Mercury 8.2 MAG Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Engine
  5. 8.2 MAG HO
  6. Manual

Mercury 8.2 MAG Manual

H.o./seacore sterndrive models (non ect)
Hide thumbs Also See for 8.2 MAG:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Operation & Maintenance Manual
NOTE: The following applies to CE‑marked products only.
Declaration of Conformity—Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Mercury Marine
Address: W6250 W. Pioneer Road, P.O. Box 1939
Town: Fond du Lac, WI
Name of Authorized Representative: Brunswick Marine in EMEA Inc.
Address: Parc Industriel de Petit‑Rechain
Town: Verviers
Name of Notified Body for exhaust emission assessment: Det Norske Veritas AS
Address: Veritasveien 1
Town: Hovik
Conformity assessment module used for exhaust emissions:
Conformity assessment module used for noise emissions:
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type
☒ z or sterndrive with integral exhaust
Identification of Engines Covered by This Declaration of Conformity
Name of engine family:
Vazer 100
Vazer 100 ECT
3.0 TKS
3.0 MPI ECT
4.3 TKS
4.3 MPI
4.3 MPI ECT
SeaCore 4.3
5.0 MPI
SeaCore 5.0
5.0 MPI ECT
SeaCore 5.0 ECT
350 MAG
SeaCore 350 MAG
350 MAG ECT
SeaCore 350 MAG ECT
377 MAG
SeaCore 377 MAG
Post Code: 54936‑1939
Post Code: 4800
Post Code: 1322
Country: Norway
Unique engine identification number: starting serial
number
1A035000
1A035000
0W319169
1A300000
0W319169
0W319169
1A300000
0W319169
0W319169
0W319169
1A300000
1A300000
0W319169
0W319169
1A300000
1A300000
0W319169
0W319169
Country: USA
Country: Belgium
ID Number: 0575
☐ B+C
☐ B+D
☐ B+E
A ☐
Fuel Type
Combustion Cycle
☒ Petrol
☒ 4 stroke
EC Module H certificate number:
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
RCD‑H‑1
☐ B+F
☐ G ☒ H
Aa ☐
G ☐ H ☒

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 8.2 MAG and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Mercury 8.2 MAG

Summary of Contents for Mercury 8.2 MAG

  • Page 1 NOTE: The following applies to CE‑marked products only. Declaration of Conformity—Mercury MerCruiser This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser’s instructions complies with the requirements of the following directives by meeting the associated standards, as amended:...
  • Page 2 8.2 MAG H.O. 1A351489 RCD‑H‑1 SeaCore 8.2 MAG H.O. 1A351489 RCD‑H‑1 8.2 MAG H.O. ECT 1A350340 RCD‑H‑1 SeaCore 8.2 MAG H.O. ECT 1A350340 RCD‑H‑1 Other normative document/ Please specify in more detail Standards Technical file Essential requirements method (* = mandatory standard) Annex 1.B—Exhaust Emissions...

  • Page 3: Read This Manual Thoroughly

    At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.
  • Page 4 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 they warn of.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Warranty Warranty Registration—United States and Canada....2 Global Warranty Application Charts (8.2 MAG/H.O./ Warranty Registration—Outside the United States and Non‑ECT)................. 12 Canada..................2 MAG Sterndrive Series Non‑Emissions Control Transfer of Warranty..............2 (Recreational Use)............12 Mercury Installation Quality Certification Program.....
  • Page 6 Gasoline Containing Alcohol..........54 Power‑Assisted Steering and Power Trim Fluids.... 56 Engine Specifications............. 54 Approved Power‑Assisted Steering Fluids....56 8.2 MAG, 8.2 MAG H.O. and SeaCore 8.2 MAG, 8.2 MAG Approved Power Trim Fluids........57 H.O.................. 54 Section 5 - Maintenance Additional Operation Instructions for Axius Systems .....
  • Page 7 Sterndrive Gear Lube............... 68 Bravo Two Models............81 Checking................68 Bravo Three Models............. 82 Filling................69 Bravo Sterndrive Propeller Installation......83 Changing................69 Bravo One Models............83 Power Trim Fluid..............71 Bravo Two Models............84 Checking................71 Bravo Three..............85 Filling..................
  • Page 8 Section 8 - Customer Assistance Information Owner Service Assistance............ 118 Contact Information for Mercury Marine Customer Service Local Repair Service............118 ..................119 Service Away From Home..........118 Customer Service Literature..........119 Stolen Power Package........... 118 English Language............119 Attention Required After Submersion......118 Other Languages............

