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Mercury HP700 SCi Manual

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Thank You
for your purchase of one of the finest marine power packages
available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy
using this product for many boating seasons. To ensure
maximum performance and carefree use, we ask that you
thoroughly read this manual.
The Operation, Maintenance & 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.
Again, thank you for purchasing one of our Mercury Marine
products. We sincerely hope your boating will be pleasant!
Warranty Message
The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard and the safety
of all occupants aboard. We strongly recommend that the
operator read this Operation, Maintenance and Warranty
Manual and thoroughly understand the operational
instructions for the power package and all related
accessories before the boat is used.
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
WARNING
!
i
7406

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  • Page 1 We suggest that this manual remain with the product for ready reference whenever you are on the water. Again, thank you for purchasing one of our Mercury Marine products. We sincerely hope your boating will be pleasant! Mercury Racing, N7480 County Road "UU"...
  • Page 2 The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not...
  • Page 3 Mariner, Verado, Vazer, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, SmartCraft, VesselView, Quicksilver, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection...

  • Page 5: Table Of Contents

    Warranty Registration United States And Canada......1 Transfer of Warranty..............2 Mercury Racing Division One Year Limited Warranty....2 Products Sold to Government Agencies........6 Warranty Against Corrosion (Worldwide)........6 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products..................7 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT .....................8 General Information Boater's Responsibilities............13...
  • Page 6 TABLE OF CONTENTS Operation Instrumentation................34 Warning System................34 Electrical System Overload Protection........37 Remote Controls (Console Mounted Zero Effort)......40 Power Trim................41 Starting, Shifting and Stopping..........46 Operation Chart.................48 Freezing Temperature Operation..........49 Drain Plug and Bilge Pump............49 Launching And Boat Operation Care.........49 Conditions Affecting Operation Weight Distribution..............50 Bottom Of Boat................50 Cavitation...................50...
  • Page 7 TABLE OF CONTENTS Maintenance Servicing High Horsepower Engines.........53 Service Responsibilities.............53 Replacement Service Parts............54 Do‑It‑Yourself Maintenance Suggestions........54 Maintenance Charts..............56 Checking Fluid Levels..............61 Changing Fluids.................72 Lubrication Points..............88 Sterndrive Cleaver Propeller Installation (NXT¹)......89 Cleaver Propeller Installation (SSM).......... 92 Flushing Cooling System............94 Seawater Pump Impeller Inspection..........94 Cleaning the Seawater (Raw Water) Section of the Engine Oil, Power Steering, Fuel, and Transmission Coolers.....95...
  • Page 8 Seawater Pressure Is Below Specification......125 Owner Service Assistance Local Repair Service..............126 Service Away from Home............126 Parts and Accessories Inquiries..........126 Service Assistance..............126 Mercury Mercruiser Service Offices.........127 Ordering Literature United States and Canada............129 Outside The United States and Canada........129 Maintenance Log Maintenance Log..............130...

  • Page 9: Warranty Information

    1. You may change your address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 10: Transfer Of Warranty

    Fond du Lac, WI 54936-1939 920-929-5054 Fax +1 920 929 5893 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.
  • Page 11 Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products...
  • Page 12 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
  • Page 13 WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and...

  • Page 14: Products Sold To Government Agencies

    WARRANTY INFORMATION 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, and if made, shall not be enforceable against Mercury Marine. For additional...

  • Page 15: Warranty Coverage And Exclusions For Mercury Racing Sterndrive Products

    Warranty is limited to defects in material or workmanship, but 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 Mercury Marine specified pre‑delivery inspection process is completed and documented.

  • Page 16: California Emission Control Warranty Statement

    6. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 7. Engine noise does not necessarily indicate a serious engine problem.
  • Page 17 As the sterndrive engine owner, you should however be aware that Mercury Racing may deny you warranty coverage if your sterndrive engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 18 WARRANTY INFORMATION a. Controlled hot air intake system b. Intake manifold c. Air filter d. Turbocharger system e. Heat riser valve and assembly 3. Ignition System a. Spark plugs b. Magneto or electronic ignition system c. Spark advance/retard system d. Ignition coil and/or control module e.

  • Page 19: Star Label

    WARRANTY INFORMATION a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware b. Pulleys, belts and idlers c. Vacuum, temperature, check, and time sensitive valves and switches d. Electronic Controls STAR LABEL Engines are labeled with one of the following star labels. The Symbol for Cleaner Marine Engines Means: Cleaner Air and Water ‑...
  • Page 20 WARRANTY INFORMATION Three Stars ‑ Ultra Low Emission The Three Star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emissions standards or the Sterndrive and Inboard marine engine 2003‑2008 exhaust emission 22533 standards.

