MerCruiser 350 Magnum MPI Operation & Maintenance Manual
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MerCruiser 350 Magnum MPI Operation & Maintenance Manual

MerCruiser 350 Magnum MPI Operation & Maintenance Manual

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OPERATION &
MAINTENANCE MANUAL
350 Magnum MPI
Tournament Ski
1995, Brunswick Corporation
90-806906960 595

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  • Page 1 OPERATION & MAINTENANCE MANUAL 350 Magnum MPI Tournament Ski 1995, Brunswick Corporation 90-806906960 595...

  • Page 2: Serial Numbers

    Boat Manufacturer Boat Model Length Serial Numbers The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your MerCruiser power package. When contacting your Authorized MerCruiser Dealer about service, always specify model and serial numbers. 74192...

  • Page 3: Table Of Contents

    CC354 Table of Contents Page Welcome! ..................Read This Manual Thoroughly .
  • Page 4 Mercury Marine Printed in 1995, Brunswick Corporation Fond du Lac, Wisconsin, U.S.A. U.S.A. The following are registered trademarks of Brunswick Corporation: Auto- blend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mer- cury Marine, Quicksilver, Ride-Guide, and Thruster.

  • Page 5: Welcome

    The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. 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! CONSUMER AFFAIRS DEPARTMENT...

  • Page 6: 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 acces- sory. The purpose of this switch is to turn off the engine ignition whenever the operator (when attached to the lan- yard) moves far enough away from the operator’s position to activate the switch.

  • Page 7: 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.

  • Page 8: Protecting People In The Water

    Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert. The operator of the boat is responsible by law to “maintain a proper lookout by sight (and hearing).” The operator must have an unobstructed view particularly to the front.

  • Page 9: 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 10: How Elevation And Climate Affect Performance

    CA12 How Elevation and Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and tempera- ture do have a noticeable effect on the density of air.

  • Page 11: Important Information

    OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance instruc- tions are complied with for safe operation and to return the unit to an Authorized MerCruiser Dealer for a periodic checkup.

  • Page 12: Freezing Temperature Operation

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

  • Page 13: Do-It-Yourself Maintenance Suggestions

    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 prob- lems with the system when they occur, and store a “Trouble Code” in the ECM’s memory. This code can then be...

  • Page 14: 20-Hour Break-In Period

    RPM. CC196 20-Hour Checkup After first 20 hours of operation, an Authorized MerCruiser Dealer should be contacted for the following mainte- nance. The boat owner is responsible for any charges. Change crankcase oil and filter. Check all fluid levels.
  • Page 15 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 16: Operation

    CC93 Operation 70515 70516 70514 70519 70517 70518 70521 70523 70522...

  • Page 17: Instrumentation

    Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments 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 18 CC180 70516 70518 72957...

  • Page 19: Audio Warning

    When the buzzer sounds with the engine running, stop engine immediately. Investigate cause and correct it, if pos- sible. If cause cannot be determined, consult your Authorized MerCruiser Dealer. IMPORTANT: Warning buzzer will sound for 2 seconds when ignition key is turned to RUN position and...
  • Page 20 CC254 71583 71585 70525 72852...

  • Page 21: Electrical System Overload Protection

    CC255 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 replacing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead. Reset by push- ing RESET button IN.
  • Page 22 CC166 73866...

  • Page 23: Remote Controls (Panel Mounted)

    CC167 Remote Controls (Panel Mounted) Neutral Lock Bar - Prevents accidental shift and throttle engagement. Neutral lock bar must be pulled “Up” to move the control handle out of neutral. Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disen- gaging the shift mechanism from the control handle.

  • Page 24: Starting, Shifting And Stopping

    CC97 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five minutes 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.

  • Page 25: Operation Chart

    CC98 Operation Chart BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Observe all gauges Observe all Turn ignition Open engine to check condition of gauges to monitor key OFF. hatch. engine. If not normal, engine condition. stop engine. If not normal, stop engine.

  • Page 26: 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. Premium gasoline [92 (R+M)/2 Octane] is also acceptable. DO NOT use leaded gasoline.
  • Page 27 The fuel system components on your MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand. Contact your boat manufacturer for specif- ic recommendations on the boats fuel system components (fuel tanks,fuel lines, and fittings). Be aware that gaso- lines containing alcohol may cause increased: Corrosion of metal parts.

  • Page 28: Seacock Size Recommendation

    CC218 Seacock Size Recommendation Seacock used, must have an internal cross-sectional area equal to or greater than hose to prevent restricting wa- terflow. Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue. A 1-1/4 in.

