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Mercury MerCruiser 4.3 TKS User Manual

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NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers' instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4)
Inboard Engine (A.5.1.1)
Fuel System (A.5.2)
Electrical System (A.5.3)
Steering system (A.5.4)
Exhaust emission requirements (B.2)
Owner's manual (B.4)
Noise emission levels (C.1)
Ignition‑protected equipment (Annex II)
Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft
in which it is to be installed has been declared in conformity, if so required, with the
relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard
Generic immunity standard
Vehicles, boats and internal combustion engine
driven devices ‑ Radio disturbance characteristics
Electrostatic discharge testing
The notified body responsible for surveillance of the quality system under Full Quality Assurance
Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
President ‑ Mercury Marine, Fond du Lac, WI USA
Applicable Requirement
Patrick C. Mackey
Standards Applied
ISO 10240
ISO 8665
ISO 15584; ISO 10088; ISO 7840; ISO 10133
ISO 10088; ISO 7840; ISO 8469
ISO 10133; ISO 8846
Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
ISO 8178
ISO 8665
ISO 14509
ISO 8846; SAE J1171; SAE J1191; SAE J 2031
EN 50081‑1
EN 50082‑1
SAE J551 (CISPR 12)
EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3

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  • Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
  • Page 2 Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

  • Page 3: Read This Manual Thoroughly

    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 Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
  • Page 4 NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard.

  • Page 5: Table Of Contents

    Consumer Application Warranty Chart....7 Canada..............2 Commercial Application Warranty Chart.....8 Transfer of Warranty..........3 Government Application Warranty Chart....9 Mercury Product Protection Plan: United States and Mercury Installation Quality Certification Program. .9 Canada..............3 Emission Control Information Label.......10 Mercury MerCruiser Limited Warranty Owner Responsibility........11 (Gasoline‑Fueled Products Only) ......4...
  • Page 6 End of First Season Checkup....... 37 Section 4 - Specifications Fuel Requirements..........40 Engine Oil.............41 Fuel Ratings.............40 Engine Specifications...........42 Using Reformulated (Oxygenated) Gasolines Fluid Specifications..........42 (USA Only)............40 Sterndrives............42 Gasolines Containing Alcohol......40 Engine..............42 Section 5 - Maintenance Owner/Operator Responsibilities......44 Cleaning The Flame Arrestor....... 58 Dealer Responsibilities.........44 Positive Crankcase Ventilation Valve (PCV)...
  • Page 7 Section 8 - Customer Assistance Information Owner Service Assistance........112 Parts and Accessories Inquiries....113 Local Repair Service........112 Resolving a Problem........113 Service Away From Home......112 Mercury Marine Service Offices......113 Stolen Power Package........112 Ordering Literature..........114 Attention Required after Submersion....112 United States and Canada......114 Replacement Service Parts......112 Outside The United States and Canada..114...
  • Page 8 Page iv 90-899883179 OCTOBER 2007...

  • Page 9: Section 1 - Warranty

    Canada............2 Commercial Application Warranty Chart ..8 Transfer of Warranty..........3 Government Application Warranty Chart ..9 Mercury Product Protection Plan: United States and Mercury Installation Quality Certification Program Canada..............3 ................9 Mercury MerCruiser Limited Warranty (Gasoline- Emission Control Information Label....

  • Page 10: Warranty Registration: United States And Canada

    A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.

  • Page 11: Transfer Of Warranty

    To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s warranty registration department. In the United States mail to:...

  • Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)

    Only) Mercury MerCruiser Limited Warranty (Gasoline-Fueled Products Only) What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. Duration of Coverage Warranty Period for Recreational Use The warranty period begins on the date the product is first sold to a recreational‑use retail purchaser or the date on which the product is first put into service, whichever occurs first.
  • Page 13 Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine will then arrange for the inspection and any covered repair.

  • Page 14: 3-Year Limited Warranty Against Corrosion

    Also, expenses associated with the removal or replacement of boat partitions or other material in order to gain access to the product are not covered by this warranty. No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation, or warranty regarding the product, other than those contained in this limited warranty.

  • Page 15: Global Warranty Charts

    Section 1 - Warranty This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less than a one year limited Product warranty;...