  • Page 21: General Information

    GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the power package.

  • Page 22: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when...

  • Page 23: Trailering Boat

    GENERAL INFORMATION WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard. WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.

  • Page 24: Protecting People In The Water

    GENERAL INFORMATION 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. 21604 Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 25 GENERAL INFORMATION Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea. WARNING Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide.

  • Page 26: Wave And Wake Jumping

    GENERAL INFORMATION While Boat is Moving 5449 Running the boat with the trim angle of the bow too high. Running the boat with no forward hatches open (station wagon effect). GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

  • Page 27: Impact With Underwater Hazards

    GENERAL INFORMATION The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.
  • Page 28 GENERAL INFORMATION Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the sterndrive or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is to control the boat speed.

  • Page 29: Safe Boating Suggestions

    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. After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts.
  • Page 30 GENERAL INFORMATION • Anchor, extra anchor line; water‑proof storage containers. • Manual bilge pump and extra drain plugs; compass and map or chart of area. • Spare operating equipment; batteries, bulbs, fuses, etc. • Transistor radio and drinking water. Know signs of weather change and avoid foul weather and rough-sea boating.
  • Page 31 GENERAL INFORMATION Never be under the influence of alcohol or drugs while boating (it is the law). Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly. Know your boating area and avoid hazardous locations. Prepare other boat operators.

  • Page 32: Stolen Power Package

    Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This Stolen Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines.

  • Page 33: Specifications

    SPECIFICATIONS Power Package Identification ENGINE IDENTIFICATION Model: HP600 SCi 502 C.I.D. Displacement: SERIAL NUMBERS Max WOT RPM: 4800 - 5200 NGK BPR6ES Spark Plugs: ENGINE Spark Plug Gap: 0.035 Inch Spark Timing: **non-adjustable 91 (R+M)/2 or Fuel Octane: DRIVE 98 RON International Engine Oil: **Kendall GT-1 TRANSOM...
  • Page 34 SERIAL NUMBERS RECORD The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting your authorized Mercury Marine dealer about service, always specify model and serial numbers.

  • Page 35: General Engine Specifications (Hp700)

    SPECIFICATIONS 6. NXT¹/SSM - The running rotation is stamped on the back of the gearcase strut. Engine Model/Horsepower: ________________________ Engine Serial Number: ________________________ Transom Assembly Serial Number: ________________________ Sterndrive Serial Number & Gear Ratio: ________________________ Propeller Number & Pitch: _________________________ Running Rotation: _________________________ Hull Identification Number: _________________________ Boat Model &...

  • Page 36: Engine Operating Limitations (Hp700)

    88° C (190° F) (Hot) Fuel Requirements Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness. WARNING Fuel leakage is a fire or explosion hazard, which can cause serious injury or death.
  • Page 37 These reformulated fuels are acceptable for use in your Mercury engine. 1. Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the combustion...

  • Page 38: Low Permeation Fuel Hose Requirement

    The fuel system components on your Mercury 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 39: Oil Recommendations

    SPECIFICATIONS • The Environmental Protection Agency (EPA) requires that any sterndrive manufactured after January 1, 2009 must use low permeation fuel hose for the primary fuel hose connecting the fuel tank to the engine. • Low permeation hose is USCG Type B1‑15 or Type A1‑15, defined as not exceeding 15/gm²/24 h with CE 10 fuel at 23 °C as specified in SAE J 1527 ‑...

  • Page 40: Capacities

    SPECIFICATIONS TEMPERATURE/OIL VISCOSITY CHART Multi-viscosity Kendall 20W 50 SJ, CF-2, CH-4 +100 9160 Capacities Unit Capacity Fluid Type Crankcase Oil Capacity with New 7.6 L (8.5 U.S. qts) Kendall Motor Oil 20W‑50 Filter Supercharger Castrol Syntec Synthetic Motor Oil 177 ml ( 6 U.S. oz) Gearcase 5W‑50 Closed Cooling...

  • Page 41: Engine Break-In

    Frequently check engine oil level. Add oil if needed. It is normal for oil consumption to be high during break‑in period. After Break‑In Period To help extend the life of your power package, Mercury Marine recommends the following: After 5 hr. Break‑in •...

