Mercury 565 Manual
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Mercury 565 Manual

Bravo sterndrive
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  • Page 3 Declaration of Conformity for Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as Amended by 2003/44/EC Manufacturer: Mercury Racing N7480 County Road UU Fond du Lac, WI 54937-9385 Authorized Representative: Brunswick Marine EMEA, Inc. Parc Industriel de Petit-Rechain...
  • Page 4 Identification of Engines Covered by This Declaration of Conformity Name of engine Unique engine identification number: EC Module H family starting serial number certificate number MCM 565 CE 0M968960 RCD‑H‑2 Rev 4 Other Please specify in Essential normative Technical more detail...
  • Page 5 John Pfeifer President–Mercury Marine, Fond du Lac, WI USA Regulatory contact: Engineering–Regulations Mercury Racing...
  • Page 6 We suggest that this manual remain with the product for ready reference whenever you are on the water. Again, thank you for purchasing one of our Mercury Marine products. We sincerely hope your boating will be pleasant! Warranty Message...
  • Page 7 California to cause cancer, birth defects or other reproductive harm. Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves...

  • Page 9: Table Of Contents

    Mercury Racing Division One‑Year Limited Warranty........2 Products Sold to Government Agencies............. 4 Warranty Against Corrosion (Worldwide)............4 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products ..........................4 California Emission Control Warranty Statement..........6 California Emission Control Warranty Statement..........9 E.P.A.
  • Page 10 Operation Instrumentation....................32 Warning System....................32 Electrical System Overload Protection............. 33 Remote Controls (Console Mounted Zero Effort)..........36 Starting, Shifting, and Stopping................ 37 Operation Chart....................38 Freezing Temperature Operation..............38 Drain Plug and Bilge Pump................39 Launching And Boat Operation Care..............39 Conditions Affecting Operation Weight Distribution....................
  • Page 11 Unusual Sounds....................97 Steering Wheel Turns Hard or Jerky..............97 Seawater Pressure Is Below Specification............98 Seawater Pressure Is Above Specification............98 Owner Service Assistance Service Information................... 99 Contact Information for Mercury Marine Customer Service......100 Maintenance Log Maintenance Log.................... 101...

  • Page 13: Warranty Information

    Outside United States and Canada–Check with your local distributor. 1. You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 14: Mercury Racing Division One-Year Limited Warranty

    COVERAGE Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified predelivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
  • Page 15 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.

  • Page 16: Products Sold To Government Agencies

    Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of this manual, incorporated by reference into this warranty.
  • Page 17 7. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 8. Engine noise does not necessarily indicate a serious engine problem. If...

  • Page 18: California Emission Control Warranty Statement

    Mercury Racing for certification from the California Air Resources Board, for the period of time, and under the conditions identified below.
  • Page 19 The customer must provide Mercury Racing with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Racing and Mercury Racing will then arrange for the inspection and any covered repair.
  • Page 20 Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

  • Page 21: California Emission Control Warranty Statement

    However, warranty coverage based on the hourly period is only permitted for engines that are equipped with hour meters as defined in s 2441(a)(13) or their equivalent. If any emission‑related part on your engine is defective under warranty, the part will be repaired or replaced by Mercury Racing.

  • Page 22: E.p.a. Emission Controls

    INTRODUCTION Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use, whichever occurs first, to the retail purchaser for electrical components of the emission control system, and one year or 150 hours of engine use, whichever occurs first, to the retail purchaser for mechanical components of the emission control system.
  • Page 23 WARRANTY INFORMATION c. Air filter d. Turbocharger systems e. Heat riser valve and assembly 3. Ignition system a. Spark plugs b. Magneto or electronic ignition system c. Spark control system d. Ignition coil or control module e. Ignition wires 4. Lubrication system a.
  • Page 24 WARRANTY INFORMATION NOTE: The EPA emission‑related warranty does not cover components whose failure would not increase an engine's emissions on any regulated pollutant.

  • Page 25: General Information

    GENERAL INFORMATION Before Operating Your Boat Read this manual carefully. Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage. If you have any questions, contact your dealer. This manual as well as safety labels posted on the engine package use safety alerts to draw your attention to special safety instructions that must be followed.

  • Page 26: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our High‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Paddle Wheel and Water Temperature Sensors Paddle wheels cannot be utilized on vessels that are capable of speeds in excess of 50 mph.
  • Page 27 GENERAL INFORMATION Accidental ejections are also likely to result from poor operating practices, such • Sitting on the back of the seat or on the gunwale at planing speeds • Standing at planing speeds • Operating at planing speeds in shallow waters or where there are many obstacles •...

