MerCruiser 4.3L TKS Sterndrive Owner's Manual

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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 Section 4 - Specifications Fuel Requirements..............38 Engine Specifications............... 39 Fuel Ratings............... 38 Fluid Specifications..............40 Using Reformulated (Oxygenated) Gasolines (USA Only) 38 Sterndrives................. 40 Gasolines Containing Alcohol..........38 Engine................40 Engine Oil................38 Section 5 - Maintenance Owner/Operator Responsibilities..........42 Changing................51 Dealer Responsibilities............
Page 7 Manual Single‑Point Drain System........84 Multi‑Point Drain (MPD) System........87 Boat in the Water............84 Boat out of the Water............ 87 Boat out of the Water............ 85 Boat in the Water............88 Three‑Point Manual Drain System........85 Draining the Sterndrive............90 Boat in the Water............
Page 8 Page iv 90-8M0053265 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 90-8M0053265 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 Identification................. 18 Console Mount Features ..........22 Engine Serial Number Decal ........18 Power Trim................22 Bravo Sterndrive Serial Number and Identification..18 Single Engine Trim/Trailer ..........
Page 26: 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 27: Bravo Transom Serial Number
The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly. Bravo transom assembly U-bolt plate Transom assembly serial Number 25904 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. Gimbal housing with serial number stamping...
Page 28: Instrumentation
Section 2 - Getting to Know Your Power Package • sitting on the seat or gunwale at planing speeds • standing at planing speeds • operating at planing speeds in shallow or obstacle infested waters • releasing your grip on the steering wheel that is pulling in one direction •...
Page 29: Remote Controls
Section 2 - Getting to Know Your Power Package Water Temperature Gauge: Indicates engine operating temperature. Fuel Gauge: Indicates quantity of fuel in tank. Hour meter: Records engine operating time. Bilge Blower Switch: Operates bilge blower. Ignition Switch: Allows operator to start and stop engine. Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in).
Page 30: Console Mount Features
Section 2 - Getting to Know Your Power Package Console Mount Features Throttle Only Button Control Handle Power Trim Switch Trailer Switch mc79503-1 Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle.
Page 31: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • In excess, cause boat porpoising (bouncing) or propeller ventilation • Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line mc78529 Trimming sterndrive unit down/in can: •...
Page 32 Section 2 - Getting to Know Your Power Package A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
Page 33 Section 2 - Getting to Know Your Power Package A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped). mc70525-1 The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump.
Page 34: 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 35 Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions............ 28 Passenger Safety in Pontoon Boats and Deck Boats..32 Be Alert to Carbon Monoxide Poisoning....... 29 Boats Having an Open Front Deck ....... 32 Good Ventilation ............
Page 36: 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 37: 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 38: 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 39: 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 40: 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 41: 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 42: 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 43: The Bottom Of The Boat
Section 3 - On The Water The Bottom of the Boat To maintain maximum speed, the boat bottom should be: • Clean, free of barnacles and marine growth • Free of distortion; nearly flat where it contacts the water • Straight and smooth, fore and aft Marine vegetation may accumulate when the boat is docked.
Page 44: Getting Started
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
Page 45 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements............... 38 Engine Oil................38 Fuel Ratings ..............38 Engine Specifications............39 Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............... 40 ..................38 Sterndrives ..............40 Gasolines Containing Alcohol ........38 Engine ................
Page 46: 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 47: Engine Specifications
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. 4. Oil pressure must be checked with the engine at normal operating temperature.
Page 48: Fluid Specifications
4.3L (262 CID) Models Capacity Fluid Type 3.8 liters (4 U.S. qt.) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W‑40 Engine Oil (With Filter) 14.1 liters (15 U.S. qt.) Propylene Glycol and Purified Water Seawater Cooling System Mercury Extended Life Coolant/Antifreeze or Extended Life Ethylene Closed Cooling System 19 liters (20 U.S.
Page 49 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities.......... 42 Changing ..............51 Dealer Responsibilities............42 Power Trim Fluid..............52 Maintenance................. 42 Checking ............... 52 Do‑It‑Yourself Maintenance Suggestions......42 Filling ................53 Inspection................43 Changing ..............53 Maintenance Schedule ‑...
Page 50: 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 51: 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 52: 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 53: 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 54: 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 55: 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) 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.
Page 56: Filling
Warm range 6631 Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling Remove the fill cap/dipstick and observe the level. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up to the proper level.
Page 57: 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. 90-8M0053265 NOVEMBER 2010 Page 49...
Page 58: 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 59: Changing
Section 5 - Maintenance Changing Remove the gear lube monitor from the bracket. Gear lube monitor 6109 Empty the contents into a suitable container. Install the gear lube monitor in the bracket. 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 60: 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 61: 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 62: 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 63: Changing The Water-Separating Fuel Filter
Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray.
Page 64 92-802865Q02 Lubricate the steering pin. Steering pin mc71904-1 Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Steering pin 92‑883725K01 SAE25W‑40 On dual engine boats: Lubricate the tie bar pivot points. Page 56 90-8M0053265 NOVEMBER 2010...
Page 65: Throttle Cable
Section 5 - Maintenance Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Oil Tie bar pivot points 92‑883725K01 SAE25W‑40 Upon first starting engine, turn steering wheel several times to starboard and then port to ensure that the steering system operates properly before getting underway.