  • Page 42: Operation

    OPERATION Instrumentation It is important to monitor critical engine and boat functions while the boat is in operation. Mercury Racing requires that the following critical engine functions be monitored: • Oil pressure • Engine RPM • Oil temperature • Water temperature •...
  • Page 43 • To stop an activated horn warning, turn off the engine. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem as soon as possible. • If on restart the beeping stops, the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault.
  • Page 44 OPERATION Guardian Activated and Monitor Engine Power Possible Cause Horn Display Reduced Charge Temperature Steady Horn Overheat MAP Sensor Error Steady Horn Oil Temperature Steady Horn High Coil Pack Failure 5 Beeps‑3 Sec. Long Fuel Injector Failure 5 Beeps‑3 Sec. Long Fuel Pump Failure 5 Beeps‑3 Sec.

  • Page 45: Electrical System Overload Protection

    OPERATION Guardian Activated and Monitor Engine Power Possible Cause Horn Display Reduced 2 Beeps‑1 Sec. Long Low Drive Lube Electrical System Overload Protection If an electrical overload occurs, a fuse or circuit breaker opens. Locate and correct the problem before replacing the fuse or resetting the circuit breaker.
  • Page 46 OPERATION 3. A 15 amp fuse, located on the engine's electrical panel, protects the keyswitch power. Check for an open fuse if the key is turned to "START" and nothing happens (and circuit breaker is not tripped). 10138 Ignition switch "I" terminal lead 4.
  • Page 47 OPERATION 6. Eight fuses are located at the upper rear of the engine in two fuse holders (four fuses in each holder). 10310 Fuse holders (2)

  • Page 48: Remote Controls (Console Mounted Zero Effort)

    OPERATION Fuse Holder ‑ C24 Fuse Holder ‑ C25 (1) ‑ 5 amp ‑ RED to RED/GRN Hour (5) ‑ 25 amp ‑ RED/BLK to RED/PNK meter Fuel pump (2) ‑ 15 amp ‑ RED/PPL to RED (6) ‑ 20 amp ‑ RED/GRN to RED/BLU Accessories, Trim switch, Key switch, Main power relay energizing power, ground through PCM...

  • Page 49: Power Trim

    OPERATION 2. Control shifting by moving the shorter control lever(s). This control shifts the unit into gear with full lever movement. Move the lever forward to engage the forward gear. Move lever backward to engage reverse gear. Place the lever in the center position to shift to neutral.
  • Page 50 OPERATION In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3° to 5° angle to the water. 7418 Boat bottom at 3° to 5° angle with water Trimming Drive Unit Up/Out Can: •...
  • Page 51 OPERATION Trimming Drive Unit Down/In Can: 7420 • Help the boat accelerate and plane off quicker. • Generally improve the ride in choppy water. • In most cases, reduce boat speed. • Lower the bow of some boats to a point at which they begin to "plow".
  • Page 52 OPERATION 7867...
  • Page 53 OPERATION Control - Used to control both drive units from the handle. Press up on the button(s) to trim drive unit up or out. Press down on button(s) to trim drive unit down or in. Trailer Button - Press button until drive unit reaches desired height to prevent the drive units from contacting the ground while the boat is being trailered.

  • Page 54: Starting, Shifting And Stopping

    OPERATION NOTE: The word trim is usually considered the first 20° up/out movement from vertical position. 7868 Trailering and trimming up/out position - Press (top) up/ out portion of switch until drive unit reaches desired trim/ trailering position. Trim drive unit in/down position - Press (bottom) in/down portion of switch until drive unit reaches desired trim position.
  • Page 55 OPERATION IMPORTANT: Observe the following: • Do not start the engine without supplying water to the seawater pickup pump (to prevent pump or engine damage). • Do not operate the starter motor continuously for more than 30 seconds. • Never shift the drive unit unless the engine is at idle RPM. Perform the following as appropriate: Check all items listed in Operation Chart.

  • Page 56: Operation Chart

    OPERATION 3. If the engine is cold, make sure the engine is idling smoothly before operating the boat. 4. After the engine has warmed up, check the water temperature gauge to ensure that the engine temperature is not abnormally high. If it is, stop the engine immediately and determine cause.

  • Page 57: Freezing Temperature Operation

    Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. The bilge drain can be used to change crankcase oil. Refer to the Maintenance section.

  • Page 58: 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) may: • Increase speed and engine RPM. • Cause the boat to porpoise. • Cause the bow to bounce in choppy water. •...