  • Page 28: Trailering The Boat

    GENERAL INFORMATION WARNING Avoid serious injury or death from sudden deceleration forces resulting from accidental or unintended switch activation. The lanyard switch is designed to quickly stop the boat when activated. Be cautious of accidental lanyard switch activation. Trailering the Boat The boat can be trailered with the drive unit in up or down position.

  • Page 29: Exhaust Emissions

    GENERAL INFORMATION Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness,...
  • Page 30 GENERAL INFORMATION Example of desired air flow through the boat: 21622 POOR VENTILATION Under certain running and/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 31: Wave And Wake Jumping

    GENERAL INFORMATION Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.
  • Page 32 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. After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts.

  • Page 33: Operating In Shallow Water

    GENERAL INFORMATION Operating in Shallow Water 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 34: Safe Boating Suggestions

    GENERAL INFORMATION NOTE: Engine block pressure at the gauge can still be low if the line to the gauge is clogged. 7759 Dual water inlet gearcase Strut inlets Low water inlets Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions.
  • Page 35 GENERAL INFORMATION • Transistor radio and drinking water. Know signs of weather change and avoid foul weather and rough‑sea boating. Tell someone where you are going and when you expect to return. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.

  • Page 36: Stolen Power Package

    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 Stolen Power Package information is placed into a file at...

  • Page 37: Specifications

    Sterndrive Serial Number and Gear Ratio: ________________________ Running Rotation: _________________________ Hull Identification Number: _________________________ Boat Model and Length: _________________________ Fuel Requirements Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness.
  • Page 38 (fuel tanks, fuel lines, and fittings). Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the...

  • Page 39: Low Permeation Fuel Hose Requirement

    SPECIFICATIONS Methanol and Ethanol Fuel Blends IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol.

  • Page 40: Crankcase Oil

    SPECIFICATIONS Crankcase Oil OIL RECOMMENDATIONS Preferred Oils NMMA Classification Mercury Racing 4‑Stroke Oil, 25W‑50 Synthetic Blend, ® FC‑W or 25W‑40 Sterndrive/Inboard Oil Use a new oil filter with every oil change IMPORTANT OIL PRACTICES Do Not Use • Straight weight oils •...

  • Page 41: General Engine Specifications

    SPECIFICATIONS General Engine Specifications 421 kW, 565 HP Crankshaft horsepower Displacement 8.7 L (533 cid) Cylinder arrangement Bore 113 mm (4.466 in.) Stroke 108 mm (4.25 in.) Compression ratio 8.6:1 Alternator 95 amp/1238 watt Battery requirements Group 31M, 1150 CCA (minimum) Electrical system 12‑volt negative (–) ground...

  • Page 42: Engine Operating Limitations

    SPECIFICATIONS Engine Operating Limitations Maximum wide‑open throttle (WOT) RPM 5000–5400 RPM 5500 RPM Rev limit Idle RPM in gear 700 RPM Idle RPM out of gear 800 RPM 170 L/hr (45 gals/hr) at 5200 Maximum fuel system flow rate Fuel pressure at idle 307 kPa (44.5 psi) Fuel pressure at wide‑open throttle 275 kPa (39.8 psi)

  • Page 43: After Break-In Period

    Frequently check engine oil level. Add oil if needed. It is normal for oil consumption to be high during break‑in period. After Break‑In Period To help extend the life of your power package, Mercury Marine recommends the following: After 5 hr. Break‑in •...

  • Page 44: Operation

    59 seconds off. • To stop the warning horn, turn off the engine. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem as soon as possible.

  • Page 45: Electrical System Overload Protection

    • If the beeping does not reoccur, the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault. If the propulsion control module (PCM) detects a fault signal from an engine sensor, it records a fault code.
  • Page 46 OPERATION 1. The power trim system is protected from overload by a 110‑amp fuse and a 20‑amp in‑line fuse on the power trim pump. 10121 20‑amp fuse 110‑amp fuse...
  • Page 47 OPERATION 2. Bravo Drive: The MerCathode system has a 20‑amp in‑line fuse in the wire, which connects to the positive (+) terminal on the controller. If the fuse is open, the MerCathode system will not operate and a loss of corrosion protection will result.

