Mercury Racing Sterndrive 600SCi User Manual

600 hp

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Declaration of Conformance – Mercury Racing Sterndrive

600SCi (600 HP)

Manufacturer:

Mercury Racing

N7480 County Road UU

Fond du Lac, WI 54935

USA

Authorized Representative:

Marine Power Europe, Inc.

Parc Industriel de Petit-Rechain B-2800

Verviers,

Belgium

Recreational Craft Directive 2003/44/EC amending 94/25/EC

Applicable Requirement

Owner's manual (A.2.5)

Handling characteristics (A.4)

Inboard Engine (A.5.1.1)

Fuel System (A.5.2)

Electrical System (A.5.3)

General Steering System (A.5.4.1)

Exhaust emission requirements

(B.2)

Owner's manual (B.4)

Module used for exhaust emission assessment: Modules B+C,

EC‑Type Examination Certificate No.: EXMERC001.

The notified body responsible for EC‑Type Examination for the engine

exhaust emissions assessment is

IMCI

Rue Abbe Cuypers 3

B – 1040, Brussels – Belgium

Notified Body No.: 0609

Standards Applied

ISO 10240

ISO 8665

ISO 15584; ISO 7840; ISO 10133

ISO 7840; ISO 8469

ISO 10133; ISO 8846

Applicable portions of: ABYC P‑21;

EN ISO 10592

ISO 8178‑1

ISO 8665

Table of Contents

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Do you have a question about the Racing Sterndrive 600SCi and is the answer not in the manual?

Questions and answers

tom bastian

May 18, 2025

600 sci how many quarts of oil are in the engine

1 comments:

Mr. Anderson

May 23, 2025

The Mercury Sterndrive 600SCi engine holds 8.5 U.S. quarts of oil with a new filter.

