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Mercury 8.2L MAG/H.O./SeaCore Sterndrive Operation And Maintenance Manual

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8.2L MAG / H.O. / SeaCore
Sterndrive Models
Non ECT
OP ERA TIO N AN D
M A INTENAN C E
M A N U AL

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Summary of Contents for Mercury 8.2L MAG/H.O./SeaCore Sterndrive

  • Page 1 8.2L MAG / H.O. / SeaCore Sterndrive Models Non ECT OP ERA TIO N AN D M A INTENAN C E M A N U AL...
  • Page 3 The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.
  • Page 4 At Mercury Marine every engine is operated and tested before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of compliance with applicable standards and regulations.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Additional Operation Instructions for Axius Systems ....2 Dual‑Handle Electronic Remote Control (ERC)—Operation Identification................2 and Adjustment..............12 Information Decal..............2 Operation..............12 Quick Response (QR) Code..........2 Adjustment..............
  • Page 6 End of First Season Checkup.......... 37 Section 3 - Specifications Fuel Requirements..............40 8.2 MAG, 8.2 MAG H.O.—Including SeaCore Models..40 Fuel Ratings..............40 Engine Oil................41 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications..............42 ..................40 Engine................42 Gasoline Containing Alcohol..........
  • Page 7 Excessive Engine Temperature........97 Sterndrive Unit Does Not Move)........98 Section 7 - Customer Assistance Information Owner Service Assistance............. 100 Contact Information for Mercury Marine Customer Service Local Repair Service............100 ..................101 Service Away From Home..........100 Customer Service Literature..........101 Stolen Power Package.............
  • Page 8 Page iv 90-8M0128976 MAY 2017...
  • Page 9 Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package Table of Contents Additional Operation Instructions for Axius Systems ..... 2 Dual‑Handle Electronic Remote Control (ERC)— Identification................2 Operation and Adjustment..........12 Information Decal.............

  • Page 10: Additional Operation Instructions For Axius Systems

    Section 1 - Getting to Know Your Power Package Additional Operation Instructions for Axius Systems If your boat has DTS engines equipped with an Axius system, refer also to the Axius Operation Manual included with the boat. Identification The serial numbers are the manufacturer's key to numerous details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers.

  • Page 11: Engine Serial Number

    Section 1 - Getting to Know Your Power Package Engine Serial Number The engine serial number stamp is located on the starboard side of the engine block next to the flywheel housing cover. Flywheel housing cover Engine serial number stamp Engine block 43554 Bravo Sterndrive Serial Number and Identification...

  • Page 12: Bravo Transom Serial Number

    Section 1 - Getting to Know Your Power Package Bravo Transom Serial Number The Bravo transom serial number is stamped in the transom assembly decal. Transom Serial No. 53651 The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser dealers.

  • Page 13: Keep The Lanyard Stop Switch And Lanyard Cord In Good Operating Condition

    Section 1 - Getting to Know Your Power Package • Bass boats • High‑performance boats Accidental ejections can also occur from: • Poor operating practices • Sitting on the seat or gunwale at planing speeds • Standing at planing speeds •...

  • Page 14: Front Controls

    650–1200 Digital Gauges A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery voltage, fuel consumption, and engine operating hours.

  • Page 15: Analog Gauges

    Section 1 - Getting to Know Your Power Package SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed between the specified RPM range. SmartCraft gauges Tachometer Speedometer LCD system view display 26238 The SmartCraft instrument package also aids in Engine Guardian diagnostics.

  • Page 16: Remote Controls (Non-Dts Models)

    Remote Controls (Non‑DTS Models) Remote Controls Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description and/or demonstration of your remote control. Panel Mount Features...

  • Page 17: Zero Effort Features

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

  • Page 18: Panel Mount Features

    Section 1 - Getting to Know Your Power Package Panel Mount Features Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw 3409 Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.