  • Page 9: Section 1 - Warranty

    Transfer of Warranty............... 2 (Recreational Use)............12 Mercury Installation Quality Certification Program....3 MAG Sterndrive Series Non‑Emissions Control Mercury Product Protection Plan: United States and Canada (Commercial Use)............12 ....................3 MAG Sterndrive Series Non‑Emissions Control Mercury MerCruiser Limited Warranty (Gasoline‑Fueled (Government Use)............

  • Page 10: Warranty Registration-United States And Canada

    Outside United States and Canada ‑ Check with your local distributor. You may change your address on file with Mercury Marine at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 11: Mercury Installation Quality Certification Program

    Boatbuilders that successfully complete the program and meet all certification requirements earn Installation Quality System Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all MerCruiser‑powered boats that are registered on and after the boatbuilder's certification date for all worldwide registrations.
  • Page 12 Section 1 - Warranty What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described following. Duration of Coverage Warranty Period for Recreational Use The warranty period begins on the date the product is first sold to a recreational‑use retail purchaser or the date on which the product is first put into service, whichever occurs first.
  • Page 13 Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine.

  • Page 14: 3-Year Limited Warranty Against Corrosion

    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 Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 15: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines

    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. Warranty coverage becomes available upon proper registration of the product by the authorized dealer.

  • Page 16: Emission Control Warranty Information

    A tamper‑resistant emission control information (ECI) label is affixed to the engine in a visible location at the time of manufacture by Mercury MerCruiser. Please note that the low emissions certification will not affect the fit, function, or performance of the engine. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

  • Page 17: Owner Responsibility

    What is Covered Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. The benefits to the consumer given by the warranty are in addition to other rights and remedies of the consumer under a law in relation to the goods or services to which the warranty relates.

  • Page 18: Warranty Period For Recreational Use

    A list of dealers and their contact details is available at http://www.mercurymarine.com.au/home.aspx. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine at the address shown above. Mercury Marine will then arrange for the inspection and any covered repair. This Limited Warranty will not cover the purchaser for all related transportation charges and travel time.

  • Page 19: Expense Of Claiming This Limited Warranty

    Improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product) • Improper service • Use of an accessory or part that was not manufactured or sold by Mercury Marine that causes damage to the Mercury product • Jet pump impellers and liners •...

  • Page 20: Global Warranty Application Charts (8.2 Mag/H.o./ Non-Ect)

    There is no charge for this service. You may change your address at any time, including at the time of the warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and hull identification number (HIN) to Mercury Marine’s Warranty Registration Department.

  • Page 21: Mag Sterndrive Series Non-Emissions Control (Government Use)

    Section 1 - Warranty MAG Sterndrive Series Non‑Emissions Control (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (MAG, High Output) Non‑Installation Quality Certified Boat Installation Quality Certified Boat Region Manufacturer Manufacturer Americas 1 Year 1 Year (Excluding Brazil) Latin America...

  • Page 22: Mag Sterndrive Series Non-Emissions Control (Commercial Use-Corrosion)

    Section 1 - Warranty MAG Sterndrive Series Non‑Emissions Control (Commercial Use—Corrosion) Commercial Application: Standard Limited Corrosion Warranty by Region for All Boat Manufacturers Region All Engines (MPI, High Output) Americas 1 Year (Excluding Brazil) Latin America 1 Year or 500 Hours Brazil 1 Year or 500 Hours Europe, CIS, South Africa...

  • Page 23: Global Warranty Application Charts (8.2 Mag/H.o./Seacore/Non-Ect)

    Section 1 - Warranty Global Warranty Application Charts (8.2 MAG/H.O./SeaCore/Non‑ECT) SeaCore Sterndrive Series Non‑Emissions Control (Recreational Use) Recreational Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (MPI, MAG, High Output) Non‑Installation Quality Certified Boat Installation Quality Certified Boat...

