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Mercury V-6 series User Manual

Gasoline engines alpha models
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Gasoline Engines - Alpha Models
1998, Mercury Marine
90 860168985 1098

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Summary of Contents for Mercury V-6 series

  • Page 1 Gasoline Engines - Alpha Models 1998, Mercury Marine 90 860168985 1098...

  • Page 2: Serial Number

    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 CA469 MERCRUISER Division of Mercury Marine Stillwater, OK, U.S.A. SPECIFICATIONS MODEL MCM 4.3LX/4.3LXH GEN + DISPLACEMENT ..262 CID IGNITION TIMING ..10 BTDC CYL. FIRING ORDER .

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Page Welcome! ..........Warranty Message .
  • Page 5 Page Power Trim ......... . Starting, Shifting And Stopping .

  • Page 6: Welcome

    Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of...

  • Page 7: Read This Manual Thoroughly

    CA755 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, 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.

  • Page 8: General Information

    CA619 General Information Lanyard Stop Switch The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch.
  • Page 9 gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating at planing speeds in shallow or obstacle-infested waters, releasing your grip on a steering wheel that is pulling in one direction, drinking alcohol or consuming drugs, or daring, high-speed boat maneuvers. While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut-down.
  • Page 10 CA641...

  • Page 11: Exhaust Emissions

    CA620 Exhaust Emissions Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, stern drives and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
  • Page 12 CA642 Courtesy of ABYC...
  • Page 13 CA643 POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an unclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 14: Safe Boating Suggestions

    CA476 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A.
  • Page 15 Know signs of weather change and avoid foul weather and rough-sea boating. Tell someone where you are going and when you expect to return. Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Just shifting the drive unit into neutral is not sufficient.
  • Page 16 Know your boating area and avoid hazardous locations. Be alert. 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 operating the boat above idle or planing transition speed.

  • Page 17: Protecting People In The Water

    For additional information, obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-849250--1) from your dealer, distributor, or Mercury Marine.

  • Page 18: Conditions Affecting Operation

    Conditions Affecting Operation Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) will: Generally increases speed and engine RPM. At extremes can cause boat to porpoise. Causes bow to bounce in choppy water. Increases danger of following wave splashing into boat when coming off plane.

  • Page 19: Cavitation

    Cavitation Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housing or propeller.
  • Page 20 IMPORTANT: The engines covered in this manual (Except 3.0L) are equipped with an RPM rev-limiter that is set to an upper (or limited) RPM amount. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM.

  • Page 21: How Elevation And Climate Affect Performance

    CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air.

  • Page 22: Important Information

    CA13 Important Information Operation And Maintenance 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 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 23: Freezing Temperature Operation

    CA407 Freezing Temperature Operation IMPORTANT: If boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Damage caused by freezing IS NOT covered by MerCruiser Limited Warranty. CA17 Drive Unit Impact Protection The Power Trim hydraulic system is designed to provide impact protection for drive unit.

  • Page 24: Emissions Information (Europe Only)

    CA621 Emissions Information (Europe Only) Your engine may be equipped with special design features and special tuning to minimize the emission output from the engine. If so, it is very important that you strictly adhere to the following: Recommended maintenance schedules particularly the ignition system.

  • Page 25: Launching And Boat Operation Care

    Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.

  • Page 26: Replacement Service Parts

    CA22 Replacement Service Parts WARNING Electrical, ignition and fuel system components on MerCruis- er gasoline power packages are designed and manufactured to comply with U.S. Coast Guard rules and regulations to mini- mize risks of fire or explosion. Use of replacement electrical, ignition or fuel system compo- nents, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.

  • Page 27: Do-It-Yourself Maintenance Suggestions

    CA410 Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. Present-day marine equipment, such as your 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 28: Multiple Efi Engine Battery Precautions

    CA742 Multiple EFI Engine Battery Precautions Situation Alternators: Alternators are designed to charge the battery that sup- plies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alterna- tor will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charg- ing current.

