Mercury Racing HP1075 SCi Dry Sump Operation, Maintenance & Warranty Manual
  1. Manuals
  2. Brands
  3. Mercury Racing Manuals
  4. Engine
  5. HP1075 SCi
  6. Operation, maintenance & warranty manual

Mercury Racing HP1075 SCi Dry Sump Operation, Maintenance & Warranty Manual

Hide thumbs Also See for HP1075 SCi Dry Sump:
Table of Contents

Advertisement

Quick Links

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!
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
i
7406

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HP1075 SCi Dry Sump and is the answer not in the manual?

Questions and answers

Related Manuals for Mercury Racing HP1075 SCi Dry Sump

Summary of Contents for Mercury Racing HP1075 SCi Dry Sump

  • 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 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.
  • Page 3 CAUTION CAUTION ‑ indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices. IMPORTANT: Indicates information or instructions that are necessary for a particular step or action.

  • Page 5: Table Of Contents

    Warranty Information Warranty Registration United States And Canada........1 Warranty Registration Outside The United States And Canada....1 Mercury Racing Demonstrator Policy............2 Transfer Of Warranty................2 Mercury RACING DIVISION 90 Day Limited Warranty......3 Warranty Against Corrosion (Worldwide)..........6 General Information Identification Record.................7 Boater's Responsibilities................8 Before Operating Your Boat..............8...
  • Page 6 TABLE OF CONTENTS Remote Controls (Console Mounted Zero Effort)........32 Power Trim.....................33 Starting, Shifting, and Stopping..............36 Operation Chart..................37 Freezing Temperature Operation............38 Drain Plug and Bilge Pump..............38 Launching And Boat Operation Care............38 Conditions Affecting Operation Weight Distribution..................39 Bottom Of Boat..................39 Cavitation....................39 Ventilation....................39 Propeller Selection..................40 Conditions That Lower Engine Performance..........40 Maintenance...
  • Page 7 TABLE OF CONTENTS Draining Instructions................77 Battery Winter Storage................80 Power Package Recommissioning............80 Troubleshooting Engine Will Not Crank................84 Engine Cranks But Will Not Start............85 Engine Runs Rough, Hard to Start, Misses, and/or Backfires....86 Poor Performance...................86 Insufficient Engine Temperature.............87 Excessive Engine Temperature..............87 Low Engine Oil Pressure................88 Battery Will Not Come Up On Charge............88 Power Trim Does Not Operate (Motor Doesn't Run)......89 Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not...
  • Page 8 viii...

  • Page 9: Warranty Information

    WARRANTY INFORMATION Warranty Registration United States And Canada 1. You may change your address 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 10: Mercury Racing Demonstrator Policy

    Warranty Claim processing, refer to the International Warranty. 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 11: Mercury Racing Division 90 Day Limited Warranty

    For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you. 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 12 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 13 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 14: Warranty Against Corrosion (Worldwide)

    WARRANTY INFORMATION DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY.

  • Page 15: 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 16: Boater's Responsibilities

    GENERAL INFORMATION Serial Numbers Engine Model/Horsepower: Engine S/N : Transom Assembly S/N: Sterndrive S/N & Gear Ratio : Propeller Number/Pitch: Running Rotation : Hull Identification Number: h - Boat Model & Length: 7425 The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package.

  • Page 17: Boat Horsepower Capacity

    GENERAL INFORMATION WARNING WARNING ‑ indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION CAUTION ‑ indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices.

  • Page 18: High-Speed And High-Performance Boat Operation

    GENERAL INFORMATION High‑Speed and High‑Performance Boat Operation If your power package is to be used on a high speed or high performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and familiarization demonstration ride with your dealer or an operator experienced with your boat/power package combination.

  • Page 19: Protecting People In The Water

    GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.

  • Page 20: Exhaust Emissions

    GENERAL INFORMATION Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat. Exhaust Emissions BE ALERT TO CARBON MONOXIDE POISONING Carbon monoxide is present in the exhaust fumes of all internal combustion engines.

  • Page 21: 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 22: 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 23 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 24: 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 25 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. 1.

  • Page 26: 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 27: Specifications

    (R+M) ÷ 2 = 91 or RON = 98* NOTE: *Research Octane Number 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...
  • Page 28 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 29: 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 30 SPECIFICATIONS TEMPERATURE/OIL VISCOSITY CHART Multi-viscosity Mercury/Quicksilver 25W 40 SJ, SL, CF-2, Premium Multi-Viscosity 20W 50 CF-4, CG-4, CH-4, CI-4 +100 7411...

  • Page 31: Engine Specifications

    SPECIFICATIONS Engine Specifications Model HP1075 SCi Displacement 9.1 liter (557 cid) Crankshaft horsepower 1075 Crankshaft Kilowatts Maximum RPM @ WOT 6000 RPM Idle RPM in gear 800 RPM Idle RPM out of gear 825RPM Fuel pump pressure at key up 400 kPa (58 psi) Fuel pump pressure at WOT 498 kPa (72 psi)
  • Page 32 SPECIFICATIONS ENGINE SPECIFICATIONS Model HP10750 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 ‑ 0.508 mm (0.020 in.) Exhaust valve lash setting Cold ‑...