  • Page 24: Seacore Sterndrive Series Non-Emissions Control (Government Use)

    Section 1 - Warranty SeaCore Sterndrive Series Non‑Emissions Control (Government Use) Government Application: Standard Limited Warranty by Region and Boat Manufacturer All Engines (MPI, MAG, High Output) Non‑Installation Quality Certified Boat Installation Quality Certified Boat Region Manufacturer Manufacturer Americas 1 Year 1 Year (Excluding Brazil) Latin America...

  • Page 25: Seacore Sterndrive Series Non-Emissions Control (Commercial Use-Corrosion)

    Engines designated as exempt from either Federal EPA or California emission control regulations are not covered by a separate emission control component warranty. The product's Mercury MerCruiser manufacturer's warranty is not affected by the engine's designation under Federal EPA or California emission control regulations.

  • Page 26: Emission Control Information Label

    A tamper‑resistant emission control information (ECI) label is affixed to the engine in a visible location at the time of manufacture by Mercury MerCruiser. Please note that the low emissions certification will not affect the fit, function, or performance of the engine. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

  • 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 Additional Operation Instructions for Axius Systems ... 20 Slim Binnacle Console Mount Features ‑ Single Engine Identification................. 20 ..................28 Information Decal............

  • Page 28: Additional Operation Instructions For Axius Systems

    Section 2 - Getting to Know Your Power Package Additional Operation Instructions for Axius Systems If your boat has DTS engines equipped with an Axius system, refer also to the Axius Operation Manual included with the boat. Identification The serial numbers are the manufacturer's key to numerous details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers.

  • Page 29: Bravo Sterndrive Serial Number And Identification

    Section 2 - Getting to Know Your Power Package Bravo Sterndrive Serial Number and Identification The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side of the sterndrive. 33533 Bravo sterndrive information on ground plate The serial number is also stamped on the driveshaft housing behind the back cover.

  • Page 30: Lanyard Stop Switch

    Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers. 44425 Serial number location on gimbal housing 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).

  • Page 31: Instrumentation

    650–1200 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 (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.

  • Page 32: Analog Gauges

    Remote Controls (Non‑DTS Models) Remote Controls Your boat may be equipped with 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 24...

  • Page 33: Panel Mount Features

    Section 2 - Getting to Know Your Power Package Panel Mount Features Neutral lock button Throttle only button Lanyard stop switch Control handle tension adjustment screw Control handle Trim/tilt button mc77019-1 Neutral lock button ‑ Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.

  • Page 34: Zero Effort Features

    Remote Controls IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

  • Page 35: Panel Mount Features

    Section 2 - Getting to Know Your Power Package Panel Mount Features Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw 3409 Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.

  • Page 36: Slim Binnacle Console Mount Features - Single Engine

    Section 2 - Getting to Know Your Power Package Throttle only/station select key ‑ Allows engine throttle advancement without shifting the engine. The throttle only/station select button also allows the boat operator to select which remote control is in control of the engine operation when operating with multiple helms.

  • Page 37: Dual Console Control With Can Trackpad Features And Operation

    Section 2 - Getting to Know Your Power Package Dual Console Control with CAN Trackpad Features and Operation Dual‑Handle Console Control With CAN Trackpad—Features and Operation Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral to the first detent for forward gear.

  • Page 38: Synchronizing Engines

    Section 2 - Getting to Know Your Power Package Sync button ‑ Pressing the "SYNC" button turns off or on the auto synchronization feature. Refer to Synchronizing Engines. Neutral LED Troll button Transfer button Dock button Throttle only button 1 Lever button NEUTRAL Sync button TROLL...

  • Page 39: Helm Transfer

    Section 2 - Getting to Know Your Power Package Helm Transfer WARNING Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be performed while engine is in neutral.

  • Page 40: Power Trim

    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 41: Single Engine Trim/Trailer

    Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
  • Page 42 Section 2 - Getting to Know Your Power Package The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. To reset the circuit breaker, push the red button. The circuit breaker is located at the starboard rear of the engine in the electrical center. 51332 A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
  • Page 43 Section 2 - Getting to Know Your Power Package The clean power harness connected to the engine starting battery minimizes voltage drop to the electrical system and is protected by a 5‑amp fuse. a b c d e Paddle wheel and tank level connector Diagnostic connector 14‑pin harness connector Clean power harness connector...
  • Page 44 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 an open fuse or an open circuit breaker if the ignition key is turned to the "START" position and nothing happens. mc70525-1 The power trim system is protected from overload by both a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump.