  • Page 59: Ventilation

    (WOT) and operating RPM range are listed in Specifications. IMPORTANT: All Mercury Racing engines have a RPM rev‑limiter that is set to an upper (or limited) RPM. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM.

  • Page 60: Conditions That Lower Engine Performance

    CONDITIONS AFFECTING OPERATION • Operating in a higher elevation. • Operating with a damaged propeller or dirty boat bottom. • Operating with increased load (additional passengers, pulling skiers, etc.). Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems.

  • Page 61: Servicing High Horsepower Engines

    Perform all safety checks. • Make sure lubrication and maintenance instructions are complied with for safe operation. • Return the unit to an authorized Mercury Marine dealer for a periodic checkup. • Perform normal maintenance service using authorized replacement parts.

  • Page 62: Replacement Service Parts

    These are but a few of the many special modifications that are required in Mercury Marine engines to provide long life and dependable performance. Do‑It‑Yourself Maintenance Suggestions If you are one of those persons who likes to do‑it‑yourself, here are...
  • Page 63 Do not telephone the dealer, service office or the factory to attempt for them to diagnose a problem or request the repair procedure. It is difficult for them to diagnose a problem over the telephone. • Your authorized Mercury Marine dealer is there to service your power package. They have qualified factory‑trained...

  • Page 64: Maintenance Charts

    Some listings can be done by the owner/operator, while others should be performed by an authorized Mercury Marine dealer. Before attempting maintenance or repair procedures not covered in this manual, Mercury Marine recommends purchasing a Mercury Marine Service Manual.
  • Page 65 MAINTENANCE Interval Task Battery ‑ Check water level and inspect for corrosion or damage Inspect external water pickups ‑ Check for marine growth or debris Every 25 hours of operation or once every 30 days, whichever occurs first Sea Pump/Fuel Pump ‑ Check the oil level and inspect for fuel contamination Engine Oil and Filter ‑...
  • Page 66 MAINTENANCE Interval Task Perform all 25 hour and 50 hour maintenance items Supercharger ‑ Change oil Power Package Exterior Surfaces ‑ Clean and paint Engine Cylinder Compression ‑ Check Engine and Power Steering Oil Coolers ‑ Clean the seawater sections Positive Crankcase Ventilation (PCV) Every 100 hours of operation or once Valve ‑...
  • Page 67 MAINTENANCE DRY SUMP NXT¹ DRIVE SCHEDULED MAINTENANCE Interval Task Drive, Transom, and Propeller ‑ Inspect. Lower Gear Housing Oil ‑ Check level. Power Trim Pump Oil ‑ Check level and Check prior to use and every 3 hours for any water contamination. Replace if of operation.
  • Page 68 Depending on the type of boat, optional equipment, the application and/or conditions of use, it may be required that the maintenance intervals be modified. Work closely with your authorized Mercury Marine dealer to develop a specific maintenance schedule designed for your application. Interval Task Drive, Transom, and Propeller ‑...

