Mercury 350 Mag MPI Manual
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Mercury 350 Mag MPI Manual

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Gasoline Engines - Ski Models
1999, Mercury Marine
90 860177990 799

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  • Page 1 Gasoline Engines - Ski Models  1999, Mercury Marine 90 860177990 799...
  • Page 2 CC941 Identification Record Please record the following information: Engine Model and Horsepower Engine Serial Number Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number Transmission Model (Inboard) Gear Ratio Transmission Serial Number Propeller Number Pitch Diameter Hull Identification Number (HIN) Purchase Date Boat Manufacturer Boat Model...
  • Page 3 The description and specifications contained herein were in effect at the time this guide was approved for print- ing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation.
  • Page 4 CA175 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 5 CA741 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important dis- claimers and limitations of damages, and other related information.

  • Page 6: Table Of Contents

    Table of Contents Page Warranty Information Owner Warranty Registration ............. . . International Owner Registration .
  • Page 7 Page Maintenance Maintenance Aids ............... . Maintenance Chart .

  • Page 8: Warranty Information

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

  • Page 9: International Owner Registration

    International Owner Registration OUTSIDE THE UNITED STATES AND CANADA • It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.

  • Page 10: Mercruiser Limited Warranty - Gasoline Engines

    Our sole and exclusive obligation under this Warranty shall be limited to repairing a defective part, or at our option, refunding the purchase price or replacing such part or parts with new or Mercury certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty.

  • Page 11: Mercruiser International Warranty - Gasoline Engines

    Our sole and exclusive obligation under this Warranty shall be limited to repairing a defective part or AT OUR OPTION, refunding the purchase price or replacing such part or parts with new or Mercury certified remanufactured parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty.

  • Page 12: Year Limited Warranty Against Corrosion Failure

    Product Warranty, and paragraphs III, IV, V and VI of the (International) Product Warranty, contained in this manual, which paragraphs are incorporated herein by reference. Mercury Marine products are built using the most advanced corrosion protection process available. This man- ufacturing system, complemented by dealer and customer participation in an anti-corrosion preventive mainte- nance program, provides protection against repair costs incurred by the effects of marine corrosion.
  • Page 13 CA458 Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warran- ty coverage. The table explains some of the types of services that are not covered by warranty. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in mate- rial and workmanship.
  • Page 14 The optional Mercury Product Protection Plan is the only Factory Plan available for your engine. Two, three or four - year term plans can be purchased up to 12 months after the original engine registration date.

  • Page 15: Read This Manual Thoroughly

    CC890 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.

  • Page 16: General Information

    CC942 General Information CA619 Lanyard Stop Switch 74608 The purpose of a lanyard stop switch (1) is to turn off the engine when the operator moves far enough away from the operator’s position (as in accidental ejection from the operator’s position) to activate the switch. Some remote control units are equipped with a lanyard stop switch.
  • Page 17 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 18 CC670 Courtesy of ABYC...

  • Page 19: Exhaust Emissions

    CA620 Exhaust Emissions Be Alert To Carbon Monoxide Poisoning Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, stern drives and inboard engines that propel boats, as well as the generators that power various boat accesso- ries.

  • Page 20: Safe Boating Suggestions

    CA476 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.

  • Page 21: Protecting People In The Water

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

  • Page 22: Conditions Affecting Operation

    Conditions Affecting Operation Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) will: • Generally increases speed and engine rpm. • At extremes can cause boat to porpoise. • Causes bow to bounce in choppy water.
  • Page 23 CC918 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open- throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s).
  • Page 24 CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxy- gen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air.

  • Page 25: Important Information

    CA13 Important Information Operation And Maintenance OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance in- structions are complied with for safe operation and to return the unit to an Authorized MerCruiser Dealer for a periodic checkup.

  • Page 26: Launching And Boat Operation Care

    Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.

  • Page 27: Do-It-Yourself Maintenance Suggestions

    CA772 Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. • Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.

  • Page 28: 20-Hour Break-In Period

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

  • Page 29: Operation

    CC830 Operation CC831 70515 70516 70514 70519 70517 70518 70521 70523 70522 CC810 Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions on the boat. Speedometer - indicates boat speed.

  • Page 30: Audio Warning System

    CC680 70518 75542 70516 CC896 Audio Warning System Your MerCruiser power package may be equipped with an Audio Warning System. The audio warning system buzzer will sound if one of the following occur: Engine Oil Pressure Too Low Engine Temperature Too Hot Transmission Fluid Temperature Too Hot NOTE: To test the system: Turn the ignition switch to the ON position without cranking the engine.
  • Page 31 CA175 THIS PAGE IS INTENTIONALLY BLANK...
  • Page 32 CC435 74830 74898 71585 72852 70525...

