Declaration of Conformance Mercury MerCruiser

Transcription

1 NOTE: The following pplies to CE mrked products only. Declrtion of Conformnce Mercury MerCruiser This sterndrive or inbord engine when instlled in ccordnce to Mercury MerCruisers instructions complies with the requirements of the following directives by meeting the ssocited stndrds, s mended: Recretionl Crft Directive 94/25/EC; 2003/44/EC Applicble Requirement Owner s mnul (A.2.5) ISO Openings in Hull, Deck nd superstructure (A.3.4) ISO ; ISO Hndling chrcteristics (A.4) ISO 8665 Stndrds Applied Inbord Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469 Electricl System (A.5.3) ISO 10133; ISO 8846 Steering system (A.5.4) Exhust emission requirements (B.2) ISO 8178 Owner s mnul (B.4) ISO 8665 Noise emission levels (C.1) ISO Applicble portions of: ISO 10592, ISO 8848 nd ABYC P 17 Ignition protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 Mercury MerCruiser declres tht our sterndrive or inbord engines without integrl exhust, when instlled in recretionl crft, in ccordnce with the mnufcturers supplied instructions, will meet the exhust emissions requirements of the directive mentioned bove. This engine must not be put into service until the recretionl crft in which it is to be instlled hs been declred in conformity, if so required, with the relevnt provision of the directive. Electromgnetic Comptibility Directive 89/336/EC, 92/31/EEC nd 93/68/EEC Generic emission stndrd EN Generic immunity stndrd EN Vehicles, bots nd internl combustion engine driven devices Rdio disturbnce chrcteristics Electrosttic dischrge testing SAE J551 (CISPR 12) EN ; EN ; EN The notified body responsible for surveillnce of the qulity system under Full Qulity Assurnce Module H of Directive 2003/44/EC is: Det Norske Verits Norwy Notified Body Number: 0575 This declrtion is issued under the sole responsibility of Mercury Mrine nd Mercury MerCruiser. Ptrick C. Mckey President Mercury Mrine, Fond du Lc, WI USA 2007 Mercury Mrine MPI Inbord nd Tow Sports Models

2 Regultory contct: Engineering - Regultory MerCruiser 3003 N. Perkins Rd Stillwter, Oklhom USA (405) Identifiction Record Plese record the following informtion: Engine Model nd Horsepower Engine Seril Number Trnsom Assembly Seril Number (Sterndrive) Ger Rtio Sterndrive Unit Seril Number Trnsmission Model (Inbord) Ger Rtio Trnsmission Seril Number Propeller Number Pitch Dimeter Hull Identifiction Number (HIN) Purchse Dte Bot Mnufcturer Bot Model Length Exhust Gs Emissions Certifiction Number The seril numbers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury MerCruiser power pckge. When contcting your Authorized Mercury MerCruiser Deler bout service, lwys specify model nd seril numbers. The description nd specifictions contined herein were in effect t the time this guide ws pproved for printing. Mercury Mrine, whose policy is one of continuous improvement, reserves the right to discontinue models t ny time, or to chnge specifictions or designs, without notice nd without incurring obligtion. Mercury Mrine, Fond du Lc, Wisconsin, U.S.A. Printed in U.S.A. 2007, Mercury Mrine Mercury, Mercury Mrine, MerCruiser, Mercury MerCruiser, Mercury Rcing, Mercury Precision Prts, Mercury Propellers, Mriner, Quicksilver, #1 On The Wter, Alph, Brvo, Pro Mx, OptiMx, Sport Jet, K Plnes, MerCthode, RideGuide, SmrtCrft, Zero Effort, M with Wves logo, Mercury with Wves logo, nd SmrtCrft logo re ll registered trdemrks of Brunswick Corportion. Mercury Product Protection logo is registered service mrk of Brunswick Corportion. Welcome You hve selected one of the finest mrine power pckges vilble. It incorportes numerous design fetures to ssure operting ese nd durbility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny boting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul.

3 Wrrnty Messge The Opertion, Mintennce nd Wrrnty 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 Mercury MerCruiser products. We sincerely hope your boting will be plesnt! Mercury MerCruiser The product you hve purchsed comes with limited wrrnty from Mercury Mrine; the terms of the wrrnty re set forth in the Wrrnty Sections of this mnul. The wrrnty sttement contins description of wht is covered, wht is not covered, the durtion of coverge, how to best obtin 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, pplicble industry stndrds nd regultions, s well s certin emissions regultions. At Mercury Mrine every engine is operted nd tested before it is boxed 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 pplicble stndrds nd regultions. All Mercury Mrine product, sold s new, receives the pplicble limited wrrnty coverge, whether the engine prticipted in one of the test progrms described bove or not. Red This Mnul Thoroughly IMPORTANT: If you don t understnd ny portion of this mnul, contct your deler for demonstrtion of ctul strting nd operting procedures. Notice Throughout this publiction, nd on your power pckge, dngers, wrnings, cutions, nd notices, ccompnied by the Interntionl Hzrd Symbol!, my be used to lert the instller/user to specil instructions concerning prticulr service or opertion tht my be hzrdous if performed incorrectly or crelessly. These sfety lerts follow ANSI stndrd Z for product sfety informtion in product mnuls, instructions, nd other collterl mterils. Observe them crefully. These Sfety Alerts 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.! DANGER Indictes hzrdous sitution which, if not voided, will result in deth or serious injury.! 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.

4 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.! WARNING The opertor (driver) is responsible for the correct nd sfe opertion of the bot, the equipment bord nd the sfety of ll occupnts bord. We strongly recommend tht the opertor red this Opertion, Mintennce nd Wrrnty Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories before the bot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, birth defects or other reproductive hrm.

5 TABLE OF CONTENTS Section 1 - Wrrnty Wrrnty Registrtion: United Sttes nd Cnd...2 Wrrnty Registrtion: Outside the United Sttes nd Cnd...2 Trnsfer of Wrrnty...3 Mercury Product Protection Pln: United Sttes nd Cnd...3 Mercury MerCruiser Limited Wrrnty (Gsoline Fueled Products Only) Yer Limited Wrrnty Aginst Corrosion Yer Limited Corrosion Wrrnty: SeCore Sterndrive Models with Gs Engines...7 Globl Wrrnty Chrts...8 Consumer Appliction Wrrnty Chrt...9 Commercil Appliction Wrrnty Chrt...10 Government Appliction Wrrnty Chrt...11 Mercury Instlltion Qulity Certifiction Progrm 11 Cliforni Emissions Limited Wrrnty...12 Wht Is Covered...12 Durtion Of Coverge...13 How To Obtin Wrrnty Coverge...13 Wht Mercury Will Do...14 Wht Is Not Covered...14 Components Of The Emission Control System 14 Disclimers And Limittions...15 Cliforni Emission Control Wrrnty Sttement..15 Your Wrrnty Rights nd Obligtions...15 Mnufcturer's Wrrnty Coverge...16 Owner's Wrrnty Responsibilities...16 Emission Control Informtion Lbel...16 Owner Responsibility...17 Emission Certifiction Str Lbel...17 Section 2 - Getting to Know Your Power Pckge Lnyrd Stop Switch...20 Instrumenttion...21 System View...21 Digitl Guges...22 Anlog Guges...22 Remote Controls (Non DTS Models)...23 Remote Controls...23 Pnel Mount Fetures...23 Console Mount Fetures...24 Zero Effort Fetures...24 Remote Controls (DTS Models)...25 Remote Controls...25 Pnel Mount Fetures...25 Console Mount Fetures Single Engine...26 Slim Binncle Console Mount Fetures Single Engine...27 Console Mount Fetures Dul Engine...28 Synchronizing Dul Engines...28 Dul Helm Sttion Trnsfer...29 Synchronizing Dul Helms Prior To Sttion Trnsfer...30 Zero Effort Fetures...30 Electricl System Overlod Protection...30 Audio Wrning System...32 Testing The Audio Wrning System...32 Engine Gurdin Strtegy...32 Trnsmission Gurdin Strtegy...33 Wrning Horn Signls...33 Section 3 - On The Wter Sfe Boting Suggestions...36 Be Alert To Crbon Monoxide Poisoning...37 Good Ventiltion...38 Poor Ventiltion...38 Bsic Bot Opertion (Non DTS Models)...38 Lunching nd Bot Opertion...38 Opertion Chrt...38 Strting nd Stopping the Engine...39 Strting the Engine...39 Stopping the Engine...40 Throttle Only Opertion...40 Freezing Temperture Opertion...40 Drin Plug nd Bilge Pump...40 Bsic Bot Opertion (DTS Models)...40 Lunching nd Bot Opertion...40 Opertion Chrt JUNE 2007 Pge i

6 Strting nd Stopping the Engine Strting the Engine Stopping the Engine...42 Throttle Only Opertion...42 Freezing Temperture Opertion...43 Drin Plug nd Bilge Pump...43 Protecting People In The Wter While You Are Cruising...43 While Bot Is Sttionry High Speed And High Performnce Bot Opertion...44 Pssenger Sfety In Pontoon Bots And Deck Bots Bots Hving An Open Front Deck...44 Bots With Front Mounted, Rised Pedestl Fishing Sets...44 Wve And Wke Jumping...45 Impct With Underwter Hzrds Conditions Affecting Opertion...46 Weight Distribution (Pssengers nd Ger) Inside the Bot Bottom Of Bot...46 Cvittion Ventiltion Elevtion And Climte...47 Getting Strted Hour Brek In Period After Brek In Period...48 End of First Seson Checkup Section 4 - Specifictions Cruising RPM Fuel Requirements...50 Fuel Rtings...50 Using Reformulted (Oxygented) Gsolines (USA Only)...50 Gsolines Contining Alcohol...50 Engine Oil...51 Engine Specifictions...52 Tow Sports Models...52 Inbord Models...53 Fluid Specifictions Engine...53 Trnsmission Section 5 - Mintennce Owner/Opertor Responsibilities...56 Deler Responsibilities...56 Mintennce...56 Do It Yourself Mintennce Suggestions Inspection...57 Mintennce Schedule Inbord Models...58 Routine Mintennce...58 Ech Dy Strt...58 Ech Dy End...58 Weekly Every Two Months or 50 Hours Scheduled Mintennce...58 After the Initil 20 Hour Brek In Period Every 100 Hours or Annully (Whichever Occurs First) Every 300 Hours or 3 Yers...58 Mintennce Log...59 Engine Oil...59 Checking...59 Filling Chnging Oil nd Filter...61 Esy Engine Oil Drin System...61 Engine Oil Drin Pump Chnging Filter...62 Trnsmission Fluid Checking While the Engine is Wrm Checking While Engine is Cold...63 Chnging Engine Coolnt...63 Checking...63 Filling Chnging Clening The Flme Arrestor Positive Crnkcse Ventiltion Vlve (PCV) Chnging...66 Chnging Wter Seprting Fuel Filter...67 GEN II Models GEN III Models In line Fuel Filter...70 Lubriction...72 Throttle Cble...72 Trnsmission Linkge Pge ii JUNE 2007

7 Serpentine Drive Belt...73 Checking...73 Replcing Belt nd/or Adjusting Tension...74 Flushing The Power Pckge Tow Sports...75 The Bot Out of the Wter...75 The Bot In the Wter...77 Bttery...79 Multiple EFI Engine Bttery Precutions...79 Section 6 - Storge Cold Wether or Extended Storge...82 Prepring Power Pckge for Storge...82 Engine nd Fuel System Preprtion...83 Drining the Sewter System...84 Drin System Identifiction...84 Air Actuted Single Point Drin System...84 Mnul Single Point Drin System...85 Three Point Mnul Drin System...85 Multi Point Drin (MPD) System...86 Air Actuted Single Point Drin System...86 Bot in the Wter...86 Bot out of the Wter...89 Mnul Single Point Drin System...91 Bot in the Wter...91 Bot out of the Wter...92 Three Point Mnul Drin System...93 Bot in the Wter...93 Bot out of the Wter...94 Multi Point Drin (MPD) System...95 Bot out of the Wter...95 Bot in the Wter...97 Bttery Storge...99 Power Pckge Recommissioning...99 Section 7 - Troubleshooting Dignosing EFI Problems Dignosing DTS Problems Engine Gurdin System Strter Motor Will Not Crnk Engine, Or Crnks Slow Engine Will Not Strt Or Is Hrd To Strt Engine Runs Rough, Misses And/Or Bckfires Poor Performnce Excessive Engine Temperture Insufficient Engine Temperture Low Engine Oil Pressure Bttery Will Not Come Up On Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free ply Or Mkes Unusul Sounds 104 Steering Wheel Turns Hrd Or Jerky Section 8 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Submersion Replcement Service Prts Prts And Accessories Inquiries Resolving A Problem Mercury Mrine Service Offices Ordering Literture United Sttes nd Cnd Outside The United Sttes nd Cnd JUNE 2007 Pge iii

8 Pge iv JUNE 2007

9 Tble of Contents Section 1 - Wrrnty Section 1 - Wrrnty 1 Wrrnty Registrtion: United Sttes nd Cnd... 2 Wrrnty Registrtion: Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 3 Mercury Product Protection Pln: United Sttes nd Cnd... 3 Mercury MerCruiser Limited Wrrnty (Gsoline- Fueled Products Only) Yer Limited Wrrnty Aginst Corrosion Yer Limited Corrosion Wrrnty: SeCore Sterndrive Models with Gs Engines... 7 Globl Wrrnty Chrts... 8 Consumer Appliction Wrrnty Chrt... 9 Commercil Appliction Wrrnty Chrt Government Appliction Wrrnty Chrt...11 Mercury Instlltion Qulity Certifiction Progrm Cliforni Emissions Limited Wrrnty Wht Is Covered Durtion Of Coverge How To Obtin Wrrnty Coverge Wht Mercury Will Do Wht Is Not Covered Components Of The Emission Control System Disclimers And Limittions Cliforni Emission Control Wrrnty Sttement Your Wrrnty Rights nd Obligtions Mnufcturer's Wrrnty Coverge Owner's Wrrnty Responsibilities Emission Control Informtion Lbel Owner Responsibility Emission Certifiction Str Lbel JUNE 2007 Pge 1

