MerCruiser 3.0 TKS User Manual
MerCruiser 3.0 TKS User Manual

MerCruiser 3.0 TKS User Manual

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NOTE: The following applies to CE marked products only.
Declaration of Conformity – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Mercury Marine MerCruiser
Address: 3003 N. Perkins Road
Town: Stillwater, OK
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers
Name of Notified Body for exhaust emission assessment: Det Norske Veritas AS
Address: Veritasveien 1
Town: Hovik
Conformity assessment module used for exhaust
emissions:
or engine type approved according to:
Conformity assessment module used for noise emissions:
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type
☒ z or sterndrive with integral exhaust
☐ Inboard engine
Identification of Engines Covered by This Declaration of Conformity
Name of engine family
Unique engine identification number: starting serial number
3.0 TKS
OW319169
4.3 TKS
OW319169
5.0 TKS
OW319169
5.7 TKS
OW319169
Essential requirements
Annex 1.B—Exhaust Emissions
B.1 engine identification
B.2 exhaust emission requirements
B.3 durability
B.4 owner's manual
Annex 1.C—Noise Emissions
C.1 Noise emission levels
C.2 Owner's manual
This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine
manufacturer that the engine(s) mentioned above complies (comply) with all applicable essential requirements in the way
specified.
Post Code: 74075
Post Code: 4800
Post Code: 1322
Country: Norway
other normative document/
standards
☒*
☒*
Country: Belgium
ID Number: 0575
☐ B+C ☐ B+D
☐ B+E
☐ stage II of Directive 97/68/EC ☐ Directive 88/77/EC
A ☐
Fuel Type
☐ Diesel
☒ Petrol
technical file
method
Country: USA
☐ B+F
☐ G
☒ H
Aa ☐
G ☐
H ☒
Combustion Cycle
☐ 2 stroke
☒ 4 stroke
EC Module H certificate number
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
Please specify in more detail
(* = mandatory standard)
* EN ISO 8178‑1:1996
ISO 8665: 1995
* EN ISO 14509
Owner's manual

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Summary of Contents for MerCruiser 3.0 TKS

  • Page 1 NOTE: The following applies to CE marked products only. Declaration of Conformity – Mercury MerCruiser This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the requirements of the following directives by meeting the associated standards, as amended:...
  • Page 2 The Operation, Maintenance and Warranty 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 Mercury MerCruiser products. We sincerely hope your boating will be pleasant! Mercury MerCruiser...
  • Page 3: Read This Manual Thoroughly

    Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages and other related information.
  • Page 5: Table Of Contents

    Section 1 - Warranty Warranty Registration: United States and Canada....2 Warranty for Government Applications....... 8 Warranty Registration: Outside the United States and Mercury MerCruiser Warranty Charts........8 Canada..................2 Consumer Application Warranty Chart......... 9 Transfer of Warranty..............2 Commercial Application Warranty Chart......10 Mercury Installation Quality Certification Program.....
  • Page 6 Engine Oil................36 Fluid Specifications..............38 Engine Specifications............. 37 Sterndrives................ 38 3.0 TKS................37 Engine................38 Section 5 - Maintenance Owner/Operator Responsibilities..........40 Cleaning the Flame Arrestor........... 50 Dealer Responsibilities............40 Positive Crankcase Ventilation Valve (PCV)....51 Maintenance................40 Changing..............51 Do‑It‑Yourself Maintenance Suggestions.......
  • Page 7 Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move)..............80 Section 8 - Customer Assistance Information Owner Service Assistance............82 Parts and Accessories Inquiries........82 Local Repair Service............82 Resolving a Problem............82 Service Away From Home..........82 Mercury Marine Service Offices.........
  • Page 8 Page iv 90-879288268 JULY 2009...
  • Page 9: Section 1 - Warranty

    Warranty for Commercial Applications......8 Warranty Registration: Outside the United States and Canada Warranty for Government Applications......8 ....................2 Mercury MerCruiser Warranty Charts........8 Transfer of Warranty............... 2 Consumer Application Warranty Chart ......9 Mercury Installation Quality Certification Program....3 Commercial Application Warranty Chart ......
  • Page 10: Warranty Registration: United States And Canada

    Federal Boat Safety Act is required. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine serial number.
  • Page 11: Mercury Installation Quality Certification Program

    Boat builders that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiser‑powered boats that are registered on and after the boat builder's certification date for all worldwide registrations. 90-879288268...
  • Page 12: Mercury Product Protection Plan: United States And Canada

    Section 1 - Warranty Mercury has designated a section of our Website to promote the Installation Quality Certification Program and communicate its benefits to consumers. For a current list of MerCruiser‑powered boat brands that have earned Installation Quality Certification, visit www.mercurymarine.com/mercruiser_warranty.
  • Page 13 Section 1 - Warranty Termination of Coverage Warranty coverage is terminated for used product obtained in any of the following ways: • Repossession from a retail customer • Purchase at auction • Purchase from a salvage yard • Purchase from an insurance company that obtained the product as a result of an insurance claim Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by...
  • Page 14: 3-Year Limited Warranty Against Corrosion

    Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
  • Page 15 Section 1 - Warranty This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair and replacement of parts, or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
  • Page 16: Global Application Warranty Charts

    1 year or 500 hours 1 year or 500 hours Japan 1 year or 500 hours South Pacific Other Asia Mercury MerCruiser Warranty Charts IMPORTANT: Please refer to www.mercurymarine.com/global_warranty for the most currant Global Warranty Charts. Page 8 90-879288268 JULY 2009...
  • Page 17: Consumer Application Warranty Chart

    Section 1 - Warranty Consumer Application Warranty Chart Limited Corrosion Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non‑Certified Boat Brand Certified Boat Brand All Boat Brands Vazer, Vazer Vazer Standard Models, Standar Models Scorpio Standar Models Scorpio and and...
  • Page 18: 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, Vazer Vazer Standard Models, Standar Models Scorpio Standar Models Scorpio and and...
  • Page 19: Government Application Warranty Chart

    Engines designated as exempt from either Federal EPA or California emission control regulations are not covered by a separate emission control component warranty. The product's Mercury MerCruiser manufacturer's warranty is not affected by the engine's designation under Federal EPA or California emission control regulations.
  • Page 20: Emission Control Information Label

    Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.
  • Page 21: Epa Emissions Limited Warranty

    Section 1 - Warranty U.S. EPA Emissions Limited Warranty Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.
  • Page 22 Section 1 - Warranty Notes: Page 14 90-879288268 JULY 2009...
  • Page 23: Section 2 - Getting To Know Your Power Package

    Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification................. 16 Console Mount Features ..........20 Alpha Sterndrive Decal Identification......16 Power Trim................20 Alpha Transom Serial Number........16 Single Engine Trim/Trailer ..........
  • Page 24: Identification

    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. Alpha Sterndrive Decal Identification The drive serial number is located on the port side of the Alpha sterndrive.
  • Page 25: Engine Serial Number Decal

    Section 2 - Getting to Know Your Power Package Engine Serial Number Decal The serial number decal is located on the aft portion of the starboard side of the block, near the starter motor. 32121 The engine, transom, and drive serial numbers are also located on the engine identification plate. Engine serial number Transom serial number Drive serial number...
  • Page 26: Instrumentation

    Section 2 - Getting to Know Your Power Package • standing at planing speeds • operating at planing speeds in shallow or obstacle infested waters • releasing your grip on the steering wheel that is pulling in one direction • consuming alcohol or drugs •...
  • Page 27: Remote Controls

    Section 2 - Getting to Know Your Power Package Fuel Gauge: Indicates quantity of fuel in tank. Hour meter: Records engine operating time. Bilge Blower Switch: Operates bilge blower. Ignition Switch: Allows operator to start and stop engine. Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in). Remote Controls Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls.
  • Page 28: Console Mount Features

    Section 2 - Getting to Know Your Power Package Console Mount Features Throttle Only Button Control Handle Power Trim Switch Trailer Switch mc79503-1 Throttle Only Button ‑ Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle.
  • Page 29: Single Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package • In excess, cause boat porpoising (bouncing) or propeller ventilation • Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line mc78529 Trimming sterndrive unit down/in can: •...
  • Page 30 Section 2 - Getting to Know Your Power Package A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
  • Page 31 Section 2 - Getting to Know Your Power Package A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped). mc70525-1 The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump.
  • Page 32: 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 33 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 26 Passenger Safety in Pontoon Boats and Deck Boats..30 Be Alert to Carbon Monoxide Poisoning....... 27 Boats Having an Open Front Deck ....... 30 Good Ventilation ............
  • 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. Ensure that everyone in the boat is properly seated.
  • Page 35: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On the Water • 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. No passengers, load or fishing seats should block the operators view when the boat is above idle or planing transition speed.
  • Page 36: Basic Boat Operation

    Section 3 - On the Water Examples of poor ventilation while a boat is moving: Operating the boat with the trim angle of the bow too high Operating the boat with no mc79556-1 forward hatches open (station wagon effect) Basic Boat Operation Launching and Boat Operation IMPORTANT: Install bilge drain plug prior to launching boat.
  • Page 37: Stopping The Engine

    Freezing Temperature Operation IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. 90-879288268 JULY 2009...
  • Page 38: Drain Plug And Bilge Pump

    It is very important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty. Protecting People in the Water While You Are Cruising It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.
  • Page 39: Boats With Front-Mounted, Raised Pedestal Fishing Seats