This answer is automatically generated

Summary of Contents for Mercury Racing Sterndrive 600SCi

Page 1 Declaration of Conformance – Mercury Racing Sterndrive 600SCi (600 HP) Manufacturer: Mercury Racing N7480 County Road UU Fond du Lac, WI 54935 Authorized Representative: Marine Power Europe, Inc. Parc Industriel de Petit-Rechain B-2800 Verviers, Belgium Recreational Craft Directive 2003/44/EC amending 94/25/EC...
Page 2 CISPR 12 Radio disturbance characteristics Electrostatic discharge testing BS EN 61000‑4‑2; BS EN 61000‑4‑3 This declaration is issued under the sole responsibility of Mercury Marine and Marine Power Europe. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
Page 3 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...
Page 4 IMPORTANT: Indicates information or instructions that are necessary for a particular step or action. NOTE: Indicates information that helps in the understanding of a particular step or action. Copyright and Trademark Information Mercury Marine, Fond du Lac, Wisconsin U.S.A. Litho in U.S.A. © 2006, Mercury Marine...
Page 5 Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.
Page 7: Table Of Contents
Warranty Registration United States And Canada......1 Transfer Of Warranty..............1 Mercury Racing Division One Year Limited Warranty....2 Products Sold to Government Agencies........6 3 Year Limited Warranty Against Corrosion........7 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products..................10 General Information Boater's Responsibilities............12 Boat Horsepower Capacity............12 High-Speed and High-Performance Boat Operation....13...
Page 8 TABLE OF CONTENTS Operation Instrumentation................34 Warning System................34 Electrical System Overload Protection........37 Remote Controls (Console Mounted Zero Effort)......42 Remote Controls................43 Power Trim................46 Freezing Temperature Operation..........53 Starting, Shifting and Stopping..........53 Operation Chart.................55 Drain Plug and Bilge Pump............56 Launching And Boat Operation Care.........57 Conditions Affecting Operation Weight Distribution..............58 Bottom Of Boat................58...
Page 9 TABLE OF CONTENTS Cleaning the Seawater (Raw Water) Section of the Engine Oil, Power Steering, and Fuel Coolers...........100 Serpentine and Supercharger Drive Belts.......102 Fuel Filters................107 Corrosion and Corrosion Protection........109 Battery..................114 Bottom of Boat.................115 Inspection and Maintenance............115 Attention Required After Submersion........116 Cold Weather or Extended Storage Power Package Lay-up............117 Draining Instructions..............119...
Page 10 TABLE OF CONTENTS Owner Service Assistance Local Repair Service..............134 Service Away From Home............134 Parts And Accessories Inquiries..........134 Service Assistance..............134 Mercury Mercruiser Service Offices.........135 Ordering Literature United States and Canada............137 Outside The United States and Canada........137 Maintenance Log Maintenance Log..............138...
Page 11: Warranty Information
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 12: Mercury Racing Division One Year Limited Warranty
Fond du Lac, WI 54936-1939 920-929-5054 Fax 920-929-5893 Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by mail. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service Center closest to you.
Page 13 Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products...
Page 14 Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time.
Page 15 WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range (see the Operation and Maintenance Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation and...
Page 16: Products Sold To Government Agencies
WARRANTY INFORMATION No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional...
Page 17: Year Limited Warranty Against Corrosion
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 18 WHAT MERCURY WILL DO: Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.
Page 19 Mercury Precision Parts or Quicksilver MerCathode system and/ or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti‑fouling paints is also not covered by this limited warranty.
Page 20: Warranty Coverage And Exclusions For Mercury Racing Sterndrive Products
Warranty is limited to defects in material or workmanship, but only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre‑delivery inspection process is completed and documented.
Page 21 6. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 7. Engine noise does not necessarily indicate a serious engine problem.
Page 22: General Information
GENERAL INFORMATION Boater's Responsibilities The operator (driver) is responsible for the correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the power package.
Page 23: High-Speed And High-Performance Boat Operation
For additional information, obtain a copy of our Hi‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Paddle Wheel and Water Temperature Sensors Paddle wheels cannot be utilized on vessels that are capable of speeds in excess of 50 mph.
Page 24 GENERAL INFORMATION While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.
Page 25: Trailering Boat
GENERAL INFORMATION • Occupants could be thrown forward due to unexpected loss of forward motion ‑ a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller. •...
Page 26: Exhaust Emissions
