2.8L and 4.2L Diesel Sterndrive Models O P E RA T ION &

Transcription

1 2.8L nd 4.2L Diesel Sterndrive Models O P E RA T ION & M A I N T E N AN C E M AN U AL

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3 Welcome You hve selected one of the finest mrine power pckges ville. It incorportes numerous design fetures to ensure operting ese nd durility. With proper cre nd mintennce, you will enjoy using this product for mny oting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. The Opertion nd Mintennce Mnul contins specific instructions for using nd mintining your product. We suggest tht this mnul remin with the product for redy reference whenever you re on the wter. Thnk you for purchsing one of our products. We sincerely hope your oting will e plesnt! Mercury Mrine, Fond du Lc, Wisconsin, U.S.A. 8M eng Nme / function: John Pfeifer, President, Mercury Mrine Red This Mnul Thoroughly IMPORTANT: If you do not understnd ny portion of this mnul, contct your deler. Your deler cn lso provide demonstrtion of ctul strting nd operting procedures. Notice Throughout this puliction, nd on your power pckge, wrnings, cutions, nd notices, ccompnied y the Interntionl Hzrd Symol!, my e used to lert the instller nd user to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. Oserve them crefully. These sfety lerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. IMPORTANT: Identifies informtion essentil to the successful completion of the tsk. NOTE: Indictes informtion tht helps in the understnding of prticulr step or ction. IMPORTANT: The opertor (driver) is responsile for the correct nd sfe opertion of the ot, the equipment ord, nd the sfety of ll occupnts ord. We strongly recommend tht the opertor red this Opertion nd Mintennce Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories efore the ot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, irth defects or other reproductive hrm. The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Mrine power pckge. When contcting Mercury Mrine out service, lwys specify model nd seril numers. Descriptions nd specifictions contined herein were in effect t the time this ws pproved for printing. Mercury Mrine, whose policies re sed on continuous improvement, reserves the right to discontinue models t ny time or to chnge specifictions or designs without notice nd without incurring oligtion Mercury Mrine 2.8L nd 4.2L Diesel Engine Sterndrive Models

4 Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Mercury Mrine; the terms of the wrrnty re set forth in the Wrrnty Mnul included with the product. The Wrrnty Mnul contins description of wht is covered, wht is not covered, the durtion of coverge, how to est otin wrrnty coverge, importnt disclimers nd limittions of dmges, nd other relted informtion. Plese review this importnt informtion. Mercury Mrine products re designed nd mnufctured to comply with our own high qulity stndrds, pplicle industry stndrds nd regultions, s well s certin emissions regultions. At Mercury Mrine every engine is operted nd tested efore it is oxed for shipment to mke sure tht the product is redy for use. In ddition, certin Mercury Mrine products re tested in controlled nd monitored environment, for up to 10 hours of engine run time, in order to verify nd mke record of complince with pplicle stndrds nd regultions. All Mercury Mrine product, sold s new, receives the pplicle limited wrrnty coverge, whether the engine prticipted in one of the test progrms descried ove or not. Copyright nd Trdemrk Informtion MERCURY MARINE. All rights reserved. Reproduction in whole or in prt without permission is prohiited. Alph, Axius, Brvo One, Brvo Two, Brvo Three, Circle M with Wves Logo, K plnes, Mriner, MerCthode, MerCruiser, Mercury, Mercury with Wves Logo, Mercury Mrine, Mercury Precision Prts, Mercury Propellers, Mercury Rcing, MotorGuide, OptiMx, Quicksilver, SeCore, Skyhook, SmrtCrft, Sport Jet, Verdo, VesselView, Zero Effort, Zeus, #1 On the Wter nd We're Driven to Win re registered trdemrks of Brunswick Corportion. Pro XS is trdemrk of Brunswick Corportion. Mercury Product Protection is registered service mrk of Brunswick Corportion. Identifiction Records Plese record the following pplicle informtion: Engine Model nd Horsepower MerCruiser Engine Seril Numer Trnsom Assemly Seril Numer (Sterndrive) Ger Rtio Sterndrive Unit Seril Numer Trnsmission Model (Inord) Ger Rtio Trnsmission Seril Numer Propeller Numer Pitch Dimeter Hull Identifiction Numer (HIN) Purchse Dte Bot Mnufcturer Bot Model Length Exhust Gs Emissions Certifiction Numer (Europe Only)

5 TABLE OF CONTENTS Section 1 - Getting to Know Your Power Pckge Identifiction... 2 Seril Numer Decl... 2 Engine Dt Lel... 2 Brvo Sterndrive Seril Numer nd Identifiction... 3 Brvo Trnsom Seril Numer... 3 Fetures nd Controls... 4 Audio Wrning System... 4 Switches... 5 Lnyrd Stop Switch... 5 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 6 Instrumenttion... 7 VesselView... 7 SmrtCrft Digitl Instruments... 7 System Link Digitl Instruments... 8 Emergency Stop Switch... 8 Remote Controls... 9 Pnel Mount Fetures... 9 Console Mount Fetures... 9 Power Trim Single Engine Trim nd Triler Dul Engine Trim nd Triler Trim without Key Overlod Protection Upper Engine Circuit Breker Pnel Overlod Protection Port Side Power Distriution Box.. 12 Vessel Integrtion Pnel (VIP) Overlod Protection Power Trim nd MerCthode Overlod Protection Engine Gurdin System SeCore Equipped Drives SeCore Components nd Cstings Stinless Steel Fsteners Section 2 - On the Wter Sfe Boting Recommendtions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Importnt Opertion Informtion Lunching Duty Cycle Rting Requirements High Output Rting Opertion Chrt Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump Trilering the Bot Strting, Shifting, nd Stopping Before Strting the Engine Importnt Informtion SmrtStrt Strting Cold Engine Engine Wrm Up Strting Wrm Engine Shifting Engine Shut Down (Stopping) Strting the Engine After Stopped While in Ger Protecting People in the Wter While You Are Cruising While Bot Is Sttionry High Speed nd High Performnce Pssenger Sfety In Pontoon Bots nd Deck Bots Bots Hving An Open Front Deck Bots With Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Sterndrive Impct Protection Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection Getting Strted Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) Engine Brek In Hour Brek In Period...28 After the 20 Hour Brek In Period End of First Seson Checkup Section 3 - Specifictions Fuel Requirements Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions L Specifiction L Specifiction Fluid Specifictions Engine L L...35 Brvo Sterndrive Fluid Specifictions Diesel M eng JUNE 2017 Pge i

6 Power Assisted Steering nd Power Trim Fluids Approved Power Assisted Steering Fluids Approved Power Trim Fluids Approved Pints Section 4 - Mintennce Owner nd Opertor Responsiilities Deler Responsiilities Clening Cre Recommendtion Do Not Use Custic Clening Chemicls Clening Guges Clening Remote Controls Mintennce Do It Yourself Mintennce Suggestions Inspection Mintennce Schedules Routine Mintennce Scheduled Mintennce Engine Oil Checking Filling Chnging Oil nd Filter Sterndrive Ger Lue Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Assisted Steering Fluid Checking Filling Chnging Engine Coolnt Check Coolnt Filling Chnging Air Filter Removl Inspection Instlltion Air Filter Removl Inspection Instlltion Wter Seprting Fuel Filter Drining Replcing Filling Fuel System Priming Filling (Bleeding) Fuel Tnk Clening nd Flushing Sewter System Drining the Sewter System Sterndrive Wter Inlets Check Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Flushing the Sewter System Sterndrive Models With the Bot out of the Wter With the Bot in the Wter Engine Sewter Pump Inspection Replcing the Engine Coolnt in the Closed Cooling System Drining the Closed Cooling System Filling the Closed Cooling System Corrosion Protection Generl Informtion Engine Corrosion Protection Components Removl Clening nd Inspection Instlltion Sterndrive Corrosion Protection Components Continuity Circuit Brvo Sterndrive MerCthode System Bttery Requirements MerCthode Theory of Opertion Power Pckge Exterior Surfces Bot Bottom Cre Pinting Your Power Pckge Sterndrive Surfce Cre Luriction Steering System Throttle Cle Shift Cle Engine Coupler Driveshft Extension Models Sterndrive, Bellows, nd Engine Alignment Mintining Torques Brvo Giml Ring U olt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belts Serpentine Belt Inspection Replcement Power Assisted Steering Pump Belt Inspection Adjustment Replcement Bttery Bttery Precutions for Multiple Engines Pge ii 90-8M eng JUNE 2017

7 Section 5 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge Cold Wether (Freezing Temperture) Storge Prepring Your Power Pckge for Sesonl or Extended Storge Sesonl Storge Instructions Extended Storge Instructions Bttery Recommissioning Section 6 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems 104 Trouleshooting Chrts Strter Motor Will Not Crnk Engine, or Crnks Slow Engine Will Not Strt, or Is Hrd to Strt Engine Runs Rough, Misses, or Bckfires Poor Performnce Incorrect Engine Temperture Low Engine Oil Pressure Bttery Will Not Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds Steering Wheel Turns Hrd or Jerky Power Trim does not Operte (Electric Motor Opertes ut Sterndrive does not Move) Power Trim Does Not Operte (Electric Motor Does Not Operte) Section 7 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Sumersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Prolem Contct Informtion for Mercury Mrine Customer Service Customer Service Literture English Lnguge Other Lnguges Ordering Literture United Sttes nd Cnd Outside the United Sttes nd Cnd Section 8 - Mintennce Log Scheduled Mintennce Log Vessel Mintennce Notes M eng JUNE 2017 Pge iii

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9 Section 1 - Getting to Know Your Power Pckge Section 1 - Getting to Know Your Power Pckge Tle of Contents 1 Identifiction... 2 Seril Numer Decl...2 Engine Dt Lel... 2 Brvo Sterndrive Seril Numer nd Identifiction... 3 Brvo Trnsom Seril Numer... 3 Fetures nd Controls... 4 Audio Wrning System... 4 Switches... 5 Lnyrd Stop Switch... 5 Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition... 6 Instrumenttion... 7 VesselView... 7 SmrtCrft Digitl Instruments... 7 System Link Digitl Instruments... 8 Emergency Stop Switch...8 Remote Controls... 9 Pnel Mount Fetures... 9 Console Mount Fetures... 9 Power Trim Single Engine Trim nd Triler Dul Engine Trim nd Triler Trim without Key Overlod Protection Upper Engine Circuit Breker Pnel...11 Overlod Protection Port Side Power Distriution Box Vessel Integrtion Pnel (VIP) Overlod Protection Power Trim nd MerCthode Overlod Protection Engine Gurdin System SeCore Equipped Drives SeCore Components nd Cstings Stinless Steel Fsteners M eng JUNE 2017 Pge 1

10 Section 1 - Getting to Know Your Power Pckge Identifiction The seril numers re the mnufcturer's keys to numerous engineering detils tht pply to your Mercury Mrine power pckge. When contcting Mercury Mrine out service, lwys specify model nd seril numers. Seril Numer Decl The seril numer decl is locted on top of the engine cover. c d e ENGINE SERIAL NUMBER TRANSOM SERIAL NUMBER DRIVE SERIAL NUMBER SPECIFICATIONS MODEL... I4 DISPLACEMENT L ENGINE ROTATION...LH MAX. W.O.T. RPM IDLE RPM IN NEUTRAL NON ADJ COLOR CODES ENGINE OIL DRIVE LUBE PR STR FLUID COOLANT QR CODE Scn for dditionl engine informtion BELT ROUTING shown, 4.2 similr - Seril numers - Engine specifictions c - Mintennce color codes d - Quick reference code e - Belt routing Engine Dt Lel A tmper resistnt engine dt lel is ffixed to the engine t the time of mnufcture. It contins importnt informtion. Note tht the engine dt lel will not ffect the fit, function, or performnce of the engine nd neither otuilders nor delers my remove the engine dt lel or the engine component it is ffixed to efore sle. If modifictions re necessry or the engine dt lel is dmged, contct Mercury Mrine out the vilility of replcement. The owner or opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow exhust gs emission levels to exceed their predetermined fctory specifictions. d c xxxxxxxx xxx xxxx xxx xxx xxx xxx e Engine dt lel exmple - Engine weight - Engine power rting c - Mximum engine speed (RPM) d - Engine seril numer e - Arevited engine description Pge M eng JUNE 2017

11 Brvo Sterndrive Seril Numer nd Identifiction Section 1 - Getting to Know Your Power Pckge The Brvo sterndrive seril numer, ger rtio, model numer, nd r code re emedded in the ground plte on the port side of the sterndrive. Brvo sterndrive informtion on ground plte The seril numer is lso stmped on the driveshft housing ehind the ck cover. This is used s permnent reference for uthorized MerCruiser delers Brvo Trnsom Seril Numer Brvo sterndrive seril numer stmping The Brvo trnsom seril numer is stmped in the trnsom ssemly decl. Trnsom Seril No M eng JUNE 2017 Pge 3

12 Section 1 - Getting to Know Your Power Pckge The seril numer is lso stmped on the giml housing. This is used s permnent reference for uthorized MerCruiser delers. Fetures nd Controls Audio Wrning System Seril numer loction on giml housing Your power pckge is equipped with n udio wrning system. The udio wrning system monitors criticl components nd informs the opertor when mlfunction hs occurred. The wrning system is not cple of protecting the power pckge from dmge cused y mlfunction. When n electronic control system detects recordle mlfunction, the udio wrning system will sound to lert the opertor. The durtion nd type of horn sound depend upon the nture of the fult condition. In the cse of ny horn sounding, the user should refer to the helm displys to understnd the specific sitution. For the opertor to view the fult code of the mlfunction indicted nd ny recommended ctions, the power pckge must e equipped with guge pckge tht supports the wrning system nd cn disply fult codes. The following instruments hve screens tht disply fult codes: VesselView SmrtCrft System Tchometer SmrtCrft System Speedometer NOTICE The sound from n udio wrning horn indictes tht criticl fult mlfunction hs occurred. Operting power pckge with criticl fult cn dmge components. If the udio wrning horn emits sound, do not continue opertions unless voiding hzrdous sitution. If the udio wrning sounds, stop the engine immeditely if you re not in hzrdous sitution. Investigte the cuse nd correct it, if possile. If you cnnot determine the cuse, consult n uthorized repir fcility. Pge M eng JUNE 2017

13 Section 1 - Getting to Know Your Power Pckge Switches Four Position Key Switch "OFF" In the "OFF" position, ll electricl circuits re off. The engine will not operte with the key switch in the "OFF" position. "ACC" In the "ACC" position, ny ccessories connected to the electricl circuits cn e operted. The engine will not operte with the key switch in the "ACC" position. "ON" In the "ON" position, ll electricl circuits nd instrumenttion receive power. The engine cn e strted with n optionl strt stop switch. "START" Turn the key to the strt position nd relese to strt the engine. NOTE: The key cn only e removed with the key switch in the "OFF" position Dul Engine Strt Stop Switch A strt stop switch is optionl equipment. The strt stop switch works in conjunction with the key switch. There is one strt stop switch for ech engine. Ech utton on multiengine strt stop switch functions independently. The key switch must e in the run position to strt stopped engine with the strt stop switch. Pressing strt stop switch utton when n engine is running will shut down the corresponding engine Bilge Blower Toggle Switch Opertes the ilge lower, if equipped. ON OFF Lnyrd Stop Switch A lnyrd switch is designed to shut down the engine in the event the opertor unexpectedly moves wy from the helm, s my hppen in n ccidentl ejection. The lnyrd is connected to the opertor's personl flottion device or wrist. 90-8M eng JUNE 2017 Pge 5

14 Section 1 - Getting to Know Your Power Pckge A decl ner the lnyrd stop switch reminds the opertor to ttch the lnyrd to his or her personl flottion device or wrist. ATTACH LANYARD RUN OFF - Lnyrd cord clip - Lnyrd decl c - Lnyrd stop switch c Accidentl ejections, such s flling overord, re more likely to occur in: Low sided sport ots Bss ots High performnce ots Accidentl ejections cn lso occur from: Poor operting prctices Sitting on the set or gunwle t plning speeds Stnding t plning speeds Operting t plning speeds in shllow or ostcle infested wters Relesing your grip on the steering wheel Crelessness cused y consuming lcohol or drugs High speed oting mneuvers The lnyrd is cord usully etween 122 nd 152 cm (4 nd 5 ft) long when stretched out, with n element on one end mde to e inserted into the switch, nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the opertor's norml position. The opertor cn shorten the lnyrd y wrpping the lnyrd round his wrist, or y tying knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, ut the ot will continue to cost for some distnce, depending upon its velocity. While the ot is costing, it cn cuse injury to nyone in the ot's pth s it would under power. Instruct ll pssengers on the proper strting nd operting procedures should they e required to operte the ot in n emergency.! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd. Accidentl or unintended ctivtion of the switch during norml opertion is lso possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y the propulsion or steering components. Loss of power nd directionl control in hevy ses, strong current, or high winds. Loss of control when docking.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition Before ech use, ensure tht the lnyrd stop switch works properly. Strt the engine, nd then stop it y pulling the lnyrd cord. If the engine does not stop, hve the switch repired efore operting the ot. Pge M eng JUNE 2017

15 Section 1 - Getting to Know Your Power Pckge Before ech use, inspect the lnyrd cord to ensure tht it is in good working condition nd tht there re no reks, cuts, or wer to the cord. Check tht the clips on the ends of the cord re in good condition. Replce ny dmged or worn lnyrd cords. Instrumenttion VesselView There re severl VesselView products ville. VesselView will disply ll engine informtion, fult codes, vessel informtion, sic nvigtion dt, nd system informtion. When n operting system error or filure occurs, VesselView displys n lrm messge. VesselView my lso e connected to other vessel systems such s GPS, genertors, nd chrtplotters. This vessel integrtion llows the opertor to monitor nd control wide rnge of vessel systems from single disply. Refer to the VesselView opertor's mnul for more informtion. VesselView SmrtCrft Digitl Instruments The SmrtCrft instrument pckge ugments the VesselView disply. The instrument pckge my include: Tchometer Speedometer Engine coolnt temperture Engine oil pressure Bttery voltge Fuel consumption Engine operting hours SmrtCrft tchometer nd speedometer - Tchometer - Speedometer c - LCD disply c The SmrtCrft instrument pckge lso ids in identifying fult codes ssocited with the engine udio wrning system. The SmrtCrft instrument pckge displys criticl engine lrm dt nd other potentil prolems on its LCD disply. For sic opertion informtion on the SmrtCrft instrument pckge nd for detils on the wrning functions monitored y the system, refer to the mnul provided with your guge pckge. 90-8M eng JUNE 2017 Pge 7

16 Section 1 - Getting to Know Your Power Pckge System Link Digitl Instruments Some instrumenttion pckges include system link guges tht ugment the informtion provided y VesselView or SmrtCrft system tchometer nd speedometer. The owner nd opertor should e fmilir with ll the instruments nd their functions on the ot. Hve your ot deler explin the guges nd norml redings tht pper on your ot. The following digitl instruments my e included with your power pckge. c d System Link digitl guges Item Guge Indictes Oil pressure guge Engine oil pressure Voltmeter Bttery voltge c Wter temperture guge Engine operting temperture d Fuel guge Quntity of fuel in tnk Emergency Stop Switch An emergency stop (E stop) switch is used to turn off the engines in n emergency sitution, such s person overord or tngled propeller. When ctivted, n E stop switch interrupts the power supply to the engine nd trnsmission. If the ot is equipped with n E stop switch, the E stop switch turns off ll of the engines. Typicl E-stop switch Activtion of n E stop switch stops the engine, or engines, immeditely, ut the ot cn continue to cost for some distnce depending upon the velocity nd degree of ny turn t shutdown. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We recommend instructing other occupnts on proper strting nd operting procedures should they need to operte the engine in n emergency. Accidentl or unintended ctivtion of the switch during norml opertion is lso possile, which cn cuse ny or ll of the following potentilly hzrdous situtions: Occupnts cn e thrown forwrd due to unexpected loss of forwrd motion, nd pssengers in the front of the ot could e ejected over the ow nd possily struck y the propulsion or steering components. The opertor cn lose power nd directionl control in hevy ses, strong current, or high winds. The opertor cn lose control of the vessel when docking. Restrting n engine using the key switch or strt utton fter n E stop shutdown without first turning the key switch to the off position for t lest 30 seconds will restrt the engine ut cuse fult codes to e set. Unless you re in potentilly hzrdous sitution, turn the key switch off nd wit t lest 30 seconds efore restrting the engine or engines. If fter restrting, some fult codes re still eing displyed, contct your uthorized Mercury Diesel repir fcility Pge M eng JUNE 2017

