Mercury MerCruiser Product Applications Manual

Mercury MerCruiser Product Applications Manual

Gasoline inboard models
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90-863758060cvr.qxp
8/31/2006
3:21 PM
Page 1
Product Applications Manual
Gasoline Inboard Models
www.mercurymarine.com.au
www.mercurymarine.com
www.marinepower.com
NOTICE
Private Bag 1420
P.O. Box 1939
(Parc Industriel de Petit-Rechain)
Dandenong South 3175
Fond du Lac, WI 54936-1939 USA
B-4822 Verviers/Belgium
Victoria, Australia
Details for specific product installation are located in the Power
Package Installation Manual that accompanies each product.
©2006, Mercury Marine. All rights reserved.
Printed in U.S.A.
90-863758060 AUGUST 2006

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Summary of Contents for Mercury MerCruiser

  • Page 1 Dandenong South 3175 Fond du Lac, WI 54936-1939 USA B-4822 Verviers/Belgium Victoria, Australia Details for specific product installation are located in the Power Package Installation Manual that accompanies each product. ©2006, Mercury Marine. All rights reserved. Printed in U.S.A. 90-863758060 AUGUST 2006...
  • Page 2 Manual Introduction and Overview This Product Applications Manual has been written and published by Mercury Marine and is targeted to the boat manufacturer's engineers and designers. It is intended to aid you, the boat manufacturer, in the proper integration of our power packages in your boats.
  • Page 3 Precision Parts, Mercury Propellers, 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 4 Manual Outline Important Information 1 - Important Information A - Important Information Transmission and Drive Line 2 - Transmission and Drive Line A - Transmission and Drive Line 3 - Engine Engine A - Engine 4 - Air Intake System A - Air Intake System Air Intake System 5 - Fuel Delivery System...
  • Page 5 Page iv...
  • Page 6: Table Of Contents

    Inside the U.S.A........1A-2 Fuel Hose............1A-4 Outside the U.S.A........1A-2 Emission Control Information......1A-5 Mercury MerCruiser Service Offices..1A-2 International Regulations Compliance..1A-5 Mercury Precision Parts / Quicksilver Products Emission Control Information Label..1A-5 .................1A-3 Star Label..........1A-8 Factory Installed Options.........1A-3 Specifications..........1A-10 Serial Number Decal Placement—Inboard and Tow Engine Specifications......1A-10...
  • Page 7: Sales And Technical Assistance

    Important Information Sales and Technical Assistance Mercury MerCruiser employs a staff of highly trained specialists to assist you with any sales or technical issues that you might have. This includes a group of Product Application Engineers (PAEs) who specialize in the application of our product and are recognized throughout the industry for their expertise in this area.
  • Page 8: Mercury Precision Parts / Quicksilver Products

    Mercury products. A complete listing of all of the latest accessories can be found in the Mercury Precision Parts and Accessories Guide.
  • Page 9: Serial Number Decal Placement-Inboard And Tow Sports

    Important Information Serial Number Decal Placement—Inboard and Tow Sports There are three engine serial number decal strips provided with each power package. One should be used for each of the following: • Engine Specification Decal • Warranty Registration Card • Operation, Maintenance and Warranty Manual identification page Affix engine serial number decal to Engine Specification Decal.
  • Page 10: Emission Control Information

    A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, FEL (emission level), date of manufacture (month, year), and the engine displacement.
  • Page 11 NOTE: The following applies to CE marked products only. DECLARATION OF CONFORMANCE – MERCURY MERCRUISER This sterndrive or inboard engine when installed in accordance to Mercury MerCruisers’ instructions complies with the requirements of the following directives by meeting the associated standards, as amended: Recreational Craft Directive 94/25/EC;...
  • Page 12 Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA Regulatory contact:...
  • Page 13: Star Label

    Beginning January 1, 2003, one Three‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating. The Three‑Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards.
  • Page 14 Important Information One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines.
  • Page 15: Specifications

    Important Information Specifications Engine Specifications TOW SPORTS MODELS Black MX 6.2 Black 5.7L 350 MAG MPI MX 6.2L MPI Scorpion Scorpion 201 kw 235 kw 246 kw 239 kw 254 kw Propshaft Power (270 hp) (315 hp) (330 hp) (320 hp) (340 hp) Displacement 5.7 liter (350 cid)
  • Page 16 Important Information INBOARD MODELS BELOW 239 KW (320 HP) 5.7L 350 MAG MPI 350 MAG MPI Horizon Propshaft Power 194 kw (260 hp) 224 kw (300 hp) 224 kw (300 hp) Displacement 5.7 liter (350 cid) Configuration / Cylinders V‑8 Bore x Stroke 102 x 88.4 mm (4.00 x 3.48 in.) Compression Ratio...
  • Page 17 Important Information INBOARD MODELS OVER 224 KW (300 HP) MX 6.2 MPI MX 6.2 MPI 8.1S HO 8.1S Horizon Horizon Propshaft Power 239 kw (320 hp) 313 kw (420 hp) 276 kw (370 hp) Displacement 6.2 liter (377 cid) 8.1 liter (496 cid) Configuration / V‑8 Cylinders...
  • Page 18: Torque Specifications

    Important Information Torque Specifications NOTE: Securely tighten all fasteners not listed below. Description lb. in. lb. ft. Engine mount bracket screws Trunnion clamping screws and nuts Thermostat housing attaching screws Propeller shaft coupling screws and nuts Tighten securely, then loosen ½ turn to Shift and throttle cable fasteners allow pivot points to rotate Apply #567 loctite pipe sealant with...
  • Page 19 Important Information Notes: Page 1A-14 90-863758060 AUGUST 2006...
  • Page 20 Transmission and Drive Line Transmission and Drive Line Section 2A - Transmission and Drive Line Table of Contents General Information.........2A-2 Propeller Shaft..........2A-4 Gear Ratio Selection.........2A-2 Propeller Shaft Log Seal Connections.....2A-4 Engine and Propeller Shaft Installation Angle Transmissions..........2A-6 ..............2A-2 Gear Ratios..........2A-6 Propeller Shaft Rotation and Spacing on Dual Model Offerings and Identification....2A-7 Installations..........2A-2...
  • Page 21: General Information

    Transmission and Drive Line General Information Gear Ratio Selection The transmission gear ratio and propeller must provide the optimum match between the engine and the boat application. Gear ratio and propeller selection are affected by numerous factors including engine horsepower, WOT RPM, hull design, propeller clearance, boat weight, and other factors.
  • Page 22: Propeller Blade Tip Clearance

