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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 4.3 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

    Mercury Installation Quality Certification Program..... 3 What Is Covered............13 Mercury Product Protection Plan: United States and Canada... 4 Duration of Coverage........... 13 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled How to Obtain Warranty Coverage....... 14 Products Only) ................4 What Mercury Will Do........... 14 3‑Year Limited Warranty Against Corrosion......
  • Page 6 Section 4 - Specifications Fuel Requirements..............40 4.3 TKS................41 Fuel Ratings..............40 5.0 TKS................42 Using Reformulated (Oxygenated) Gasolines (USA Only) 5.7 TKS................42 ..................40 Fluid Specifications..............43 Gasolines Containing Alcohol........... 40 Sterndrives................ 43 Engine Oil................40 Engine................43 Engine Specifications.............
  • Page 7 Multi‑Point Drain (MPD) System........91 Draining the Sterndrive............94 Boat out of the Water............ 91 Battery Storage................ 95 Boat in the Water............93 Recommissioning the Power Package........95 Section 7 - Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow..... 98 Battery Will Not Recharge............
  • Page 8 Page iv 90-8M0053372 NOVEMBER 2010...
  • Page 9 Mercury Product Protection Plan: United States and Canada What Is Covered ............ 13 ....................4 Duration of Coverage ..........13 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled How to Obtain Warranty Coverage ....... 14 Products Only) ............... 4 What Mercury Will Do ..........14 3‑Year Limited Warranty Against Corrosion......
  • 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. 90-8M0053372...
  • 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

    Brazil) 2 years 2 years Brazil Europe, Middle East, 2 years 3 years Africa 3 years 4.3 TKS, 5.0 TKS, 5.7 TKS 2 years Australia, New Zealand 1 year 1 year 1 year Japan 2 years 2 years 2 years...
  • Page 17: Mercury Mercruiser Warranty Charts

    Section 1 - Warranty Mercury MerCruiser Warranty Charts IMPORTANT: Please refer to www.mercurymarine.com/global_warranty for the most currant Global Warranty Charts. Consumer Application Warranty Chart Limited Corrosion Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non‑Certified Boat Brand...
  • 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

    A tamper‑resistant emission control information (ECI) label is affixed to the engine in a visible location at the time of manufacture by Mercury MerCruiser. Please note that the low emissions certification will not affect the fit, function, or performance of the engine. 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: Owner Responsibility

    California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
  • Page 22: How To Obtain Warranty Coverage

    Your Warranty Rights and Obligations NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
  • Page 23: Manufacturer's Warranty Coverage

    Section 1 - Warranty The California Air Resources Board is pleased to explain the emission control system warranty on your 2003 model year and later inboard or sterndrive engine. In California, new inboard and sterndrive engines must be designed, built and equipped to meet the State's stringent anti‑smog standards.
  • Page 24: Emission Certification Star Label

    Beginning January 1, 2003, one Three‑Star or Four‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating or Four‑Star Super Ultra Low Emission rating. The Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2007 and later exhaust emission standards.
  • Page 25 Section 1 - Warranty One Star ‑ Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
  • Page 26 Section 1 - Warranty Notes: Page 18 90-8M0053372 NOVEMBER 2010...
  • Page 27: 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................. 20 Console Mount Features ..........24 Engine Serial Number Decal ........20 Power Trim................24 Bravo Sterndrive Serial Number and Identification..20 Single Engine Trim/Trailer ..........
  • Page 28: 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. Engine Serial Number Decal The serial number decal is located on the engine cover.
  • Page 29: Bravo Transom Serial Number

    The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly. Bravo transom assembly U-bolt plate Transom assembly serial Number 25904 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. Gimbal housing with serial number stamping...
  • Page 30: Instrumentation

    Section 2 - Getting to Know Your Power Package • 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 • high speed boating maneuvers The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
  • Page 31: Remote Controls

