MerCruiser Sterndrive 4.3L TKS Owner's Manual
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MerCruiser Sterndrive 4.3L TKS Owner's Manual

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

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  • Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
  • Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.

  • Page 3: Read This Manual Thoroughly

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

  • Page 5: Table Of Contents

    How To Obtain Warranty Coverage....12 Mercury Product Protection Plan: United States and What Mercury Will Do........13 Canada..............3 What Is Not Covered........13 Mercury MerCruiser Limited Warranty Components Of The Emission Control System 13 (Gasoline‑Fueled Products Only) ......4 Disclaimers And Limitations......14 3‑Year Limited Warranty Against Corrosion....6 California Emission Control Warranty Statement.
  • Page 6 Operating With Low Water Inlets In Shallow Ventilation............. 41 Water..............40 Elevation And Climate........42 Conditions Affecting Operation......41 Propeller Selection........42 Weight Distribution (Passengers and Gear) Getting Started............. 42 Inside the Boat..........41 20‑Hour Break‑In Period....... 42 Bottom Of Boat..........41 After Break‑In Period........43 Cavitation............
  • Page 7 Serpentine Drive Belt..........80 Sterndrive Water Pickups.........82 Checking............80 Alternative Water Pickups.........84 Replacing Belt and/or Adjusting Tension..80 Battery..............85 Flushing the Power Package.........81 Corrosion Protection..........86 Flushing Attachments........82 Painting Your Power Package......90 Section 6 - Storage Cold Weather or Extended Storage....... 94 Manual Single Point Drain System....104 Preparing Power Package for Storage...94 Boat in the Water........104 Engine and Fuel System Preparation..95...
  • Page 8 Page iv 90-860171061 DECEMBER 2006...
  • Page 9 Mercury Product Protection Plan: United States and What Is Not Covered ........13 Canada..............3 Components Of The Emission Control System Mercury MerCruiser Limited Warranty (Gasoline- ..............13 Fueled Products Only) ......... 4 Disclaimers And Limitations ......14 3-Year Limited Warranty Against Corrosion..6...

  • Page 10: Warranty Registration: United States And Canada

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

  • Page 11: Transfer Of Warranty

    Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.

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

    One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
  • Page 13 Section 1 - Warranty 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 Mercury Marine is completed and documented.

  • 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: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines

    This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or 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 Warranty Charts

    Section 1 - Warranty This limited warranty does not cover the following: • Electrical system corrosion • Corrosion resulting from damage • Corrosion that causes purely cosmetic damage • Abuse or improper service • Corrosion to accessories, instruments, and steering systems •...

  • Page 17: 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 Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...

  • Page 18: Government Application Warranty Chart

    Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...

  • Page 19: Mercury Installation Quality Certification Program 10 California Emissions Limited Warranty

    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 20: Duration Of Coverage

    Duration Of Coverage 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...

  • Page 21: What Mercury Will Do

    Section 1 - Warranty What Mercury Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product.

  • Page 22: Components Of The Emission Control System 13 Disclaimers And Limitations

    Mercury Marine. 1. 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: Owner's Warranty Responsibilities

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

  • Page 24: Owner Responsibility

    Beginning January 1, 2003, one Three‑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. The Three‑Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards.
  • Page 25 Section 1 - Warranty The Three‑Star label will be affixed on the left side of the hull as shown. XX 1234 XX mc79531 Recommended location Secondary location 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.
  • Page 26 Section 1 - Warranty Notes: Page 18 90-860171061 DECEMBER 2006...

  • 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 ......25 Engine Serial Number Decal ......20 Power Trim............25 Bravo Sterndrive Serial Number and 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

    Bravo transom assembly U‑bolt plate Transom assembly serial Number The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. 25905 Gimbal housing with serial number stamping Transom assembly serial Number...

  • Page 30: Lanyard Stop Switch

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

  • Page 31: Instrumentation

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

  • Page 32: Remote Controls

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

  • Page 33: Console Mount Features

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

  • Page 34: Single Engine Trim/Trailer

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

  • Page 35: Dual Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only. Dual Engine Trim/Trailer CAUTION Avoid twisting or binding dual engine tie bars. Damage to the tie bar and sterndrives could occur.
  • Page 36 Section 2 - Getting to Know Your Power Package 2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs. mc74907-1 3.

  • Page 37: 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 38: Testing The Audio Warning System

    If the warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation. If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System 1.
  • Page 39 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........32 Boats Having An Open Front Deck ....38 Be Alert To Carbon Monoxide Poisoning... 33 Boats With Front-Mounted, Raised Pedestal Good Ventilation ........... 34 Fishing Seats ..........