10 Section 1 - Wrrnty Wrrnty Registrtion: United Sttes nd Cnd To ensure tht your wrrnty coverge begins promptly, your selling deler should fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product. The Wrrnty Registrtion Crd identifies the nme nd ddress of the originl purchser, product model nd seril number(s), dte of sle, type of use nd selling deler s code, nme, nd ddress. The deler lso certifies tht you re the originl purchser nd user of the product. A temporry Owner Wrrnty Registrtion Crd will be presented to you when you purchse the product. Upon receipt of the Wrrnty Registrtion Crd t the fctory, Mercury MerCruiser will send you n owner resource guide tht includes your wrrnty registrtion confirmtion. If you do not receive your owner resource guide within 60 dys from dte of new product sle, plese contct your selling deler. Becuse of your selling deler s ongoing interest in your stisfction, the product should be returned to him for wrrnty service. The product wrrnty is not effective until the product is registered t the fctory. NOTE: Registrtion lists must be mintined by the fctory nd deler on mrine products sold in the United Sttes in the event tht sfety recll notifiction under the Federl Bot Sfety Act is required. You my chnge your ddress t ny time, including t time of wrrnty clim, by clling Mercury MerCruiser or sending letter or fx to Mercury MerCruiser s wrrnty registrtion deprtment with your nme, old ddress, new ddress, nd engine seril number. Your deler cn lso process this chnge of informtion. United Sttes customers or delers my contct: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Cndin customers or delers my contct: Mercury Mrine Cnd Limited 2395 Medowpine Blvd. Mississug, ON Cnd, L5N 7W6 Fx Wrrnty Registrtion: Outside the United Sttes nd Cnd To ensure tht your wrrnty coverge begins promptly, your selling deler should fill out the wrrnty registrtion crd completely nd mil it to the distributor responsible for dministering the wrrnty registrtion nd clim progrm for your re. Pge JUNE 2007

11 Trnsfer of Wrrnty Section 1 - Wrrnty The wrrnty registrtion crd identifies your nme nd ddress, product model nd seril numbers, dte of sle, type of use, nd the selling distributor s nd deler s code number, nme, nd ddress. The distributor or deler lso certifies tht you re the originl purchser nd user of the product. A copy of the wrrnty registrtion crd, designted s the purchser s copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor or deler. This crd represents your fctory registrtion identifiction. Keep the crd; if you ever need wrrnty service on this product, your deler my sk you for the wrrnty registrtion crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim forms. In some countries, the distributor will issue permnent (plstic) wrrnty registrtion crd to you within 30 dys fter receiving the fctory copy of the wrrnty registrtion crd from your distributor or deler. If you receive plstic wrrnty registrtion crd, you my discrd the purchser s copy tht you received from the distributor or deler when you purchsed the product. Ask your distributor or deler if this plstic crd progrm pplies to you. For further informtion concerning the wrrnty registrtion crd nd its reltionship to wrrnty clim processing, refer to the Interntionl Wrrnty. See Tble of Contents. NOTE: Registrtion lists must be mintined by the fctory nd deler on mrine products sold in the United Sttes in the event of sfety recll notifiction under the Federl Bot Sfety Act. The limited wrrnty is trnsferble to subsequent purchser, but only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the subsequent owner, send or fx copy of the bill of sle or purchse greement, new owner s nme, ddress nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. In the United Sttes mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx In Cnd mil to: Mercury Mrine Cnd Limited 2395 Medowpine Blvd. Mississug, ON Cnd, L5N 7W6 Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product by mil. There is no chrge for this service. For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the distributor closest to you. Mercury Product Protection Pln: United Sttes nd Cnd (Certin performnce products, triple engine instlltions, nd commercil pplictions re excluded.) JUNE 2007 Pge 3

12 Section 1 - Wrrnty The Mercury Product Protection Pln provides coverge ginst unexpected mechnicl nd electricl brekdowns tht my occur beyond the stndrd limited wrrnty. The optionl Mercury Product Protection Pln is the only Fctory Pln vilble for your engine. One, two, three, four, or five yer term plns cn be purchsed up to 12 months fter the originl engine registrtion dte. See your prticipting Mercury MerCruiser deler for complete progrm detils. Mercury MerCruiser Limited Wrrnty (Gsoline Fueled Products Only) MERCURY MERCRUISER LIMITED WARRANTY (GASOLINE-FUELED PRODUCTS ONLY) Wht is Covered Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described following. Durtion of Coverge Wrrnty Period for Recretionl Use The wrrnty period begins on the dte the product is first sold to recretionl use retil purchser or the dte on which the product is first put into service, whichever occurs first. Products instlled by n Instlltion Qulity Certified Instller receive one (1) yer of dditionl wrrnty coverge. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. The wrrnty period is specific to the model covered; see your model for the bse coverge period: Horizon Sterndrive nd Inbord Models, nd MX 6.2 Blck Scorpion Tow Sport Model Coverge The Limited Wrrnty for the Horizon Sterndrive nd Inbord Models, nd MX 6.2 Blck Scorpion Tow Sport Models is four (4) yers when instlled by n Instlltion Qulity Certified Instller or three (3) yers for noncertified instlltions. SeCore Sterndrive Model Coverge The Limited Wrrnty for SeCore Sterndrive Models is four (4) yers when instlled by n Instlltion Qulity Certified Instller or three (3) yers for noncertified instlltions. Stndrd Model Coverge The Limited Wrrnty for Stndrd Models, which do not include Horizon Sterndrive nd Inbord Models, MX 6.2 Blck Scorpion Tow Sport Models, or SeCore Sterndrive Models, is two (2) yers when instlled by n Instlltion Qulity Certified Instller or one (1) yer for noncertified instlltions. Wrrnty Period for Commercil Use The wrrnty period begins on the dte the product is first sold to commercil use retil purchser or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge for either one (1) yer from the dte of first retil sle or the ccumultion of of opertion, whichever occurs first. Commercil use is defined s ny work relted or employment relted use of the product, or ny use of the product tht genertes income for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Trnsfer of Coverge Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper reregistrtion of the product. Unexpired wrrnty coverge cnnot be trnsferred either to or from commercil use customer. Pge JUNE 2007

13 Section 1 - Wrrnty Termintion of Coverge Wrrnty coverge is terminted for used product obtined in ny of the following wys: Repossession from retil customer Purchse t uction Purchse from slvge yrd Purchse from n insurnce compny tht obtined the product s result of n insurnce clim Conditions Tht Must Be Met in Order to Obtin Wrrnty Coverge Wrrnty coverge is vilble only to retil customers tht purchse from deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the pre delivery inspection process specified by Mercury Mrine is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use or subsequent chnge of use from recretionl to commercil (unless properly reregistered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce must be performed ccording to the mintennce schedule in the Opertion, Mintennce & Wrrnty mnul in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Wht Mercury Mrine Will Do Mercury Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. How to Obtin Wrrnty Coverge The customer must provide Mercury Mrine with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury Mrine deler uthorized to service the product. If the purchser cnnot deliver the product to such deler, written notice must be given to Mercury Mrine. Mercury Mrine will then rrnge for the inspection nd ny covered repir. The purchser in tht cse shll py for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered by this wrrnty, the purchser shll py for ll relted lbor nd mteril nd ny other expenses ssocited with tht service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge JUNE 2007 Pge 5

14 Section 1 - Wrrnty Wht Is Not Covered This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused by buse Abnorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce & Wrrnty mnul) Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce & Wrrnty mnul Neglect Accident Submersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Use of n ccessory or prt tht ws not mnufctured or sold by Mercury Mrine nd tht dmges the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or lubricnts tht re not suitble for use with the product (see the Opertion, Mintennce & Wrrnty mnul) Altertion or removl of prts Wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body Running the engine out of wter Mounting the engine too high on the trnsom Operting the bot with the engine over trimmed Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even by previous owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl or replcement of bot prtitions or other mteril in order to gin ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Yer Limited Wrrnty Aginst Corrosion 3-YEAR LIMITED WARRANTY AGAINST CORROSION Wht Is Covered Durtion of Coverge Mercury Mrine wrrnts tht ech new Mercury, Mriner, Mercury Rcing, Sport Jet, M 2 Jet Drive, Trcker by Mercury Mrine Outbord, MerCruiser Inbord or Sterndrive engine (Product) will not be rendered inopertive s direct result of corrosion for the period of time described below. Pge JUNE 2007

15 Section 1 - Wrrnty This limited corrosion wrrnty provides coverge for three (3) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir nd replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent (noncommercil use) purchser upon proper re registrtion of the product. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. Condition Tht Must Be Met in Order to Obtin Wrrnty Coverge Wht Mercury Will Do How to Obtin Wrrnty Coverge Wht Is Not Covered Wrrnty coverge is vilble only to retil customers tht purchse from deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Corrosion prevention devices specified in the Opertion, Mintennce & Wrrnty mnul must be in use on the bot, nd routine mintennce outlined in the Opertion, Mintennce & Wrrnty mnul must be timely performed (including without limittion the replcement of scrificil nodes, use of specified lubricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. Mercury's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, buse or improper service; corrosion to ccessories, instruments, steering systems; corrosion to fctory instlled jet drive unit; dmge due to mrine growth; product sold with less thn one yer limited Product wrrnty; replcement prts (prts purchsed by the Customer); products used in commercil ppliction. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of wrrnty period, even if the product is only occsionlly used for such purposes. 4 Yer Limited Corrosion Wrrnty: SeCore Sterndrive Models with Gs Engines 4-YEAR LIMITED CORROSION WARRANTY: SEACORE STERNDRIVE MODELS WITH GAS ENGINES Wht Is Covered Durtion of Coverge Mercury Mrine wrrnts tht ech new MerCruiser SeCore engine, trnsom, nd sterndrive pckge will not be rendered inopertive s direct result of corrosion for the period of time described below JUNE 2007 Pge 7

16 Section 1 - Wrrnty This limited corrosion wrrnty provides coverge for four (4) yers from either the dte on which the MerCruiser SeCore engine, trnsom, nd sterndrive pckge is first sold or the dte on which it is first put into service, whichever occurs first. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent (noncommercil use) purchser upon proper reregistrtion of the product. Wrrnty coverge is terminted for used product obtined in ny of the following wys: Repossession from retil customer Purchse t uction Purchse from slvge yrd Purchse from n insurnce compny tht obtined the product s result of n insurnce clim Condition Tht Must Be Met in Order to Obtin Wrrnty Coverge Wht Mercury Mrine Will Do How to Obtin Wrrnty Coverge Wht Is Not Covered Wrrnty coverge is vilble only to retil customers tht purchse from deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the pre delivery inspection process specified by Mercury Mrine is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Corrosion prevention devices specified in the Opertion, Mintennce & Wrrnty mnul must be in use on the bot, nd routine mintennce outlined in the Opertion, Mintennce & Wrrnty mnul must be performed ccording to the mintennce schedule in the Opertion, Mintennce & Wrrnty mnul (including without limittion the replcement of scrificil nodes, use of specified lubricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. Mercury's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. The customer must provide Mercury Mrine with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury Mrine deler uthorized to service the product. If the purchser cnnot deliver the product to such deler, written notice must be given to Mercury Mrine. Mercury Mrine will then rrnge for the inspection nd ny covered repir. The purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, the purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. This limited wrrnty does not cover the following: Electricl system corrosion Corrosion resulting from dmge Corrosion tht cuses purely cosmetic dmge Abuse or improper service Corrosion to ccessories, instruments, nd steering systems Corrosion to fctory instlled jet drive unit Dmge due to mrine growth Globl Wrrnty Chrts Replcement prts (prts purchsed by the customer) Product sold with less thn one yer limited product wrrnty Products used in commercil ppliction. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of wrrnty period, even if the product is only occsionlly used for such purposes. IMPORTANT: Plese refer to for the most currnt Globl Wrrnty Chrts. Pge JUNE 2007

17 Section 1 - Wrrnty Consumer Appliction Wrrnty Chrt Region USA nd Cnd Ltin Americ Consumer Appliction: Stndrd Fctory Limited Wrrnty by Region & Bot Brnd Limited Corrosion Wrrnty Non-Certified Bot Brnd Certified Bot Brnd All Bot Brnds Stndrd SeCore Horizon 6.2 Scorpion Stndrd SeCore Horizon 6.2 Scorpion Stndrd nd Horizon SeCore 1 yer 3 yers 3 yers 3 yers 2 yers 4 yers 4 yers 4 yers 3 yers 4 yers 1 yer 3 yers 1 yer 1 yer 2 yers 4 yers 2 yers 2 yers 3 yers 4 yers Mexico 1 yer 3 yers 1 yer 1 yer 1 yer 4 yers 1 yer 1 yer 1 yer 4 yers Europe 2 yers 3 yers 2 yers 2 yers 3 yers 4 yers 3 yers 3 yers 3 yers 4 yers Jpn 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer Austrli nd New Zelnd 2 yers 3 yers 3 yers 3 yers ll Tow Sports 2 yers 3 yers 3 yers 3 yers ll Tow Sports 3 yers 4 yers South Pcific 1 yer 3 yers 1 yer 1 yer 1 yer 3 yers 1 yer 1 yer 3 yers 4 yers Asi (excluding Jpn, South Pcific, Austrli, New Zelnd) 2 yers 2 yers 2 yers 3 yers ll Tow Sports 2 yers 2 yers 2 yers 3 yers ll Tow Sports NOTE: In regions where the Certified Bot Builder progrm is not pplicble, the regulr wrrnty lwys pplies. 2 yers 2 yers NOTE: In regions where TBD (To Be Determined) is listed, check with your locl deler for wrrnty length nd conditions JUNE 2007 Pge 9