  • Page 69: Checking Fluid Levels

    MAINTENANCE Interval Task Perform 25 Hour Maintenance Items. Drive Mounting Nuts ‑ Tighten to 136 Nm (100 lb. ft.) Every 50 hours of operation. Steering System ‑ Inspect for loose, damaged or missing parts. Lubricate the steering cylinder pivot points. Peform 25 and 50 Hour Maintenance Items.
  • Page 70 MAINTENANCE 1. Stop the engine. 2. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water or at the approximate angle that it would be if setting in the water. 3.
  • Page 71 If the oil level increases, decreases, or changes to an abnormal color, there may be an internal problem with the supercharger. Contact your authorized Mercury Marine dealer. 1. Stop the engine. 2. Allow approximately 5 minutes for the oil in the supercharger case to settle and the sight‑glass to clear.
  • Page 72 MAINTENANCE 2. Remove the fill cap/dipstick and observe the level. The oil level must be between the lower and upper marks. 3. Add power steering fluid if required to bring the oil level up to the full mark on the cap/dipstick. 21834 Reservoir cap Full fluid mark...
  • Page 73 MAINTENANCE NOTE: Vapor or condensation can occur in the tube and is acceptable. 16981 Fuel pump sight tube (routed from pump, past the intake manifold, and into the throttle body) CHECKING SEAWATER/FUEL PUMP OIL IMPORTANT: Change the oil at specified intervals. Refer to the Maintenance Chart for specific requirements.
  • Page 74 2. Oil should be up to the bottom of the fill hole. A low oil level indicates that there is an internal problem, and that you should contact your authorized Mercury Marine dealer for appropriate service. Do not operate engine if this oil level is low.
  • Page 75 MAINTENANCE 1. Check the coolant level in the coolant reservoir when the engine is cold. Coolant should be at the "COLD FULL" line marked on the front of the reservoir or to the top of the raised bosses on the back of the reservoir. Add specified coolant by turning the cap 1/4 turn to allow any pressure to escape slowly, then push down and turn the cap all the way off.
  • Page 76 MAINTENANCE 1. Place the sterndrive unit in the full down/in position. 2. Check the fluid level in the trim pump reservoir. The level should be between the "MIN" and "MAX" level marks on the reservoir. 3. If necessary, remove the fill cap and add Power Trim and Steering Fluid until the level in the reservoir reaches the "MIN"...
  • Page 77 MAINTENANCE CHECKING TRANSOM INPUT SHAFT BEARING HOUSING (DRIVE-LINE MODELS ONLY) 1. Remove the level indication (middle) pipe plug from the input shaft housing. Gear lube level should be to the bottom of the hole. If not, remove the pipe plug from the top of the input shaft housing.
  • Page 78 MAINTENANCE CHECKING NXT¹ DRIVE UNIT GEAR LUBE 1. Remove the upper vent plug from the gearcase. The gear lube level should be to the bottom of the vent plug hole with the propeller shaft level. 2. If gear lube level is low, add High Performance Gear Lube until gear lube comes out of the vent plug opening.
  • Page 79 MAINTENANCE 3. Install the vent plug. 7429 Vent Plug Fill/Drain Plug Tube Ref Description Where Used Part No. VI Drive Gear Torco MTF Gear Oil 92-849684 1 Housing CHECKING TRANSMISSION FLUID LEVEL IMPORTANT: Wait at least 30 minutes before checking the transmission fluid level to avoid inaccurate readings.

  • Page 80: Changing Fluids

    MAINTENANCE 2. Remove the fill plug and add High Performance Gear Lube as necessary to bring the fluid level within the cross‑hatched area above the "ADD" mark on the dipstick. 21710 Dipstick Fill plug ADD mark Tube Ref No. Description Where Used Part No.
  • Page 81 MAINTENANCE IMPORTANT: Change oil when the engine is warm from operation. Warm oil flows more freely, carrying away more Specifications ). impurities. Use only recommended motor oil (see NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum (approximately 1/4 turn).
  • Page 82 MAINTENANCE 3. Insert the hose end of the crankcase oil pump into an appropriate container and pump out the oil until the crankcase is empty. 10460 Crankcase oil pump Crankcase oil pump hose 4. Remove the crankcase oil pump. 5. Place a container below the oil filter. 6.
  • Page 83 MAINTENANCE 8. Tighten the filter securely by hand. Do not overtighten. 25262 Oil filter sealing ring 9. Remove the oil filler cap (port or starboard). 10. Add enough oil to bring the oil level into the "OK RANGE" on the dipstick; approximately 8 L (8.5 qts.). IMPORTANT: Engine crankcase capacity is 8 L (8.5 qts.).
  • Page 84 MAINTENANCE 11. Start the engine and check for proper oil pressure. Allow the engine to idle for one minute and verify that no oil is leaking. 12. Shut off the engine. 13. Wait a few minutes for the engine oil to return to the crankcase and then check the oil level.
  • Page 85 MAINTENANCE 1. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up. 2. Open the water tap to supply enough flow to the sea pump so that suction created by the sea pump, does not collapse the supply hose.
  • Page 86 MAINTENANCE 5. Remove the bilge plug. The oil drain hose is tethered to the plug. 6150 Bilge drain plug Bilge drain flange Tether Oil drain hose Oil drain plug 6. Pull the oil drain hose through the bilge drain flange. 7.
  • Page 87 MAINTENANCE 11. Coat the sealing ring on the new filter with new motor oil. Install the sealing ring and filter. Tighten the filter securely by hand. Do not overtighten. 25262 Oil filter sealing ring 12. Using two wrenches, connect the oil drain hose plug to the oil drain hose and place it back into the boat.
  • Page 88 Contact your authorized Mercury Marine dealer. 1. Attach a water hose to the boat's external water pickup, to allow water to be supplied to the engine block during engine warm‑up.
  • Page 89 MAINTENANCE 7. Remove the drain plug and drain the oil. 8. Clean and inspect the plug O‑rings, the gearcase fill and drain hole threads, and the plug threads. 9. Install the drain plug in the gearcase and tighten to specifications. 10.
  • Page 90 MAINTENANCE CHANGING ENGINE COOLANT Contact your authorized Mercury Marine dealer. CHANGING TRANSMISSION OIL 1. Remove the bilge plug and pull the drain hose through the transom. 2. Using two wrenches, separate the drain plug from the hose. 6150 Bilge plug...
  • Page 91 MAINTENANCE Tube Ref No. Description Where Used Part No. High Performance Transmission 92-858064K01 Gear Lubricant Capacity Fluid Type Transmission 1 Liter (1.1 Qts.) High Performance Gear Lubricant CHANGING NXT¹ DRIVE UNIT GEAR LUBE 1. Remove propeller, position drive unit so propeller shaft is level.
  • Page 92 4. Remove fill/drain screw and vent screw from gear housing and drain the gear lube. IMPORTANT: If any water drained, or if gear lube appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser Dealer. 21210 Tab washer Fill/drain screw 5.
  • Page 93 MAINTENANCE 6. Install vent screw and remove tube from fill/drain hole. Quickly install the fill/drain screw. Tighten securely. 21733 Oil level hole Level 7. Install tab washer. 21210 Tab washer Fill/drain screw...
  • Page 94 2. Remove the fill/drain screw, sealing washer, vent screw, and sealing washer from the gear housing. IMPORTANT: If any water drained, or if gear lube appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser Dealer.
  • Page 95 MAINTENANCE 3. Fill the drive unit through the fill/drain hole with Torco MTF Gear Oil until an air‑free stream of lubricant flows from the gear oil level hole of gear housing. 7429 Top vent screw Fill/drain screw Tube Ref Description Where Used Part No.