  • Page 19: Special Digital Throttle And Shift (Dts) Features

    Section 1 - Getting to Know Your Power Package Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn screw clockwise to increase tension and counterclockwise to decrease tension.

  • Page 20: Dual-Handle Electronic Remote Control (Erc)-Operation And Adjustment

    Section 1 - Getting to Know Your Power Package Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment Operation The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from the forward position to the neutral position to decrease speed and eventually stop.

  • Page 21: Special Digital Throttle And Shift (Dts) Features

    Section 1 - Getting to Know Your Power Package Special Digital Throttle and Shift (DTS) Features The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed features can operate simultaneously. 51853 Dual-engine ERC Item Control Function...

  • Page 22: Dock

    Section 1 - Getting to Know Your Power Package Dock Dock mode is available with joystick operation and remote control lever operation. Dock mode reduces throttle capacity to approximately 70% of normal joystick throttle demand, allowing finer control of engine power in close quarter situations. If more power is needed for vessel maneuvering when environmental conditions require more thrust, use the electronic remote control levers.

  • Page 23: Lever

    Section 1 - Getting to Know Your Power Package 1 Lever The outboard joystick system features the ability to command both engines with a single lever on a dual‑engine application. This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both engines simultaneously.

  • Page 24: Transfer (Boats Equipped With Dual Helms)

    Section 1 - Getting to Know Your Power Package Transfer (Boats equipped with dual helms) The "TRANSFER" button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on boats equipped with dual helms. Refer to Helm Transfer. 51858 "TRANSFER"...

  • Page 25: Power Trim

    Section 1 - Getting to Know Your Power Package Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its forward position.

  • Page 26: Single Engine Trim/Trailer

    Section 1 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
  • Page 27 Section 1 - Getting to Know Your Power Package The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. To reset the circuit breaker, push the red button. The circuit breaker is located at the starboard rear of the engine in the electrical center. 51332 A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
  • Page 28 Section 1 - Getting to Know Your Power Package The clean power harness connected to the engine starting battery minimizes voltage drop to the electrical system and is protected by a 5‑amp fuse. a b c d e Paddle wheel and tank level connector Diagnostic connector 14‑pin harness connector Clean power harness connector...
  • Page 29 Section 1 - Getting to Know Your Power Package A 20‑amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for an open fuse or an open circuit breaker if the ignition key is turned to the "START" position and nothing happens. mc70525-1 The power trim system is protected from overload by both a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump.

  • Page 30: Visual And Audio Warning Systems

    Section 1 - Getting to Know Your Power Package The MerCathode has a 5‑amp fuse that connects to the positive (+) terminal on the controller. If the fuse is open, the system will not operate, resulting in a loss of corrosion protection. MerCathode Red/purple wire 5‑amp fuse...

  • Page 31: Testing The Audio Warning System

    If the debris passes through, and full water flow is restored, Guardian restores engine power to normal. To avoid recurrence of the problem, contact an authorized Mercury MerCruiser dealer. 90-8M0128976...
  • Page 32 Section 1 - Getting to Know Your Power Package Notes: Page 24 90-8M0128976 MAY 2017...
  • Page 33 Section 2 - On the Water Section 2 - On the Water Table of Contents Additional Operation Instructions for Axius Systems ... 26 Freezing Temperature Operation........32 Safe Boating Recommendations.......... 26 Drain Plug and Bilge Pump..........32 Carbon Monoxide Exposure..........27 Protecting People in the Water..........

  • Page 34: Additional Operation Instructions For Axius Systems

    Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer. Ensure that everyone in the boat is properly seated.

  • Page 35: Carbon Monoxide Exposure

    Section 2 - On the Water Never operate a boat while under the influence of alcohol or drugs. It is the law. • Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly. Know your boating area and avoid hazardous locations. Be alert.