  • Page 45: Audio Warning System

    50534 Audio Warning System The 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 46 Section 2 - Getting to Know Your Power Package Notes: Page 38 90-8M0074352 OCTOBER 2012...

  • Page 47: Section 3 - On The Water

    Section 3 - On the Water Section 3 - On the Water Table of Contents Additional Operation Instructions for Axius Systems ... 40 Freezing Temperature Operation........47 Safe Boating Suggestions............ 40 Drain Plug and Bilge Pump..........47 Carbon Monoxide Exposure..........41 Protecting People in the Water..........

  • Page 48: Additional Operation Instructions For Axius Systems

    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 49: Carbon Monoxide Exposure

    Section 3 - On the Water Never be under the influence of alcohol or drugs while boating (it is the law). • They impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert.

  • Page 50: Poor Ventilation

    Section 3 - On the Water Example of desired air flow through the boat: 43367 Poor Ventilation Under certain running 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 open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 51: Starting And Stopping The Engine

    Section 3 - On the Water Operation Chart Before Starting After Starting While Underway After Stopping Check for fuel, oil, water, Listen for the audio Turn battery switch to the Open engine hatch. fluid and exhaust leaks. alarm. "OFF" position. Check shift and throttle Turn battery switch on.

  • Page 52: 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 53: Operation Chart

    Section 3 - On the Water Operation Chart Operation Chart Before Starting After Starting While Underway After Stopping Observe all gauges Observe all gauges to to check condition of check condition of engine. Turn the ignition key to Install the bilge drain plug. engine.

  • Page 54: Stopping The Engine

    Section 3 - On the Water Turn the ignition key to "START." Release key when the engine starts and allow the switch to return to the "ON" position. If the engine does not start after step 5: Move the remote control handle or throttle lever to the full throttle position, then return to 1/4 throttle. Turn the ignition key to "START."...

  • Page 55: Trailering The Boat

    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 56: Boats With Front-Mounted, Raised Pedestal Fishing Seats

    Section 3 - On the Water Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. mc79555-1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.

  • Page 57: Impact With Underwater Hazards

    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 58: Operating With Low Water Inlets In Shallow Water

    Section 3 - On the Water Operating with Low Water Inlets in Shallow Water Low water inlets mc75827-1 NOTICE Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling water supply to the engine.

  • Page 59: Elevation And Climate

    Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period. After Break‑In Period To help extend the life of your Mercury MerCruiser power package, follow these recommendations: •...

  • Page 60: End Of First Season Checkup

    End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss 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 61: Section 4 - Specifications

    Gasoline Containing Alcohol ........54 Power‑Assisted Steering and Power Trim Fluids..56 Engine Specifications............54 Approved Power‑Assisted Steering Fluids .... 56 8.2 MAG, 8.2 MAG H.O. and SeaCore 8.2 MAG, 8.2 Approved Power Trim Fluids ......... 57 MAG H.O............... 54 90-8M0074352...

  • Page 62: Fuel Requirements

    Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and are acceptable for use in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasoline Containing Alcohol.

  • Page 63: Engine Oil

    Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40 oil is unavailable, use the following lubricants, listed in order of recommendation. If you are servicing a catalyst engine, use these for short periods of time only.

  • Page 64: Fluid Specifications

    NOTE: We do not recommend nondetergent oils, multi‑viscosity oils (other than as specified), non FC‑W–rated synthetic oils, low‑quality oils, or oils that contain solid additives. Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rated MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle MerCruiser oil...

  • Page 65: Approved Power Trim Fluids

    Section 4 - Specifications Approved Power Trim Fluids Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 90-8M0074352 OCTOBER 2012 Page 57...
  • Page 66 Section 4 - Specifications Notes: Page 58 90-8M0074352 OCTOBER 2012...
  • Page 67 Section 5 - Maintenance Section 5 - Maintenance Table of Contents Additional Operation Instructions for Axius Systems ... 60 Steering System............76 Owner/Operator Responsibilities.......... 60 Throttle Cable..............78 Dealer Responsibilities............60 Shift Cable ‑ Typical............78 Maintenance................. 60 Shift Cable ‑ DTS............78 Do‑It‑Yourself Maintenance Suggestions......

