Mercury Racing HP850 SCi Manual
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Mercury Racing HP850 SCi Manual

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Thank You
for your purchase of one of the finest marine power packages
available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using
this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this
manual.
The Operation, Maintenance & Warranty Manual contains specific
instructions for using and maintaining your product. We suggest that
this manual remain with the product for ready reference whenever
you are on the water.
Again, thank you for purchasing one of our Mercury Marine products.
We sincerely hope your boating will be pleasant!
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 Information section of this manual. The warranty
statement contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty
coverage, important disclaimers and limitations of damages, and
other related information. Please review this important information.
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
i
7406

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  • Page 1 Again, thank you for purchasing one of our Mercury Marine products. We sincerely hope your boating will be pleasant! Mercury Racing, N7480 County Road "UU" Fond du Lac, WI 54935-9585 7406...
  • Page 2 WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
  • Page 3 Litho in U.S.A. © 2005, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation.

  • Page 5: Table Of Contents

    Mercury RACING DIVISION 90 Day Limited Warranty......2 HP850 SCi 6 Month Limited Warranty...........5 Mercury Racing Division 6 Month Limited Warranty......5 Products Sold to Government Agencies..........8 Warranty Against Corrosion (Worldwide)..........8 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products....................8 General Information Identification Record................11 Boater's Responsibilities..............12 Boat Horsepower Capacity..............13...
  • Page 6 TABLE OF CONTENTS Operation Instrumentation..................31 Warning System...................31 Electrical System Overload Protection..........33 Remote Controls (Console Mounted Zero Effort)......... 36 Power Trim...................37 Starting, Shifting, and Stopping............40 Operation Chart..................41 Freezing Temperature Operation............42 Drain Plug and Bilge Pump..............42 Launching And Boat Operation Care........... 43 Conditions Affecting Operation Weight Distribution................44 Bottom Of Boat..................44...
  • Page 7 TABLE OF CONTENTS Inspection and Maintenance..............81 Attention Required After Submersion........... 82 Maintenance Log..................82 Cold Weather or Extended Storage Power Package Lay-up................84 Draining Instructions................85 Battery Winter Storage.................88 Power Package Recommissioning............88 Troubleshooting Engine Will Not Crank................92 Engine Cranks But Will Not Start............93 Engine Runs Rough, Hard to Start, Misses, and/or Backfires.....94 Poor Performance................94 Insufficient Engine Temperature............95...
  • Page 8 TABLE OF CONTENTS Outside The United States and Canada..........101 viii...

  • Page 9: Warranty Information

    If this registration verification is not received within 30 days, please contact your selling dealer immediately. Mercury Racing Demonstrator Policy Mercury Racing products used by a dealer, boat builder, their representatives or agents for personal, recreational or promotional purposes, or products that accumulate more than 10 hours of demonstration run time MUST BE REGISTERED as a demonstrator by the dealer, boat builder or person(s) using those products.

  • Page 10: Transfer Of Warranty

    Marine Power Service Center closest to you. HP1075 SCi 90 Day Limited Warranty Mercury RACING DIVISION 90 Day Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
  • Page 11 WARRANTY INFORMATION CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented.
  • Page 12 WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and...

  • Page 13: Hp850 Sci 6 Month Limited Warranty

    WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. HP850 SCi 6 Month Limited Warranty Mercury Racing Division 6 Month Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below.
  • Page 14 WARRANTY INFORMATION WHAT MERCURY WILL DO Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product.
  • Page 15 WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and...

  • Page 16: Products Sold To Government Agencies

    ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Products Sold to Government Agencies Contact the Mercury Racing Sales Department for a copy of the Government Agencies Warranty Packet Kit which explains the conditions required for government agencies to receive warranty when purchasing Mercury Racing Outboard or Sterndrive product.
  • Page 17 WARRANTY INFORMATION Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but 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...
  • Page 18 WARRANTY INFORMATION 11. Valve or valve seat grinding required because of wear.