17 Remote Controls Section 1 - Getting to Know Your Power Pckge Your ot my e equipped with Mercury Precision Prts or Quicksilver remote controls. All controls my not hve ll fetures shown. Consult your deler for description nd/or demonstrtion of your remote control. Pnel Mount Fetures f e - Neutrl lock utton - Throttle only utton c - Lnyrd stop switch d - Control hndle tension djustment screw e - Control hndle f - Trim nd tilt utton c d mc Neutrl lock utton. Prevents ccidentl shift nd throttle enggement. The neutrl lock utton must e pushed into move the control hndle out of neutrl. Throttle only utton. Allows engine throttle dvncement without shifting the engine. This is done y disengging the shift mechnism from the control hndle. The throttle only utton cn e depressed only when the remote control hndle is in the neutrl position, nd should only e used to ssist in strting the engine. Lnyrd stop switch. Turns the ignition off whenever the opertor (when ttched to the lnyrd) moves fr enough wy from the opertor's position to ctivte the switch. See Lnyrd Stop Switch for informtion on the use of this switch. Control hndle. The shift nd throttle re controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle ck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing ck to increse speed. Control hndle tension djustment screw (not visile). This screw is used to djust the effort required to move the remote control hndle. Refer to the instructions provided with the remote control for complete djustment instructions. Trim (tilt) utton. See Power Trim. Console Mount Fetures d c - Throttle only utton - Control hndle c - Power trim switch d - Triler switch c d mc M eng JUNE 2017 Pge 9

18 Section 1 - Getting to Know Your Power Pckge Throttle only utton. Allows engine throttle dvncement without shifting the engine. This is done y disengging the shift mechnism from the control hndle. The throttle only utton cn e depressed only when the remote control hndle is in the neutrl position. Control hndles. The shift nd throttle re controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger nd continue pushing forwrd to increse speed. Pull the control hndle ck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing ck to increse speed. Control hndle tension djustment screw (not visile). This screw is used to djust the effort required to move the remote control hndle. Refer to the instructions provided with the remote control for complete djustment instructions. Power trim switch. See the Power Trim section for detiled power trim operting procedures. Triler switch. Used to rise the sterndrive for trilering, lunching, eching, or shllow wter opertion. See Power Trim for detiled triler switch opertion. Power Trim Power trim llows the opertor to djust the sterndrive ngle while underwy to provide the idel ot ngle for vrying lod nd wter conditions. Also, the trilering feture llows the opertor to rise nd lower the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM engine speed), nd shllow wter opertion.! WARNING Excessive trim cn cuse serious injury or deth t high speeds, nd single rm trim systems do not provide trim out limiting device or trim indictor. Use cution when trimming with single rm trim system nd never trim out eyond the unit's side support flnges while the ot is underwy or t engine speeds ove 1200 RPM. For est performnce, trim the sterndrive so tht the ot ottom is t 3 5 ngle to the wter. 3-5 mc79528 Trimming the sterndrive up (out) cn: Generlly increse top speed Increse clernce over sumerged ojects or shllow ottom Cuse the ot to ccelerte nd plne off slower In excess, cuse ot porpoising (ouncing) or propeller ventiltion Cuse engine overheting if trimmed up (out) to point where ny cooling wter intke holes re ove the wterline mc78529 Trimming the sterndrive down (in) cn: Help the ot ccelerte nd plne off quicker Generlly improve the ride in choppy wter In most cses, reduce ot speed Pge M eng JUNE 2017

19 Section 1 - Getting to Know Your Power Pckge If excessively trimmed down (in), my lower the ows of some ots to point t which they egin to plow with their ow in the wter while on plne. This cn result in n unexpected turn in either direction clled ow steering or oversteering if ny turn is ttempted or if significnt wve is encountered. mc79530 Single-Engine Trim nd Triler Single engine pplictions hve utton tht cn e pressed to trim the sterndrive up (out) or down (in). To rise the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM), nd shllow wter opertion, push the trim utton to rise the sterndrive to the full up (out) position. Some controls lso hve triler utton tht trims the sterndrive to position suitle for triler purposes only. NOTE: The Engine Control Module (ECM) limits the extent to which the sterndrive cn e trimmed up (out) when engine speed is ove 1200 RPM. Dul-Engine Trim nd Triler NOTICE If using externl tie rs, rising or lowering the drives independently of ech other cn dmge the drive nd steering systems. If using n externl tie r, rise nd lower ll drives together s unit. Dul engine pplictions my hve single integrl utton to operte oth sterndrives simultneously or my hve seprte uttons for ech sterndrive. Some controls lso hve triler utton tht trims the sterndrives to position suitle for triler purposes only. Trim without Key! CAUTION The Trim Without Key mode llows trim opertion fter the ignition key switch is turned off. To void injury or product dmge, do not ttempt ny engine or sterndrive relted repirs or mintennce until performing the Wide Open Throttle Reverse opertion to end the Trim Without Key mode. Trim without key llows trim opertion for up to 15 minutes fter the ignition key switch is turned off. On multiengine pplictions, the trim without key time is mnged seprtely for ech engine. The trim without key period my e ended t ny time y moving the control hndle to Wide Open Throttle Reverse with the key off. Overlod Protection Upper Engine Circuit Breker Pnel If n electricl overlod occurs, fuse will urn out (low) or circuit reker will trip open. Find nd correct the cuse for the electricl overlod efore replcing the fuse or resetting the circuit reker. NOTE: In n emergency, when the engine must e operted nd the cuse for the high current drw cnnot e locted nd corrected, turn off or disconnect ll the ccessories connected to the engine nd instrumenttion wiring. Reset the circuit reker. If the reker remins open, the electricl overlod hs not een eliminted. Further checks must e mde on the electricl system. Contct your Mercury Diesel uthorized repir fcility. 90-8M eng JUNE 2017 Pge 11

20 Section 1 - Getting to Know Your Power Pckge Circuit rekers provide protection for the engine electricl system. The circuit reker pnel is locted eneth smll ccess pnel in the engine cover on top of the engine. Typicl engine cover with ccess pnel - Engine cover - Circuit rekers After finding nd correcting the cuse of the overlod, reset the circuit reker y pressing the reset utton c d e f Circuit rekers viewed from the port side of the engine Reference Circuit reker rting Protection Loction on fuse pnel 20 A Key unswitched power to helm Lower left 10 A Switched power to ECM Upper left c 10 A Key switch to ECM Middle left d 15 A Switched power to ECM Middle right e 15 A ECM switched power to SIM Upper right f 5 A Power dignostic connector Lower right Overlod Protection Port Side Power Distriution Box If n electricl overlod occurs, fuse will urn out (low) or circuit reker will trip open. Find nd correct the cuse for the electricl overlod efore replcing the fuse or resetting the circuit reker. NOTE: In n emergency, when the engine must e operted nd the cuse for the high current drw cnnot e locted nd corrected, turn off or disconnect ll the ccessories connected to the engine nd instrumenttion wiring. The circuit reker should utomticlly reset. If the reker remins open, the electricl overlod hs not een eliminted. Further checks must e mde on the electricl system. Contct your Mercury Diesel uthorized repir fcility. Circuit rekers provide protection for the engine electricl system s indicted. The circuit reker pnel is locted within power distriution ox mounted on the engine control module. Pge M eng JUNE 2017

21 Section 1 - Getting to Know Your Power Pckge After finding nd correcting the cuse of the overlod, connect the strting ttery nd turn the ignition switch to the run position. The circuit reker should utomticlly reset. If circuit reker fils to reset, contct your Mercury Diesel uthorized repir fcility. Port side power distriution ox Vessel Integrtion Pnel (VIP) Overlod Protection A vessel integrtion pnel (VIP) is typiclly mounted in the engine comprtment. The VIP contins three circuit rekers tht help protect system wiring c - Helm circuit reker (10 A) - Ger circuit reker (15 A) c - SIM/Vessel circuit reker (10 A) Power Trim nd MerCthode Overlod Protection If n electricl overlod on the electricl system occurs, fuse will open (low). Find nd correct the cuse efore replcing the fuse. NOTE: If you must operte the engine in n emergency, turn off nd disconnect ll ccessories from the engine nd instrumenttion wiring in n ttempt to isolte the electricl overlod or excessive current drw. Replce the fuse. If the fuse urns out, the electricl overlod hs not een eliminted nd further checks must e mde on the electricl system. Contct your Mercury Diesel uthorized repir fcility. 90-8M eng JUNE 2017 Pge 13

22 Section 1 - Getting to Know Your Power Pckge 1. The power trim system is protected from overlod y 110 mp fuse nd 20 mp in line fuse on the power trim pump mp in line fuse holder mp fuse The MerCthode system hs fuse connected to the positive (+) terminl on the controller. If the fuse is open (lown), the system will not operte, resulting in loss of corrosion protection. Replce the fuse with one of the sme mp rting. - MerCthode - Red/purple wire c - Fuse c Engine Gurdin System The Engine Gurdin system monitors the criticl sensors on the engine for ny erly indictions of prolems. Engine Gurdin is functionl whenever your engine is operting, so you never hve to e concerned out whether or not you re protected. The system will respond to prolem y sounding the wrning horn for six seconds nd/or reducing engine power in order to provide engine protection. If Engine Gurdin hs een ctivted, reduce the engine speed. The prolem will need to e identified nd corrected. The system must e reset efore the engine will operte t higher speeds. Moving the throttle lever ck to the idle position will reset the Engine Gurdin system. If the Engine Gurdin system hs determined the reset hs not corrected the prolem, Engine Gurdin will remin ctivted, limiting the throttle. The prolem must e identified nd corrected efore Engine Gurdin will llow the engine to rech norml operting RPM. SeCore Equipped Drives SeCore Components nd Cstings Mercury MerCruiser SeCore power pckges re equipped with dditionl stinless steel components nd prticulr luminum cstings with specil cotings. Do not replce SeCore components with non SeCore. Use only the specified Mercury MerCruiser SeCore components nd cstings on these power pckges. Stinless Steel Fsteners SeCore models re equipped with dditionl stinless steel fsteners to mximize corrosion resistnce in sltwter environments. Pge M eng JUNE 2017

23 Section 1 - Getting to Know Your Power Pckge Stinless steel fsteners re suject to glling when instlled without luriction. Glling cn result in fstener destruction, improper clmp lods, or oth. Glled fsteners my pper to torque properly, ut still hve incorrect clmp lods. Apply luricnt 2 4 C with PTFE or n equivlent, on the threds of stinless steel fsteners during instlltion to void glling. Luricte t lest the first 8 mm (1/4 in.) of the threds efore instlltion. Tue Ref No. Description Where Used Prt No C with PTFE Threds of stinless steel fsteners A M eng JUNE 2017 Pge 15

24 Section 1 - Getting to Know Your Power Pckge Notes: Pge M eng JUNE 2017

25 Tle of Contents Sfe Boting Recommendtions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Importnt Opertion Informtion Lunching Duty Cycle Rting Requirements...20 High Output Rting Opertion Chrt Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump...22 Trilering the Bot Strting, Shifting, nd Stopping Before Strting the Engine...22 Importnt Informtion SmrtStrt Strting Cold Engine Engine Wrm Up Strting Wrm Engine...23 Shifting Engine Shut Down (Stopping) Strting the Engine After Stopped While in Ger Protecting People in the Wter While You Are Cruising Section 2 - On the Wter Section 2 - On the Wter While Bot Is Sttionry High Speed nd High Performnce...25 Pssenger Sfety In Pontoon Bots nd Deck Bots Bots Hving An Open Front Deck Bots With Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Sterndrive Impct Protection Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection...28 Getting Strted Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers)...28 Engine Brek In Hour Brek In Period After the 20 Hour Brek In Period End of First Seson Checkup M eng JUNE 2017 Pge 17

26 Section 2 - On the Wter Sfe Boting Recommendtions To sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl oting regultions nd restrictions nd consider the following suggestions. Know nd oey ll nuticl rules nd lws of the wterwys. We recommend tht ll powerot opertors complete oting sfety course. In the U.S., the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil oting lw enforcement gency provide courses. For more informtion in the U.S., cll the Bot U.S. Foundtion t BOAT (2628). Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment onord. Here re some suggestions of the types of sfety equipment to crry when oting: Approved fire extinguishers Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Tools necessry for minor repirs Anchor nd extr nchor line Mnul ilge pump nd extr drin plugs Drinking wter Rdio Pddle or or Spre propeller, thrust hus, nd n pproprite wrench First id kit nd instructions Wterproof storge continers Spre operting equipment, tteries, uls, nd fuses Compss nd mp or chrt of the re Personl flottion device (one per person onord) Wtch for signs of wether chnge nd void foul wether nd rough se oting. Tell someone where you re going nd when you expect to return. Pssenger ording. Stop the engine whenever pssengers re ording, unloding, or re ner the ck (stern) of the ot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl lw requires tht there e U.S. Cost Gurd pproved life jcket (personl flottion device), correctly sized nd redily ccessile for every person onord, plus throwle cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the ot. Prepre other ot opertors. Instruct t lest one person onord in the sics of strting nd operting the engine nd ot hndling in cse the driver ecomes disled or flls overord. Do not overlod your ot. Most ots re rted nd certified for mximum lod (weight) cpcities (refer to your ot's cpcity plte). Know your ot's operting nd loding limittions. Know if your ot will flot if it is full of wter. When in dout, contct your uthorized Mercury Mrine deler or the ot mnufcturer. Ensure tht everyone in the ot is properly seted. Do not llow nyone to sit or ride on ny prt of the ot tht ws not intended for such use. This includes the cks of sets, gunwles, trnsom, ow, decks, rised fishing sets, nd ny rotting fishing set. Pssengers should not sit or ride nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of ot control, or sudden ot movement could cuse person to e thrown overord or into the ot. Ensure tht ll pssengers hve proper set nd re in it efore ny ot movement. Never operte ot while under the influence of lcohol or drugs. It is the lw. Alcohol or drugs cn impir your judgment nd gretly reduce your ility to rect quickly. Know your oting re nd void hzrdous loctions. Pge M eng JUNE 2017

27 Be lert. Section 2 - On the Wter The opertor of the ot is responsile y lw to mintin proper lookout y sight nd hering. The opertor must hve n unostructed view prticulrly to the front. No pssengers, lod, or fishing sets should lock the opertor's view when the ot is ove idle or plning trnsition speed. Wtch out for others, the wter, nd your wke. Never drive your ot directly ehind wter skier. Your ot trveling t 40 km/h (25 mph) will overtke fllen skier who is 61 m (200 ft) in front of you in five seconds. Wtch fllen skiers. When using your ot for wterskiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the ot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never ck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required y lw to file oting ccident report with their stte oting lw enforcement gency when their ot is involved in certin oting ccidents. A oting ccident must e reported if 1) there is loss of life or prole loss of life, 2) there is personl injury requiring medicl tretment eyond first id, 3) there is dmge to ots or other property where the dmge vlue exceeds $500.00, or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Cron monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl comustion engines, including the engines tht propel ots, nd the genertors tht power ot ccessories. By itself, CO is odorless, colorless, nd tsteless, ut if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of cron monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse.! WARNING Inhling engine exhust gses cn result in cron monoxide poisoning, which cn led to unconsciousness, rin dmge, or deth. Avoid exposure to cron monoxide. Sty cler from exhust res when engine is running. Keep the ot well ventilted while t rest or underwy. Sty Cler of Exhust Ares co co co co co co co co co co co co co co co co co co co co Engine exhust gses contin hrmful cron monoxide. Avoid res of concentrted engine exhust gses. When engines re running, keep swimmers wy from the ot, nd do not sit, lie, or stnd on swim pltforms or ording ldders. While underwy, do not llow pssengers to e positioned immeditely ehind the ot (pltform drgging, tek/ody surfing). This dngerous prctice not only plces person in n re of high engine exhust concentrtion, ut lso sujects them to the possiility of injury from the ot propeller. Good Ventiltion Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the ot: M eng JUNE 2017 Pge 19

28 Section 2 - On the Wter Poor Ventiltion Under certin running or wind conditions, permnently enclosed or cnvs enclosed cins or cockpits with insufficient ventiltion my drw in cron monoxide. Instll one or more cron monoxide detectors in your ot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry ot tht contins or is ner running engine my e exposed to hzrdous level of cron monoxide. 1. Exmples of poor ventiltion while the ot is sttionry: - Operting the engine when the ot is moored in confined spce - Mooring close to nother ot tht hs its engine operting 2. Exmples of poor ventiltion while the ot is moving: Operting the ot with the trim ngle of the ow too high - Operting the ot with no forwrd htches open (sttion wgon effect) Importnt Opertion Informtion Lunching IMPORTANT: Instll the ilge drin plug efore lunching the ot. Duty Cycle Rting Requirements IMPORTANT: Dmge cused y incorrect ppliction or filure to operte the power pckge within the specified operting prmeters will not e covered y the Mercury Mrine Limited Wrrnty. Mercury Diesel engines must e used in pplictions tht meet the opertion specifictions indicted y Mercury Diesel product ppliction engineer. The power pckge must e equipped with ger rtio nd propeller tht llows the engine to operte t wide open throttle (WOT) t the engine's rted speed (RPM). Use of Mercury Diesel engines in pplictions tht do not meet specified opertionl prmeters is not pproved. High Output Rting A high output rting pplies to plesure (nonrevenue generting) pplictions tht operte 500 hours or less per yer, where full power is limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion must e t or elow cruise speed (RPM). Cruise speed is dependnt on the engine's mximum rted speed (RPM). Pge M eng JUNE 2017

29 Section 2 - On the Wter Opertion Chrt Strting Procedure After Strting While Underwy Stopping nd Shut Down Open the engine htch. Air out the ilge completely. Turn the ttery switch on, if equipped. Turn on nd run the engine comprtment ilge lower, if equipped, for five minutes. Check for leks: fuel, oil, wter, fluid, etc. Open the fuel shut off vlve, if equipped. Open the secock, if equipped. Prime the fuel injection system, if necessry. Turn the key switch to "START" position. Relese the key when the engine strts. Wrm up the engine t fst idle RPM for severl minutes. Oserve ll instrumenttion to monitor the condition of the engine. If not norml, stop the engine. Check for fuel, oil, wter, fluid, nd exhust leks, etc. Check shift nd throttle control opertion. Check steering opertion. Freezing Temperture nd Cold Wether Opertion Frequently review ll instrumenttion to monitor engine condition. Listen for the udio lrm. Shift the remote control lever to the neutrl position. Run the engine t idle RPM for severl minutes to llow the turochrger nd engine to cool. Turn the key switch to "OFF" position. Turn the ttery switch off, if equipped. Close the fuel shut off vlve, if equipped. Close the secock, if equipped. Flush the sewter cooling circuit, if operting in sltwter, rckish wter, or polluted wter. IMPORTANT: If the ot is operted during periods of freezing temperture, tke precutions to prevent freezing dmge to the power pckge. Dmge cused y freezing is not covered y the Mercury Mrine Limited Wrrnty. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the ot reminding the opertor to open the secock or unplug nd connect the wter inlet hose efore strting the engine. In order to operte the engine in tempertures of 0 C (32 F) or lower, oserve the following instructions: At the end of ech dily opertion, completely drin the sewter section of the cooling system to protect ginst dmge y freezing. At the end of ech dily opertion, drin the wter from the wter seprtor, if equipped. Fill the fuel tnk t the end of dily opertion to prevent condenstion. Use the required permnent type ntifreeze solution to protect components ginst dmge y freezing. Use proper cold wether luriction oil; ensure tht the crnkcse contins sufficient mount. Mke certin tht the ttery is of sufficient size nd is fully chrged. Check tht ll other electricl equipment is in optimum condition. At tempertures of 20 C ( 4 F) nd elow, use coolnt heter to improve cold strting. If operting in rctic tempertures of 29 C ( 20 F) or lower, consult your Mercury Diesel uthorized repir fcility for informtion out specil cold wether equipment nd precutions. Refer to Storge for cold wether or extended storge relted informtion. 90-8M eng JUNE 2017 Pge 21