  • Page 36: Poor Ventilation

    Section 2 - On the Water Example of desired air flow through the boat: 43367 Poor Ventilation Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

  • Page 37: Starting And Stopping The Engine

    Section 2 - On the Water Operation Chart Before Starting After Starting While Underway After Stopping Check shift and throttle Turn battery switch on. Close fuel shut off valve. control operation. Close seacock, if Operate bilge blowers. Check steering operation. equipped.

  • Page 38: Starting The Engine After It Has Been Stopped While In Gear

    IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 39: Starting And Stopping The Engine

    Section 2 - On the Water Operation Chart Before Starting After Starting While Underway After Stopping Check shift and throttle Turn battery switch on. Close fuel shutoff valve. control operation. Close seacock, if Operate bilge blowers. Check steering operation. equipped. Flush cooling system if in Open fuel shutoff valve.

  • Page 40: Stopping The Engine

    IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.

  • Page 41: Protecting People In The Water

    For additional information, refer to Hi‑Performance Boat Operation booklet (90‑849250R03) from your dealer, distributor, or Mercury Marine. Passenger Safety in Pontoon Boats and Deck Boats Whenever the boat is in motion, observe the location of all passengers.

  • Page 42: Wave And Wake Jumping

    Section 2 - On the Water Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat. mc79557-1 Wave and Wake Jumping WARNING Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

  • Page 43: Drive Unit Impact Protection

    After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.

  • Page 44: The Bottom Of The Boat

    The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer to Mercury Marine's web page https://www.mercurymarine.com/en/us/propellers/selector/#/step‑one. Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating RPM range with a normal load.

  • Page 45: Getting Started

    End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
  • Page 46 Section 2 - On the Water Notes: Page 38 90-8M0128976 MAY 2017...
  • Page 47 Section 3 - Specifications Section 3 - Specifications Table of Contents Fuel Requirements............... 40 8.2 MAG, 8.2 MAG H.O.—Including SeaCore Models.. 40 Fuel Ratings ..............40 Engine Oil................41 Using Reformulated (Oxygenated) Gasoline (USA Only) Fluid Specifications............... 42 ..................40 Engine................

  • Page 48: Fuel Requirements

    Using Reformulated (Oxygenated) Gasoline (USA Only) Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).

  • Page 49: Engine Oil

    Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the MerCruiser Limited Warranty. If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation.

  • Page 50: Fluid Specifications

    Section 3 - Specifications Use the following information for selecting the type of oil according to the order of preference. Mercury/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W Catalyst Compatible rated 4-cycle oil Mercury/Quicksilver 25W-40 Mineral NMMA FC-W Catalyst Compatible rated 4-cycle oil...

  • Page 51: Approved Power Trim Fluids

    Section 3 - Specifications Approved Power Trim Fluids Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W‑30 Obtain locally SAE Engine Oil 10W‑40 90-8M0128976 MAY 2017 Page 43...
  • Page 52 Section 3 - Specifications Notes: Page 44 90-8M0128976 MAY 2017...
  • Page 53 Section 4 - Maintenance Section 4 - Maintenance Table of Contents Additional Operation Instructions for Axius Systems ... 46 Changing the Positive Crankcase Ventilation Valve (PCV).. 59 Owner/Operator Responsibilities.......... 46 Water‑Separating Fuel Filter..........59 Dealer Responsibilities............46 Removal and Installation..........60 Maintenance.................

  • Page 54: Additional Operation Instructions For Axius Systems

    It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.

  • Page 55: Inspection

    Check plug leads and electrical leads for damage. • Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your authorized Mercury MerCruiser dealer. • Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.

  • Page 56: Three Years Or 300 Hours

    Section 4 - Maintenance • Check the battery condition and connections—dealer item • Touch up any paint nicks and spray the power package with Corrosion Guard • Change the engine oil and filter • Change the sterndrive gear oil • Check the closed cooling fluid level and concentration for freeze protection, if equipped •...

  • Page 57: Filling

    Add the specified engine oil to bring the level up to, but not over, the operating range mark on the dipstick. Check the oil level. Replace the fill cap. All Models Capacity Fluid Type Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine oil (with filter) 6.5 Liter (7 US qt) Engine Oil Engine Oil and Filter Replace the oil filter at every oil change.