  • Page 40: Safe Boating Suggestions

    Know and obey all nautical rules and laws of the waterways. • Mercury MerCruiser strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency.

  • Page 41: Be Alert To Carbon Monoxide Poisoning

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

  • Page 42: Good Ventilation

    Section 3 - On The Water Good Ventilation Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.

  • Page 43: Starting And Stopping The Engine

    Section 3 - On The Water Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Close seacock, if Operate bilge blowers. Check steering operation. equipped. Flush cooling system if in Open fuel shut off valve. saltwater. Open seacock, if Drain bilge.

  • Page 44: Stopping The Engine

    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. Page 36 90-860171061 DECEMBER 2006...

  • Page 45: Drain Plug And Bilge Pump

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

  • Page 46: Passenger Safety In Pontoon Boats And Deck Boats

    Section 3 - On The Water Passenger Safety In Pontoon Boats And Deck Boats Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed.

  • Page 47: Wave And Wake Jumping

    Section 3 - On The Water Wave And Wake Jumping WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to any boat hand hold.

  • Page 48: 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 49: Conditions Affecting Operation

    Section 3 - On The Water NOTICE Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict cooling water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water.

  • Page 50: Elevation And Climate

    Section 3 - On The Water Elevation And Climate Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by: • Higher elevations • Higher temperatures • Low barometric pressures • High humidity For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating...

  • Page 51: 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 52 Section 3 - On The Water Notes: Page 44 90-860171061 DECEMBER 2006...

  • Page 53: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........46 Engine Oil............47 Fuel Ratings ..........46 Engine Specifications......... 48 Using Reformulated (Oxygenated) Gasolines Fluid Specifications..........48 (USA Only) ........... 46 Sterndrives ........... 48 Gasolines Containing Alcohol ...... 46 Engine ............

  • Page 54: Fuel Requirements

    The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand.

  • Page 55: Engine Oil

    To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of the following oils listed in the order of recommendation: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC‑W rated, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC‑W rated oil.

  • Page 56: Engine Specifications

    1. Performance obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power. 2. Measured using an accurate service tachometer with the engine at normal operating temperatures 3. A special procedure must be followed to adjust idle RPM. Consult your Authorized Mercury MerCruiser Dealer before attempting this procedure.
  • Page 57 Section 4 - Specifications 4.3L (262 CID) Models Capacity Fluid Type Mercury/Quicksilver Synthetic Blend MerCruiser 3.8 liters (4 U.S. qt.) Engine Oil (With Filter) Engine Oil 25W‑40 14.1 liters (15 U.S. qt.) Propylene Glycol and Purified Water Seawater Cooling System...
  • Page 58 Section 4 - Specifications Notes: Page 50 90-860171061 DECEMBER 2006...
  • Page 59 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......52 Changing ............63 Dealer Responsibilities........52 Power Trim Fluid..........65 Maintenance............52 Checking ............65 Do It Yourself Maintenance Suggestions... 53 Filling ............65 Inspection............53 Changing ............

  • Page 60: Owner/Operator Responsibilities

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

  • Page 61: Do It Yourself Maintenance Suggestions

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

  • Page 62: Maintenance Schedule - Sterndrive Models

    Scheduled Maintenance NOTE: Only perform maintenance which applies to your particular power package. AFTER THE INITIAL 20 HOUR BREAK-IN PERIOD To help extend the life of your Mercury MerCruiser power package, we reccommend the following: • Change the engine oil and filter •...

  • Page 63: Every 200 Hours Or 3 Years

    Section 5 - Maintenance • Driveshaft extension models: Lubricate the driveshaft U‑joints, and tailstock input and output bearings. EVERY 200 HOURS OR 3 YEARS • Inspect the U‑joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting.

  • Page 64: Sealed Carburetor Mixture Screw

    Section 5 - Maintenance Date Maintenance Performed Engine Hours Sealed Carburetor Mixture Screw CAUTION Do not remove mixture screw seals and/or attempt to adjust fuel mixture setting. Tampering with the mixture setting on this engine could affect the exhaust emissions level, thus voiding the emissions certification.

  • Page 65: Changing Oil And Filter

    Fluid type 4.3L (262 cid) 3.8 liters (4 U.S. qt.) 5.0L (305 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 4.25 liters (4.5 U.S. qt.) 5.7L (350 cid) 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 66: Engine Oil Drain Pump

    4.3L (262 cid) 3.8 liters (4 U.S. qt.) 5.0L (305 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 4.25 liters (4.5 U.S. qt.) 5.7L (350 cid) 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.