  • Page 29: Diagnosing Efi Problems (If Equipped)

    CA623 Diagnosing EFI Problems (If Equipped) NOTE: All references to EFI models apply to EFI and MPI engines. Your Authorized 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”...

  • Page 30: 20-Hour Break-In Period

    CA413 20-Hour Break-In Period IMPORTANT: The first 20 hours of operation is the engine break-in period. Correct break-in is essential to obtain minimum oil consumption and maximum engine performance. During this break-in period, the following rules must be observed: Do not operate below 1500 RPM for extended periods of time for first 10 hours.

  • Page 31: After Break-In Period

    CA211 After Break-In Period To help extend the life of your MerCruiser power package, the following recommendations should be considered; Use a propeller that allows the engine to operate at or near the top of the maximum RPM range (See “Specifications” section) when at full throttle with a normal boat load.
  • Page 32 CA26 70515 70516 70514 70517 70523 70522 70518 70520 70521 70519...

  • Page 33: Operation

    CA470 Operation Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will appear on your style gauges.
  • Page 34 CB218 70516 70518 71987...

  • Page 35: Audio Warning System

    CA625 Audio Warning System Your MerCruiser power package may be equipped with an Audio Warning System. The audio warning system horn will sound if one of the following occur: Engine Oil Pressure Too Low Engine Temperature Too Hot Drive Oil Level Too Low NOTE: To test the system: Turn the ignition switch to the ON position without cranking the en- gine.
  • Page 36 CA756 74898 76037 74907...

  • Page 37: Electrical System Overload Protection

    CA698 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replacing fuse or resetting circuit breaker. On the following models, a circuit breaker provides protection for engine wiring harness and instrumentation power lead.
  • Page 38 CA697 5A 5B 70525 70526 70528 70527...
  • Page 39 CA696 4.3L EFI Models: Three fuses are located in a single block in the fuel injection system electrical box. These fuses control various EFI circuits. A Fuel Pump Fuse - 15 Amp B ECM / Injector Fuse - 10 Amp C ECM / Battery Fuse - 15 Amp A 20 amp fuse may be located in ignition switch “I”...
  • Page 40 CB181...

  • Page 41: Remote Controls (Panel Mounted)

    CB182 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control.
  • Page 42 CB183...

  • Page 43: Remote Controls (Console Mounted)

    CB184 Remote Controls (Console Mounted) Control Handle(s) - Operation of the shift and throttle are controlled by the movement of the control handle. “Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward” gear. Continue pushing forward to increase speed.
  • Page 44 CB185 71339 70537...

  • Page 45: Remote Controls (Two Lever)

    CB186 Remote Controls (Two Lever) Shift Lever - shifts unit into gear with full lever movement. Move lever forward to shift to FORWARD gear. Move lever backward to shift to REVERSE gear. Lever in full vertical position shifts to NEUTRAL. CAUTION Never shift unit into or out of gear unless throttle lever is at idle RPM.
  • Page 46 CA34 3 TO 5 DEGREES 71338...

  • Page 47: Power Trim

    CA418 Power Trim Power Trim allows the operator to adjust the drive angle, while underway, to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system “Trailering” feature allows the operator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 RPM engine speed), shallow water operation.
  • Page 48 CB187 73976 73977...
  • Page 49 CB188 POWER TRIM OPERATION - PANEL MOUNT REMOTE CONTROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed.
  • Page 50 CB190 73979 73978...
  • Page 51 CA627 POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 52 CB192 70540 70540 70540...
  • Page 53 CB193 POWER TRIM OPERATION - THREE BUTTON TRIM PANEL (USED ON MODELS WITH TWO-LEVER CONTROL) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button(s) and allow motor to cool for about one minute.