30 Section 2 - On the Wter Drin Plug nd Bilge Pump The engine comprtment in your ot is nturl plce for wter to collect. For this reson, ots re normlly equipped with drin plug or ilge pump. It is importnt to check these items on regulr sis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will e dmged if sumerged. Dmge cused y sumersion is not covered y the Mercury Mrine Limited Wrrnty. Trilering the Bot Your ot cn e trilered with the sterndrive in the up (out) or down (in) position. Adequte clernce is required etween the rod nd sterndrive when trnsporting. If dequte rod clernce is prolem, plce the sterndrive in full triler position nd support it with n optionl triler kit, which is ville from your Mercury Mrine uthorized repir fcility. Strting, Shifting, nd Stopping! WARNING Vpors cn ignite nd cuse n explosion, resulting in engine dmge or severe personl injury. Do not use voltile strting ids such s ether, propne, or gsoline in the engine ir intke system.! WARNING Fuel vpors trpped in the engine comprtment my e n irritnt, cuse difficulty rething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment efore servicing the power pckge. Before Strting the Engine NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. IMPORTANT: Oserve the following efore strting: If running the engine with the ot out of the wter, provide wter to oth the engine nd sterndrive sewter pickup pumps. Refer to Section 4 Flushing the Sewter System. Trim the sterndrive to the full down (in) position. Ensure tht the engine crnkcse is filled to the correct level with the specified engine oil. Refer to Section 3 Specifictions Engine Oil. Ensure ll electricl connections re secure. Check ll items listed in Section 4 Mintennce Schedules nd the Opertion Chrt. Perform ny other necessry procedures s indicted y your deler or Mercury Diesel uthorized repir fcility. Importnt Informtion SmrtStrt IMPORTANT: This power pckge is equipped with SmrtStrt. SmrtStrt performs ll pproprite strting opertions upon initil strt switch ctution. To egin the SmrtStrt sequence, turn the ignition key switch to the "START" position nd relese, or turn the ignition key switch to the run position nd press nd relese the strt/stop switch, if equipped. SmrtStrt controls the strting process utomticlly. When the strt switch is ctuted, the system signls the engine's electronic controller to strt the engine. The strter will receive power until the engine strts nd will time out fter few seconds, or when the engine reches 400 RPM. Attempting to strt the engine with the engine running will turn the engine off. Strting Cold Engine! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. NOTE: Check the fluid levels efore strting the engine. Refer to Section 4 Mintennce Schedule. IMPORTANT: Mercury Mrine DTS nd Axius models re equipped with SmrtStrt. SmrtStrt fetures push nd relese strting. The PCM completely controls the strting process fter it receives strt commnd from the ignition key or strt utton. The strting process will time out if the engine does not strt fter few seconds or when crnking speed reches 400 RPM. Attempting to strt the engine with the engine lredy running will turn the engine off. 1. Turn on nd run the engine comprtment ilge lower (if equipped) for five minutes. Or, open the engine htch to ir out the ilge efore ttempting to strt the engine. Pge M eng JUNE 2017

31 2. Plce the control hndle in neutrl. Section 2 - On the Wter NOTE: If the engine hs not een run for period of time nd will not redily strt with the stndrd strting procedure, use the fuel primer locted on the fuel filter heder. Cycle the primer plunger up nd down four or five strokes then ttempt to strt the engine. 3. Turn the ignition key to the "RUN" position. 4. Turn the ignition key switch to the "START" position then relese, or press the strt/stop utton nd relese. If the engine is cold, llow the engine to operte t idle for 6 10 minutes or until the engine reches norml operting temperture. IMPORTANT: Engine oil pressure should exceed 69 kp (10 psi) within seconds of strting the engine. Stop the engine if the engine oil pressure does not meet this specifiction. Locte nd correct the prolem. If you re unle to correct the prolem, see Mercury Diesel uthorized repir fcility. 5. Ensure ll instrumenttion is functioning properly nd indicting norml redings. Engine Wrm Up NOTICE Engine wer cused y incresed friction nd limited oil flow is gretest when n engine is cold. Decrese engine wer y llowing the engine coolnt temperture to rech norml operting rnge efore hrd ccelertion or pplying full throttle. 1. After strting, ensure tht ll instrumenttion is functioning properly. 2. Operte the engine t 1,000 to 1,200 RPM until the engine temperture is within the norml operting rnge. It is very importnt tht ny engine e wrmed up efore pplying full lod. The wrm up period provides time for the luricting oil to estlish film etween moving prts. NOTE: Engine wrm up time during cold wether cn e reduced y operting the vessel t reduced engine speed. Begin norml vessel opertion when systems rech operting tempertures. 3. After the engine hs reched operting temperture:. The oil pressure should e within the rnge specified. Refer to Section 3 Specifictions Engine Specifictions. Stop the engine if the oil pressure is not within the rnge specified.. Check the fuel system for lekge from the injection pump, fuel pipes, fuel filter, or fuel lines. c. Check for oil lekge. Check the engine nd the sterndrive for oil lekge. Especilly check the oil filter, oil lines, oil line connectors, nd oil pn. d. Check for coolnt leks. Check the coolnt hoses nd connection pipes of the het exchnger, fluid coolers, ftercooler, wter pump, nd drin fittings. 4. Locte nd correct ny prolems, or see your Mercury Diesel uthorized repir fcility if you re unle to determine the prolem. Strting Wrm Engine! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. NOTE: Check the fluid levels efore strting the engine. Refer to Section 4 Mintennce Schedule. IMPORTANT: Mercury Mrine SmrtCrft equipped models feture push nd relese strting. The PCM completely controls the strting process fter it receives strt commnd from the ignition key or strt utton. The strting process will time out if the engine does not strt fter few seconds or when crnking speed reches 400 RPM. Attempting to strt the engine with the engine lredy running will turn the engine off. 1. Turn on nd run the engine comprtment ilge lower (if equipped) for 5 minutes. Or, open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Plce the control hndle in neutrl. 3. Turn the ignition key to the "RUN" position. 4. Turn the ignition key switch to the "START" position then relese, or depress the strt/stop utton nd relese. IMPORTANT: Stop the engine if the oil pressure does not exceed 69 kp (10 psi) within seconds of strting the engine. Stop the engine if the engine oil pressure does not meet this specifiction. Locte nd correct the prolem. If you re unle to correct the prolem, see Mercury Diesel uthorized repir fcility. 5. Ensure tht ll instrumenttion is functioning properly nd indicting norml redings. 90-8M eng JUNE 2017 Pge 23

32 Section 2 - On the Wter Shifting NOTICE Shifting into ger t engine speeds ove idle will dmge the drive system. Shift the drive into ger only when the engine is operting t idle. NOTICE Filure to rotte the propeller shft when shifting gers or forcing the shift mechnism while the engine is not operting cn result in product dmge. If you must shift gers with the engine off, mnully rotte the propeller shft in the pproprite direction. 1. Ensure tht the remote control shift lever is in neutrl. 2. To shift the sterndrive, move the remote control shift lever with firm, quick motion forwrd to shift to forwrd ger, or ckwrd to shift to reverse. 3. After shifting the sterndrive, dvnce the throttle to the desired setting. IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, refer to the following procedure:. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting ove idle RPM when the engine stopped.. After the hndle returns to the neutrl detent position, resume norml strting procedures. Engine Shut Down (Stopping) 1. Plce the remote control lever in neutrl. NOTICE Immeditely stopping the engine fter high lod opertion cn dmge the turochrger erings. Idle the engine for severl minutes efore shutdown. 2. Operte the engine t idle speed for severl minutes to llow the turochrger nd engine to cool. 3. Turn the key switch to the "OFF" position or press the strt stop switch utton if equipped. Strting the Engine After Stopped While in Ger IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, see the following procedure: 1. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting ove idle RPM when the engine stopped. 2. After the hndle returns to the neutrl detent position, resume norml strting procedures. Protecting People in the Wter While You Are Cruising It is very difficult for person in the wter to tke quick ction to void ot heding in their direction, even t slow speeds Alwys slow down nd exercise extreme cution ny time you re oting in n re where there might e people in the wter. Whenever ot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force y the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. While Bot Is Sttionry! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. Pge M eng JUNE 2017

33 Section 2 - On the Wter Shift into neutrl nd shut off the engine efore llowing people to swim or e in the wter ner your ot. High Speed nd High Performnce If your ot is considered high speed or high performnce ot, we recommend tht you never operte it t its high speed cpility without first requesting n initil orienttion nd demonstrtion ride with your deler or n opertor experienced with your ot. For dditionl informtion, refer to the Hi Performnce Bot Opertion ooklet from your Mercury Diesel uthorized repir fcility. Pssenger Sfety In Pontoon Bots nd Deck Bots Whenever the ot is in motion, oserve the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in ot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of ot direction, could throw them over the front of ot. Flling over the front of the ot etween the two pontoons will position them to e run over. Bots Hving An Open Front Deck No one should ever e on the deck in front of the ril while the ot is in motion. Keep ll pssengers ehind the front ril or enclosure. Persons on the front deck could esily e thrown overord or persons dngling their feet over the front edge could get their legs cught y wve nd pulled into the wter. mc ! WARNING Sitting or stnding in n re of the ot not designed for pssengers t speeds ove idle cn cuse serious injury or deth. Sty ck from the front end of deck ots or rised pltforms nd remin seted while the ot is in motion. Bots With Front-Mounted, Rised Pedestl Fishing Sets Elevted fishing sets re not intended for use when the ot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Any unexpected, sudden reduction in ot speed could result in the elevted pssenger flling over the front of the ot. mc Wve nd Wke Jumping! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts eing thrown within or out of the ot. Avoid wve or wke jumping whenever possile. mc M eng JUNE 2017 Pge 25

34 Section 2 - On the Wter Operting recretionl ots over wves nd wkes is nturl prt of oting. However, when this ctivity is done with enough speed to force the ot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the ot reenters the wter. The primry concern is the ot chnging direction while in the midst of the jump. In such cses the lnding my cuse the ot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to e thrown out of their sets or out of the ot. There is nother less common hzrdous result from llowing your ot to lunch off of wve or wke. If the ow of your ot pitches down fr enough while irorne, upon wter contct it my penetrte under the wter surfce nd sumrine for n instnt. This will ring the ot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The ot my lso veer shrply to one side. Impct with Underwter Hzrds Reduce speed nd proceed with cution whenever you're driving ot in shllow wter or in res where the wters re suspected of hving underwter ostcles tht could e struck y the underwter drive components, rudder, or the ot ottom. mc IMPORTANT: The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter oject is control the ot speed. Under these conditions, ot speed should e kept to mximum speed of 24 to 40 km/h (15 to 25 mph). The following demonstrte some, ut not ll, exmples of wht cn hppen if the ot strikes n oject: The ot could move suddenly in new direction. Such shrp chnge in direction or turn cn throw occupnts out of their sets or out of the ot. A rpid reduction in speed. This will cuse occupnts to e thrown forwrd, even out of the ot. Impct dmge to the underwter drive components, rudder, or ot. Keep in mind tht one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the ot speed. Bot speed should e kept to minimum plning speed when driving in wters known to hve underwter ostcles. After striking sumerged oject, stop the engine s soon s possile nd inspect the drive system for ny roken or loose prts. If dmge is present or suspected, the power pckge should e tken to n uthorized Mercury Diesel repir fcility for thorough inspection nd ny necessry repir. The ot should e checked for hull frctures, trnsom frctures, nd wter leks. Operting with dmged underwter drive components, rudder, or ot ottom could cuse dditionl dmge to other prts of the power pckge, or could ffect control of the ot. If continued opertion is necessry, do so t gretly reduced speeds.! WARNING Operting ot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Sterndrive Impct Protection The power trim hydrulic system is designed to provide impct protection for the sterndrive. If sumerged oject is struck while the ot is moving forwrd, the hydrulic system will cushion the kickup of the sterndrive s it clers the oject, reducing dmge to the sterndrive. After the sterndrive hs clered the oject, the hydrulic system llows the sterndrive to return to its originl operting position, preventing loss of steering control nd engine overspeed. Use extreme cution when operting in shllow wter or where underwter ojects re known to e present. No impct protection is provided in reverse; use extreme cre to prevent striking sumerged ojects while operting in reverse. IMPORTANT: Impct protection system cnnot e designed to ensure totl protection from impct dmge under ll conditions. Pge M eng JUNE 2017

35 Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Shifting weight to rer (stern): Generlly increses speed nd engine RPM Cuses ow to ounce in choppy wter Increses dnger of following wve splshing into the ot when coming off plne At extremes, cn cuse the ot to porpoise Shifting weight to front (ow): Improves ese of plning Improves rough wter ride At extremes, cn cuse the ot to veer ck nd forth (ow steer) Bottom of Bot To mintin mximum speed, ensure tht the ot ottom is: Clen, free of rncles nd mrine growth. Free of distortion, nerly flt where it contcts wter. Stright nd smooth, fore nd ft. Section 2 - On the Wter Mrine vegettion my ccumulte when the ot is docked. This growth must e removed efore opertion; it my clog wter inlets nd cuse the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter oject, such s ger housing or propeller. Cvittion increses propeller speed while reducing ot speed. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other deris sngged on the propeller Bent propeller lde Rised urrs or shrp edges on the propeller Ventiltion Ventiltion is cused y surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in ot speed. Air ules strike the propeller lde nd cuse erosion of the lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Excessive ventiltion is usully cused y: Drive unit trimmed out too fr A missing propeller diffuser ring A dmged propeller or ger housing, which llows exhust gses to escpe etween propeller nd ger housing Drive unit instlled too high on trnsom Elevtion nd Climte NOTE: Engines equipped with n Engine Control Module (ECM) reduce the effects of chnges in elevtion nd climte y utomticlly djusting fuel flow for wether conditions nd elevtion. ECM controlled engines, however, do not compenste for incresed loding or hull conditions. Elevtion nd climte chnges ffect the performnce of your power pckge. Loss of performnce cn e cused y: High elevtions High tempertures Low rometric pressures High humidity For optimum engine performnce under chnging wether conditions nd high elevtion, use propeller tht llows the engine to operte t rted RPM t wide open throttle (WOT) with mximum ot lod during your norml oting. In most cses, the rted RPM t WOT cn e chieved y chnging to lower pitch propeller. 90-8M eng JUNE 2017 Pge 27

36 Section 2 - On the Wter Propeller Selection NOTICE Operting the engine with the wrong propeller instlled cn limit power, increse fuel consumption, overhet the engine, or cuse internl powerhed dmge. Choose propeller tht llows the engine to operte t the specified wide open throttle RPM. The ot mnufcturer nd the selling deler re responsile for equipping the power pckge with the correct propellers. IMPORTANT: The engines covered in this mnul re equipped with n ECM tht limits engine RPM. Be sure tht the propeller eing used does not llow the engine to run ginst the limiter, s significnt loss in performnce will result. NOTE: Use n ccurte service tchometer to verify RPM. Select propeller tht will llow the engine power pckge to operte t the rted engine RPM with mximum lod. If full throttle opertion is elow the engine rted RPM, the propeller must e chnged to prevent loss of performnce nd possile engine dmge. On the other hnd, operting n engine ove the rted engine RPM will cuse higher thn norml wer or dmge. After initil propeller selection, the following common prolems my require tht the propeller e chnged to lower pitch: Wrmer wether nd greter humidity cuse n RPM loss (not s significnt on these models). Operting in higher elevtion cuses n RPM loss (not s significnt on these models). Operting with dmged propeller or dirty ot ottom cuses n RPM loss. Operting with incresed lod (dditionl pssengers, pulling skiers). For etter ccelertion, such s is needed for wterskiing, use the next lower pitch propeller. Do not operte t full throttle when using the lower pitch propeller ut not pulling skiers. Getting Strted Initil Brek In Procedure It is importnt to follow this procedure to properly rek in the engine. IMPORTANT: Mercury Mrine recommends tht the ot not e ccelerted hrd until this procedure hs een completed. IMPORTANT: Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit one minute to llow the strter motor to cool; then, repet the strting procedure. 1. Refer to the pproprite Strting, Shifting, nd Stopping section nd strt the engine. 2. Operte the engine t fst idle until it hs reched norml operting temperture. 3. Operte the engine in ger for three minutes t ech of the following: 1200 RPM, 2400 RPM, nd 3000 RPM. 4. Operte the engine in ger for three minutes t ech of the following: 1500 RPM, 2800 RPM, nd 3400 RPM. 5. Operte the engine in ger for three minutes t ech of the following: 1800 RPM, 3000 RPM, nd mximum rted full throttle RPM. Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) It is importnt tht the following procedure e used on new sterndrives nd reuilt sterndrives with new replcement gers. This rek in procedure llows the proper seting of the sterndrive gers nd relted components, which gretly reduces the likelihood of prolems. Avoid full throttle strts. Do not operte t ny one constnt speed for extended periods of time. Do not exceed 75% of full throttle during the first 5 hours. During the next 5 hours, operte t intermittent full throttle. The sterndrive should e shifted into forwrd ger minimum of 10 times during rek in, with run in time t moderte RPM fter ech shift. Engine Brek In 20-Hour Brek-In Period IMPORTANT: The first 20 hours of opertion re considered to e the engine rek in period. Correct rek in is essentil to otin minimum oil consumption nd mximum engine performnce. During this rek in period, oserve the following rules: Do not operte elow 1500 RPM for extended periods of time for the first 10 hours. Shift into ger s soon s possile fter strting, nd dvnce the throttle ove 1500 RPM if conditions permit sfe opertion. Do not operte t one constnt speed for extended periods. Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occsionl opertion t full throttle is permissile (five minutes t time mximum). Pge M eng JUNE 2017

37 Section 2 - On the Wter Avoid full throttle ccelertion from idle speed. Do not operte t full throttle until the engine reches norml operting temperture. Check the engine oil level frequently. Add oil s needed. High oil consumption is norml during the rek in period. After the 20-Hour Brek-In Period To help extend the life of your power pckge, Mercury Mrine recommends the following: Chnge the engine oil nd filter nd the trnsmission fluid t the intervl indicted in the Mintennce Schedule. Refer to Specifictions nd Mintennce. Use propeller tht llows the engine to operte t the rted engine RPM when t full throttle with fully loded ot. Refer to Specifictions nd Mintennce. Opertion t 3/4 throttle setting or lower is recommended. Refrin from prolonged opertion t wide open throttle RPM. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized repir fcility to discuss or perform scheduled mintennce items. If you re in n re where the product is operted continuously, yer round, you should contct your deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. 90-8M eng JUNE 2017 Pge 29

38 Section 2 - On the Wter Notes: Pge M eng JUNE 2017

39 Tle of Contents Section 3 - Specifictions Section 3 - Specifictions Fuel Requirements Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions L Specifiction L Specifiction Fluid Specifictions Engine L L Brvo Sterndrive Fluid Specifictions Diesel Power Assisted Steering nd Power Trim Fluids Approved Power Assisted Steering Fluids Approved Power Trim Fluids Approved Pints M eng JUNE 2017 Pge 31

40 Section 3 - Specifictions Fuel Requirements! WARNING Filure to comply with regultions cn result in injury from fire or explosion. Electricl system components on this engine re not rted s externl ignition protected (EIP). Do not store or use gsoline on ots equipped with these engines, unless provisions hve een mde to exclude gsoline vpors from the engine comprtment (REF: 33 CFR).! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement efore further engine opertion.! WARNING This engine requires diesel fuel. Mixing gsoline, gsohol, or lcohol nd diesel fuel cn cuse serious injury or deth due to fire or explosion. Never mix gsoline, gsohol, or lcohol with diesel fuel. IMPORTANT: Use of improper or wter contminted diesel fuel cn seriously dmge your engine. Use of improper fuel is considered misuse of the engine, nd dmge cused therey will not e covered y the wrrnty. Mercury diesels re required to use grde 2 D ULSD (ultr low sulphur diesel) fuel meeting ASTM Stndrds D975 (or fuel rted Diesel DIN EN 590), nd hving minimum cetne rting of 51. BIODIESEL: The lend of diesel fuel used my not contin more thn 7% iodiesel fuel. Use of LSD or lends of ULSD fuel contining more thn 7% iodiesel fuel my result in fuel system degrdtion, injection nozzle clogging, hrd strting, incresed oil chnge intervls, or excessive exhust smoke. The cetne numer is mesure of the ignition qulity of diesel fuel. Incresing the cetne numer will not improve overll engine performnce, ut it my e necessry to rise the cetne rting for low temperture or high ltitude use. A lower cetne numer could cuse hrd strting nd slower wrm up, nd could increse engine noise nd exhust emissions. NOTE: If your engine suddenly ecomes noisy fter fill up, you possily received sustndrd fuel with low cetne rting. On engines tht use high sulphur content diesel fuel, this will gretly increse: Corrosion on metl prts Deteriortion of elstomer nd plstic prts Excessive wer of internl engine prts, prticulrly erings, nd corrosion nd extensive dmge to other engine prts Difficulty strting nd operting the engine Diesel Fuel in Cold Wether Unltered diesel fuels thicken nd gel in cold tempertures unless treted. Virtully ll diesel fuels re climtized to llow their use in the prticulr region for tht time of the yer. If it ecomes necessry to further tret diesel fuel, it is the owner/opertor's responsiility to dd commercil stndrd rnd of ntigel diesel fuel dditive, following tht product's directions. Antifreeze/Coolnt NOTICE Using propylene glycol ntifreeze in the closed cooling system cn dmge the cooling system or the engine. Fill the closed cooling system with n ethylene glycol ntifreeze solution suitle to the lowest temperture to which the engine will e exposed. Diesel engines re high compression engines tht operte t higher tempertures thn typicl internl comustion engines. Therefore, the closed cooling system nd engine, including relted cooling pssges, must remin s clen s possile to provide dequte engine cooling. To ensure proper cooling, we recommend filling the closed cooling section of the cooling system with low silicte formul of ethylene glycol ntifreeze in solution with deionized wter. Common tp wter or softened wter contins unwnted minerls tht cn leve lrge deposits in the system tht restrict the cooling system efficiency. A low silicte formul prevents the ntifreeze from seprting nd forming silicte geltin. This geltin cn lock pssges in the engine nd het exchnger, cusing the engine to overhet. Only premixed coolnt should e dded to the closed cooling system. Additives nd inhiitors introduced into cceptle coolnt solutions will form protective film on the internl pssges nd provide protection ginst internl cooling system erosion. Pge M eng JUNE 2017