18 Section 1 - Wrrnty Commercil Appliction Wrrnty Chrt Commercil Appliction: Stndrd Fctory Limited Wrrnty by Region & Bot Brnd Limited Corrosion Wrrnty Non-Certified Bot Brnd Certified Bot Brnd All Bot Brnds Region Stndrd SeCore Horizon USA nd Cnd Ltin Americ 500 hours 500 hours 6.2 Scorpion Stndrd SeCore Horizon 6.2 Scorpion 500 hours 500 hours Stndrd nd Horizon none SeCore Mexico 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer Europe Jpn Austrli nd New Zelnd South Pcific Asi (excluding Jpn, South Pcific, Austrli, New Zelnd) 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours NOTE: In regions where the Certified Bot Builder progrm is not pplicble, the regulr wrrnty lwys pplies none none none none none none none none none none none none none Pge JUNE 2007

19 Government Appliction Wrrnty Chrt Section 1 - Wrrnty Government Appliction: Stndrd Fctory Limited Wrrnty by Region & Bot Brnd Limited Corrosion Wrrnty Non-Certified Bot Brnd Certified Bot Brnd All Bot Brnds Region Stndrd SeCore Horizon USA nd Cnd Ltin Americ 6.2 Scorpion Stndrd SeCore Horizon 6.2 Scorpion Stndrd nd Horizon SeCore 1 yer 3 yers 3 yers 3 yers 2 yers 4 yers 4 yers 4 yers 3 yers 4 yers 500 hours 500 hours Mexico 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1 yer 1yer Europe Jpn Austrli nd New Zelnd South Pcific Asi (excluding Jpn, South Pcific, Austrli, New Zelnd) 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours NOTE: In regions where the Certified Bot Builder progrm is not pplicble, the regulr wrrnty lwys pplies Mercury Instlltion Qulity Certifiction Progrm none none none none none none none none none none none none JUNE 2007 Pge 11

20 Section 1 - Wrrnty Mercury MerCruiser products instlled by Mercury Instlltion Qulity Certified Mnufcturer re Instlltion Qulity certified products nd my receive n dditionl one (1) yer of limited wrrnty coverge. The Instlltion Qulity Certifiction progrm ws developed to recognize MerCruiser botbuilder customers who hve chieved higher mnufcturing stndrds. It is the first nd only comprehensive mnufcturer instlltion certifiction progrm in the industry. The progrm hs three gols: 1. To enhnce overll product qulity. 2. To improve the bot ownership experience. 3. To enhnce overll customer stisfction. The certifiction process is designed to review ll fcets of mnufcturing nd engine instlltion. The progrm is composed of design, mnufcturing nd instlltion review stges with which builders must comply. Certifiction pplies leding edge methodologies to crete: Efficiencies nd best prctices specific to engine instlltion. World clss ssembly nd component specifictions. Efficient instlltion processes. Industry stndrd end of line test procedures Bot builders tht successfully complete the progrm nd meet ll certifiction requirements ern Instlltion Qulity System Certified Mnufcturer sttus nd receive n dditionl one (1) yer of Mercury limited fctory wrrnty coverge on ll MerCruiser powered bots tht re registered on nd fter the bot builder's certifiction dte for ll worldwide registrtions. Mercury hs designted section of our Website to promote the Instlltion Qulity Certifiction Progrm nd communicte its benefits to consumers. For current list of MerCruiser powered bot brnds tht hve erned Instlltion Qulity Certifiction, visit Cliforni Emissions Limited Wrrnty Wht Is Covered NOTE: Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer The Cliforni Air Resources Bord hs promulgted ir emissions regultions for inbord nd sterndrive engines. The regultions pply to ll inbord nd sterndrive engines tht were mnufctured for the 2003 model yer nd lter. Mercury Mrine, in complince with those regultions, provides this limited wrrnty for the emission control systems (see the components of the emission control system listed following), nd further wrrnts tht the inbord or sterndrive engine ws designed, built, nd equipped to conform with ll pplicble regultions dopted by the Cliforni Air Resources Bord pursunt to its uthority in Chpters 1 nd 2, Prt 5, Division 26 of the Helth nd Sfety Code. For informtion regrding the limited wrrnty for the non emissions relted components of the inbord or sterndrive engine, plese see the limited wrrnty sttement for your engine. NOTE: Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer Pge JUNE 2007

21 Durtion Of Coverge Section 1 - Wrrnty NOTE: Your deler will register your engine for wrrnty coverge for you. The wrrnty registrtion process is not relted in ny wy to the process of obtining license, title or registrtion from stte boting uthorities. You should sk your deler to updte your wrrnty registrtion informtion to reflect chnge of ddress or trnsfer of ownership. (This chnge my be mde t ny time.) See the Wrrnty Registrtion section of your mnul or your deler for more informtion. Mercury Mrine wrrnts the components of the emissions control systems (see the components of the emission control system listed following) of its new, 2003 model yer nd lter Cliforni certified inbord nd sterndrive engines, registered to Cliforni resident, to be free from defects in mteril or workmnship tht cuse the filure of wrrnted prt to be identicl in ll mteril respects to tht prt s described in the ppliction of Mercury Mrine for certifiction from the Cliforni Air Resources Bord, for the period of time, nd under the conditions identified below. The cost to dignose wrrnty filure is covered under the wrrnty (if the wrrnty clim is pproved). Dmge to other engine components cused by the filure of wrrnted prt will lso be repired under wrrnty. NOTE: Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer 2003 This limited wrrnty provides coverge for the components of the emissions control systems of new model yer inbord nd sterndrive engines for 2 yers from either the dte the product is first sold, or first put into service, whichever occurs first. Emission relted norml mintennce items such s sprk plugs nd filters, tht re on the wrrnted prts list (see following) re wrrnted up to their first required replcement intervl only. (See Mintennce Schedule). The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent purchser. (See instructions on trnsfer of wrrnty). Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. How To Obtin Wrrnty Coverge The customer must provide Mercury with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, plese notify Mercury Mrine nd Mercury will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge JUNE 2007 Pge 13

22 Section 1 - Wrrnty Wht Mercury Will Do Wht Is Not Covered Mercury Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our expense nd t our option, repiring or replcing defective prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended wide open throttle RPM rnge (see Specifictions), opertion of the product in mnner inconsistent with the recommended opertion procedures, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see Specifictions), ltertion or removl of prts, or wter entering the engine through the fuel intke, ir intke or exhust system. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. Non wrrnty mintennce, replcement, or repir of emission control devices nd systems my be performed by ny mrine engine repir estblishment or individul. The use of non Mercury prts for non wrrnty mintennce or repirs will not be grounds for disllowing other wrrnty work. The use of dd on (s defined t section 1900 (b)(1) nd (b)(10) of Title 13 of the Cliforni Code of Regultions) or modified prts not exempted by the Cliforni Air Resources Bord my be grounds for disllowing wrrnty clim, t the discretion of Mercury Mrine. Filures of wrrnted prts cused by the use of non exempted dd on or modified prt will not be covered. Components Of The Emission Control System 1. Fuel Metering System. Crburetor nd internl prts (nd/or pressure regultor or fuel injection system) b. Intke vlves 2. Air Induction System. Intke mnifold 3. Ignition System. Sprk plugs b. Electronic ignition c. Ignition coil nd/or control module d. Ignition wires 4. Positive Crnkcse Ventiltion (PCV) System. PCV Vlve b. Oil filler cp Pge JUNE 2007

23 5. Exhust System.. Exhust mnifold b. Exhust elbow c. Intermedite exhust elbow d. Lower exhust pipe e. Tilpipe f. Exhust vlve 6. Miscellneous Items Used in Above Systems Section 1 - Wrrnty. Hoses, clmps, fittings, tubing, seling gskets or devices, nd mounting hrdwre b. Pulleys, belts, nd idlers c. Vcuum, temperture, check nd time sensitive vlves nd switches d. Electronic controls. Disclimers And Limittions DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. If you hve ny questions regrding your wrrnty rights nd responsibilities, refer to Owner Service Assistnce for contct informtion. Cliforni Emission Control Wrrnty Sttement Your Wrrnty Rights nd Obligtions The Cliforni Air Resources Bord is plesed to explin the emission control system wrrnty on your 2003 model yer 1. nd lter inbord or sterndrive engine. In Cliforni, new inbord nd sterndrive engines must be designed, built nd equipped to meet the Stte's stringent nti smog stndrds. Mercury Mrine must wrrnt the emission control system on your inbord or sterndrive engine for the periods of time listed below provided there hs been no buse, neglect or improper mintennce of your inbord or sterndrive engine. Your emission control system my include prts such s the crburetor or fuel injection system, the ignition system, nd ctlytic converter. Also included my be hoses, belts, connectors nd other emission relted ssemblies. Where wrrntble condition exists, Mercury Mrine will repir your inbord or sterndrive engine t no cost to you; including dignosis, prts nd lbor. 1. Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer JUNE 2007 Pge 15

24 Section 1 - Wrrnty Mnufcturer's Wrrnty Coverge For sprk ignition inbord nd sterndrive mrine engines: Select emission control prts from model yer inbord nd sterndrive engines re wrrnted for 2 yers. If ny emission relted prt on your engine is defective under wrrnty, the prt will be repired or replced by Mercury Mrine. Owner's Wrrnty Responsibilities As the inbord or sterndrive engine owner, you re responsible for the performnce of the required mintennce listed in your owner's mnul. Mercury Mrine recommends tht you retin ll receipts covering mintennce on your inbord or sterndrive engine, but Mercury Mrine cnnot deny wrrnty solely for the lck of receipts or your filure to ensure the performnce of ll scheduled mintennce. As the inbord or sterndrive engine owner, you should however be wre tht Mercury Mrine my deny you wrrnty coverge if your inbord or sterndrive engine or prt hs filed due to buse, neglect, improper mintennce or unpproved modifictions. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. You re responsible for presenting your inbord or sterndrive engine to Mercury Mrine deler uthorized to service the product s soon s problem exists. The wrrnty repirs will be completed in resonble mount of time, not to exceed 30 dys. If you hve ny questions regrding your wrrnty rights nd responsibilities, refer to Owner Service Assistnce for contct informtion. Emission Control Informtion Lbel A tmper resistnt Emission Control Informtion lbel is ffixed in visible loction to the engine t time of mnufcture by Mercury MerCruiser. In ddition to the required emissions sttement, the lbel lists the engine seril number, fmily, FEL (emission level), dte of mnufcture (month, yer), nd the engine displcement. Plese note tht the low emissions certifiction will not ffect the fit, function, or performnce of the engines. Botbuilders nd delers my not remove the lbel or the prt it is ffixed to before sle. If modifictions re necessry, contct Mercury MerCruiser bout the vilbility of replcement decls before proceeding. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# OMXXXXXXXX D.O.M. JAN FAMILY XXXXX_XXXXXX DISP X.XL FEL. XX.X g/kw-hr Emission Control Lbel Non CE Mrked "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "FEL." Fmily Emission Limit "D.O.M." Dte of Mnufcture Pge JUNE 2007

25 Section 1 - Wrrnty "DISP" Piston Displcement EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# FAMILY OMXXXXXX XXXXX XXXXXX D.O.M. Dec 2004 FEL. XX.X g/kw-hr DISP. X.XL 0575 Emission Control Lbel CE Mrked Owner Responsibility "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "FEL." Fmily Emission Limit "D.O.M." Dte of Mnufcture "DISP" Piston Displcement CE When this mrk is present in the lower right corner of the Emission Control Informtion Lbel, on the engine, the Declrtion of Conformnce pplies. Refer to the front pge of this Mnul for further informtion. The owner/opertor is required to hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. The owner/opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow emissions levels to exceed their predetermined fctory specifictions. Emission Certifiction Str Lbel Your bot is lbeled on the hull with one of the following str lbels. The Symbol for Clener Mrine Engines Mens: 1. Clener Air nd Wter for helthier lifestyle nd environment. 2. Better Fuel Economy burns up to percent less gs nd oil thn conventionl crbureted two stroke engines, sving money nd resources. 3. Longer Emission Wrrnty Protects consumer for worry free opertion. Beginning Jnury 1, 2003, one Three Str lbel will be included with ech fctory certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp nd below) will hve Three Str Ultr Low Emission rting. The Three Str lbel identifies tht these engines meet the Cliforni Air Resources Bord's Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emissions engines JUNE 2007 Pge 17

26 Section 1 - Wrrnty The Three Str lbel will be ffixed on the left side of the hull s shown. XX 1234 XX - Recommended loction b mc79531 b - Secondry loction One Str - Low emission Two Strs - Very Low emission mc The one str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2001 exhust emission stndrds. Engines meeting these stndrds hve 75% lower emissions thn conventionl crbureted two stroke engines. These engines re equivlent to the U.S. EPA's 2006 stndrds for mrine engines. FO IDA mc The two str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2004 exhust emission stndrds. Engines meeting these stndrds hve 20% lower emissions thn One Str Low Emission engines. Three Strs - Ultr Low emission A SS D mc The three str lbel identifies engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2008 exhust emission stndrds or the Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emission engines. Four Strs - Super Ultr Low emission RN F T mc The Four Str lbel identifies engines tht meet the Air Resources Bord's Sterndrive nd Inbord mrine engine 2009 exhust emission stndrds. Personl Wtercrft nd Outbord mrine engines my lso comply with these stndrds. Engines meeting these stndrds hve 90% lower emissions thn One Str Low Emission engines. Pge JUNE 2007