    In these cases, a rigid propeller shaft coupling can be used. Rigid propeller shaft couplings can be ordered with the engine or purchased through Mercury Precision Parts and Accessories. Alignment with these couplings is critical; See Section 3 — Engine.
  • Page 23: Propeller Shaft

    Propeller Shaft Log Seal Connections CAUTION Avoid overheating damage. Mercury MerCruiser is not responsible for engine damage caused by improper cooling system connections for the propeller shaft log seal. The propeller shaft log seal hose should be routed so that a portion of the hose extends above the top of the engine exhaust elbows to prevent a siphoning action when the engine is not running.
  • Page 24 Transmission and Drive Line 5.7 LITER (350 CID) AND 6.2 LITER (377 CID) MODELS A fitting is installed at the factory into the proper port on the port exhaust elbow. 7641 Propeller shaft log seal connection — 5.7L and 6.2L models Shaft log seal fitting SCORPION MODELS A brass plug is installed at the factory into the proper port on the port exhaust elbow.
  • Page 25: Transmissions

    Transmission and Drive Line Transmissions Gear Ratios Walter V-Drive Velvet Drive Gear Ratios ZF Marine Gear Ratios Gear Ratios 5000A 5000V 63IV Tow Sports 5.7L 1.0:1 1.0:1 350 MAG 1.0:1 1.5:1 1.0:1 Black 1.0:1 1.46:1 1.46:1 1.0:1 Scorpion MX6.2L Black 1.0:1 1.46:1 1.46:1...
  • Page 26: Model Offerings And Identification

    Transmission and Drive Line Model Offerings and Identification VELVET DRIVE 71C AND 72C TRANSMISSIONS On all Velvet Drive In-Line 71C and 72C series transmissions, the gear ratio in FORWARD gear is marked on the identification plate. Transmission output flange rotation in FORWARD gear is indicated on a decal on the transmission case.
  • Page 27 Transmission and Drive Line 7370 Identification plate ZF MARINE 630 AND 800 SERIES TRANSMISSIONS On the ZF Marine Down-Angle and V-Drive transmissions, the identification plate indicates gear ratio, serial number, and model. 14911 8° down angle 12° V-drive 7449 Identification plate Page 2A-8 90-863758060 AUGUST 2006...
  • Page 28 Transmission and Drive Line ZF MARINE/HURTH 45C The transmission identification plate is located on the top rear of the transmission. 14913 ZF Marine/Hurth 45C Identification plate WALTER V-DRIVE TRANSMISSIONS On the Walter V-Drive transmissions, the identification plate indicates gear ratio, serial number, and model.
  • Page 29: Propeller Rotation

    Transmission and Drive Line Propeller Rotation ZF MARINE 630 AND 800 AND VELVET DRIVE 5000 SERIES TRANSMISSION The ZF Marine 630 and 800 and Velvet Drive 5000 Series transmissions are full power reversing transmissions, allowing a standard LH rotation engine (viewed from flywheel end) to be used for both propeller rotations.
  • Page 30 Transmission and Drive Line 7650 ZF Marine 630A and 800 — down-angle transmissions 7651 ZF Marine 630V — V-drive transmissions Direction of shift lever Transmission output / propeller engagement (toward flywheel) shaft rotation direction (LH as viewed at propeller) Engine/transmission input shaft rotation direction (LH) Transmission output / propeller shaft rotation direction (RH as...
  • Page 31 Engine Engine Section 3A - Engine Table of Contents General Information.........3A-2 Engine Compartment Seams....3A-4 Engine Rotation........3A-2 Clearance..........3A-4 Engine Lifting Provisions......3A-3 Engine Bed Requirements......3A-4 Engine Oil Dipstick Relocation....3A-3 Serviceability..........3A-5 Engine Compartment Construction....3A-4 Engine Alignment........3A-18 Engine Compartment Ventilation....3A-4 90-863758060 AUGUST 2006 Page 3A-1...
  • Page 32: General Information

    Engine rotation is described when observed from the rear of the engine (transmission end) looking forward (water pump end). All Mercury MerCruiser engines are left hand (LH) rotation. Propeller rotation is not necessarily the same as engine rotation; See Section 2 —Transmission and Drive Line.
  • Page 33: Engine Lifting Provisions

    Engine Engine Lifting Provisions Engines are equipped with a lifting eye at the front and the rear. Use a suitable sling with the proper weight rating when lifting the engine. CAUTION 9375 Typical engine Center lifting eye (engine Lifting eye alignment only) NOTE: 8.1L (496 cid) engines require alignment hook (91-863375-1).
  • Page 34: Engine Compartment Construction

    The proper design of the engine bed varies considerably from one boat design to the next. Therefore, Mercury MerCruiser makes no attempt to provide detailed engine bed design requirements to cover all possible applications. The proper design of the engine bed is left to the boat manufacturer.
  • Page 35: Serviceability

