MerCruiser 350 Magnum EFI GEN+ Alfa One Operation And Maintenance Manual
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MerCruiser 350 Magnum EFI GEN+ Alfa One Operation And Maintenance Manual

5.7l/5.7lx efi
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OPERATION &
MAINTENANCE MANUAL
5.7L EFI
5.7LX EFI
350 Magnum EFI Gen+
Alpha One
1995, Brunswick Corporation
OPERATION &
MAINTENANCE MANUAL
5.7L EFI
5.7LX EFI
350 Magnum EFI Gen+
Alpha One
1995, Brunswick Corporation
90-806582963 196
90-806582963 196

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  • Page 1 OPERATION & MAINTENANCE MANUAL 5.7L EFI 5.7LX EFI 350 Magnum EFI Gen+ Alpha One 1995, Brunswick Corporation 90-806582963 196 OPERATION & MAINTENANCE MANUAL 5.7L EFI 5.7LX EFI 350 Magnum EFI Gen+ Alpha One 1995, Brunswick Corporation 90-806582963 196...
  • Page 2 MerCruiser power package. When contacting your Authorized MerCruiser Dealer about service, always specify model and serial numbers. 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 CA365 71352 74031 71718 ABC12345Z123 71345 48-12345 74849...

  • Page 4: Table Of Contents

    CA353 Table Of Contents Page Welcome ..........Read This Manual Thoroughly .
  • Page 5 ........Mercruiser Limited Warranty - Gasoline Engines .

  • Page 6: Welcome

    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 MerCruiser products. We sincerely hope your boating will be pleasant!

  • Page 7: Read This Manual Thoroughly

    CA166 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, WARN- INGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instruc- tions concerning a particular service or operation that may be haz-...

  • Page 8: Lanyard Stop Switch

    CA280 Lanyard Stop Switch 74608 Some boats come equipped with a lanyard stop switch. A lanyard stop switch can also be installed as an accessory. The purpose of this switch is to turn off the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch.
  • Page 9 ADVANTAGES: The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. This would occur if the operator falls or moves within the boat a sufficient distance from the operator’s position.

  • Page 10: Safe Boating Suggestions

    CA281 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. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A.
  • Page 11 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. Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Just shifting the drive unit into neutral is not sufficient.
  • Page 12 Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 25 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front of you. Watch fallen skiers.

  • Page 13: Protecting People In The Water

    CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.

  • Page 14: 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) will: Generally increases speed and engine RPM. At extremes can cause boat to porpoise. Causes bow to bounce in choppy water. Increases danger of following wave splashing into boat when coming off plane.

  • Page 15: Cavitation

    Cavitation Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear hous- ing or propeller.
  • Page 16 IMPORTANT: The engines covered in this manual are equipped with an RPM rev-limiter that is set to an upper (or limited) RPM amount. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from ex- cessive engine RPM.

  • Page 17: How Elevation And Climate Affect Performance

    CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle pow- er of an engine. Since air (containing oxygen) gets thinner as eleva- tion increases, the engine begins to starve for air. Humidity, baromet- ric pressure and temperature do have a noticeable effect on the density of air.

  • Page 18: Important Information

    In general, a dealer’s responsibilities to the customer include prede- livery inspection and preparation such as: Make sure that the boat is properly equipped. Prior to delivery, make certain that the MerCruiser power package and other equipment are in proper operating condition. Make all necessary adjustments for maximum efficiency.

  • Page 19: Freezing Temperature Operation

    Refer to “COLD WEATHER or EX- TENDED STORAGE” for draining instructions. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. CA17 Drive Unit Impact Protection The Power Trim hydraulic system is designed to provide impact pro- tection for drive unit.

  • Page 20: Emissions Information

    Proper engine tuning procedures to ensure these features remain in good operating order. Proper steps to maintain the engine within specifications. Use only MerCruiser replacement parts to ensure compliance with emission regulations. IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this en- gine.

  • Page 21: Launching And Boat Operation Care

    CA20 Launching And Boat Operation Care CAUTION During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat may enter the water rap- idly and at a steep angle. This may force water through the ex- haust system into the cylinders.