GENERAL INFORMATION WHILE BOAT IS STATIONARY WARNING Stop your engine immediately whenever anyone in the water is near your boat. Serious injury to the person in the water is likely if contacted by a rotating propeller, a moving boat, a moving gearcase, or any solid device rigidly attached to a moving boat or gearcase.
Page 27 GENERAL INFORMATION While Boat Is Stationary 21626 Running the engine when the boat is moored in a confined space. Mooring close to another boat that has its engine running. 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).
Page 28: Wave And Wake Jumping
GENERAL INFORMATION Wave And Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the water.
Page 29: Impact With Underwater Hazards
GENERAL INFORMATION Impact With Underwater Hazards WARNING Avoid serious injury or death. When operating in shallow water or areas with underwater obstacles, maintain a minimum and safe speed. Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the sterndrive or the boat bottom.
Page 30: Operating In Shallow Water
GENERAL INFORMATION Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles. WARNING Avoid serious injury or death from loss of boat control due to sudden component failure.
Page 31 GENERAL INFORMATION Extreme care should be exercised when operating a boat equipped with only low water inlets while maneuvering in shallow water. Due to a small amount of total water inlet area, there is high suction at the water inlets. These inlets will easily clog with bottom contact and are susceptible to clogging when operated in shallow or weedy water.
Page 32: Safe Boating Suggestions
GENERAL INFORMATION NOTE: Engine block pressure at the gauge can still be low if the line to the gauge is clogged. 7759 Dual Water Inlet Gear Case Strut inlets Low water inlets Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions.
Page 33 GENERAL INFORMATION • Anchor, extra anchor line; water‑proof storage containers. • Manual bilge pump and extra drain plugs; compass and map or chart of area. • Spare operating equipment; batteries, bulbs, fuses, etc. • Transistor radio and drinking water. Know signs of weather change and avoid foul weather and rough-sea boating.
Page 34 GENERAL INFORMATION Never be under the influence of alcohol or drugs while boating (it is the law). Alcohol or drug use impairs your judgment and greatly reduces your ability to react quickly. Know your boating area and avoid hazardous locations. Prepare other boat operators.
Page 35: Stolen Power Package
Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This Stolen Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines.
Page 36: Specifications
SPECIFICATIONS Engine Identification Model: HP600 SCi 502 C.I.D. Displacement: SERIAL NUMBERS 4800 - 5200 Max WOT RPM: NGK BPR6ES Spark Plugs: ENGINE Spark Plug Gap: 0.035 Inch Spark Timing: **non-adjustable 91 (R+M)/2 or DRIVE Fuel Octane: 98 RON International Engine Oil: **Kendall GT-1 TRANSOM SAE 20W50...
Page 37: General Engine Specifications
SPECIFICATIONS General Engine Specifications Horsepower 600 HP (447 kW) Displacement 8.2 L (502 c.i.) Cylinder arrangement V‑8 Bore 114 mm (4.47 in.) Stroke 102 mm (4.00 in.) Compression ratio 7.5:1 Supercharger 3.3 L Screw‑type compressor Altenator 65 amp / 917 watt Battery requirements 750 CCA 950 MCA Ignition type...
Page 38: Engine Operating Limitations (Hp600)
Maxiumum oil temperature 85° C (185° F) Fuel Requirements Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness. WARNING FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death.
Page 39 Increasing the percentage of alcohol in the fuel can also worsen these adverse effects. 1. Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the combustion...
Page 40 The fuel system components on your Mercury engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand.
Page 41: Oil Recommendations
SPECIFICATIONS Oil Recommendations ENGINE CRANKCASE OIL Preferred Oils API Classification Kendall Motor Oil 20W‑50 SJ, CF‑2, CH‑4 Oil Filter Should Always Be Changed With Oil SUPERCHARGER GEARCASE OIL Preferred Oils API Classification Castrol Syntec Synthetic Motor Oil 5W‑50 SL, SJ, CF IMPORTANT OIL PRACTICES Do Not Use •...
Page 42: Capacities
SPECIFICATIONS Capacities Model HP600 SCi 8 L (8.5 U.S. qts) Crankcase Oil Capacity with New Filter Supercharger Gearcase 177 ml ( 6 U.S. oz) Bravo ‑ Drive Unit Oil Capacity (with Monitor) 2.65 L (2.8 U.S. qts) Closed Cooling System 13 L (14 U.S.
Page 43: After Break-In Period
Frequently check engine oil level. Add oil if needed. It is normal for oil consumption to be high during break‑in period. After Break‑In Period To help extend the life of your power package, Mercury Marine recommends the following: After 5 hr. Break‑in •...
Page 44: Operation
It is important to monitor critical engine and boat functions while the boat is in operation. The SmartCraft boat information system uses gauges and/or a System View monitor screen to display the information. Mercury Racing requires that the following critical engine functions be monitored: • Oil pressure •...
Page 45 • To stop an activated horn warning, turn off the engine. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem as soon as possible. • If on restart the beeping stops, the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault.
Page 46 OPERATION Guardian Activated and Engine Power Possible Cause Horn Monitor Display Reduced PCM Error Steady Horn Forced Idle Battery charging high Steady Horn or low Low Seawater Steady Horn Pressure Low Oil Pressure Steady Horn Engine Overspeed Steady Horn Charge Temperature Steady Horn Overheat MAP Sensor Error...