41 Section 3 - Specifictions Do not drin the closed cooling section for storge. The closed cooling section should e kept filled yer round with n cceptle ntifreeze/coolnt solution to void rust forming on the internl surfces. If the engine will e exposed to freezing tempertures, ensure tht the closed cooling section is filled with properly mixed ntifreeze/coolnt solution to protect the engine nd closed cooling system to the lowest temperture to which they will e exposed. NOTE: It is recommended tht 50/50 solution of coolnt (ntifreeze) nd deionized, purified wter e used. A 50/50 solution will provide freeze protection to 35 C ( 31 F). Decresing the solution to 40/60 will provide freeze protection to 25 C ( 13 F). Even in the wrmest climtes, never decrese the solution elow 40/60. Incresing the solution to 60/40 will provide freeze protection to 50 C ( 58 F). IMPORTANT: The ntifreeze/coolnt used in these mrine engines must e low silicte ethylene glycol, contining specil dditives, nd deionized, purified wter. Using other types of engine coolnt my cuse fouling of the het exchngers nd overheting of the engine. Do not comine different types of coolnts without knowing tht they re comptile. Refer to the coolnt mnufcturer's instructions. The cceptle ntifreeze/coolnts is listed in the following tle. Refer to Section 4 Mintennce for respective chnge intervls. Tue Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/Coolnt Closed-cooling system K1 Engine Oil NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. To help otin optimum engine performnce nd to provide mximum protection, the engine requires engine oil with rting of HD SAE API CG 4 nd CH 4. We strongly recommend the use of: Tue Ref No. Description Where Used Prt No W-40 4-Cycle Diesel Engine Oil Engine crnkcse K01 This oil is specilly lended 15W 40 oil with mrine dditives for ll temperture opertion. It exceeds requirements for API CF 2, CF 4, CG 4, nd CH 4 oils. Other recommended oils: Description Where Used Prt Numer Shell Myrin Mopr Texco Urs Super TD Wintershll Multi Rekord Veedol Turostr Wintershll VIiv 1 Engine crnkcse Otin Loclly These oils re pproved y Mercury Mrine nd Mrine Power Europe. For ll temperture opertion use 15W 40 oil. 90-8M eng JUNE 2017 Pge 33

42 Section 3 - Specifictions Engine Specifictions 2.8L Specifiction Engine type Displcement Description Specifictions In line 4 cylinder diesel 2.8 L (169 cid) Horsepower 220 Kilowtts 162 Firing order Bore Stroke 94 mm (3.700 in.) 100 mm (3.937 in.) Rted engine RPM 3800 Idle RPM in neutrl (engine t norml operting temperture) 700 Oil pressure t idle Oil pressure t 3800 RPM 2.4 r (240 kp [35 psi]) 6.2 r (620 kp [87 psi]) Thermostt (wter) 83 C (181 F) Thermostt (oil) 95 C (203 F) Coolnt temperture C ( F) Electricl system Alterntor rting Recommended ttery rting 4.2L Specifiction Engine type Displcement Description 12 volt negtive ( ) ground 1540 W, 14 V, 110 A 750 CCA, 950 MCA, or 180 Ah Specifictions In line 6 cylinder diesel 4.2 L (254 cid) Horsepower Kilowtt Firing order Bore Stroke 94 mm (3.700 in.) 100 mm (3.937 in.) Rted engine RPM 3800 Idle RPM in neutrl (engine t norml operting temperture) Oil pressure t idle Oil pressure t 3800 RPM r (210 kp [30 psi]) 6.6 r (660 kp [93 psi]) Thermostt (wter) 89 C (192 F) Thermostt (oil) 87 C (187 F) Coolnt temperture C ( F) Electricl system Alterntor rting Recommended ttery rting Fluid Specifictions IMPORTANT: All cpcities re pproximte fluid mesures. Engine 12 volt negtive ( ) ground 1540 W, 14 V, 110 A 750 CCA, 950 MCA, or 180 Ah IMPORTANT: You my need to djust oil levels depending on the instlltion ngle nd cooling systems (het exchnger nd fluid lines). Alwys use the dipstick to determine the exct quntity of oil or fluid required. Pge M eng JUNE 2017

43 Section 3 - Specifictions 2.8L All models Cpcity liters (US qt) Fluid Type Prt Numer Engine oil (with filter) 8.9 (9.4) 15W 40 4 cycle Diesel Engine Oil K01 Closed cooling system 11 (11.6) Mercury Extended Life Antifreeze K1 4.2L All models Cpcity liters (US qt) Fluid Type Prt Numer Engine oil (with filter) 13.8 (14.6) 15W 40 4 cycle Diesel Engine Oil K01 Closed cooling system (18.2) Mercury Extended Life Antifreeze K1 Brvo Sterndrive Fluid Specifictions Diesel Sterndrive Model Fluid Cpcity includes the Sterndrive nd the Gerlue Monitor Fluid Type Fluid Prt Numer Brvo One X Diesel Brvo One XR Brvo Two X Diesel Brvo Three X Diesel Brvo Three XR 2736 ml (92 1/2 oz) 3209 ml (108 1/2 oz) 2972 ml (100 1/2 oz) High Performnce Ger Luricnt K01 Power Assisted Steering nd Power Trim Fluids Approved Power-Assisted Steering Fluids Description Prt Numer Power Trim nd Steering Fluid K01 Approved Power Trim Fluids Description Prt Numer Power Trim nd Steering Fluid K01 SAE Engine Oil 10W 30 SAE Engine Oil 10W 40 Otin loclly Approved Pints Description Prt Numer Mercury Diesel White 8M Mercury Light Gry Primer Mercury Phntom Blck Q1 90-8M eng JUNE 2017 Pge 35

44 Section 3 - Specifictions Notes: Pge M eng JUNE 2017

45 Tle of Contents Section 4 - Mintennce Section 4 - Mintennce Owner nd Opertor Responsiilities Deler Responsiilities Clening Cre Recommendtion Do Not Use Custic Clening Chemicls Clening Guges Clening Remote Controls...38 Mintennce Do It Yourself Mintennce Suggestions Inspection Mintennce Schedules Routine Mintennce Scheduled Mintennce Engine Oil Checking Filling Chnging Oil nd Filter Sterndrive Ger Lue Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Assisted Steering Fluid Checking Filling Chnging Engine Coolnt Check Coolnt Filling Chnging Air Filter Removl...52 Inspection Instlltion Air Filter Removl...53 Inspection Instlltion...54 Wter Seprting Fuel Filter Drining Replcing Filling Fuel System Priming...59 Filling (Bleeding) Fuel Tnk Clening nd Flushing Sewter System Drining the Sewter System Sterndrive Wter Inlets Check Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Flushing the Sewter System Sterndrive Models With the Bot out of the Wter With the Bot in the Wter Engine Sewter Pump Inspection...67 Replcing the Engine Coolnt in the Closed Cooling System Drining the Closed Cooling System Filling the Closed Cooling System Corrosion Protection Generl Informtion Engine Corrosion Protection Components Removl Clening nd Inspection Instlltion Sterndrive Corrosion Protection Components Continuity Circuit Brvo Sterndrive MerCthode System Bttery Requirements MerCthode Theory of Opertion Power Pckge Exterior Surfces Bot Bottom Cre Pinting Your Power Pckge Sterndrive Surfce Cre Luriction Steering System Throttle Cle Shift Cle Engine Coupler Driveshft Extension Models Sterndrive, Bellows, nd Engine Alignment Mintining Torques Brvo Giml Ring U olt Nuts...84 Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belts Serpentine Belt Inspection Replcement Power Assisted Steering Pump Belt Inspection Adjustment Replcement Bttery Bttery Precutions for Multiple Engines M eng JUNE 2017 Pge 37

46 Section 4 - Mintennce Owner nd Opertor Responsiilities It is the opertor's responsiility to perform ll sfety checks, to ensure tht ll luriction nd mintennce instructions re complied with for sfe opertion, nd to return the unit to Mercury Diesel uthorized repir fcility for periodic checkup. Norml mintennce service nd replcement prts re the responsiility of the owner or opertor nd, s such, re not considered defects in workmnship or mteril within the terms of the wrrnty. Individul operting hits nd usge contriute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependility nd will keep your overll operting expenses t minimum. See your Mercury Diesel uthorized repir fcility for service ids. Deler Responsiilities It is the deler's responsiility to provide predelivery inspection nd preprtion: Before delivery, mking certin tht the Mercury power pckge is in proper operting condition. Mking ll necessry djustments for mximum efficiency. Explining nd demonstrting the opertion of the power pckge nd the ot. Providing copy of the Predelivery Inspection Checklist. Completing the wrrnty registrtion nd immeditely sumitting it to Mercury Mrine vi MercNET, e mil, or mil. All power pckges must e registered for wrrnty purposes. Clening Cre Recommendtion Do Not Use Custic Clening Chemicls IMPORTANT: Do not use custic clening chemicls on ny prt of the Mercury Diesel power pckge. Some clening products contin strong custic gents. For exmple, some hull cleners contin hydrochloric cid. These cleners cn degrde some of the components they contct, including criticl steering fsteners. Dmge to steering fsteners my not e ovious during visul inspection, nd this dmge my led to ctstrophic filure. Some custic clening chemicls my cuse or ccelerte corrosion. Exercise cution when using clening chemicls round the power pckge, nd follow the recommendtions on the pckging of the clening product. Clening Guges IMPORTANT: Never use high pressure wter to clen guges. Routine clening of the guges is recommended to prevent uildup of slt nd other environmentl deris. Crystlized slt cn scrtch the guge disply lens when using dry or dmp cloth. Ensure tht the cloth hs sufficient mount of fresh wter to dissolve nd remove slt or minerl deposits. Do not pply ggressive pressure on the disply lens while clening. When wter mrks cnnot e removed with dmp cloth, mix 50/50 solution of wrm wter nd isopropyl lcohol to clen the disply lens. Do not use cetone, minerl spirits, turpentine type solvents, or mmoni sed clening products. The use of strong solvents or detergents my dmge the coting, the plstics, or the ruer keys on the guges. If the guge hs sun cover ville, it is recommended tht the cover e instlled when the unit is not in use to prevent UV dmge to the plstic ezels nd ruer keys. Clening Remote Controls IMPORTANT: Never use high pressure wter to clen remote controls. Routine clening of the remote control externl surfces is recommended to prevent uildup of slt nd other environmentl deris. Use cloth towel which hs sufficient mount of fresh wter to dissolve nd remove slt or minerl deposits. When wter mrks cnnot e removed with dmp cloth, mix 50/50 solution of wrm wter nd isopropyl lcohol to clen the remote control. Do not use cetone, minerl spirits, turpentine type solvents, or mmoni sed clening products. The use of strong solvents or detergents my dmge the coting, the plstics, or the ruer components on the remote control. Mintennce! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components.! WARNING Fuel vpors trpped in the engine comprtment my e n irritnt, cuse difficulty rething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment efore servicing the power pckge. Pge M eng JUNE 2017

47 Section 4 - Mintennce IMPORTANT: Refer to Mintennce Schedule for complete listing of ll scheduled mintennce to e performed. Some listings cn e done y the owner or opertor, while others should e performed y Mercury Diesel uthorized repir fcility. Before ttempting mintennce or repir procedures not covered in this mnul, we recommended tht you purchse the pproprite Mercury or Mercury MerCruiser Service Mnul nd red thoroughly. NOTE: Mintennce points re color coded for ese of identifiction. Refer to the decl on the engine for identifiction. Blue Coolnt Yellow Engine oil Ornge Trnsmission fluid Blck Ger lue oil Do It Yourself Mintennce Suggestions Mercury power pckges re highly technicl, complex pieces of mchinery. Only qulified personnel using the proper tools should ttempt mjor repir. Your sfety is our concern. Alwys red nd understnd the Cutions, Wrnings, Importnt Notices, nd Notes. Do not ttempt repirs unless specificlly trined in tht procedure. Reference the correct service mnul for the product. Do not ttempt repirs unless qulified. Specil tools nd equipment re required to perform certin repirs. Filure to use the correct specil tools nd equipment cn result in severe dmge to the product. Alwys hve Mercury Diesel uthorized repir fcility service your power pckge nd do periodic mintennce inspections to help provide sfe nd troule free oting. Inspection Inspect your power pckge often nd t regulr intervls to help mintin its top operting performnce nd correct potentil prolems efore they occur. The entire power pckge should e checked crefully, including ll ccessile engine prts. 1. Check for loose, dmged, or missing prts, hoses nd clmps; tighten or replce s necessry. 2. Check electricl connections nd leds for dmge. 3. Remove nd inspect the propeller. If dly nicked, ent, or crcked, contct your Mercury Diesel uthorized repir fcility. 4. Repir nicks nd corrosion dmge on power pckge exterior finish. Contct your Mercury Diesel uthorized repir fcility. It my e necessry to remove the engine cover during some mintennce inspections nd procedures. To remove the engine cover: NOTE: The engine cover contins n ccess pnel which cn e used to ccess the engine circuit rekers nd the oil fill cp nd dipstick without removing the entire engine cover. 1. Lift nd detch the engine cover from the mounts Typicl engine cover - Engine cover - Engine cover ccess pnel loction Engine cover with ccess pnel showing 90-8M eng JUNE 2017 Pge 39

48 Section 4 - Mintennce 2. Set the engine cover over the mounts nd press the cover down in the mount res to rettch the engine cover. Mintennce Schedules Routine Mintennce IMPORTANT: Some procedures cn e done y the owner or opertor, while others should e performed y Mercury Diesel uthorized repir fcility. Before ttempting mintennce or repir procedures not covered in this mnul we recommended tht you purchse the pproprite Mercury Service Mnul, nd red it thoroughly. NOTE: Only perform mintennce tht pplies to your prticulr power pckge. Tsk Intervl Ech dy strt Ech dy end Weekly Every two months Mintennce to Be Performed Check the engine oil level. This tsk intervl cn e extended sed on opertor experience with the product. Check the engine coolnt level. Check the power ssisted steering fluid level. Check the sterndrive ger lue level in the ger lue monitor. If operting in sltwter, rckish wter, or polluted wter, flush the sewter section of the cooling system fter ech use. Drin ny wter from the primry fuel filter fter ech use. Drin ny wter from oth fuel filters if operting in freezing tempertures. Drin ny wter from the fuel filters. Check the trim pump fluid level. Check the sewter inlets for deris or mrine growth. Check nd clen the sewter striner. Inspect the sterndrive nodes nd replce if eroded 50% or more. Check the ttery connections nd fluid level. Luricte the propeller shft nd tighten the propeller nut to the specified torque. If operting in only freshwter, this mintennce my e extended to every four months. Tret the engine surfces with Corrosion Gurd if operting in sltwter, rckish, or polluted wters. Inspect the ir filter every two months or every 50 hours, whichever occurs first. Inspect the engine nodes nd replce if 50% or more eroded. Ensure tht the guges nd the wiring connections re secure. Clen the guges every two months or every 50 hours, whichever occurs first. If operting in sltwter, the intervl is reduced to every 25 hours or 30 dys whichever occurs first. Scheduled Mintennce Tsk Intervl Mintennce to Be Performed Annully Touch up the power pckge with pint nd spry with Corrosion Gurd. Pge M eng JUNE 2017

49 Tsk Intervl Every 100 hours or nnully (whichever occurs first) Every 200 hours or nnully (whichever occurs first) Chnge the sterndrive ger lue. Torque the giml ring U olt locknuts. Mintennce to Be Performed Section 4 - Mintennce Check the steering system nd the remote control for loose, missing, or dmged prts. Luricte the cles nd linkges. Inspect nd luricte the sterndrive U joint splines. Inspect the ellows, the exhust tue, nd check the clmps. Luricte the engine coupler (luricte the engine coupler every 50 hours if operted t idle for prolonged periods of time). Check the continuity circuit for loose or dmged connections. If the ot is equipped with MerCthode system, test the unit's output. Check the engine lignment. Torque the engine mounts. Check the electricl system for loose, dmged, or corroded terminls. On driveshft extension models, luricte the driveshft U joints, trnsom end (tilstock) erings, nd engine end (output) erings. Inspect the cooling system nd the exhust system for dmge or leks. Check oth systems hose clmps for tightness. Chnge the engine oil nd filter. Replce the fuel filters. Replce the ir filter. Inspect the condition nd tension of the engine ccessory drive elts. Disssemle nd inspect the engine sewter pump nd replce worn components. Check the sewter pump drive elt. Clen the sewter section of the closed cooling system. Clen, inspect, nd test the pressure cp. Check the nodes nd replce if eroded y 50% or more. Check the closed cooling fluid level nd level of protection. Clen the sewter striner. Check the run history for fults. Check the engine timing elt. Every 2 yers Replce the engine coolnt. Every 700 hours or 3 yers (whichever occurs first) Every 1000 hours or 5 yers (whichever occurs first) Engine Oil Replce the power ssisted steering pump drive elt. Replce the engine timing elt. Clen the fuel tnk. Clen the ftercooler core. NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking IMPORTANT: Check the engine oil t the intervls specified y the mintennce schedule. It is norml for n engine to use smll mount of oil during opertion. The mount of oil consumed depends upon engine speed. Oil consumption is the highest t wide open throttle nd decreses sustntilly s engine speed is reduced. NOTICE With the engine running, the crnkshft journls or rod journls my strike nd rek the dipstick, resulting in dmge to internl engine components. Stop the engine completely efore removing or inserting the dipstick. 90-8M eng JUNE 2017 Pge 41

50 Section 4 - Mintennce 1. To check the engine oil level during opertion, stop the engine nd llow five minutes for the oil to drin into the pn. 2. Remove the dipstick, wipe clen, nd reinstll. 3. Remove the dipstick nd oserve the oil level. The oil level must e etween the mrks on the dipstick. If necessry, dd oil. Refer to Filling. c d Typicl - Oil fill cp - Dipstick c - Mximum mrk d - Minimum mrk Filling IMPORTANT: Do not overfill the engine with oil. 1. Remove the oil fill cp. c d Typicl - Engine cover - Oil fill cp c - Access pnel removed d - Engine oil dipstick 2. Add the specified oil to ring the oil level up to, ut not over, the mximum mrk on the dipstick. 2.8L Cpcity Fluid Type Engine oil (with filter) 8.9 L (9.4 U.S. qt) 4 Cycle 15W 40 Mrine Engine Oil 4.2L Cpcity Fluid Type Engine oil (with filter) 13.8 L (14.6 U.S. qt) 4 Cycle 15W 40 Mrine Engine Oil IMPORTANT: Alwys use the dipstick to determine the mount of oil required to refill the engine oil. 3. Instll the oil fill cp. Chnging Oil nd Filter See the Mintennce Schedule for the chnge intervl. You should chnge the engine oil efore plcing the ot in storge. IMPORTANT: Chnge the engine oil when the engine is wrm from opertion. Wrm oil flows more freely, crrying wy more impurities. Use only recommended engine oil. See Specifictions. 1. Strt the engine nd llow it to wrm up to norml operting temperture. 2. Stop the engine nd llow some time for the oil to drin into the oil pn (pproximtely five minutes). 3. Remove the fitting from the end of crnkcse oil drin hose. Pge M eng JUNE 2017