  • Page 22: Replacement Service Parts

    These are but a few of the many special modifications that are re- quired in MerCruiser marine engines to provide long life and depend- able performance.

  • Page 23: Do-It-Yourself Maintenance Suggestions

    If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of machinery. Electronic ig- nition and special fuel injection systems provide greater fuel econ- omies, but also are more complex for the untrained mechanic.

  • Page 24: Diagnosing Efi Problems

    CB129 Diagnosing EFI Problems Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on the Electronic Fuel Injection (EFI) System. The Electronic Control Module (ECM) on this engine has the ability to detect some problems with the system when they occur, and store a “Trouble Code”...

  • Page 25: 20-Hour Break-In Period

    SPECIFICATIONS). CA211 After Break-In Period To help extend the life of your MerCruiser power package, the follow- ing recommendations should be considered; Use a propeller that allows the engine to operate at or near the top of the maximum RPM range (See “Specifications” section) when at full throttle with a normal boat load.

  • Page 26: 20-Hour Checkup

    CA239 20-Hour Checkup After first 20 hours of operation, an Authorized MerCruiser Dealer should be contacted for the following maintenance. The boat owner is responsible for any charges. Change crankcase oil and filter. Check all fluid levels. Cooling System - Inspect all hoses for damage and deterioration;...
  • Page 27 CA175 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 28 CA26 70515 70516 70514 70517 70523 70522 70518 70520 70521 70519...

  • Page 29: Operation

    CA197 Operation Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instru- ments and their functions on the boat. Speedometer: Indicates boat speed. Tachometer: Indicates engine RPM. Oil Pressure Gauge: Indicates engine oil pressure. Battery Meter: Indicates battery voltage.
  • Page 30 CB218 70518 70516 71987...

  • Page 31: Audio Warning System

    When the buzzer sounds with the engine running, stop engine im- mediately. Investigate cause and correct it, if possible. If cause can- not be determined, consult your Authorized MerCruiser Dealer. IMPORTANT: Warning buzzer will sound for 2 seconds when ig- nition key is turned to RUN position and engine is not started.
  • Page 32 CB294 72852 71583 71585 70525 70526 70527 70528...

  • Page 33: Electrical System Overload Protection

    CB293 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replac- ing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead.
  • Page 34 CB181...

  • Page 35: Remote Controls (Panel Mounted)

    CB182 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. If boat is equipped with a remote control oth- er than shown, consult your dealer for a description and/or demon- stration of the control.
  • Page 36 CB183...

  • Page 37: Remote Controls (Console Mounted)

    CB184 Remote Controls (Console Mounted) Control Handle(s) - Operation of the the shift and throttle are controlled by the movement of the control handle. “Push” the control handle forward from “Neutral” with a quick firm motion to the first det- ent for “Forward”...
  • Page 38 CB185 71339 70537...

  • Page 39: Remote Controls (Two Lever)

    CB186 Remote Controls (Two Lever) Shift Lever - shifts unit into gear with full lever movement. Move lever forward to shift to FORWARD gear. Move lever backward to shift to REVERSE gear. Lever in full vertical position shifts to NEU- TRAL.
  • Page 40 CA34 3 TO 5 DEGREES 71338...

  • Page 41: Power Trim

    CA284 Power Trim Power Trim allows the operator to adjust the drive angle, while under- way, to provide the ideal boat angle for varying load and water condi- tions. Also, the Power Trim system “Trailering” feature allows the op- erator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 RPM engine speed), shallow water operation.
  • Page 42 CB187 73976 73977...
  • Page 43 CB188 POWER TRIM OPERATION - PANEL MOUNT REMOTE CONTROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed.
  • Page 44 CB190 73979 73978...
  • Page 45 CA285 POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 46 CB192 70540 70540 70540...
  • Page 47 CB193 POWER TRIM OPERATION - THREE BUTTON TRIM PANEL (USED ON MODELS WITH TWO-LEVER CONTROL) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button(s) and allow motor to cool for about one minute.