  • Page 67: Power Steering Fluid

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

  • Page 68: Filling

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

  • Page 69: Changing

    92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat.

  • Page 70: Filling

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

  • Page 71: Changing

    Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 6109 Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
  • Page 72 IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of...

  • Page 73: Power Trim Fluid

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

  • Page 74: Changing

    9. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover. Positive Crankcase Ventilation Valve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with emission regulations. Page 66 90-860171061 DECEMBER 2006...

  • Page 75: Changing Water Separating Fuel Filter

    Wipe up any spilled fuel immediately. Ensure that no fuel leaks exist before closing the engine hatch. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped.

  • Page 76: Lubrication

    10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Steering System WARNING Do not grease the steering cable while it is extended.
  • Page 77 3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.

  • Page 78: Throttle Cable

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

  • Page 79: Sterndrive Unit And Transom Assembly

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

  • Page 80: 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 81: Propellers

    Section 5 - Maintenance Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Avoid Injury: Remote Control must be in neutral and ignition key removed from switch before removing and/or installing propeller.

  • Page 82: Bravo One Propeller Removal

    Section 5 - Maintenance 1. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865A1 Anti-Corrosion Grease Propeller shaft 92-802867A1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon...

  • Page 83: Bravo Two Propeller Removal

    Section 5 - Maintenance IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. 6215 Propeller shaft Drive sleeve Thrust hub Locking tab washer Flo‑Torq II drive hub Propeller nut Propeller 1.

  • Page 84: Bravo Two Propeller Installation

    Section 5 - Maintenance WARNING A rotating propeller can cause injury. Place a block of wood between the anti‑ventilation plate and the propeller to protect hands from the propeller blades, and to prevent the propeller from rotating when removing or installing the propeller nut. 1.

  • Page 85: Bravo Three Propeller Removal

    Section 5 - Maintenance 6. Bend 3 tabs on the tab washer down into the grooves in spline washer. After the first use, bend the 3 tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.

  • Page 86: Bravo Three Propeller Installation

    Section 5 - Maintenance NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304 Rear propeller nut Front propeller thrust hub Rear propeller Propeller shaft anode screw Rear propeller thrust hub Flat washer Front propeller nut...

  • Page 87: December

    Section 5 - Maintenance 2. Apply a liberal coat of one of the following lubricants to the propeller shaft. Tube Ref No. Description Where Used Part No. Special Lubricant 101 Propeller shaft 92-802865A1 Anti-Corrosion Grease Propeller shaft 92-802867A1 2-4-C Marine Lubricant with Propeller shaft 92-802859A1 Teflon...

  • Page 88: Serpentine Drive Belt

    Section 5 - Maintenance Description lb. in. lb. ft. Propeller shaft anode screw 38 mm (0.3125‑18 x 1.5 in.) long Serpentine Drive Belt WARNING Avoid possible serious injury. Make sure that the engine is turned off and the ignition key is removed before inspecting belts.

  • Page 89: Flushing The Power Package

    The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation. 90-860171061 DECEMBER 2006...

  • Page 90: Flushing Attachments

    9194 Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
  • Page 91 Section 5 - Maintenance CAUTION If flushing the engine with the boat in the water, seawater can flow into the engine causing damage. The water inlet must be closed when flushing the engine. 1. On seawater cooled models: Proceed to Step 5. or Step 6. NOTE: Closed cooled models are equipped with a heat exchanger on the front of the engine.

  • Page 92: Alternative Water Pickups

    Section 5 - Maintenance CAUTION Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range. 10. Observe the water temperature gauge to ensure that the engine is operating in the normal range.

  • Page 93: Battery

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

  • Page 94: Corrosion Protection

    Section 5 - Maintenance WARNING Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine. Do not recharge a weak battery in the boat. Remove battery and recharge in a ventilated area away from fuel vapors, sparks or flames. WARNING Batteries contain acid which can cause severe burns.
  • Page 95 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System...
  • Page 96 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 88 90-860171061 DECEMBER 2006...
  • Page 97 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. 6206 MerCathode controller MerCathode assembly Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. 5643 Trim cylinder anodes 90-860171061 DECEMBER 2006...