Page 66: 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 67: 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 68: Propellers
Section 5 - Maintenance Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Alpha Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. 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 69: Bravo One Propeller Removal
Section 5 - Maintenance Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.
Page 70: Bravo Two Propeller Removal
Section 5 - Maintenance Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of operation. Do not operate with loose propeller.
Page 71: Bravo Three Propeller Removal
Slide propeller and thrust hub off propeller shaft. Turn front propeller shaft nut 70 mm (2‑3/4 in.) counterclockwise to remove nut. Slide propeller and thrust hub off propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut Rear propeller...
Page 72: Bravo Three Propeller Installation
Section 5 - Maintenance Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. Rear propeller nut Rear propeller Rear propeller thrust hub...
Page 73: Serpentine Drive Belt
Section 5 - Maintenance 11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw. Propeller Propeller shaft nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 5303 Tube Ref No.
Page 74: Replacing Belt And/Or Adjusting Tension
Section 5 - Maintenance • Cracks NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are NOT acceptable. • Fraying • Glazed surfaces • Proper tension ‑ 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the belt at the location that has the longest distance between two pulleys.
Page 75: Flushing The Power Package
Sterndrive Water Pickups There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
Page 76: Alternative Water Pickups
Section 5 - Maintenance NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine. Keep the seacock closed until starting the engine. On seawater cooled models: Proceed to Step 5.
Page 77: Battery
Section 5 - Maintenance Lower sterndrive unit to full down/in position. If flushing the cooling system with the boat out of the water: Lower sterndrive unit to full down/in position. WARNING Rotating propellers can cause serious injury or death. 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 78: Corrosion Protection
Section 5 - Maintenance WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.
Page 79 Section 5 - Maintenance Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed (some models have a MerCathode System as standard equipment).
Page 80 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 72...
Page 81 Section 5 - Maintenance IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash. MerCathode controller MerCathode assembly 6206 Anode Kit (if equipped) ‑ Mounted to the boat transom. 5642 Trim Cylinder Anodes ‑ Mounted on each trim cylinder. Trim cylinder anodes 5643 Bearing Carrier Anode (Alpha and Bravo One) ‑...
Page 82: 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 83: Section 6 - Storage
Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........76 Manual Single‑Point Drain System........ 84 Preparing Power Package for Storage......76 Boat in the Water ........... 84 Engine and Fuel System Preparation ....77 Boat out of the Water ..........
Page 84: 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 85: 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 86: Drain System Identification
IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
Page 87: Manual Single Point Drain System
Section 6 - Storage Manual Single Point Drain System 6128 Blue handle Blue drain plug location Three Point Manual Drain System Blue drain plug 6126 Multi-Point Drain (MPD) System Side of cylinder block Bottom of exhaust manifolds 6129 90-8M0053265 NOVEMBER 2010 Page 79...
Page 88: Air Actuated Single Point Drain System
Section 6 - Storage 6130 Water circulating pump hose Fuel cooler to thermostat housing Check valve (if equipped) 6131 Air Actuated Single Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. Close the seacock (if equipped) or remove and plug the water inlet hose.
Page 89 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 90: Boat Out Of The Water
Section 6 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. Boat out of the Water NOTE: This procedure is written for the air pump that is attached to the engine.
Page 91 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 92: Manual Single-Point Drain System
Section 6 - Storage 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Green indicators 6135 Manual Single‑Point Drain System Boat in the Water Close the seacock (if equipped) or remove and plug the water inlet hose. Rotate the blue handle counterclockwise until it stops (approximately two turns).
Page 93: Boat Out Of The Water
Section 6 - Storage Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine.
Page 94: Boat Out Of The Water
Section 6 - Storage Remove the blue drain plug from the distribution housing (lower front, port side). Blue drain plug 6138 To properly vent the cooling system, remove the blue drain plug from the side of the thermostat housing within 30 seconds. Blue drain plug location 6139 Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
Page 95: Multi-Point Drain (Mpd) System
Section 6 - Storage Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side). 6142 Blue drain plug Verify that water is draining from each opening. Allow the system to drain for a minimum of five minutes.
Page 96: Boat In The Water
Section 6 - Storage Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
Page 97 Section 6 - Storage Bottom of exhaust manifolds Cylinder block drain plug Exhaust manifold drain plug 6129 Water‑circulating pump hose Drain plug 6143 Fuel‑cooler‑to‑thermostat‑housing hose Drain plug 6144 Check valve Drain plug (if equipped) 6131 90-8M0053265 NOVEMBER 2010 Page 89...
Page 98: Draining The Sterndrive
Section 6 - Storage On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses. 6145 Hose clamps Blue drain plugs...
Page 99: Battery Storage
Section 6 - 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 and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for storage. Recommissioning the Power Package Ensure that all cooling system hoses are connected properly and hose clamps are tight.
Page 100 Section 6 - Storage Notes: Page 92 90-8M0053265 NOVEMBER 2010...
Page 101: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Starter Motor Will Not Crank Engine, Or Cranks Slow..94 Battery Will Not Recharge............ 95 Engine Will Not Start Or Is Hard To Start......94 Remote Control Is Difficult to Move, Has Excessive Play, or Engine Runs Rough, Misses or Backfires......
Page 102: 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 103: 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 104: 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 105: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance............ 98 Parts and Accessories Inquiries ......98 Local Repair Service ............ 98 Resolving a Problem ............ 98 Service Away From Home ..........98 Mercury Marine Service Offices ........
Page 106: 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 107: 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 108: 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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