  • Page 96: Lubrication Points

    MAINTENANCE 4. Remove the plug from the fill level hole. 5. Pour High Performance Gear lube into the fill hole until fluid starts to come from the fill level hole. 6. Install both plugs and tighten securely. 21730 Fill hole Fill level Drain Lubrication Points...

  • Page 97: Sterndrive Cleaver Propeller Installation (Nxt¹)

    MAINTENANCE • Throttle linkage and cable ‑ Lubricate cable and swivels. 10305 Lubrication points Tube Ref No. Description Where Used Part No. MerCruiser 4-cycle Pivot points 92-858048K01 25W40 Engine Oil Sterndrive Cleaver Propeller Installation (NXT¹) IMPORTANT: Ensure that the propeller direction of rotation matches the propeller shaft direction of rotation.
  • Page 98 25.4 mm (1 in.) gap between propeller tips to prevent damage to the propellers and other equipment. 21685 Nylon Nut Bushing Jam nut Retaining ring Washer Adaptor (Mercury Racing sterndrive cleaver propeller) 1. Install the adaptor into the propeller, as shown.
  • Page 99 MAINTENANCE 2. Install the bushing and secure with the retaining ring as shown. 21686 Propeller Bushing Adaptor Retaining ring 3. Coat the propeller shaft splines with Anti‑Corrosion Grease. 4. Install the propeller/adaptor assembly to the propeller shaft. 21685 Nylon nut Bushing Jam nut Retaining ring (installed...

  • Page 100: Cleaver Propeller Installation (Ssm)

    MAINTENANCE 5. Place a wooden block between the blades and the anti‑ventilation plate to prevent the propeller from turning. Tighten the jam nut to specification and install the nylon nut and tighten to specification. Description lb. in. lb. ft. Nylon nut, Jam nut 6.
  • Page 101 MAINTENANCE NOTICE Improper installation can cause gear housing damage. Always use a new propeller bushing when installing the propeller on a IIIa, IV, or V SSM Drive. 16141 Plastic bushing retainer Washer Plastic bushing Prop nut Tube Ref Description Where Used Part No.

  • Page 102: Flushing Cooling System

    10 minutes or until discharge water is clear. Stop the engine, shut off the water, and remove the flushing hose. Seawater Pump Impeller Inspection Service should be performed by an authorized Mercury MerCruiser dealer.

