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GASOLINE ENGINES SKI MODELS
After Completing Installation, These Instructions Should Be Placed With The Product For The Own-
er's Future Use.
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
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90-860178001 APRIL 2000
NOTICE to INSTALLER
NOTICE to COMMISSIONING DEALER
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Printed in U.S.A. - 2000, Mercury Marine
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The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser,
Mercury,
Mercury
Quicksilver, and Ride-Guide.
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INDEX
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Table of Contents
Related Manuals for Mercury SKI
Summary of Contents for Mercury SKI
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Page 1: Table Of Contents
Hot Water Heater Installation Information Predelivery Inspection ....Printed in U.S.A. - 2000, Mercury Marine 90-860178001 APRIL 2000 Page 1 of 48... - Page 2 INDEX GASOLINE ENGINES SKI MODELS THIS PAGE IS INTENTIONALLY BLANK Page 2 of 48...
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Page 3: General Information
It is assumed that these personnel are familiar with marine product application and the installation procedures of these products, or like or similar products manufactured and mar- keted by Mercury Marine. Furthermore, it is assumed that they are familiar with, if not trained in, the recommended installation procedures of these products. -
Page 4: Quicksilver Products
INDEX GASOLINE ENGINES SKI MODELS Quicksilver Products Quicksilver gauges, remote controls, steering systems, propeller shaft couplers, etc. are available for this product. Refer to “Quicksilver Accessories Guide” for complete listing. This “Guide” is available from: Attn: Parts Department Mercury Marine W6250 W. -
Page 5: Transmission
INDEX GASOLINE ENGINES SKI MODELS Transmission IDENTIFICATION Velvet Drive Transmissions On Velvet Drive In-Line Transmissions the gear ratio (in forward gear) is marked on trans- mission identification plate. Transmission output shaft rotation and propeller rotation re- quired (in forward gear) is indicated on a decal on transmission case. Transmission rotation is described when viewed from the rear of transmission. -
Page 6: Installation Requirements
INDEX GASOLINE ENGINES SKI MODELS ENGINE/PROPELLER SHAFT INSTALLATION ANGLE The transmission and engine should be mounted so that the angle relative to horizontal is as shown in the installation drawings. Refer to individual installation drawings for each spe- cific engine and transmission. - Page 7 INDEX GASOLINE ENGINES SKI MODELS Over the last several years, engine compartments have been designed to be quieter. The most common material used to deaden the engine sound is some type of insulation material. Normally, the quieter the engine compartment is, the more insulation material used, which results in less air space inside.
- Page 8 INDEX GASOLINE ENGINES SKI MODELS Compartment Temperature - Specifications Air temperatures inside of engine compartments have been measured in excess of 200° F (82° C). The long term effect to fuel system components running at these excessive temper- atures is not known at this time.
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Page 9: Exhaust System
INDEX GASOLINE ENGINES SKI MODELS Exhaust System IMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to properly locate the engine and install the exhaust system. Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine. -
Page 10: Fuel Delivery System
NOTE: On Ski Boat Applications: If during testing for a particular application, you experi- ence fuel starvation in sharp high speed turns, baffles or a fuel sump may be needed in the tank to help correct this condition. - Page 11 INDEX GASOLINE ENGINES SKI MODELS The following, but not limited to the following, additional fuel connection related points, ap- plying to all engines unless otherwise stated, must be considered [Refer to boating stan- dards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: 1.
- Page 12 INDEX GASOLINE ENGINES SKI MODELS SPECIAL INFORMATION FOR ALL GASOLINE ENGINES WARNING Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and/or cause a fuel leak. IMPORTANT: The following information is provided to ensure proper installation of brass fittings or plugs installed into fuel pump or fuel filter base: •...