  • Page 98: Painting Your Power Package

    Section 5 - Maintenance Bearing Carrier Anode (Alpha and Bravo One) ‑ Located in front of the propeller, between the front side of the propeller and the gear housing. 5644 Bearing carrier anode Propshaft Anode (Bravo Three) ‑ Located behind the aft propeller. 5821 Propshaft anode In addition to the corrosion protection devices, the following steps should be taken to inhibit...
  • Page 99 Section 5 - Maintenance • Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.
  • Page 100 Section 5 - Maintenance Notes: Page 92 90-860171061 DECEMBER 2006...

  • Page 101: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....94 Manual Single Point Drain System....104 Preparing Power Package for Storage..94 Boat in the Water ......... 104 Engine and Fuel System Preparation ..95 Boat out of the Water ......

  • Page 102: Cold Weather Or Extended Storage

    Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. NOTICE Avoid cooling system and engine damage.

  • Page 103: Engine And Fuel System Preparation

    Section 6 - Storage NOTICE Avoid cooling system and engine damage. Water trapped in the seawater section of the cooling system can cause corrosion damage, freeze damage, or both. Ensure the seawater section of the cooling system is drained immediately after operation, or before any length of storage in cold weather, if the possibility of freezing temperatures exists.

  • Page 104: Draining The Seawater System

    Part No. Corrosion Guard Outside of engine 92-802878-55 8. For sterndrive unit lay‑up, refer to appropriate Mercury MerCruiser sterndrive service manual. 9. Replace the fuel filter. Refer to the Maintenance section for proper procedure. 10. Change the oil and oil filter.

  • Page 105: Drain System Identification

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

  • Page 106: Three Point Manual Drain System

    Section 6 - Storage THREE POINT MANUAL DRAIN SYSTEM 6126 Blue drain plug MULTI-POINT DRAIN (MPD) SYSTEM 6129 Side of cylinder block Bottom of exhaust manifolds 6130 Water circulating pump hose Fuel cooler to thermostat housing Page 98 90-860171061 DECEMBER 2006...

  • Page 107: Air Actuated Single Point Drain System

    Section 6 - Storage 6131 Check valve (if equipped) Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1.
  • Page 108 Section 6 - Storage 7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system. 6125 6124 Closed Cooled Models Seawater Cooled Models Blue drain plug location Air manifold...

  • Page 109: Boat Out Of The Water

    12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
  • Page 110 Section 6 - Storage 3. Ensure that the lever on top of the pump is flush with the handle (horizontal). 4. Install the air pump on the actuator fitting. 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump...
  • Page 111 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 112: Manual Single Point Drain System

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

  • Page 113: Boat Out Of The Water

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

  • Page 114: Three Point Manual Drain System

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

  • Page 115: Boat Out Of The Water

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

  • Page 116: Multi-Point Drain (Mpd) System

    Blue drain plug 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
  • Page 117 Section 6 - Storage Water‑circulating pump hose 6143 Drain plug Fuel‑cooler‑to‑thermostat‑housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) 90-860171061 DECEMBER 2006 Page 109...

  • Page 118: Boat In The Water

    Section 6 - Storage 3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
  • Page 119 Section 6 - Storage Water‑circulating pump hose 6143 Drain plug Fuel‑cooler‑to‑thermostat‑housing hose 6144 Drain plug Check valve 6131 Drain plug (if equipped) 90-860171061 DECEMBER 2006 Page 111...

  • Page 120: Draining The Sterndrive

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

  • Page 121: Battery Storage

    Section 6 - Storage NOTICE The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position. 2.
  • Page 122 Section 6 - Storage Notes: Page 114 90-860171061 DECEMBER 2006...
  • Page 123 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Come Up On Charge....117 Slow..............116 Remote Control Operates Hard, Binds, Has Engine Will Not Start Or Is Hard To Start..116 Excessive Free-play Or Makes Unusual Sounds Engine Runs Rough, Misses And/Or Backfires ................

  • Page 124: 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 125: Excessive Engine Temperature

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

  • Page 126: Remote Control Operates Hard, Binds, Has Excessive Free-Play Or Makes Unusual Sounds

    Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level.

  • Page 127: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 120 Parts And Accessories Inquiries ..121 Local Repair Service ........120 Resolving A Problem ........121 Service Away From Home ......120 Mercury Marine Service Offices ....

  • Page 128: Owner Service Assistance

    These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance. 1. Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser sterndrives and inboards.

  • Page 129: Parts And Accessories Inquiries

    Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If additional assistance is required, take these steps: 1.

  • Page 130: Ordering Literature

    • 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 Mercury Marine Publications P.O. Box 1939...

This manual is also suitable for:

Sterndrive 5.0l tksSterndrive 5.7l tks

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