  • Page 103: Cleaning The Seawater (Raw Water) Section Of The Engine Oil, Power Steering, Fuel, And Transmission Coolers

    MAINTENANCE 1. Inspect seawater pump impeller if insufficient seawater flow occurs or if operating temperature exceeds normal range. 8022 Seawater pump Cleaning the Seawater (Raw Water) Section of the Engine Oil, Power Steering, Fuel, and Transmission Coolers NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat.
  • Page 104 MAINTENANCE 3. Flush the passages with fresh water. 4. Inspect the gaskets for deterioration and replace if necessary. 5. Install the gaskets and end plates. Tighten the screws securely. POWER STEERING COOLER NOTE: The power steering cooler is located on the lower port side of the engine.
  • Page 105 MAINTENANCE 2. If the fuel hoses need to be removed from the cooler, have this service done by an authorized Mercury Marine dealer. 10262 Hose clamps to the fuel cooler 3. Re‑install the cooler and tighten the hose clamps securely.

  • Page 106: Serpentine And Supercharger Drive Belts

    MAINTENANCE 5. Install the hoses and clamps. Tighten the screws securely. Serpentine and Supercharger Drive Belts SERPENTINE DRIVE BELT ROUTING AND TENSION 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.
  • Page 107 MAINTENANCE Description New Belt Used Belt 2. Loosen the 5/8 in. locking nut on the adjusting screw. Leave the wrench on the adjustment nut. 3. Use a 5/16 in. socket and tighten the adjusting screw until the belt tension conforms to the correct setting on the gauge. 4.
  • Page 108 MAINTENANCE SUPERCHARGER DRIVE BELT ROUTING AND TENSION 10289 Supercharger pulley Idler pulley Self adjusting belt Supercharger belt tensioner Crankshaft pulley The supercharger belt uses a self tensioner and does not require tension adjustment.

  • Page 109: Fuel Filters

    MAINTENANCE INSPECTING BELTS NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable. 6164 Fraying Transverse cracks Longitudinal cracks The belt will have to be replaced for the following conditions: •...
  • Page 110 Fuel System Prior to Starting in the Cold Weather or Extended Storage section of this manual.) 5. Check the filter for gasoline leaks. If leaks exist, re‑check the filter installation. 6. If leaks continue, stop the engine immediately and contact your authorized Mercury Marine dealer.
  • Page 111 MAINTENANCE Final Fuel Filter WARNING Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing.
  • Page 112 MAINTENANCE 5. To replace the spring, use a needle‑nose pliers and grasp the edge of the spring and screw it into the cannister inlet opening in a counter‑clockwise direction. The spring must be centered in the cannister to engage the pocket on the inlet side of the fuel filter.

  • Page 113: Corrosion And Corrosion Protection

    MAINTENANCE Corrosion and Corrosion Protection Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals.
  • Page 114 Replace sacrificial anodes if eroded 50% or more. Mercury Marine recommends using anodes sold through Mercury Precision Parts only. Some other manufacturers of aluminum anodes use alloys that are insufficiently pure to adequately protect critical drive components for the duration of the anodes' expected life.
  • Page 115 MAINTENANCE b. If using copper or tin based anti‑fouling paints, avoid any electrical interconnection between the Mercury Marine Product, anodic blocks, and the paint by allowing a minimum of 40 mm (1.5 in.) unpainted area on the transom of the boat around these items.

  • Page 116: Battery

    MAINTENANCE • Paint the drive unit and transom assembly with a good quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct electrical current. Do not paint drain holes, anodes, or items specified by the boat manufacturer.

  • Page 117: Bottom Of Boat

    2. Check plug leads and electrical leads for damage. 3. Remove and inspect the propeller. If nicked, bent or cracked, see your authorized Mercury Marine dealer. 4. Repair nicks and corrosion damage on the power package's exterior finish. Use Quicksilver spray paints ‑ see your...

  • Page 118: Attention Required After Submersion

    MAINTENANCE Attention Required After Submersion • Before recovery, contact an authorized Mercury Marine dealer. • After recovery, immediate service by an authorized Mercury Marine dealer is required to prevent serious damage to power package.

  • Page 119: Cold Weather Or Extended Storage

    Mercury Marine dealer. NOTE: Mercury Marine recommends that the power package lay‑up be performed by an authorized Mercury Marine dealer. Flushing the cooling system and preparing the fuel system for extended storage can be done at the same time. Perform all annual inspections, lubrication, and fluid changes as outlined in the Maintenance Charts of this manual.
  • Page 120 COLD WEATHER OR EXTENDED STORAGE 7. Connect the remote outboard fuel tank supply line to the mechanical fuel pump inlet. 13030 Mechanical fuel pump 23 L (6 U.S. gal) remote outboard fuel tank Fuel inlet Primer bulb (optional) 8. Open the water tap to supply enough water flow to the sea pump so that suction created by the sea pump, does not collapse the supply hose and cause the engine to overheat while running.
  • Page 121 COLD WEATHER OR EXTENDED STORAGE IMPORTANT: Do not run the engine's fuel system dry of the fogging mixture in the 23 liter (6 U.S. gal) remote outboard fuel tank. 11. Check the water discharge from the engine. It should be clear when the system is properly flushed.