51 Section 4 - Mintennce 4. Instll the crnkcse oil pump (order seprtely) onto the threded fitting of the oil drin hose. c Typicl - Threded fitting - Oil drin hose c - Crnkcse oil pump Crnkcse oil pump A 5 Aids in the removl of engine oil without drining the crnkcse Pump the oil out of the crnkcse into the drin pn. 6. Contin nd dispose of the oil or oil wste s directed y locl uthorities. 7. Remove the crnkcse oil pump nd instll the crnkcse oil drin hose fitting when the crnkcse is empty. Tighten securely. 8. Instll the oil dipstick. 9. Plce suitle continer under the oil filter housing to contin ny oil lekge tht my occur. Use n pproprite socket to loosen the oil filter top piece. 10. Remove the top piece nd crtridge type oil filter. 11. Disconnect nd discrd the old filter element. Discrd the old O ring from the top piece. Typicl - Top piece - O ring c - Filter element c Instll the new O ring. Apply luricnt to the O ring. Tue Ref No. Description Where Used Prt No W40 4-cycle Diesel Engine Oil Oil filter O-rings K M eng JUNE 2017 Pge 43

52 Section 4 - Mintennce 13. Push the filter element onto the top piece until it is locked. Listen for click. 14. Instll the top piece with the new filter element into the oil filter housing. IMPORTANT: Overtightening the top piece will cuse deformtion resulting in oil lekge. 15. Turn the oil filter top piece until the seling surfce contcts the housing. Torque the top piece using n pproprite socket. - Top piece - Oil filter housing Description Nm l in. l ft Oil filter top piece Remove the oil fill cp nd refill the engine with new oil. See Filling. IMPORTANT: When refilling the engine with oil, lwys use the dipstick to determine how much oil is required. 17. Strt the engine nd check for leks. Sterndrive Ger Lue NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking NOTE: The ger lue level will fluctute during opertion. The ger lue level should e checked with the engine cold, efore strting. 1. Check the ger lue monitor to determine the ger lue level. Keep the ger lue level within the recommended operting rnge. Refer to Filling Ger lue level shown is t the correct operting rnge - "ADD" mrk - "OPERATING RANGE" mrk IMPORTANT: If ny wter is visile t the ottom of the ger lue monitor or ppers t the fill nd drin plug hole, or if the ger lue ppers discolored, contct your Mercury Diesel uthorized repir fcility immeditely. Both conditions my indicte wter lek in the sterndrive. Pge M eng JUNE 2017

53 Filling Section 4 - Mintennce IMPORTANT: If more thn 59 ml (2 fl oz) of High Performnce Ger Lue is required to fill the ger lue monitor, sel my e leking. Dmge to the sterndrive my occur due to lck of luriction. Contct your Mercury Diesel uthorized repir fcility. 1. If the ger lue level is elow or ner the "ADD" mrk, the specified ger lue must e dded. 2. Remove the ger lue monitor cp. 3. Fill the ger lue monitor with the specified ger lue so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Ger lue monitor K01 4. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll the cp. Do not overtighten. - Ger lue monitor cp NOTE: When filling the entire sterndrive, refer to Chnging. Chnging Remove the ger lue monitor from the rcket. - Ger lue monitor rcket - Ger lue monitor nd cp c - Retining strp c Empty the contents of the ger lue monitor into suitle continer. 3. Instll the ger lue monitor in the rcket. 4. Remove the propeller. Refer to Propellers. 5. Brvo One models:. Lower the sterndrive to the full down (in) position.. Remove the ger lue fill nd drin plug nd seling wsher. 90-8M eng JUNE 2017 Pge 45

54 Section 4 - Mintennce c. Drin the ger lue into suitle continer. - Fill nd drin plug - Seling wsher mc Brvo Two models nd Brvo Three models:. Plce the sterndrive in full trim limit out (up) position.. Remove the fill nd drin plug nd seling wsher. c. Drin the ger lue into suitle continer Brvo Two - Fill nd drin plug - Seling wsher Brvo Three 7. Remove the vent plug nd seling wsher. Allow the ger lue to drin completely. - Vent plug - Seling wsher IMPORTANT: If ny wter drins from the fill nd drin plug hole, or if the ger lue ppers milky, the sterndrive is leking nd should e checked immeditely y your Mercury Diesel uthorized repir fcility. 8. Lower the sterndrive so tht the propeller shft is level. 9. Fill the sterndrive through the fill nd drin plug hole with the specified ger lue until n ir free strem of lue flows from the vent plug hole. Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Sterndrive unit K01 IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lue in the sterndrive. Pge M eng JUNE 2017

55 10. Instll the vent plug nd seling wsher. Section 4 - Mintennce 11. Continue to pump ger lue into the drive through the fill nd drin plug hole until the ger lue ppers in the ger lue monitor. 12. Fill the ger lue monitor so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Sterndrive Model Brvo One X Diesel Brvo One XR Brvo Two X Diesel Brvo Three X Diesel Brvo Three XR Fluid Cpcity includes the Sterndrive nd the Ger lue Monitor 2736 ml (92 1/2 oz) 3209 ml (108 1/2 oz) 2972 ml (100 1/2 oz) Fluid Type High Performnce Ger Lue 13. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll. Do not overtighten. - Ger lue monitor cp Fluid Prt Numer A Remove the pump from the sterndrive fill nd drin plug hole. 90-8M eng JUNE 2017 Pge 47

56 Section 4 - Mintennce 15. Quickly instll the seling wsher nd the fill nd drin plug. Torque to the following specifictions. mc All Brvo Models Shown - Fill nd drin plug - Seling wsher Description Nm l in. l ft Fill nd drin plug Instll the sterndrive propeller. Refer to Propellers. 17. Recheck the ger lue level t the ger lue monitor fter the first use. Refer to Checking. IMPORTANT: The ger lue level in the ger lue monitor will rise nd fll during sterndrive opertion; lwys check the ger lue level when the sterndrive is cool nd the engine is shut down. Power Trim Fluid Checking IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only. 1. Plce the sterndrive in full down (in) position. 2. Oserve the fluid level. The fluid level must e etween the "MIN" nd "MAX" lines on the reservoir. - Reservoir - "MIN" nd "MAX" lines 3. Fill s necessry with the specified fluid. See Filling Pge M eng JUNE 2017

57 Section 4 - Mintennce Tue Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power trim pump K01 Filling 1. If the fluid level is elow the "MIN" line, the specified fluid must e dded. 2. Remove the fill cp from the reservoir. NOTE: The fill cp is vented. Power trim pump reservoir shows the fluid level is elow "MIN" line - Fill cp ssemly - Fill cp instlled 3. Add the specified fluid to ring the fluid level to within the "MIN" nd "MAX" lines on the reservoir Reservoir - "MIN" nd "MAX" lines 7876 Tue Ref No. Description Where Used Prt No. 4. Instll the fill cp. Chnging 114 Power Trim nd Steering Fluid Power trim pump K01 Power trim fluid does not require chnging unless it ecomes contminted with wter or deris. Contct your Mercury Diesel uthorized repir fcility. Power Assisted Steering Fluid IMPORTANT: Use only Quicksilver Power Trim nd Steering Fluid or Dexron III utomtic trnsmission fluid (ATF) in the power ssisted steering system. IMPORTANT: Running the pump dry will dmge the pump. Alwys check steering fluid levels efore operting the ot. Checking 1. Center the sterndrive nd stop the engine. 2. Remove the fill cp nd dipstick from the fluid reservoir nd oserve the level.. The proper fluid level with the engine cold should e etween the full cold mrk nd the end of the dipstick. 90-8M eng JUNE 2017 Pge 49

58 Section 4 - Mintennce. With the engine t norml operting temperture, the fluid level should e etween the full hot nd full cold mrks. c Typicl - Fill cp nd dipstick - Full hot mrk c - Full cold mrk d - Fluid reservoir d IMPORTANT: If fluid is not visile in the fluid reservoir, see your Mercury Diesel uthorized repir fcility. Filling Remove the fill cp nd dipstick nd oserve the fluid level. 2. Add the specified fluid to ring the fluid level up to the proper level. Tue Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power-ssisted steering system K01 28 Dexron III Automtic Trnsmission Fluid 3. Instll the fill cp nd dipstick. Chnging Power-ssisted steering system Otin Loclly Power ssisted steering fluid does not require chnging unless it ecomes contminted. See your Mercury Diesel uthorized repir fcility. Engine Coolnt! CAUTION A sudden loss of pressure cn cuse hot coolnt to oil nd dischrge violently, resulting in serious injury from urns. Allow the engine to cool down efore removing the coolnt pressure cp. Check Coolnt IMPORTANT: When possile, check the engine coolnt efore strting the engine. 1. Allow the engine to cool. 2. Remove the pressure cp from the coolnt expnsion tnk. Pge M eng JUNE 2017

59 Section 4 - Mintennce 3. The coolnt level in the coolnt expnsion tnk should e ove the coolnt level indictor ttched to the ottom of the coolnt cp. - Filler neck - Coolnt cp c - Level indictor c 4. If the coolnt level is low:. Inspect the coolnt recovery system for leks.. Inspect the gsket in the pressure cp for dmge nd replce if necessry. c. The pressure cp mintins pressure on the cooling system nd my not e holding pressure properly. To hve the cp tested, contct your Mercury Diesel uthorized repir fcility. d. Add the specified coolnt s necessry. IMPORTANT: Tighten the pressure cp to prevent coolnt loss. 5. If the coolnt level is correct, instll the pressure cp nd tighten. Filling 1. Allow the engine to cool. 2. Remove the pressure cp from the coolnt expnsion tnk. 3. If the coolnt is low in the coolnt expnsion tnk, dd the specified coolnt s necessry to ring the level to within 25 mm (1 in.) of the ottom of the fill neck or etween the upper nd lower mrks, if pplicle Pressure cp - Bottom of fill neck Description Where Used Prt Numer Mercury Extended Life Antifreeze Closed cooling system K1 IMPORTANT: When instlling the pressure cp, e sure to tighten it securely to prevent coolnt loss. 4. Instll the pressure cp. Tighten securely. 90-8M eng JUNE 2017 Pge 51

60 Section 4 - Mintennce Chnging Chnge (replce) the engine coolnt t the prescried intervl. See Replcing the Engine Coolnt in the Closed Cooling System. 2.8 Air Filter Removl IMPORTANT: Keep ger lue monitor ottle in n upright position to prevent fluid from spilling. NOTE: It is not necessry to drin the ger lue monitor to perform this procedure. 1. Remove the ger lue monitor retining strp nd remove the ger lue monitor from the rcket nd set side. 2. Remove the ir filter cover retining nut from the ger lue monitor rcket on the ir filter. 3. Remove the ger lue monitor rcket. e c - Ger lue monitor - Ger lue monitor retining strp c - Ger lue monitor rcket d - Air filter cover retining nut e - Ger lue monitor rcket retining olts d Remove the ir filter cover. NOTE: It is not necessry to remove the ir filter rcket mounted on the turochrger inlet. 5. Remove the ir filter crtridge from the ir filter rcket mounted on the turochrger inlet. Shown removed from the engine for clrity only - Air filter crtridge - Air filter rcket Inspection 1. The ir filter cnnot e clened. Replce the ir filter if it is dirty or contminted. 2. Replce the ir filter if the fom element is deteriorted or torn. 3. Replce the ir filter t the recommended intervl. See Mintennce Schedules for the replcement intervl under norml conditions Pge M eng JUNE 2017

61 Instlltion Section 4 - Mintennce IMPORTANT: Tretment such s prtil oil sturtion is not required nd is not recommended on the fom element efore use. The fom element must e clen nd dry for proper filtrtion. 1. Instll the ir filter crtridge onto the ir filter rcket. 2. Instll the ir filter cover, ger lue monitor rcket, nd nuts. 3. Torque the ir filter cover retining nut nd ger lue monitor rcket nuts. Description Nm l in. l ft Air filter cover retining nut Ger lue monitor rcket nuts Instll the ger lue monitor in the rcket nd hold in plce with the retining strp. e c - Ger lue monitor - Ger lue monitor retining strp c - Ger lue monitor rcket d - Air filter cover retining nut e - Ger lue monitor rcket retining olts d Air Filter Removl 1. Loosen the clmp nd remove the oil seprtor vent hose. 2. Loosen the clmp nd remove the ir filter housing from the turochrger inlet. c - Oil seprtor vent hose - Air filter housing c - Turochrger d - Clmp d d M eng JUNE 2017 Pge 53

62 Section 4 - Mintennce 3. Remove the ir filter element from the ir filter housing - Air filter housing - Air filter element Inspection 1. The ir filter cnnot e clened. Replce the ir filter if it is dirty or contminted. 2. Replce the ir filter if the fom element is deteriorted or torn. 3. Replce the ir filter t the recommended intervl. See Mintennce Schedules for the replcement intervl under norml conditions. Instlltion Slide the filter element into the ir filter housing. Ensure tht the element is seted fully into the ir filter housing. - Air filter housing - Air filter element NOTE: The wrning lels on the ir filter housing must e visile fter the ir filter housing is instlled. 2. Instll the ir filter housing on to the turochrger inlet. 3. Torque the ir filter housing clmp. Description Nm l in. l ft Air filter housing clmp Pge M eng JUNE 2017

63 Section 4 - Mintennce 4. Instll the oil seprtor vent house. Tighten the oil seprtor vent hose clmp securely. c - Oil seprtor vent hose - Air filter housing c - Turochrger d - Clmp d d Wter Seprting Fuel Filter 25881! WARNING Fuel is flmmle nd explosive. Ensure tht the key switch is off nd the lnyrd is positioned so tht the engine cnnot strt. Do not smoke or llow sources of sprk or open flme in the re while servicing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys check for leks efore ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. NOTICE Wter entering the fuel injection system will cuse corrosion nd rusting of the injectors nd other components, disling the fuel injection system. Check dily for wter in the wter seprting fuel filter nd hve the engine inspected immeditely if there is evidence of wter in the fuel system. IMPORTANT: Use suitle continer to collect fuel. Clen up ny spills immeditely nd dispose of fuel in sfe mnner in ccordnce with ll locl, federl, nd interntionl regultions. The engine mounted wter seprting fuel filter is equipped with wter in fuel (WIF) sensor tht should lert the opertor when wter is present in the filter. This fuel filter needs to e replced t specified intervls or whenever wter is detected in the fuel, whichever comes first. The opertor my e lerted tht the WIF sensor hs detected wter in the fuel, depending upon the ot instrumenttion pckge nd if equipped: A messge my e displyed on n instrument An indictor lmp my e illuminted See Instrumenttion. Drin or replce the remote mounted primry filter (such s Rcor filter) t specified intervls, or whenever wter is detected in the engine mounted fuel filter. Drining The engine mounted wter seprting fuel filter cn e drined of wter nd smll dirt prticles y opening the drin cp on the ottom of the filter. NOTE: To ensure complete drining in wrm wether, drin the filter efore strting dily opertions. In cold wether, where there is possiility tht the condensed wter will freeze, drin the filter shortly fter the end of dily opertions. NOTE: Plce suitle continer under the fuel filter to ctch contminted fuel or wter. Dispose of properly. 1. Plce continer under the drin cp on the filter. 90-8M eng JUNE 2017 Pge 55

64 Section 4 - Mintennce 2. Open the drin y turning the drin cp counterclockwise (s viewed from the ottom of the filter) until fuel strts drining. Do not remove the drin cp. Typicl wter-seprting fuel filter - WIF sensor wire connection - Filter c - Drin cp c 3. Drin until the fuel is cler in ppernce. 4. Close the drin cp y turning clockwise. Tighten securely. 5. Fill the fuel filter. See Filling. Replcing! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components. IMPORTANT: The element cnnot e clened nd reused. It must e replced. 1. Disconnect oth ttery cles from the ttery. 2. Disconnect the WIF sensor wires, if equipped Remove the wter seprting fuel filter nd seling ring from the mounting rcket. Do not use filter wrench. Typicl - Wter seprting fuel filter NOTE: It my e necessry to keep the existing drin cp nd use it on the new filter. Be sure to replce the O ring on the drin cp. Pge M eng JUNE 2017

65 Section 4 - Mintennce 4. Remove the drin cp nd O ring sel from the ottom of the existing fuel filter. Note the position of the O ring sel. Typicl - Drin cp - O ring sel Discrd the used filter nd O ring sel s defined y locl uthorities. 6. Instll the O ring nd drin cp on the new wter seprting fuel filter. Typicl - Drin cp - O ring sel 7. Luricte the fuel filter sels Typicl - Wter seprting fuel filter - Sels Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Wter-seprting fuel filter seling ring Otin Loclly 90-8M eng JUNE 2017 Pge 57

66 Section 4 - Mintennce 8. Align the filter to the rcket. Twist the filter y hnd to secure the filter to the rcket. Do not use filter wrench. Typicl - Wter seprting fuel filter 9. Ensure tht the drin cp is securely tightened. 10. Connect the WIF sensor wires, if equipped. 11. Fill the wter seprting fuel filter with fuel. Refer to Filling. 12. Check the filter nd drin cp for fuel leks. 13. Connect the ttery cles. 14. Strt nd operte the engine. Check the filter connection for fuel leks. If leks exist, recheck filter instlltion. If leks continue, stop the engine immeditely nd contct your Mercury Diesel uthorized repir fcility. Filling A type of hnd pump nd primer plunger is locted on the fuel filter rcket nd is used to Refill the fuel filter when drining or chnging the filter. Refill the fuel system on the engine if the system ws run dry. Prime the fuel system if the engine hs not een run for n extended period. IMPORTANT: Only fill the fuel filter with the hnd pump nd primer plunger to ensure tht unfiltered fuel does not get into the fuel system. NOTE: Follow this procedure fter instlling new filter or if the fuel hs een drined from the filter checking for wter. 1. Loosen the ir vent (leed) screw on the fuel filter rcket. Typicl - Air vent screw Pge M eng JUNE 2017

67 Section 4 - Mintennce 2. Move the primer plunger up nd down repetedly. The filter is full when n ir free strem of fuel flows from the ir vent screw. Typicl - Air vent screw - Primer plunger 3. Securely tighten the ir vent screw Typicl - Air vent screw Fuel System Priming Prime the engine if it hs not een run for n extended period or if the engine will not strt. 1. Move the hnd pump nd primer plunger up nd down severl times s previously outlined. 2. Attempt to strt the engine. Filling (Bleeding) NOTE: Follow this procedure if the fuel system ws run dry or if prt of the fuel system ws drined for service function. 1. See Wter Seprting Fuel Filter Filling nd fill the fuel filter. 2. Check the filter nd drin cp for fuel leks. Ensure tht the leed screw on the fuel filter rcket is closed. Fuel Tnk Clening nd Flushing IMPORTANT: Diesel fuel should not e left in the tnk during winter storge, s n ccumultion of rust, sludge, nd wx residue will form. Refer to the ot mnufcturer's instructions nd clen the fuel tnk t specified intervls. Unless specified otherwise, flush nd clen the diesel fuel tnk every 1000 hours or five yers, whichever occurs first. Sewter System Drining the Sewter System! CAUTION Wter cn enter the ilge when the drin system is open, dmging the engine or cusing the ot to sink. Remove the ot from the wter or close the secock, disconnect nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open M eng JUNE 2017 Pge 59

68 Section 4 - Mintennce IMPORTANT: The engine must e s level s possile to ensure complete drining of the cooling system. Drin the sewter system of the power pckge efore cold wether (freezing temperture), sesonl storge, or extended storge. IMPORTANT: The ot must not e operting during this procedure.! CAUTION Wter cn enter the ilge when the drin system is open, dmging the engine or cusing the ot to sink. Remove the ot from the wter or close the secock, disconnect nd plug the sewter inlet hose, nd ensure the ilge pump is opertionl efore drining. Do not operte the engine with the drin system open. 1. Remove the ot from the wter if possile. 2. If the ot is to remin in the wter, turn on the ilge pump, close the secock (if equipped), or disconnect nd plug the sewter inlet hose. 3. Mke the engine s level s possile to ensure complete drining of the sewter system. NOTE: The node ssemly on the ck of the fluid cooler cn e used s drin plug. 4. Remove the drin plug from the ft end cover of the fluid cooler. Typicl engine - Anode ssemly drin plug - Fluid cooler Remove the drin plug, or fitting (if equipped), from the ft end cover of the engine oil cooler. Typicl engine - Engine oil cooler - Drin plug, or fitting if equipped NOTE: In the following steps, the hoses my require lowering or ending to llow sewter to drin completely. Pge M eng JUNE 2017