27 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tble of Contents Lnyrd Stop Switch Instrumenttion System View Digitl Guges Anlog Guges Remote Controls (Non-DTS Models) Remote Controls...23 Pnel Mount Fetures Console Mount Fetures Zero Effort Fetures...24 Remote Controls (DTS Models) Remote Controls...25 Pnel Mount Fetures...25 Console Mount Fetures - Single Engine...26 Slim Binncle Console Mount Fetures - Single Engine...27 Console Mount Fetures- Dul Engine...28 Synchronizing Dul Engines...28 Dul Helm Sttion Trnsfer...29 Synchronizing Dul Helms Prior To Sttion Trnsfer Zero Effort Fetures...30 Electricl System Overlod Protection Audio Wrning System Testing The Audio Wrning System Engine Gurdin Strtegy Trnsmission Gurdin Strtegy Wrning Horn Signls JUNE 2007 Pge 19

28 Section 2 - Getting to Know Your Power Pckge Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor's position (s in ccidentl ejection from the opertor's position). b RUN c - Stop switch b - Lnyrd c - Clips to the opertor Accidentl ejections, such s flling overbord, re more likely to occur in: low sided sport bots bss bots high performnce bots 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 obstcle infested wters relesing your grip on the steering wheel tht is pulling in one direction consuming lcohol or drugs high speed boting mneuvers The lnyrd is cord usully between 122 nd 152 cm (4 nd 5 feet) in length when stretched out, with n element on one end mde to be 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 possible to minimize the likelihood of lnyrd entnglement with nerby objects. 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 norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, but the bot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the bot will not complete full circle. While the bot is costing, it cn cuse injury to nyone in the bot's pth s seriously s the bot would when under power. We strongly recommend tht other occupnts be instructed on proper strting nd operting procedures should they be required to operte the engine in n emergency (e.g. if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the bot, stop the engine immeditely to reduce the possibility of serious injury or deth from being struck by the bot. Alwys properly connect the opertor to the stop switch using lnyrd. Pge JUNE 2007

29 Instrumenttion System View Section 2 - Getting to Know Your Power Pckge Accidentl or unintended ctivtion of the switch during norml opertion is lso possibility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could be thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the bot who could be ejected over the bow nd possibly struck by 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 bot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. SmrtCrft SELECT System View HOME 5650 Your power pckge my be connected to the Mercury SC5000 SmrtCrft System View disply. The disply monitors nd reports informtion rnging from bsic operting dt to engine lrm dt. The SC5000 System View Disply is comprehensive bot informtion center. System View llows the bot opertor to receive welth of criticl opertionl informtion, displyed clerly nd instntly t the helm on the LCD disply. The System View continuously monitors nd reports informtion rnging from bsic operting dt to detiled vessel environment informtion. System View displys wter temperture nd depth, engine trim sttus, bot speed, steering ngle, system preventive mintennce reminders nd systems dignostics. System View lso cn be fully integrted with the bot's GPS, if equipped, to provide up to the minute loction, course, speed, nd fuel to destintion informtion. When problem is detected with the engine or system, the System View will lert the opertor to the potentil problem by displying the lrm messge in the informtion window, locted t the bottom of the view screen. If the problem cn cuse immedite engine dmge, the Engine Gurdin System will respond to the problem by limiting engine power. Immeditely reduce throttle speed to idle. Refer to the System View Opertion Mnul for further explntion of the problem nd the correct ction to tke JUNE 2007 Pge 21

30 Section 2 - Getting to Know Your Power Pckge Digitl Guges Anlog Guges A Mercury SmrtCrft System instrument pckge cn be purchsed for this product. A few of the functions the instrument pckge will disply re engine RPM, coolnt temperture, oil pressure, bttery voltge, fuel consumption nd engine operting hours. The SmrtCrft Instrument pckge will lso id in Engine Gurdin dignostics. The SmrtCrft Instrument pckge will disply criticl engine lrm dt nd potentil problems. Refer to the mnul with your guge pckge for the wrning functions monitored nd bsic opertion of the SmrtCrft Instrument pckge. The following is brief explntion of the instrumenttion typiclly found on some bots. The owner/opertor should be fmilir with ll instruments nd their functions. Becuse of the lrge vriety of instrumenttion nd mnufcturers, you should hve your bot deler explin the prticulr guges nd norml redings for your bot KPH MPH X R P M L OIL H BATT C TEMP H b c d e FUEL CRUISELOG f g h i Speedometer f - Fuel guge b - Tchometer g - Hour meter c - Oil pressure guge h - Bilge blower switch d - Voltmeter i - Ignition switch e - Wter temperture guge Speedometer: Indictes bot speed. Tchometer: Indictes engine RPM. Oil Pressure Guge: Indictes engine oil pressure. Voltmeter: Indictes bttery voltge. Wter Temperture Guge: Indictes engine operting temperture. Fuel Guge: Indictes quntity of fuel in tnk. Hour meter: Records engine operting time. Bilge Blower Switch: Opertes bilge blower. Ignition Switch: Allows opertor to strt nd stop engine. Pge JUNE 2007

31 Section 2 - Getting to Know Your Power Pckge Remote Controls (Non DTS Models) Remote Controls PANEL MOUNT FEATURES Your bot my be 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. e b c d - Neutrl lock button b - Throttle only button c - Lnyrd stop switch d - Control hndle tension djustment screw e - Control hndle Neutrl Lock Button - Prevents ccidentl shift nd throttle enggement. Neutrl lock button must be pushed in to move the control hndle out of neutrl. Throttle Only Button - Allows engine throttle dvncement without shifting the engine. This is done by disengging the shift mechnism from the control hndle. The throttle only button cn be depressed only when the remote control hndle is in the neutrl position, nd should only be 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. Refer to Lnyrd Stop Switch for informtion on the use of this switch. Control Hndle - Opertion of the shift nd throttle re controlled by 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 bck from neutrl with quick firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Control Hndle Tension Adjustment Screw - (not visible) This screw is used to djust the effort required to move the remote control hndle. Refer to instructions provided with remote control for complete djustment instructions JUNE 2007 Pge 23

32 Section 2 - Getting to Know Your Power Pckge CONSOLE MOUNT FEATURES b - Throttle Only Button b b - Control Hndle Throttle Only Button - Allows engine throttle dvncement without shifting the engine. This is done by disengging the shift mechnism from the control hndle. The throttle only button cn be depressed only when the remote control hndle is in the neutrl position. Control Hndles - Opertion of the the shift nd throttle re controlled by 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 bck from neutrl with quick firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Control Hndle Tension Adjustment Screw - (not visible) This screw is used to djust the effort required to move the remote control hndle. Refer to instructions provided with remote control for complete djustment instructions. Zero Effort Fetures b - Shift ever b - Throttle lever Shift Lever - Shift functions re controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its ft position. Shift into neutrl by moving the shift lever to its center position. Shift into forwrd by moving the shift lever to its forwrd position. Pge JUNE 2007

33 Section 2 - Getting to Know Your Power Pckge Throttle Lever - Throttle functions re controlled by the movement of the throttle lever. Increse the RPM by moving the throttle lever forwrd. Achieve Wide Open Throttle (WOT) by plcing the throttle lever in its full forwrd position. Decrese RPM by moving the throttle lever bck. Achieve minimum RPM (idle) by plcing the throttle lever in its full ft position. Remote Controls (DTS Models) Remote Controls IMPORTANT: Your bot must be equipped with Mercury Mrine electronic remote control. Strt in ger protection is provided by this control system nd prevents the engine from strting when the control is ctuted in forwrd or reverse. Refer to the Mercury Precision Prts/Quicksilver Accessories Guide. The Digitl Throttle nd Shift System (DTS) required to operte this engine pckge provides strt nd stop functions, throttle control, shift control, strt in ger protection, nd emergency lnyrd stop functions. The DTS system works with specilized helm components such s commnd module kit nd electronic remote control. Consult your deler for description nd/or demonstrtion of your remote control. Pnel Mount Fetures c b d e f - + g Lnyrd stop switch b - Control hndle c - Shift lock d - Trim/tilt switch e - Throttle only button f - Detent tension djustment screw g - Control hndle friction djustment screw 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. Refer to Lnyrd Stop Switch for informtion on the use of this switch. Control Hndle - Opertion of the shift nd throttle re controlled by 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 bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Shift Lock - Pressing the shift lock llows the engine to shift. The shift lock must lwys be pressed when moving the control hndle out of the neutrl position JUNE 2007 Pge 25

34 Section 2 - Getting to Know Your Power Pckge Throttle Only Button - Allows engine throttle dvncement without shifting the engine. The throttle only button cn be depressed only when the remote control is in the neutrl position, nd should only be used to ssist in strting or wrming up the engine. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Console Mount Fetures Single Engine c - + d g b f - Control hndle b - Active light c - Neutrl light d - Select key e - Arrow trckpd f - Throttle only/sttion select key g - Detent tension djustment h - Control hndle friction djustment screw e h Control Hndle - Opertion of the shift nd throttle re controlled by 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 bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Active Light - The ctive light is illuminted to show the remote control is ctive nd redy for use. Neutrl Light - The neutrl light is illuminted when the engine is in neutrl ger position. Select Key - Selects System View on screen options nd confirms dt entries. Arrow Trckpd - Nvigtes through System View on screen function messges. Throttle Only/Sttion Select Key - Allows engine throttle dvncement without shifting the engine. The throttle only/sttion select button lso llows the bot opertor to select which remote control is in control of the engine opertion when operting with multiple helms. Refer to Dul Helm Sttion Trnsfer. Pge JUNE 2007

35 Section 2 - Getting to Know Your Power Pckge Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Slim Binncle Console Mount Fetures Single Engine c d f + START STOP b - Control hndle b - Active light c - Neutrl light d - Strt/stop button e - Throttle only/sttion select key f - Detent tension djustment g - Control hndle friction djustment screw e g Control Hndle - Opertion of the shift nd throttle re controlled by 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 bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Active Light - The ctive light is illuminted to show the remote control is ctive nd redy for use. Neutrl Light - The neutrl light is illuminted when the engine is in neutrl ger position. Strt/Stop Button - Allows the bot opertor to strt or stop the engine without using the ignition key. Throttle Only/Sttion Select Key - Allows engine throttle dvncement without shifting the engine. The throttle only/sttion select button lso llows the bot opertor to select which remote control is in control of the engine opertion when operting with multiple helms. Refer to Dul Helm Sttion Trnsfer. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension JUNE 2007 Pge 27

36 Section 2 - Getting to Know Your Power Pckge Console Mount Fetures Dul Engine c - + d h ACTIVE THROTTLE ONLY SYNC e i b STATION SELECT g f Control hndles b - Active light c - Neutrl light d - Select key e - Arrow trckpd f - Sync light g - Throttle only/sttion select key h - Detent tension djustment i - Control hndle friction djustment screw Control Hndle - Opertion of the shift nd throttle re controlled by 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 bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Active Light - The ctive light is illuminted to show the remote control is ctive nd redy for use. Neutrl Light - The neutrl light is illuminted when the engine is in neutrl ger position. Select Key - Selects System View on screen options nd confirms dt entries. Arrow Trckpd - Nvigtes through System View on screen function messges. Sync Light - The sync light is illuminted when the RPM of the two engines re being synchronized by the DTS system. Throttle Only/Sttion Select Key - Allows engine throttle dvncement without shifting the engine. The throttle only/sttion select button lso llows the bot opertor to select which remote control is in control of the engine opertion when operting with multiple helms. Refer to Dul Helm Sttion Trnsfer. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Synchronizing Dul Engines The uto synchronizing feture, when engged, will utomticlly djust the port engine speed to mtch the speed of the strbord engine. Synchronizing of engines will utomticlly engge when the speed of both engines re over 900 RPM for two seconds nd remote control hndles re positioned within 5 of ech other. Pge JUNE 2007

37 Section 2 - Getting to Know Your Power Pckge Auto Synchronizing will sty engged up to 95% throttle opening. The Sync light will turn on when the engines re synchronized. To disengge, move one or both control hndles until they re more thn 5 prt, reduce engine speed below 900 RPM, or increse engine speed beyond 95%. Dul Helm Sttion Trnsfer ACTIVE THROTTLE ONLY STATION SELECT SYNC The throttle only/sttion select button llows the bot opertor to select which remote control is in control of the engine opertion. The ctive light is illuminted t the remote control sttion tht is in control of the engine. 3434! WARNING Avoid serious injury or deth from loss of bot control. The bot opertor should never leve the ctive sttion while engine is in ger. Helm trnsfer should only be ttempted while both sttions re mnned. One person helm trnsfer should only be performed while engine is in neutrl. NOTE: Idle position is preferred when doing sttion trnsfer. If conditions do not llow the remote control to be plced t idle position, sttion trnsfer cn be done while in ger. NOTE: Pressing nd relesing sttion select button t new sttion llows the engine control to be trnsferred to the new sttion. The control will utomticlly strt djusting engine RPM nd ger position to mtch the control hndle setting t the new sttion. Adjust control hndles to the desired throttle nd ger position. 1. Plce ctive remote control lever to idle position. 2. Proceed to the inctive helm sttion nd position remote control lever to the idle position. 3. Press throttle only/sttion select button once. The "ACTIVE" light will illuminte to indicte the remote control sttion is in control of the engine. b b ACTIVE THROTTLE ONLY STATION SELECT ACTIVE SYNC THROTTLE ONLY STATION SELECT Active light b - Throttle only/sttion select button 4. The ctive light will switch off t the originl remote control sttion JUNE 2007 Pge 29