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Page 13: Battery
INDEX GASOLINE ENGINES SKI MODELS Battery IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing battery. Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. -
Page 14: Efi Electrical System Precautions
INDEX GASOLINE ENGINES SKI MODELS EFI Electrical System Precautions NOTE: All references to EFI models apply to all EFI and MPI engines. CAUTION Avoid damage to the EFI electrical system and components. Refer to the following precautions when working on or around the EFI electrical harness or when adding other electrical accessories: •... -
Page 15: Propeller Selection
INDEX GASOLINE ENGINES SKI MODELS Propeller Selection GENERAL INFORMATION IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open-throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s). -
Page 16: Throttle/Shift Remote Control And Cables
INDEX GASOLINE ENGINES SKI MODELS SPECIAL INFORMATION FOR GASOLINE ENGINES IMPORTANT: When selecting a propeller consider this additional information, if ap- plicable: The engines listed in the following chart are equipped with an rpm rev-limiter that is set to an upper (or limited) rpm amount. This limit is slightly above the normal operat- ing range of the engine and is designed to help prevent damage from excessive en- gine rpm. -
Page 17: Seawater Connections - General Information
INDEX GASOLINE ENGINES SKI MODELS Seawater Connections - General Information SEAWATER PICKUP AND HOSE IMPORTANT: DO NOT install water pickup directly in line with propeller as pickup may create turbulence and allow air to flow into the “propeller slipstream.” This will cause propeller ventilation and will adversely affect boat performance. -
Page 18: Hot Water Heater Installation Information
INDEX GASOLINE ENGINES SKI MODELS Hot Water Heater Installation Information IMPORTANT: When connecting a cabin heater or hot water heater, certain require- ments must be met, including, but not limited to the following: • Supply hose (from engine to heater) and return hose (from heater to engine) MUST NOT EXCEED 5/8 in. -
Page 19: Engine Installation
INDEX GASOLINE ENGINES SKI MODELS RETURN HOSE CONNECTION 75480 Location for Hot Water Return (Install Bayonet Fitting Here) Engine Installation NOTICE to INSTALLER Before Starting Installation, Read “General Information” and “Installation Require- ments” completely. Battery Cable Connection IMPORTANT: Engine electrical system is negative (–) ground. -
Page 20: Engine Mount Pre-Adjustment
INDEX GASOLINE ENGINES SKI MODELS 3. Coat negative and positive battery connections with Liquid Neoprene. After Liquid Neo- prene has dried, slide rubber boot over positive battery cable connection. 74171 Negative (–) Battery Cable Positive (+) Battery Cable 90 Amp System Fuse DO NOT Remove (EFI and MPI Models) Engine Mount Pre-Adjustment 1. - Page 21 INDEX GASOLINE ENGINES SKI MODELS 4. Loosen clamping screws and nuts on all 4 engine mount brackets to ensure the follow- ing: • Large diameter of mount trunnion extended as shown. • Mount base slotted mounting hole forward, if so designed.
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Page 22: Initial Engine Alignment
INDEX GASOLINE ENGINES SKI MODELS Initial Engine Alignment 1. Lift engine into boat and position on engine bed so that transmission output flange and propeller shaft coupler are visibly aligned (no gap can be seen between coupling faces when butted together). Adjust engine bed height, if necessary, to obtain proper align- ment. - Page 23 INDEX GASOLINE ENGINES SKI MODELS 4. If coupling centerlines are not aligned or if coupling faces are more than .003 in. out of parallel, adjust engine mounts. a. TO ADJUST ENGINE UP OR DOWN: Loosen locking nut (a) on mounts requiring adjustment and turn adjusting nuts in desired direction to raise or lower.
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Page 24: Seawater Pickup Pump Connection
INDEX GASOLINE ENGINES SKI MODELS 8. Bend one of the tabs on tab washer down onto flat of adjusting nut. 70646 Clamping Screws and Nuts Locknut Tab On Tab Washer 1-3/4 in. (45 mm) 9. Connect propeller shaft coupler to transmission output flange. Secure coupling together with bolts, lockwashers and nuts. -
Page 25: Throttle/Shift Cable
INDEX GASOLINE ENGINES SKI MODELS Throttle/Shift Cable Lubricate cable ends and barrels and then attach to engine and transmission. IMPORTANT: When installing throttle cable, be sure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to throttle cable. - Page 26 INDEX GASOLINE ENGINES SKI MODELS ATTACHING/ADJUSTING THROTTLE CABLE - EFI MODELS 1. Place remote control handle in neutral idle position. 2. Remove flame arrestor. 3. Attach cable to the lowest hole on the throttle body unit following cable manufacturer’s instructions.
- Page 27 INDEX GASOLINE ENGINES SKI MODELS ATTACHING/ADJUSTING SHIFT CABLE - ALL MODELS IMPORTANT: Velvet Drive Transmission Warranty is jeopardized if the shift lever pop- pet ball or spring is permanently removed, if the shift lever is repositioned or changed in any manner or if remote control and cable do not position shift lever correctly.
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Page 28: Fuel Supply Connection
INDEX GASOLINE ENGINES SKI MODELS ROUTING OF SHIFT CABLES - BLACK SCORPION 1. Shift Cable - Route shift cable from the starboard to the port side of engine and then between intake manifold and elbow. Position cable so it will not interfere with flame arrestor. - Page 29 INDEX GASOLINE ENGINES SKI MODELS 2. 5.7L Model if remote mounting water separating fuel filter: Install inverted flare swivel (provided) into base of fuel pump. Finger tighten and then grip hex fitting on end of fuel pump with wrench while tightening swivel an additional 1-3/4 to 2-1/4 turns with a wrench.
