MerCruiser 3.0L TKS Alpha Owner's Manual
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MerCruiser 3.0L TKS Alpha Owner's Manual

MerCruiser 3.0L TKS Alpha 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
Applicable Requirement
Owner's manual (A.2.5)
Openings in Hull, Deck and superstructure (A.3.4)
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 MerCruiser, Stillwater, OK, USA
Regulatory contact:
Regulations and Product Safety Department
Mercury Marine
W6250 W. Pioneer Road
Fond du Lac, WI 54936
USA
Identification Record
Please record the following information:
ISO 10240
ISO 9093‑1; ISO 9093‑2
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
Kevin Grodzki
Standards Applied

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  • Page 1 Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 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.

  • Page 2: Read This Manual Thoroughly

    Boat Model Length 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. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.
  • Page 3 Notice Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully. These Safety Alerts alone cannot eliminate the hazards that they signal.

  • Page 5: Table Of Contents

    Transfer of Warranty..............2 Duration of Coverage............11 Mercury Product Protection Plan: United States and Canada... 3 How to Obtain Warranty Coverage........12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Mercury Will Do............12 Products Only) ................3 What Is Not Covered............12 3‑Year Limited Warranty Against Corrosion......5 Disclaimers and Limitations..........12...
  • Page 6 Fluid Specifications..............38 Engine................38 Sterndrives................38 Section 5 - Maintenance Owner/Operator Responsibilities..........40 Changing................48 Dealer Responsibilities............40 Power Trim Fluid..............49 Maintenance................40 Checking................49 Do‑It‑Yourself Maintenance Suggestions....... 40 Filling................50 Inspection................41 Changing................50 Maintenance Schedule ‑ Sterndrive Models......41 Cleaning the Flame Arrestor........... 50 Routine Maintenance............
  • Page 7 Excessive Engine Temperature..........79 Steering Wheel Jerks or Is Difficult to Turn......80 Insufficient Engine Temperature..........79 Power Trim Does Not Operate (Motor Does Not Operate)..80 Low Engine Oil Pressure............79 Power Trim Does Not Operate (Motor Operates but Sterndrive Battery Will Not Recharge............
  • Page 8 Page iv 90-8M0053263 NOVEMBER 2010...
  • Page 9 Mercury Product Protection Plan: United States and Canada How to Obtain Warranty Coverage ....... 12 ....................3 What Mercury Will Do ........... 12 Mercury MerCruiser Limited Warranty (Gasoline‑Fueled What Is Not Covered ............ 12 Products Only) ............... 3 Disclaimers and Limitations .......... 12 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 Product Protection Plan: United States And Canada

    The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. 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 12 Section 1 - Warranty Transfer of Coverage Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use customer.

  • Page 13: 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 14: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines

    4-YEAR LIMITED CORROSION WARRANTY: SEACORE STERNDRIVE MODELS WITH GAS ENGINES What Is Covered Mercury Marine warrants that each new MerCruiser SeaCore engine, transom, and sterndrive package will not be rendered inoperative as a direct result of corrosion for the period of time described below.

  • Page 15: Global Warranty Charts

    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: Consumer Application Warranty Chart

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

  • 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: 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: 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 21: Manufacturer's Warranty Coverage

    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 22: 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 23 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 24 Section 1 - Warranty Notes: Page 16 90-8M0053263 NOVEMBER 2010...

  • Page 25: 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 Lanyard Stop Switch............. 18 Single Engine Trim/Trailer ..........21 Instrumentation..............19 Dual Engine Trim/Trailer ..........21 Remote Controls..............19 Electrical System Overload Protection‑Carbureted Engines Panel Mount Features ..........

  • Page 26: 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). Stop switch Lanyard Clips to the operator...

  • Page 27: Instrumentation

    Section 2 - Getting to Know Your Power Package Instrumentation The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.

  • Page 28: Console Mount Features

    Section 2 - Getting to Know Your Power Package 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, and should only be used to assist in starting the engine.