  • Page 48: Starting, Shifting And Stopping

    CB151 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five min- utes to remove any explosive fumes from engine compartment. If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. IMPORTANT: Observe the following: Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage).
  • Page 49 E Turn ignition key to START Release key when engine starts and allow switch to return to RUN position. F Check oil pressure gauge immediately after engine starts If oil pressure is not within specified range (see SPECIFICATIONS), stop engine immediately and determine cause. G After engine has warmed up, check water temperature gauge to ensure that engine temperature is not abnormally high.

  • Page 50: Operation Chart

    CA41 Operation Chart BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Open engine Observe all Observe all Turn ignition hatch. gauges to gauges to key OFF. monitor check engine condition of condition. engine. If not normal, stop engine. Turn battery Check Turn bat- switch ON, if so...

  • Page 51: Specifications

    FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows: USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum.
  • Page 52 The fuel system components on your MerCruiser engine will with- stand 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 boats fuel system components (fuel tanks,fuel lines, and fittings).

  • Page 53: Crankcase Oil

    CA43 Crankcase Oil To help obtain optimum engine performance and to provide maxi- mum protection, we strongly recommend the use of Quicksilver 4-Cycle Marine Engine Oil. If not available, a good grade, straight weight, detergent automotive oil of correct viscosity, with an API clas- sification of CD or SG, may be used.

  • Page 54: Engine Specifications

    CA370 Engine Specifications 350 Mag 5.7L EFI 5.7LX EFI MODEL EFI Gen+ Propshaft Horsepower (256 (BSO/SAV Rating) Propshaft Kilowatts (BSO/SAV Rating) (191 350 C.I.D. (5.7 L) Displacement Engine Type 4.00 in. (101.6mm) Bore 3.48 in. (88.39 mm) Stroke Compression Ratio 9.3:1 9.4:1 180 psi (1241 kPa)

  • Page 55: Tune-Up Specification

    CA355 Tune-Up Specification 350 Mag 5.7L EFI 5.7LX EFI MODEL EFI Gen+ AC-MR43LTS AC-MR43T Spark Plug Champion Champion RV15YC4 Type RS9YC NGK BR6FS BPR6ESS .045 in. Spark Plug .040 in. (1.1mm) (1mm) Timing @ Idle 8 BTDC Firing Order 1-8-4-3-6-5-7-2 12-Volt Negative (-) Electrical System Ground...

  • Page 56: Capacities

    CA356 Capacities 350 Mag MODEL 5.7L EFI 5.7LX EFI EFI Gen+ Crankcase Oil Approx. 5.5 U.S. Quarts. Capacity (5.2 L) w/New Filter Drive Unit Oil Approximately 39.2 fl. oz. Capacity (1160ml) Drive Unit Oil Approximately 64 fl. oz. Capacity (1892ml) (w/Reservoir) Seawater Cooling 15 U.S.

  • Page 57: Maintenance

    Authorized MerCruiser Dealer. Before attempt- ing maintenance or repair procedures not covered in this manu- al, it is recommended that a MerCruiser Service Manual(s) be purchased and read thoroughly. NOTE: Maintenance points are color coded for ease of identifica- tion.
  • Page 58 Crankcase Oil - Quicksilver 4-Cycle Marine Engine Oil (Refer to SPECIFICATIONS for alternatives and oil recommendations for varying ambient temperatures.) Closed Cooling System Coolant - 50/50 mixture of ethylene glycol antifreeze (must meet GM specification 1825 M) and tap water. Areas where temperatures generally do not go below 32 F (0 C), rust inhibitor and tap water is acceptable.