  • Page 19: General Information

    GENERAL INFORMATION Identification Record Model 1075 SCI Displacement 557 CI / 9.1 Liter Fuel Octane 92 AKI [(R+M)/2] or 98 RON Preferred Mercury 25W-40 5600-6000 Max. WOT RPM Spark Plugs NKG BRCECS Engine Oil Spark Plug Gap Alternative API CI-4, CH-4, CG-4 0.76 mm 0.03 in.

  • Page 20: Boater's Responsibilities

    GENERAL INFORMATION Engine Model/ Propeller Number & Pitch: Horsepower: ________________________ _______________________ Running Rotation Engine Serial Number ________________________ _______________________ Hull Identification Number: Transom Assembly Serial ________________________ Numer: _______________________ Boat Model & Length: ________________________ Sterndrive Serial Number & Gear Ratio _______________________ The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package.

  • Page 21: Boat Horsepower Capacity

    GENERAL INFORMATION Boat Horsepower Capacity WARNING Avoid serious injury, death or property damage from overpowering a boat. Using a power package that exceeds the maximum horsepower limit of a boat can: • Cause loss of boat control. • Place too much weight at the transom altering the designed flotation characteristics of the boat •...
  • Page 22 GENERAL INFORMATION 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. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

  • Page 23: Protecting People In The Water

    GENERAL INFORMATION • Loss of power and directional control in heavy seas, strong current or high winds. • Loss of control when docking. 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.
  • Page 24 GENERAL INFORMATION Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea. WARNING Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death.

  • Page 25: Wave And Wake Jumping

    GENERAL INFORMATION While Boat is Moving 5449 Running the boat with the trim angle of the bow too high. Running the boat with no forward hatches open (station wagon effect). GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

  • Page 26: Impact With Underwater Hazards

    GENERAL INFORMATION The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to veer violently in a new direction. Such a sharp change in direction can cause occupants to be thrown out of their seats, or out of the boat.
  • Page 27 GENERAL INFORMATION • Fast acceleration will drive the sterndrive deeper into the water. 11419 Distance from depth finder Distance from waterline to to bottom of skeg. obstacle. Distance from waterline to Distance from waterline to bottom of depth finder. sea bottom. Distance from waterline to Depth finder bottom of skeg.

  • Page 28: Trailering Boat

    GENERAL INFORMATION Operating a damaged sterndrive could cause additional damage to other parts of the sterndrive, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds. Trailering Boat The boat can be trailered with the drive unit in up or down position. Adequate road clearance is required between road and gear housing skeg when trailering with the drive unit in down position.
  • Page 29 GENERAL INFORMATION 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. 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 30: Stolen Power Package

    GENERAL INFORMATION Watch for fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or downed skier on the operator's side of the boat while returning to assist the skier. The operator should always have the downed skier in sight and never back up to the skier or anyone in the water.

  • Page 31: Specifications

    Premium Unleaded NOTE: *Research Octane Number 1. Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the combustion...
  • Page 32 SPECIFICATIONS USING REFORMULATED (OXYGENATED) FUELS (USA ONLY) This type of fuel is required in certain areas of the U.S. The two types of oxygenates used in these fuels are alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section.

  • Page 33: Crankcase Oil

    SPECIFICATIONS If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required. Crankcase Oil OIL RECOMMENDATIONS Preferred Oils API Classification Mercury 4‑cycle Marine Engine Oil 25W40 SJ, SL, CF‑2, CH‑4 Other Recommendations If Preferred Oils Are Not Available Premium multi‑viscosity 20W‑50 commercial oil CG‑4, CH‑4, CI‑4 Premium multi‑viscosity 15W‑40 commercial oil CG‑4, CH‑4, CI‑4...