    In addition to customer and dealer satisfaction, consider the implications of serviceability with respect to our warranty policy. The Mercury MerCruiser warranty policy states, in part, that reasonable access must be provided to the product for warranty service.
  • Page 36 Engine The following is a list of the major service points to consider when designing the engine compartment. Typical illustrations are shown to assist you in identifying these locations. These are typical views and may not accurately represent the model that you are working with.
  • Page 37 Engine ENGINE VIEW 24889 Typical 8.1L inboard side view Transmission output flange Dipstick Engine mounts (4) Engine cover Transmission dipstick Exhaust manifold and elbow (2) Starter (inboard style) Gen III Cool Fuel Module (Inboard models) Transmission fluid cooler Seawater pump Ignition components 90-863758060 AUGUST 2006 Page 3A-7...
  • Page 38 Engine 14926 Typical 8.1L inboard front view Drive belt Electrical bracket Heat exchanger Thermostat housing Coolant reservoir Alternator Pressure cap Circulating pump Flame arrestor OIL FILTERS 14333 Typical tow sports engine oil filter Engine-mounted oil filter 14928 Typical inboard engine oil filter Engine oil fill cap Remote oil filter Page 3A-8...
  • Page 39 Engine FUEL CONNECTIONS 14851 Models with boost pump Models without boost pump Fuel inlet fitting 8269 Gen III Cool Fuel Module (Inboard models) Fuel inlet fitting Tube Ref No. Description Where Used Part No. Loctite 567 PST Pipe Sealant Fuel inlet fitting 92-809822 90-863758060 AUGUST 2006 Page 3A-9...
  • Page 40 Engine ELECTRICAL 14957 Typical electrical components bracket THROTTLE 7926 Typical throttle cable and linkages Flat washer and locknut Flat washer and locknut Cable barrel Page 3A-10 90-863758060 AUGUST 2006...
  • Page 41 Engine 11527 Typical quick connect throttle cable Jam nut Throttle body bracket Cable barrel SHIFT 11531 Typical quick connect shift cable Jam nut Bracket Cable barrel 90-863758060 AUGUST 2006 Page 3A-11...
  • Page 42 Engine 7670 Typical transmission Shift cable 7657 Typical dual station transmission Cable end guide Spacer Cable barrel Cable end guide stud Cable barrel stud Elastic stop nut and washer Elastic stop nut and washer Page 3A-12 90-863758060 AUGUST 2006...
  • Page 43 Engine NOTE: Shift cables are not used on DTS transmissions 20418 ZF Marine (Hurth) transmission with electric shift— DTS models FLUSH 6090 Typical flush connector (models so equipped) Flush connector COOLANT 8295 Typical heat exchanger (closed cooled models) Heat exchanger Fastener Gasket End cap...
  • Page 44 Engine 7804 Coolant recovery bottle (closed cooled engines except 8.1S) Coolant recovery bottle Hose Mounting holes Hose clamp SEA STRAINER 7533 Typical sea strainer (optional) Page 3A-14 90-863758060 AUGUST 2006...
  • Page 45 Engine STARTER 7766 Typical starter Rubber boot 90-amp fuse Starter solenoid THERMOSTAT 8219 Typical thermostat housing Housing 90-863758060 AUGUST 2006 Page 3A-15...
  • Page 46 Engine FUEL AND AIR INDUCTION 14339 Typical Fuel/Air Induction System FUEL SYSTEMS 14931 Typical fuel filter Water-separating fuel filter cover Water-separating fuel filter (MPI tow sports models only) Page 3A-16 90-863758060 AUGUST 2006...
  • Page 47 Engine 14340 Fuel cooler (Gen II) Fuel cooler 8837 Gen III Cool Fuel Module Cool Fuel Module Fuel filter element Cool Fuel Module harness Filter cup Filter cap Cool Fuel Module filter reservoir Filter assembly retaining screw Filter cup seal 90-863758060 AUGUST 2006 Page 3A-17...
  • Page 48: Engine Alignment

    Engine CYLINDER HEADS 12728 6338 Typical cylinder head Engine Alignment Proper alignment between the transmission, and the propeller shaft is essential to minimize noise, vibration, and power loss and to avoid overstressing the transmission and drive line components. A preliminary alignment should be performed at the time of installing the engine.
  • Page 49 Engine • Check alignment by holding the flange and the coupler together and checking at 90° intervals with a feeler gauge. The coupler should be rotated 180° and alignment rechecked to ensure that the coupler and flange are in alignment. 7535 Propeller shaft coupler Transmission output flange...
  • Page 50 Engine • Trunnions must not extend more than 45 mm (1¾ in.) and no less than 10 mm (3/8 in.). 7537 Trunnion extension Locknut 45 mm (1¾ in.). 10 mm (3/8 in.) is Tab washer nominal Trunnion clamping screws and nuts •...
  • Page 51: Zf Marine Transmissions-Dts

    Transmission and Drive Line The 1:1 and 1.5:1 gear ratio versions of these transmissions have a LH output flange rotation when in FORWARD gear. This is the same as the engine rotation and is referenced from the rear of the engine. A LH rotation propeller must be used on these applications (except a Walter V-drive application where the rotation is established by the gear box).
  • Page 52: Remote Control And Shift Cable

    Transmission and Drive Line Remove the allen plug and install the oil temperature sensor. Connect the wire connections, of the harness, to the oil temperature sensor. 12122 ZF Marine transmission—DTS (oil temperature sensor installed) Oil temperature sensor Oil temperature sensor wire connections Remote Control and Shift Cable See Section 9 —...
  • Page 53 Transmission and Drive Line Notes: Page 2A-14 90-863758060 AUGUST 2006...
  • Page 54 Air Intake System Air Intake System Section 4A - Air Intake System Table of Contents Engine Compartment Ventilation.....4A-2 Running Test..........4A-4 Engine Compartment and Fuel System Pressure Heat Soak Test.........4A-4 and Temperature Test........4A-3 Interpreting Results........4A-5 Connections..........4A-3 90-863758060 AUGUST 2006 Page 4A-1...
  • Page 55: Engine Compartment Ventilation

    Air Intake System Engine Compartment Ventilation Adequate ventilation is required to properly evacuate the fumes from the engine compartment and for proper engine operation. Insufficient ventilation will result in less than optimum engine performance. This is of particular concern on boats with tight engine compartments and those that use insulation to reduce engine noise.
  • Page 56: Engine Compartment And Fuel System Pressure And Temperature Test

    Air Intake System 6. The engine physical volumes are included in the table for use in computing the volume of air in the engine compartment. This information is needed for determining the ventilation requirements for venting fumes (refer to appropriate standards). 7.
  • Page 57: Running Test

    Air Intake System 5. Route the manometer hose to allow reading the engine compartment differential pressure. 6. Position another thermocouple above the flame arrestor on the engine to read the peak engine compartment temperatures. 7. Be sure the hoses, thermocouples, and fittings stay away from moving parts. Use a tie strap if necessary.
  • Page 58: Interpreting Results

    Air Intake System Interpreting Results Changes must be made to the fuel system or ventilation system if the readings fall outside of the specifications or the engine bogs or stalls under hard acceleration. Potential causes may be: Condition Symptom The throttle is opened and there is a 1–2 second hesitation before the engine responds Hesitation and possibly a backfire.
  • Page 59 Air Intake System Notes: Page 4A-6 90-863758060 AUGUST 2006...
  • Page 60 Fuel Delivery System Fuel Delivery System Section 5A - Fuel Delivery System Table of Contents Fuel Delivery System........5A-2 Fuel Inlet Connection........5A-5 Fuel Tank..........5A-3 Inline Fuel Filter........5A-7 Anti‑Siphon Valve........5A-4 Special Fitting Installation Procedure ..5A-8 Fuel Lines and Fittings......5A-5 Cool Fuel Insulator Covers......5A-9 90-863758060 AUGUST 2006 Page 5A-1...
  • Page 61: Fuel Delivery System