  • Page 59: Maintenance Chart

    CA200 Maintenance Chart Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR TASK INTERVAL Engine Crankcase Oil - Check level Power Steering Fluid - Check level Stern Drive Unit Oil - Check level Battery - Check level and inspect for damage Weekly...
  • Page 60 CA49 Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR TASK INTERVAL Drive Belts (All) - Every 100 Hours of Operation or Inspect condition and 120 Days, Whichever Occurs First. check tension Propeller Shaft - Saltwater use: Every 50 Hours of Lubricate...
  • Page 61 CA357 Only perform maintenance which applies to your particular power package. Scheduled Maintenance to be Performed by Dealer TASK INTERVAL 20-Hour Checkup (See At First 20 Hours of Operation NOTE 1) Seawater Pickup Pump Whenever Insufficient Seawater Flow -Disassemble and is Suspected.
  • Page 62 CA51 Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL Engine Alignment - Check (See Note 2) Saltwater use: Every 300 Hours of Engine Coupling, Operation or Once Yearly, Whichever Universal Joint Shaft Occurs First.
  • Page 63 CA240 Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL Saltwater use: Every 50 Hours of Engine Exhaust System Operation or 60 Days, Whichever -Inspect externally for Occurs First damage, deterioration Freshwater use: Every 100 Hours and restrictions.
  • Page 64 CA187 70543 71448 74107 71341 70545 70546...

  • Page 65: Checking Fluid Levels

    CA55 CHECKING POWER STEERING PUMP FLUID Stop engine and position drive unit Straight back. Remove FILLCAP/DIPSTICK and observe level. Add specified fluid if required. Reinstall FILLCAP/DIPSTICK. IMPORTANT: If fluid is not visible in pump, contact your Autho- rized MerCruiser Dealer.
  • Page 66 CA189 74107 71345 70551 70979...
  • Page 67 Check gear lube monitor oil level; keep oil level at or near “Fill” line. Check for water at bottom of monitor and/or if oil appears a milk- tan, contact your Authorized MerCruiser Dealer immediately; both conditions indicate a water leak somewhere in the drive unit. See “Filling Reservoir.”...
  • Page 68 CA201 74025 70571 71344 71345...

  • Page 69: Changing Fluids

    Power Trim or Power Steering fluids do not require changing. Coolant in closed cooling system should be changed at specified in- tervals by your Authorized MerCruiser Dealer. CHANGING CRANKCASE OIL AND FILTER IMPORTANT: Change oil when engine is warm from operation.
  • Page 70 CA190 74107 70021 71345 70569...
  • Page 71 IMPORTANT: It any water drained from OIL FILL/DRAIN hole, or it oil appears milky brown, drive unit is leaking and should be checked immediately by your Authorized MerCruiser Dealer. Lower drive unit so anti-ventilation plate is level. Fill drive unit through OIL FILL/ DRAIN hole with Specified Gear Lube, until an air-free stream of lubricant flows from OIL VENT hole.
  • Page 72 CB221 73752 71345 70573 50681...

  • Page 73: Water Separating Fuel Filter

    Do not use a filter wrench. Start and run engine. Check filter connection for gasoline leaks. If leaks exist recheck filter installation. If leaks continue stop engine im- mediately and contact your Authorized MerCruiser Dealer. WARNING Make sure no leaks exist before closing engine hatch.
  • Page 74 CA70 71903 71904 71901 71357 71359...

  • Page 75: Lubrication

    CA286 Lubrication STEERING SYSTEM If Steering Cable Has Grease Fittings: With cable fully retracted into cable housing, lubricate fitting with 2-4-C Marine Lubricant with Teflon. WARNING Do not grease steering cable while extended. Hydraulic lock could occur and cause loss of steering control. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased.
  • Page 76 CA74 70558 71569...
  • Page 77 The Perm-a-Lube U-joints do not require lubrication. The engine coupler is lubricated with Quicksilver Engine Coupler Spline Grease. Contact your Authorized MerCruiser Dealer for this service. CAUTION Speedometer water hose must be disconnected from drive unit BEFORE removing drive unit.
  • Page 78 CA76 70560...

  • Page 79: Propeller

    CA77 Propeller WARNING Remote Control must be in NEUTRAL and ignition key removed from switch before removing and/or installing propeller. WARNING Place a block of wood between anti-ventilation plate and propel- ler to protect hands from propeller blades and to prevent pro- peller from rotating when removing propeller nut.
  • Page 80 CA80 70134...
  • Page 81 CA288 INSTALLATION IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon.
  • Page 82 CA202 70565 71353 70564 71354...