  • Page 48: Remote Controls (Console Mounted Zero Effort)

    OPERATION • 25‑amp fuel pump circuit breaker 49704 Odd cylinders fuel and ignition Main power relays and diagnostics Even cylinders fuel and ignition 110‑amp fuse 50‑amp main power circuit breaker 25‑amp fuel pump circuit breaker Remote Controls (Console Mounted Zero Effort) 1.

  • Page 49: Starting, Shifting, And Stopping

    OPERATION Starting, Shifting, and Stopping WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. NEW ENGINES OR ENGINES COMING OUT OF STORAGE Refer to Recommissioning the Power Package.

  • Page 50: Operation Chart

    The seawater section of the engine must be drained after use to prevent freezing. Damage caused by freezing is not covered by Mercury Racing's Limited Warranty.

  • Page 51: Drain Plug And Bilge Pump

    It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package. Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. Launching And Boat Operation Care NOTICE Some boating maneuvers can introduce water into the engine through the exhaust system, causing severe engine damage.

  • Page 52: Conditions Affecting Operation

    CONDITIONS AFFECTING OPERATION Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) may: • Increase speed and engine RPM. • Cause the boat to porpoise. • Cause the bow to bounce in choppy water. •...

  • Page 53: Propeller Selection

    Specified engine wide‑open throttle (WOT) and operating RPM range are listed in Specifications. IMPORTANT: All Mercury Racing engines have an RPM rev‑limiter that is set to an upper (or limited) RPM. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM.
  • Page 54 CONDITIONS AFFECTING OPERATION EXAMPLE: An engine running at an elevation of 2,438 m (8,000 ft) will have over a 30% power loss while engine power on a hot and humid day can be reduced by as much as 14%. These losses apply to both normally aspirated and supercharged engines.

  • Page 55: Maintenance

    • Perform all safety checks. • Return the unit to an authorized Mercury Marine dealer for a periodic checkup. Proper maintenance and care of your power package will ensure optimum performance and dependability, and will keep your overall operating expenses at a minimum.

  • Page 56: Do-It-Yourself Maintenance Suggestions

    It is difficult for them to diagnose a problem over the telephone. • Your authorized Mercury Marine dealer is there to service your power package. They have qualified factory‑trained mechanics. Mercury Marine recommends that you have the dealer do periodic maintenance checks on your power package.

  • Page 57: Servicing High-Horsepower Engines

    Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastrophic engine failure and increased owner expense. Engine Maintenance Charts NOTE: Only perform maintenance which applies to your particular power package.
  • Page 58 MAINTENANCE Interval Task Perform all 25‑hour maintenance items. Serpentine and drive belts (all) ‑ Inspect condition and check tension. Cooling system hoses and clamps ‑ Inspect for damage and deterioration. Check clamps for tightness. Electrical system ‑ Check for loose or damaged wiring.

  • Page 59: Bravo Drive Maintenance Charts

    MAINTENANCE Interval Task Power package exterior surfaces ‑ Clean and paint. Check engine cylinder compression. Oil coolers for the engine and power steering ‑ Clean seawater section. Flame arrestor and crankcase Every 100 hours of operation or once a ventilation hose ‑ Inspect, clean, year, whichever occurs first.
  • Page 60 MAINTENANCE Interval Task Gear housing water pickups ‑ Check for marine growth or debris. Every 25 hours of operation or once Anodes ‑ Inspect for erosion. every 30 days, whichever occurs first. Sterndrive unit oil ‑ Check level. Trim pump ‑ Check oil level. Saltwater use: Every 50 hours of operation or 60 days, whichever occurs Propeller shaft ‑...

  • Page 61: Checking Fluid Levels

    MAINTENANCE Interval Task Power package exterior surfaces ‑ Clean and paint. Steering head and remote control ‑ Inspect and lubricate. Drive unit bellows and clamps ‑ Inspect. Every 100 hours of operation or once a Propeller shaft bearing ‑ Inspect by year, whichever occurs first.
  • Page 62 Part No. 25W50 Synthetic Blend 4-Stroke Engine crankcase 8M0078013 Racing Engine Oil POWER STEERING PUMP Stop the engine and position the drive unit straight back. IMPORTANT: If fluid is not visible in the reservoir, contact your authorized Mercury MerCruiser dealer.
  • Page 63 MAINTENANCE 1. Remove the fill cap/dipstick and observe the level. The oil level must be at the lower mark when the engine is cold and at the upper mark when the engine is warm. Cap/dipstick Power steering pump reservoir 26191 Tube Ref Description Where Used...
  • Page 64 MAINTENANCE 2. The oil must come up to the fill hole. If the oil level is low, contact your authorized Mercury MerCruiser dealer for appropriate service. Do not operate engine if this oil level is low. 49708 Tube Ref Description Where Used Part No.
  • Page 65 1. Check the gear lube monitor oil level; keep the oil level at or near the "FULL" line. 2. If there is water at bottom of the monitor and/or if the oil appears a milky tan, contact your authorized Mercury MerCruiser dealer immediately; both conditions indicate a water leak somewhere in the drive unit.
  • Page 66 IMPORTANT: If more than 59 ml (2 fl oz) of gear lube is required to fill the monitor, a seal may be leaking. Damage to the drive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer for service.