38 Section 2 - Getting to Know Your Power Pckge SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER Pressing the sttion select button nd holding it in llows the bot opertor 10 seconds to mtch up the control hndle settings t the new sttion with the hndle settings tht re t the old (to be inctive) sttion. If the hndles re not mtched, the neutrl light will flsh. The light blinks fster s the hndles re nering mtch position. Once the light stys on continuously, the hndles re mtched nd the button cn be relesed. Trnsfer process is complete nd the new sttion is now in control. If the button is held for over 10 seconds, the sttion trnsfer is cncelled. Zero Effort Fetures b - Shift ever b - Throttle lever Shift Lever - Shift functions re controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its ft position. Shift into neutrl by moving the shift lever to its center position. Shift into forwrd by moving the shift lever to its forwrd position. Throttle Lever - Throttle functions re controlled by the movement of the throttle lever. Increse the RPM by moving the throttle lever forwrd. Achieve Wide Open Throttle (WOT) by plcing the throttle lever in its full forwrd position. Decrese RPM by moving the throttle lever bck. Achieve minimum RPM (idle) by plcing the throttle lever in its full ft position. Electricl System Overlod Protection If n electricl overlod occurs, fuse will blow or the circuit breker will trip open. Find nd correct the cuse before replcing the fuse or resetting the circuit breker. NOTE: In n emergency, when the engine must be operted nd the cuse for the high current drw cnnot be locted nd corrected, turn off or disconnect ll ccessories connected to the engine nd instrumenttion wiring. Reset the circuit breker. If the breker remins open, the electricl overlod hs not been eliminted. Further checks must be mde on the electricl system. Contct your uthorized deler. Pge JUNE 2007

39 Section 2 - Getting to Know Your Power Pckge 1. A circuit breker protects the engine wiring hrness nd the instrumenttion power led. Test the circuit breker by pushing the red button. If the circuit breker is functioning properly, the yellow lever will pper. Reset fter testing, or if tripped, by pushing the yellow lever bck into the housing. b Yellow lever style circuit breker typicl - Yellow lever shown tripped b - Red test button 2. A 90 mp fuse is locted on the lrge post of the strter solenoid. This fuse protects the engine wiring hrness if n electricl overlod occurs. mc Four fuses re locted on the port side of the engine. These fuses protect the min power, fuel pump, ignition, nd ccessory circuits JUNE 2007 Pge 31

40 Section 2 - Getting to Know Your Power Pckge 4. A 20 mp fuse my be locted in the ignition switch "I" terminl led to protect the electricl system. Check for blown fuse if the ignition key is turned to the "START" position nd nothing hppens (nd circuit breker is not tripped). mc Audio Wrning System Your Mercury MerCruiser power pckge my be equipped with n Audio Wrning System. The Audio Wrning System will not protect the engine from dmge. It is designed to wrn the opertor tht problem hs occurred. The udio wrning system will sound with continuous horn if one of the following occurs: Engine oil pressure too low Engine temperture too hot Sewter pressure too low The udio wrning system will sound with n intermittent beeping if the following occurs: Trnsmission fluid temperture too hot Trnsmission pressure too low NOTICE A continuous horn indictes criticl fult. Operting the engine during criticl fult cn dmge components. If the wrning horn emits continuous beep, do not operte the engine unless voiding hzrdous sitution. If the lrm sounds, stop the engine immeditely. Investigte cuse nd correct it, if possible. If the cuse cnnot be determined, contct your uthorized Mercury MerCruiser deler. Testing The Audio Wrning System 1. Turn the ignition switch to the "ON" position without crnking the engine. 2. Listen for the udio lrm. The lrm will sound if the system is functioning correctly. Engine Gurdin Strtegy IMPORTANT: Bot speed could be reduced to idle nd my not respond to the throttle. Engine Gurdin Strtegy is designed to help reduce the potentil for engine dmge by reducing engine power when potentil problem is sensed by the ECM. Engine Gurdin monitors: Oil pressure Coolnt temperture Sewter pressure Pge JUNE 2007

41 Engine overspeed Section 2 - Getting to Know Your Power Pckge Exhust Mnifold Temperture [8.1 liter (496 cid) engines only] Also the Engine Gurdin Strtegy will reduce engine power to 90 percent of mximum if ny sensor on the power pckge fils. For exmple, if the wter inlet becomes prtilly blocked, Engine Gurdin Strtegy will reduce the vilble power level of the engine to help prevent dmge from decresed wter flow to the engine. If the debris psses through nd full wter flow is restored, engine power levels re restored to norml. To void possible recurrence of the problem you should contct n uthorized deler. The ECM stores the fult nd with this informtion the technicin will be ble to more rpidly dignose problems. Trnsmission Gurdin Strtegy Wrning Horn Signls IMPORTANT: Bot speed could be reduced to idle nd my not respond to the throttle. Trnsmission Gurdin is MerCruiser DTS feture tht protects trnsmissions from clutch dmge. Trnsmission Gurdin monitors the clutch pck pressure in forwrd nd reverse gers. If the trnsmission fluid pressure drops below predetermined level, Trnsmission Gurdin lowers the engine torque nd speed to prevent clutch slippge. To void possible recurrence of the problem, you should contct n uthorized deler. The ECM stores the fult nd with this informtion the technicin will be ble to more rpidly dignose problems. Most fults will cuse the wrning horn circuit to ctivte. How the wrning horn ctivtes depends on how serious the problem is. There re four wrning horn sttes: Cution horn signl vries with product line nd clibrtion. Miniml gurdin. Wrning horn signl vries with product line nd clibrtion. Severe horn is beeping constntly. Criticl horn is beeping constntly nd gurdin will be t forced idle. In ddition, depending on the guge pckge, there will be wrning icons nd fult messges on the dsh mounted guges JUNE 2007 Pge 33

42 Section 2 - Getting to Know Your Power Pckge Notes: Pge JUNE 2007

43 Tble of Contents Section 3 - On The Wter Section 3 - On The Wter Sfe Boting Suggestions Be Alert To Crbon Monoxide Poisoning Good Ventiltion Poor Ventiltion Bsic Bot Opertion (Non-DTS Models) Lunching nd Bot Opertion...38 Opertion Chrt Strting nd Stopping the Engine...39 Strting the Engine Stopping the Engine Throttle Only Opertion...40 Freezing Temperture Opertion...40 Drin Plug nd Bilge Pump...40 Bsic Bot Opertion (DTS Models) Lunching nd Bot Opertion...40 Opertion Chrt Strting nd Stopping the Engine...41 Strting the Engine Stopping the Engine Throttle Only Opertion...42 Freezing Temperture Opertion...43 Drin Plug nd Bilge Pump...43 Protecting People In The Wter While You Are Cruising While Bot Is Sttionry High-Speed And High-Performnce Bot Opertion Pssenger Sfety In Pontoon Bots And Deck Bots Bots Hving An Open Front Deck Bots With Front-Mounted, Rised Pedestl Fishing Sets Wve And Wke Jumping Impct With Underwter Hzrds Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot...46 Bottom Of Bot...46 Cvittion...47 Ventiltion...47 Elevtion And Climte...47 Getting Strted Hour Brek-In Period...47 After Brek-In Period...48 End of First Seson Checkup JUNE 2007 Pge 35

44 Section 3 - On The Wter Sfe Boting Suggestions In order to sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl boting regultions nd restrictions, nd consider the following suggestions. Know nd obey ll nuticl rules nd lws of the wterwys. Mercury MerCruiser strongly recommends tht ll powerbot opertors complete boting sfety course. Courses re offered in the U.S.A. by: The U.S. Cost Gurd Auxiliry, The Power Squdron, The Red Cross nd your stte or provincil boting lw enforcement gency. Inquiries my be mde to the Boting Hotline t or the Bot U.S. Foundtion t BOAT. Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment on bord. Here re some suggestions of the types of sfety equipment to crry when boting: 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 bilge pump nd extr drin plugs Drinking wter Trnsistor rdio Pddle or or Spre propeller, thrust hubs, nd n pproprite wrench First id kit nd instructions Wter proof storge continers Spre operting equipment, btteries, bulbs nd fuses Compss nd mp or chrt of the re Personl flottion device (1 per person on bord) Wtch for signs of wether chnge nd void foul wether nd rough-se boting. Tell someone where you re going nd when you expect to return. Pssenger bording. Stop the engine whenever pssengers re bording, unloding or re ner the bck (stern) of the bot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl Lw requires tht there be U. S. Cost Gurd pproved life jcket (personl flottion device), correctly sized nd redily ccessible for every person on bord, plus throwble cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the bot. Prepre other bot opertors. Instruct t lest 1 person on bord in the bsics of strting nd operting the engine nd bot hndling in cse the driver becomes disbled or flls overbord. Do not overlod your bot. Pge JUNE 2007

45 Section 3 - On The Wter Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot cpcity plte). Know your bot's operting nd loding limittions. Know if your bot will flot if full of wter. When in doubt, contct your uthorized Mercury MerCruiser deler or the bot mnufcturer. Ensure tht everyone in the bot is properly seted. Do not llow nyone to sit or ride on ny prt of the bot tht ws not intended for such use. This includes the bcks of sets, gunwles, trnsom, bow, decks, rised fishing sets nd ny rotting fishing set; nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of bot control or sudden bot movement could cuse person to be thrown overbord or into the bot. Ensure tht ll pssengers hve proper set nd re in it before ny bot movement. Never be under the influence of lcohol or drugs while boting (it is the lw). They impir your judgment nd gretly reduce your bility to rect quickly. Know your boting re nd void hzrdous loctions. Be lert. The opertor of the bot is responsible by lw to mintin proper lookout by sight nd hering. The opertor must hve n unobstructed view prticulrly to the front. No pssengers, lod or fishing sets should block the opertors view when the bot is bove idle or plning trnsition speed. Wtch out for others, the wter nd your wke. Never drive your bot directly behind wter skier in cse the skier flls. As n exmple, your bot trveling t 40 km/h (25 MPH) will overtke fllen skier who ws 61 m (200 ft.) in front of you in 5 seconds. Wtch fllen skiers. When using your bot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the bot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never bck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required by lw to file Boting Accident Report with their stte boting lw enforcement gency when their bot is involved in certin boting ccidents. A boting ccident must be reported if 1) there is loss of life or probble loss of life, 2) there is personl injury requiring medicl tretment beyond first id, 3) there is dmge to bots or other property where the dmge vlue exceeds $ or 4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement. Be Alert To Crbon Monoxide Poisoning Crbon monoxide is present in the exhust fumes of ll internl combustion engines including the outbords, sterndrives nd inbord engines tht propel bots, s well s the genertors tht power vrious bot ccessories. Crbon monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of crbon monoxide poisoning, which should not be confused with sesickness or intoxiction, include hedche, dizziness, drowsiness nd nuse.! WARNING Crbon monoxide poisoning cn led to unconsciousness, brin dmge, or deth. Keep the bot well ventilted while t rest or underwy nd void prolonged exposure to crbon monoxide JUNE 2007 Pge 37

46 Section 3 - On The Wter Good Ventiltion Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes. 1. Exmple of desired ir flow through the bot. Poor Ventiltion mc Under certin conditions, permnently enclosed or cnvs enclosed cbins or cockpits with insufficient ventiltion my drw in crbon monoxide. Instll one or more crbon monoxide detectors in your bot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry bot tht contins or is ner n operting engine my be exposed to hzrdous level of crbon monoxide. 1. Exmples of poor ventiltion while bot is sttionry: - Operting the engine when the bot is moored in confined spce b mc b - Mooring close to nother bot with its engine operting 2. Exmples of poor ventiltion while bot is moving: - Operting the bot with the trim ngle of the bow too high b mc b - Operting the bot with no forwrd htches open (sttion wgon effect) Bsic Bot Opertion (Non DTS Models) Lunching nd Bot Opertion IMPORTANT: Instll bilge drin plug prior to lunching bot. OPERATION CHART Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Instll bilge drin plug. Observe ll guges to check condition of engine. If not norml, stop engine. Observe ll guges to check condition of engine. If not norml, stop engine. Turn ignition key to the "OFF" position. Open engine htch. Check for fuel, oil, wter, fluid nd exhust leks. Listen for the udio lrm. Turn bttery switch to the "OFF" position. Turn bttery switch on. Check shift nd throttle control opertion. Close fuel shut off vlve. Pge JUNE 2007

47 Section 3 - On The Wter Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Operte bilge blowers. Open fuel shut off vlve. Open secock, if equipped. Close the drin system. Check the engine oil. Perform ll other checks specified by your deler nd/or bot builder. Listen for Audio Wrning Alrm to sound when the ignition switch is in the "ON" position. Check steering opertion. Close secock, if equipped. Flush cooling system if in sltwter. Drin bilge. Strting nd Stopping the Engine STARTING THE ENGINE NOTE: Only perform those functions pplicble to your power pckge. 1. Check ll items listed in the Opertion Chrt. 2. Plce the remote control hndle in neutrl. NOTICE Filure to provide sufficient cooling wter will dmge the wter pump nd cuse the engine to overhet. Provide sufficient supply of wter t the wter inlets during opertion.! WARNING Explosive fumes contined in the engine comprtment cn cuse serious injury or deth from fire or explosion. Before strting the engine, operte the bilge blower or vent the engine comprtment for t lest five minutes. 3. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. Allow engine to wrm up (6 10 minutes on first strt of the dy). 4. If engine does not strt fter 3 ttempts:. Push the throttle only button nd position the remote control hndle/throttle lever to the 1/4 throttle position. b. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. 5. If engine does not strt fter step 4:. Move the remote control hndle/throttle lever to full throttle position, then return to 1/4 throttle. b. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. 6. Inspect the power pckge for fuel, oil, wter nd exhust leks. 7. Move control hndle with firm, quick motion forwrd to shift to forwrd ger, or bckwrd to shift to reverse. After shifting, dvnce throttle to desired setting JUNE 2007 Pge 39

