    Flushing the Power Package (Bravo) General Information Your authorized Mercury MerCruiser dealer can explain how to properly flush your power package. Flushing the Power Package The boat can be equipped with a combination of any of three different types of water pickups: through‑the‑hull, through‑the‑transom, and through‑the‑sterndrive.

  • Page 64: Sterndrive Water Pickups

    Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).

  • Page 65: Alternative Water Pickups

    Section 4 - Maintenance On models using the sterndrive water pickups for water supply: proceed to Step 4. or Step 5. If flushing the cooling system with the boat in the water: Raise sterndrive to trailer position. Install the appropriate flushing attachment over the water inlet holes in the gear housing. Lower sterndrive to full down (in) position.

  • Page 66: Seacore Power Package Flushing Procedure

    Section 4 - Maintenance Remove the seawater inlet hose from the seawater pump at the location shown. Plug the hose to prevent water from siphoning into the engine or boat. 33208 Seawater inlet hose connection Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
  • Page 67 Section 4 - Maintenance IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends. Remove the boat from the water. Close the seacock, if equipped.
  • Page 68 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. Quick-connect fitting stored in the boat Quick‑connect fitting (water hose end)

  • Page 69: Battery

    The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer. Maintaining Ground Circuit Continuity The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the engine, transom assembly, and sterndrive components.

  • Page 70: Sterndrive Corrosion Protection Components

    Section 4 - Maintenance Sterndrive Corrosion Protection Components To help control the effects of galvanic corrosion, sterndrives come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection, refer to the Marine Corrosion Protection Guide.
  • Page 71 Section 4 - Maintenance Do not pressure‑wash the MerCathode assembly, if equipped. Doing so will damage the coating on the reference electrode wire and decrease the corrosion protection. MerCathode mounted to the underside of the gimbal housing, if equipped MerCathode reference electrode, if equipped Do not paint Do not pressure wash...

  • Page 72: Mercathode System Battery Requirements

    Flush the cooling system periodically, preferably after each use. MerCathode System Battery Requirements The Mercury MerCruiser MerCathode system requires a minimum battery charge of 12.6 volts at all times to maintain functionality. Boats equipped with a MerCathode system that use shore power, and are not run for a long period of time, must use a battery charger to maintain a minimum battery charge of 12.6 volts or above.

  • Page 73: Power Package Exterior Surfaces

    1 long flash every 60 terminals, or the boat is out of seconds • If the boat is in the water, contact your local Mercury Service the water/dry docked. dealer for assistance. • Check the battery voltage; it must be 12.6 V or higher.

  • Page 74: Sterndrive Surface Care

    Maintain a complete paint covering on the sterndrive. • Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tin‑based antifouling paint or its equivalent on or near aluminum surfaces below the waterline.
  • Page 75 Section 4 - Maintenance • Spray all electrical connections with sealant. Tube Ref No. Description Where Used Part No. Liquid Neoprene All electrical connections 92- 25711 3 • Inspect the sacrificial trim tab or anode plate if equipped, at regular intervals and replace it before it is half gone. If a stainless steel propeller is installed, additional anodes or a MerCathode system will be required.
  • Page 76 Section 4 - Maintenance Notes: Page 68 90-8M0113857 DECEMBER 2015...

  • Page 77: Section 5 - Storage

    Section 5 - Storage Section 5 - Storage Table of Contents Cold Weather or Extended Storage........70 Air Actuated Single‑Point Drain System......74 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 70 Boat in the Water ........... 74 Fuel Containing Alcohol..........70 Boat Out of the Water ..........76 Preparing Power Package for Storage—Carburetor Manual Single‑Point Drain System (Alpha)....

  • Page 78: Cold Weather Or Extended Storage

    (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).

  • Page 79: Preparing Power Package For Storage-Carburetor Models

    Always ventilate the engine compartment before servicing the power package. 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...

  • Page 80: 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. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 81: Manual Single-Point Drain System, Seawater Cooled Models

    Section 5 - Storage Manual Single-Point Drain System, Seawater cooled models 6128 Non-ECT shown, ECT similar Blue handle Blue drain plug location 4.3 ECT Single-Point Drain System with Plug 45951 Blue drain plug Three-Point Manual Drain System, Seawater cooled Note two plugs on seawater pump Blue drain plug 6126...

  • Page 82: Multipoint Drain (Mpd) System

    Section 5 - Storage Multipoint Drain (MPD) System Side of cylinder block (port and starboard) Bottom of exhaust manifolds (port and starboard) 6129 33155 Fuel cooler to thermostat housing Check valve (if equipped) 6131 Air Actuated Single‑Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that is included with the engine.
  • Page 83 Section 5 - Storage Pull the lever on the air pump (vertical) to lock the pump onto the fitting. Actuator fitting Green indicators Manual release valve Blue 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.