    6.9 kPa (1 psi) vacuum or less and fuel inlet temperature to 44 °C (110 °F) or less. The fuel delivery system is an integral part of the boat. Mercury MerCruiser makes no attempt in this manual to cover all aspects of design and integration of the fuel delivery system due to the broad range of possible configurations and the numerous regulations and standards that cover this area.
  • Page 62: Fuel Tank

    Fuel Delivery System The fuel tank is an integrated component of the boat. Refer to the special information on service and maintenance, which you have received from the tank manufacturer. Only a few points related to function and safety are listed here [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: •...
  • Page 63: Anti-Siphon Valve

    Fuel Delivery System • The vent and fuel fill systems must be carefully designed to inhibit water entry, a common source of engine problems. Proper location of the fill and vent fittings and the use of a good sealing fill cap is critical. A goose‑neck in the vent hose can also be used to impede water entry.
  • Page 64: Fuel Lines And Fittings

    Fuel Delivery System Fuel Lines and Fittings • U.S. boating standards and regulations specify the sole use of USCG Type A1 fuel lines in the engine compartment or in any location in the boat where a break in the line could result in a discharge of 150 cc (5 oz.) of fuel in 2½...
  • Page 65 Fuel Delivery System Model Size All models, including 8.1S with standard fitting 3/8 in. × 18 NPSF 8.1S models with special order fitting Compression fitting (½ in. SAE) 14354 V‑8 carbureted models Fuel inlet Water‑separating fuel filter 14851 Typical Fuel inlet fitting Page 5A-6 90-863758060 AUGUST 2006...
  • Page 66: Inline Fuel Filter

    4. Remove 76 mm (3 in.) of fuel line in the mounting location. 5. Select the appropriate size connector for the fuel line. IMPORTANT: Use of fittings other than those supplied by Mercury MerCruiser is acceptable as long as they do not exceed the maximum specified fuel pressure drop. Refer to the Mercury MerCruiser Applications Manual for more information on fuel pressure specifications.
  • Page 67: Special Fitting Installation Procedure

    Fuel Delivery System Description lb. in. lb. ft. Fuel line connector 19–27 14–20 9. Insert the filter into the mounting clip. 11212 Inline filter Mounting clip Connectors IMPORTANT: Per Coast Guard Regulation (CFD 183.570), "each fuel filter and strainer must be supported on the engine or the boat structure independent from its fuel line connections, unless the fuel filter or strainer is inside a fuel tank."...
  • Page 68: Cool Fuel Insulator Covers

    Vapor lock problems that result from the removal of these covers are not the responsibility of Mercury MerCruiser. A space should be provided for the removal of the lower cover to allow servicing of the filter.
  • Page 69 Fuel Delivery System 14340 Fuel cooler Gen II fuel cooler Page 5A-10 90-863758060 AUGUST 2006...
  • Page 70 Exhaust System Exhaust System Section 6A - Exhaust System Table of Contents Exhaust System..........6A-2 Measuring Exhaust Elbow Height....6A-15 Important Information........6A-2 General Information........6A-15 Carbon Monoxide Poisoning.....6A-2 Boat Requirements.........6A-16 Exhaust Connections........6A-3 Loading Requirements......6A-17 Exhaust Through‑Hull Fittings....6A-5 Loading the Boat with a Capacity Plate Exhaust Resonators.........6A-5 ..............6A-17 Exhaust System Design........6A-7...
  • Page 71: Exhaust System

    Exhaust systems that are installed improperly will allow water to enter the exhaust manifolds and combustion chambers severely damaging the engine. Water Ingestion Damage to the engine will not be covered by Mercury MerCruiser Warranty unless the damage results from defective Mercury Marine parts.
  • Page 72: Exhaust Connections

    Exhaust System WARNING Avoid prolonged exposure to carbon monoxide. Carbon monoxide poisoning can lead to unconsciousness, brain damage or death. Ensure that the boat, while at rest or underway, is well ventilated. GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 1.
  • Page 73 Exhaust System Exhaust hoses must be properly installed on exhaust elbow outlets. Discharge water from the exhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots that could burn through the hose. Exhaust hoses must be installed at the angle shown following.
  • Page 74: Exhaust Through-Hull Fittings

    This is a requirement on all applications except water lift mufflers, where it is still recommended. A variety of fittings is available through Mercury Precision Parts and Accessories. 13377 NOTE: For exhaust accessories, refer to Section 10 — Miscellaneous Accessories.
  • Page 75 In some cases, a performance increase is actually realized by using the resonators. Mercury MerCruiser recommends the use of the resonators on all models that have water present after water intrusion testing has been completed, and the exhaust system has been confirmed to meet all specifications, as outlined in this manual.
  • Page 76: Exhaust System Design

    Exhaust system tuning can be affected by various factors that are beyond the control of Mercury MerCruiser. Following are several factors that can affect exhaust system tuning: • Type and configuration of exhaust outlet.
  • Page 77: Collector Inlet And Outlet Specifications

    Exhaust System • Exhaust back pressure must meet the required specification. (See Exhaust Back Pressure Test) Models Exhaust Back Pressure 1 psi (7 kPa) Minimum All gasoline powered engines 2 psi (14 kPa) Optimal 11 psi (76 kPa) Maximum IMPORTANT: Exhaust collectors must drain sufficiently during engine shutdown and idle to provide the drainage necessary for these operational conditions.
  • Page 78 Exhaust System 15631 Typical single engine inboard with water standing in muffler (tow sports) Water line Muffler (must be self draining) Minimum exhaust elbow height 3° downward slope minimum with maximum load External flappers Exhaust back pressure check Drain fitting point 46 cm (18 in.) minimum between exhaust elbow and muffler...
  • Page 79: T Junction With In-Line Muffler

    Exhaust System • Every exhaust hose connection must be secured with at least two hose clamps. The clamps should be stainless steel and at least 13 mm (½ in.) wide. Clamps that rely solely on spring tension should not be used. (ABYC Standard) •...
  • Page 80: V-Pipe And In-Line Muffler

