Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used. 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.
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.
TABLE OF CONTENTS Section 1 - Getting to Know Your Power Package Hang Tag..................2 Panel Mount ERC..............7 Identification.................. 2 TowSports Panel Mount Features.......... 8 Information Decal..............2 Electrical System Overload Protection......... 8 Quick Response (QR) Code............. 3 Visual and Audio Warning Systems..........10 Engine Serial Number ............
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Steering Wheel Jerks or Is Difficult to Turn....... 60 Poor Performance............... 59 Section 7 - Customer Assistance Information Owner Service Assistance............62 Contact Information for Mercury Marine Customer Local Repair Service............. 62 Service .................. 63 Service Away From Home............ 62 Customer Service Literature............63 Stolen Power Package............
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Section 1 - Getting to Know Your Power Package Section 1 - Getting to Know Your Power Package 1 Table of Contents Hang Tag..................2 TowSports Panel Mount Features........8 Identification................2 Electrical System Overload Protection........8 Information Decal..............2 Visual and Audio Warning Systems......... 10 Quick Response (QR) Code..........
Section 1 - Getting to Know Your Power Package Hang Tag 66974 Proposition 65 hang tag Identification The serial numbers are the manufacturer's key to numerous details that apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Information Decal The information decal is located on the coolant reservoir.
Section 1 - Getting to Know Your Power Package Quick Response (QR) Code Scan the QR code link with a smartphone to access additional product information. 77563 QR code 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 block Engine serial number stamp...
Section 1 - Getting to Know Your Power Package Accidental ejections can also occur from: • Poor operating practices • Sitting on the seat or gunwale at planing speeds • Standing at planing speeds • Operating at planing speeds in shallow or obstacle‑infested waters •...
Section 1 - Getting to Know Your Power Package Refer to the VesselView operator's manual for more information. 61325 VesselView SmartCraft Digital Instruments The SmartCraft instrument package augments the VesselView display. The instrument package may include: • Tachometer • Speedometer • Engine coolant temperature •...
Quantity of fuel in tank 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.
The light flashes when the engine is in throttle‑only mode. Increases and decreases the brightness settings for the Brightness (+ and –) lights on the ERC and Mercury helm components. Allows the boat operator to increase engine RPM without THROTTLE ONLY shifting into gear.
Section 1 - Getting to Know Your Power Package TowSports Panel Mount Features Lanyard stop switch Control handle and shift lock Detent tension adjustment screw Control handle tension adjustment screw Throttle only button (on helm‑mounted CAN pad) 33173 Lanyard stop switch—The lanyard turns the ignition off whenever the operator moves far enough away from the operator's position to activate the switch, assuming the operator is attached.
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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. 51332 A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
Section 1 - Getting to Know Your Power Package A 15‑amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine. Fuse cover 15‑amp fuse Accessory harness 32206 The DTS control system is protected by a 5‑amp fuse located near the battery. 5‑amp fuse Positive battery terminal (harness lead with fuse) Negative battery terminal...
Section 1 - Getting to Know Your Power Package The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning correctly. Audio Warning System IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from damage.
Section 1 - Getting to Know Your Power Package The PCM stores the fault for diagnostics. For example, if the water inlet becomes partially blocked, Engine Guardian reduces the available power level of the engine to help prevent damage from decreased water flow to the engine. If the debris passes through, and full water flow is restored, Engine Guardian restores engine power to normal.
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Section 2 - On the Water Section 2 - On the Water Table of Contents 2 Safe Boating Recommendations..........14 Operation Chart ............19 Carbon Monoxide Exposure............. 15 Starting and Stopping the Engine........19 Be Alert To Carbon Monoxide Poisoning ......15 Starting the Engine ..........
Most boats are rated and certified for maximum load (weight) capacities (refer to the boat's capacity plate). Know the boat's operating and loading limitations. Know if the boat will float if it is full of water. When in doubt, contact a Mercury Marine Authorized Dealer or the boat manufacturer.
Section 2 - On the Water • Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the boat.
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.
Section 2 - On the Water Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water. mc79555-1 WARNING Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
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.
WARNING Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have a Mercury Marine Authorized Dealer inspect and repair the vessel or power package.
Section 2 - On the Water WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes. NOTE: This power package is equipped with SmartStart.
Freezing Temperature Operation 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 Marine Limited Warranty. Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect.
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/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.
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).
Catalysts damaged by lubricants containing high levels of phosphorus may not be covered by the Mercury Marine Limited Warranty. If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of recommendation.
Fluid Specifications Engine IMPORTANT: All capacities are approximate fluid measures. All Models Capacity Fluid Type Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA Engine oil (with filter) 6.5 L (7 US qt) FC‑W Seawater cooling system 20 L (21 US qt) Propylene glycol and purified water...
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.
IMPORTANT: Refer to the Inspection and Maintenance Schedule for the complete list of all scheduled maintenance. Some items should be performed only by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair procedures not covered in this manual, purchase the appropriate Mercury MerCruiser service manual and read it thoroughly.