    Section 3 - On the Water WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion. Boats With Front‑Mounted, Raised Pedestal Fishing Seats Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed.
  • Page 40: Drive Unit Impact Protection

    After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
  • Page 41: Cavitation

    Section 3 - On the Water Cavitation Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear housing or the propeller.
  • Page 42: After Break-In Period

    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 the first 100 hours of operation or once yearly, whichever occurs first.
  • Page 43: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 36 Engine Specifications............37 Fuel Ratings ..............36 3.0 TKS................37 Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............... 38 ..................36 Sterndrives ..............38 Gasolines Containing Alcohol ........36 Engine ................
  • Page 44: 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. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).
  • Page 45: Engine Specifications

    Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rated MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle MerCruiser oil Mercury/Quicksilver 25W-40, NMMA FC-W rated 4-cycle MerCruiser oil Other recognized brands of NMMA FC-W rated oils...
  • Page 46: Fluid Specifications

    Fluid Type Engine oil (with filter) 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser 20W‑40, NMMA FC‑W rated oil. Seawater cooling system 9 L (8.5 US qt) Propylene glycol and purified water Mercury Extended Life Coolant Antifreeze or extended life ethylene glycol 5/100 Closed cooling system 9 L (8.5 US qt)
  • Page 47: Section 5 - Maintenance

    Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 40 Cleaning the Flame Arrestor..........50 Dealer Responsibilities............40 Positive Crankcase Ventilation Valve (PCV) ....51 Maintenance................. 40 Changing ............... 51 Do‑It‑Yourself Maintenance Suggestions......40 Changing the Water‑Separating Fuel Filter......52 Inspection................
  • Page 48: Owner/Operator Responsibilities

    It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.
  • Page 49: Inspection

    Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.
  • Page 50: Maintenance Log

    Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting. • Inspect the gimbel bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Vazer models, Alpha models, and 496 MAG Bravo models only: Lubricate the engine coupler.
  • Page 51: Sealed Carburetor Mixture Screw

    Section 5 - Maintenance Date Maintenance Performed Engine Hours 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 52: Filling

    Fluid Type 3.0 TKS 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser Oil 20W‑40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage. IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
  • Page 53: Engine Oil Drain Pump

    Section 5 - Maintenance Pull tether through the bilge drain. 7284 Bilge drain plug Tether Clip Oil drain hose plug Oil drain hose Bilge drain flange Place the oil drain hose in a suitable container. Remove the drain plug from the oil drain hose. After oil has drained completely, install the drain plug in the oil drain hose.
  • Page 54: Power Steering Fluid

    Warm range 7158 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. 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 55: Filling

    17291 The coolant level in the thermostat housing should be at the bottom of the filler neck. If the coolant level is low, contact your authorized Mercury MerCruiser dealer. Install the cap onto the thermostat housing. IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck.
  • Page 56: Changing

    IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lubricant is required to fill the monitor, a seal may be leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer.
  • Page 57 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. 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 lubricant flows from oil vent hole.
  • Page 58: Power Trim Fluid

    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 that the key switch is off and the lanyard is positioned so that the engine cannot start.
  • Page 59: Positive Crankcase Ventilation Valve (Pcv)

    Positive Crankcase Ventilation Valve (PCV) Changing NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations. NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover.
  • Page 60: Changing The Water-Separating Fuel Filter

    The engine fuel pump is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphram. IMPORTANT: If fuel is visible in tube, the fuel pump should be replaced by your Authorized Mercury MerCruiser Dealer immediately.
  • Page 61: Lubrication

    Section 5 - Maintenance Lubrication Steering System WARNING Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely retract the end of the steering cable before applying lubricant. NOTE: If the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased. If the steering cable has grease fittings: Turn the steering wheel until the steering cable is fully retracted into the cable housing.
  • Page 62: Manual Steering System

    Lubricate the steering pin. Steering pin mc71904-1 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Steering pin 92‑883725K01 SAE25W‑40 On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
  • Page 63: Throttle Cable

    Lubricate the pivot points and the guide contact surfaces. Pivot points 7169 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Throttle cable pivot points & 92‑883725K01 SAE25W‑40 guide contact surfaces Shift Cable ‑ Typical Lubricate the pivot points and the guide contact surfaces.
  • Page 64: Sterndrive Unit And Transom Assembly

    Section 5 - Maintenance Sterndrive Unit and Transom Assembly Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun. Gimbal bearing grease fitting mc77068-1 Tube Ref No. Description Where Used Part No. U-joint and Gimbal Gimbal bearing 92-802870A1 Bearing Grease...
  • Page 65: Driveshaft Extension Models

    Where Used Part No. U-Joint and Gimbal Transom end grease fitting, engine end grease fitting, 92-802870A1 Bearing Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 90-879288268 JULY 2009 Page 57...
  • Page 66: Alpha Propeller Removal