69 Section 4 - Mintennce 6. Disconnect the sewter inlet hose from the connector on the sewter pump hose nd drin. c c Sewter inlet hose - Connector c - Sewter pump hose 7. Repetedly clen out the drin holes using stiff piece of wire until the sewter section is completely drined. 8. On models equipped with sewter striner:. Remove the drin plug nd wsher if equipped.. Remove oth hoses from the sewter striner nd drin them completely. c. Drin nd empty the sewter striner. d. Connect the hoses nd tighten the hose clmps. e. Instll the seling wsher nd drin plug, if equipped. Typicl 9. After the sewter hs completely drined, pply selnt to the threds of the drin plugs or fittings (if equipped). Instll nd tighten the drin plugs or fittings Tue Ref No. Description Where Used Prt No. 19 Perfect Sel Drin plug or fitting threds Q Connect ll hoses. Tighten the hose clmps. Sterndrive Wter Inlets Check 1. Otin piece of wire the pproprite size to insert into the wter inlets holes. 2. Insert the wire in nd out of the sterndrive wter inlets to ensure tht they re open nd to remove deris or mrine growth. Do not scrpe the sterndrive pint. 90-8M eng JUNE 2017 Pge 61

70 Section 4 - Mintennce 3. Remove the wire from the sterndrive nd retin for periodic wter inlet checks. - Dul wter pickup wter inlets - Side pickup wter inlets Checking the Sewter Pickups Verify tht the wter inlet holes for the sewter pickup re clen nd not ostructed. Clening the Sewter Striner, if Equipped Typicl through-the-hull sewter pickup NOTICE An open sewter striner or secock during some service or mintennce procedures cn introduce wter into the ot, cusing dmge or sinking the ot. Alwys close the wter supply from the sewter pump, wter inlet, or secock when performing service or mintennce on the cooling system. 1. With the engine off, close the secock, if equipped, or remove nd plug the sewter inlet hose. 2. For metl sewter striners:. Remove the screws, wshers, nd cover.. Remove the striner, drin plug, nd seling wsher. c. Clen ny deris from the striner housing. d. Flush oth the striner nd housing with clen wter. Pge M eng JUNE 2017

71 Section 4 - Mintennce e. Inspect the cover gsket nd replce if dmged. f - Screws nd wshers - Cover with glss c - Striner d - Housing e - Drin plug nd seling wsher f - Sel c d e For plstic sewter striners:. Remove the cover.. Remove the striner. c. Clen ny deris from the striner housing. d. Flush oth the striner nd housing with clen wter. e. Inspect the cover gsket nd replce if dmged. - Striner cover - Striner sket c - Sel c 37287! CAUTION Sewter leking from the sewter striner could cuse excess wter in the ilge, dmging the engine or cusing the ot to sink. Do not overtighten the cover screws, or the cover my wrp nd introduce sewter into the ilge. 4. For metl sewter striners:. Instll the striner, drin plug, nd seling wsher.. Instll the striner sket. c. Assemle the cover. 90-8M eng JUNE 2017 Pge 63

72 Section 4 - Mintennce d. Tighten the cover screws. Do not overtighten. f - Screws nd wshers - Cover with glss c - Striner d - Housing e - Drin plug nd seling wsher f - Sel c d e For plstic sewter striners:. Insert the plstic striner sket.. Check the cover sel instlltion. c. Screw the striner cover on. - Striner cover - Striner sket c - Sel c 6. Open the secock, if equipped, or remove the plug nd reconnect the sewter inlet hose. 7. Upon first strting the engine, check for leks or ir in the system tht would indicte n externl lek. Flushing the Sewter System Sterndrive Models Flushing the sewter system with fresh wter is needed only for pplictions operting in sltwter, rckish wter, polluted wter, or wter with high minerl content to void slt or silt uildup. For est results we recommend flushing the sewter system fter ech outing. After ech opertion in sltwter nd efore storge, the sewter cooling system must e flushed. With the Bot out of the Wter 1. Lower the sterndrive to the full down (in) position.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. 2. Remove the propeller. See Propellers Pge M eng JUNE 2017

73 Section 4 - Mintennce 3. Instll the pproprite flushing ttchment over the wter inlet holes in the ger housing Dul wter pickup Side pickup Flushing Device Q 2 Attches to the wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine Dul Wter Pick up Flush Gercse Sel Kit K 1 Blocks off the front wter inlet holes on the dul wter inlet gercses Connect flushing hose from wter tp to the flushing ttchment. Typicl - Flushing ttchment - Hose IMPORTANT: Engines with the sterndrive wter inlet locked off t the giml housing nd using through the hull or through the trnsom wter inlet need supply of cooling wter ville to oth the sterndrive nd to the engine during opertion. 90-8M eng JUNE 2017 Pge 65

74 Section 4 - Mintennce 5. If your power pckge uses through the hull or through the trnsom pickup, connect second flushing hose from wter tp to the sewter inlet hose connected to the sewter pump inlet using n pproprite dpter. d c 2.8L shown, 4.2L similr - Adpter - Flushing hose c - Wter tp d - Sewter inlet hose 6. Prtilly open the wter source to out 1/2 mximum. Do not use full wter pressure. 7. Plce the remote control in neutrl, idle speed position nd strt the engine. NOTICE Operting the engine out of the wter t high speeds cretes suction, which cn collpse the wter supply hose nd overhet the engine. Do not operte the engine ove 1400 RPM out of the wter nd without sufficient cooling wter supply. 8. Operte the engine t idle speed in neutrl for out ten minutes or until the dischrge wter is cler. 9. Oserve the wter temperture guge to ensure tht the engine is operting in the norml rnge. 10. Stop the engine. 11. Shut off the wter tp. 12. Remove the sterndrive flushing ttchment. 13. If your power pckge uses through the hull pickup,. Remove the dpter from the sewter pump inlet hose connection.. Reconnect the sewter inlet hose. Tighten the hose clmps securely. With the Bot in the Wter NOTICE Disconnecting the sewter inlet hose will cuse wter to enter the ilge, resulting in engine dmge. Close the secock efore disconnecting the sewter inlet hose. Plug the sewter inlet hose immeditely fter disconnecting it Close the secock, if equipped, or disconnect nd plug the sewter inlet hose. c Typicl - Secock - Sewter inlet hose c - Plug Pge M eng JUNE 2017

75 Section 4 - Mintennce 2. Using n pproprite dpter, connect flushing hose from wter tp to the sewter inlet hose connected to the sewter pump inlet. d c 2.8L shown, 4.2L similr - Adpter - Flushing hose c - Wter tp d - Sewter inlet hose 3. Lower the sterndrive to the full down (in) position. 4. Prtilly open the wter source to out 1/2 mximum. Do not use full wter pressure. 5. Plce the remote control in neutrl, idle speed position nd strt the engine. NOTICE Operting the engine out of the wter t high speeds cretes suction, which cn collpse the wter supply hose nd overhet the engine. Do not operte the engine ove 1400 RPM out of the wter nd without sufficient cooling wter supply. 6. Operte the engine t idle speed in neutrl for out ten minutes or until the dischrge wter is cler. 7. Oserve the wter temperture guge to ensure tht the engine is operting in the norml rnge. 8. Stop the engine. 9. Shut off the wter tp. 10. Remove the dpter from the sewter pump inlet hose connection. 11. Do not open the secock or reconnect the wter inlet hose t this time to prevent wter from siphoning into the ot or engine. 12. Plce n pproprite tg on the key switch stting tht the secock must e opened or the sewter inlet hose must e reconnected efore operting the engine. Engine Sewter Pump Inspection IMPORTANT: Mercury strongly recommends tht this service e performed y Mercury Diesel uthorized repir fcility. Remove nd inspect the engine sewter pump t the intervl specified in the Mintennce Schedule. See your Mercury Diesel uthorized repir fcility. Replcing the Engine Coolnt in the Closed Cooling System Drining the Closed Cooling System NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. NOTE: For instructions on drining the sewter section, refer to Drining the Sewter System in this section. IMPORTANT: Oserve the following points. Ensure tht the engine is s level s possile to promote complete drining of the cooling system. The closed cooling section must e filled yer round with the required coolnt. If the engine will e exposed to freezing tempertures, ensure tht the closed cooling section is filled with solution of ethylene glycol ntifreeze nd wter properly mixed to protect the engine to the lowest temperture to which it will e exposed Do not use propylene glycol ntifreeze in the closed cooling section of the engine. 90-8M eng JUNE 2017 Pge 67

76 Section 4 - Mintennce! CAUTION A sudden loss of pressure cn cuse hot coolnt to oil nd dischrge violently, resulting in serious injury from urns. Allow the engine to cool down efore removing the coolnt pressure cp. 1. Allow the engine to cool. 2. Remove the pressure cp from the expnsion tnk nd coolnt reservoir. NOTE: Drin coolnt into suitle continer. Dispose of old coolnt properly. 3. Remove the intke nd exhust mnifold drin plug. 4. Remove the het exchnger drin plug. 4.2L shown, 2.8L similr - Intke nd exhust mnifold drin plug - Fluid cooler drin plug 5. Open the engine lock drin plug L shown, 2.8L similr - Engine lock drin plug 6. After the coolnt hs drined completely, instll the intke nd exhust mnifold drin plug, the het exchnger drin plug, nd the engine lock drin plug. Tighten ll drin plugs securely. 7. If required, clen the closed cooling system. See your locl Mercury Diesel uthorized repir fcility. 8. Fill the system with the specified coolnt. Refer to Filling the Closed Cooling System. Pge M eng JUNE 2017

77 Section 4 - Mintennce Filling the Closed Cooling System 1. Remove the pressure cp. - Pressure cp - Coolnt expnsion tnk IMPORTANT: Use only the specified coolnt. 2. If the coolnt is eing replced or the level is low, slowly dd the specified coolnt to the level indicted in the tle. Coolnt level in expnsion tnk All models Within 25 mm (1 in.) of the ottom of the filler neck, or etween the upper nd lower mrks, if mrked Description Where Used Prt Numer Mercury Extended Life Antifreeze Closed cooling system K1 NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. 3. Ensure tht the sewter pickup pump is supplied cooling wter. 4. Do not instll the pressure cp. Strt nd operte the engine t fst idle ( RPM). Add coolnt if necessry to mintin the coolnt t the level specified previously. IMPORTANT: When instlling the pressure cp, e sure to tighten it securely to void coolnt loss. 5. Instll the pressure cp fter the engine hs reched norml operting temperture (with the thermostt fully open) nd the coolnt level remins constnt. 6. Test the engine opertion. Oserve the temperture guge nd check the engine for coolnt leks. If the temperture guge indictes excessive temperture or if the coolnt is leking, stop the engine immeditely nd inspect for the cuse. 7. After the first opertion, llow the engine to cool. 8. Remove the pressure cp nd dd the specified coolnt to the level indicted in the tle. Coolnt level in expnsion tnk All models Within 25 mm (1 in.) of the ottom of the filler neck, or etween the upper nd lower mrks, if mrked 9. Instll nd securely tighten the pressure cp. Corrosion Protection Generl Informtion Whenever two or more dissimilr metls (such s those found on this power pckge) re sumerged in conductive solution such s sltwter, polluted wter, or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow etween metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This erosion is known s glvnic corrosion nd, if it is not controlled, it will eventully cuse the need for replcement of power pckge components exposed to wter. To help control the effects of glvnic corrosion, Mercury power pckges come with severl scrificil nodes nd other corrosion protection devices. For more comprehensive explntion of corrosion nd corrosion protection refer to the Mrine Corrosion Protection Guide. IMPORTANT: Replce scrificil nodes if eroded 50% or more. Mercury strongly recommends voiding the use of nodes from other mnufcturers. Refer to your Mercury Diesel uthorized repir fcility for dditionl informtion. 90-8M eng JUNE 2017 Pge 69

78 Section 4 - Mintennce Engine Corrosion Protection Components The engine is equipped with scrificil node locted on top of the ftercooler end cover to ssist in protecting the engine nd the sewter cooling system from corrosion. 4.2L models contin second scrificil node ssemly on the stern end of the fluid cooler. Removl 1. Allow the engine to cool. NOTICE Filure to close the sewter inlet or secock when removing or replcing the node plugs cn led to wter dmge. Close the secock or remove nd plug the sewter inlet hose to prevent wter from entering the node plug holes. 2. With the engine off, close the secock, if equipped, or remove nd plug the sewter inlet hose. 3. Drin the sewter system. See Drining the Sewter System. 4. Remove the node ssemly (node plug nd the scrificil node) from the top of the ftercooler end cover. - Aftercooler end cover - Anode ssemly On 4.2L models, remove the node ssemly (node plug nd the scrificil node) from the ft end of the fluid cooler. 4.2L - Anode ssemly - Fluid cooler Clening nd Inspection Inspection nd replcement intervl will vry ccording to the condition of the sewter nd the mode of engine opertion. NOTE: Using sndpper, fier rush, or clening pd, remove the deposits from the surfce of the node efore trying to determine the mount of erosion. Do not use mild steel rush, which might leve deposits tht could ccelerte corrosion. 1. Remove the deposits. 2. Inspect nd mesure the node. Compre the mesurements to the specifictions for new scrificil node nd replce the node ssemly when deteriorted 50% Pge M eng JUNE 2017

79 NOTE: Scrificil nodes re ville only s n ssemly. Replce oth the plug nd node s unit. Section 4 - Mintennce d e Anode ssemly - Anode plug - Scrificil node c - Length d - Dimeter e - Seling wsher c Scrificil node mesurements (new) Length Dimeter 3. Discrd the seling wsher. Instlltion 19 mm (3/4 in.) 16 mm (5/8 in.) 1. Instll new seling wsher on the node ssemly (node plug with the scrificil node). - Anode ssemly - Seling wsher Instll the node ssemly nd wsher into the ftercooler end cover. Tighten securely. - Aftercooler end cover - Anode ssemly M eng JUNE 2017 Pge 71

80 Section 4 - Mintennce 3. On 4.2L models, instll the node ssemly nd wsher into the ft end of the fluid cooler. Tighten securely. 4.2L - Anode ssemly - Fluid cooler 4. Unplug nd connect the sewter inlet hose, or open the secock if equipped NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. 5. Ensure tht the sewter pickup pump is supplied cooling wter. 6. Strt the engine nd check for leks Sterndrive Corrosion Protection Components To help control the effects of glvnic corrosion, sterndrives come with severl scrificil nodes nd other corrosion protection devices. For more comprehensive explntion of corrosion nd corrosion protection, refer to the Mrine Corrosion Protection Guide. f Typicl single sterndrive - Anode (Alph models), MerCthode (Brvo models) - Ventiltion plte node c - Trim cylinder nodes d - Bering crrier nodes e - Gercse nodic plte f - Anode kit on lower hull c d e Pge M eng JUNE 2017

81 Section 4 - Mintennce f Dul sterndrive - Anode (Alph models), MerCthode (Brvo models) - Ventiltion plte node c - Trim cylinder nodes d - Bering crrier nodes e - Gercse nodic plte f - Anode kit on lower hull c e c e d d NOTICE Wshing the MerCthode ssemly cn dmge components nd led to rpid corrosion. Do not use ny clening equipment such s rushes or high pressure wshers to clen the MerCthode ssemly. Do not pressure wsh the MerCthode ssemly, if equipped. Doing so will dmge the coting on the reference electrode wire nd decrese the corrosion protection. c MerCthode mounted to the underside of the giml housing, if equipped - MerCthode reference electrode, if equipped - Do not pint c - Do not pressure wsh IMPORTANT: Replce scrificil nodes if eroded 50% or more. The following scrificil nodes re instlled t different loctions on your power pckge. These nodes help protect ginst glvnic corrosion y scrificing its metl to e slowly eroded insted of the metl components on the power pckge. MerCthode System The electrode ssemly, if equipped, replces the node lock. The system should e tested to ensure dequte output. Perform the test when the ot is moored, using Quicksilver reference electrode nd test meter. Contct your Mercury Diesel uthorized repir fcility M eng JUNE 2017 Pge 73

82 Section 4 - Mintennce Description Loction Figure Alph sterndrive gercse nodic plte Mounted on the underside of the lower gercse Alph sterndrive giml housing node Mounted on the underside of the giml housing Brvo sterndrive gercse node plte Mounted on the underside of the lower gercse Alph nd Brvo sterndrive ventiltion plte node Mounted on the front of the gercse Alph nd Brvo sterndrive trim cylinder nodes Mounted on ech of the trim cylinders Alph nd Brvo sterndrive ering crrier node Locted in front of the propeller, etween the front side of the propeller nd the ger housing MerCthode System The MerCthode electrode, if equipped, is mounted to the underside of the giml housing. The MerCthode controller is mounted on the engine or on the ot trnsom. The controller hrness connects to the electrode hrness Anode kit (if equipped) Mounted to the ot trnsom In ddition to the corrosion protection devices, tke the following steps to inhiit corrosion: Pge M eng JUNE 2017

83 1. Pint the power pckge. Section 4 - Mintennce 2. Annully spry the power pckge components on the inside of the ot with Corrosion Gurd to protect the finish from dulling nd corrosion. You my lso spry externl power pckge components. 3. Keep ll luriction points, especilly the steering system, shift, nd throttle linkges, well luricted. 4. Flush the cooling system periodiclly, preferly fter ech use. Continuity Circuit Brvo Sterndrive The trnsom ssemly nd sterndrive hve ground circuit wires to ensure good electricl continuity etween the engine, trnsom ssemly, nd sterndrive components. Good continuity to ground is essentil for the node nd MerCthode system to function effectively. 1. Inspect the steering lever ground wire for loose connections, roken connectors, or fryed wiring. 2. Inspect the inner trnsom plte ground wire for loose connections, roken connectors, or fryed wiring Steering lever continuity wire - Continuity wire Trnsom plte continuity wires 3. Inspect the flywheel housing grounding stud nd ground wire, nd the inner trnsom plte grounding screw for loose connections, roken connectors, or fryed wiring. c Typicl - Flywheel housing screw or grounding stud - Continuity circuit (ground) wire c - Inner trnsom plte grounding screw M eng JUNE 2017 Pge 75

84 Section 4 - Mintennce 4. Inspect the driveshft housing to ger housing ground plte inside the node cvity for loose or fulty connection. Sterndrive nodic plte cvity - Ground plte (inside node cvity) Inspect the giml housing ground wires for loose connections, roken connectors, or fryed wiring. - Giml housing to giml ring ground wire - Giml housing to trim cylinder ground wires 6. Inspect the giml ring ground wire for loose connections, roken connectors, or fryed wiring Giml ring to ell housing ground wire Pge M eng JUNE 2017

85 Section 4 - Mintennce 7. Inspect the sterndrive ground plte for loose or roken connections. - Sterndrive to ell housing ground plte Inspect the continuity wshers under the hydrulic mnifold lock fsteners for loose or fulty connection. - Continuity wshers 9. Inspect the sterndrive U joint ellows ground clips nd exhust tue ground clip for loose or fulty connections Exhust tue ground clip shown, U-joint ellows ground clips similr - Exhust tue ground clip MerCthode System Bttery Requirements The Mercury MerCruiser MerCthode system requires minimum ttery chrge of 12.6 volts t ll times to mintin functionlity. Bots equipped with MerCthode system tht use shore power, nd re not run for long period of time, must use ttery chrger to mintin minimum ttery chrge of 12.6 volts or ove. Bots equipped with MerCthode system tht do not hve ccess to shore power must e operted often enough to mintin minimum ttery chrge of 12.6 volts or ove t ll times. MerCthode Theory of Opertion The MerCthode system provides corrosion protection y impressing reverse locking current tht stops the destructive flow of glvnic currents. The MerCthode controller will regulte output to mintin 0.94 volts t the reference electrode. A constnt LED indictes tht the system is operting correctly. A flshing LED indictes tht fult hs occurred, or tht n norml condition exists. 90-8M eng JUNE 2017 Pge 77