    Exhaust System V‑Pipe and In‑Line Muffler 15635 Typical Water line Y‑pipe Minimum exhaust elbow height 30°–60° angle at junction with maximum load 3° downward slope minimum Exhaust back pressure check Muffler point External flappers Resonator Drain fitting 46 cm (18 in.) minimum between exhaust elbow and Y‑pipe Minimum of 10°...
  • Page 81 The exhaust hose attached to the exhaust elbow must have a minimum of 10° downward slope. On longer hose applications, slope can be reduced to 3° in the portion of the exhaust system that is more than 46 cm (18 in.) away from elbow. NOTE: Mercury MerCruiser's recommendations more stringent than ABYC recommendation of a minimum drop in the exhaust system of ½...
  • Page 82 • Install a siphon break (vacuum valve) in the exhaust cooling water circuit if the exhaust elbows or muffler are at or below water level. Refer to Mercury's and exhaust system manufacturer's recommendations. • Provide a drain to the drain muffler.
  • Page 83: Collector And Water Lift Muffler

    Exhaust System • Install risers or lower the muffler if necessary to meet minimum exhaust elbow height. • The water line inside the muffler is the beginning measurement point to determine the correct elbow height. Collector and Water Lift Muffler 15636 Typical Water line...
  • Page 84: Measuring Exhaust Elbow Height

    3° If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers. The maximum exhaust riser height is specified in the table below.
  • Page 85: Boat Requirements

    Exhaust System EXHAUST ANGLE MEASUREMENT Measure the exhaust angle of each section of the exhaust system using an inclinometer as shown in the diagram below. Begin the measurement at the exhaust elbow outlet continuing along each section to the exhaust exit point of the boat. All exhaust angle measurements must be performed with the boat at rest in the water.
  • Page 86: Loading Requirements

    • Measurements used for official Mercury MerCruiser audit at the OEM boat builder must be performed on current production boats. No prototype hulls or light layup hulls will be considered for official audit purposes.
  • Page 87 Exhaust System • 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons. • 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.
  • Page 88 • 1100 lb. – 400 lb. = 700 lb. 2. Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the boat • 700 lb. ÷ 165 lb. = 4.24 persons 3.
  • Page 89: Loading The Boat-Without A Capacity Plate

    1. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person weight = maximum passenger load for measurement. • Number of persons × 165 lb. (MerCruiser person weight) = XXXX lb. maximum passenger load. 2. Maximum passenger load from the calculation above – swim platform load if applicable.
  • Page 90 • 1485 lb. – 500 lb. = 985 lb. 7. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat. •...
  • Page 91: Clear Hose Measurement Method

    • 1550 lb. + 165 lb. = 1715 lb. 24864 Cargo, swim platform, and passenger weight loading diagram Swim platform load MerCruiser person weight (five) MerCruiser person weight (one) MerCruiser person weight (six) MerCruiser person weight (two) Aft storage MerCruiser person weight (three)
  • Page 92: Clear Hose Measurement Method From Seacock Or Muffler Drain

    Exhaust System IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water. 2. Put the weighted end of the clear hose over the side of the boat (port or starboard) that is sitting lower in the water.
  • Page 93: Testing The Exhaust System

    Clear hose for measuring waterline with maximum load Testing the Exhaust System Through‑Transom Exhaust Back Pressure IMPORTANT: Mercury MerCruiser recommends checking the exhaust back pressure on all new applications with through‑transom or through‑hull exhaust to ensure that it is within specifications. Page 6A-24...
  • Page 94: Exhaust Back Pressure Test

    Exhaust System All exhaust systems have some restriction to flow or exhaust back pressure. The power output of an engine is directly related to the amount of exhaust that can flow out of the exhaust system. For example, large displacement engines will generally lose approximately 10 horsepower for the first 7 kPa (1 psi) of exhaust back pressure.
  • Page 95: Check For Water Intrusion

    The manifolds must be replaced after performing this check, so the procedure is best performed by Mercury MerCruiser's product applications engineer or where repeated testing will be performed at your facility.
  • Page 96 NOTE: A suction device with a rubber hose attached to the end can be used to suck the water from the manifold and discharge it into a container. 4. Replace the elbows using new gaskets. Refer to the appropriate Mercury MerCruiser Service Manual.
  • Page 97 Exhaust System • Improperly sized or incorrectly installed exhaust system components. • Leaking exhaust elbows or risers (i.e. loose screws, damaged gasket). • Improperly designed collector or Y‑pipe. See Exhaust System Design . • Exhaust system causing a tuning effect. See Exhaust Resonators. •...
  • Page 98 Cooling System Cooling System Section 7A - Cooling System Table of Contents General Information.........7A-2 Closed Cooling..........7A-10 Seawater Supply System ........7A-3 Description..........7A-10 Specifications..........7A-3 Antifreeze Recommendations....7A-10 Seawater Inlet Hose.........7A-4 Coolant Recovery System......7A-11 Through-Hull Seawater Pickup System Water Heaters..........7A-12 ..............7A-5 Water Heater Hose Connection Points...7A-13 Seawater Pickup........7A-5 5.7L Tow Sport Water Flow Diagram.....7A-17 Seacock............7A-7...
  • Page 99: General Information

    Australia - (03) 9544-6222 General Information Mercury MerCruiser engines have either a seawater cooling system or a closed cooling system. Seawater cooling systems are sometimes called raw water cooling or standard cooling, while closed cooling systems are sometimes called fresh water cooling. On engines with seawater cooling, the engine is cooled entirely by the seawater in which the boat is being operated.
  • Page 100: Seawater Supply System

    Cooling System Seawater Supply System Specifications SEAWATER SUPPLY HOSE Seawater Supply Hose Specifications Seawater inlet hose 32 mm (1-1/4 in.) I.D. (wire reinforced) Seawater pickup Seacock (optional) Low restriction with 32 mm (1-1/4 in.) connections Sea strainer (optional) SEAWATER INLET Seawater Inlet Specifications See Seawater Inlet Restriction Test;...
  • Page 101: Seawater Inlet Hose

    Cooling System Seawater Inlet Hose • A reinforced hose capable of supporting 10 in. Hg vacuum must be used to prevent the seawater inlet hose from collapsing from pump suction. • The hose should be oil and seawater resistant. • Use the shortest hose length possible with the least number of bends to minimize restriction.
  • Page 102: Through-Hull Seawater Pickup System

    Cooling System Through-Hull Seawater Pickup System IMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction is created by seawater pump impeller. 7924 Typical installation shown with a through the hull seawater pickup Quicksilver seawater pickup and Seawater hose to engine seacock Seawater pump hose connector (if...
  • Page 103 Cooling System Openings in seawater pickup should be approximately 3 mm (1/8 in.) maximum to prevent larger debris from entering and clogging the cooling system. IMPORTANT: Use a seawater strainer if the seawater pickup openings exceed 3 mm (1/8 in.). Provisions should be made to minimize galvanic corrosion, given the hull material being used and the composition of the surrounding components.
  • Page 104: Seacock