  • Page 16: Commercial Application Warranty Chart

    Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Standard Vazer and Vazer and Models, Models Models Scorpion Scorpion and and...

  • Page 17: Government Application Warranty Chart

    500 hours 500 hours 500 hours 500 hours 500 hours Pacific, Australia, Zealand) NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies Mercury Installation Quality Certification Program 15502 90-899883179 OCTOBER 2007 Page 9...

  • Page 18: Emission Control Information Label

    A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement.

  • Page 19: Owner Responsibility

    Section 1 - Warranty NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION...
  • Page 20 Section 1 - Warranty Notes: Page 12 90-899883179 OCTOBER 2007...
  • Page 21 Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............14 Console Mount Features ......19 Engine Serial Number Decal ......14 Power Trim............19 Bravo Sterndrive Serial Number and Single Engine Trim/Trailer ......

  • Page 22: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal The serial number decal is located on the engine cover.

  • Page 23: Bravo Transom Serial Number

    Section 2 - Getting to Know Your Power Package Bravo Transom Serial Number The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly. 25904 Bravo transom assembly U‑bolt plate Transom assembly serial Number The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers.

  • Page 24: Lanyard Stop Switch

    Section 2 - Getting to Know Your Power Package Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in accidental ejection from the operator's position). 74608 Stop switch Clips to the operator...

  • Page 25: Instrumentation

    Section 2 - Getting to Know Your Power Package Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations: • Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.

  • Page 26: Remote Controls

    Section 2 - Getting to Know Your Power Package Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control.

  • Page 27: Console Mount Features

    Section 2 - Getting to Know Your Power Package Console Mount Features mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.

  • Page 28: Single Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package For best performance trim the sterndrive unit so that the boat bottom is at a 3‑5° angle to the water. 3 - 5 mc79528 Trimming sterndrive unit up/out can: • Generally increase top speed •...

  • Page 29: Dual Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only. Dual Engine Trim/Trailer NOTICE If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems.
  • Page 30 Section 2 - Getting to Know Your Power Package 2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs. mc74907-1 3.

  • Page 31: Audio Warning System

    Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.

  • Page 32: Testing The Audio Warning System

    If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation. If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System 1.
  • Page 33 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........26 Boats Having An Open Front Deck ....32 Be Alert to Carbon Monoxide Poisoning..... 27 Boats With Front-Mounted, Raised Pedestal Good Ventilation ........... 27 Fishing Seats ..........

  • Page 34: Safe Boating Suggestions

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.

  • Page 35: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On The Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat;...

  • Page 36: Poor Ventilation

    Section 3 - On The Water 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain 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.

  • Page 37: Starting And Stopping The Engine

    Section 3 - On The Water Operation Chart WHILE BEFORE STARTING AFTER STARTING AFTER STOPPING UNDERWAY Check shift and Turn battery switch on. throttle control Close fuel shut off valve. operation. Check steering Close seacock, if Operate bilge blowers. operation. equipped.

  • Page 38: Stopping The Engine

    If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer.

  • Page 39: Drain Plug And Bilge Pump

    Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.

  • Page 40: Boats Having An Open Front Deck

    Section 3 - On The Water Boats Having An Open Front Deck No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence or enclosure. Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.

  • Page 41: Impact With Underwater Hazards

    WARNING 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.

  • Page 42: Drive Unit Impact Protection

    Section 3 - On The Water Drive Unit Impact Protection The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object, reducing damage to the unit.

  • Page 43: Cavitation

    RPM range, normal engine operation resumes. The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer to Mercury Marine's web page http:// www.mercurymarine.com/everything_you_need_to_know_about_propellers6. Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load.

  • Page 44: Getting Started

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

  • Page 45: End Of First Season Checkup

    Section 3 - On The Water End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of...
  • Page 46 Section 3 - On The Water Notes: Page 38 90-899883179 OCTOBER 2007...

  • Page 47: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........40 Engine Oil............41 Fuel Ratings ..........40 Engine Specifications......... 42 Using Reformulated (Oxygenated) Gasolines Fluid Specifications..........42 (USA Only) ........... 40 Sterndrives ........... 42 Gasolines Containing Alcohol ...... 40 Engine ............