  • Page 58: Oil Removal With Drain Pump

    NOTE: Adding 0.95 L (1 US qt) of engine oil raises the level from the bottom of the operating range to the top of the operating range. All Models Capacity Fluid Type Engine oil (with filter) 6.5 L (7 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil Start the engine and operate for three minutes, checking for leaks. Page 50 90-8M0128976 MAY 2017...

  • Page 59: Power-Assisted Steering Fluid

    Stop the engine and center the sterndrive unit. IMPORTANT: If fluid is not visible on the fill cap dipstick, contact your authorized Mercury MerCruiser dealer. Remove the fill cap from the power steering fluid reservoir and observe the level. The oil level should be at the full mark on the dipstick.

  • Page 60: Checking Coolant Level

    Section 4 - Maintenance Tube Ref No. Description Where Used Part No. Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1 Checking Coolant Level CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently, resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.

  • Page 61: Draining

    Maintain the coolant level in the reservoir at or near the full mark with the engine cold. Draining Contact your authorized Mercury MerCruiser dealer. Cleaning Contact your authorized Mercury MerCruiser dealer.

  • Page 62: Filling

    Inspect the lubricant condition. If any water is visible at the bottom of the gear lube monitor, if water appears at the fill and drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately.
  • Page 63 Lower the sterndrive unit so the propeller shaft is level. IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant flows from the oil vent hole.

  • Page 64: Power Trim Fluid

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

  • Page 65: Multiple Efi Engine Battery Precautions

    Section 4 - Maintenance WARNING An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries. Multiple EFI Engine Battery Precautions Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on.

  • Page 66: Cleaning The Iac Muffler (Non-Dts Models Only)

    Section 4 - Maintenance Loosen the flame arrestor clamp and remove the flame arrestor. Flame arrestor Flame arrestor clamp 50396 Clean the flame arrestor with solvent and dry with compressed air or set aside and allow to air dry completely. Install the flame arrestor and tighten the clamp to the specified torque.

  • Page 67: Changing The Positive Crankcase Ventilation Valve (Pcv)

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

  • Page 68: Removal And Installation

    Removal Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. Close fuel supply valve, if equipped. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 69: Lubrication

    10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Check the filter installation, clean spilled fuel, and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication...

  • Page 70: Throttle Cable

    Lubricate the steering pin. Steering pin mc71904-1 Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Steering pin 92-8M0078629 4-Stroke Engine Oil On dual engine boats: Lubricate the tie bar pivot points. Tube Ref No. Description Where Used Part No.

  • Page 71: Shift Plate Control Cable Lubrication

    43662 Tube Ref No. Description Where Used Part No. Mercury 25W-40 Synthetic Blend Shift cable pivot points and guide contact surfaces 92-8M0078629 4-Stroke Engine Oil Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit Removed) Apply grease to the driveshaft U‑joint splines and O‑rings.

  • Page 72: Engine Coupler

    Tube Ref No. Description Where Used Part No. Transom end grease fitting, engine end grease fitting, driveshaft grease Extreme Grease 8M0071842 fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Page 64 90-8M0128976 MAY 2017...

  • Page 73: Bravo One Propeller Removal

    Section 4 - Maintenance Bravo One Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 74: Bravo Two Propeller Removal

    Section 4 - Maintenance Bravo Two Propeller Removal WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

  • Page 75: Bravo Three Propeller Removal

    Turn the front propeller nut 70 mm (2‑3/4 in.) counterclockwise to remove the nut. Slide the propeller and thrust hub off the propeller shaft. NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Rear propeller nut...

  • Page 76: Bravo Three Propeller Installation

    Section 4 - Maintenance Bravo Three Propeller Installation NOTICE Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval. Rear propeller nut Rear propeller Rear propeller thrust hub...