Page 47: Electrical System Overload Protection
OPERATION Guardian Activated and Engine Power Possible Cause Horn Monitor Display Reduced Fuel Pressure Sensor 3 Beeps‑1.5 Sec. Failure Long Block Pressure 3 Beeps‑1.5 Sec. Sensor Failure Long Charge Temperature 3 Beeps‑1.5 Sec. Sensor Failure Long Coolant Temperature 3 Beeps‑1.5 Sec. Sensor Long Throttle Position...
Page 48 OPERATION A circuit breaker protects the engine wiring harness and instrumentation power lead. Reset by pushing the reset button. 7764 Reset button In an emergency, if you cannot locate and correct the cause of the high current draw, and you must operate the engine, perform the following: 1.
Page 49 OPERATION 4. The power trim system is protected from overload by a 110 amp fuse and a 20 amp in‑line fuse on the power trim pump. 10121 20 amp fuse holder 110 amp fuse...
Page 50 OPERATION 5. The MerCathode system has a 20 amp in‑line fuse in the wire, which connects to the positive (+) terminal on the controller. If the fuse is open, the MerCathode system will not operate and a loss of corrosion protection will result. MERCATHODE 7775 20 amp in‑line fuse...
Page 51 OPERATION 7. Eight fuses are located at the upper rear of the engine in two fuse holders (four fuses in each holder). 10310 Fuse holders (2)
Page 52: Remote Controls (Console Mounted Zero Effort)
OPERATION Fuse Holder ‑ C26 Fuse Holder ‑ C27 (1) ‑ 15 amp ‑ RED to RED/BLU constant (5) ‑ 20 amp ‑ RED/BLK to RED/PNK power coil (2) ‑ 5 amp ‑ PPL to PPL/WHT (6) ‑ 20 amp ‑ RED/GRN to RED/ accessories WHT fuel injection (3) ‑...
Page 53: Remote Controls
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.
Page 54 OPERATION 7820...
Page 55 OPERATION Neutral Lock Bar - Prevents accidental shift and throttle engagement. The neutral lock bar must be pulled up to move the control handle out of neutral. Throttle Only Button - Allows throttle advancement without shifting the engine by disengaging the shift mechanism from the control handle.
Page 56: Power Trim
OPERATION Power Trim Power Trim allows the operator to adjust the drive unit(s) angle to provide the ideal boat angle for varying load and water conditions. The operator must use caution while underway to prevent trimming the drive unit up/out to far which could cause damage too the drive unit.
Page 57 OPERATION • Increase clearance over submerged objects or a shallow bottom. • Cause the boat to accelerate and plane off slower. • In excess, cause boat porpoising (bouncing) or propeller ventilation. 7419 Trimming Drive Unit Down/In Can: 7420 • Help the boat accelerate and plane off quicker. •...
Page 58 Mercury recommends that a mechanical (cable actuated) or electrical trim position indicator be used to provide drive unit trim angle information to the operator, and that the trim gauge be marked clearly to indicate the maximum up or out position (12°)
Page 59 OPERATION CAUTION Avoid twisting or binding dual engine tie bars. Damage to the tie bar and sterndrives could occur. Always raise or lower the sterndrive units evenly. 7868 Trailering and trimming up/out position - Press the (top) up/out portion of the switch until drive unit reaches desired trim/trailering position.
Page 60 Mercury recommends that a mechanical (cable actuated) or electrical trim position indicator be used to provide drive unit trim angle information to the operator, and that the trim gauge be marked clearly to indicate the maximum up or out position (12°)
Page 61 OPERATION...
Page 62 OPERATION 7867...
Page 63: Freezing Temperature Operation
The seawater section of the engine must be drained after use to prevent freezing. Damage caused by freezing is not covered by Mercury Racing's Limited Warranty. Starting, Shifting and Stopping WARNING Avoid fire or explosion.
Page 64 OPERATION IMPORTANT: Observe the following: • Do not start the engine without supplying water to the seawater pickup pump (to prevent pump or engine damage). • Do not operate the starter motor continuously for more than 30 seconds. • Never shift the drive unit unless the engine is at idle RPM. Perform the following as appropriate: Check all items listed in Operation Chart.
Page 65: Operation Chart
OPERATION 3. If the engine is cold, make sure the engine is idling smoothly before operating the boat. 4. After the engine has warmed up, check the water temperature gauge to ensure that the engine temperature is not abnormally high. If it is, stop the engine immediately and determine cause. 5.
Page 66: Drain Plug And Bilge Pump
Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. The bilge drain can be used to change crankcase oil. Refer to the...
Page 67: Launching And Boat Operation Care
OPERATION Launching And Boat Operation Care CAUTION Avoid product damage. The following situations could cause water to enter the engine through the exhaust system, which could cause engine component failure: • Unloading a boat from a trailer • Slowing down rapidly or stopping suddenly •...
Page 68: 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 69: Ventilation
(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 70: Conditions That Lower Engine Performance
CONDITIONS AFFECTING OPERATION • Operating in a higher elevation • Operating with a damaged propeller or dirty boat bottom • Operating with increased load (additional passengers, pulling skiers, etc.) Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems: •...
Page 71: Maintenance