    Section 2 - Getting to Know Your Power Package 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 32: 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 33: 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 34 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 35 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 36: 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 37 Section 3 - On the Water Section 3 - On the Water Table of Contents Safe Boating Suggestions............ 30 Passenger Safety in Pontoon Boats and Deck Boats..34 Be Alert to Carbon Monoxide Poisoning....... 31 Boats Having an Open Front Deck ....... 34 Good Ventilation ............
  • Page 38: 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 39: 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 40: 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 41: 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. 90-8M0053372 NOVEMBER 2010...
  • Page 42: 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 43: 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 44: 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 45: Conditions Affecting Operation

    Section 3 - On the Water Conditions Affecting Operation Weight Distribution (Passengers and Gear) Inside the Boat Shifting weight to rear (stern): • Generally increases speed and engine RPM • Causes bow to bounce in choppy water • Increases danger of following wave splashing into the boat when coming off plane •...
  • Page 46: Getting Started

    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 47 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 40 4.3 TKS................41 Fuel Ratings ..............40 5.0 TKS................42 Using Reformulated (Oxygenated) Gasolines (USA Only) 5.7 TKS................42 ..................40 Fluid Specifications............... 43 Gasolines Containing Alcohol ........40 Sterndrives ..............
  • 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. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).
  • Page 49: 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 50: Tks

    Section 4 - Specifications 5.0 TKS NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. All measurements are taken with the engine at normal operating temperature. RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures. Oil pressure must be checked with the engine at normal operating temperature.
  • Page 51: Fluid Specifications

    IMPORTANT: Your application may require more or less than the listed capacity. Use the dipstick to determine the exact quantity of oil or fluid required. 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 52 Section 4 - Specifications Notes: Page 44 90-8M0053372 NOVEMBER 2010...
  • Page 53 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 46 Cleaning the Flame Arrestor..........57 Dealer Responsibilities............46 Positive Crankcase Ventilation Valve (PCV) ....58 Maintenance................. 46 Changing ............... 58 Do‑It‑Yourself Maintenance Suggestions......46 Changing the Water‑Separating Fuel Filter......59 Inspection................
  • Page 54: 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 55: 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 56: Maintenance Log

    • Clean the flame arrestor, IAC muffler, and the crankcase ventilation hoses. Inspect the PCV valve, if equipped. NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal component of the valve cover assembly. • Inspect the condition and the tension of the belts.
  • Page 57: 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 58: Filling

    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 59: Engine Oil Drain Pump

    Section 5 - Maintenance Loosen the oil filter to vent the system. 7284 Bilge drain plug Tether Clip Oil drain hose plug Oil drain hose Bilge drain flange Remove the bilge drain plug. Pull tether through the bilge drain. Place the oil drain hose in a suitable container. Remove the drain plug from the oil drain hose.
  • Page 60: Power Steering Fluid

    Warm range 6631 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 61: Filling

    6101 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. Install the cap onto the heat exchanger. IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck.
  • Page 62: 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 63: Changing

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. High Performance Gear Gear lube monitor 92-858064K01 Lubricant Replace the cap. NOTE: When filling the entire sterndrive unit refer to Changing. Changing Remove the gear lube monitor from the bracket. Gear lube monitor 6109 Empty the contents into a suitable container.
  • Page 64 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 65: 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 66: 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 67: Changing The Water-Separating Fuel Filter

    Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray.
  • Page 68 92-802865Q02 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. Page 60 90-8M0053372 NOVEMBER 2010...
  • Page 69: Throttle Cable

    Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Tie bar pivot points 92‑883725K01 SAE25W‑40 Upon first starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway.
  • Page 70: 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 71: 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 72: 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.
  • Page 73: Bravo One Propeller Removal

    Section 5 - Maintenance Description lb‑in. lb‑ft Propeller nut (minimum) – Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation.
  • Page 74: Bravo Two Propeller Removal

    Section 5 - Maintenance Description lb. in. lb. ft. Propeller nut Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation.
  • Page 75: Bravo Three Propeller Removal

    Slide propeller and thrust hub off propeller shaft. Turn front propeller shaft nut 70 mm (2‑3/4 in.) counterclockwise to remove nut. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut Rear propeller...
  • Page 76: Bravo Three Propeller Installation

    Section 5 - Maintenance Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. Rear propeller nut Rear propeller Rear propeller thrust hub...
  • Page 77: Serpentine Drive Belt