  • Page 34: Capacities

    CF-4, CG-4, CH-4, CI-4 +100 7411 Capacities Model HP850 SCi & 1075 SCi Approximately 15.2 liters (16 U.S. qt.) Oil reservoir capacity with new filter 19 liter (20 U.S. qt.) Seawater cooling system Approximately 2.84 liters (3.0 U.S. qt.) Transmission fluid capacity Transom Bearing Cavity Liter (U.S.

  • Page 35: Engine Specifications

    SPECIFICATIONS Engine Specifications Model HP850 SCi HP1075 SCi Displacement 9.1 liter (557 cid) Crankshaft horsepower 1075 Crankshaft Kilowatts 5800 RPM 6000 RPM Maximum RPM @ WOT Idle RPM in gear 800 RPM Idle RPM out of gear 825RPM Fuel pump pressure at key up...
  • Page 36 SPECIFICATIONS ENGINE SPECIFICATIONS Model HP850 SCi & 1075 SCi Spark Plug Type NGK BR9ECS (Only) Spark Plug Gap 0.75 mm (0.030 in.) Firing Order 1‑8‑4‑3‑6‑5‑7‑2 Hot ‑ 0.508 mm (0.020 in.) Inlet valve lash setting Cold ‑ 0.41 mm (0.016 in.) Hot ‑...

  • Page 37: California Emissions Regulations

    SPECIFICATIONS California Emissions Regulations An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE IS RATED AT GREATER THAN 500 HP (CRANKSHAFT) AND IS THEREFORE EXEMPT FROM CALIFORNIA EMISSIONS REGULATIONS FOR SPARK - IGNITION MARINE ENGINES.
  • Page 38 SPECIFICATIONS After 5 hr. Break‑in • 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. • Do not advance the throttle until the engine runs smoothly at idle and water temperature reaches a minimum of 54 °C (130 °F).

  • Page 39: Instrumentation

    OPERATION Instrumentation Mercury Racing requires that the following critical engine functions be monitored: • Oil pressure • Engine RPM • Oil temperature • Water temperature • System voltage • Guardian fault messages The use of SmartCraft instrumentation will display all of the above critical engine functions as well as others not listed.
  • Page 40 OPERATION Engine Monitor Guardian Power Problem Horn Display Activated Reduced By Battery range high 3 Beeps‑1.5 100% down or low Sec. Long to 5% Low Seawater 100% down Steady Horn Pressure to 5% Boost Valve Error Steady Horn Guardian Steady Horn Envoked 100% down Low Oil Pressure...

  • Page 41: Electrical System Overload Protection

    OPERATION Engine Monitor Guardian Power Problem Horn Display Activated Reduced By Crankshaft Steady Horn Sensor Problem 5 Beeps‑3 Sec. Cam Sensor Long 5 Beeps‑3 Sec. RPM limit to MAP Sensor Error Long 5150 Fuel Pressure 3 Beeps‑1.5 Sensor Failure Sec. Long Block Pressure 3 Beeps‑1.5 Sensor Failure...
  • Page 42 OPERATION • Four fuses are located at the upper rear of the engine containing a 5 and three 20 amp fuses. A circuit breaker protects the fuel pump wire harness. 4112 Fuse 50 amp main power circuit breaker Fuse block A 50 amp fuel pump circuit Fuse block B breaker...
  • Page 43 OPERATION In an emergency, if you cannot locate and correct the cause of the high current draw, and you must operate the engine; perform the following: 1. Turn "OFF" or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker. 2.

  • Page 44: Remote Controls (Console Mounted Zero Effort)

    OPERATION Analog gauges (if equipped) are protected with a 5 amp fuse. 7412 Helm harness connection Ground Fuse (5 amp) Fused 12V (5 amp maximum) Relay Switched 12V Remote Controls (Console Mounted Zero Effort) 1. Control the throttle by moving the longer control lever(s) or, to increase speed, push the control lever forward.