  • Page 83: Flushing Cooling System

    Stop engine, shut off water and remove flushing attachment. CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer. Seawater pump impeller should be inspected whenever insuffi- cient seawater flow is suspected (if operating temperature exceeds...
  • Page 84 CA89 70562 71349 71351 70563...

  • Page 85: Drive Belts

    (if so equipped) and seawater pickup pump drive belt (closed cooling). If any drive belts need replacement or tension needs adjustment, see your Authorized MerCruiser Dealer. Alternator Drive Belt - Inspect drive belt for excessive wear or damage.
  • Page 86 CA204 73919 70578 71335 70577 70033 70576...

  • Page 87: Corrosion And Corrosion Protection

    System should be tested to ensure adequate output. Test should be made where boat is moored, using Quicksilver Refer- ence Electrode and Test Meter. Contact your Authorized MerCruiser Dealer to arrange for this test. Anode Kit (if so equipped) - Mounted to boat transom. Acts as...
  • Page 88 CA162 71957 71958...
  • Page 89 CA163 Trim Cylinder Anodes - are mounted on each trim cylinder. To replace the trim cylinder anodes: A Remove two screws from each anode. B Install new anodes and tighten securely. CA164 Propeller Anode - is located in front of the propeller, between the front side of the propeller and the gear housing.
  • Page 90 CA93 71176...
  • Page 91 If using copper or tin based anti-fouling paints, observe the following: Avoid any electrical interconnection between the MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by al- lowing a minimum of 1-1/2 in. (40mm) UNPAINTED area on transom of the boat around these items.
  • Page 92 CA359 74807 74820...

  • Page 93: Emissions

    Recommended maintenance schedules particularly as to the igni- tion system. Proper engine tuning procedures to ensure these features remain in good operating order. Proper steps to maintain the engine within specifications. Use only MerCruiser replacement parts to ensure compliance with emission regulations.
  • Page 94 CA362 71926 74819...
  • Page 95 CA102 INSTALLING TEST PROBES IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this en- gine. The only item that must be supplied by the boat owner/op- erator is the exhaust elbow test probes. These test probes should have been provided with your power package.

  • Page 96: Miscellaneous Maintenance

    CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days, or when specific gravity drops below battery manufactur- er’s specifications. Refer to specific instructions and warnings accompanying your bat- tery. If this information is not available, observe the following precau- tions when handling a battery.

  • Page 97: Bottom Of Boat

    Check plug leads and electrical leads for damage. Remove and inspect propeller. If badly nicked, bent or cracked, see your dealer. Repair nicks and corrosion damage on power package exterior fin- ish. Use Quicksilver spray paints - see your Authorized MerCruiser Dealer.
  • Page 98 CA175 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 99: Cold Weather Or Extended Storage

    Power Package Lay Up IMPORTANT: MerCruiser strongly recommends that this ser- vice should be performed by an Authorized MerCruiser Dealer. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. CAUTION Avoid Engine or Stern Drive Damage: DO NOT operate engine...
  • Page 100 CA192 74107...
  • Page 101 CA304 WARNING Avoid Fire or Explosion: Be sure engine compartment is well venti- lated and no gasoline vapors are present during the following opera- tion. WARNING Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Do not attempt to remove plug from vapor separator tank until pressure is relieved;...
  • Page 102 CB232 71332 74158...

  • Page 103: Draining Instructions

    CA234 Draining Instructions DRAINING SEAWATER (RAW-WATER) COOLED MODELS CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses.
  • Page 104 CA193 71334 74108 71216...
  • Page 105 Quicksilver Perfect Seal and reinstall drain plugs. Reconnect hoses and tighten all hose clamps securely. IMPORTANT: MerCruiser recommends that propylene glycol antifreeze (nontoxic and biodegradable, which makes it friendly to lakes and rivers) be used in seawater section of the cooling system for cold weather or extended storage.

  • Page 106: Battery Winter Storage

    CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. CA116 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not in- stall battery until all maintenance has been performed on en- gine. Check that all cooling system hoses are connected properly and hose clamps are tight.