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Page 30: Audio Warning System
INDEX GASOLINE ENGINES SKI MODELS Audio Warning System 1. Install audio warning system horn as follows: a. Select a location for audio warning horn which meets all of the following: • horn can be easily heard yet is out of sight. -
Page 31: Electrical Connections
INDEX GASOLINE ENGINES SKI MODELS Electrical Connections 1. Connect instrumentation wiring harness to engine and secure with clamp. 75532 Instrumentation Wiring Harness Connection Exhaust System Hoses/Tubes Connection 1. Exhaust hoses/tubes must be connected to exhaust elbows so that they do not restrict the flow of discharge water from the elbow. -
Page 32: Predelivery Preparation
INDEX GASOLINE ENGINES SKI MODELS Predelivery Preparation NOTICE to INSTALLER Before starting Predelivery, read “General Information” and “Installation Require- ments” completely. Battery Connection IMPORTANT: Engine electrical system is negative (–) ground. 1. Connect engine positive (+) battery cable (usually red) to positive (+) battery terminal. -
Page 33: Cold Weather Or Extended Storage Draining Instructions
INDEX GASOLINE ENGINES SKI MODELS IMPORTANT: Be sure to disconnect the jumper wire from the ignition system test lead before attempting to resume normal operations. If the jumper wire is left in place, the ignition module will operate in the “Base Timing Mode.” This means that the addition- al timing advance features would not be functioning. - Page 34 INDEX GASOLINE ENGINES SKI MODELS CARBURETED MODELS 1. Ensure engine is as level as possible to ensure complete draining of cooling system. 2. Remove drain plugs from following locations: a. Port Side - cylinder block. CAUTION Avoid product damage. Do not disturb the Y-fitting when removing the drain plug.
- Page 35 INDEX GASOLINE ENGINES SKI MODELS 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Crank engine over slightly to purge any water trapped in seawater pickup pump.
- Page 36 INDEX GASOLINE ENGINES SKI MODELS c. From water inlet hose (bottom) from seawater pickup pump. 75533 Seawater Inlet Hose 5. After cooling system has been drained completely, install drain plugs, reconnect hoses and tighten all hose clamps securely. IMPORTANT: MerCruiser recommends that propylene glycol (a nontoxic and envi- ronmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage.
- Page 37 INDEX GASOLINE ENGINES SKI MODELS EFI AND MPI MODELS 1. Ensure engine is as level as possible to ensure complete draining of cooling system. 2. Remove drain plugs from the following locations: a. Port Side - cylinder block. CAUTION Avoid product damage. Do not disturb the Y-fitting when removing the drain plug.
- Page 38 INDEX GASOLINE ENGINES SKI MODELS 3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Crank engine over slightly to purge any water trapped in seawater pickup pump.
- Page 39 INDEX GASOLINE ENGINES SKI MODELS c. From engine circulating pump or remove drain plug, if equipped. 76038 Engine Circulating Pump Hose Drain Plug, if equipped 5. After cooling system has been drained completely, install drain plugs, reconnect hoses and tighten all hose clamps securely.
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Page 41: Quicksilver Instrumentation Wiring Diagrams
INDEX GASOLINE ENGINES SKI MODELS Quicksilver Instrumentation Wiring Diagrams MIE Gasoline Engine - Typical Single Station Installation Refer to gauge manufacturer’s instructions for specific connections. NOTE 1. Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection. -
Page 42: Mie Gasoline Engine Wiring Diagrams
INDEX GASOLINE ENGINES SKI MODELS MIE Gasoline Engine Wiring Diagrams MIE 5.7L Inboard Engines BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red... - Page 43 INDEX GASOLINE ENGINES SKI MODELS A - Ignition Components Distributor Timing Lead Knock Sensor Ignition Coil B - Starting, Charging and Choke Components Alternator Electric Choke Ground Plug Starter Motor Oil Pressure Switch Fuel Pump Circuit Breaker Neutral Safety Switch...
- Page 44 INDEX GASOLINE ENGINES SKI MODELS MIE 350 Mag MPI, Black Scorpion and MX 6.2L MPI Engines- Starting and Charging System Harness NOTE: Taped back BROWN-WHITE wire may be used for an Accessory. LOAD MUST NOT EXCEED 5 AMPS. BLK = BLACK...
- Page 45 INDEX GASOLINE ENGINES SKI MODELS A - Audio Warning Components Transmission Temperature Switch B - Instrumentation Components Oil Pressure Sender Wire Not Used C - Charging and Starting Components Alternator Ground Stud Starter 90 Amp Fuse (DO NOT REMOVE) Circuit Breaker...
- Page 46 6 - Manifold Absolute Pressure (MAP) Sensor 17- Oil Pressure (Audio Warning System) 7 - Idle Air Control (IAC) 18- Gear Lube Bottle (Not used on Ski models) 8 - Throttle Position (TP) Sensor 19- Fuel Pressure Switch 9 - Engine Coolant Temperature (ECT) Sensor...
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Page 47: Mie Water Flow Diagram
INDEX GASOLINE ENGINES SKI MODELS MIE Water Flow Diagram Gasoline Engines with Seawater (Raw-Water) Cooling System ALL V8 350 AND 377 CID ENGINES NOTE: Certain components in the following diagram may look different than on your particu- lar power package, but the water flow paths remain similar on all engines. -
Page 48: Predelivery Inspection
INDEX GASOLINE ENGINES SKI MODELS Predelivery Inspection Check/ Check/ Applicable Adjust Applicable Adjust CHECK BEFORE RUNNING ON THE WATER TEST Drain plug in and petcocks Engine alignment (Inboards only) closed Seawater inlet valve open Starter neutral safety switch operation Engine mounts tight...