  • Page 45: Power Trim

    OPERATION 2. Control shifting by moving the shorter control lever(s). This control shifts the unit into gear with full lever movement. Move the lever forward to engage the forward gear. Move lever backward to engage reverse gear. Place the lever in the center position to shift to neutral. Shifting should occur only with the engine at idle speed.
  • Page 46 OPERATION In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3° to 5° angle to the water. 7418 Boat bottom at 3° to 5° angle with water Trimming Drive Unit Up/Out Can: •...

  • Page 47: Power Trim Operation

    OPERATION • Help the boat accelerate and plane off quicker. • Generally improve the ride in choppy water. • In most cases, reduce boat speed. • 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.

  • Page 48: Starting, Shifting, And Stopping

    OPERATION • Raise the drive unit: Press (top) up/out button on trim switch until the drive unit(s) reaches the desired trim position. This switch can also be used to bring the drive to a trailering positon. • Lower the drive unit: Press (bottom) down/in button on trim switch until drive unit(s) reaches the desired position.

  • Page 49: Operation Chart

    OPERATION NOTE: Engines that have not been started for extended periods or have had fuel filter changes may not stay running on the first few initial attempts to start. Do not advance the throttle to keep the engine running. Continue to restart the engine until it idles smoothly which means the fuel system is primed.

  • Page 50: Freezing Temperature Operation

    It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package. Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty.

  • Page 51: Launching And Boat Operation Care

    OPERATION Launching And Boat Operation Care CAUTION Avoid product damage. The following situations could cause water to enter the engine through the exhaust system, which could cause engine component failure: • Unloading a boat from a trailer • Slowing down rapidly or stopping suddenly •...

  • Page 52: 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) may: • Increase speed and engine RPM. • Cause the boat to porpoise. • Cause the bow to bounce in choppy water. •...

  • Page 53: Propeller Selection

    (WOT) and operating RPM range are listed in Specifications. IMPORTANT: All Mercury Racing engines have a RPM rev‑limiter that is set to an upper (or limited) RPM. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM.
  • Page 54 CONDITIONS AFFECTING OPERATION • High humidity. The conditions listed above reduce air density to the engine which in turn reduces the following: • Boost pressure on supercharged engines • Horsepower and torque throughout the RPM range • Peak RPM • Cranking compression EXAMPLE: An engine running at an elevation of 2,438 m (8,000 ft) will have over a 30% power loss while engine power on a hot and humid day...

  • Page 55: Maintenance

    MAINTENANCE Service Responsibilities OWNER/OPERATOR RESPONSIBILITIES It is the owner/operator's responsibility to perform the following: • Perform all safety checks. • Make sure lubrication and maintenance instructions are complied with for safe operation. • Return the unit to an authorized Mercury Marine dealer for a periodic checkup.

  • Page 56: Replacement Service Parts

    MAINTENANCE Replacement Service Parts WARNING Avoid fire or explosion hazard. Electrical, ignition and fuel system components on Mercury Marine gasoline power packages are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize risks of fire or explosion. Do not use replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations.

  • Page 57: Servicing High Horsepower Engines

    MAINTENANCE • Do not attempt any repairs that are not covered in this manual unless you are aware of the precautions (Cautions and Warnings) and procedures required. Your safety is of our concern. • If you attempt to service the product yourself, we suggest you order the service manual for that model.

  • Page 58: Maintenance Charts

    MAINTENANCE Maintenance Charts ENGINE AND TRANSMISSION Interval Task Engine oil (reservoir), power steering and transmission fluid ‑ Check level Check prior to every use and every 3 Battery ‑ Check water level and hours of operation inspect for damage Seawater pickups ‑ Check for marine growth or debris Flush the cooling system if used in After each use...
  • Page 59 MAINTENANCE Interval Task Perform 25 hour maintenance items Change transmission fluid Inspect condition and tension of all drive belts Every 50 hours of operation or once a Inspect cooling system hoses and year, whichever occurs first. clamps Inspect exhaust system condition and tighten clamps Inspect electrical system for loose or damaged wires...
  • Page 60 MAINTENANCE Interval Task Lower Gear Housing Oil Filter and Oil ‑ Initial break‑in at 25 hours. Change the oil and filter. Tie‑bar Mounting Bracket Nuts ‑ Inspect and tighten to specifications as needed. Propeller Shaft ‑ Lubricate Every 25 hours of operation or every 90 days, whichever occurs first.