86 Section 4 - Mintennce IMPORTANT: When ot or new drive is first put into service, the LED my initilly indicte tht the protective current is not eing supplied through the MerCthode node. This condition is norml, nd, in such cses, the LED my flsh for period. The light from the LED will ecome stedy fter the ot is moored for period of eight hours without opertion. MerCthode LED Codes MerCthode LED Definition Required Action Solid green 2 flshes per second 1 flsh per 4 seconds LED not on Power Pckge Exterior Surfces No fult. The controller is working properly. There is n open or short in the reference electrode/node, high temperture, or sensed reference electrode voltge in excess of 1.4 V. The reference voltge is outside of the norml, expected rnge: either ove 1.04 V or elow 0.86 V. There is no power to the controller or oth the reference electrode nd node re open. No ction is necessry. This is the norml LED indiction for properly functioning MerCthode system. The system is not operting correctly. Contct your locl Mercury Service deler for ssistnce. The system is stilizing. Monitor it for further chnge. If the ot is out of the wter, no ction is necessry. Check the ttery voltge; it must e 9 V or higher. Check the 5 mp fuse in the controller wire hrness. If further ssistnce is required, contct your locl Mercury Service deler. 1. Spry the entire power pckge t recommended intervls with Corrosion Gurd. Follow the instructions on the cn for proper ppliction. Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Pinted surfces Clen the entire power pckge. Externl surfces tht hve ecome re should e repinted with the recommended primer nd spry pint t recommended intervls. Description Prt Numer Mercury Light Gry Primer Pinted surfces Mercury Phntom Blck Q 1 Bot Bottom Cre To chieve mximum performnce nd fuel economy, the ot ottom must e kept clen. Accumultion of mrine growth or other foreign mtter cn gretly reduce ot speed nd increse fuel consumption. To ensure est performnce nd efficiency, periodiclly clen the ot ottom in ccordnce with mnufcturer's recommendtions. In some res, it my e dvisle to pint the ottom to help prevent mrine growth. Refer to the following informtion for specil notes out the use of ntifouling pints. Pinting Your Power Pckge IMPORTANT: Corrosion dmge tht results from the improper ppliction of ntifouling pint will not e covered y the limited wrrnty. 1. Pinting the ot hull or trnsom: you my pply ntifouling pint to the ot hull nd trnsom. However, oserve the following: IMPORTANT: Do not pint nodes or MerCthode System reference electrode nd node. Pint will render them ineffective s inhiitors of glvnic corrosion. IMPORTANT: If ntifouling protection is required for the ot hull or trnsom, you cn use copper sed or tin sed pints where not prohiited y lw. If using copper sed or tin sed ntifouling pints, oserve the following: Pge M eng JUNE 2017

87 Section 4 - Mintennce Avoid ny electricl interconnection etween the pint nd the Mercury MerCruiser product, nodic locks, or MerCthode system y llowing minimum of 40 mm (1 1/2 in.) unpinted re on the trnsom of the ot round these items. - Pinted ot trnsom - Unpinted re on trnsom Pinting the sterndrive unit or trnsom ssemly: The sterndrive unit nd trnsom ssemly should e pinted with good qulity mrine pint or n ntifouling pint tht does not contin copper, tin, or ny other mteril tht could conduct electricl current. Do not pint drin holes, nodes, MerCthode system, or items specified y the ot mnufcturer. Sterndrive Surfce Cre e c d Stndrd Brvo sterndrive - Scrificil trim cylinder node - Scrificil nodic plte c - Steering lever ground wire d - Ground wire etween the giml ring nd ell housing e - Stinless steel hoses f - Ground wire etween the giml housing nd trim cylinder g - Ground wire etween the giml ring nd giml housing f g We recommend the following mintennce items to help keep your sterndrive corrosion free: Mintin complete pint covering on the sterndrive. Check the finish regulrly. Prime nd pint nicks nd scrtches using Mercury enmel pint nd touch up pint. Use only tin sed ntifouling pint or its equivlent on or ner luminum surfces elow the wterline. If re metl is showing, pply two cots of pint. Description Where used Prt numer Mercury Phntom Blck Bre metl Spry ll electricl connections with selnt Tue Ref No. Description Where Used Prt No. 25 Liquid Neoprene All electricl connections M eng JUNE 2017 Pge 79

88 Section 4 - Mintennce Inspect the scrificil trim t or node plte if equipped, t regulr intervls nd replce it efore it is hlf gone. If stinless steel propeller is instlled, dditionl nodes or MerCthode system will e required. Inspect the propeller shft for fishing line, which cn cuse corrosion on stinless steel shft. Remove the propeller t lest every 60 dys nd luricte the propeller shft. Do not use luricnts contining grphite on or ner the luminum in sltwter. Do not pint trim ts or the mounting surfce. Luriction Steering System! WARNING Incorrect cle luriction cn cuse hydrulic lock, leding to serious injury or deth from loss of ot control. Completely retrct the end of the steering cle efore pplying luricnt. NOTE: If the steering cle does not hve grese fitting, the inner wire of the cle cnnot e gresed. 1. If the steering cle hs grese fittings, turn the steering wheel until the steering cle is fully retrcted into the cle housing. Apply pproximtely three pumps of grese from typicl hnd operted grese gun. - Steering cle grese fitting 6221 Tue Ref No. Description Where Used Prt No C with PTFE Steering cle grese fitting A 1 2. Turn the steering wheel until the steering cle is fully extended. Lightly luricte the exposed prt of the cle. - Extended steering cle 6222 Tue Ref No. Description Where Used Prt No C with PTFE Steering cle A 1 Pge M eng JUNE 2017

89 Section 4 - Mintennce 3. Luricte the steering pin. - Steering pin Tue Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W On dul engine ots: Luricte the tie r pivot points. Steering pin 8M Tue Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie r pivot points 8M Upon first strting the engine, turn the steering wheel severl times to strord nd then port to ensure tht the steering system opertes properly efore getting underwy. Throttle Cle mc Luricte the pivot points nd guide contct surfces. - Pivot points - Guide contct surfces Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Throttle cle pivot points nd guide contct surfces Otin Loclly 90-8M eng JUNE 2017 Pge 81

90 Section 4 - Mintennce Shift Cle Luricte the pivot points nd guide contct surfces Typicl sterndrive model shift cle - Pivot points - Guide contct surfce Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Shift cle pivot points nd guide contct surfces Otin Loclly Engine Coupler IMPORTANT: These engines re equipped with seled engine coupler. The seled coupler nd the shft splines cn e luricted without removing the sterndrive. Luricte the engine coupler splines through the grese fitting on the coupler y pplying pproximtely 8 10 pumps of Extreme Grese from typicl hnd operted grese gun. NOTE: If the ot is operted t idle for prolonged periods of time, the coupler should e luricted on Brvo models every 50 hours. - Grese fitting - Coupler splines Tue Ref No. Description Where Used Prt No. Extreme Grese Engine coupler nd shft splines 8M Pge M eng JUNE 2017

91 Driveshft Extension Models Section 4 - Mintennce 1. Luricte the trnsom end grese fitting nd engine end grese fitting y pplying pproximtely pumps of grese from typicl hnd operted grese gun. 2. Luricte the driveshft grese fittings y pplying pproximtely 3 4 pumps of grese from typicl hnd operted grese gun. c Driveshft grese fittings - Trnsom end grese fitting c - Engine end grese fitting Tue Ref No. Description Where Used Prt No. Extreme Grese Sterndrive, Bellows, nd Engine Alignment Trnsom end grese fitting, engine end grese fitting, driveshft grese fittings 8M IMPORTANT: Hve your Mercury Diesel uthorized repir fcility perform the mintennce procedures listed, or refer to the pproprite Mercury MerCruiser Brvo Sterndrive Service Mnul. 1. Luricte the U joint shft splines nd the O rings. - U joint shft splines - U joint shft O rings Tue Ref No. Description Where Used Prt No. Extreme Grese U-joint shft splines nd O-rings 8M Inspect the U joint ellows for crcks or other signs of deteriortion. Ensure tht the ellows clmps re tight. 90-8M eng JUNE 2017 Pge 83

92 Section 4 - Mintennce 3. Rotte the ell housing in the upwrd nd side to side directions to inspect the exhust tue, shift cle ellows, nd clmps. c e f - U joint ellow - Exhust tue c - Bell housing d - Giml ring e - Giml housing f - Shift cle ellows d Check the engine lignment. c d Alignment tool - End of lignment tool to insert through giml housing ssemly c - Giml ering d - Engine coupler Mintining Torques Brvo Giml Ring U olt Nuts NOTE: The giml ring is component of the trnsom ssemly. Pge M eng JUNE 2017

93 Section 4 - Mintennce Tighten the giml ring U olt nuts to the specified torque. - Trnsom ssemly - Giml ring U olt nuts Description Nm l in. l ft Giml ring U olt nuts for 7/16 in. U olt Engine Mounts Loosen the rer engine mount olts 1 to 1 1/2 turns. Retorque the rer engine mount olts. - Rer engine mount - Trnsom plte mount c - Rer engine mount olt c Description Nm l in. l ft Rer engine mounts Propellers Brvo Sterndrive Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. 90-8M eng JUNE 2017 Pge 85

94 Section 4 - Mintennce Brvo One Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise nd remove the nut. 4. Slide the propeller nd the ttching hrdwre from the propeller shft. c d e f g Brvo One models - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut 5301 Brvo Two Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut 4750 Pge M eng JUNE 2017

95 Section 4 - Mintennce 2. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise to remove the nut. 4. Slide the propeller nd ttching hrdwre from the propeller shft. c d f Brvo Two - Propeller shft splines - Forwrd thrust hu c - Propeller d - Spline wsher e - T wsher f - Propeller nut e 8566 Brvo Three Models 1. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. 2. Remove the olt nd wshers securing the propeller shft node. 3. Remove the propeller shft node. c - Propeller - Propeller shft nut c - Propeller shft node d - Propeller shft node screw e - Flt wsher f - Str wsher d f e Turn the ft propeller shft nut counterclockwise to remove the nut. 5. Slide the propeller nd thrust hu off of the propeller shft. 6. Using the propeller nut tool, turn the front propeller shft nut counterclockwise nd remove the nut. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut M eng JUNE 2017 Pge 87

96 Section 4 - Mintennce 7. Slide the propeller nd the thrust hu off the propeller shft. g i h j c d e f 5304 Brvo Three - Aft propeller nut - Aft propeller c - Aft propeller thrust hu d - Front propeller nut e - Front propeller f - Front propeller thrust hu g - Propeller shft node screw h - Flt wsher i - Str wsher j - Propeller shft node Brvo Sterndrive Propeller Instlltion! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket Brvo One Models IMPORTANT: Use the correct rottion propeller. The propeller rottion must mtch the direction of rottion of the propeller shft. 1. Lierlly cot the propeller shft spline with one of the following luricnts. Tue Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Instll the propeller with the ttching hrdwre s shown. Pge M eng JUNE 2017

97 Section 4 - Mintennce 3. Tighten the propeller nut to the specified torque. c d e f g Typicl Brvo One models - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut NOTE: The propeller torque stted is minimum torque vlue. Description Nm l in. l ft Brvo One propeller nut Then lign ts with grooves 4. Models equipped with the t wsher: Continue to tighten the propeller nut until the three ts on the t wsher lign with the grooves on the spline wsher. 5. Bend the three ts down into the grooves c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut 4750 Brvo Three 1. Lierlly cot the propeller shft spline with one of the following luricnts. Tue Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Slide the forwrd thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 3. Align splines nd plce front propeller on propeller shft. 4. Instll the front propeller locknut nd tighten to the specified torque using the propeller nut tool. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Description Nm l in. l ft Brvo Three front propeller nut Slide the ft thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 90-8M eng JUNE 2017 Pge 89

98 Section 4 - Mintennce 6. Align the splines nd instll the ft propeller. 7. Instll the propeller nut nd torque. NOTE: The propeller torque stted is minimum torque vlue. Description Nm l in. l ft Brvo Three rer propeller nut Instll the propeller shft node nd secure with the screw. Tighten the screw to the specified torque. g i h j c d e f 5304 Brvo Three - Rer propeller nut - Rer propeller c - Rer propeller thrust hu d - Front propeller nut e - Front propeller f - Front propeller thrust hu g - Propeller shft node screw h - Flt wsher i - Str wsher j - Propeller shft node Description Nm l in. l ft Propeller shft node screw Drive Belts All drive elts must e periodiclly inspected for tension nd condition, such s excessive wer, crcks, frying, or glzed surfces.! WARNING Inspecting the elts with the engine running my cuse serious injury or deth. Turn off the engine nd remove the ignition key efore djusting tension or inspecting elts. e g c d f 2.8L shown, 4.2L similr - Wter circulting pump pulley - Alterntor pulley c - Idler d - Automtic tensioner e - Crnkshft pulley f - Sewter pump pulley g - Power ssisted steering pulley h - Power ssisted steering elt i - Serpentine elt h Serpentine Belt Inspection 1. Inspect the elt for proper tension nd for the following: Excessive wer Crcks NOTE: Minor, trnsverse crcks (cross the elt width) my e cceptle. Longitudinl crcks (in the direction of elt length) tht join trnsverse crcks re not cceptle. i Pge M eng JUNE 2017

99 Section 4 - Mintennce Frying Glzed surfces Check the opertion of the utomtic tensioner nd ssocited components.. Position suitle tool in the utomtic tensioner relese slot.. Rotte the utomtic tensioner in the direction of the rrow. - Automtic tensioner - Relese slot c. Relese the utomtic tensioner nd llow it to glide ck slowly. d. The utomtic tensioner must return to the initil position nd hold tension on the serpentine elt. Replcement IMPORTANT: If elt is to e reused, it should e instlled in the sme direction of rottion s when first used. 1. Position suitle tool in the utomtic tensioner relese slot. 2. Rotte the utomtic tensioner in the direction of the rrow to remove the tension on the serpentine elt. - Serpentine elt - Relese slot Remove the serpentine elt. 4. Replce the serpentine elt. 5. Crefully relese the utomtic tensioner with the reker r, ensuring tht the elt stys positioned properly. 90-8M eng JUNE 2017 Pge 91

100 Section 4 - Mintennce Power Assisted Steering Pump Belt Inspection 1. Inspect the elt for proper tension nd for the following: Excessive wer Crcks Frying Glzed surfces 2. Replce the elt if worn or dmged. See Replcement. 3. Check elt tension y depressing the upper strnd of the elt, with moderte hnd pressure, t the point shown. The elt must correspond to the specifictions in the following tle. 2.8L shown, 4.2L similr - Power steering pump elt Power ssisted steering drive elt tension Belt deflection, with moderte hnd pressure 4. Adjust the tension if necessry. See Adjustment. Adjustment 1. Loosen the power ssisted steering pump mounting olts. 5 mm (3/16 in.) 2.8L shown, 4.2L similr - Mounting olts Use the djustment screw to move the power ssisted steering pump to tension the power ssisted steering elt. - Mounting olts - Adjustment screw Pge M eng JUNE 2017

101 Section 4 - Mintennce Power ssisted steering drive elt tension Belt deflection, with moderte hnd pressure 3. Torque the power ssisted steering pump mounting nd tensioning flnge olts. 5 mm (3/16 in.) 2.8L shown, 4.2L similr - Mounting olts Description Nm l in. l ft Power ssisted steering pump mounting olts Replcement 1. Remove the serpentine elt. See Serpentine Belt. 2. Loosen the power ssisted steering pump mounting olts. 2.8L shown, 4.2L similr - Mounting olts Loosen the existing power ssisted steering pump elt y turning the djustment screw counterclockwise. - Mounting olts - Adjustment screw 4. Remove the existing power ssisted steering pump elt. 5. Instll the new power ssisted steering pump elt M eng JUNE 2017 Pge 93

102 Section 4 - Mintennce 6. Use the djustment screw to move the power ssisted steering pump to tension the power ssisted steering elt. - Mounting olts - Adjustment screw Power ssisted steering drive elt tension Belt deflection, with moderte hnd pressure 7. Torque the power ssisted steering pump mounting nd tensioning olts. 5 mm (3/16 in.) 2.8L shown, 4.2L similr - Mounting olts Description Nm l in. l ft Power ssisted steering pump mounting nd tensioning flnge olt Instll the serpentine elt. See Serpentine Belt. Bttery Refer to the specific instructions nd wrnings ccompnying your ttery. If this informtion is not ville, oserve the following precutions when hndling ttery.! WARNING Rechrging wek ttery in the ot, or using jumper cles nd ooster ttery to strt the engine, cn cuse serious injury or product dmge from fire or explosion. Remove the ttery from the ot nd rechrge in ventilted re wy from sprks or flmes.! WARNING An operting or chrging ttery produces gs tht cn ignite nd explode, sprying out sulfuric cid, which cn cuse severe urns. Ventilte the re round the ttery nd wer protective equipment when hndling or servicing tteries. Bttery Precutions for Multiple Engines Alterntors: Alterntors re designed to chrge single ttery tht supplies electricl power to the individul engine on which the lterntor is mounted. Connect only one ttery to one lterntor. Do not connect two tteries to the sme lterntor unless ttery isoltor is used. Engine Control Module (ECM): The ECM requires stle voltge source. During multiple engine opertion, n onord electricl device my cuse sudden drin of voltge t the engine's ttery. The voltge my go elow the ECM's minimum required voltge. Also, the lterntor on the other engine my now strt chrging. This could cuse voltge spike in the engine's electricl system. Pge M eng JUNE 2017

103 Section 4 - Mintennce In either cse, the ECM could shut off. When the voltge returns to the rnge tht the ECM requires, the ECM will reset itself. The engine will now run normlly. This ECM shut down usully hppens so fst tht the engine just ppers to hve n ignition miss. Btteries: Bots with multiengine electronic control power pckges require ech engine e connected to its own ttery, ensuring tht the engine s electronic control module (ECM) hs stle voltge source. Bttery Switches: Bttery switches should lwys e positioned so tht ech engine is operting off of its own ttery. Do not operte engines with switches in oth or ll position. In n emergency, nother engine's ttery cn e used to strt n engine with ded ttery. Bttery Isoltors: Isoltors cn e used to chrge n uxiliry ttery used for powering ccessories in the ot. They should not e used to chrge the ttery of nother engine in the ot unless the type of isoltor is specificlly designed for this purpose. Genertors: The genertor's ttery should e considered nother engine's ttery. 90-8M eng JUNE 2017 Pge 95

104 Section 4 - Mintennce Notes: Pge M eng JUNE 2017

105 Tle of Contents Section 5 - Storge Section 5 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge Cold Wether (Freezing Temperture) Storge Prepring Your Power Pckge for Sesonl or Extended Storge Sesonl Storge Instructions Extended Storge Instructions Bttery Recommissioning M eng JUNE 2017 Pge 97

106 Section 5 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge IMPORTANT: Mercury recommends this service e performed y Mercury Diesel uthorized repir fcility. Dmge cused y freezing is not covered y the Mercury Limited Wrrnty. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the ot reminding the opertor to open the secock or unplug nd reconnect the wter inlet hose efore strting the engine. You should consider ot is in storge whenever it is not in opertion. The mount of time tht the power pckge is not operted my e for rief period, such s during dy, overnight, for seson, or for n extended period of time. Certin precutions nd procedures must e oserved to protect the power pckge from freeze dmge, corrosion dmge, or oth types of dmge during storge. Freeze dmge cn hppen when wter trpped in the sewter cooling system freezes. For exmple, fter operting the ot, exposure to freezing tempertures for even rief period of time could result in freeze dmge. Corrosion dmge is the result of sltwter, polluted wter, or wter with high minerl content trpped in the sewter cooling system. Sltwter should not sty in n engine's cooling system for even rief storge time; drin nd flush the sewter cooling system fter ech outing. Cold wether opertion refers to operting the ot whenever the possiility of freezing tempertures exists. Likewise, cold wether (freezing temperture) storge refers to whenever the ot is not eing operted nd the possiility of freezing tempertures exists. In such cses, the sewter section of the cooling system must e completely drined immeditely fter opertion. Sesonl storge refers to when the ot is not eing operted for one month or more. The length of time vries depending on the geogrphic loction of the ot in storge. Sesonl storge precutions nd procedures include ll of the steps for cold wether (freezing temperture) storge nd some dditionl steps tht must e tken when storge will lst longer thn the short time of cold wether (freezing temperture) storge. Extended storge mens storge for period of time tht my lst for severl sesons or longer. Extended storge precutions nd procedures include ll of the steps for cold wether (freezing temperture) storge nd sesonl storge plus some dditionl steps. Refer to the specific procedures in this section relted to the conditions nd the length of storge for your ppliction. Cold Wether (Freezing Temperture) Storge NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the ot reminding the opertor to open the secock or unplug nd reconnect the wter inlet hose efore strting the engine. 1. Red ll precutions nd perform ll procedures found in Drining the Sewter System nd drin the sewter section of the cooling system. 2. Plce cution tg t the helm dvising the opertor to unplug nd connect the wter inlet hose or open the secock, if equipped, efore operting the ot. 3. For dditionl ssurnce ginst freezing nd corrosion fill the sewter cooling system with mixture of propylene glycol ntifreeze nd tp wter. See Sesonl Storge instructions in this section. Prepring Your Power Pckge for Sesonl or Extended Storge NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. IMPORTANT: If the ot hs lredy een removed from the wter, supply wter to the wter inlet holes efore strting the engine. Follow ll wrnings nd flushing ttchment procedures stted in Flushing the Sewter System. Pge M eng JUNE 2017