  • Page 29: Engine Specifications

    CC353 Engine Specifications MODEL 350 MAGNUM MPI TOURNAMENT SKI Propshaft Horsepower Propshaft Kilowatts 350 C.I.D. Displacement (5.7 L) Engine Type 4.00 in. Bore (101.6 mm) 3.48 in. Stroke (88.39 mm) Compression Ratio 9.3:1 150 psi (1035 kPa) Compression Pressure Maximum RPM @ WOT...

  • Page 30: Tune-Up Specifications

    CC352 Tune-up Specifications MODEL 350 MAGNUM MPI TOURNAMENT SKI Spark Plug Type AC-MR43T/Champion RV15YC4/NGK BR6FS Spark Plug Gap .035 in. (.9mm) 8 BTDC Timing @ Idle RPM Firing Order 1-8-4-3-6-5-7-2 Electrical System 12-Volt Negative (-) Ground Alternator 65 Amps Recommended...

  • Page 31: Capacities

    CC351 Capacities 350 MAGNUM MPI TOURNAMENT SKI MODEL Crankcase Oil Approx. 5 U.S. Capacity w/New Filter Quarts (4.7L) Seawater Cooling System 15 Qts. (14.2L) Transmission (Velvet Drive) 2 Qts. (1.9L) Always use dipstick to determine exact quantity of oil required.

  • Page 32: Maintenance

    CC233 Maintenance 74192 71459...

  • Page 33: Efi System Maintenance Precautions

    MerCruiser Service Manual(s) be purchased and read thoroughly. CAUTION Avoid damage to transmission. The transmission on your MerCruiser product is filled with Dexron III trans- mission fluid at the factory. Do not mix other transmission fluids with Dexron III transmission fluid.

  • Page 34: Maintenance Schedules

    CC285 Maintenance Schedules WARNING Always disconnect battery cables from battery BEFORE working around electrical system components to prevent injury to yourself or damage to electrical system should a wire be accidentally shorted. Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR INTERVAL TASK...

  • Page 35: Maintenance Chart

    CB310 Maintenance Chart Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL At First 20 Hours of Operation 20 - Hour Checkup (NOTE 1) Whenever Insufficient Seawater Flow is Sus- Seawater Pickup Pump - Disassemble pected.
  • Page 36 CC224 74176 70543 73749 71419 74192...

  • Page 37: Checking Fluid Levels

    CC37 Checking Fluid Levels CHECKING CRANKCASE OIL Stop engine. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water. Remove dipstick. Wipe clean and reinstall fully into dipstick tube. Remove dipstick and observe oil level. Oil level must be between FULL and ADD. If oil level is below ADD: Remove oil filler cap.
  • Page 38 CC225 74176 74195 71344 73684...

  • Page 39: Changing Fluids

    See MAINTENANCE CHART for lubricant change frequency. Lubricant should be changed before placing boat in storage. Transmission fluid should be changed at specified intervals by your Authorized MerCruiser Dealer. CHANGING CRANKCASE OIL AND FILTER IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
  • Page 40 CC226 74174 74183 71457 70659...

  • Page 41: Lubrication

    CC51 Lubrication THROTTLE CABLE Lubricate pivot points with specified motor oil. CC319 SHIFT CABLE Lubricate pivot points with specified motor oil. Lubricate poppet ball and holes in lever with specified motor oil. IMPORTANT: Poppet Ball MUST BE centered in detent hole for each F-N-R position. Shift lever must be over this letter when propelling boat FORWARD.
  • Page 42 CC232 74192 71170 71118...

  • Page 43: Flushing Cooling System

    Tighten hose clamp securely. CC58 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer. Seawater pump impeller should be inspected whenever insufficient seawater flow is suspected (if operating temperature exceeds normal range).
  • Page 44 CC231 Maintenance (continued) 70562 74192 71349...

  • Page 45: Drive Belts

    Perform the following inspections of alternator drive belt and seawater pickup pump drive belt. 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 46 CC374 74637 73694 70573...

  • Page 47: Sight Tube Inspection

    Both of the tubes are joined together and drain into the intake manifold. If there is fuel visible in the sight tube, have your engine repaired by an Authorized MerCruiser Dealer immediately. A. Fuel Pump Sight Tube - See Illustration B.
  • Page 48 CC69 71449 70140 70057 TYPICAL FRONT MOUNT TYPICAL REAR MOUNT...