  • Page 61: Checking Fluid Levels

    MAINTENANCE Checking Fluid Levels CHECKING ENGINE OIL (RESERVOIR) Oil consumption is greatly dependant upon engine speed, with consumption being highest at wide‑open‑throttle and decreasing substantially as engine speed is reduced. It is not uncommon for big block high performance engines to use up to one quart of oil in one to five hours if the engine is operated continuously at the upper end of the RPM range.
  • Page 62 MAINTENANCE NOTE: Oil level will fluctuate during operation. Check the oil level with a cold engine before starting. Check The Input Shaft Housing Oil Level On Driveline Models As Follows: 1. Remove the reservoir level pipe plug "c." The oil level should be even with the bottom of the hole.
  • Page 63 MAINTENANCE Check Drive Unit Oil Level As Follows: 1. Remove the drive vent plug "a." The oil level should be even with the bottom of the hole. If low, remove the drain/fill plug and sealing washer "b" from the gearcase and fill until oil comes out of the top vent plug "a"...
  • Page 64 MAINTENANCE CHECKING POWER TRIM PUMP FLUID 1. Place the drive unit in the full down/in position. 7432 Fill/Vent screw "FULL" mark "ADD" mark Tube Ref No. Description Where Used Part No. Power Trim and Trim pump 92-802880A1 Steering Fluid...
  • Page 65 MAINTENANCE 2. Remove the fill/vent screw. Wipe clean and re‑insert back into the pump, but do not thread it into place. 3. Remove it again and note the oil level, which must be between the "ADD" and "FULL" marks on the dipstick. If necessary, add Power Trim and Steering Fluid or SAE 10W‑30 motor oil through the fill/vent hole to bring the oil level up to the "FULL"...
  • Page 66 MAINTENANCE 2. Shut the engine off and check the dipstick level. The fluid level should be up to the "FULL" mark on the dipstick or the mark established when the boat was first run. 6790 Dipstick "FULL" mark Dipstick tube Tube Ref No.

  • Page 67: Changing Fluids

    MAINTENANCE 5. Do not use the transmission expansion bottle as a fluid reservoir. 7434 Transmission expansion bottle IMPORTANT: Only use the bottle for fluid expansion and overflow. Changing Fluids CHANGING CRANKCASE OIL (RESERVOIR) AND FILTERS 1. Place a sufficiently sized container, 19 liters (20 U.S. qt.) below the oil reservoir.
  • Page 68 MAINTENANCE 4. Drain the oil overflow canister into a suitable container. 7438 Vent canister 5. To replace the spin‑on the oil filter: 7439 Retaining clamp Stop screw a. Loosen the filter retaining clamp "a" and slide it off the filter. b.
  • Page 69 MAINTENANCE 6. Remove the cover of the Oberg screen‑style filter and mark the element so it can be returned to its original orientation with the correct side up. Clean the element with solvent. IMPORTANT: The screen‑style filter element must always be returned to its original orientation (correct side up) to prevent the oil from flowing through it in the wrong direction.
  • Page 70 MAINTENANCE 8. Install the bottom oil reservoir plug and tighten securely. 7436 Oil drain plug 9. Begin by filling the oil reservoir with 11.4 liters (12 U.S. qt.) of oil.
  • Page 71 MAINTENANCE 10. Using an electric drill motor, manually turn the oil pump pulley (clockwise) to prime the engine oiling system until reaching an oil pressure of 276 kPa (40 psi). 7443 Oil pump pulley Clockwise direction of electric drill motor Electric drill motor 11.