  • Page 77: Serpentine Drive Belt

    Section 4 - Maintenance 11. Apply Loctite 271 Threadlocker onto the propeller shaft anode screw threads. Propeller Rear propeller nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer 5303 Tube Ref No. Description Where Used Part No. Loctite 271 Threadlocker Propeller shaft anode screw threads 92-809819...

  • Page 78: Checking

    Section 4 - Maintenance Checking Inspect the drive belt for: • Proper belt tension deflection • Excessive wear • Cracks • Fraying • Glazed surfaces • Proper tension Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys. Description Deflection 13 mm (1/2 in.)

  • Page 79: Corrosion Protection

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

  • Page 80: Anodes And Mercathode System Locations

    1 long flash every 60 terminals, or the boat is out of seconds • If the boat is in the water, contact your local Mercury Service the water/dry docked. dealer for assistance. • Check the battery voltage; it must be 12.6 V or higher.

  • Page 81: Do Not Use Caustic Cleaning Chemicals

    Section 4 - Maintenance Description Location Figure Mounted on the underside of the Gearcase anode plate lower gearcase. 20336 Ventilation plate anode Mounted on the front of the gearcase. 20338 The MerCathode electrode is mounted to the underside of the gimbal housing.

  • Page 82: Power Package Exterior Surfaces

    If you are using copper based antifouling paint, observe the following precaution: • Avoid an electrical interconnection between the Mercury MerCruiser product, anodic blocks, or MerCathode system and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.

  • Page 83: Sterndrive Surface Care

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

  • Page 84: Flushing The Seawater System-Sterndrive Models

    Section 4 - Maintenance • Remove the propeller at least every 60 days and lubricate the propeller shaft. • Do not use lubricants containing graphite on or near the aluminum in saltwater. • Do not paint trim tabs or the mounting surface. Flushing the Seawater System—Sterndrive Models Flushing the Power Package—Bravo Models The boat can be equipped with a combination of any of three different types of water pickups: through‑the‑hull,...

  • Page 85: Sterndrive Water Pickups

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

  • Page 86: Alternative Water Pickups

    Section 4 - Maintenance Connect the hose between the flushing attachment and the water source. With the sterndrive in a normal operating position, open the water source fully. Disengage the E‑stop switch, place the remote control in the neutral idle speed position and start the engine. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine.

  • Page 87: Seacore Power Package Flushing Procedure

    Section 4 - Maintenance Remove the seawater inlet hose from the seawater pump at the location shown. Plug the hose to prevent water from siphoning into the engine or boat. 55049 Seawater inlet hose connection Use a suitable adapter to connect the flushing hose from the water source to the water inlet of the seawater pump. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.
  • Page 88 Section 4 - Maintenance WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
  • Page 89 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 63788 Quick-connect fitting: store on the boat, NOT the engine 19.
  • Page 90 Section 4 - Maintenance Notes: Page 82 90-8M0128976 MAY 2017...
  • Page 91 Section 5 - Storage Section 5 - Storage Table of Contents Cold Weather or Extended Storage........84 Air‑Actuated Single‑Point Drain System......88 Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 84 Boat in the Water ........... 88 Fuel Containing Alcohol..........84 Boat Out of the Water ..........89 Preparing Power Package for Storage—MPI Models..

  • Page 92: Cold Weather Or Extended Storage

    (phase) of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings).

  • Page 93: Special Fuel Mix

    Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation. Check the antifreeze concentration where applicable. Refer to the Specifications section. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks and proceed with the following: Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add...

  • Page 94: Maintenance

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

  • Page 95: Drain System Identification

    Section 5 - Storage Drain System Identification Air-Actuated Single-Point Drain System Manual pressure release valve Threaded cap for air connection Green indicators 50399 50407 Starboard side air‑actuated drain location Port side air‑actuated drain location Manual Drain System 50408 Starboard side blue drain plugs Port side blue drain plug 90-8M0128976 MAY 2017...