  • Page 29: 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 30: Electrical System Overload Protection-Carbureted Engines

    Section 2 - Getting to Know Your Power Package Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have separate buttons for each sterndrive unit. Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only. Electrical System Overload Protection‑Carbureted Engines If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open.
  • Page 31 Section 2 - Getting to Know Your Power Package A 15 amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits. A 20 amp fuse is located on the top of the engne to protect the TKS circuit. 7524 A 20 amp fuse may be located in the ignition switch "I"...

  • Page 32: Audio Warning System

    Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
  • Page 33 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions............ 26 Passenger Safety in Pontoon Boats and Deck Boats..30 Be Alert to Carbon Monoxide Poisoning....... 27 Boats Having an Open Front Deck ....... 30 Good Ventilation ............

  • Page 34: Safe Boating Suggestions

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

  • Page 35: Be Alert To Carbon Monoxide Poisoning

    Section 3 - On The Water • The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when the boat is above idle or planing transition speed.

  • Page 36: Basic Boat Operation

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

  • Page 37: Stopping The Engine

    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. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 38: Protecting People In The Water

    Section 3 - On The Water 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 39: Wave And Wake Jumping

    Section 3 - On The Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

  • Page 40: Drive Unit Impact Protection

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

  • Page 41: Ventilation

    Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered; 90-8M0053263...

  • Page 42: End Of First Season Checkup

    End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

  • Page 43: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 36 Engine Oil................36 Fuel Ratings ..............36 Engine Specifications............37 Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............... 38 ..................36 Sterndrives ..............38 Gasolines Containing Alcohol ........36 Engine ................

  • Page 44: Fuel Requirements

    The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 45: Engine Specifications

    NOTE: The use of non‑detergent oils, multi‑viscosity oils (other than as specified), non FC‑W rated synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. MerCruiser/ Quicksilver Synthetic Blend, NMMA FC-W rated, 4-cycle oil MerCruiser / Quicksilver 25W40 NMMA FC-W rated oil...

  • Page 46: Fluid Specifications

    IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines). 3.0L (181 CID) Model Capacity Fluid Type Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 3.8 liters (4 U.S qts) Engine Oil (With Filter) 25W‑40 9 liters (8.5 U.S. qts)
  • Page 47 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 40 Changing ..............48 Dealer Responsibilities............40 Power Trim Fluid..............49 Maintenance................. 40 Checking ............... 49 Do‑It‑Yourself Maintenance Suggestions......40 Filling ................50 Inspection................41 Changing ..............50 Maintenance Schedule ‑...

  • Page 48: Owner/Operator Responsibilities

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

  • Page 49: Inspection

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

  • Page 50: Every 100 Hours Or Annually (Whichever Occurs First)

    Section 5 - Maintenance Every 100 Hours or Annually (Whichever Occurs First) • Touch‑up the paint on the power package. • Change the crankcase oil and filter. • Change the drive unit oil • Retorque the connection of the gimbal ring to the steering shaft. •...

  • Page 51: Sealed Carburetor Mixture Screw

    Section 5 - Maintenance Date Maintenance Performed Engine Hours Sealed Carburetor Mixture Screw IMPORTANT: Changing the mixture setting on this engine can affect the exhaust emissions level and void the emissions certification. Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury dealer or emissions testing agency.

  • Page 52: Changing Oil And Filter

    Fluid Type 3.8 liters 3.0L (181 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 (4 U.S. Quart) 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 53: Engine Oil Drain Pump

    Fluid Type 3.8 liters 3.0L (181) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 ( 4 U.S. Quart) Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water.

  • Page 54: Filling

    Warm range 7158 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.

  • Page 55: Filling

    Fill to the "FULL" line with the specified coolant. Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/ Closed Cooling System 92-877770K1 Coolant Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. 90-8M0053263 NOVEMBER 2010 Page 47...

  • Page 56: Drive Unit Oil

    Check the gear lube oil level. Keep the oil level within the recommended operating range. 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.

  • Page 57: Power Trim Fluid

    IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of lubricant flows from oil vent hole.