  • Page 54: Starting, Shifting And Stopping

    CA757 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five minutes to remove any explosive fumes from engine compart- ment. If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. IMPORTANT: Observe the following: Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage).
  • Page 55 B EFI Engine - Position throttle setting as follows: COLD ENGINE - Leave in neutral/idle speed position. WARM ENGINE - Leave in neutral/idle speed position. FLOODED ENGINE - Turn ignition switch to ON position. Push the THROTTLE ONLY button and place the throttle lever at 50% position.
  • Page 56 CC829 CAUTION To avoid possible ingestion of water that can damage engine components: Do not turn the ignition key off when the engine is running above idle speed. Do not use the lanyard stop switch to shut off the engine above idle speed.

  • Page 57: Operation Chart

    CA41 Operation Chart BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Open engine Observe all Observe all Turn ignition hatch. gauges to gauges to key to OFF. check check condition of condition of engine. If not engine. If not normal, stop normal, stop engine.

  • Page 58: Specifications

    CA261 Specifications Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine seriously. Engine damage resulting from use of improper gasoline is considered misuse of engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows: USA and Canada - having a posted pump Octane Rating of...
  • Page 59 The fuel system components on your 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 boats fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 60: Crankcase Oil

    CA420 FUEL SYSTEM ADDITIVES (V6 MODELS) To maximize the life of valves and valve seats on your MerCruiser engine, use Quicksilver Valve Lubricant (92-826259A12) regularly. CA693 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil.

  • Page 61: Engine Specifications (4 Cyl. Models)

    CA759 Engine Specifications (4 Cyl. Models) Models 3.0L Propshaft Horsepower (SAV1 Rating) (114 Propshaft Kilowatts (SAV1 Rating) Displacement 181 cid (3.0L) Maximum RPM @ W.O.T. 4400-4800 RPM Idle RPM in NEUTRAL 700 RPM Oil Pressure @ 2000 RPM 30-60 psi (207-414 kPa) Min.

  • Page 62: Engine Specifications (V-6 Models)

    CA760 Engine Specifications (V-6 Models) Models 4.3L 4.3LH 4.3L EFI Propshaft Horsepower (SAV1 Rating) (190 (188 Propshaft Kilowatts (SAV1 Rating) (142 (140 Displacement 262 cid (4.3L) Maximum RPM @ W.O.T. 4400-4800 RPM Idle RPM in NEUTRAL 650 RPM 600 RPM Oil Pressure @ 2000 RPM 30-70 psi (207-483 kPa) Min.

  • Page 63: Engine Specifications (V-8 Models)

    CA761 Engine Specifications (V-8 Models) Models 5.0L 5.0L EFI Propshaft Horsepower Propshaft Kilowatts Displacement 305 CID (5.0L) Maximum RPM @ W.O.T. 4400-4800 RPM Idle RPM in NEUTRAL 650 RPM 600 RPM Oil Pressure @ 2000 RPM 30-60 psi (207-414 kPa) Min.

  • Page 64: Engine Specifications

    CA758 Engine Specifications (V-8 Models) Models 5.7L 5.7L 350 Mag Propshaft Horsepower (SAV1 Rating) (233 (259 Propshaft Kilowatts (SAV1 Rating) (174 (193 Displacement 350 cid (5.7L) Maximum RPM @ W.O.T. 4400-4800 RPM 4600-5000 Idle RPM in NEUTRAL 650 RPM 600 RPM Oil Pressure @ 2000 RPM 30-60 psi (207-414 kPa) Min.

  • Page 65: Maintenance

    CA749 Maintenance WARNING Always disconnect battery cables from battery before work- ing around electrical system components to prevent injury to yourself or damage to electrical system should a wire be acci- dentally shorted. IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed.