48 Section 3 - On The Wter STOPPING THE ENGINE NOTICE Shifting into ger t engine speeds bove idle will dmge the gercse. Shifting into ger when the engine is not running cn cuse mislign the clutch, preventing proper shifting. Alwys shift the gercse into ger when the engine is operting t idle. If you must shift while the engine is not operting, rotte the propeller shft in the pproprite direction during shifting. 1. Move the remote control hndle to neutrl/idle nd llow the engine to slow to idle speed. If engine hs been operted t high speed for long period of time, llow the engine to cool t idle speed for 3 to 5 minutes. 2. Turn ignition key to the "OFF" position. Throttle Only Opertion 1. Refer to Remote Controls section for remote control fetures. 2. Move the control lever to the idle/neutrl position. 3. Depress nd hold the throttle only button, nd move the control lever to the idle/forwrd or idle/reverse position. 4. Advncing the control lever beyond the idle/forwrd or idle/reverse position will cuse engine speed to increse. IMPORTANT: Moving the control lever bck to the idle/neutrl position will disengge the throttle only button nd llow the engine to shift into ger. 5. Throttle only mode is dectivted by moving the control lever to the idle/neutrl position. Moving the control lever from the idle/neutrl position to the idle/forwrd or idle/reverse position without pressing the throttle only button will shift the unit into the chosen ger. Freezing Temperture Opertion IMPORTANT: If the bot is operted during periods of freezing temperture, precutions must be tken to prevent freeze dmge to the power pckge. Dmge cused by freezing is not covered by Mercury MerCruiser Limited Wrrnty. Drin Plug nd Bilge Pump The engine comprtment in your bot is nturl plce for wter to collect. For this reson, bots re normlly equipped with drin plug nd/or bilge pump. It is very importnt to check these items on regulr bsis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will be dmged if submerged. Dmge cused by submersion is not covered by the Mercury MerCruiser Limited Wrrnty. Bsic Bot Opertion (DTS Models) Lunching nd Bot Opertion OPERATION CHART IMPORTANT: Instll bilge drin plug prior to lunching bot. Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Instll bilge drin plug. Observe ll guges to check condition of engine. If not norml, stop engine. Observe ll guges to check condition of engine. If not norml, stop engine. Turn ignition key to the "OFF" position. Pge JUNE 2007

49 Section 3 - On The Wter Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Open engine htch. Check for fuel, oil, wter, fluid nd exhust leks. Listen for the udio lrm. Turn bttery switch to the "OFF" position. Turn bttery switch on. Check shift nd throttle control opertion. Close fuel shut off vlve. Operte bilge blowers. Check steering opertion. Close secock, if equipped. Open fuel shut off vlve. Flush cooling system if in sltwter. Open secock, if equipped. Drin bilge. Close the drin system. Check the engine oil. Perform ll other checks specified by your deler nd/or bot builder. Listen for Audio Wrning Alrm to sound when the ignition switch is in the "ON" position. Strting nd Stopping the Engine STARTING THE ENGINE NOTE: Perform only those functions pplicble to your power pckge. 1. Check ll items listed in the Opertion Chrt. 2. Plce the remote control hndle in neutrl. NOTICE Filure to provide sufficient cooling wter will dmge the wter pump nd cuse the engine to overhet. Provide sufficient supply of wter t the wter inlets during opertion.! WARNING Explosive fumes contined in the engine comprtment cn cuse serious injury or deth from fire or explosion. Before strting the engine, operte the bilge blower or vent the engine comprtment for t lest five minutes. NOTE: MerCruiser DTS models re equipped with SmrtStrt. The SmrtStrt feture incorportes push button strting. Rther thn holding the strt button or key switch to strt the engine nd then relesing it when the engine strts, SmrtStrt completely controls the strting process. When the strt button is pushed, the DTS system signls the engine PCM to strt the engine. If the engine does not strt, the strting process times out fter few seconds or when the engine reches 400 RPM. Attempting to strt the engine with the engine lredy running will turn the engine off. 3. Turn ignition key to "RUN" position. 4. Turn the ignition key switch to the "START" position then relese, or depress the strt/ stop button nd relese. If the engine is cold, llow the engine to operte t idle for 6 10 minutes or until the engine temperture reches 60 C (140 F). 5. If the engine does not strt fter three ttempts: JUNE 2007 Pge 41

50 Section 3 - On The Wter STOPPING THE ENGINE. Push the throttle only button nd position the remote control hndle or throttle lever to the 1/4 throttle position. b. Turn the ignition key to "strt." Relese key when the engine strts nd llow the switch to return to the "on" position. 6. If the engine does not strt fter step 5:. Move the remote control hndle.throttle lever to the full throttle position, then return to 1/4 throttle. b. Turn the ignition key to "strt." Relese key when the engine strts nd llow the switch to return to the "on" position. 7. Inspect the power pckge for fuel, oil, wter, nd exhust leks. 8. Move the control hndle with firm, quick motion forwrd to shift to forwrd ger, or bckwrd to shift to reverse. After shifting, dvnce throttle to desired setting. NOTICE Shifting into ger t engine speeds bove idle will dmge the gercse. Shifting into ger when the engine is not running cn cuse mislign the clutch, preventing proper shifting. Alwys shift the gercse into ger when the engine is operting t idle. If you must shift while the engine is not operting, rotte the propeller shft in the pproprite direction during shifting. 1. Move the remote control hndle to neutrl/idle nd llow the engine to slow to idle speed. If engine hs been operted t high speed for long period of time, llow the engine to cool t idle speed for 3 to 5 minutes. 2. The engine cn be stopped by ny one of the following 4 methods:. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop nd the control system will be dectivted. b. Depress the strt/stop button, if equipped. The engine will stop nd the control system will remin ctive. c. Momentrily move the ignition key switch to the "START" position, then relese immeditely. The control system will recognize tht the engine is running nd will stop the engine. The control system will remin ctive. Moving the ignition key switch to the "START" position gin will issue strt request to the control system nd the control system will strt the engine, if pproprite. d. Activte the lnyrd stop switch, if equipped. The engine will stop, but the control system will remin ctive. The control system will not llow the engine to strt if the lnyrd stop switch is ctivted. Throttle Only Opertion NOTE: When operting in throttle only (neutrl) mode, the DTS Control System will not llow the engine speed to increse bove 3500 RPM. Zero effort remote controls: Zero effort remote controls hve seperte throttle control nd shift control levers. Advncing the throttle control lever beyond the idle position while the shift control lever is in the neutrl position will cuse engine speed to increse, but only up to the mximum neutrl engine speed of 3500 RPM. Pge JUNE 2007

51 Section 3 - On The Wter! WARNING The Digitl Throttle nd Shift (DTS) Zero Effort control cn shift the engine or trnsmission t speeds greter thn idle, cusing unexpected bot movement, which my result in injury, deth, or property dmge due to loss of bot control. Alwys plce the throttle control lever in the idle position before moving the shift control lever into forwrd or reverse ger position. Pnel Mount nd Console Mount Remote Controls: Pnel mount nd console mount remote controls re equipped with throttle only button. To ctivte throttle only mode: 1. Refer to Remote Controls section for remote control fetures. 2. Move the control lever to the idle/neutrl position. 3. Depress the throttle only button, nd move the control lever to the idle/forwrd or idle/ reverse position. The DTS control system will sound two beeps on the udio wrning horn to indicte throttle only mode is ctive. On console mount remote controls, the neutrl light will begin to blink. 4. Advncing the control lever beyond the idle/forwrd or idle/reverse position will cuse engine speed to increse. IMPORTANT: Moving the control lever bck to the idle/neutrl position will dectivte the throttle only mode nd llow the engine to shift into ger. 5. Throttle only mode is dectivted by moving the control lever to the idle/neutrl position. Moving the control lever from the idle/neutrl position to the idle/forwrd or idle/reverse position without pressing the throttle only button will shift the unit into the chosen ger. Freezing Temperture Opertion IMPORTANT: If the bot is operted during periods of freezing temperture, precutions must be tken to prevent freeze dmge to the power pckge. Dmge cused by freezing is not covered by Mercury MerCruiser Limited Wrrnty. Drin Plug nd Bilge Pump The engine comprtment in your bot is nturl plce for wter to collect. For this reson, bots re normlly equipped with drin plug nd/or bilge pump. It is very importnt to check these items on regulr bsis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will be dmged if submerged. Dmge cused by submersion is not covered by the Mercury MerCruiser Limited Wrrnty. Protecting People In The Wter While You Are Cruising It is very difficult for person in the wter to tke quick ction to void bot heding in their direction, even t slow speeds. Alwys slow down nd exercise extreme cution ny time you re boting in n re where there might be people in the wter JUNE 2007 Pge 43

52 Section 3 - On The Wter While Bot Is Sttionry Whenever bot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force by the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury.! WARNING A spinning propeller, moving bot, or ny solid device ttched to the bot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your bot. Shift into neutrl nd shut off the engine before llowing people to swim or be in the wter ner your bot. High Speed And High Performnce Bot Opertion If your bot is considered high speed or high performnce bot with which you re unfmilir, we recommend tht you never operte it t its high speed cpbility without first requesting n initil orienttion nd demonstrtion ride with your deler or n opertor experienced with your bot. For dditionl informtion, refer to Hi-Performnce Bot Opertion booklet ( R2) from your deler, distributor or Mercury Mrine. Pssenger Sfety In Pontoon Bots And Deck Bots Whenever the bot is in motion, observe 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 bot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of bot direction, could throw them over the front of bot. Flling over the front of the bot between the two pontoons will position them to be run over. Bots Hving An Open Front Deck No one should ever be on the deck in front of the fence while the bot is in motion. Keep ll pssengers behind the front fence or enclosure. Persons on the front deck could esily be thrown overbord or persons dngling their feet over the front edge could get their legs cught by wve nd pulled into the wter. mc ! WARNING Sitting or stnding in n re of the bot not designed for pssengers t speeds bove idle cn cuse serious injury or deth. Sty bck from the front end of deck bots or rised pltforms nd remin seted while the bot is in motion. Bots With Front Mounted, Rised Pedestl Fishing Sets Elevted fishing sets re not intended for use when the bot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Pge JUNE 2007

53 Section 3 - On The Wter Any unexpected, sudden reduction in bot speed could result in the elevted pssenger flling over the front of the bot. Wve And Wke Jumping! WARNING mc Wve or wke jumping cn cuse serious injury or deth from occupnts being thrown within or out of the bot. Avoid wve or wke jumping whenever possible. mc Operting recretionl bots over wves nd wkes is nturl prt of boting. However, when this ctivity is done with enough speed to force the bot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the bot re enters the wter. The primry concern is the bot chnging direction while in the midst of the jump. In such cses the lnding my cuse the bot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to be thrown out of their sets or out of the bot. There is nother less common hzrdous result from llowing your bot to lunch off of wve or wke. If the bow of your bot pitches down fr enough while irborne, upon wter contct it my penetrte under the wter surfce nd submrine for n instnt. This will bring the bot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The bot my lso veer shrply to one side. Impct With Underwter Hzrds Reduce speed nd proceed with cution whenever you're driving bot in shllow wter or in res where the wters re suspected of hving underwter obstcles tht could be struck by the underwter drive components, rudder or the bot bottom JUNE 2007 Pge 45

54 Section 3 - On The Wter IMPORTANT: The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter object is control the bot speed. Under these conditions, bot speed should be kept to mximum speed of 24 to 40 km/h (15 to 25 MPH). Striking floting/underwter object my result in n infinite number of situtions. Some of these situtions could result in the following: The bot could move suddenly in new direction. Such shrp chnge in direction or turn cn cuse occupnts to be thrown out of their sets or out of the bot. A rpid reduction in speed. This will cuse occupnts to be thrown forwrd, even out of the bot. Impct dmge to the underwter drive components, rudder nd/or bot. Keep in mind, one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the bot speed. Bot speed should be kept to minimum plning speed when driving in wters known to hve underwter obstcles. After striking submerged object, stop the engine s soon s possible nd inspect the drive system for ny broken or loose prts. If dmge is present or suspected, the power pckge should be tken to n uthorized Mercury MerCruiser deler for thorough inspection nd necessry repir. The bot should be checked for hull frctures, trnsom frctures nd wter leks. Operting with dmged underwter drive components, rudder or bot bottom could cuse dditionl dmge to other prts of the power pckge, or could ffect control of the bot. If continued opertion is necessry, do so t gretly reduced speeds.! WARNING Operting bot 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. Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot Shifting weight to rer (stern): Generlly increses speed nd engine RPM Cuses bow to bounce in choppy wter Increses dnger of following wve splshing into the bot when coming off plne At extremes, cn cuse the bot to porpoise Shifting weight to front (bow): Improves ese of plning Improves rough wter ride At extremes, cn cuse the bot to veer bck nd forth (bow steer) Bottom Of Bot To mintin mximum speed, the bot bottom should be: Clen, free of brncles nd mrine growth Free of distortion; nerly flt where it contcts the wter Stright nd smooth, fore nd ft Mrine vegettion my ccumulte when the bot is docked. This growth must be removed before opertion; it my clog the wter inlets nd cuse the engine to overhet. Pge JUNE 2007

55 Cvittion Ventiltion Section 3 - On The Wter Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter object, such s ger housing or propeller. Cvittion permits the propeller to speed up, but the bot speed to reduce. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other debris sngged on the propeller Bent propeller blde Rised burrs or shrp edges on the propeller Ventiltion is cused by surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in bot speed. Air bubbles strike the propeller blde nd cuse erosion of the blde surfce. If llowed to continue, eventul blde filure (brekge) will occur. Excessive ventiltion is usully cused by: Drive unit trimmed out too fr. A missing propeller diffuser ring. A dmged propeller or ger housing, which llows exhust gses to escpe between propeller nd ger housing. Drive unit instlled too high on trnsom. Elevtion And Climte Getting Strted Elevtion nd climte chnges will ffect the performnce of your power pckge. Loss of performnce cn be cused by: Higher elevtions Higher tempertures Low brometric pressures High humidity 20 Hour Brek In Period For you to hve optimum engine performnce under chnging wether conditions, it is essentil tht the engine be propped to llow the engine to operte t or ner the top end of the specified mximum RPM rnge with norml bot lod during your norml boting wether conditions. In most cses, recommended RPM cn be chieved by chnging to lower pitch propeller. IMPORTANT: The first 20 hours of opertion is the engine brek in period. Correct brek in is essentil to obtin minimum oil consumption nd mximum engine performnce. During this brek in period, the following rules must be observed: Do not operte below 1500 RPM for extended periods of time for the first 10 hours. Shift into ger s soon s possible fter strting nd dvnce the throttle bove 1500 rpm if conditions permit sfe opertion. Do not operte t one speed consistently 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 permissible (5 minutes t time mximum). Avoid full throttle ccelertion from idle speed. Do not operte t full throttle until the engine reches norml operting temperture JUNE 2007 Pge 47