  • Page 107: Troubleshooting

    CA194 Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off Turn switch on Remote control not in neu- Position control lever in tral position neutral Open circuit breaker or Check and reset circuit blown fuse breaker or replace fuse Check all electrical con-...
  • Page 108 Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Improper starting proce- Read starting procedure dure Empty fuel tank or fuel Fill tank or open valve shutoff valve closed Faulty fuel pump Check sight tube for fuel. Have Authorized Mer-...

  • Page 109: Poor Performance

    Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Idle speed too low Have EFI system checked by an Authorized Mer- Cruiser Dealer Faulty ignition system com- Service ignition system. ponent Clogged fuel filters Replace filters Stale or contaminated fuel If contaminated, drain tank.

  • Page 110: Insufficient Engine Temperature

    Excessive Engine Tempera- ture Possible Cause Remedy Seacock closed Open Drive belt loose or in poor Replace and/or adjust belt. condition Seawater pickups Remove obstruction structed Faulty thermostat Replace Faulty seawater pickup Repair pump Seawater discharge re- Clean exhaust elbows stricted or plugged Insufficient Engine Temperature Possible Cause...

  • Page 111: Low Engine Oil Pressure

    Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase Check and add oil Excessive oil in crankcase Check and remove re- (causing it to become quired amount of oil. Check aerated) for cause of excessive oil (improper filling, bad fuel pump, etc.).

  • Page 112: Steering Wheel Turns Hard Or Jerky

    Insufficient lubrication on Check all parts and fasten- steering system compo- ers. If any are loose or nents missing, see Authorized Loose or missing steering MerCruiser Dealer immedi- fasteners or parts ately. Contaminated power Drain and replace. steering fluid...
  • Page 113 Power Trim Does Not Operate (Motor Doesn’t Run) Possible Cause Remedy Blown fuse Replace fuse Loose or dirty electrical Check all associated elec- connections or damaged trical connections wiring wires (especially battery cables). Clean and tighten faulty connection. Repair or replace wiring. Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)

  • Page 114: Warranty Information

    CA320 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Regis- tration Card completely and mails it to the factory immediately upon sale of the new product. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.

  • Page 115: International Owner Registration

    International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Regis- tration 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 116: Warranty Policies

    UNITED STATES AND CANADA ONLY I. We warrant each new production (not those made for high per- formance purposes) MerCruiser Stern Drive Power Package, Inboard Engine and accessories attached thereto, (hereafter referred to as “Product”) to be free from defects in material and workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us.
  • Page 117 V. Claim shall be made under this warranty by delivering the Prod- uct for inspection to a MerCruiser dealer authorized to service the Purchaser’s product. If purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Company.

  • Page 118: Mercruiser International Warranty - Gasoline Engines

    Product. IV. Claim shall be made under this warranty by delivering the Prod- uct for inspection to a MerCruiser dealer authorized to service the Product If purchaser cannot deliver Product to such autho- rized dealer, he may give notice in writing to the Marine Power Service Center or distributor.
  • Page 119 V. Purchaser must provide “proof of purchase” and substantiate “date of purchase” by presenting the “Purchaser’s Copy” of the “Warranty Registration Card” or the plastic “Warranty Registra- tion Card” to the dealer authorized to service the Product. lf ei- ther of these items is not available purchaser must provide a copy of the original ”Bill of Sale”...

  • Page 120: Year Limited Warranty Against Corrosion Failure

    CANADA AND AUSTRALIA) I. We warrant parts and assemblies of each 1988 and newer pro- duction MerCruiser (Product) sold with a one year limited Prod- uct warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inopera- tive as a direct result of corrosion, provided the following simple precautionary steps which are specified in Owner’s Manuals...
  • Page 121 IV. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY. IMPLIED WARRANTIES ARE LIM- ITED TO THE LIFE OF THIS WARRANTY. SOME STATES (OR COUNTRIES) DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLU- SION OR LIMITATION OF INCIDENTAL OR CONSEQUEN- TIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLU-...