  • Page 68: Additional Operation Instructions For Axius Systems

    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 69: 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 70: Scheduled Maintenance

    Inspect the U‑joints, the splines, the bellows, and check the clamps. • Lubricate the U‑joint splines and cross bearings, if equipped with grease fittings. • Inspect the gimbal bearing for roughness. Replace if necessary. See your certified Mercury MerCruiser dealer. • Lubricate the engine coupler.

  • Page 71: Engine Oil

    Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

  • Page 72: Filling

    Add the specified engine oil to bring the level up to, but not over, the operating range mark on the dipstick. Recheck the oil level. Replace the fill cap. All Models Capacity Fluid Type Mercury Full‑Synthetic MerCruiser Engine oil (with filter) 6.5 L (7 US qt) Engine Oil 20W‑40 Engine Oil and Filter Replace the oil filter at every oil change.

  • Page 73: Changing The Oil Filter

    Engine oil (with filter) 6.5 L (7 US qt) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40 Start the engine and operate for three minutes, checking for leaks. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.

  • Page 74: Closed Cooling System

    Section 5 - Maintenance The fluid level should be in the operating range on the dipstick. Reservoir Hot level Cold level Add mark 50868 If the fluid level is in the add range, add the required amount of fluid through the fill cap opening to bring the level up to the operating range on the dipstick.

  • Page 75: Checking Coolant Level

    Section 5 - Maintenance Checking Coolant Level CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap. IMPORTANT: When reinstalling the coolant reservoir cap, ensure that it is tightened securely.

  • Page 76: Draining

    "FULL" mark, repeat the warm‑up/cool‑down cycle, and check the coolant level again. Maintain the coolant level in the reservoir at or near the "FULL" mark with the engine cold. Draining Contact your authorized Mercury MerCruiser dealer. Cleaning Contact your authorized Mercury MerCruiser dealer.

  • Page 77: Filling

    Inspect the lubricant condition. If any water is visible at the bottom of the gear lube monitor, if water appears at the fill and drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately.
  • Page 78 Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant flows from the oil vent hole.

  • Page 79: Power Trim Fluid

    Section 5 - Maintenance 10. Continue to pump gear lubricant into the drive through the oil fill and drain hole until gear lubricant appears in the gear lube monitor. 11. Fill the monitor so that the oil level is in the operating range. Do not overfill. 12.

  • Page 80: Changing

    Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

  • Page 81: Cleaning The Iac Muffler (Non-Dts Models Only)

    Section 5 - Maintenance Gently lift the top back edge of the silencer and pull forward to remove. Silencer Flame arrester 50395 Loosen the flame arrester clamp and remove the flame arrester. Flame arrester Flame arrester clamp 50396 Clean the flame arrester with solvent and dry with compressed air or set aside and allow to air dry completely. Install the flame arrester and tighten the clamp to the specified torque.

  • Page 82: Changing The Positive Crankcase Ventilation Valve (Pcv)

    Inspect the PCV valve and replace if necessary. Install the PCV valve into the intake manifold. Ensure that the PCV valve is tightly seated into the intake manifold. We recommend the use of Mercury MerCruiser replacement parts. Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive.

  • Page 83: Gen Iii Models

    Removal 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. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 84: Lubrication

    10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel, and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication...
  • Page 85 Section 5 - Maintenance Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable. Extended steering cable 6222 Tube Ref No. Description Where Used Part No. Special Lubricant 101 Steering cable 802859A1 Lubricate the steering pin.

  • Page 86: Throttle Cable

    Section 5 - Maintenance Throttle Cable Lubricate the pivot points and the guide contact surfaces. Pivot points Guide contact surfaces 43552 Tube Ref. No. Description Where Used Part No. Throttle cable pivot points Synthetic Blend MerCruiser Engine Oil SAE25W‑40 92‑883725K01 and guide contact surfaces Shift Cable ‑...

  • Page 87: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)

    Section 5 - Maintenance Sterndrive U‑Joint Shaft Splines and O‑Rings (Sterndrive Unit Removed) Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. Driveshaft splines U‑joint O‑rings (3) 8591 Tube Ref No. Description Where Used Part No. Engine Coupler Spline Driveshaft splines and U-joint O-rings 8M0071842 Grease For propeller shaft lubrication, refer to Propellers.

  • Page 88: Propellers

    Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo Sterndrive Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.