  • Page 67: Changing Fluids

    MAINTENANCE Tube Ref Description Where Used Part No. Power Trim and Power trim pump reservoir 92-858074K01 Steering Fluid 3. Add power trim and steering fluid, if required, to bring the level to the bottom of the filler neck. 4. Reinstall the fill cap. NOTE: The fill cap is vented;...
  • Page 68 MAINTENANCE NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum. Let the oil drain back into the system for 15 minutes prior to complete removal of the filter. Crankcase oil filter 7984 6.
  • Page 69 MAINTENANCE NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
  • Page 70 Racing Engine Oil DRIVE UNIT OIL (BRAVO ONE XR MODELS) Mercury Racing Gear Lube is now available for use in your drive unit. This oil will increase the service life of your drive unit when used in place of other oils.
  • Page 71 Oil vent screw 3. Adjust the drive unit so the propeller shaft is level. 4. Fill the drive unit through the oil fill/drain hole with SAE 85W90 Mercury Racing Gear Oil until an air‑free stream of lubricant flows from the oil vent hole.
  • Page 72 8. Continue adding gear lube until the oil level is at the top line marked "OPERATING RANGE" on the bottle. 9. Lubricate the O‑ring on the neck with SAE 85W90 Mercury Racing Gear Oil to ensure ease of installation and removal of the cap.

  • Page 73: Lubrication

    IMPORTANT: The sterndrive must be removed in order to lubricate the U‑joints. Contact your authorized Mercury MerCruiser dealer for this service. NOTE: The engine coupling and shaft splines are greased with engine coupler...
  • Page 74 MAINTENANCE Lubricate the gimbal bearing with 2‑4‑C with PTFE lubricant. Gimbal bearing grease fitting mc77068-1 Tube Ref Description Where Used Part No. 2-4-C with PTFE Gimbal bearing 92-802859A 1 ENGINE COUPLER Lubricate the engine coupler and shaft splines with Engine Coupler Spline Grease.

  • Page 75: Propellers

    MAINTENANCE DRIVESHAFT EXTENSION MODELS Lubricate driveshaft grease fittings at the transom end with 2‑4‑C with PTFE lubricant. 8015 8016 Tube Ref Description Where Used Part No. 2-4-C with PTFE Driveshaft grease fittings 92-802859A 1 Propellers BRAVO 1 XR MODEL PROPELLERS WARNING Rotating propellers can cause serious injury or death.
  • Page 76 MAINTENANCE 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. Installation 1. Apply the following lubricant to the entire exposed surface of the propeller shaft: Tube Ref Description...
  • Page 77 MAINTENANCE Removal 1. Place a wood block between the propeller blade and the anti‑ventilation plate to prevent rotation. Wood block Propeller nut 7448 2. Remove the propeller nut.

  • Page 78: Flushing The Power Package

    Propeller assembly Washer Belleville washer Washer Locknut NOTE: Some damaged propellers can be repaired. See your authorized Mercury Marine dealer. Flushing the Power Package The following procedure explains flushing the power package through the sterndrive water pickups. FLUSHING ATTACHMENTS Flushing Device 91‑44357Q 2...
  • Page 79 MAINTENANCE Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases. 9194 Flushing Kit 91‑849996T 1 Use for flushing gearcases with low water inlets. 9195 Flushing Attachment 91‑843122A01 Attaches to the water intakes;...
  • Page 80 MAINTENANCE STERNDRIVE WATER PICKUPS There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water, and side pickups. Dual water pickups require the flushing attachment (91‑44357Q 2) and the flush seal kit (91‑881150K 1). The High‑Performance low water pickup drive requires the flushing attachment (91‑849996T 1) while the SportMaster low water pickup...
  • Page 81 MAINTENANCE NOTE: Flushing is needed only for salty, brackish, mineral‑laden or polluted water applications. Flushing is recommended after each outing. NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine.