  • Page 49: Engine Alignment

    CC70 Engine Alignment Engine alignment should be checked by your Authorized MerCruiser Dealer at specified intervals. IMPORTANT: Engine alignment must be checked with boat in the water, fuel tanks filled and with a normal load on board. Engine must be aligned so that transmission and propeller shaft coupling centerlines are aligned and coupling faces are parallel within .003 in.
  • Page 50 THIS PAGE IS INTENTIONALLY BLANK...

  • Page 51: Miscellaneous Maintenance

    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 finish. Use Quicksilver spray paints - see your Au- thorized MerCruiser Dealer.
  • Page 52 CC228 74179...

  • Page 53: Cold Weather Or Extended Storage

    CC73 Cold Weather or Extended Storage Power Package Layup IMPORTANT: This service should be performed by an Authorized MerCruiser Dealer. CAUTION DO NOT operate engine without water flowing thru seawater pickup pump, as pump impeller may be dam- aged and subsequent overheating damage to engine or stern drive unit may result.
  • Page 54 CC229 74165 71334 71170 71758 74140...

  • Page 55: Draining Instructions

    After cooling system has drained completely, coat drain plug threads with 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 56: Battery Winter Storage

    Carefully inspect engine for fuel, oil, fluid, water and exhaust leaks. Check steering system, shift and throttle control for proper operation. Check fuel system sight tube for evidence of fuel. If fuel is present, contact your Authorized MerCruiser Dealer for repairs.

  • Page 57: Troubleshooting

    Fuel line or tank vent line kinked Replace kinked lines or blow out lines with or clogged compressed air to remove obstruction. EFI System Fault Have EFI System checked by an Authorized MerCruiser Dealer.
  • Page 58 Flame arrestor plugged with Clean flame arrestor. foreign material. EFI System Fault Have EFI System checked by an Authorized MerCruiser Dealer. Poor performance Throttle not fully open Inspect cable and linkages for binding, ob- struction or loose fasteners. Damaged or improper propeller Replace.
  • Page 59 Trouble Possible Cause Remedy Excessive engine Coolant level low in fresh water Check for cause of low coolant level and repair. temperature section Fill system with proper coolant solution. (continued) Heat exchanger cores plugged Clean. with foreign material Loss of pressure in fresh water Check for leaks.

  • Page 60: Water Flow Diagram

    CC163 Water Flow Diagram 73854...

  • Page 61: Wiring Diagrams

    CC117 Wiring Diagrams Quicksilver Instrumentation 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. NOTE: 2 Power for a Fused Accessory Panel May Be Taken from This Connection. Load Must Not Exceed 40 Amps.

  • Page 62: Starting And Charging System Harness

    CC253 Starting And Charging System Harness BLK = BLACK BLU = BLUE BRN = BROWN GRN = GREEN GRY = GRAY ORN = ORANGE PNK= PINK PUR= PURPLE RED= RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT DRK= DARK A - Charging and Starting Circuit B - Audio Warning/Power Reduction Circuit...

  • Page 63: E.f.i. System Harness

    CC234 E.F.I. System Harness BLK = BLACK 1 - Vapor Separator Tank (VST) BLU = BLUE 2 - Throttle Body BRN = BROWN 3 - Distributor 4 - Coil GRN = GREEN 5 - Electronic Spark Control (KS) Module GRY = GRAY 6 - Data Link Connector (DLC) ORN = ORANGE 7 - Manifold Absolute Pressure (MAP) Sensor...

  • Page 64: Warranty Information

    CA272 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the facto- ry 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 65: Warranty Policies

    Product. V. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho- rized 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 66: Mercruiser International Warranty

    Product. IV. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer autho- rized to service the Product If purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Marine Power Service Center or distributor.

  • Page 67: Year Limited Warranty Against Corrosion Failure

    MerCruiser boating applications. 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 transom assembly. In addition, care must be taken to avoid an electrical interconnection between the MerCruiser Product and the paint.

  • Page 68: Warranty Coverage

    Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The table explains some of the types of services that are not covered by warranty. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship.

  • Page 69: 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 70: Q-Guard Product Protection Plan

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

  • Page 71: Resolving A Problem

    Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser. Any problems with ser- vice, 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. Should there be a misunderstanding,...

  • Page 72: 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 73: Customer Service Literature

    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 74: General Maintenance Parts

    CC350 General Maintenance Parts Engine Parts PART 350 MAGNUM MPI TOURNAMENT SKI Oil Filter 14957 Spark Plug 33-59571 Distributor Cap 808483 Ignition Coil 806673 Spark Plug Wire Set 816608A68 Thermostat (160 F) 807252--2 Thermostat Gaskets 27-47510, 27-53045--1 Alternator Belt 57-48120A1...

  • Page 75: Literature Order Form

    CC178 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 76 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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