  • Page 33: Electrical System Overload Protection

    A circuit breaker provides protection for engine wiring harness and instrumentation power lead. Reset by pushing RESET button IN. 5.7L and 350 Mag MPI Models Black Scorpion Models In an emergency, when engine must be operated and cause for high current draw cannot be located and cor- rected, turn OFF or disconnect all accessories connected to engine and instrumentation wiring.

  • Page 34: Remote Controls

    CC166 73866 CC791 Remote Controls (Panel Mounted) Neutral Lock Bar - Prevents accidental shift and throttle engagement. Neutral lock bar must be pulled “Up” to move the control handle out of neutral. Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disen- gaging the shift mechanism from the control handle.

  • Page 35: Starting, Shifting And Stopping

    Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five minutes to remove any explosive fumes from engine compartment. If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. IMPORTANT: Observe the following: •...

  • Page 36: Operation Chart

    CC829 CAUTION To avoid possible ingestion of water that can damage engine components: • Do not turn the ignition key off when the engine is running above idle speed. • Do not use the lanyard stop switch to shut off the engine above idle speed. •...

  • Page 37: Specifications

    CA261 Specifications Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine seriously. Engine damage resulting from use of improper gasoline is considered misuse of engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows: USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum.

  • Page 38: Crankcase Oil

    Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol-free gasoline be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, in- creased inspection frequency for leaks and abnormalities is required. IMPORTANT: When operating a MerCruiser engine on gasoline containing alcohol, storage of gasoline in the fuel tank for long periods should be avoided.

  • Page 39: Engine Specifications

    CC792 Engine Specifications Models 5.7L Propshaft Horsepower Propshaft Kilowatts Displacement 350 cid (5.7L) Maximum rpm @ W.O.T 4400-4800 rpm Idle rpm in NEUTRAL 650 rpm Oil Pressure @ 2000 rpm 30-70 psi (207-414 kPa) Min. Oil Pressure @ Idle 4 psi (28 kPa) Thermostat 160°...
  • Page 40 CC910 Engine Specifications Models 350 Mag MPI Black Scorpion Propshaft Horsepower (SAV1 Rating) (290 Propshaft Kilowatts (SAV1 Rating) (216 Displacement 350 cid (5.7L) Maximum rpm @ W.O.T 4600-5000 rpm 4800-5200 rpm Idle rpm in NEUTRAL 600 rpm Oil Pressure @ 2000 rpm 30-70 psi (207-483 kPa) Min.

  • Page 41: Maintenance

    CC793 Maintenance WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed. Some listings can be done by owner/operator, while others should be performed by an Authorized MerCruiser Dealer.
  • Page 42 Gas Inboard(Continued) Scheduled Maintenance * Every Every Every Every Every 1000 Every Every hours hours hours hours Annu- hours or or 3 or 3 or 5 or 5 ally Annually years years years years years years Touch-up paint power package and spray with corrosion guard.

  • Page 43: Checking Fluid Levels

    CC920 74827 76385 71419 74832 CC822 Checking Fluid Levels CHECKING CRANKCASE OIL Stop engine. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water. Remove dipstick. Wipe clean and reinstall fully into dipstick tube. Remove dipstick and observe oil level.
  • Page 44 CA514 70571 74767 70544 74766...

  • Page 45: Changing Fluids

    CA844 Changing Fluids See MAINTENANCE SCHEDULE for lubricant change frequency. Lubricant should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. Changing Crankcase Oil and Filter IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
  • Page 46 CC739 74941 71359 71480 75454 71457 50946...

  • Page 47: Lubrication

    Velvet Drive Marine and Industrial Transmissions Theodore Rice Boulevard Industrial Park New Bedford, MA 02745 U.S.A. CC846 To obtain service and/or parts literature for your Hurth transmission, contact: Mercury Marine Publications Department P.O. Box 1939 Fond du Lac, WI 54936-1939...

  • Page 48: Flushing Cooling System

    CC518 76038 75533 CC921 Flushing Cooling System WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove propeller. CAUTION Do not run engine above 1500 rpm when flushing. Suction created by seawater pickup pump may col- lapse flushing hose, causing engine to overheat.