  • Page 96: Air-Actuated Single-Point Drain System

    12. Remove the air pump from the air connection and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 97: Boat Out Of The Water

    Section 5 - Storage 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. Manual pressure release valve Threaded cap for air connection Green indicators 50399 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. Boat Out of the Water NOTE: This procedure is written for the air pump that is attached to the engine.

  • Page 98: Manual Drain System

    11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.

  • Page 99: Boat Out Of The Water

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

  • Page 100: Draining Water From The Cool Fuel Module

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

  • Page 101: Battery Storage

    IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.
  • Page 102 Section 5 - Storage Notes: Page 94 90-8M0128976 MAY 2017...
  • Page 103 Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing EFI Problems............. 96 Insufficient Engine Temperature........97 Diagnosing DTS Problems........... 96 Low Engine Oil Pressure..........97 Additional Operation Instructions for Axius Systems ... 96 Battery Will Not Recharge..........98 Engine Guardian System............

  • Page 104: Diagnosing Efi Problems

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

  • Page 105: Engine Runs Rough, Misses, Or Backfires

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

  • Page 106: Battery Will Not Recharge

    Check all linkages. If any are loose or missing, see authorized Loose or missing shift and throttle linkages. Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury MerCruiser dealer Shift or throttle cable kinked. replace cable if damaged beyond repair.
  • Page 107 Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance..........100 Contact Information for Mercury Marine Customer Local Repair Service ..........100 Service ............... 101 Service Away From Home .......... 100 Customer Service Literature..........101 Stolen Power Package ..........

  • Page 108: Owner Service Assistance

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

  • Page 109: Contact Information For Mercury Marine Customer Service

    Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939 Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information. When ordering be sure to: •...

  • Page 110: Other Languages

    Section 7 - Customer Assistance Information Other Languages To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
  • Page 111 Section 8 - Checklists Section 8 - Checklists Table of Contents Predelivery Inspection (PDI)..........104 Customer Delivery Inspection (CDI)........105 90-8M0128976 MAY 2017 Page 103...

  • Page 112: Predelivery Inspection (Pdi)

    Section 8 - Checklists Predelivery Inspection (PDI) IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual. Perform these tasks before the Customer Delivery Inspection (CDI). Check/ Item Adjust...

  • Page 113: Customer Delivery Inspection (Cdi)

    Approve the external appearance of the product (paint, cowl, decals, etc.) ⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services. ⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only) Operation of equipment—explain and demonstrate: ⃞ E‑stop switch/lanyard stop switch operation (all helms) ⃞...
  • Page 114 Section 8 - Checklists N/A Completed Item ⃞ Boat (lights, battery switch location, fuses/breakers) ⃞ ⃞ Trailer (if applicable) Registration: ⃞ Complete and submit warranty registration—provide the customer with a copy Page 106 90-8M0128976 MAY 2017...

  • Page 115: Section 9 - Maintenance Log

    Section 9 - Maintenance Log Section 9 - Maintenance Log Table of Contents Scheduled Maintenance Log..........108 Vessel Maintenance Notes..........109 90-8M0128976 MAY 2017 Page 107...

  • Page 116: Scheduled Maintenance Log

    Section 9 - Maintenance Log Scheduled Maintenance Log 100 Hours Actual Hours Service Notes Dealer Name Signature Date 200 Hours Actual Hours Service Notes Dealer Name Signature Date 300 Hours Actual Hours Service Notes Dealer Name Signature Date 400 Hours Actual Hours Service Notes Dealer Name...

  • Page 117: Vessel Maintenance Notes

    Section 9 - Maintenance Log Vessel Maintenance Notes Record all general maintenance performed on your power package here. Save all work orders and receipts. Engine Date Maintenance Completed Servicing Dealer Hours 90-8M0128976 MAY 2017 Page 109...
  • Page 119 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0128976 MAY 2017 Printed in U.S.A.

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