MerCruiser 8.1S HO Owner's Manual
  1. Manuals
  2. Brands
  3. MerCruiser Manuals
  4. Engine
  5. 8.1S HO
  6. Owner's manual
MerCruiser 8.1S HO Owner's Manual

MerCruiser 8.1S HO Owner's Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 8.1S HO and is the answer not in the manual?

Questions and answers

Related Manuals for MerCruiser 8.1S HO

Summary of Contents for MerCruiser 8.1S HO

  • 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 Starting and Stopping the Engine....41 Wave And Wake Jumping........45 Starting the Engine........41 Impact With Underwater Hazards......45 Stopping the Engine........42 Conditions Affecting Operation......46 Throttle Only Operation.........42 Weight Distribution (Passengers and Gear) Freezing Temperature Operation....43 Inside the Boat..........46 Drain Plug and Bilge Pump......43 Bottom Of Boat..........46 Protecting People In The Water......
  • Page 7 Section 6 - Storage Cold Weather or Extended Storage....... 74 Boat in the Water.........77 Preparing Power Package for Storage...74 Boat out of the Water........79 Engine and Fuel System Preparation..75 Manual Drain System........81 Draining the Seawater System......76 Boat in the Water.........81 Drain System Identification......
  • Page 8 Page iv 90-864841062 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 90-864841062 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 Lanyard Stop Switch........... 20 Slim Binnacle Console Mount Features - Single Instrumentation........... 21 Engine............27 System View ..........21 Console Mount Features- Dual Engine..28 Digital Gauges ..........

  • Page 28: 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 29: 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 30: Digital Gauges

    Section 2 - Getting to Know Your Power Package Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure, battery voltage, fuel consumption and engine operating hours. The SmartCraft Instrument package will also aid in Engine Guardian diagnostics.

  • Page 31: Remote Controls (Non-Dts Models)

    Section 2 - Getting to Know Your Power Package Remote Controls (Non‑DTS Models) 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 32: Console Mount Features

    Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES 17356 Throttle Only Button Control Handle 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 33: Remote Controls (Dts Models)

    Section 2 - Getting to Know Your Power Package Throttle Lever - Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle lever back.

  • Page 34: Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package Throttle Only Button - Allows engine throttle advancement without shifting the engine. The throttle only button can be depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up the engine. Start/Stop Button - Allows the boat operator to start or stop the engine without using the ignition key.

  • Page 35: Engine

    Section 2 - Getting to Know Your Power Package Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease the effort required to move the control handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension. Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or decrease the tension on the control handle (cover must be removed).

  • Page 36: Console Mount Features- Dual Engine

    Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 17365 Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw Arrow trackpad Control Handle - Operation of the shift and throttle are controlled by the movement of the...

  • Page 37: Dual Helm Station Transfer

    Section 2 - Getting to Know Your Power Package Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn on when the engines are synchronized. SYNC ACTIVE THROTTLE ONLY STATION SELECT 3434 To disengage, move one or both control handles until they are more than 5° apart, reduce engine speed below 900 RPM, or increase engine speed beyond 95%.

  • Page 38: Synchronizing Dual Helms Prior To Station Transfer

    Section 2 - Getting to Know Your Power Package SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER Pressing the station select button and holding it in allows the boat operator 10 seconds to match up the control handle settings at the new station with the handle settings that are at the old (to be inactive) station.
  • Page 39 Section 2 - Getting to Know Your Power Package 1. A circuit breaker protects the engine wiring harness and the instrumentation power lead. Test the circuit breaker by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset after testing, or if tripped, by pushing the yellow lever back into the housing.