  • Page 48: Fuel Requirements

    The fuel system components on your Mercury 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.

  • Page 49: Engine Oil

    All MerCruiser engines Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of recommendation: 1. Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W–rated 4‑cycle MerCruiser 2.

  • Page 50: Engine Specifications

    Listed capacities are approximate. 4.3 TKS Models Capacity Fluid Type Mercury MerCruiser Full‑Synthetic Engine Oil, Engine oil (with filter) 3.8 L (4 US qt) 20W‑40, NMMA FC‑W rated Seawater cooling system 14.1 L (15 US qt)
  • Page 51 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......44 Positive Crankcase Ventilation Valve Dealer Responsibilities........44 (PCV) ............59 Maintenance............44 Changing ..........59 Do-It-Yourself Maintenance Suggestions... 45 Changing the Water-Separating Fuel Filter..59 Inspection............45 Lubrication............

  • Page 52: Owner/Operator Responsibilities

    • Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...

  • Page 53: Do-It-Yourself Maintenance Suggestions

    Transmission (inboard models only) Do‑It‑Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.

  • Page 54: Maintenance Schedule-Sterndrive Models

    Section 5 - Maintenance Maintenance Schedule–Sterndrive Models Routine Maintenance NOTE: Only perform maintenance that applies to your particular power package. Task Interval Maintenance to Be Performed • Check the engine oil level. (You can extend this interval based on experience with the product.) •...

  • Page 55: Maintenance Log

    Section 5 - Maintenance Task Interval Maintenance to Be Performed • Inspect the U‑joints, the splines, and the bellows. Check the clamps. • Check the engine alignment. • Lubricate the U‑joint splines and cross bearing, if equipped with grease Every 200 hours or 3 fittings.

  • Page 56: Sealed Carburetor Mixture Screw

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

  • Page 57: Changing Oil And Filter

    Fluid type 4.3 TKS 3.8 liters (4 U.S. qt.) 5.0 TKS Mercury Full‑Synthetic MerCruiser Oil 20W‑40 4.25 liters (4.5 U.S. qt.) 5.7 TKS Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.

  • Page 58: Engine Oil Drain Pump

    Fluid type 4.3 TKS 3.8 liters (4 U.S. qt.) 5.0 TKS Mercury Full‑Synthetic MerCruiser Oil 20W‑40 4.25 liters (4.5 U.S. qt.) 5.7 TKS 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.

  • Page 59: Power Steering Fluid

    Power steering pump Warm range Cold range 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.

  • Page 60: Filling

    Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. 3. Install the cap onto the heat exchanger.

  • Page 61: Changing

    92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat.

  • Page 62: Filling

    If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.

  • Page 63: Changing

    Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 6109 Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
  • Page 64 Sealing washer IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of...

  • Page 65: Power Trim Fluid

    Section 5 - Maintenance Model Capacity Fluid Type Alpha One 1892 mL (64 oz) Bravo One 2736 mL (92‑1/2 oz) High Performance Gear Lubricant Bravo Two 3209 mL (108‑1/2 oz) Bravo Three 2972 mL (100‑1/2 oz) 11. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and oil fill/drain screw.

  • Page 66: Changing

    3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Cleaning The Flame Arrestor WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start.

  • Page 67: Section 5 - Maintenance

    Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped.

  • Page 68: Lubrication

    10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop the engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Steering System...
  • Page 69 Section 5 - Maintenance 2. Turn steering wheel until steering cable fully extended. Lightly lubricate the exposed part of cable. 6222 Extended steering cable Tube Ref No. Description Where Used Part No. Special Lubricant 101 Steering cable 92-802865Q02 3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref.

  • Page 70: Throttle Cable

    Section 5 - Maintenance Throttle Cable 1. Lubricate the pivot points and the guide contact surfaces. 6208 Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Throttle cable pivot points & 92‑883725K01 Oil SAE25W‑40 guide contact surfaces Shift Cable ‑...

  • Page 71: Sterndrive Unit And Transom Assembly

    Section 5 - Maintenance Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. mc77068-1 Gimbal bearing grease fitting Tube Ref No. Description Where Used Part No. U-joint and Gimbal Bearing Gimbal bearing 92-802870A1 Grease...