  • Page 33: Capacities

    SPECIFICATIONS Capacities Model HP1075 SCi Oil reservoir capacity with new Approximately 15.2 liters (16 U.S. filter qt.) Seawater cooling system 19 liter (20 U.S. qt.) Approximately 1.9 liters (2.0 U.S. Transmission fluid capacity qt.) Transom Bearing Liter (U.S. qt.) to Cavity (Close Drive Type Liter (U.S.

  • Page 34: Engine Break-In

    SPECIFICATIONS Engine Break‑in CAUTION Severe damage to the engine can result by not complying with the Engine Break‑in Procedure. 1 Hr. Break‑in Procedure • Do not exceed 5000 RPM 5 Hr. Break‑in Procedure • Allow engine to warm‑up for 3‑5 minutes. •...

  • Page 35: Operation

    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 36 OPERATION Engine Power Monitor Guardian Reduced Problem Horn Display Activated Battery range 3 Beeps‑1.5 100% down high or low Sec. Long to 5% Low Seawater 100% down Steady Horn Pressure to 5% Boost Valve Steady Horn Error Guardian Steady Horn Envoked Low Oil 100% down...
  • Page 37 OPERATION Engine Power Monitor Guardian Reduced Problem Horn Display Activated Idle Air Control 5 Beeps‑3 Failure Sec. Long Transmission 3 Beeps‑1.5 Overtemp Sec. Long Knock Sensor 3 Beeps‑1.5 Failure Sec. Long Oil Pressure 3 Beeps‑1.5 Sensor Failure Sec. Long Oil Temperature 3 Beeps‑1.5 Sensor Failure Sec.

  • Page 38: Electrical System Overload Protection

    OPERATION Electrical System Overload Protection If an electrical overload occurs, a fuse or circuit breaker opens. Locate and correct the problem before replacing the fuse or resetting circuit breaker. • A circuit breaker protects the engine wiring harness and instrumentation power lead. Reset by pushing the reset button. •...
  • Page 39 OPERATION Fuse Holder (b) Fuse Holder (c) 5 amp Hour Meter A‑RED/ 5 amp Fuel Pump A‑RED/ Relay B‑RED/ B‑RED/ 15 amp CAN/Main C‑RED 20 amp IAC Boost C‑RED/ Remote Bypass D‑RED/ D‑RED/ 15 amp Constant E‑RED 20 amp Coil Power E‑RED/ Power F‑RED/...

  • Page 40: Remote Controls (Console Mounted Zero Effort)

    OPERATION A 90 amp fuse is located on the starter. 7417 90 amp fuse 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.

  • Page 41: 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 42 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 43 OPERATION • 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. This can result in an unexpected turn in either direction, called bow steering or over steering.

  • Page 44: Starting, Shifting, And Stopping

    OPERATION Starting, Shifting, and Stopping WARNING Avoid fire or explosion. Before starting the engine, operate the bilge blower for at least five minutes to remove any explosive fumes from the engine compartment. If the boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine.

  • Page 45: Operation Chart

    OPERATION 3. Start the engine. Release the key when the engine starts and allow switch to return to the "ON" position. 4. Check the oil pressure gauge immediately after the engine starts. If oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause.

  • Page 46: Freezing Temperature Operation

    Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. Launching And Boat Operation Care CAUTION Avoid product damage.

  • Page 47: 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 48: 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 49 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 can be...

  • Page 50: 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 51: 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 52: Servicing High Horsepower Engines

    MAINTENANCE • If you attempt to service the product yourself, we suggest you order the service manual for that model. This manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't understand. Do not attempt repairs if you do not understand the procedures.

  • Page 53: Maintenance Charts

    MAINTENANCE Maintenance Charts Interval Task Cooling system ‑ Flush Engine oil ‑ (reservoir) Check level Power steering fluid ‑Check level Sterndrive unit oil ‑ Check level Transmission fluid ‑ Check level Check every 3 hours of operation Battery ‑ Check level and inspect for damage Power trim pump oil ‑...
  • Page 54 MAINTENANCE Interval Task Perform 25 hour maintenance items VI SSM Tie bar mounting bracket nuts. Tighten nuts to 102 Nm (75 lb. ft.) Lubricate and inspect universal joint cross bearings Lubricate drive input shaft Tighten drive mounting nuts 136 Nm Every 50 hours of operation or (100 lb.

  • Page 55: Checking Fluid Levels

    MAINTENANCE Interval Task Perform 25 and 50 hour maintenance items Every 100 hours of operation or once yearly, whichever occurs Seawater pickup pump ‑ first. Disassemble and Inspect Engine alignment ‑ Check Inspect all rotating and reciprocating Every 100 to 120 hours of components for wear.
  • Page 56 MAINTENANCE IMPORTANT: Do not overfill engine oil. NOTE: If the engine is not operated for a period of time (several days or longer), a certain amount of oil may drain from the reservoir back into the engine oil pan. When the engine is started this oil will be pumped back into the reservoir.
  • Page 57 MAINTENANCE 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. If low, fill the input shaft housing "b" through the top fill pipe plug hole "a"...
  • Page 58 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" opening.
  • Page 59 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...
  • Page 60 MAINTENANCE Tube Ref No. Description Where Used Part No. Power Trim and 92-802880A Trim pump Steering Fluid 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"...
  • Page 61 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 62: 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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. 7429 Oil level plug Fill/Drain plug and sealing washer...