  • Page 72: Changing Fuel Filter

    MAINTENANCE 13. Start the engine and observe the engine oil level in the reservoir. The oil level should be even with the bottom of the reservoir split ring. Shut off the engine if it is necessary to add oil. 7423 Oil reservoir sight tube 14.
  • Page 73 MAINTENANCE 7. Stop the engine and check the transmission oil level with the dipstick. If addition oil is required, add it through the dipstick tube to bring the level up to the "FULL" mark. 6790 Dipstick "FULL" mark Dipstick tube Tube Ref No.
  • Page 74 MAINTENANCE Driveline Models Only 1. Place a container below the input shaft housing and remove the bottom pipe plug. 7445 Input shaft housing Oil drain pipe plug WARNING Avoid damage to the input shaft housing. Do Not Overfill the input shaft housing reservoir or damage to transom components could occur.
  • Page 75 MAINTENANCE Tube Ref. Description Where Used Part No. Transom input shaft Torco MTF Gear Oil reservoir and dry 92‑849684‑1 sump drive All Models 1. Place the drive unit in a position so that the propshaft is level. 2. Remove the upper oil level plug and sealing washer from the gearcase.

  • Page 76: Lubrication

    MAINTENANCE 5. Install the upper oil level plug and sealing washer. 6. Remove filler tube and quickly install the lower fill/drain plug and sealing washer. Lubrication Lubricate the following grease fittings with Optimal PD‑2: • Engine driveshaft. • Transmission shift lever ‑ Lubricate poppet ball. Lubricate pivot points with SAE 25W40 motor oil: •...

  • Page 77: Propellers

    MAINTENANCE Propellers WARNING Avoid serious injury or death. Place the remote control in neutral and remove the ignition key from the switch before removing and/or installing the propeller. Place a block of wood between the anti‑ventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating when removing the propeller nut.

  • Page 78: Seawater Pump Impeller Inspection

    MAINTENANCE INSTALLATION 1. Apply a liberal coat of Optimal Longtime PD2 Extreme Pressure Grease to propeller shaft. 2. Align splines and install propeller, washer and propeller nut. 5915 Propshaft Flat washer Cleaver propeller Propeller nut Tube Ref. Description Where Used Part No.

  • Page 79: Flushing Cooling System

    MAINTENANCE The seawater pump impellers (three in one pump assembly) should be inspected whenever insufficient seawater flow is suspected. The two rear impellers supply the engine with water and the front impeller supplies the charge air cooler (CAC). The impellers supplying the engine should be inspected if the engine operating temperature exceeds the normal range.

  • Page 80: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE 2. Completely open the water tap. Place the remote control in neutral position and start the engine. Operate the engine at idle speed, in neutral, for about 10 minutes or until discharge water is clear. Stop the engine, shut off the water, and remove the flushing hose. Cleaning Seawater (Raw Water) Section of Oil Cooler ENGINE COOLERS...

  • Page 81: Cleaning The Flame Arrestors

    MAINTENANCE 9. Start the engine and check all hoses for leaks. Cleaning the Flame Arrestors External contamination on the outside of the filter such as fiberglass particals or insects can be removed with a lint free cloth or a vacuum cleaner.
  • Page 82 MAINTENANCE 2. Power Steering Pump Drive Belt 2851 Power steering pump Power steering pump pulley (adjust belt drive belt tension here) Crankshaft pulley Idler pulley Recirculating pump pulley Tensioner gauge Description Seawater pump/alternator belt 360‑440 80‑100 3. Oil Pump Belt ‑ Belt Should Twist 1/4 Turn rmc21 Crankshaft pulley Oil pump drive belt...