  • Page 72: Driveshaft Extension Models

    Section 5 - Maintenance NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated Bravo Models ‑ every 50 hours; Alpha Models ‑ every 150 hours. 6212 6213 Alpha drive coupler Bravo drive coupler Grease fitting Tube Ref No.

  • Page 73: Propellers

    Section 5 - Maintenance Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 74: Bravo One Propeller Removal

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon 2. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub. 3. Install Flo‑Torq II Drive Hub into propeller. NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued.
  • Page 75 Section 5 - Maintenance IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. 6215 Propeller shaft Drive sleeve Thrust hub Locking tab washer Flo‑Torq II drive hub Propeller nut Propeller 1.

  • Page 76: Bravo Two Propeller Removal

    Section 5 - Maintenance Bravo Two Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.

  • Page 77: Bravo Three Propeller Removal

    Section 5 - Maintenance 3. Align splines and place propeller on propeller shaft. 4. Install spline washer and tab washer. 5. Install and torque the propeller nut. Description lb‑in. lb‑ft Propeller nut (minimum) – 6. Bend 3 tabs on the tab washer down into the grooves in spline washer. After the first use, bend the 3 tabs straight and retorque the propeller nut.

  • Page 78: Bravo Three Propeller Installation

    Section 5 - Maintenance NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304 Rear propeller nut Front propeller thrust hub Rear propeller Propeller shaft anode screw Rear propeller thrust hub Flat washer Front propeller nut...
  • Page 79 Section 5 - Maintenance Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865Q02 Anti-Corrosion Grease Propeller shaft 92-802867Q 1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon 3. Align splines and place propeller on propeller shaft. 4.

  • Page 80: Serpentine Drive Belt

    Section 5 - Maintenance Serpentine Drive Belt 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. 6117 6116 With a seawater pump Without a seawater pump Idler pulley Alternator pulley...

  • Page 81: Flushing The Power Package

    The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Bravo models equipped with closed cooling require dual water pickups and must be equipped with a through the hull or through the transom pickup in addition to the sterndrive water inlets.

  • Page 82: Flushing Attachments

    9194 Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
  • Page 83 Section 5 - Maintenance 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. Keep the seacock closed until starting the engine. 1.

  • Page 84: Alternative Water Pickups

    Section 5 - Maintenance 9. Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM). 10. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 11.

  • Page 85: Battery

    Section 5 - Maintenance 5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine or boat. 6147 6. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.

  • Page 86: Corrosion Protection

    Section 5 - Maintenance WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.
  • Page 87 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System...
  • Page 88 MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. Page 80...
  • Page 89 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. 6206 MerCathode controller MerCathode assembly Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. 5643 Trim cylinder anodes 90-899883179 OCTOBER 2007...

  • Page 90: Painting Your Power Package

    Section 5 - Maintenance Bearing Carrier Anode (Alpha and Bravo One) ‑ Located in front of the propeller, between the front side of the propeller and the gear housing. 5644 Bearing carrier anode Propshaft Anode (Bravo Three) ‑ Located behind the aft propeller. 5821 Propshaft anode In addition to the corrosion protection devices, the following steps should be taken to inhibit...

  • Page 91: October

    Section 5 - Maintenance • Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.
  • Page 92 Section 5 - Maintenance Notes: Page 84 90-899883179 OCTOBER 2007...

  • Page 93: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....86 Manual Single Point Drain System....96 Preparing Power Package for Storage..86 Boat in the Water ........96 Engine and Fuel System Preparation ..87 Boat out of the Water ......

  • Page 94: Preparing Power Package For Storage

    Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage.

  • Page 95: Engine And Fuel System Preparation

    While operating engine at fast idle (1300 RPM), fog internal surfaces of induction system and combustion changers by spraying approximately 227 g (8 oz.) of Mercury/Quicksilver Storage Seal or SAE 20W engine oil into carburetor bores. Spray the remaining 57 g (2 oz.) of Storage Seal (or oil) rapidly into carburetor, just as the engine begins to stall, due to lack of fuel.