107 1. Supply cooling wter to the wter inlet holes or sewter pump inlet. 2. Strt the engine nd operte until it reches norml operting temperture. 3. Stop the engine. 4. Chnge the engine oil nd filter. 5. Strt the engine nd run for out 15 minutes. Check for oil leks. 6. Flush the sewter cooling system. See Flushing the Sewter System. Sesonl Storge Instructions Section 5 - Storge 1. Oserve ll precutions nd perform ll procedures found in Prepring Your Power Pckge for Sesonl or Extended Storge. 2. Oserve ll precutions nd perform ll procedures found in Drining the Sewter System nd drin the sewter section of the cooling system. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. IMPORTANT: Mercury recommends the use of propylene glycol ntifreeze in the sewter section of the cooling system for cold wether (freezing temperture), sesonl storge, or extended storge. Mke sure tht the propylene glycol ntifreeze contins rust inhiitor nd is recommended for use in mrine engines. Be certin to follow the propylene glycol mnufcturer's recommendtions. 3. Fill continer with pproximtely 5.6 liters (6 U.S. qurts) of propylene glycol ntifreeze nd tp wter mixed to mnufcturer's recommendtion to protect the engine to the lowest temperture to which it will e exposed during cold wether or extended storge. 4. Disconnect the sewter inlet hose from the sewter pump. Using n dpter, if necessry, temporrily connect hose of pproprite length to the sewter pump nd plce the other end of the hose into the continer of propylene glycol ntifreeze nd tp wter. Typicl - Sewter pump - Temporry hose c - Continer of propylene glycol ntifreeze nd tp wter NOTE: Dischrge of propylene glycol into the environment my e restricted y lw. Dispose of propylene glycol in ccordnce with federl, stte, nd locl lws nd guidelines. 5. Strt the engine nd operte t idle speed until the ntifreeze mixture hs een pumped into the engine sewter cooling system. 6. Stop the engine. 7. Remove the temporry hose from the sewter pump. c 8. Clen the outside of the engine nd repint required res with primer nd spry pint. After the pint hs dried, cot the engine with the specified corrosion inhiiting oil or equivlent M eng JUNE 2017 Pge 99

108 Section 5 - Storge Description Where Used Prt Numer Corrosion Gurd Light gry primer Outside of engine Mercury Diesel White 8M Mercury Phntom Blck Shift plte nd ir filter housing Q1 9. Your Mercury Diesel uthorized repir fcility should now perform ll checks, inspections, lurictions, nd fluid chnges outlined in Mintennce Schedules. NOTICE The universl joint ellows my develop set when stored in rised or up position, cusing the ellows to fil when returned to service nd llowing wter to enter the ot. Store the sterndrive in the full down position. 10. On Sterndrive models, plce the sterndrive in the full down (in) position. 11. Follow the ttery mnufcturer's instructions for storge nd store the ttery. Extended Storge Instructions IMPORTANT: Mercury recommends tht this service e performed y Mercury Diesel uthorized repir fcility. 1. Red ll precutions nd perform ll procedures found in Prepring Your Power Pckge for Sesonl or Extended Storge. 2. Red ll precutions nd perform ll procedures found in Drining the Sewter System. 3. Red ll precutions nd perform ll procedures found in Sesonl Storge instructions. IMPORTANT: The sewter pump impeller mteril cn e dmged y prolonged exposure to direct sunlight. 4. Remove the sewter pump impeller nd store wy from direct sunlight. Refer to Mercury Diesel uthorized repir fcility for dditionl informtion nd service. 5. Plce cution tg t the instrument pnel nd in the engine comprtment stting tht the sewter pump is out nd not to operte the engine. Bttery Follow the ttery mnufcturer's instructions for storge. Recommissioning NOTE: Dischrge of propylene glycol into the environment my e restricted y lw. Contin nd dispose of propylene glycol in ccordnce with federl, stte, nd locl lws nd guidelines. 1. On engines prepred for extended storge, hve Mercury Diesel uthorized repir fcility instll the sewter pump impeller, if it ws removed for storge. 2. On engines tht were prepred for cold wether (freezing temperture), sesonl, or extended storge, refer to Drining the Sewter System nd drin the propylene glycol into suitle continer. Dispose of the propylene glycol in ccordnce with federl, stte, nd locl lws nd guidelines. 3. Ensure tht ll cooling system hoses re in good condition, connected properly, nd clmped tightly. Verify tht ll drin vlves nd drin plugs re instlled nd tight. 4. Inspect ll drive elts. 5. Perform ll luriction nd mintennce specified for completion ccording to the Mintennce Schedules, except items tht were performed t time of engine service. 6. Fill the fuel tnks with fresh diesel fuel. Do not use old fuel. Check the generl condition of the fuel lines nd inspect the connections for leks. 7. Replce the wter seprting fuel filter or filters (some engines my hve more thn one).! CAUTION Disconnecting or connecting the ttery cles in the incorrect order cn cuse injury from electricl shock or cn dmge the electricl system. Alwys disconnect the negtive ( ) ttery cle first nd connect it lst. 8. Instll fully chrged ttery. Clen the ttery cle clmps nd terminls. Reconnect the cles (refer to the CAUTION listed ove). Secure ech cle clmp when connecting. Cot terminls with ttery terminl nti corrosion spry to help retrd corrosion. 9. Perform ll checks in the Strting Procedure column found in the Opertion Chrt. Refer to the On the Wter section. Pge M eng JUNE 2017

109 NOTICE Section 5 - Storge Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. 10. Supply cooling wter to the wter inlet openings. 11. Strt the engine nd closely oserve instrumenttion. Ensure tht ll systems re functioning correctly. 12. Crefully inspect the engine for fuel, oil, fluid, wter, nd exhust leks. 13. Check the steering system, shift, nd throttle control for proper opertion. 90-8M eng JUNE 2017 Pge 101

110 Section 5 - Storge Notes: Pge M eng JUNE 2017

111 Tle of Contents Section 6 - Trouleshooting Section 6 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems Trouleshooting Chrts Strter Motor Will Not Crnk Engine, or Crnks Slow. 104 Engine Will Not Strt, or Is Hrd to Strt Engine Runs Rough, Misses, or Bckfires Poor Performnce Incorrect Engine Temperture Low Engine Oil Pressure Bttery Will Not Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds Steering Wheel Turns Hrd or Jerky Power Trim does not Operte (Electric Motor Opertes ut Sterndrive does not Move) Power Trim Does Not Operte (Electric Motor Does Not Operte) M eng JUNE 2017 Pge 103

112 Section 6 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems A Mercury Diesel uthorized repir fcility hs the proper service tools for dignosing prolems on electroniclly controlled fuel systems. The engine control module (ECM) on these engines hs the ility to detect prolems with the system when they occur, nd store troule code in the ECM's memory. This code cn then e red lter y service technicin using specil dignostic tool. Trouleshooting Chrts Strter Motor Will Not Crnk Engine, or Crnks Slow Bttery switch turned off. Possile Cuse Remote control not in neutrl position. Open circuit reker or lown fuse. Loose or dirty electricl connections or dmged wiring. Bd ttery. Engine Will Not Strt, or Is Hrd to Strt Possile Cuse Lnyrd stop switch ctivted. Improper strting procedure. Turn switch on. Position control lever in neutrl. Remedy Check nd reset circuit reker or replce fuse. Check ll electricl connections nd wires (especilly ttery cles). Clen nd tighten fulty connection. Test nd replce if d. Check lnyrd stop switch. Red strting procedure. Empty fuel tnk or fuel shut off vlve closed. Fill tnk or open vlve. Throttle not operting properly. Fulty electricl stop circuit. Clogged fuel filters. Stle or contminted fuel. Fuel line or tnk vent line kinked or clogged. Air in fuel injection system. Fulty wire connections. Electronic fuel system fult. Engine Runs Rough, Misses, or Bckfires Possile Cuse Throttle not operting properly. Idle speed too low. Clogged fuel or ir filters. Stle or contminted fuel. Kinked or clogged fuel line or fuel tnk vent line. Air in fuel system. Electronic fuel system fulty. Poor Performnce Remedy Check the throttle for freedom of movement. Hve Mercury Diesel uthorized repir fcility service the electricl stop circuit. Replce fuel filters. Drin tnk. Fill with fresh fuel. Replce kinked lines or low out the lines with compressed ir to remove ostruction. Purge fuel injection system. Check wire connections. Hve the electronic fuel system checked y Mercury Diesel uthorized repir fcility. Remedy Check the throttle for inding or n ostruction. Hve idle speed checked nd djusted y Mercury Diesel uthorized repir fcility. Replce fuel or ir filters. If fuel is contminted, drin tnk. Fill with fresh fuel. Replce kinked lines or low out lines with compressed ir to remove ostruction. Purge fuel injection system. Hve electronic system checked y Mercury Diesel uthorized repir fcility. Possile Cuse Throttle not fully open. Trim limiter engged. Dmged or improper propeller. Remedy Inspect throttle cle nd linkges for proper opertion. Trim sterndrive elow trim limit. Replce propeller. See Mercury Diesel uthorized repir fcility. Pge M eng JUNE 2017

113 Possile Cuse Excessive ilge wter. Drin nd check for cuse of entry. Bot overloded or improperly distriuted. Reduce lod or redistriute more evenly. Bot ottom fouled or dmged. Electronic fuel system fult. Incorrect Engine Temperture Clen or repir s necessry. Remedy Section 6 - Trouleshooting Hve electronic fuel system checked y Mercury Diesel Authorized Repir Fcility. Possile Cuse Wter inlet or secock closed. Drive elt loose or in poor condition. Sewter pickups or se striner ostructed. Fulty thermostt. Coolnt level low in closed cooling section. Het exchnger cores plugged with foreign mteril. Loss of pressure in closed cooling section. Fulty sewter pickup pump. Sewter dischrge restricted or plugged. Sewter inlet hose kinked (restricted). Use of improperly designed hose on inlet side of sewter pump llowing it to collpse. Fulty thermostts. Open. Replce or djust elt. Remove ostruction. Remedy Replce. See Mercury Diesel uthorized repir fcility. Check for cuse of low coolnt level nd repir. Fill system with proper coolnt solution. Clen het exchnger. See Mercury Diesel uthorized repir fcility. Check for leks. Clen, inspect, nd test pressure cp. See Mercury Diesel uthorized repir fcility. Repir. See Mercury Diesel uthorized repir fcility. Clen exhust elows. See Mercury Diesel uthorized repir fcility. Position hose to prevent kinking (restriction). Replce hose with wire reinforced design. Replce. See Mercury Diesel uthorized repir fcility. Low Engine Oil Pressure Fulty senders. Possile Cuse Insufficient oil in crnkcse. Excessive oil in crnkcse (cusing it to ecome erted). Diluted or improper viscosity oil. Remedy Hve system checked y Mercury Diesel uthorized repir fcility. Check nd dd oil. Check nd remove required mount of oil. Check for cuse of excessive oil (improper filling). Chnge oil nd oil filter, using correct grde nd viscosity oil. Determine cuse for dilution (excessive idling). Bttery Will Not Chrge Possile Cuse Excessive current drw from ttery. Loose or dirty electricl connections or dmged wiring. Alterntor drive elt loose or in poor condition. Uncceptle ttery condition. Turn off nonessentil ccessories. Remedy Check ll ssocited electricl connections nd wires (especilly ttery cles). Clen nd tighten fulty connections. Repir or replce dmged wiring. Replce or djust. Test ttery. Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds Possile Cuse Insufficient luriction on shift nd throttle linkge fsteners. Ostruction in the shift or throttle linkges. Loose or missing shift nd throttle linkges. Luricte. Remove the ostruction. Remedy Check ll throttle linkges. If ny re loose or missing, see Mercury Diesel uthorized repir fcility immeditely. 90-8M eng JUNE 2017 Pge 105

114 Section 6 - Trouleshooting Possile Cuse Shift or throttle cle kinked. Improper shift cle djustment. Remedy Strighten cle or hve Mercury Diesel uthorized repir fcility replce cle if dmged eyond repir. Hve djustment checked y Mercury Diesel uthorized repir fcility. Steering Wheel Turns Hrd or Jerky Possile Cuse Low power steering pump fluid level. Drive elt loose or in poor condition. Remedy Check for lek. Refill the system with fluid. Replce or djust. Insufficient luriction on the steering components. Luricte. Loose or missing steering fsteners or prts. Contminted power steering fluid. Check ll prts nd fsteners; if ny re loose or missing, see Mercury Diesel uthorized repir fcility immeditely. See Mercury Diesel uthorized repir fcility. Power Trim does not Operte (Electric Motor Opertes ut Sterndrive does not Move) Possile Cuse The trim pump oil level is low. The drive unit is inding in the giml ring. Fill the trim pump with oil. Remedy Check for ostruction. See Mercury Diesel uthorized repir fcility. Power Trim Does Not Operte (Electric Motor Does Not Operte) Blown fuse. Possile Cuse Loose or dirty electricl connections or dmged wiring. Replce the fuse. Remedy Check ll the ssocited electricl connections nd the wires (especilly the ttery cles). Clen nd tighten the fulty connection. Repir or replce the wiring. Pge M eng JUNE 2017

115 Section 7 - Customer Assistnce Informtion Section 7 - Customer Assistnce Informtion Tle of Contents Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Sumersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Prolem Contct Informtion for Mercury Mrine Customer Service Customer Service Literture English Lnguge Other Lnguges Ordering Literture United Sttes nd Cnd Outside the United Sttes nd Cnd M eng JUNE 2017 Pge 107

116 Section 7 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service If you need service for your Mercury MerCruiser powered ot, tke it to your uthorized deler. Only uthorized delers specilize in Mercury MerCruiser products nd hve fctory trined mechnics, specil tools nd equipment, nd genuine Quicksilver prts nd ccessories to properly service your engine. NOTE: Quicksilver prts nd ccessories re engineered nd uilt y Mercury Mrine specificlly for Mercury MerCruiser sterndrives nd inords. Service Awy From Home If you re wy from your locl deler nd the need rises for service, contct the nerest uthorized deler. If, for ny reson, you cnnot otin service, contct the nerest regionl service center. Outside the United Sttes nd Cnd, contct the nerest Mrine Power Interntionl service center. Stolen Power Pckge If your power pckge is stolen, immeditely inform the locl uthorities nd Mercury Mrine of the model nd seril numers nd to whom the recovery is to e reported. This informtion is mintined in dtse t Mercury Mrine to id uthorities nd delers in recovery of stolen power pckges. Attention Required After Sumersion 1. Before recovery, contct n uthorized Mercury MerCruiser deler. 2. After recovery, immedite service y n uthorized Mercury MerCruiser deler is required to reduce the possiility of serious engine dmge. Replcement Service Prts! WARNING Avoid fire or explosion hzrd. Electricl, ignition, nd fuel system components on Mercury Mrine products comply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replcement electricl or fuel system components tht do not comply with these stndrds. When servicing the electricl nd fuel systems, properly instll nd tighten ll components. Mrine engines re expected to operte t or ner full throttle for most of their life. They re lso expected to operte in oth fresh nd sltwter environments. These conditions require numerous specil prts. Exercise cre when replcing mrine engine prts ecuse specifictions re different from those of the stndrd utomotive engine. For exmple, one of the most importnt specil replcement prts is the cylinder hed gsket. Mrine engines cnnot use steel type utomotive hed gskets ecuse sltwter is highly corrosive. A mrine engine hed gsket uses specil mterils to resist corrosion. Becuse mrine engines must e cple of running t or ner mximum RPM much of the time, they lso hve specil vlve springs, vlve lifters, pistons, erings, cmshfts, nd other hevy duty moving prts. Mercury MerCruiser mrine engines hve other specil modifictions to provide long life nd dependle performnce. Prts nd Accessories Inquiries Direct ny inquiries concerning Quicksilver replcement prts nd ccessories to your locl uthorized deler. The deler hs the necessry informtion to order prts nd ccessories for you. Only uthorized delers cn purchse genuine Quicksilver prts nd ccessories from the fctory. Mercury Mrine does not sell to unuthorized delers or retil customers. When inquiring out prts nd ccessories, the deler requires the engine model nd seril numers to order the correct prts. Resolving Prolem Stisfction with your Mercury MerCruiser product is importnt to your deler nd to us. If you ever hve prolem, question, or concern out your power pckge, contct your deler or ny uthorized Mercury MerCruiser delership. If you need dditionl ssistnce: 1. Tlk with the delership's sles mnger or service mnger. Contct the owner of the delership if the sles mnger nd service mnger hve een unle to resolve the prolem. 2. If your question, concern, or prolem cnnot e resolved y your delership, plese contct Mercury Mrine Service Office for ssistnce. Mercury Mrine will work with you nd your delership to resolve ll prolems. The following informtion will e needed y Customer Service: Your nme nd ddress Dytime telephone numer Model nd seril numers for your power pckge The nme nd ddress of your delership Pge M eng JUNE 2017

117 Section 7 - Customer Assistnce Informtion Nture of the prolem Contct Informtion for Mercury Mrine Customer Service For ssistnce, cll, fx, or write. Plese include your dytime telephone numer with mil nd fx correspondence. United Sttes, Cnd Telephone Fx Wesite English Frnçis English Frnçis Mercury Mrine W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Austrli, Pcific Telephone Fx Brunswick Asi Pcific Group Bessemer Drive Dndenong South, Victori 3175 Austrli Europe, Middle Est, Afric Telephone Fx Brunswick Mrine Europe Prc Industriel de Petit-Rechin B-4800 Verviers, Belgium Mexico, Centrl Americ, South Americ, Crien Telephone Fx Mercury Mrine Interchnge Circle North Mirmr, FL U.S.A. Jpn Telephone Fx Kisk Co., Ltd Knnecho Ski-shi Ski-ku Osk, Jpn Asi, Singpore Telephone Fx Brunswick Asi Pcific Group T/A Mercury Mrine Singpore Pte Ltd 29 Loyng Drive Singpore, Customer Service Literture English Lnguge English lnguge pulictions re ville from: Mercury Mrine Attn: Pulictions Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Outside the United Sttes nd Cnd, contct the nerest Mercury Mrine or Mrine Power Interntionl Service Center for further informtion. When ordering e sure to: List your product, model, yer, nd seril numers. Check the literture nd quntities you wnt. Enclose full remittnce in check or money order (NO COD). 90-8M eng JUNE 2017 Pge 109

118 Section 7 - Customer Assistnce Informtion Other Lnguges To otin n Opertion, Mintennce nd Wrrnty Mnul in nother lnguge, contct the nerest Mercury Mrine or Mrine Power Interntionl Service Center for informtion. A list of prt numers for other lnguges is provided with your power pckge. Ordering Literture Before ordering literture, hve the following informtion out your power pckge ville: Model Horsepower Seril Numer Yer United Sttes nd Cnd For dditionl literture for your Mercury Mrine power pckge, contct your nerest Mercury Mrine deler or contct: Mercury Mrine Telephone Fx Mil (920) (USA only) Outside the United Sttes nd Cnd (920) (USA only) Mercury Mrine Attn: Pulictions Deprtment P.O. Box 1939 Fond du Lc, WI Contct your nerest Mercury Mrine uthorized service center to order dditionl literture tht is ville for your prticulr power pckge. Sumit the following order form with pyment to: Mercury Mrine Attn: Pulictions Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Ship To: (Copy this form nd print or type This is your shipping lel) Nme Address City, Stte, Province ZIP or postl code Country Quntity Item Stock Numer Price Totl Totl Due. Pge M eng JUNE 2017

119 Tle of Contents Section 8 - Mintennce Log Section 8 - Mintennce Log Scheduled Mintennce Log Vessel Mintennce Notes M eng JUNE 2017 Pge 111

120 Section 8 - Mintennce Log Scheduled Mintennce Log Actul Hours Service Notes 100 Hours Deler Nme Signture Dte Actul Hours Service Notes 200 Hours Deler Nme Signture Dte Actul Hours Service Notes 300 Hours Deler Nme Signture Dte Actul Hours Service Notes 400 Hours Deler Nme Signture Dte Actul Hours Service Notes 500 Hours Deler Nme Signture Dte Actul Hours Service Notes 600 Hours Deler Nme Signture Dte Pge M eng JUNE 2017

121 Section 8 - Mintennce Log Vessel Mintennce Notes Record ll generl mintennce performed on your power pckge here. Sve ll work orders nd receipts. Dte Engine Hours Mintennce Completed Servicing Deler 90-8M eng JUNE 2017 Pge 113

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123 Bessemer Drive Dndenong South, Victori 3175 Austrli Mercury Mrine. All rights reserved. Printed in U.S.A. P.O. Box 1939 Fond du Lc, WI USA Prc Industriel de Petit-Rechin B-4800 Verviers, Belgium 90-8M JUNE 2017