    Cooling System Tube Ref No. Description Where Used Part No. Hose fitting threads and plastic Loctite 567 PST Pipe Sealant 92-809822 plug threads Tube Ref No. Description Where Used Part No. RTV 587 Ultra Blue Silicone Sealing surfaces and screw 92-809825 Sealer shaft...
  • Page 105: Sea Strainer

    Cooling System Sea Strainer A sea strainer is recommended if the boat is to be operated in an area with a high debris content. The strainer must be sized to minimize restriction (See Specifications) and to provide a reasonable service interval. Locate the strainer in an area that will be easily accessible for servicing.
  • Page 106: Seawater Pressure Test For Mpi Models

    Cooling System 2. Zero the pressure gauge. 3. Connect the pressure gauge to the connection on the adapter. 4. With boat in the seawater and while underway, operate engine at 1000, 2000, 3000, 4000, and WOT while observing gauge. 5. Pressure should be steady and not exceed 17 kPa (2.5 psi). Check the following if abnormal readings are obtained.
  • Page 107: Closed Cooling

    Contact your sales representative to order your closed cooling systems factory installed or refer to the Mercury Precision Parts and Accessories Guide to obtain the part numbers for the accessory kits.
  • Page 108: Coolant Recovery System

    19 liters (20 quarts) Coolant Recovery System All Mercury MerCruiser closed cooling systems (except for 8.1S models) are equipped with a coolant recovery system that must be installed by the boat manufacturer. Coolant recovery bottle mounting location must meet these requirements: •...
  • Page 109: Water Heaters

    CAUTION Avoid overheating damage. Mercury MerCruiser is not responsible for engine damage caused by improper heater installation. Mercury MerCruiser engines are designed to allow connection of a water heater. Ensure that the water heater complies with the following: Description Specification Engine operating temperature range 71–79°...
  • Page 110: Water Heater Hose Connection Points

    Cooling System • On models with closed cooling systems, additional coolant must be added to the fresh water system to fill the heater. See Antifreeze Recommendation. Operate the engine while filling and recheck the level several times to ensure that all air has been purged from the system.
  • Page 111 Cooling System 7564 Water circulating pump housing Location for return hose connection WATER HEATER CONNECTIONS: CARBURETED MODELS 7562 Location for hot water supply connection 7564 Water circulating pump housing Location for return hose connection Page 7A-14 90-863758060 AUGUST 2006...
  • Page 112 Cooling System WATER HEATER CONNECTIONS: SCORPION MODELS NOTE: Some models may be equiped with additional fittings. 11478 11479 Port side intake manifold plug Starboard side intake manifold plug Location for hot water supply Thermostat housing connection 7564 Water circulating pump housing Location for return hose connection 90-863758060 AUGUST 2006 Page 7A-15...
  • Page 113 Cooling System IMPORTANT: When connecting a cabin shower: • Supply hose Must Not Exceed 16 mm (5/8 in.) inside diameter (ID). • Do not reposition shaft log seal. 11460 Hose for cold water supply WATER HEATER CONNECTIONS: 8.1S MODELS 8238 Location for hot water supply Location for return hose connection connection...
  • Page 114: 5.7L Tow Sport Water Flow Diagram

    Cooling System 5.7L Tow Sport Water Flow Diagram Inboard and Tow Sport (Carburetor) Water Flow Diagram SEAWATER COOLING SYSTEM 7567 Seawater inlet Engine block and cylinder head assembly Seawater pump Exhaust manifold, typical Transmission cooler Exhaust elbow assembly, typical Thermostat housing and cover assembly Exhaust outlet Engine water circulating pump...
  • Page 115: Inboard V8 Water Flow Diagrams

    Cooling System Inboard V8 Water Flow Diagrams Mie Water Flow Diagrams CLOSED COOLED INLINE EXHAUST MODELS NOTE: Certain components in the following diagram may look different than on your particular power package, but the water flow paths remain similar on all engines. 8182 Seawater inlet 14 degree exhaust elbow...
  • Page 116 Cooling System CLOSED COOLED V-DRIVE EXHAUST MODELS 8183 Seawater inlet Exhaust elbow Transmission cooler Seawater pump Gen III Cool Fuel module Heat exchanger Exhaust and seawater outlet To transmission cooler Exhaust manifold -From seawater pump Distribution housing Seawater Water circulating pump Ethylene glycol mix Thermostat housing 90-863758060 AUGUST 2006...
  • Page 117 Cooling System SEAWATER COOLED MODELS 8184 Seawater inlet Thermostat housing Transmission cooler Exhaust elbow Gen III Cool Fuel module Seawater pump Exhaust and seawater outlet Drain from starboard exhaust manifold Exhaust manifold To power steering cooler Distribution housing -From seawater pump Water circulating pump Page 7A-20 90-863758060 AUGUST 2006...
  • Page 118: 8.1S And Ho Inboard Water Flow Diagram

    Cooling System 8.1S and HO Inboard Water Flow Diagram Coolant and Water Flow Diagrams NOTE: Certain components in the following diagram may look different than on your particular power package, but the water and coolant flow paths remain similar on all engines.
  • Page 119 Cooling System Notes: Page 7A-22 90-863758060 AUGUST 2006...
  • Page 120 Electrical System Electrical System Section 8A - Electrical System Table of Contents Finding Other Diagrams........8A-2 SmartCraft Product........8A-8 General Information.........8A-2 Engine Harness........8A-8 Precautions............8A-2 Audio Warning System......8A-10 Industry Standards and Regulations....8A-3 Multiple EFI Engine Battery Precautions..8A-10 Battery and Battery Cables Requirements..8A-4 Situation..........8A-10 Battery .............8A-4 Recommendations........8A-11 Battery Cables..........8A-5...
  • Page 121: Finding Other Diagrams

    All electrical connections Finding Other Diagrams NOTICE Refer to the appropriate Mercury MerCruiser Diagram Binder for wiring diagrams or other diagrams not found in this manual. General Information This section covers the engine portion of the electrical system. For instrumentation related information, see Section 9.
  • Page 122: Industry Standards And Regulations

    Conductors should be routed as far away as practical from exhaust pipes and other heat sources. Unless an equivalent thermal barrier is provided, a clearance of 51 mm (2 in.) should be provided between conductors and the water cooled Mercury MerCruiser exhaust system components.
  • Page 123: Battery And Battery Cables Requirements