MAINTENANCE Special Tools Dual Water Pick‑Up Flush Gear 91‑881150Q1 Case Seal Kit Description: Use to block‑off the front water inlet holes on the dual water inlet gearcases. 5321 Flushing Device 91‑44357Q2 Description: Attaches to the drive unit water intakes, provides a fresh water connection when flushing the cooling system or operating the engine.
Page 72: Servicing High Horsepower Engines
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. • Perform normal maintenance service using authorized replacement parts.
Page 73: Replacement Service Parts
These are but a few of the many special modifications that are required in Mercury Marine engines to provide long life and dependable performance.
Page 74: Do-It-Yourself Maintenance Suggestions
Do not telephone the dealer, service office or the factory to attempt for them to diagnose a problem or request the repair procedure. It is difficult for them to diagnose a problem over the telephone. • Your authorized Mercury Marine dealer is there to service your power package. They have qualified factory‑trained...
Page 75: Engine Maintenance Charts
MAINTENANCE Mercury Marine recommends that you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble‑free boating pleasure.
Page 76 MAINTENANCE Interval Task Perform all 25 hour maintenance items. Serpentine and Drive belts (All) ‑ Inspect condition and check tension. Cooling system hoses and clamps ‑ Inspect for damage and deterioration. Check clamps for tightness. Electrical system ‑ Check for loose or damaged wiring.
Page 77: Bravo Drive Maintenance Charts
MAINTENANCE Interval Task Supercharger ‑ Change oil. Power package exterior surfaces ‑ Clean and paint. Check engine cylinder compression. Oil coolers for the engine and power steering ‑ Clean seawater section. Replace positive crankcase ventilation (PCV) valve. Flame arrestor and crankcase ventilation hose ‑...
Page 78 MAINTENANCE Interval Task Check prior to every use and every 3 Drive, transom, and propeller ‑ Inspect hours of operation. Gear housing water pickups ‑ Check for Every 25 hours of operation or once marine growth or debris. every 30 days, whichever occurs Anodes ‑...
Page 79: Checking Fluid Levels
MAINTENANCE Interval Task Supercharger ‑ Change oil. Power package exterior surfaces ‑ Clean and paint. Check engine cylinder compression. Oil coolers for the engine and power steering ‑ Clean seawater section. Replace positive crankcase ventilation (PCV) valve. Flame arrestor and crankcase ventilation hose ‑...
Page 80 MAINTENANCE NOTE: Oil consumption is greatly dependant on engine speed. Consumption is highest at wide‑open‑throttle and decreases substantially as engine speed is reduced. It is common for big block, high‑performance engines to use up to one quart of oil in one to five hours, if the engine is operated continuously at the upper end of the RPM range.
Page 81 The oil should be covering approximately half of the sight‑glass. If the oil level increases, decreases, or changes to an abnormal color, it would indicate that there is an internal problem with the supercharger. Contact your authorized Mercury Marine dealer. 1. Stop the engine.
Page 82 MAINTENANCE 1. Stop the engine and turn the drive unit the straight ahead position. 2. Remove the fill cap/dipstick and observe the level. The oil level must be between the lower and upper marks. 3. Add power steering fluid if required to bring the oil level up to the full mark on the cap/dipstick.
Page 83: Engine Coolant
2. Oil should be up to the bottom of the fill hole. A low oil level indicates that there is an internal problem and that you should contact your authorized Mercury Marine dealer for appropriate service. Do not operate engine if this oil level is low.
Page 84 Where Used Part No. Extended Life Closed cooling 92-877770K1 Antifreeze/Coolant system 2. If coolant is low, inspect coolant recovery system for leaks. 3. Inspect the cap for damage and replace if necessary. CHANGING ENGINE COOLANT Contact your authorized Mercury Marine dealer.
Page 85 "FULL" line. 2. Check for water at the bottom of the monitor and/or if the oil appears a milky tan color. Contact your authorized Mercury Marine dealer immediately because both conditions indicate a water leak somewhere in the drive unit.
Page 86: Changing Fluids
MAINTENANCE 3. If the oil level is below the "MIN" mark, remove the fill cap and add Power Trim and Steering Fluid to bring the oil level up to the "MAX" mark on the reservoir. 10160 Vented trim pump fill cap Trim pump filter and vents (4) Tube Ref No.
Page 87 MAINTENANCE IMPORTANT: Change oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use Specifications ). only recommended motor oil (see NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum (approximately 1/4 turn).
Page 88 MAINTENANCE 3. Insert the hose end of the crankcase oil pump into an appropriate container and using the pump handle, pump until the crankcase is empty. 10460 Crankcase oil pump Crankcase oil pump hose 4. Remove the crankcase oil pump. 5.
Page 89 MAINTENANCE 8. Tighten the filter securely by hand. Do not overtighten. 9998 Oil filter sealing ring 9. Remove the oil filler cap (port or starboard). 10. Add oil to bring level up to, but not over, the "OK RANGE" mark on the dipstick.
Page 90 IMPORTANT: Change oil when the engine is warm from operation. Warm oil flows more freely, carrying away more impurities. Use Mercury Precision Parts or flushing attachment(s) over the water intake holes and attach a water hose. Use only recommended Specifications.