  • Page 66: Maintenance Chart

    CA426 Maintenance Chart SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR NOTE: Only perform maintenance which applies to your particular power package. Task Interval Engine Crankcase Oil - Check level Closed Cooling Coolant - Check level Power Steering Fluid - Check level Sterndrive Unit Oil - Check level...
  • Page 67 CA427 SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR NOTE: Only perform maintenance which applies to your particular power package. Task Interval Every 100 hours of operation Drive Belt(s) - Inspect or 120 days, whichever occurs condition and check tension first.
  • Page 68 CA742 SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER NOTE: Only perform maintenance which applies to your particular power package. Task Interval Whenever insufficient seawater flow is suspected. Seawater Pickup Pump - (If operating temperature Disassemble and inspect. exceeds normal range.) Crankcase Oil and Filter - Change.
  • Page 69 CA429 SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering System - Lubricate and inspect for loose, damaged or missing parts. Electrical System - Check for loose or damaged wiring.
  • Page 70 CA740 SCHEDULED MAINTENANCE THAT SHOULD BE PERFORMED BY A DEALER NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering Head and Remote Control - Inspect and lubricate. End of first boating season and End of first boating season and Carburetor Equipped) thereafter, every 100 hours of...
  • Page 71 CA175 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 72 CA431 75028 70543 74766 70546 74764 71340 70547...

  • Page 73: Checking Fluid Levels

    CA54 Checking Fluid Levels CHECKING CRANKCASE OIL Stop engine. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water. Remove dipstick. Wipe clean and reinstall fully into dipstick tube. Remove dipstick and observe oil level. Oil level must be between FULL and ADD.
  • Page 74 CA763 75028 70979 70551 71425...

  • Page 75: Fuel Pump Sight Tube Inspection 3.0L Models

    CA632 CHECKING DRIVE UNIT OIL NOTE: Oil level will fluctuate during operation. Oil level should be checked with cold engine before starting. Check gear lube monitor oil level. Keep oil level at or near FULL line. If any water is visible at the bottom of monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your Authorized MerCruiser Dealer immediately.
  • Page 76 CA473 75492...

  • Page 77: Propeller

    CA77 Propeller WARNING Avoid Injury: Remote Control must be in NEUTRAL and igni- tion key removed from switch before removing and/or install- ing propeller. WARNING Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.
  • Page 78 CA634 75492...
  • Page 79 CA635 INSTALLATION IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon.
  • Page 80 CA202 70565 71353 70564...

  • Page 81: Flushing Cooling System

    CA83 Flushing Cooling System WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, re- move propeller. CAUTION Do not run engine above 1500 RPM when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine and/or drive unit to overheat.
  • Page 82 CA150 71428...

  • Page 83: V-Belts (3.0L Model)

    CA438 V-Belts (3.0L Model) WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt. All drive belts must be periodically inspected for condition and tension. Perform the following inspections of alternator drive belt and power steering pump drive belt (if so equipped).
  • Page 84 CA436...

  • Page 85: Serpentine Drive Belt (All Other Models)

    CA636 Serpentine Drive Belt (All Other Models) WARNING Avoid possible serious injury. Make sure engine is shut off and ignition key is removed before inspecting belt. Belt must be periodically inspected for condition and tension. NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys.
  • Page 86 CA204 73919 70578 71335 70577 70033 70576...

  • Page 87: Corrosion And Corrosion Protection

    CA439 Corrosion And Corrosion Protection Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals.
  • Page 88 CA162 71957 71958...
  • Page 89 CA440 Trim Cylinder Anodes - are mounted on each trim cylinder. CA646 Bearing Carrier Anode - is located in front of the propeller, between the front side of the propeller and the gear housing. Refer to “Propeller” section in this manual for propeller removal and installation.
  • Page 90 CA93 71176...
  • Page 91 CA168 In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty. Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: DO NOT paint anodes or MerCathode System...
  • Page 92 CA97 “SEE CAUTION” 71918 71925...

  • Page 93: Emissions (Europe Only)

    CA474 Emissions (Europe Only) CA399 The following information applies only to engines with a special emissions kit installed. If the kit has been installed, your engine complies with “Stage 1” Bodensee and Swiss Regulations. CA398 Sealed Carburetor Mixture Screws The carburetor on this engine has seals on the carburetor mixture screws.
  • Page 94 CA637 75319 71926 75324...