    Section 5 - Maintenance 11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw. Propeller Propeller shaft nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 5303 Tube Ref No.
  • Page 78: Replacing Belt And/Or Adjusting Tension

    Section 5 - Maintenance • Excessive wear • Cracks 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. • Fraying • Glazed surfaces •...
  • Page 79: Flushing The Power Package

    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 80: Alternative Water Pickups

    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. On seawater cooled models: Proceed to Step 5.
  • Page 81 Section 5 - Maintenance Install the appropriate flushing attachment over the water inlet holes in the gear housing. Lower sterndrive unit to full down/in position. If flushing the cooling system with the boat out of the water: Lower sterndrive unit to full down/in position. WARNING Rotating propellers can cause serious injury or death.
  • Page 82: Battery

    Section 5 - Maintenance Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. 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.
  • Page 83 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 be installed (some models have a MerCathode System as standard equipment).
  • Page 84 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 76...
  • Page 85 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 5643 Bearing Carrier Anode (Alpha and Bravo One) ‑...
  • Page 86: 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 87: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........80 Manual Single‑Point Drain System........ 88 Preparing Power Package for Storage......80 Boat in the Water ........... 88 Engine and Fuel System Preparation ....81 Boat out of the Water ..........
  • Page 88: 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 89: 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 90: Drain System Identification

    IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 91: Manual Single Point Drain System

    Section 6 - Storage Manual Single Point Drain System 6128 Blue handle Blue drain plug location Three Point Manual Drain System Blue drain plug 6126 Multi-Point Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 90-8M0053372 NOVEMBER 2010 Page 83...
  • Page 92: Air-Actuated Single-Point Drain System

    Section 6 - Storage 6130 Water circulating pump hose Fuel cooler to thermostat housing Check valve (if equipped) 6131 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. Close the seacock (if equipped) or remove and plug the water inlet hose.
  • Page 93 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 94: Boat Out Of The Water

    Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. Boat out of the Water NOTE: This procedure is written for the air pump that is attached to the engine.
  • Page 95 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 96: 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. Green indicators 6135 Manual Single‑Point Drain System Boat in the Water Close the seacock (if equipped) or remove and plug the water inlet hose. Rotate the blue handle counterclockwise until it stops (approximately two turns).
  • Page 97: Boat Out Of The Water

    Section 6 - Storage Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine.
  • Page 98: Boat Out Of The Water

    Section 6 - Storage Remove the blue drain plug from the distribution housing (lower front, port side). Blue drain plug 6138 To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. Blue drain plug location 6139 Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
  • Page 99: Multi-Point Drain (Mpd) System

    Section 6 - Storage Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug Verify that water is draining from each opening. Allow the system to drain for a minimum of five minutes.
  • Page 100 Section 6 - Storage Water‑circulating pump hose Drain plug 6143 Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 Page 92 90-8M0053372 NOVEMBER 2010...
  • Page 101: Boat In The Water

    Section 6 - Storage 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 102: Draining The Sterndrive

    Section 6 - Storage Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 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 103: Battery Storage

    Section 6 - Storage Insert a small wire repeatedly to make sure that vent holes, water drain holes, and passages are unobstructed and open. 6146 Sterndrive Water Drain Holes Speedometer pitot tube Trim tab cavity vent hole Trim tab cavity drain passage Gear housing water drain hole (one each at port and starboard) Gear housing cavity vent hole Gear housing cavity drain hole...
  • Page 104 Section 6 - Storage Notes: Page 96 90-8M0053372 NOVEMBER 2010...
  • Page 105: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, Or Cranks Slow..98 Battery Will Not Recharge............ 99 Engine Will Not Start Or Is Hard To Start......98 Remote Control Is Difficult to Move, Has Excessive Play, or Engine Runs Rough, Misses or Backfires......
  • Page 106: 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 107: 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 108: 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 109: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........102 Parts and Accessories Inquiries ......102 Local Repair Service ..........102 Resolving a Problem ..........102 Service Away From Home .......... 102 Mercury Marine Service Offices .........
  • Page 110: 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 111: 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 112: 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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