  • Page 40: 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 41: Transmission Guardian Strategy

    Transmission Guardian Strategy IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle. Transmission Guardian is a MerCruiser DTS feature that protects transmissions from clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and reverse gears.
  • Page 42 Section 2 - Getting to Know Your Power Package Notes: Page 34 90-864841062 DECEMBER 2006...
  • Page 43 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........36 While You Are Cruising ........ 43 Be Alert To Carbon Monoxide Poisoning... 37 While Boat Is Stationary ....... 44 Good Ventilation ........... 38 High-Speed And High-Performance Boat Operation Poor Ventilation ...........

  • Page 44: 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 45: 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 46: 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 47: 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 48: Stopping The Engine

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

  • Page 49: Starting And Stopping The Engine

    NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.

  • Page 50: Stopping The Engine

    Section 3 - On The Water Push the throttle‑only button and position the remote control handle or throttle lever to the 1/4 throttle position. Turn the ignition key to "start." Release key when the engine starts and allow the switch to return to the "on" position. 6.

  • Page 51: Freezing Temperature Operation

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

  • Page 52: While Boat Is Stationary

    Section 3 - On The Water While Boat Is Stationary WARNING Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or any solid device rigidly attached to a moving boat or gearcase.

  • Page 53: 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 Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake.

  • Page 54: Conditions Affecting Operation

    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 55: Cavitation

    Section 3 - On The Water Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the water inlets and cause the engine to overheat. Cavitation Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a propeller.

  • Page 56: 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 57: Section 4 - Specifications

    Section 4 - Specifications Section 4 - Specifications Table of Contents Cruising RPM............50 Engine Oil............51 Fuel Requirements..........50 Engine Specifications......... 52 Fuel Ratings ..........50 Fluid Specifications..........53 Using Reformulated (Oxygenated) Gasolines Transmission ..........53 (USA Only) ........... 50 Engine ............

  • Page 58: Cruising Rpm

    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 59: 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 60: 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 A NMMA FC-W rated oil...

  • Page 61: Fluid Specifications

    IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling systems (heat exchanger and fluid lines). All Models Capacity Fluid Type Mercury/Quicksilver Synthetic Blend MerCruiser Engine 8.5 liters (9 U.S. qt.) Engine Oil (With Filter) Oil 25W‑40 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water...
  • Page 62 Section 4 - Specifications Notes: Page 54 90-864841062 DECEMBER 2006...
  • Page 63 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......56 Engine Oil Drain Pump ......61 Dealer Responsibilities........56 Changing Filter ........62 Maintenance............56 Transmission Fluid..........62 Do It Yourself Maintenance Suggestions... 57 Checking While the Engine is Warm .... 62 Inspection............

  • Page 64: 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 65: 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 66: Maintenance Schedule - Inboard Models

    Scheduled Maintenance NOTE: Only perform maintenance which applies to your particular power package. AFTER THE INITIAL 20 HOUR BREAK-IN To help extend the life of your Mercury MerCruiser power package, the following is recommended: 1. Change the engine oil and filter 2.

  • Page 67: Every 5 Years

    Section 5 - Maintenance • Check the electrical system for loose, damaged, or corroded fasteners. • Check the cooling system and the exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. • Disassemble and inspect the seawater pump and replace worn components. •...

  • Page 68: Checking

    Section 5 - Maintenance Checking 1. 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. 2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.

  • Page 69: Changing Oil And Filter

    3. Replace the fill cap. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W‑40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.

  • Page 70: Changing Filter

    OK range. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W‑40 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.

  • Page 71: Checking While Engine Is Cold

    2. Remove the dipstick, wipe clean and reinsert. 3. Remove the dipstick, observe the fluid level and mark the cold fluid level. 4. Reinstall the dipstick, tighten the T‑handle securely. Do not overtighten. Changing Contact your authorized Mercury MerCruiser dealer. Engine Coolant Checking WARNING Allow the engine to cool down before removing the coolant pressure cap.

  • Page 72: Filling

    92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Cleaning The Flame Arrestor WARNING Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Be careful when cleaning flame arrestor; ensure that ignition is off.