  • Page 89: Bravo Two Models

    Section 5 - Maintenance Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket Turn the propeller shaft nut counterclockwise and remove the nut. Slide the propeller and the attaching hardware from the propeller shaft. Bravo One models Propeller shaft splines Forward thrust hub...

  • Page 90: Bravo Three Models

    Section 5 - Maintenance Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate. Wood block Propeller Propeller nut under socket Turn propeller shaft nut counterclockwise to remove nut. Slide the propeller and attaching hardware from the propeller shaft. Bravo Two Propeller shaft splines Forward thrust hub...

  • Page 91: Bravo Sterndrive Propeller Installation

    Section 5 - Maintenance Slide the propeller and the thrust hub off the propeller shaft. Bravo Three Aft propeller nut Aft propeller Aft propeller thrust hub Front propeller nut Front propeller Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode 5304...

  • Page 92: Bravo Two Models

    Section 5 - Maintenance Tighten the propeller nut to the specified torque. Typical Bravo One models Propeller shaft splines Forward thrust hub Flo‑Torque II drive hub Propeller Drive sleeve adapter Tab washer Propeller nut 5301 Bravo One XR models Propeller shaft Propeller hub insert with snubbers Propeller Thick washer...

  • Page 93: Bravo Three

    Section 5 - Maintenance Tube Ref No. Description Where Used Part No. 2-4-C with PTFE Propeller shaft splines 92-802859A 1 Anti-Corrosion Grease Propeller shaft splines Obtain Locally NOTE: Anti‑Corrosion Grease is for saltwater applications only. Install the propeller with the attaching hardware as shown. Tighten the propeller nut to the specified torque.
  • Page 94 Section 5 - Maintenance Propeller Nut Tool 91‑805457T 1 Aids in the removal and installation of the front propeller nut. 10677 Description lb‑in. lb‑ft Bravo Three front propeller nut – Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub. Align the splines and install the aft propeller.

  • Page 95: Serpentine Drive Belt

    Section 5 - Maintenance Serpentine Drive Belt Inspection WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before inspecting the belts. Alternator pulley Idler pulley Power steering pump pulley Water circulating pump pulley Crankshaft pulley Tensioner pulley...

  • Page 96: Replacing

    This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer. 1. Use moderate thumb pressure on the belt at the location that has the longest distance between two pulleys.

  • Page 97: Maintaining Ground Circuit Continuity

    MerCathode System Battery Requirements The Mercury MerCruiser MerCathode system requires a minimum battery charge of 12.6 volts at all times to maintain functionality. Boats equipped with a MerCathode system that use shore power, and are not run for a long period of time, must use a battery charger to maintain a minimum battery charge of 12.6 volts or above.

  • Page 98: Checking The Quicksilver Mercathode System

    Checking the Quicksilver MerCathode System The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information. Page 90...

  • Page 99: Power Package Exterior Surfaces

    Clean the entire power package. External surfaces that have become bare should be repainted with the recommended primer and spray paint at recommended intervals. Description Part Number Mercury Light Gray Primer 92‑802878 52 Painted surfaces Mercury Phantom Black 92‑802878Q 1 Boat Bottom Care To achieve maximum performance and fuel economy, the boat bottom must be kept clean.
  • Page 100 If you are using copper based antifouling paint, observe the following precaution: • Avoid an 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 101: Sterndrive Surface Care

    Maintain a complete paint covering on the sterndrive. • Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tin‑based antifouling paint or its equivalent on or near aluminum surfaces below the waterline.

  • Page 102: Flushing Attachments

    Sterndrive Water Pickups There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), low water pickups require the flushing attachment (849996T 1), and side pickups require the flushing attachment (44357Q 2).

  • Page 103: Boat In The Water-Bravo Sterndrive

    13. Stop the engine. 14. Immediately shut off the supply water and remove the flushing attachment. 15. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. Boat in the Water—Bravo Sterndrive IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.

  • Page 104: Boat Out Of The Water-Alternative Water Pickups

    15. Immediately shut off the supply water and remove the flushing attachment. 16. Install the water inlet hose to the seawater inlet of the seawater pump. Tighten the hose clamp securely. 17. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual. Boat in the Water—Alternative Water Pickups IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of the water.