  • Page 71: Lubrication

    MAINTENANCE 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: • Shift cable. • Throttle linkage and cable ‑ Lubricate cable and swivels. F - N - R 7446 Tube Ref.

  • Page 72: 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 73: 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 74: 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 75: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE Cleaning Seawater (Raw Water) Section of Oil Cooler ENGINE COOLERS IMPORTANT: Cleaning of the engine oil coolers should be performed by an authorized Mercury Marine dealer. 3712 Transmission/Power Steering Cooler ‑ (Starboard Side) Water hose clamps Cooler End plate/gaskets Retaining clamps 1.

  • Page 76: Drive Belts

    MAINTENANCE Drive Belts WARNING Avoid possible serious injury or death. Make sure engine is shut off and ignition key is removed before inspecting belts. Periodically inspect all of the following drive belts for condition and tension. See your authorized Mercury Marine dealer for replacement or tension adjustments.
  • Page 77 MAINTENANCE 2. Power Steering Pump Drive Belt 2851 Power steering pump pulley Power steering pump drive (adjust belt tension here) belt Idler pulley Crankshaft pulley Tensioner gauge Recirculating pump pulley 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 78: 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 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 79 MAINTENANCE IMPORTANT: Mercury Marine recommends a MerCathode System or Anti‑Corrosion Kit be installed whenever using a stainless steel propeller, or if the boat is equipped with stainless steel components (immersed below the waterline) that are connected into the engine ground system. If a boat is equipped with stainless steel after planes, a large anode should be installed on each to handle the increased galvanic corrosion potential.
  • Page 80 MAINTENANCE 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. 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 81: Battery

    MAINTENANCE 2. Painting Drive Unit or Transom Assembly • 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 82: 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 83: Attention Required After Submersion

    MAINTENANCE 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. Repair nicks and corrosion damage on the power package's exterior finish. Use Quicksilver spray paints ‑ see your authorized Mercury Marine dealer.

  • Page 84: 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 85: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE 6. After the specified running time is complete, slowly return the throttle to idle RPM and shut off the engine. IMPORTANT: Maintain an adequate supply of the fuel/fogging mixture in the remote 23 liter (6 U.S. gal) tank to complete the fuel system treatment and flushing procedure.
  • Page 86 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 wire to Center/bottom of bell housing clean out drain holes until (drains the engine oil coolers). entire system is drained.
  • Page 87 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)

  • Page 88: Battery Winter Storage

    COLD WEATHER OR EXTENDED STORAGE 3. Charge Air Cooler Draining: 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 89 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 90 COLD WEATHER OR EXTENDED STORAGE 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. 8. Do not advance the throttle until the engine idles and runs smoothly and the water temperature reaches a minimum of 54 °C (130 °F).
  • Page 91 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 92: 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 blown fuse. replace fuse. Check all electrical connections Loose or dirty electrical and wires (especially battery connections or damaged wiring.

  • Page 93: Engine Cranks But Will Not Start

    TROUBLESHOOTING Engine Cranks But Will Not Start Possible Cause Remedy Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shut off Fill tank or open valve. valve closed. Faulty fuel pump, wiring, 5 amp fuse, 50 amp circuit breaker or one Replace faulty component.

  • Page 94: 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 Stale or contaminated fuel. with fresh fuel. Replace kinked lines or blow out Kinked or clogged fuel line or fuel tank lines with compressed air to vent line.

  • Page 95: 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 Clean Charge Air Cooler.

  • Page 96: 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 Excessive oil in system (causing it level. Check for cause of to become aerated). excessive oil (improper filling, defective fuel pump, etc.).

  • Page 97: Power Trim Does Not Operate (Motor Doesn't Run)

    TROUBLESHOOTING Power Trim Does Not Operate (Motor Doesn't Run) Possible Cause Remedy Open fuse. Replace fuse. Check all associated electrical connections and wires (especially Loose dirty electrical battery cables). Clean and tighten connections or damaged wiring. faulty connections. Repair or replace damaged wiring.

  • Page 98: Steering Wheel Turns Hard Or Jerky

    TROUBLESHOOTING Steering Wheel Turns Hard or Jerky Possible Cause Remedy Low power steering pump fluid Refill system with fluid and check level. for leaks. Drive belt loose or damaged. Replace and/or adjust. Insufficient lubrication on steering Lubricate. system components. Check all parts and fasteners. If Loose or missing steering fasteners any are loose or missing, see or parts.

  • Page 99: 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 100: Mercury Marine 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 101 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...

  • Page 102: Ordering Literature

    ORDERING LITERATURE United States and Canada Before ordering literature, please have the following information about your power package available: Engine Horsepower: Model: 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...

  • Page 103: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

Table of Contents