Page 91 MAINTENANCE 1. Install the appropriate flushing attachment(s) over the water intake holes and attach a water hose. 6155 Flushing attachment over water intake holes (SportMaster Gearcase) Fresh water source Flushing attachment for dual water inlet drives Nose cone water pickup cover for dual water inlet drives 2.
Page 92 MAINTENANCE NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum (approximately 1/4 turn). Then turn the filter back clockwise until the oil filter seal makes light contact with the housing (approximately an 1/8 turn) to prevent unwanted oil leakage.
Page 93 MAINTENANCE 10. Remove the oil filter from the adaptor and discard the old oil filter and sealing ring. 11. Coat the sealing ring on the new filter with motor oil. Install the sealing ring and filter. Tighten the filter securely by hand. Do not overtighten.
Page 94 Contact your authorized Mercury Marine dealer. 1. Remove the fill plug from the top of the supercharger gearcase.
Page 95 MAINTENANCE 2. Place a catch pan under the drain plug in the bottom of the supercharger gearcase. 3. Remove the drain plug and drain the oil. 4. Clean and inspect the plug o‑rings, the gearcase fill and drain hole threads and the plug threads. 5.
Page 96 3. Remove the fill/drain screw and sealing washer and drain the oil. IMPORTANT: If any water drained from the oil fill/drain hole, or if oil appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury Marine dealer. 7986 Oil fill/drain plug...
Page 97 MAINTENANCE 4. Remove the oil vent screw and sealing washer. Allow oil to drain completely. 7987 Sealing washer Oil vent screw 5. Adjust the drive unit so that the propeller shaft is level. 6. Fill the drive unit through the oil fill/drain hole with High Performance Gear Lube until an air‑free stream of lubricant flows from the oil vent hole.
Page 98 MAINTENANCE 7. Remove the tube from the oil fill/drain hole and quickly install the sealing washer and the oil fill/drain screw. Tighten securely. 8. Add specified gear lube to the monitor bottle. 9. When oil starts to run out of the oil vent hole of the drive, re‑install the oil vent screw and sealing washer.
Page 99: Lubrication
MAINTENANCE 13. Grease the propeller shaft with anti‑corrosion grease. Re‑install the propeller and torque the prop nut to specification. 7990 Tube Ref No. Description Where Used Part No. Anti-Corrosion Propeller shaft 92-802867A1 Grease Description lb. in. lb. ft. Propeller nut IMPORTANT: Oil level in the gear lube monitor will rise and fall during drive operation.
Page 100 IMPORTANT: The sterndrive must be removed to lubricate the U‑joints. Contact your authorized Mercury Marine dealer for this service. NOTE: The engine coupling and shaft splines are greased with engine coupler spline grease.
Page 101 MAINTENANCE Lubricate the gimbal bearing with 2‑4‑C with Teflon lubricant. 8013 Tube Ref No. Description Where Used Part No. 2-4-C Marine Lubricant Gimbal bearing 92-802859A1 with Teflon ENGINE COUPLER Lubricate the engine coupler and shaft splines with engine coupler spline grease. 8014 Tube Ref No.
Page 102: Propellers
MAINTENANCE DRIVE SHAFT EXTENSION MODELS Lubricate the drive shaft grease fittings at the transom end with 2‑4‑C with Teflon lubricant. 8015 8016 Tube Ref No. Description Where Used Part No. 2-4-C Marine Lubricant Drive shaft grease 92-802859A1 with Teflon fittings Propellers XR MODEL PROPELLERS WARNING...
Page 103 MAINTENANCE CAUTION Avoid Injury: Periodically check propeller nut for tightness during boating season. A minimum of 75 Nm (55 lb. ft.) torque is required. Removal 1. Place a wood block between the propeller blade and the anti‑ventilation plate to prevent rotation. 7448 Wood block Propeller nut...
Page 104 MAINTENANCE 3. Remove the washers, propeller and prop hub assembly. 8018 Propshaft Belleville washer Prop hub assembly Washer Propeller assembly Locknut Washer NOTE: Some damaged propellers can be repaired. See your dealer.
Page 105 MAINTENANCE Installation 1. Install the Bravo XR replaceable hub propeller components in the order shown: 8020 Propshaft Belleville washer Prop hub assembly Washer Propeller assembly Locknut Washer Tube Ref No. Description Where Used Part No. Anti-Corrosion Exposed surfaces of 92-802867A1 Grease propeller shaft 2.
Page 106: Flushing The Power Package
MAINTENANCE Flushing the Power Package The following procedure explains flushing the power package through the sterndrive water pickups. FLUSHING ATTACHMENTS Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1...
Page 107 MAINTENANCE STERNDRIVE WATER PICKUPS There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water and side pickups. Dual water pickups require the flushing attachment (91‑44357Q 2) and the flush seal kit (91‑881150K 1). The Hi‑Performance low water pickup drive requires the flushing attachment (91‑849996T...
Page 108 MAINTENANCE NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing. CAUTION If flushing the engine with the boat in the water, seawater can flow into the engine causing damage. The water inlet must be closed when flushing the engine.
Page 109: Seawater Pump Impeller Inspection
1. Inspect the seawater pump impeller if insufficient seawater flow occurs (if operating temperature exceeds normal range). 2. If service is required, have the work performed by an authorized Mercury Marine dealer. 8022 Seawater pump...
Page 110: Cleaning The Seawater (Raw Water) Section Of The Engine Oil, Power Steering, And Fuel Coolers
MAINTENANCE Cleaning the Seawater (Raw Water) Section of the Engine Oil, Power Steering, and Fuel Coolers CAUTION Avoid seawater entry into the boat. When cleaning engine oil or power steering coolers with the boat in the water, be sure to close off the water supply from the seawater pump to the cooler or water may enter the boat when end plates or hoses are removed.