  • Page 95: Emissions Testing

    CA100 Emissions Testing Your engine is equipped with special design features and special tuning to minimize the emission output from the engine. You should follow: Recommended maintenance schedules particularly as to the ignition system. Proper engine tuning procedures to ensure these features remain in good operating order.

  • Page 96: Miscellaneous Maintenance

    CA478 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days, or when specific gravity drops below battery manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

  • Page 97: Bottom Of Boat

    CA104 Bottom Of Boat To maintain maximum speed, the following conditions of the boat bottom should be observed: Clean, free of barnacles and marine growth. Free of distortion, nearly flat where it contacts water. Straight and smooth, fore and aft. ANTI-FOULING PAINTS See Anti-Fouling Paint recommendations and related information on previous pages.

  • Page 98: Cold Weather Or Extended Storage

    CA639 Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage.

  • Page 99: Power Package Recommissioning

    CA116 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not in- stall battery until all maintenance has been performed on en- gine. Check that all cooling system hoses are connected properly and hose clamps are tight. CAUTION When installing battery, be sure to connect NEGATIVE (–) bat- tery cable to NEGATIVE (–) battery terminal and POSITIVE (+)

  • Page 100: Troubleshooting

    CA442 Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral Position control lever in neutral. position. Open circuit breaker or blown Check and reset circuit breaker fuse.
  • Page 101 CA640 Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shutoff Fill tank or open valve. valve closed. 3.0L: Check sight tube for fuel. Have Authorized MerCruiser Faulty fuel pump.
  • Page 102 CA445 Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy EFI Models: Have EFI system Idle speed too low. checked by an Authorized MerCruiser Dealer. Carburetor Models: Check Choke not operating properly. choke linkages for binding or an obstruction. Faulty ignition system Service ignition system.

  • Page 103: Poor Performance

    CA446 Poor Performance Possible Cause Remedy Inspect throttle cable and Throttle not fully open. linkages for proper operation. Damaged or improper propeller. Replace propeller. Drain and check for cause of Excessive bilge water. entry. Boat overloaded or load Reduce load or redistribute improperly distributed.

  • Page 104: Insufficient Engine Temperature

    CA448 Insufficient Engine Temperature Possible Cause Remedy Faulty Thermostat. Replace. CA449 Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase. Check and add oil. Check and remove required amount of oil. Check for cause Excessive oil in crankcase of excessive oil (improper (causing it to become aerated).

  • Page 105: Steering Wheel Turns Hard Or Jerky

    CA451 Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift Lubricate. and throttle linkage fasteners. Check all throttle linkages. If any are loose or missing, see Loose or missing shift and Authorized MerCruiser Dealer throttle linkages.
  • Page 106 CA453 Power Trim Does Not Operate (Motor Doesn’t Run) Possible Cause Remedy Blown fuse. Replace fuse. Check all associated electrical connections and wires Loose or dirty electrical (especially battery cables). connections or damaged Clean and tighten faulty wiring. connection. Repair or replace wiring.

  • Page 107: Warranty Information

    CA455 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.

  • Page 108: International Owner Registration

    International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. The Warranty Registration Card identifies your name and address, product model and serial number(s), date of sale, type of use and the selling distributor’s/dealer’s code number, name...

  • Page 109: Warranty Policies

    CB756 Warranty Policies MerCruiser Limited Warranty - Gasoline Engines UNITED STATES AND CANADA ONLY I. We warrant each new production (not those made for high performance purposes) MerCruiser Sterndrive Power Package, Inboard Engine and accessories attached thereto, (hereafter referred to as “Product”) to be free from defects in material and workmanship, but only when the customer purchases or obtains predelivery service from a Dealer authorized by us to distribute MerCruiser Product...
  • Page 110 Mercury certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty.