  • Page 82: Seawater Pump Impeller Inspection

    MAINTENANCE 10. Shut off the water and remove the flushing attachment. Seawater Pump Impeller Inspection Service should be performed by an authorized Mercury MerCruiser dealer. Inspect seawater pump impeller if insufficient seawater flow occurs (if operating temperature exceeds normal range).

  • Page 83: Changing Positive Crankcase Ventilation Valve

    • Pull valve out of intake manifold and remove valve from hose. • Install new PCV valve into hose, and install into intake manifold. • Ensure that the valve is tightly seated in manifold. Use only Mercury MerCruiser replacement parts.

  • Page 84: Serpentine Drive Belt

    MAINTENANCE Serpentine Drive Belt DRIVE BELT ROUTING AND TENSION WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. IMPORTANT: Drive belt must be routed as shown or damage may result. 1.
  • Page 85 MAINTENANCE 6. Run the engine for a short period of time and recheck tension. 6163 Crankshaft pulley Water circulating pump pulley Alternator pulley Power steering pump pulley (Non‑power steering models have an idler pulley) Idler pump Seawater pump pulley Belt tension gauge Description New Belt Used Belt...

  • Page 86: Changing Fuel Filters

    MAINTENANCE • Cracks or fraying • Glazed surfaces 6164 Fraying Transverse cracks Longitudinal cracks Changing Fuel Filters WATER SEPARATING FUEL FILTER WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.
  • Page 87 Starting in the Cold Weather or Extended Storage section of this manual). 5. Check the filter connection for fuel leaks. If leaks exist, recheck the filter installation. 6. If leaks continue, stop the engine immediately and contact your authorized Mercury MerCruiser dealer.

  • Page 88: Corrosion And Corrosion Protection

    MAINTENANCE FUEL FILTER ELEMENT 1. Remove the fuel line from the filter head. Fuel filter head Fuel line Fuel filter element 2. Turn the filter head and remove. 3. Remove the internal filter element. 4. Insert the new filter element. 5.
  • Page 89 The MerCathode system should be tested to ensure adequate output. NOTE: This test should be made where the boat is moored, using a reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer to arrange for this test. MerCathode...
  • Page 90 MAINTENANCE 1. Replace the anodes when they have eroded to 50% of their original size. 54401 Splash plate anode Trim actuator anode Steering actuator anode Upper gear housing anode...
  • Page 91 MAINTENANCE 2. Gear housing with integrated splash plate anode ‑ is located in the splash plate, just above the propellers. 6205 XR Bravo One XR Bravo Three Gear housing anode 3. SportMaster splash plate anode ‑ is located on the splash plate that is attached to the gear housing just above the propeller.
  • Page 92 MAINTENANCE 4. Anodic block kit (optional) ‑ is mounted to the boat transom. Acts as a sacrificial anode. Replace as required. Anodic block 8033 5. Trim cylinder anodes ‑ are mounted on each trim cylinder. To replace the trim cylinder anodes: a.
  • Page 93 MAINTENANCE d. Reinstall the propeller. See Propeller Installation for proper torque. Bearing carrier anode 5644 PAINTING THE BOAT HULL OR TRANSOM 1. If antifouling protection is required for boat hull or boat transom, copper or tin base paints can be used unless otherwise prohibited by law.
  • Page 94 MAINTENANCE 2. If using copper or tin based antifouling paints, avoid any electrical interconnection between the Mercury Marine product, anodic blocks, and the paint by allowing a minimum of 40 mm (1.5 in.) unpainted area on the transom of the boat around these items.

  • Page 95: Battery

    MAINTENANCE ADDITIONAL CORROSION PREVENTION TIPS 1. Spray the power package components on the inside of the boat every two to three weeks with Corrosion Guard to protect the finish from dulling and corrosion. External power package components may also be sprayed. Tube Ref Description Where Used...

  • Page 96: Inspection And Maintenance

    4. Repair nicks and corrosion damage on the power package's exterior finish. Attention Required After Submersion • Before recovery, contact an authorized Mercury Marine dealer. • After recovery, immediate service by an authorized Mercury Marine dealer is required to prevent serious damage to power package.