    Electrical System • Conductors should be routed to clear sources of chafing such as steering cable and linkages, throttle connections, and other moving engine components. • Conductors should be supported throughout their length and should be secured at least every 46 cm (18 in.), using industry approved fasteners. •...
  • Page 124: Battery Cables

    Electrical System IMPORTANT: Do not use a battery with wing nut connectors. • The battery has tapered post or side terminal connectors. • The battery capacity rating meets or exceeds the recomended Cranking Battery Specifications: Cranking Battery Specifications Model Minimum required rating 5.7L (350 cid) carbureted models 375 cca / 475 mca / 90 Ah 5.7L (350 cid) / 6.2 L (377 cid) MPI models...
  • Page 125: Battery Cable Connections

    Electrical System 3.7–4.6 m (12–15 ft.) 95 mm (000) 4.6–5.8 m (15–19 ft.) 120 mm (0000) • Multiple engine installations (including generator sets) require that a negative cable be run between the engines. The cable must be of sufficient size to carry the highest cranking current that could be encountered.
  • Page 126 Electrical System 15513 Typical tow sports battery cable to engine connections Positive (+) battery cable (RED) 90-amp fuse (DO NOT REMOVE) Boot (side over positive terminal to Negative (-) battery cable (BLACK) prevent accidental shorting) Ground stud (one each side of B+ starter terminal flywheel housing) •...
  • Page 127: Electrical Connections

    All electrical connections 92-25711-3 SmartCraft Product 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, water pressure, battery voltage, fuel consumption, and engine operating hours.
  • Page 128 15-amps. For protection, the main power relay fuse may blow if an excess of 15-amps is applied. Refer to the Mercury Precision Parts Accessories Guide for an optional accessory power relay kit that will accommodate higher amperage draw.
  • Page 129: Audio Warning System

    Electrical System Connect the power harness (Clean Power with 5-amp fuse) connector (DTS only). 12118 Typical 14-pin DTS harness Engine harness connector DLc/depth transducer connector Transmission harness connector Power harness connector/clean power with 5-amp fuse (DTS only) Paddle wheel/tank level connector Audio Warning System 1.
  • Page 130: Recommendations

    Electrical System EFI Electronic Control Module (ECM): The ECM requires a stable voltage source. During multiple engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may go below the ECM's minimum required voltage.
  • Page 131: Battery Isolator

    The alternators used on Mercury MerCruiser products are equipped with a special external sensing circuit to ensure optimum charging performance in these types of applications (by compensating for the voltage drop across the isolator).
  • Page 132: Battery Isolator Diagram

    Electrical System Battery Isolator Diagram 24376 Alternator Ground stud Starter Auxiliary battery Cranking battery Isolator CAUTION Avoid wiring damage. Do not cut the orange wire flush with the wiring loom. Doing so will damage other wires in the loom. 1. Disconnect the orange wire from the alternator battery terminal. Splice sufficient gauge wire to the orange wire and connect as shown.
  • Page 133 Electrical System Notes: Page 8A-14 90-863758060 AUGUST 2006...
  • Page 134 Instrumentation and Controls Instrumentation and Controls Section 9A - Instrumentation and Controls Table of Contents Instrumentation..........9A-2 10-Pin Instrument Harness Dual Station Requirements and Recommendations..9A-2 ..............9A-10 Important Installation Information.....9A-2 14-Pin Instrument Harness.....9A-11 Accessory Connections......9A-3 Remote Control and Cables......9A-12 Dual Station Instrumentation....9A-3 Requirements and Recommendations.
  • Page 135: Instrumentation

    (cable-actuated) remote controls. Refer to the Smart Craft applications manual for information on Mercury's new digital instrumentation and remote controls. Mercury MerCruiser inboard and tow sports engines, designed to comply with the ABYC Standards, use the four basic gauges shown below: •...
  • Page 136: Accessory Connections

    15-amps. For protection, the main power relay fuse may blow if an excess of 15-amps is applied. Refer to the Mercury Precision Parts Accessories Guide for an optional accessory power relay kit that will accommodate higher amperage draw.
  • Page 137: Audio Warning System

    Instrumentation and Controls 15529 Typical oil pressure sender Audio Warning System All models are equipped with an audio warning system as standard equipment to alert the operator of insufficient engine oil pressure, excessive engine temperature, or a low drive unit lubricant condition. The following items are particularly noteworthy for proper installation of the system: WARNING Fire or explosion hazard.
  • Page 138: Engine Guardian

    Engine Guardian be called on to protect the engine. This is covered in the Operation, Maintenance, and Warranty manual. Mercury MerCruiser MPI models are equipped with an Engine Guardian to provide additional protection against engine damage. The system is designed to help reduce the potential for engine damage by reducing engine power when a potential problem is sensed.
  • Page 139: Lanyard Stop Switch Information

    Instrumentation and Controls Lanyard Stop Switch Information WARNING Avoid abrupt deceleration of the boat from lanyard stop switch activation. Boat damage and personal injury or death could occur. Never leave the operator's station with the engine operating and in gear. 74608 Stop switch Clips to operator...
  • Page 140: Instrumentation Harness Receptacle

    Instrumentation and Controls WARNING Avoid contact with the boat hull and propeller from accidental ejection. Personal injury or death could occur. Always properly connect both ends of the lanyard stop switch. Accidental or unintended activation of the switch during normal operation is also a possibility.
  • Page 141 Instrumentation and Controls 12118 Typical 14-pin DTS harness Engine harness connector DLC/depth transducer connector Transmission harness connector Power harness connector/clean power with 5-amp fuse (DTS only) Paddle wheel/tank level connector Page 9A-8 90-863758060 AUGUST 2006...
  • Page 142: 10-Pin Instrument Harness

    Instrumentation and Controls 10-Pin Instrument Harness UNSW LT T SEND SEND SEND SEND 7865 Audio warning buzzer Ignition switch Tachometer Trim indicator (Sterndrive only) Oil pressure See Note 1 and Note 2 Water temperature See Note 3 Battery meter To engine wiring harness Refer to gauge manufacturer's instructions for specific connections.
  • Page 143: 10-Pin Instrument Harness Dual Station