  • Page 111: Mercruiser International Warranty - Gasoline Engines

    MerCruiser International Warranty - Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA I. We warrant each new production (not those made for high performance purposes) MerCruiser Sterndrive Power Package, Inboard Engine and accessories attached there- to, (hereafter referred to as “Product”) to be free from de- fects in material and workmanship, but only when the cus- tomer purchases or obtains predelivery service from a Dealer authorized by us to distribute MerCruiser Product in...
  • Page 112 IV. Claim shall be made under this warranty by delivering the Product for inspection to a MerCruiser dealer authorized to service the Product. If purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Marine Power Service Center or distributor.
  • Page 113 AT OUR OPTION, refunding the purchase price or replacing such part or parts with new or Mercury certified remanufactured parts as shall be neces- sary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty. We...

  • Page 114: Year Limited Warranty Against Corrosion Failure

    CA457 3 Year Limited Warranty Against Corrosion Failure (Applicable In The United States, Canada And Australia) I. We warrant parts and assemblies of each 1988 and newer production MerCruiser (Product) sold with a one year limited Product warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inoperative as a direct result of corrosion, provided the following simple precautionary...
  • Page 115 Warranty, and paragraphs III, IV, V and VI of the (International) Product Warranty, contained in this manual, which paragraphs are incorporated herein by reference. Mercury Marine products are built using the most advanced corrosion protection process available. This manufacturing system, complemented by dealer and customer participation in...

  • Page 116: Warranty Coverage

    OWNER’S RESPONSIBILITY Protection against certain types of corrosion damage must be provided by using such systems as the Quicksilver MerCathode System and/or Galvanic Isolator. These certain types of corrosion damage are: damage due to stray electrical currents (on-shore power connections, nearby boats, submerged metal), or improper application of copper base anti-fouling paint.
  • Page 117 Warranty Does Not Apply To The Following: Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs, ignition components, carburetor settings, filters, belts, controls, and checking lubrication made in connection with normal services. Damage caused by neglect, lack of maintenance, accident, abnormal operation or improper installation or service, or freezing temperatures.
  • Page 118 Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty. Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard.

  • Page 119: Transferable Warranty

    Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 West Pioneer Road P.O. Box 1939...

  • Page 120: Q-Guard Product Protection Plan

    CA460 Q-Guard Product Protection Plan United States And Canada Only (Certain performance products, triple engine installations, and commercial applications are excluded) The Mercury Marine Q-Guard Product Protection Plan provides coverage against unexpected mechanical electrical breakdowns that may occur beyond the standard limited warranty.

  • Page 121: Owner Service Assistance

    Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring on parts and accessories, the dealer requires the motor model and serial number(s) to order the correct parts.

  • Page 122: Resolving A Problem

    The following information will be needed by the service office: Your name and address Daytime telephone number Model and serial numbers for your power package The name and address of your dealership Nature of problem Mercury Marine Service Offices are listed on the next page.

  • Page 123: Mercury Marine Service Offices

    (32) (87) 32 32 11 (32) (87) 31 19 65 Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America & Caribbean (305) 385-9585 (305) 385-5507 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.

  • Page 124: Customer Service Literature

    To obtain an Operation and Maintenance Manual or Maintenance Procedures Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 125 Um eine Betriebs– und Wartungsanleitung oder ein Handbuch der Wartungsverfahren in einer anderen Sprache zu erhalten, wenden Sie sich an das nächste Mercury Marine oder Marine Power Interna- tional Service Center. Eine Liste mit Teilenummern für Fremdspra- chen ist im Lieferumfang Ihres Motors enthalten.
  • Page 126 Procedimentos de Manutenção em outro idioma, contate o Cen- tro de Serviço Internacional de “Marine Power” (Potência Marinha) ou a Mercury Marine mais próxima para obter informações. Uma lis- ta de números de referência para outros idiomas é fornecida com o seu pacote de propulsão.

  • Page 127: Ordering Literature

    Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone Mail Mercury Marine Attn: Publications Department (920) 929–5110...

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