  • Page 105: Seacore Power Package Flushing Procedure

    Section 5 - Maintenance NOTICE Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug the seawater inlet hose immediately after disconnecting it. Close the seacock, if equipped, then disconnect the seawater inlet hose to prevent water from siphoning into the engine or boat.
  • Page 106 Section 5 - Maintenance Close the seacock, if equipped. For visual clarity, the seacock shown is not installed Hose fitting to engine Seacock Handle (closed position) To water source pickup attachment 18510 If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive.
  • Page 107 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. Quick-connect fitting stored in the boat Quick‑connect fitting (water hose end)
  • Page 108 Section 5 - Maintenance 19. Insert the dust cover in the flush socket on the engine. Dust cover installed in the flush socket Dust cover Flush socket 43065 IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock.
  • Page 109 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage........102 Boat in the Water ..........105 Preparing Power Package for Storage......102 Boat Out of the Water .......... 106 Engine and Fuel System Preparation ....102 Manual Drain System..........

  • Page 110: Cold Weather Or Extended Storage

    If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Mercury/Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank.

  • Page 111: Maintenance

    Certain other items should be performed only by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, we recommend that you purchase a Mercury MerCruiser service manual and read it thoroughly.

  • Page 112: Drain System Identification

    Section 6 - Storage IMPORTANT: The engine must not be operating at any point during the draining procedure. Drain System Identification Air-Actuated Single-Point Drain System Manual pressure release valve Threaded cap for air connection Green indicators 50399 50407 Starboard side air‑actuated drain location Port side air‑actuated drain location Manual Drain System 50408...

  • Page 113: Air-Actuated Single-Point Drain System

    12. Remove the air pump from the air connection 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 114: 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. Manual pressure release valve Threaded cap for air connection Green indicators 50399 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 115: Section 6 - Storage

    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 116: Boat Out Of The Water

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

  • Page 117: Draining Water From The Cool Fuel Module

    Draining Water from the Cool Fuel Module Mercury MerCruiser recommends draining the Gen 3 Cool Fuel Module if it is equipped with a drain plug. Remove the drain plug from the Gen 3 Cool Fuel Module and allow the water to completely drain from the module.

  • Page 118: Battery Storage

    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. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 119: Section 7 - Troubleshooting

    Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems........... 112 Insufficient Engine Temperature........113 Diagnosing DTS Problems..........112 Low Engine Oil Pressure..........114 Additional Operation Instructions for Axius Systems ..112 Battery Will Not Recharge........... 114 Engine Guardian System............

  • Page 120: Diagnosing Efi Problems

    Diagnosing DTS Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift (DTS) systems. The electronic control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory.

  • Page 121: Engine Runs Rough, Misses, Or Backfires

    Clean flame arrestor. Faulty ignition system component. Service ignition system. Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer. EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer. Poor Performance Possible Cause Remedy Throttle not fully open.

  • Page 122: Low Engine Oil Pressure

    Check all 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 123: Power Trim Does Not Operate (Motor Operates But Sterndrive Unit Does Not Move)

    Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive unit binding in gimbal ring. Check for obstruction. 90-8M0074352 OCTOBER 2012 Page 115...
  • Page 124 Section 7 - Troubleshooting Notes: Page 116 90-8M0074352 OCTOBER 2012...
  • Page 125 Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance..........118 Contact Information for Mercury Marine Customer Local Repair Service ..........118 Service ............... 119 Service Away From Home .......... 118 Customer Service Literature..........119 Stolen Power Package ..........

  • Page 126: Owner Service Assistance

    If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

  • Page 127: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: 90-8M0074352...

  • Page 128: Other Languages

    Enclose full remittance in check or money order (NO COD). Other Languages To obtain an Operation, Maintenance and Warranty 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 129: Section 9 - Checklists

    Section 9 - Checklists Section 9 - Checklists Table of Contents Predelivery Inspection (PDI)..........122 Customer Delivery Inspection (CDI)........123 90-8M0074352 OCTOBER 2012 Page 121...

  • Page 130: Predelivery Inspection (Pdi)

    Section 9 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...

  • Page 131: Customer Delivery Inspection (Cdi)

    Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
  • Page 132 Section 9 - Checklists Completed Item ⃞ ⃞ Functions of SmartCraft accessories (if applicable) ⃞ Off‑season storage and maintenance schedule ⃞ Engine (starting, stopping, shifting, using throttle) ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞...

Table of Contents

Save PDF