  • Page 84: 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 85 Section 5 - Storage Pull the lever on the air pump (vertical) to lock the pump onto the fitting. Actuator fitting Green indicators Manual release valve Blue 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.

  • Page 86: Manual Single-Point Drain System (Alpha)

    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 87: Boat Out Of The Water

    Section 5 - Storage 5.0 MPI ECT—Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not force the handle as this will create new threads. 4.3 MPI ECT and 5.0 MPI ECT—Immediately remove the blue drain plug from the side of the thermostat housing.
  • Page 88 Section 5 - Storage • 4.3 MPI ECT—Remove the blue plug at the distribution housing at the lower front right corner of the engine. 45951 4.3 MPI ECT • 5.0 MPI ECT—Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open.

  • Page 89: Three-Point Manual Drain System-Seawater Cooled

    Section 5 - Storage Three‑Point Manual Drain System—Seawater Cooled Boat in the Water NOTE: Use this procedure if your engine is not equipped with an air actuated single‑point drain system or if the air actuated single‑point drain system fails. Close the seacock (if equipped) or remove and plug the water inlet hose. Remove the blue drain plug from the distribution housing (lower front, port side).

  • Page 90: Draining Water From The Gen Iii Cool Fuel Module

    Draining Water from the Gen III Cool Fuel Module Mercury MerCruiser recommends draining the Gen III Cool Fuel Module if it is equipped with a drain plug. Remove the drain plug from the Gen III Cool Fuel Module and allow the water to completely drain from the module.

  • Page 91: Battery Storage

    Section 5 - Storage Insert a small wire repeatedly to make sure that vent holes, water drain holes, and passages are unobstructed and open. 6146 Sterndrive water drain holes Speedometer pitot tube Trim tab cavity vent hole Trim tab cavity drain passage Gear housing water drain hole (one each at port and starboard) Gear housing cavity vent hole Gear housing cavity drain hole...
  • Page 92 Section 5 - Storage Notes: Page 84 90-8M0113857 DECEMBER 2015...

  • Page 93: Section 6 - Troubleshooting

    Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, or Cranks Slow..86 Battery Will Not Recharge............ 87 Engine Will Not Start or Is Hard to Start....... 86 Remote Control Is Difficult to Move, Has Excessive Play, or Engine Runs Rough, Misses, or Backfires......

  • Page 94: Starter Motor Will Not Crank Engine, Or Cranks Slow

    Boat bottom fouled or damaged. Clean or repair as necessary. Ignition problem. See Engine Runs Rough, Misses, or Backfires. Engine overheating. See Excessive Engine Temperature. Running rich. Have authorized Mercury MerCruiser dealer check and repair. Page 86 90-8M0113857 DECEMBER 2015...

  • Page 95: Excessive Engine Temperature

    Check all 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 96: Steering Wheel Jerks Or Is Difficult To Turn

    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. Power Trim Does Not Operate (Motor Does Not Operate) Possible Cause Remedy Replace fuse.

  • Page 97: Section 7 - Customer Assistance Information

    Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............ 90 Contact Information for Mercury Marine Customer Local Repair Service ............ 90 Service ................. 91 Service Away From Home ..........90 Customer Service Literature..........91 Stolen Power Package ..........

  • Page 98: Owner Service Assistance

    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.

  • Page 99: Contact Information For Mercury Marine Customer Service

    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: •...

  • Page 100: Other Languages

    Section 7 - Customer Assistance Information 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.
  • Page 101 Section 8 - Checklists Section 8 - Checklists Table of Contents Predelivery Inspection (PDI)..........94 Customer Delivery Inspection (CDI)........95 90-8M0113857 DECEMBER 2015 Page 93...

  • Page 102: Predelivery Inspection (Pdi)

    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...

  • Page 103: Customer Delivery Inspection (Cdi)

    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) ⃞...
  • Page 104 Section 8 - Checklists N/A Completed Item ⃞ Complete and submit warranty registration—provide the customer with a copy Page 96 90-8M0113857 DECEMBER 2015...

  • Page 105: Section 9 - Maintenance Log

    Section 9 - Maintenance Log Section 9 - Maintenance Log Table of Contents Scheduled Maintenance Log..........98 Vessel Maintenance Notes........... 99 90-8M0113857 DECEMBER 2015 Page 97...

  • Page 106: Scheduled Maintenance Log

    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...

  • Page 107: Vessel Maintenance Notes

    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 90-8M0113857 DECEMBER 2015 Page 99...
  • Page 109 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0113857 NOVEMBER 2015 Printed in U.S.A.

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