56 Section 3 - On The Wter Frequently check engine oil level. Add oil s needed. It is norml for oil consumption to be high during the brek in period. After Brek In Period To help extend the life of your Mercury MerCruiser power pckge, the following recommendtions should be considered; Ensure tht propeller llows the engine to operte t or ner the top of the specified WOT RPM rnge (Refer to Specifictions nd Mintennce) when t full throttle with norml bot lod. Opertion t 3/4 throttle setting or lower is recommended. Refrin from prolonged opertion t WOT RPM. Chnge the engine oil nd oil filter. Refer to Mintennce. Chnge the trnsmission oil nd filter. Refer to Mintennce (ZF Trnsmission models). 1. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized Mercury MerCruiser deler to discuss nd/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. 1. Require fluid nd filter chnge fter the first 25 hours nd then every 100 hours. Pge JUNE 2007

57 Tble of Contents Section 4 - Specifictions Section 4 - Specifictions Cruising RPM Fuel Requirements Fuel Rtings Using Reformulted (Oxygented) Gsolines (USA Only)...50 Gsolines Contining Alcohol Engine Oil Engine Specifictions Tow Sports Models Inbord Models Fluid Specifictions Engine Trnsmission JUNE 2007 Pge 49

58 Section 4 - Specifictions Cruising RPM Modern inbord engines operte t higher engine speeds thn those produced just few yers go. This incresed RPM long with better brething is lrgely responsible for the significnt increse in horsepower of these new engines. Along with the higher WOT RPM comes higher cruising RPM. This higher RPM is criticl for optimum performnce nd efficiency. The mterils nd design of the new engines llow these higher speeds without durbility penlty. In fct, over propping the bot to reduce the cruising RPM to previous levels will increse the susceptibility to engine dmge from detontion nd pre ignition. The recommended cruising RPM rnges re: Cruising RPM for Pek Efficiency Model RPM Rnge Fuel Requirements Fuel Rtings 350 MAG MPI MAG MPI Horizon MX 6.2L MPI IMPORTANT: Use of improper gsoline cn dmge your engine. Engine dmge resulting from the use of improper gsoline is considered misuse of the engine, nd dmge cused thereby will not be covered under the limited wrrnty. Mercury MerCruiser engines will operte stisfctorily when using mjor brnd of unleded gsoline meeting the following specifictions: USA nd Cnd hving posted pump Octne Rting of 87 (R+M)/2 minimum. Premium gsoline [92 (R+M)/2 Octne] is lso cceptble. Do not use leded gsoline. Outside USA nd Cnd hving posted pump Octne Rting of 90 RON minimum. Premium gsoline (98 RON) is lso cceptble. If unleded gsoline is not vilble, use mjor brnd of leded gsoline. Using Reformulted (Oxygented) Gsolines (USA Only) This type of gsoline is required in certin res of the USA. The 2 types of oxygentes used in these fuels is Alcohol (Ethnol) or Ether (MTBE or ETBE). If Ethnol is the oxygente tht is used in the gsoline in your re, refer to Gsolines Contining Alcohol. These Reformulted Gsolines re cceptble for use in your Mercury MerCruiser engine. Gsolines Contining Alcohol If the gsoline in your re contins either methnol (methyl lcohol) or ethnol (ethyl lcohol), you should be wre of certin dverse effects tht cn occur. These dverse effects re more severe with methnol. Incresing the percentge of lcohol in the fuel cn lso worsen these dverse effects. Some of these dverse effects re cused becuse the lcohol in the gsoline cn bsorb moisture from the ir, resulting in seprtion of the wter/lcohol from the gsoline in the fuel tnk. The fuel system components on your Mercury MerCruiser engine will withstnd up to 10% lcohol content in the gsoline. We do not know wht percentge your bot's fuel system will withstnd. Contct your bot mnufcturer for specific recommendtions on the bot's fuel system components (fuel tnks, fuel lines, nd fittings). Be wre tht gsolines contining lcohol my cuse incresed: Pge JUNE 2007

59 Section 4 - Specifictions Corrosion of metl prts Deteriortion of rubber or plstic prts Fuel permetion through rubber fuel lines Strting nd operting difficulties! 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 before further engine opertion. Becuse of possible dverse effects of lcohol in gsoline, it is recommended tht only lcohol free gsoline be used where possible. If only fuel contining lcohol is vilble, or if the presence of lcohol is unknown, incresed inspection frequency for leks nd bnormlities is required. IMPORTANT: When operting Mercury MerCruiser engine on gsoline contining lcohol, storge of gsoline in the fuel tnk for long periods should be voided. Long periods of storge, common to bots, crete unique problems. In crs lcohol blend fuels normlly re consumed before they cn bsorb enough moisture to cuse trouble, but bots often sit idle long enough for phse seprtion to tke plce. In ddition, internl corrosion my tke plce during storge if lcohol hs wshed protective oil films from internl components. Engine Oil To help obtin optimum engine performnce nd to provide mximum protection, we strongly recommend the use of the following oils listed in the order of recommendtion: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC W rted, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC W rted oil. 3. A NMMA FC W rted oil. 4. MerCruiser / Quicksilver 4 cycle 25W40, non FC W rted oil. 5. A good grde stright weight detergent utomotive oil per the operting chrt below JUNE 2007 Pge 51

60 Section 4 - Specifictions NOTE: The use of non detergent oils, multi viscosity oils (other thn s specified), non FC W rted synthetic oils, low qulity oils or oils tht contin solid dditives re specificlly not recommended. MerCruiser/ Quicksilver Synthetic Blend, NMMA FC-W rted, 4-cycle oil ORDER OF PREFERENCE MerCruiser / Quicksilver 25W40 NMMA FC-W rted oil A NMMA FC-W rted oil MerCruiser / Quicksilver 4-cycle 25W40, non FC-W rted oil SAE40W SAE30W SAE 20W Engine Specifictions Tow Sports Models 32 F 0 C 50 F 10 C AIR TEMPERATURE 8082 Models 350 MAG MPI Tow Sports MX 6.2 MPI Tow Sports Horsepower Kilowtts Displcement 5.7 L (350cid) 6.2 L (377cid) Specified WOT RPM Rnge Idle RPM in Neutrl Minimum Oil Idle kp (6 psi) Thermostt, sewter cooled models 71 C (160 F) Thermostt, closed cooled models 77 C (170 F) Idle 3. Not djustble Firing Order Electricl System 12 volt negtive ( ) ground Alterntor Rting 65 mp Recommended Bttery Rting (Minimum) 750 CCA, 950 MCA, or 180 Ah 1. Performnce obtined nd corrected in ccordnce with SAE J1228/ISO 8665 Crnkshft Power. 2. Mesured using n ccurte service tchometer with the engine t norml operting tempertures. 3. Idle speed nd timing on EFI models re not djustble 4. Oil pressure must be checked with the engine t norml operting temperture. Pge JUNE 2007

61 Section 4 - Specifictions Models 350 MAG MPI Tow Sports MX 6.2 MPI Tow Sports Sprk Plug Type AC Pltinum (AC ) Sprk Plug Gp 1.5 mm (0.060 in.) Inbord Models Models 350 MAG MPI 350 MAG MPI Horizon MX 6.2 MPI MX 6.2 MPI Horizon Horsepower Kilowtts Displcement 5.7 L (350 cid) 6.2 L (377 cid) Specified WOT RPM Rnge Idle RPM in Neutrl Minimum Oil Idle 8. Thermostt, sewter cooled models Thermostt, closed cooled models Idle kp (6 psi) 71 C (160 F) 77 C (170 F) Not Adjustble Firing Order Electricl System Alterntor Rting Recommended Bttery Rting (DTS Models) (Minimum) Recommended Bttery Rting (Non DTS Models) (Minimum) 12 volt negtive ( ) ground 65 mp 750 CCA, 950 MCA, or 180 Ah 800 CCA, 1000 MCA, or 190 Ah Sprk Plug Type AC Pltinum (AC ) Sprk Plug Gp Fluid Specifictions 1.5 mm (0.060 in.) Engine IMPORTANT: All cpcities re pproximte fluid mesures. IMPORTANT: It my be necessry to djust oil levels depending on instlltion ngle nd cooling systems (het exchnger nd fluid lines). All Models Cpcity Fluid Type Engine Oil (With Filter) liters (4.5 U.S qts) Quicksilver Synthetic Blend, NMMA FC W rted, 4 cycle oil Sewter Cooling System liters (21 U.S. qts) Propylene Glycol nd Purified Wter Closed Cooling System 19 liters (20 U.S. qts) Mercury Extended Life Coolnt/Antifreeze or Extended Life Ethylene Glycol 5/100 Antifreeze/ Coolnt mixed 50/50 with Purified Wter 5. Performnce obtined nd corrected in ccordnce with SAE J1228/ISO 8665 Crnkshft Power. 6. Mesured using n ccurte service tchometer with the engine t norml operting tempertures. 7. Idle speed nd timing on EFI models re not djustble 8. Oil pressure must be checked with the engine t norml operting temperture. 1. Alwys use the dipstick to determine the exct quntity of oil or fluid required. 2. Sewter Cooling System cpcity informtion is for winteriztion use only JUNE 2007 Pge 53

62 Section 4 - Specifictions Trnsmission Model Cpci Fluid Type 5000A 2.84L (3 qts) 5000V 3.30L (3 1/2 qts) Dexron III Automtic Trnsmission Fluid 71C In Line 1.66L (1 3/4 qts) 71C Ger Reduction 2.84L (3 qts) Dexron III Automtic Trnsmission Fluid 71C Remote V Drive L (1 3/4 qts) 72C In Line 1.66L (1 3/4 qts) 72C Ger Reduction 1.66L (1 3/4 qts) Dexron III Automtic Trnsmission Fluid 72C Remote V Drive L (1 3/4 qts) 72C V Drive 3.79L (4 qts) 63A 4.00L (4 1/2 qts) 63V 4.00L (4 1/2 qts) 45C Tow Sports 1.77L (60 oz) Dexron III Automtic Trnsmission Fluid 45C Remote V Drive L (64 oz) 45C In Line 1.94L (66 oz) 3. Wlters V Drive pplictions hve 2 fluid service points, the trnsmission nd the v drive ger box. Refer to the Wlters owner's mnul for cpcity nd intervls. Pge JUNE 2007

63 Tble of Contents Section 5 - Mintennce Section 5 - Mintennce Owner/Opertor Responsibilities Deler Responsibilities Mintennce Do It Yourself Mintennce Suggestions Inspection Mintennce Schedule - Inbord Models Routine Mintennce Ech Dy Strt Ech Dy End Weekly Every Two Months or 50 Hours Scheduled Mintennce After the Initil 20 Hour Brek-In Period Every 100 Hours or Annully (Whichever Occurs First)...58 Every 300 Hours or 3 Yers Mintennce Log Engine Oil Checking Filling Chnging Oil nd Filter Esy Engine Oil Drin System Engine Oil Drin Pump Chnging Filter Trnsmission Fluid Checking While the Engine is Wrm Checking While Engine is Cold Chnging Engine Coolnt Checking Filling Chnging Clening The Flme Arrestor Positive Crnkcse Ventiltion Vlve (PCV) Chnging Chnging Wter Seprting Fuel Filter GEN II Models GEN III Models In-line Fuel Filter Lubriction Throttle Cble...72 Trnsmission Linkge...72 Serpentine Drive Belt Checking Replcing Belt nd/or Adjusting Tension Flushing The Power Pckge Tow Sports The Bot Out of the Wter The Bot In the Wter Bttery Multiple EFI Engine Bttery Precutions JUNE 2007 Pge 55

64 Section 5 - Mintennce Owner/Opertor Responsibilities Deler Responsibilities Mintennce It is the opertor's responsibility to perform ll sfety checks, to ensure tht ll lubriction nd mintennce instructions re complied with for sfe opertion nd to return the unit to n uthorized Mercury MerCruiser deler for periodic checkup. Norml mintennce service nd replcement prts re the responsibility of the owner/ opertor nd s such, re not considered defects in workmnship or mteril within the terms of the wrrnty. Individul operting hbits nd usge contribute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependbility nd will keep your overll operting expenses t minimum. See your uthorized Mercury MerCruiser deler for service ids. In generl, deler's responsibilities to the customer include predelivery inspection nd preprtion such s: Ensure tht the bot is properly equipped. Prior to delivery, mke certin tht the Mercury MerCruiser power pckge nd other equipment re in proper operting condition. Mke ll necessry djustments for mximum efficiency. Fmilirize the customer with the on bord equipment. Explin nd demonstrte the opertion of the power pckge nd bot. Provide you with copy of Predelivery Inspection Checklist. Your selling deler should fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product.! WARNING Performing service or mintennce without first disconnecting the bttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the bttery cbles from the bttery before mintining, servicing, instlling, or removing engine or drive components.! WARNING Fuel vpors trpped in the engine comprtment my be n irritnt, cuse difficulty brething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment before servicing the power pckge. IMPORTANT: Refer to the mintennce schedule for complete listing of ll scheduled mintennce to be performed. Some listings cn be done by owner/opertor, while others should be performed by n uthorized Mercury MerCruiser deler. Before ttempting mintennce or repir procedures not covered in this mnul, it is recommended tht Mercury MerCruiser Service Mnul be purchsed nd red thoroughly. NOTE: Mintennce points re color coded for ese of identifiction. See the decl on engine for identifiction. Pge JUNE 2007