  • Page 97: Cold Weather Or Extended Storage

    COLD WEATHER OR EXTENDED STORAGE Power Package Lay‑up IMPORTANT: This service should be performed by an authorized Mercury MerCruiser dealer. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

  • Page 98: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE IMPORTANT: Do not run the engine's fuel system dry of this fogging mixture in the 23 liter (6 U.S. gal) remote outboard fuel tank. NOTE: Refer to Fuel Requirements for additional information. 9. Close fuel shut off valve, if equipped. 10.
  • Page 99 COLD WEATHER OR EXTENDED STORAGE • Bottom of power steering cooler (plastic wingnut plug) 8039 Exhaust manifold balance rail wingnut Fuel cooler wingnut Power steering cooler wingnut 2. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained.
  • Page 100 COLD WEATHER OR EXTENDED STORAGE 4. After draining seawater cooling system, install drain plugs (Perfect Seal is not required on wingnut type plugs), reconnect hoses and tighten all hose clamps securely. 5. Make sure the following passages are open and unobstructed: Speedometer pitot tube Trim tab cavity vent hole Trim tab cavity drain passage...

  • Page 101: Battery Winter Storage

    COLD WEATHER OR EXTENDED STORAGE a. Remove seawater inlet hose leading to the seawater pump and place the hose into a container of ethylene glycol antifreeze to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage.
  • Page 102 COLD WEATHER OR EXTENDED STORAGE 2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable clamp securely when connecting. 3. Coat the battery terminal connections with an anti‑corrosion agent. 4. Perform all checks in Operation Chart in the Before Starting column. 5.
  • Page 103 COLD WEATHER OR EXTENDED STORAGE PRIMING THE FUEL SYSTEM PRIOR TO STARTING WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.
  • Page 104 COLD WEATHER OR EXTENDED STORAGE WARNING If the primer bulb is hard when removing the remote fuel tank, pressurized fuel will be sprayed in the engine compartment creating an explosive condition that could result in serious injury or death. When removing the remote fuel tank line from the engine connection, ensure that the primer bulb is soft.

  • Page 105: Troubleshooting

    TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch turned "OFF." Turn switch "ON." Gearshift not in neutral Position control lever to neutral. position. Open circuit breaker or blown Check and reset circuit breaker or replace fuse. fuse. Loose or dirty electrical Check all electrical connections and wires connections or damaged (especially battery cables).

  • Page 106: Engine Hard To Start, Runs Rough, Misses, And/Or Backfires

    TROUBLESHOOTING Possible Cause Remedy Test and replace if faulty. Do not Faulty fuel pressure regulator attempt to start the engine if the fuel diaphragm. pressure regulator diaphragm is ruptured. Engine Hard to Start, Runs Rough, Misses, and/or Backfires Possible Cause Remedy Faulty ignition system component.

  • Page 107: Insufficient Engine Temperature

    TROUBLESHOOTING Insufficient Engine Temperature Possible Cause Remedy Faulty water thermostat. Replace water thermostat. Faulty gauge or sender. Test with shop gauge; test sender. Faulty oil thermostat. Replace. High Engine Temperature Possible Cause Remedy Seacock closed. Open. Serpentine belt loose or in poor condition. Replace or adjust belt.

  • Page 108: Low Engine Oil Pressure

    TROUBLESHOOTING Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in system. Check and add oil. Check and bring oil to required level. Check Excessive oil in system (causing for cause of excessive oil (improper filling, it to become aerated). defective fuel pump, etc.).

  • Page 109: Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)

    Insufficient lubrication on shift and Lubricate. throttle linkage fasteners. Check all linkages. If any are loose Loose or missing shift and throttle or missing, see authorized Mercury linkage fasteners. Marine dealer immediately. Shift or throttle cable kinked. Replace cable. Friction adjustment excessive.

  • Page 110: Seawater Pressure Is Below Specification

    TROUBLESHOOTING Seawater Pressure Is Below Specification Possible Cause Remedy Check if seacock is completely open. Check supply hoses for obstruction. Insufficient water supply. Check for external water pick‑up obstruction. Check for sea strainer obstruction. Check condition of sea pump. Seawater Pressure Is Above Specification Possible Cause Remedy High boat speed causing high ram...

  • Page 111: Owner Service Assistance

    OWNER SERVICE ASSISTANCE Service Information LOCAL REPAIR SERVICE If you need service for your Mercury Marine product, take it to your authorized dealer. Only authorized dealers have factory‑trained mechanics, special tools, equipment, and genuine Quicksilver parts and accessories. NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser sterndrives, inboards, and outboards.

  • Page 112: Contact Information For Mercury Marine Customer Service

    The name and address of your dealership • Nature of the problem Contact Information for Mercury Marine Customer Service For assistance, call, fax, or write to the geographic office in your area. Please include your daytime telephone number with mail and fax correspondence.

  • Page 113: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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