  • Page 58: Filling

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

  • Page 59: Positive Crankcase Ventilation Valve (Pcv)

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

  • Page 60: Changing The Water-Separating Fuel Filter

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

  • Page 61: Lubrication

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

  • Page 62: Manual Steering System

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

  • Page 63: Throttle Cable

    Lubricate the pivot points and the guide contact surfaces. Pivot points 7169 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Throttle cable pivot points & 92‑883725K01 SAE25W‑40 guide contact surfaces Shift Cable ‑ Typical Lubricate the pivot points and the guide contact surfaces.

  • Page 64: Sterndrive Unit And Transom Assembly

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

  • Page 65: Driveshaft Extension Models

    Where Used Part No. U-joint and Gimbal Transom end grease fitting, engine end grease fitting, 92-802870A1 Bearing Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 90-8M0053263 NOVEMBER 2010 Page 57...

  • Page 66: Alpha Propeller Removal

    Section 5 - Maintenance Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 67: Drive Belts

    Section 5 - Maintenance Drive Belts WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts. Power steering pump pulley Water circulating pump pulley Crankshaft pulley Alternator pulley 7170...

  • Page 68: Replacing - Side Mount Models

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

  • Page 69: Flushing Attachments

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

  • Page 70: Battery

    Section 5 - Maintenance Connect hose between flushing attachment and water source. With sterndrive in normal operating position, open the water source completely. Place the remote control in the neutral idle speed position and start engine. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine.
  • Page 71 Refer to the Marine Corrosion Protection Guide (90‑88181301). Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed (some models...
  • Page 72 MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your authorized Mercury MerCruiser dealer. Page 64...
  • Page 73 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. MerCathode controller MerCathode assembly 6206 Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. Trim cylinder anodes 7460 Bearing Carrier Anode (Alpha) ‑...

  • Page 74: Painting Your Power Package

    If using copper or tin based anti‑fouling paints, observe the following: • Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.

  • Page 75: Section 6 - Storage

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........68 Clearing Clogged Blue Drain Hoses......73 Preparing Power Package for Storage......68 Draining the Sterndrive..........74 Engine and Fuel System Preparation ....69 Battery Storage..............

  • Page 76: Cold Weather Or Extended Storage

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

  • Page 77: Engine And Fuel System Preparation

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

  • Page 78: Single Point Drain System

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

  • Page 79: Draining The Seawater Section Of Models With Closed Cooling

    Section 6 - Storage Draining the Seawater Section of Models With Closed Cooling NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
  • Page 80 Section 6 - Storage Remove and lower the hose from the water inlet to the power steering cooler (if equipped), or the water inlet to the heat exchanger. 7327 Power steering cooler, if equipped Water inlet to heat exchanger hose Ensure the gear housing water vent and drain holes, speedometer pitot hole, and trim tab cavity vent and drain holes are open and unobstructed.

  • Page 81: Clearing Clogged Blue Drain Hoses

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

  • Page 82: Draining The Sterndrive

    13. Check for water draining from the blue drain hose. If the blue drain hose is still clogged, shut off the bilge pump and reattach the blue drain hoses following the steps below. The unit will need to be serviced by an authorized Mercury MerCruiser dealer.

  • Page 83: Battery Storage

    Section 6 - Storage Lower the sterndrive to the full down/in position. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol mixed to the manufacturer's recommendation to protect the engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage Battery Storage Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully charged...
  • Page 84 Section 6 - Storage Notes: Page 76 90-8M0053263 NOVEMBER 2010...

  • Page 85: Section 7 - Troubleshooting

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

  • Page 86: Starter Motor Will Not Crank Engine, Or Cranks Slow

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

  • Page 87: Excessive Engine Temperature

    Section 7 - Troubleshooting Possible Cause Remedy 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. Replace or adjust belt.

  • Page 88: Remote Control Is Difficult To Move, Has Excessive Play, Or Makes Unusual Sounds

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

  • Page 89: Section 8 - Customer Assistance Information

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

  • Page 90: Owner Service Assistance

    Resolving a Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need additional assistance: Talk with the dealership's sales manager or service manager.

  • Page 91: Mercury Marine Service Offices

    • Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact us at: Mercury Marine Publications P.O. Box 1939...

  • Page 92: Outside The United States And Canada

    Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature. Print or type your mailing address, which be used as your shipping label, and include your order and payment. Mail to:...

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