  • Page 83: Corrosion And Corrosion Protection

    MAINTENANCE 4. Supercharger Belt ‑ Self‑tensioning rmc23 Supercharger pulley Idler pulleys Supercharger drive belt Belt tensioner Crankshaft pulley Corrosion and Corrosion Protection Add info about replacing anodes in the flywheel coolers 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 84 MAINTENANCE CAUTION Avoid corrosion damage. Do not use magnesium anodes in salt water. They will provide overprotection, resulting in a different electrochemical reaction that will create hydrogen on the metal surface of the drive, under the paint. This causes the paint to blister and peel completely from the surface of the overprotected drive.
  • Page 85 MAINTENANCE IMPORTANT: Mercury Marine recommends installing an Anti‑Corrosion Kit. If the boat is equipped with stainless steel after planes, a large anode should be installed on each to handle the increased galvanic corrosion potential. Replace sacrificial anodes if eroded 50% or more. Mercury Marine recommends using anodes sold through Mercury Precision Parts only.
  • Page 86 MAINTENANCE 18998 Anodes Oil cooler drain fittings Fittings Flywheel housing drain fitting In addition to the corrosion protection devices, follow these steps to inhibit corrosion: 1. Painting Boat Hull or Boat Transom a. If anti‑fouling protection is required for boat hull or boat transom, copper or tin base paints can be used unless otherwise prohibited by law.
  • Page 87 MAINTENANCE b. If using copper or tin based anti‑fouling paints, avoid any electrical interconnection between the Mercury Marine Product, anodic blocks, and the paint by allowing a minimum of 40 mm (1.5 in.) unpainted area on the transom of the boat around these items.

  • Page 88: Battery

    MAINTENANCE • Paint the drive unit and transom assembly with a good quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct electrical current. Do not paint drain holes, anodes, or items specified by the boat manufacturer.

  • Page 89: Bottom Of Boat

    MAINTENANCE WARNING Observe the following when jump starting, charging or handling a battery: • Do not use jumper cables and a booster battery to start engine. • When charging batteries, ensure battery compartment or area where batteries are located, is well‑vented. •...

  • Page 90: Attention Required After Submersion

    MAINTENANCE 1. Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as required. 2. Check plug leads and electrical leads for damage. 3. Remove and inspect the propeller. If nicked, bent or cracked, see your authorized Mercury Marine dealer. 4.
  • Page 91 MAINTENANCE Date Maintenance Performed Engine Hours...

  • Page 92: Cold Weather Or Extended Storage

    COLD WEATHER OR EXTENDED STORAGE Power Package Lay‑up IMPORTANT: This service should be performed by an authorized Mercury Marine dealer. CAUTION Avoid engine or sterndrive damage; Do not operate the engine without water flowing through the seawater pickup pump. The pump impeller can be damaged and damage to the engine or sterndrive unit may result.

  • Page 93: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE 5. Have the engine ready for flushing as explained in the Flushing Cooling System section of this manual (cooling system flushing and the fuel system storage procedures are performed together). Start and run the engine at 1000 RPM for a minimum of five minutes or longer (if required) to complete the fuel system preperation and the cooling system flushing.
  • Page 94 COLD WEATHER OR EXTENDED STORAGE 1. Drain the cooling system at the following locations: 3713 Cylinder block (port and Seawater pump starboard). Use a stiff Center/bottom of bell wire to clean out drain housing (drains the engine holes until entire system oil coolers).
  • Page 95 COLD WEATHER OR EXTENDED STORAGE NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. 2. Remove the drain plugs "a" from the water distribution tubes at the headers (port and starboard). Location may vary. 3721 Header drain plugs (port and starboard) 3.

  • Page 96: Battery Winter Storage

    COLD WEATHER OR EXTENDED STORAGE a. Disconnect the charge air cooler's exhaust hose "a" and inlet hose "c." The exhaust hose location varies, depending on engine location. 3720 Charge air cooler (CAC) exhaust hose Plug Charge air cooler inlet hose b.