Section 4 - Maintenance • Clean the seawater strainer, if equipped • Check the coolant level, if equipped • Check the transmission fluid level 20 Hour Break In • Change the transmission fluid and filter—ZF requirement to maintain warranty—dealer item Annually or 100 Hours •...
Section 4 - Maintenance Engine Oil Checking NOTICE Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
Fluid Type Engine oil (with filter) 6.5 L (7 US qt) Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Check the oil level and replace the fill cap. Changing Oil and Filter Refer to Maintenance Schedule for the change interval. Engine oil should be changed before placing the boat in storage.
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. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.
Section 4 - Maintenance The coolant level should be at the full mark on the coolant reservoir when the engine is cold. Coolant recovery bottle Coolant reservoir cap Sight window Coolant reservoir Full mark (engine hot) Full mark (engine cold) FILL COLD 50916 Filling the Closed Cooling System...
"FULL" mark, repeat the warm‑up/cool‑down cycle, and check the coolant level again. Maintain the coolant level in the reservoir at or near the "FULL" mark with the engine cold. Draining Contact your authorized Mercury MerCruiser dealer. Cleaning Contact your authorized Mercury MerCruiser dealer.
Section 4 - Maintenance 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. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries.
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. 90-8M0215801 FEBRUARY 2024 Page 37...
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.
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. Serpentine Drive Belt...
Section 4 - Maintenance • 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.) NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable.
Section 4 - Maintenance NOTE: Proper tension is a measurement of deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys. 50920 Deflection measurement point Description Deflection 13 mm (½ in.) Flushing the Power Package—Models without a Flushing Attachment Boat Out of the Water WARNING Rotating propellers can cause serious injury or death.
Section 4 - Maintenance NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the engine. Do not supply flush water for more than 15 seconds without the engine operating. Open the water source to provide maximum water supply. Place the remote control in the neutral idle speed position.
Section 4 - Maintenance NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
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Section 4 - Maintenance Snap the quick‑connect fitting with the water hose into the flush socket on the engine. Water hose Quick‑connect fitting (water hose end) Flush socket 18489 Open the water source of the water hose to a full flow. Place the remote control in neutral idle speed position and start the engine.
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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 Marine Limited Warranty. 63788 Quick-connect fitting: store on the boat, NOT the engine 16.
(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).
Fill a 23 liter (6 US gal) remote fuel tank with 19 L (5 US gal) regular unleaded 87 octane (90 RON) gasoline. Pour into the remote fuel tank 1.89 L (2 US qt) of Premium Plus 2‑Cycle TC‑W3 Outboard Oil and 29.5 ml (1 oz) of Mercury Quickstor Fuel Stabilizer.
IMPORTANT: The engine must not be operating at any point during the draining procedure. 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.
Section 5 - Storage Starboard side air‑actuated drain location Port side air‑actuated drain location 50411 Manual Drain System Starboard side blue drain plugs Port side blue drain plug 50412 Air‑Actuated Single‑Point Drain System Boat in the Water NOTE: This procedure is written for the air pump that was shipped with the engine from the factory. However, any air source can be used.
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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.
Section 5 - Storage Boat Out of the Water NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. Place the boat on a level surface and ensure the boat is level. Obtain the air pump.
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.
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.
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Section 5 - Storage CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable clamp securely when connecting.
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Section 6 - Troubleshooting Section 6 - Troubleshooting Table of Contents Diagnosing EFI Problems............58 Excessive Engine Temperature......... 59 Diagnosing DTS Problems............58 Insufficient Engine Temperature........59 Engine Guardian System............58 Low Engine Oil Pressure............ 59 Troubleshooting Charts............58 Battery Will Not Recharge..........60 Starter Motor Will Not Crank Engine, or Cranks Slowly...
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.
Clean the 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...
Steering Wheel Jerks or Is Difficult to Turn Possible Cause Remedy Insufficient lubrication on steering components. Lubricate. Check all parts and fasteners. If any are loose or missing, see authorized Loose or missing steering fasteners or parts. Mercury MerCruiser dealer immediately. Page 60 90-8M0215801 FEBRUARY 2024...
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Section 7 - Customer Assistance Information Section 7 - Customer Assistance Information Table of Contents Owner Service Assistance............62 Contact Information for Mercury Marine Customer Local Repair Service ............62 Service ................63 Service Away From Home ..........62 Customer Service Literature............ 63 Stolen Power Package .............
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 the recovery of stolen power packages.
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: •...
Section 7 - Customer Assistance Information Model Serial Number Horsepower Year United States and Canada For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact: Mercury Marine Telephone Mail Mercury Marine Attn: Publications Department (920) 929‑5110...
⃞ 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: ⃞ ⃞ Identify MerCathode location on engine (if equipped). Refer customer to Operation Manual for functions.
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Section 8 - Checklists N/A Completed Item ⃞ Importance of personal flotation devices (PFDs or life vests) and throwable PFDs (throw cushions) ⃞ ⃞ Functions of SmartCraft accessories (if applicable) ⃞ Off‑season storage and maintenance schedule ⃞ Explain the power package flushing procedure ⃞...
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 ...
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 ...
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