  • Page 96: Draining The Seawater System

    6. Service batteries according to the manufacturer's instructions. 7. Clean the outside of the engine and repaint any areas required with Mercury/ Quicksilver Light Gray Primer and Phantom Black Paint. After paint has dried, wipe down the outside of the engine with Corrosion Guard.

  • Page 97: Drain System Identification

    Section 6 - Storage Drain System Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM 6125 6124 Closed Cooled Models Seawater Cooled Models Blue drain plug location Air manifold Blue air pump Green indicators 21125 Scorpion Models Blue air pump Green indicators Air manifold Blue drain plug locations MANUAL SINGLE POINT DRAIN SYSTEM...

  • Page 98: Three Point Manual Drain System

    Section 6 - Storage THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 6130 Water circulating pump hose Fuel cooler to thermostat housing Page 90 90-899883179 OCTOBER 2007...

  • Page 99: Air-Actuated Single-Point Drain System

    Section 6 - Storage 6131 Check valve (if equipped) Air‑Actuated Single‑Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2.
  • Page 100 Section 6 - Storage 7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system. 6125 6124 Closed Cooled Models Seawater Cooled Models Blue drain plug location Air manifold...

  • Page 101: Boat Out Of The Water

    12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
  • Page 102 Section 6 - Storage 3. Ensure that the lever on top of the pump is flush with the handle (horizontal). 4. Install the air pump on the actuator fitting. 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump...
  • Page 103 10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 104: Manual Single Point Drain System

    Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators Manual Single Point Drain System BOAT IN THE WATER 1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2.

  • Page 105: Boat Out Of The Water

    6137 Drain location ‑ orange or red Blue drain plug 5. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. 6. Reinstall the blue drain plug in the thermostat housing.

  • Page 106: Three Point Manual Drain System

    Drain location ‑ orange or red Blue drain plug 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained.

  • Page 107: Boat Out Of The Water

    Blue drain plugs 5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.

  • Page 108: Multi-Point Drain (Mpd) System

    Blue drain plug 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
  • Page 109 Section 6 - Storage Water‑circulating pump hose 6143 Drain plug Fuel‑cooler‑to‑thermostat‑housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) 90-899883179 OCTOBER 2007 Page 101...

  • Page 110: Boat In The Water

    Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
  • Page 111 Section 6 - Storage Water‑circulating pump hose 6143 Drain plug Fuel‑cooler‑to‑thermostat‑housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) 90-899883179 OCTOBER 2007 Page 103...

  • Page 112: Draining The Sterndrive

    Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...

  • Page 113: Battery Storage

    Section 6 - Storage NOTICE The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position. 2.
  • Page 114 Section 6 - Storage Notes: Page 106 90-899883179 OCTOBER 2007...

  • Page 115: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Recharge........ 109 Slow..............108 Remote Control Is Difficult to Move, Has Excessive Engine Will Not Start Or Is Hard To Start..108 Play, or Makes Unusual Sounds.......

  • Page 116: Starter Motor Will Not Crank Engine, Or Cranks Slow

    Section 7 - Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn the switch on. Remote control not in neutral position. Position the control lever in neutral. Open circuit breaker or blown fuse. Check and reset the circuit breaker or replace fuse.

  • Page 117: Excessive Engine Temperature

    Clean or repair as necessary. See Engine Runs Rough, Misses or Backfires. Ignition problem. Engine overheating. See Excessive Engine Temperature. Running rich. Have authorized Mercury MerCruiser dealer check and repair. Excessive Engine Temperature Possible Cause Remedy Water inlet or seacock closed. Open.

  • Page 118: Remote Control Is Difficult To Move, Has Excessive Play, Or Makes Unusual Sounds

    Check all throttle linkages. If any are loose or missing, Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair.

  • Page 119: Section 8 - Customer Assistance Information

    Parts and Accessories Inquiries ... 113 Local Repair Service ........112 Resolving a Problem ........113 Service Away From Home ......112 Mercury Marine Service Offices ....113 Stolen Power Package ....... 112 Ordering Literature..........114 Attention Required after Submersion ..112 United States and Canada ......

  • Page 120: Owner Service Assistance

    Owner Service Assistance Local Repair Service If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.

  • Page 121: Parts And Accessories Inquiries

    Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership.

  • Page 122: Ordering Literature

    Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Please return with payment to:...

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