Page 111 MAINTENANCE IMPORTANT: If the oil hoses need to be removed from the cooler, be prepared to cap or plug them to avoid draining the power steering reservoir. 10518 Hose clamps (2) 2. Re‑install the cooler and tighten the hose clamps securely. 3.
Page 112: Serpentine And Supercharger Drive Belts
MAINTENANCE 2. If the fuel hoses need to be removed from the cooler, have this service done by an authorized Mercury Marine dealer. 10262 Hose clamps to the fuel cooler 3. Re‑install the cooler and tighten the hose clamps securely.
Page 113 MAINTENANCE 1. Install the belt tension gauge onto the belt. 10286 Seawater pump pulley Belt tension gauge Belt adjustment pulley Power steering pulley (non‑power steering Re‑circulating pump models have an idler pulley pulley) Crankshaft pulley Alternator pulley 2. Loosen the 5/8 in. locking nut on the adjusting screw. Leave the wrench on the adjustment nut.
Page 114 MAINTENANCE 4. Hold the adjustment stud and tighten the 5/8 in locking nut. 10287 Belt tensioner pulley Adjustment locking nut Adjustment screw 5. Remove the belt tension gauge from the belt.
Page 115 MAINTENANCE 6. Run the engine for a short period of time and re‑check the tension. 10286 Seawater pump pulley Belt tension gauge Belt adjustment pulley Power steering pulley (non‑power steering Re‑circulating pump models have an idler pulley pulley) Crankshaft pulley Alternator pulley Description New Belt...
Page 116 MAINTENANCE SUPERCHARGER DRIVE BELT ROUTING AND TENSION 10289 Supercharger pulley Supercharger belt Self adjusting belt Crankshaft pulley tensioner Idler pulley The supercharger belt uses a self tensioner and does not require tension adjustment.
Page 117: Fuel Filters
MAINTENANCE INSPECTING BELTS 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. 6164 Fraying Transverse cracks Longitudinal cracks The belt will have to be replaced for the following conditions: •...
Page 118 Fuel System Prior to Starting in the Cold Weather or Extended Storage section of this manual.) 5. Check the filter for gasoline leaks. If leaks exist, re‑check the filter installation. 6. lf leaks continue, stop the engine immediately and contact your authorized Mercury Marine dealer.
Page 119: Corrosion And Corrosion Protection
CAUTION Avoid corrosion damage. Mercury Marine recommends using anodes sold through Mercury Precision Parts only. Some other manufacturers of aluminum anodes use alloys that are insufficiently pure to adequately protect critical drive components for the duration of the anodes' expected life.
Page 120 NOTE: The MerCathode system should be tested to ensure adequate output. The test should be made where boat is moored, using a reference electrode and test meter. Contact your authorized Mercury Marine dealer to arrange for this test. 9322 MerCathode...
Page 121 Do not use lubricants containing graphite on or near aluminum in saltwater. Refer to the drive unit service manual for complete information on anode mainteinance and replacement. Or, contact your authorized Mercury Marine dealer. In addition to the anode corrosion protection devices, follow these steps to inhibit corrosion: •...
Page 122 MAINTENANCE • Check the finish regularly. Prime and paint nicks and scratches using Mercury Phantom Black paint. Use only tin based anti‑fouling paint or equivalent on or near aluminum surfaces below the waterline. • If the surface is showing bare metal, apply 2 coats of paint.
Page 123 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...
Page 124: Battery
MAINTENANCE NOTE: Do not paint the anodes or the MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors. PAINTING THE 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.
Page 125: Bottom Of Boat
MAINTENANCE WARNING Avoid serious injury or death. Observe the following when jump starting, charging or handling a battery: • Do not use jumper cables or a booster battery to start an engine. • Do not recharge a weak battery in the boat. Remove the battery and recharge it in a well ventilated area away from fuel vapors, sparks or flames.
Page 126: Attention Required After Submersion
Use Quicksilver spray paints ‑ see your authorized Mercury Marine dealer. Attention Required After Submersion • Before recovery, contact an authorized Mercury Marine dealer. • After recovery, immediate service by an authorized Mercury Marine dealer is required to prevent serious damage to power package.
Page 127: Cold Weather Or Extended Storage
COLD WEATHER OR EXTENDED STORAGE Power Package Lay‑up IMPORTANT: This service should be performed by an authorized Mercury MerCruiser 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 128 RPM and shut off the engine. CAUTION When operating a Mercury engine with fuel containing alcohol, avoid storing the fuel in the fuel tank for long periods of time. Long storage periods, common to boats, create unique problems.
Page 129: Draining Instructions
COLD WEATHER OR EXTENDED STORAGE Draining Instructions CAUTION To prevent damage from freezing temperatures, remove and plug the seawater inlet hose. This prevents a siphoning action that may occur, allowing seawater to flow into the drain holes or hoses. Completely drain the cooling system for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist.