  • Page 122: Cooling System Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE Cooling System Draining Instructions 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 124 COLD WEATHER OR EXTENDED STORAGE 16941...
  • Page 125 COLD WEATHER OR EXTENDED STORAGE Exhaust header balance Exhaust header rail plastic wing‑nut plugs distribution rail plastic (2, Starboard side) wing‑nut plugs (2, Port side, one plug is hidden) Fuel cooler plastic wing‑nut plug Transmission cooler ‑ remove hose to drain Sea water inlet hose ‑...

  • Page 126: Battery Storage

    COLD WEATHER OR EXTENDED STORAGE 4. Place the hose into the container of premixed antifreeze. The antifreeze mixture should be at the correct concentration level to protect the engine to the lowest temperature to which it will be exposed during cold weather or extended storage. 13180 Seawater inlet valve To the seawater pump...
  • Page 127 COLD WEATHER OR EXTENDED STORAGE 1. Ensure that all cooling system hoses are connected properly and hose clamps are tight, all removed drain plugs have been installed and are tight. CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system.
  • Page 128 COLD WEATHER OR EXTENDED STORAGE 7. Check shifting and throttle control for proper operation.

  • Page 129: Troubleshooting

    TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch "OFF". Switch to "ON" position. Remote control not in neutral position. Position control lever to neutral. Open 50 amp circuit breaker or 15 or 90 Check and reset circuit breaker or amp fuse circuit.

  • Page 130: Engine Hard To Start, Runs Rough, Misses, And/Or Backfires

    TROUBLESHOOTING Engine Hard to Start, Runs Rough, Misses, and/or Backfires Possible Cause Remedy Faulty ignition system component. Service ignition system. Dirty fuel filter. Replace filters. Drain the fuel tank and fill it with fresh Stale or contaminated fuel. fuel. Replace damaged lines or clean out lines Fuel line or fuel tank obstructed.

  • Page 131: Engine Coolant Temperature Too High

    TROUBLESHOOTING Engine Coolant Temperature Too High Possible Cause Remedy Seacock closed. Open. Serpentine belt loose or in poor condition. Replace or adjust belt. Recirculating pump defective. Replace. Seawater pickups obstructed. Inspect. Faulty thermostat. Replace. Oil cooler cores plugged with foreign Clean cooler cores.

  • Page 132: Power Trim Does Not Operate (Motor Doesn't Run)

    TROUBLESHOOTING Power Trim Does Not Operate (Motor Doesn't Run) Possible Cause Remedy Open fuse. Replace fuse. Check all associated electrical connections and Loose or dirty electrical wires (especially battery cables). Clean and connections or damaged tighten faulty connections. Repair or replace wiring.

  • Page 133: Remote Control Operates Hard, Binds, Has Excessive Free-Play Or Makes Unusual Sounds

    Insufficient lubrication on shift and throttle Lubricate. linkage fasteners. Check all linkages. If any are loose Loose or missing shift and throttle linkage or missing, see authorized Mercury fasteners. Marine dealer immediately. Shift or throttle cable kinked. Replace cable. Friction adjustment excessive.

  • Page 134: Owner Service Assistance

    If you ever have a problem, question or concern about your Sterndrive or Inboard product, contact your dealer or any authorized Mercury Marine dealer. If additional assistance is required, take these steps. 1. Talk with the dealership's sales manager or service manager.

  • Page 135: Mercury Mercruiser Service Offices

    Model and serial number of your outboard • The name and address of your dealership • Nature of problem Mercury Mercruiser Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone Mercury MerCruiser 3003 N.
  • Page 136 Mexico, Central America, South America, Caribbean Telephone Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3500 (954) 744‑3535 U.S.A. Japan Telephone Mercury Marine - Japan 283-1 Anshin-cho Hamamatsu Shizuoka, 435-0005 81‑53‑423‑2500 81‑53‑423‑2510 Japan Asia, Singapore Telephone Mercury Marine- Singapore 72 Loyang Way...

  • Page 137: Ordering Literature

    Horsepower: Model: Serial Model year: Number: 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: MERCURY MARINE Telephone Mail Mercury Marine Attn: Publications Department (920) 929‑5110 (920) 929‑4894...

  • Page 138: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

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