  • Page 73: 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 74 Section 5 - Maintenance 6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the filter assembly retaining screws from the filter cap. 8837 Cool Fuel Module Fuel filter element Cool Fuel Module harness Filter cup Filter cap...

  • Page 75: Serpentine Drive Belt

    21. 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. Serpentine Drive Belt WARNING Avoid possible serious injury.

  • Page 76: Replacing

    Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the limits. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION The belt tensioner assembly contains a high tension spring. Rapid release of the tensioner, or allowing the tensioner to snap back quickly, could injure the operator or cause product damage.

  • Page 77: Flushing The Seawater System-Inboard Models

    Section 5 - Maintenance 2. Remove the belt and reroute the replacement belt according to the belt routing diagram. 3. Use a breaker bar and appropriate socket to position the tensioner back to the engine running location and slide the belt over the tensioner pulley. Slowly relieve the tensioner to the belt.

  • Page 78: The Boat In The Water-Inboard Models

    Section 5 - Maintenance CAUTION Flush water will collect in the exhaust system when the engine is not operating, resulting in engine damage. Do not supply flush water for more than 15 seconds without the engine operating. 4. Completely open the water source to provide maximum water supply. 5.
  • Page 79 Section 5 - Maintenance CAUTION Excess water in the bilge can damage the engine or cause the boat to sink. Disconnecting the seawater inlet hose will cause water to enter the bilge. Disconnect and immediately plug the seawater inlet hose to prevent water from siphoning into the engine or boat. 2.

  • Page 80: 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 Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine.

  • Page 81: December

    Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....74 Air Actuated Single Point Drain System..77 Preparing Power Package for Storage..74 Boat in the Water ........77 Engine and Fuel System Preparation ..75 Boat out of the Water ......

  • Page 82: 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 83: Engine And Fuel System Preparation

    Section 6 - Storage 9. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.

  • Page 84: Draining The Seawater System

    Identification to determine which instructions apply to your power package. 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.

  • Page 85: Manual Drain System

    Section 6 - Storage 17254 Port side drain location Starboard side drain location MANUAL DRAIN SYSTEM 17255 Blue drain plug locations 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.
  • Page 86 Section 6 - Storage 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump Green indicators Lever (locking) Manual release valve 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine.

  • Page 87: Boat Out Of The Water

    11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. 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 88 Section 6 - Storage 5. Pull lever on air pump (vertical) to lock pump on the fitting. 8293 Actuator fitting Air pump Green indicators Lever (locking) Manual release valve 6. Pump air into the system until both green indicators extend and water drains from both sides of the engine.

  • Page 89: Manual Drain System

    11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. 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 90: Boat Out Of The Water

    Blue drain plug locations 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 91: Battery Storage

    Section 6 - Storage 6. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 7. Prior to launching the boat or starting the engine, close the drain system by installing the two blue drain plugs.
  • Page 92 Section 6 - Storage Notes: Page 84 90-864841062 DECEMBER 2006...
  • Page 93 Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........86 Excessive Engine Temperature......87 Diagnosing DTS Problems......... 86 Insufficient Engine Temperature......88 Engine Guardian System........86 Low Engine Oil Pressure........88 Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Come Up On Charge....

  • Page 94: Diagnosing Efi Problems

    Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.

  • Page 95: Engine Runs Rough, Misses And/Or Backfires

    Section 7 - Troubleshooting Possible Cause Remedy Have EFI System checked by an authorized Mercury EFI system fault. MerCruiser dealer. Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Clogged fuel filter. Replace filter. Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.

  • Page 96: Insufficient Engine Temperature

    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 97: Section 8 - Customer Assistance Information

    Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........90 Parts And Accessories Inquiries .... 91 Local Repair Service ........90 Resolving A Problem ........91 Service Away From Home ......90 Mercury Marine Service Offices ....

  • Page 98: 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 99: 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 100: 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:

8.1s horizon

Table of Contents

Save PDF