  • Page 97: Before Starting

    COLD WEATHER OR EXTENDED STORAGE BEFORE STARTING WARNING To prevent possible injury or damage to equipment, do not install the battery until all engine maintenance has been performed. CAUTION Avoid severe engine damage. Prime the engine oiling system before starting the engine. 1.
  • Page 98 COLD WEATHER OR EXTENDED STORAGE 6. If the engine does not stay running, repeat the starting procedure until the engine starts and runs smoothly. 7. Check the oil pressure gauge immediately after the engine starts. If the oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause.
  • Page 99 COLD WEATHER OR EXTENDED STORAGE WARNING Avoid fuel spillage and fire hazard. When removing the remote fuel tank line from the engine connection, ensure that the primer bulb is soft. If the primer bulb is hard, pressurized fuel will be sprayed in the engine compartment.

  • Page 100: Troubleshooting

    TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch turned "OFF." Turn switch "ON." Gearshift not in neutral position. Position control lever to neutral. Check and reset circuit breaker or Open circuit breaker or fuse. replace fuse. Check all electrical connections and Loose or dirty electrical connections or wires (especially battery cables).

  • Page 101: Engine Cranks But Will Not Start

    TROUBLESHOOTING Engine Cranks But Will Not Start Possible Cause Remedy Improper starting procedure Read starting procedure Low battery voltage Charge the battery Empty fuel tank or fuel shut off valve Fill tank or open valve closed Faulty fuel pump, wiring, fuel pump fuse, 50 amp circuit breaker or a fuel Replace faulty component pump relay...

  • Page 102: Engine Runs Rough, Hard To Start, Misses, And/Or Backfires

    TROUBLESHOOTING Engine Runs Rough, Hard to Start, Misses, and/or Backfires Possible Cause Remedy Faulty ignition system component. Service ignition system. Clogged fuel filter. Replace filters. If contaminated, drain tank. Fill with Stale or contaminated fuel. fresh fuel. Replace kinked lines or blow out Kinked or clogged fuel line or fuel tank lines with compressed air to remove vent line.

  • Page 103: Insufficient Engine Temperature

    TROUBLESHOOTING Insufficient Engine Temperature Possible Cause Remedy Faulty water thermostat. Replace water thermostat. Faulty gauge or sender. Test with shop gauge; test sender. Faulty oil thermostat. Replace. Excessive Engine Temperature Possible Cause Remedy Seacock closed. Open. Charge Air Cooler plugged with foreign Clean Charge Air Cooler.

  • Page 104: Low Engine Oil Pressure

    TROUBLESHOOTING Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in system. Check and add oil. Check and bring oil to required level. Excessive oil in system (causing it to Check for cause of excessive oil become aerated). (improper filling, defective fuel pump, etc.).

  • Page 105: Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)

    TROUBLESHOOTING Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move) Possible Cause Remedy Trim pump oil level low. Fill pump with oil. Drive binding in gimbal ring. Check for obstruction. Remote Control Operates Hard, Binds, Has Excessive Free‑Play or Makes Unusual Sounds Possible Cause Remedy...

  • Page 106: Owner Service Assistance

    OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur. He knows your engine best.

  • Page 107: Mercury Mercruiser Service Offices

    United States Telephone Mercury MerCruiser 3003 N. Perkins Road (405) 743‑6566 (405) 743‑6570 Stillwater, OK 74075 United States (Mercury Racing) Telephone Mercury Racing N7480 County Rd. UU (920) 924‑2088 (920) 924‑2096 Fond du Lac, WI 54935-9585 Canada Telephone Mercury Marine Ltd.
  • Page 108 OWNER SERVICE ASSISTANCE Europe, Middle East, Africa Telephone Marine Power - Europe, Inc. Parc Industriel de Petit-Rechain B-4800 (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Verviers, Belgium Mexico, Central America, South America, Caribbean Telephone Mercury Marine 11650 Interchange Circle North...

  • Page 109: Ordering Literature

    ORDERING LITERATURE United States and Canada Before ordering literature, please have the following information about your power package available: Engine Model: Horsepower: Serial Model year: Number: For information on additional literature that is available for your particular Mercury/MerCruiser power package and how to order that literature contact your nearest dealer or contact: MERCURY MARINE Telephone...

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