    Section 5 - Maintenance 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 67: Drive Belts

    Section 5 - Maintenance Drive Belts 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. Power steering pump pulley Water circulating pump pulley Crankshaft pulley Alternator pulley 7170...
  • Page 68: Replacing - Side Mount Models

    Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Alpha engines with the sterndrive water inlet blocked off at the gimbal housing, and using a through the hull...
  • Page 69: Flushing Attachments

    9192 Sterndrive Water Pickups This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q 5773 Side Pickup NOTE: Flushing is needed only for salty, brackish, mineral‑laden, or polluted water applications. Flushing is recommended after each outing for best results.
  • Page 70: Battery

    Section 5 - Maintenance Connect hose between flushing attachment and water source. With sterndrive in normal operating position, open the water source completely. Place the remote control in the neutral idle speed position and start engine. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine.
  • Page 71 Refer to the Marine Corrosion Protection Guide (90‑88181301). 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 be installed...
  • Page 72 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 64...
  • Page 73 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. MerCathode controller MerCathode assembly 6206 Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. Trim cylinder anodes 7460 Bearing Carrier Anode (Alpha) ‑...
  • Page 74: Painting Your Power Package

    If using copper or tin based anti‑fouling paints, observe the following: • 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 75 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........68 Clearing Clogged Blue Drain Hoses......73 Preparing Power Package for Storage......68 Draining the Sterndrive..........74 Engine and Fuel System Preparation ....69 Battery Storage..............
  • Page 76: Cold Weather Or Extended 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. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures.
  • Page 77: Engine And Fuel System Preparation

    Corrosion Guard Outside of engine 92-802878 55 For sterndrive unit lay‑up, refer to appropriate Mercury MerCruiser sterndrive service manual. Replace the fuel filter. Refer to the Maintenance section for proper procedure. 10. Change the oil and oil filter. Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink.
  • Page 78: Single Point Drain System

    Section 6 - Storage Single Point Drain System CAUTION Disconnecting the blue drain hoses can cause serious burns due to hot water. Check all hose connections before operating the engine and never disconnect the hoses until the engine has had suffient time to cool. NOTICE If the boat is at rest in the water with the engine off, an open seacock or water inlet hose could introduce water into the engine's cooling system or the boat.
  • Page 79: Draining The Seawater Section Of Models With Closed Cooling

    Section 6 - Storage Draining the Seawater Section of Models With Closed Cooling NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
  • Page 80 Section 6 - Storage Remove and lower the hose from the water inlet to the power steering cooler (if equipped), or the water inlet to the heat exchanger. 48856 Power steering cooler, if equipped Water inlet to heat exchanger hose Ensure the gear housing water vent and drain holes, speedometer pitot hole, and trim tab cavity vent and drain holes are open and unobstructed.
  • Page 81: Clearing Clogged Blue Drain Hoses

    Section 6 - Storage Tube Ref No. Description Where Used Part No. Perfect Seal Aft heat exchanger plug 92-34227Q02 Prior to launching the boat or starting the engine, install the drain plugs, reconnect the hoses, and tighten all hose clamps securely.
  • Page 82: Draining The Sterndrive

    13. Check for water draining from the blue drain hose. If the blue drain hose is still clogged, shut off the bilge pump and reattach the blue drain hoses following the steps below. The unit will need to be serviced by an authorized Mercury MerCruiser dealer. Pull the T‑handle until the quick connect fittings on the blue drain hoses are within reach.
  • Page 83: 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. Lower the sterndrive to the full down/in position.
  • Page 84 Section 6 - Storage Notes: Page 76 90-879288268 JULY 2009...
  • Page 85: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, Or Cranks Slow..78 Battery Will Not Recharge............ 79 Engine Will Not Start Or Is Hard To Start......78 Remote Control Is Difficult to Move, Has Excessive Play, or Engine Runs Rough, Misses or Backfires......
  • Page 86: 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 87: Excessive Engine Temperature

    Section 7 - Troubleshooting Possible Cause Remedy 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. Drive belt loose or in poor condition.
  • Page 88: Remote Control Is Difficult To Move, Has Excessive Play, Or Makes Unusual Sounds

    Check all throttle linkages. If any are loose or missing, see Loose or missing shift and throttle linkages. authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair.
  • Page 89: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 82 Parts and Accessories Inquiries ......82 Local Repair Service ............ 82 Resolving a Problem ............ 82 Service Away From Home ..........82 Mercury Marine Service Offices ........
  • Page 90: Owner Service Assistance

    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. If you need additional assistance: Talk with the dealership's sales manager or service manager.
  • Page 91: Mercury Marine Service Offices

    • Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact us at: Mercury Marine Publications P.O. Box 1939...
  • Page 92: 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. Print or type your mailing address, which be used as your shipping label, and include your order and payment. Mail to:...

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