Page 130 COLD WEATHER OR EXTENDED STORAGE • Power steering cooler (plastic wing‑nut plug, Port side of the engine) 10095 Exhaust header Exhaust header balance rail plastic balance rail plastic wing‑nut plugs (2, wing‑nut plugs (2, Port Starboard side) side, one plug is hidden) Fuel cooler plastic Power steering cooler wing‑nut plug...
Page 131 COLD WEATHER OR EXTENDED STORAGE 3. Loosen the hose clamp and remove the hose from the inlet fitting of the seawater pickup pump. NOTE: Lift or bend hoses to allow water to drain completely. 8040 Hose clamp 4. After draining the seawater cooling system, install the drain plugs (Perfect Seal is not required on wing nut type plugs), reconnect the hoses and tighten all hose clamps securely.
Page 132 COLD WEATHER OR EXTENDED STORAGE IMPORTANT: A nontoxic and environmentally safe ethylene glycol antifreeze containing a rust inhibitor must be used when preparing the seawater section of the cooling system for cold weather or extended storage. Be certain to follow the manufacturer's recommendations.
Page 133: Battery Winter Storage
COLD WEATHER OR EXTENDED STORAGE Battery Winter Storage Follow the battery manufacturer's instructions for storage. Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not install the battery until all engine maintenance has been performed. 1. Ensure that all cooling system hoses are connected properly and hose clamps are tight, all removed drain plugs have been installed and are tight.
Page 134 COLD WEATHER OR EXTENDED STORAGE 2. Do not advance the throttle until the engine idles and runs smoothly and the water temperature reaches a minimum of 54 °C (130 °F). 3. Crank the engine over for 10 seconds at a time and stop. 4.
Page 135 COLD WEATHER OR EXTENDED STORAGE 1. Remove the plug from the water separating filter/fuel pressure regulator housing as shown and install a 1/8 in. NPT barbed fitting (obtain locally) into the housing. 10308 Water separating filter/fuel pressure regulator housing Plug 1/8 in.
Page 136 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 137: Troubleshooting
TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch "OFF". Switch to "ON" position. Remote control not in neutral position. Position control lever to neutral. Open 50 amp circuit breaker or 15 or 90 Check and reset circuit breaker or amp fuse circuit.
Page 138: Engine Cranks But Will Not Start
TROUBLESHOOTING Engine Cranks But Will Not Start Possible Cause Remedy Improper starting procedure Read starting procedure Low battery voltage Charge the battery Empty fuel tank or fuel shut off valve Fill tank or open valve closed Faulty fuel pump, wiring, fuel pump fuse, 50 amp circuit breaker or a fuel Replace faulty component pump relay...
Page 139: Poor Performance
TROUBLESHOOTING Poor Performance Possible Cause Remedy Inspect throttle cable and linkages for Throttle not fully open. proper operation. Damaged or incorrect propeller. Replace propeller. Excessive bilge water. Drain and check for cause of entry. Boat overloaded or load improperly Reduce load or redistribute load more distributed.
Page 140: Engine Coolant Temperature Too High
TROUBLESHOOTING Engine Coolant Temperature Too High Possible Cause Remedy Seacock closed. Open. Serpentine belt loose or in poor Replace or adjust belt. condition. Recirculating pump defective. Replace. Seawater pickups obstructed. Inspect. Faulty thermostat. Replace. Oil cooler cores plugged with foreign Clean cooler cores.
Page 141: 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 or dirty electrical connections or battery cables). Clean and tighten faulty damaged wiring. connections. Repair or replace damaged wiring.
Page 142: Electrical Analog Trim Gauge Malfunction
Insufficient lubrication on shift and Lubricate. throttle linkage fasteners. Check all linkages. If any are loose or Loose or missing shift and throttle missing, see authorized Mercury Marine linkage fasteners. dealer immediately. Shift or throttle cable kinked. Replace cable. Friction adjustment excessive.
Page 143: Seawater Pressure Is Below Specification
TROUBLESHOOTING Seawater Pressure Is Below Specification Possible Cause Remedy Check if seacock is completely open. Check supply hoses for obstruction. Insufficient water supply. Check for external water pick‑up obstruction. Check for sea strainer obstruction. Check condition of sea pump. Seawater Pressure Is Above Specification Possible Cause Remedy High boat speed causing high ram...
Page 144: Owner Service Assistance
If you ever have a problem, question or concern about your Sterndrive or Inboard product, contact your dealer or any authorized Mercury Marine dealer. If additional assistance is required, take these steps. 1. Talk with the dealership's sales manager or service manager.
Page 145: Mercury Mercruiser Service Offices
Model and serial number of your outboard • The name and address of your dealership • Nature of problem Mercury Mercruiser Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States Telephone Mercury MerCruiser 3003 N.
Page 146 Mexico, Central America, South America, Caribbean Telephone Mercury Marine 11650 Interchange Circle North Miramar, FL 33025 (954) 744‑3500 (954) 744‑3535 U.S.A. Japan Telephone Mercury Marine - Japan 283-1 Anshin-cho Hamamatsu Shizuoka, 435-0005 81‑53‑423‑2500 81‑53‑423‑2510 Japan Asia, Singapore Telephone Mercury Marine- Singapore 72 Loyang Way...
Page 147: Ordering Literature
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 Mail Mercury Marine Attn: Publications Department (920) 929‑5110 (920) 929‑4894...
Page 148: 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...

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