    Instrumentation and Controls 10-Pin Instrument Harness Dual Station NOTE 4 NOTE 3 NOTE 1 BRN/WHT NOTE 2 NOTE 3 NOTE 3 NOTE 1 NOTE 3 NOTE 4 14925 A - Primary Station B - Secondary Station 1 - Start/stop panel 1 - Ignition switch 2 - Tachometer 2 - Tachometer...
  • Page 144: 14-Pin Instrument Harness

    Note 1: The BROWN/WHITE wire is taped back at the instrument end. If installing on a Mercury MerCruiser inboard, the BROWN/WHITE wire is taped back at the engine end, or it may be used for an accessory limited to 5 amperes. Power must be taken from accessory panel connection.
  • Page 145: Remote Control And Cables

    An extensive array of Quicksilver remote controls and cables are available through the Mercury Precision Parts Accessories Guide. A single lever control (shift and throttle function in same lever) or a two-lever control (separate shift and throttle levers) can be used on single station applications.
  • Page 146: Installation

    Instrumentation and Controls • A neutral start safety switch is included in the transmission. The switch in the remote control should not be used. Installation Install the remote and cables in accordance with the instructions which accompany them and the instructions in the power package installation manual. To ensure minimal shift and throttle effort, be sure to observe the following important information: •...
  • Page 147: Dual Station (Helm) Cable Setup

    On some applications, it may be preferable to connect both sets of cable directly to the engine, using a parallel connection. Mercury MerCruiser inboard engines come equipped with the necessary hardware for making either type of connection.
  • Page 148: Cable Attachment Hardware

    Instrumentation and Controls Cable Attachment Hardware INBOARD MODELS Inboard models can accommodate forward or aft shift cable entry and single or dual cable attachment. Hardware must be installed as shown. 7672 Typical single cable: forward entry Cable end guide Cable barrel location Locknut and washer Spacer (fits over stud) Spacer (fits over bushings)
  • Page 149 Instrumentation and Controls 7674 Typical dual cable: forward entry Cable end guides Cable barrel locations Locknut and washer Cable barrel stud Spacer (fits over stud) Cable end guide stud Bushings 7675 Typical dual cable: rear entry Cable end guides Cable barrel locations Locknut and washer Cable barrel stud Spacer (fits over stud)
  • Page 150: Cable Adjustment

    Instrumentation and Controls TOW SPORTS MODELS Tow sports models accommodate single cable forward entry only. Attaching hardware is provided for a Morse cable. 15535 Throttle lever stud Locknut Cable end Cable Adjustment CAUTION Transmission failure may occur. Velvet Drive Transmission Warranty is jeopardized if the shift lever poppet ball or spring is permanently removed, if the shift lever is repositioned or changed in any manner or if remote control and shift cable do not position shift lever exactly as shown.
  • Page 151 Instrumentation and Controls • On Velvet Drive models, the shift lever must be in the designated detent position for each gear. 7665 Velvet Drive 5000 series (8 degree down angle shown, V-drive similar) Transmission shift lever Poppet ball must be centered in this detent hole for neutral position Poppet ball must be centered in this detent hole when left-hand...
  • Page 152 Instrumentation and Controls • Velvet Drive In-line 71C and 72C transmissions must be operated with the shift lever in the FORWARD gear selector position when propelling the boat forward. Damage to transmission will result if it is operated in REVERSE (with the wrong rotation propeller) under full power.
  • Page 153 Instrumentation and Controls Notes: Page 9A-20 90-863758060 AUGUST 2006...
  • Page 154 Predelivery Preparation Predelivery Preparation Section 10A - Predelivery Preparation Table of Contents Predelivery Inspection........10A-2 Power Package Preparation for Shipment..10A-6 Operating Engine With the Boat out of the Water Extended Storage........10A-6 ...............10A-2 Draining the Cooling System....10A-7 Propeller Selection.........10A-3 Engine Corrosion Protection....10A-7 Selection Procedure.......10A-3 Disconnecting the Battery.......10A-7 Cruising RPM..........10A-5...
  • Page 155: Predelivery Inspection

    Predelivery Preparation Predelivery Inspection It is the boat manufacturer's responsibility to perform the checks called out on the checklist included in the literature packet with each engine (see the copy at the end of this section) to verify that the power package has been properly installed and is performing correctly. Each check on the list should be checked-off to indicate to the dealer and customer that it has been completed.
  • Page 156: Propeller Selection

    Propeller Selection NOTE: A book called Everything You Need to Know About Propellers (90-86144--92) is available from Mercury Precision Parts and Accessories. This full-color book provides the latest in propellers, how they work, types, design and manufacturing, how to select the proper propeller for a given application, and answers to many commonly asked questions about boating performance.
  • Page 157 Select model and initial pitch propeller to begin testing with using information provided in the Mercury Precision Parts and Accessories Guide. A vast array of propeller models and pitches are available to suit virtually any boat application. Initial selection is typically done by boat weight.
  • Page 158: Cruising Rpm

    Predelivery Preparation For better acceleration, such as is needed for water skiing, the next lower pitch propeller can be used. Care must be exercised when not pulling skiers to prevent over-revving the engine. When cruising, the next highest pitch propeller should be used. Because of the many variables of boat design, only testing will determine the best propeller for a particular application.
  • Page 159: Power Package Preparation For Shipment

    Predelivery Preparation Although some performance can be regained by dropping to a lower pitch propeller, the basic problem still exists. In some cases, a gear ratio change to more reduction is possible and very beneficial. Summer conditions of high temperature, low barometric pressure, and high humidity all combine to reduce the engine power.
  • Page 160: Draining The Cooling System

    Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing is not covered by the Mercury MerCruiser Limited Warranty.
  • Page 161: Disconnecting The Propeller Shaft Coupling

    Predelivery Preparation Disconnecting the Propeller Shaft Coupling CAUTION Failure to disconnect the coupling for shipment could result in damage to transmission and propeller shaft. On applications with a rigid propeller shaft coupling, the coupling must be disconnected from the transmission flange before boat is removed from the water for shipment. Coupling should not be reconnected until the boat is in the water at its final destination and the engine alignment has be rechecked.
  • Page 162: Predelivery Inspection Checklist

    Predelivery Preparation Predelivery Inspection Checklist Check / Check / Not Applicable CHECK BEFORE RUNNING Not Applicable ON THE WATER TEST Adjust Adjust Drain plug in and petcocks closed Engine alignment (Inboards only) Starter neutral safety switch Seawater inlet valve open operation Engine mounts tight Water pump operation...
  • Page 163 Predelivery Preparation Notes: Page 10A-10 90-863758060 AUGUST 2006...

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