  • Page 122: Warranty Coverage

    In areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law, copper base paints can be used on the boat hull and transom. Do not apply paint to the MerCruiser drive unit or tran- som assembly. In addition, care must be taken to avoid an electrical interconnection between the MerCruiser Product and the paint.
  • Page 123 Warranty Does Not Apply To The Following: Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs, ignition components, carburetor settings, filters, belts, controls, and checking lubrication made in connec- tion with normal services. Damage caused by neglect, lack of maintenance, accident, ab- normal operation or improper installation or service, or freezing temperatures.
  • Page 124 Engine noise does not necessarily indicate a serious engine prob- lem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty. Lower unit and/or propeller damage caused by striking a sub- merged object is considered a marine hazard.

  • Page 125: Transferable Warranty

    Transferable Warranty The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. Direct Sale By Owner The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership.

  • Page 126: Q-Guard Product Protection Plan

    The optional Q-Guard Product Protection Plan is the only Factory Plan available for your engine. Two, three or four - year term plans can be purchased up to 180 days after the original engine purchase date. See your participating MerCruiser dealer for complete program de- tails.

  • Page 127: Owner Service Assistance

    Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local Autho- rized Dealer, should the need for service arise. Only he has the facto- ry trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur.

  • Page 128: Resolving A Problem

    Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser. Any problems with service, sales, warranty or operation of your MerCruiser power package will be resolved by your dealer. He also is your primary source of information on your boat, power package and trailer.
  • Page 129 FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RE- SOLVED. STEP THREE -CONTACT CONSUMER AFFAIRS DEPARTMENT United States: MERCRUISER 3003 N. Perkins Road Stillwater, OK 74075-2299 Telephone (405) 743-6515 Canada: Contact Nearest Regional Service Center...

  • Page 130: Service Centers

    Service Centers UNITED STATES MerCruiser 3003 N. Perkins Road Stillwater, OK 74075-2299 Telephone (405) 743-6566 Fax (405) 743-6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga, Ontario L4Y 2C2 Canada Telephone (905) 270-4481 Fax (905) 270-4510 MEXICO, CENTRAL AMERICA, SOUTH AMERICA, CARIBBEAN Marine Power International 9350 SW 72nd St.
  • Page 131 AUSTRALIA, PACIFIC Marine Power International Pty. Ltd. P. B. 1420 132-140 Frankston Road Dandenong, Victoria 3164 Australia Telephone (61) (3) 791-5822 Fax (61) (3) 791-5880 ASIA Marine Power International Ltd. Block 1002 Jalan Bukit Merah #07-08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone (65) 270-7680 Fax (65) 270-7898...

  • Page 132: Customer Service Literature

    Customer Service Literature English language publications are available from: Mercury Marine Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Ma- rine Power International Service Center for further information. When ordering be sure to: 1.

  • Page 133: General Maintenance Parts

    CA363 General Maintenance Parts Engine Parts Part 5.7L EFI 350 Magnum EFI 5.7LX EFI Gen+ Alpha One Alpha One Oil Filter 14957 14957 Spark Plug 33-59571 816336 Distributor Cap 808483 808483 Ignition Coil 806673 806673 Spark Plug Wire Set 816608A68 816608A68 Thermostat 807252--2...
  • Page 134 Drive Parts Part Alpha One Propeller Nut 11-52707A1 Rear Propeller Washer 12-31211A2 Tab Washer 14-816629 Grounding Washer 13-42351--1 Thrust Hub 13171 Decal Set 37-13722A13 D.S.H. Anodic Plate 76214A2 Anodic Plate (Propeller) 76214A5 Trim Cylinder Anodes 806189A1 Gimbal Housing Anode 821631A1 Bearing Carrier Anode 806105A1 Drain Screw...

  • Page 135: Literature Order Form

    CC172 Literature Order Form Model __________ Horsepower__________ Serial Number__________ Year_____ Service Manual - shows the complete assembly and disassembly of the engine or stern drive. Parts Manual - shows the exploded view of the engine or stern drive with corresponding part number. Operation and maintenance manual (Owner’s Guide) - explains basic operation and maintenance.
  • Page 136 Please Return with Payment to: Mercury Marine Attn: Publications Dept. P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Please Print or Type - This is your Shipping Label) Name Address City State METHOD OF PAYMENT: (NO CASH OR C.O.D.) Personal Check Cashiers Check Money Order...

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