  • Page 49: Serpentine Drive Belt

    CC823 76389 CC911 Serpentine Drive Belt WARNING Avoid injury caused by hands or clothing being caught between belts and pulleys. Make sure engine is shut off and ignition key is removed before inspecting belts. Belt must be periodically inspected for condition and tension. NOTE: Belt deflection is to be measured on the belt at the location that has the longest distance between two pulleys.

  • Page 50: Emissions (Europe Only)

    CA97 “SEE CAUTION” 71918 71925 CA474 Emissions (Europe Only) CC899 The following information applies only to engines with a special emissions kit installed. If the kit has been installed, your engine complies with SAV 1 Swiss Regulations. CA398 Sealed Carburetor Mixture Screws The carburetor on this engine has seals on the carburetor mixture screws.
  • Page 51 CA825 71926 75319 75324 CA638 Installing Test Probes IMPORTANT: The testing dealer or agency will be equipped with the appropriate test equipment and adapters for this engine. The test probes should be installed as follows: Remove plugs from both exhaust elbows. Install exhaust elbow adapter fittings as follows.

  • Page 52: Battery

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

  • Page 53: Cold Weather Or Extended Storage

    CC926 Cold Weather Or Extended Storage Power Package Lay Up ALL MODELS IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. WARNING Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation to prevent a potential fire hazard.
  • Page 54 CC839 75533...
  • Page 55 CC927 Power Package Lay Up (continued) EFI MODELS WARNING Avoid Fire or Explosion: Be sure engine compartment is well ventilated and no gasoline vapors are present during the following operation. WARNING Avoid Fire or Explosion: Fuel injection system is pressurized during operation. Use care when remov- ing water separating fuel filter.
  • Page 56 CC928 75432 74073 76038 74493 71170 74967...

  • Page 57: Draining Instructions

    CC946 Draining Instructions CARBURETED MODELS CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses. IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.
  • Page 58 CC930 71170 75432 2A & B 75081 74493...
  • Page 59 CC945 Draining Instructions EFI MODELS CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses. IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.

  • Page 60: Battery Winter Storage

    CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. CA645 Do-It-Yourself Maintenance If you desire to perform your own maintenance, contact an Authorized MerCruiser Dealer to obtain a “Mainte- nance Procedures Manual.” Refer to the Do-It-Yourself Maintenance Suggestions at the front of the manual for additional information.

  • Page 61: Troubleshooting

    CA442 Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral position. Position control lever in neutral. Open circuit breaker or blown fuse. Check and reset circuit breaker or replace fuse. Check all electrical connections and wires Loose or dirty electrical connections or damaged (especially battery cables).
  • Page 62 CA445 Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy EFI Models: Have EFI system checked by an Idle speed too low. Authorized MerCruiser Dealer. Carburetor Models: Check choke linkages for Choke not operating properly. binding or an obstruction. Ignition System Fault. Service ignition system.
  • Page 63 CC522 Excessive Engine Temperature Possible Cause Remedy Water inlet valve closed (If So Equipped). Open valve completely. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups obstructed. Remove obstruction. Faulty thermostat. Replace. Coolant level low in fresh water section. (If So Check for cause of low coolant level and repair.
  • Page 64 CC524 Excessive Transmission Fluid Temperature or Slipping Transmission Possible Cause Remedy Low fluid level. Maintain fluid level. Transmission shift lever not positioned properly Inspect shift linkages and shift lever positioning. (causing clutches to slip and overheat fluid). Fluid cooler hoses kinked. Straighten hoses or replace, if damaged.

  • Page 65: Owner Service Assistance

    Only Authorized Dealers can purchase genuine Quicksilver parts and accessories from the facto- ry. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring on parts and acces- sories, the dealer requires the motor model and serial number(s) to order the correct parts.
  • Page 66 Should you have a question, concern or problem that cannot be resolved by your deal- ership, please contact Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
  • Page 67 (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America (305) 385-9585 (305) 385-5507 & Caribbean 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.
  • Page 68 Other Languages To obtain an Operation and 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 69 Altre lingue Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza internazionale Mercury Marine o Marine Power più vicino. In dotazione con il gruppo motore, viene fornito l’elenco dei codici prodotto dei componenti venduti all’estero.
  • Page 70 CB755 Literature Order Form Model __________ Horsepower__________ Serial Number__________ Year_____ Operation, Maintenance and Warranty Manual (Owner’s Guide) - explains basic operation, maintenance and warranty policies. Maintenance Procedure Manual - explains basic do-it-yourself maintenance procedures. Service Manual - shows the complete assembly and disassembly of the engine or sterndrive. Parts Manual - shows the exploded view of the engine or sterndrive with corresponding part number.

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