65 Section 5 - Mintennce Mintennce Point Color Codes Blue Yellow Ornge Blck Brown Coolnt Engine Oil Fuel Ger Lube Oil (Sterndrive models only) Trnsmission (Inbord models only) Do It Yourself Mintennce Suggestions Inspection Present dy mrine equipment, such s your Mercury MerCruiser power pckge, re highly technicl pieces of mchinery. Electronic ignition nd specil fuel delivery systems provide greter fuel economies, but lso re more complex for the untrined mechnic. If you re one of those persons who likes to do it yourself, here re some suggestions for you. Do not ttempt ny repirs unless you re wre of the Cutions, Wrnings nd procedures required. Your sfety is our concern. If you ttempt to service the product yourself, we suggest you order the service mnul for tht model. The service mnul outlines the correct procedures to follow. It is written for the trined mechnic, so there my be procedures you don't understnd. Do not ttempt repirs if you do not understnd the procedures. There re specil tools nd equipment tht re required to perform some repirs. Do not ttempt these repirs unless you hve these specil tools nd/or equipment. You cn cuse dmge to the product in excess of the cost deler would chrge you. Also, if you prtilly disssemble n engine or drive ssembly nd re unble to repir it, the deler's mechnic must ressemble the components nd test to determine the problem. This will cost you more thn tking it to the deler immeditely upon hving problem. It my be very simple djustment to correct the problem. Do not telephone the deler, service office or the fctory to ttempt for them to dignose problem or to request the repir procedure. It is difficult for them to dignose problem over the telephone. Your uthorized deler is there to service your power pckge. They hve qulified fctory trined mechnics. It is recommended you hve the deler do periodic mintennce checks on your power pckge. Hve them winterize it in the fll nd service it before the boting seson. This will reduce the possibility of ny problems occurring during your boting seson when you wnt trouble free boting plesure. Inspect your power pckge often, nd t regulr intervls, to help mintin its top operting performnce nd correct potentil problems before they occur. The entire power pckge should be checked crefully, including ll ccessible engine prts. Check for loose, dmged or missing prts, hoses nd clmps; tighten or replce s necessry. Check plug leds nd electricl leds for dmge. Remove nd inspect the propeller. If bdly nicked, bent or crcked, contct your uthorized Mercury MerCruiser deler. Repir nicks nd corrosion dmge on power pckge exterior finish. Contct your uthorized Mercury MerCruiser deler JUNE 2007 Pge 57

66 Section 5 - Mintennce Mintennce Schedule Inbord Models Routine Mintennce EACH DAY START NOTE: Only perform mintennce which pplies to your prticulr power pckge. Check the crnkcse oil (intervl cn be extended bsed on experience). Check the trnsmission fluid level. EACH DAY END WEEKLY If operting in slt, brckish or polluted wters, flush the cooling system fter ech use. Check the wter inlets for debris or mrine growth. Check the sewter striner nd clen. Check the coolnt level. Check the trnsmission fluid. EVERY TWO MONTHS OR 50 HOURS Scheduled Mintennce Operting in sltwter or brckish or polluted wter only: tret the power pckge with Corrosion Gurd. Check the bttery connections nd the fluid level. Ensure tht the guges nd the wiring connections re secure. Clen the guges. 1. NOTE: Only perform mintennce which pplies to your prticulr power pckge. AFTER THE INITIAL 20 HOUR BREAK-IN PERIOD To help extend the life of your Mercury MerCruiser power pckge, we recommend the following: Chnge the engine oil nd filter Chnge the trnsmission oil nd filter on inbord models. NOTE: ZF Mrine requires the trnsmission to be chnged to preserve the wrrnty. EVERY 100 HOURS OR ANNUALLY (WHICHEVER OCCURS FIRST) Touch up the pint on the power pckge. Chnge the crnkcse oil nd filter. Chnge the trnsmission fluid (ZF Trnsmission Models) 2. Replce the wter seprting fuel filter element. Check the steering system nd the remote control for loose, missing or dmged prts. Lubricte the cbles nd the linkges. Inspect the condition of the belts. Clen the flme rrestor, IAC muffler 3., nd the crnkcse ventiltion hoses. Inspect the PCV vlve, if equipped. EVERY 300 HOURS OR 3 YEARS Check the engine mount for tightness nd retorque if necessry. Check the distributor cp, if equipped. Check the electricl system for loose, dmged, or corroded fsteners. 1. If operting in sltwter, intervl is reduced to every 25 hours or 30 dys whichever occurs first. 2. Require fluid nd filter chnge fter the first 25 hours nd then every 100 hours. 3. Contct your uthorized Mercury MerCruiser deler to replce the IAC muffler. Pge JUNE 2007

67 Mintennce Log Section 5 - Mintennce Check the cooling system nd the exhust system hose clmps for tightness. Inspect both systems for dmge or leks. Disssemble nd inspect the sewter pump nd replce worn components. Clen the sewter section of the closed cooling system. Clen, inspect, nd test the pressure cp. Inspect the exhust system components nd verify tht the flpper vlves re not missing or worn, if equipped. Record ll mintennce performed on your power pckge here. Be sure to sve ll work orders nd receipts. Dte Mintennce Performed Engine Hours Engine Oil NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted by lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your bot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking 1. Stop the engine. Allow pproximtely 5 minutes for the oil to drin into the oil pn. The bot must be t rest in the wter. 2. Remove the dipstick. Wipe clen nd reinstll fully into the dipstick tube. Wit 60 seconds to llow trpped ir to vent JUNE 2007 Pge 59

68 Section 5 - Mintennce NOTE: Ensure tht dipstick is instlled with oil level indiction mrks fcing the rer of the engine (flywheel end). - Dipstick tube 6076 Filling IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK rnge mrk on the dipstick. 3. Remove the dipstick nd observe the oil level. Oil level must be between full or OK rnge nd dd. Reinstll dipstick into dipstick tube. IMPORTANT: Do not overfill the engine with oil. IMPORTANT: Alwys use the dipstick to determine the exct quntity of oil or fluid required. 1. Remove oil fill cp Oil fill cp IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK rnge mrk on the dipstick. 2. Add the specified engine oil to bring the level up to, but not over, the full or OK rnge mrk on the dipstick. Recheck oil level. 3. Replce the fill cp. Pge JUNE 2007

69 Section 5 - Mintennce Models Cpcity Fluid Type Engine Oil (With Filter) 4.25 liters (4.5 U.S. Qurt) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 Chnging Oil nd Filter Refer to the Mintennce schedule for the chnge intervl. Engine oil should be chnged before plcing the bot in storge. IMPORTANT: Chnge engine oil when the engine is wrm from opertion. Wrm oil flows more freely, crrying wy more impurities. Use only recommended engine oil (refer to Specifictions). EASY ENGINE OIL DRAIN SYSTEM NOTE: Bot must be out of wter to perform this procedure. 1. Loosen the oil filter to vent the system. 2. Remove the bilge drin plug. 3. Pull tether through the bilge drin. b c f - Binge drin plug b - Tether c - Clip d e d - Oil drin hose plug e - Oil drin hose f - Bilge drin flnge Plce the oil drin hose in suitble continer. 5. Remove the drin plug from the oil drin hose. 6. After oil hs drined completely, instll the drin plug in the oil drin hose. 7. Push the hose through bilge drin nd instll the plug. ENGINE OIL DRAIN PUMP 1. Loosen the oil filter to vent the system. 2. Remove the dipstick JUNE 2007 Pge 61

70 Section 5 - Mintennce 3. Instll the oil pump onto the dipstick tube. b c mc Typicl oil pump b - Dipstick tube c - Oil drin hose 4. Insert the hose end of the crnkcse oil pump onto n pproprite continer nd, using the hndle, pump until the crnkcse is empty. 5. Remove the pump. 6. Instll the dipstick. CHANGING FILTER 1. Remove nd discrd oil filter. In line exhust - Oil filter 6083 V-drive exhust Cot seling ring on new filter with engine oil nd instll. 3. Tighten oil filter securely (following filter mnufcturer's instructions). Do not overtighten. 4. Remove oil fill cp. IMPORTANT: Alwys use dipstick to determine exctly how much oil is required. 5. Add recommended engine oil to bring level up to the bottom of the OK rnge on the dipstick. 6. With the bot t rest in the wter, check the oil level nd dd specified fluid to bring the oil level up to, but not over, the full or OK rnge. NOTE: Adding 0.95 liters (1 qurt) of engine oil will rise the level from the dd mrk to the top of the OK rnge. Models Cpcity Fluid Type Engine Oil (With Filter) 4.25 liters (4.5 U.S. Qurt) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 Pge JUNE 2007

71 Trnsmission Fluid Section 5 - Mintennce 7. Strt the engine, run the engine for three minutes, nd check for leks. Stop the engine. Allow pproximtely 5 minutes for the oil to drin into the oil pn. The bot must be t rest in the wter. Checking While the Engine is Wrm 1. Velvet Drive Trnsmissions Stop the engine nd immeditely check fluid level by turning T hndle counterclockwise, to remove dipstick. Fluid level should be up to full mrk. If low, dd specified fluid through dipstick tube on trnsmissions. 2. ZF Mrine Trnsmissions Stop the engine nd remove the dipstick to check level. If fluid is below top (full) line, dd specified fluid through dipstick hole. Do not overfill. Reinstll dipstick with cp fully seted. 3. Wlter V Drive Trnsmissions Stop the engine nd remove the dipstick to check the level. If the fluid is below the top (full) line, dd the specified fluid through the brether elbow. Do not overfill. Reinstll the dipstick with the cp fully seted. Checking While Engine is Cold Chnging Engine Coolnt Checking NOTE: Cold fluid level check: To ese checking the fluid level, the dipstick cn be mrked or scribed with cold level mrk. 1. Follow the procedure for the wrm fluid level check, then llow the bot to sit overnight. IMPORTANT: Be sure to push the dipstick ll the wy down into the dipstick tube when checking the fluid level. 2. Remove the dipstick, wipe clen nd reinsert. 3. Remove the dipstick, observe the fluid level nd mrk the cold fluid level. 4. Reinstll the dipstick, tighten the T hndle securely. Do not overtighten. Contct your uthorized Mercury MerCruiser deler.! CAUTION A sudden loss of pressure could cuse hot coolnt to boil nd dischrge violently cusing serious injury from burns. Allow the engine to cool down before removing the coolnt pressure cp JUNE 2007 Pge 63

72 Section 5 - Mintennce 1. Remove the cp from the het exchnger nd observe the fluid level. - Het exchnger cp The coolnt level in the het exchnger should be t the bottom of the filler neck. If the coolnt level is low, contct your uthorized Mercury MerCruiser deler. 3. Instll the cp onto the het exchnger. IMPORTANT: When reinstlling the pressure cp, be sure to tighten it until it sets on the filler neck. 4. With the engine t norml operting temperture, check the coolnt level in the coolnt recovery bottle. 5. The coolnt level should be between the "ADD" nd "FULL" mrks Add the specified fluid s necessry. Tube Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/ Coolnt Closed Cooling System K1 Filling 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 suitble to the lowest temperture to which the engine will be exposed. Pge JUNE 2007

73 NOTICE Section 5 - Mintennce Filure to provide sufficient cooling wter will dmge the wter pump nd cuse the engine to overhet. Provide sufficient supply of wter t the wter inlets during opertion. NOTICE Air trpped in the closed cooling system cn cuse the engine to overhet, resulting in engine dmge. Minimize the possibility of trpping ir when initilly filling the closed cooling system by positioning the bot so tht the front of the engine is higher thn the rer of the engine. NOTE: Add coolnt only when engine is t norml operting temperture. 1. Remove the fill cp from the coolnt recovery bottle. 2. Fill to the "FULL" line with the specified coolnt. Tube Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/ Coolnt Closed Cooling System K1 3. Instll the fill cp onto the coolnt recovery bottle. Chnging Contct your uthorized Mercury MerCruiser deler. Clening The Flme Arrestor! WARNING Fuel is flmmble nd explosive. Ensure 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 before ttempting to strt the engine nd wipe up ny spilled fuel immeditely. 1. Remove the engine cover. 2. Disconnect nd remove the crnkcse ventiltion hose from the fitting on the flme rrestor nd vlve cover JUNE 2007 Pge 65

74 Section 5 - Mintennce 3. Remove the flme rrestor. b c d e 6110 f - Engine cover knob b - Engine cover c - Nuts, flme rrestor d - Cover mount brcket e - Flme rrestor f - Crnkcse ventiltion hose 4. Clen the flme rrestor with wrm wter nd mild detergent. 5. Inspect the flme rrestor for holes, crcks or deteriortion. Replce if necessry. 6. Allow the flme rrestor to ir dry completely before use. 7. Clen the crnkcse ventiltion hose with wrm wter nd mild detergent. Dry with compressed ir or llow to ir dry completely. 8. Inspect the crnkcse ventiltion hose for crcks or deteriortion. Replce if necessry. 9. Instll the flme rrestor nd flme rrestor brcket. Torque the flme rrestor brcket nuts. Description Nm lb. in. lb. ft. Flme rrestor brcket nut Connect the crnkcse ventiltion hose to the fitting on the flme rrestor nd vlve cover. 11. Instll the engine cover. Positive Crnkcse Ventiltion Vlve (PCV) CHANGING IMPORTANT: Use only Mercury MerCruiser replcement prts to ensure complince with emission regultions. NOTE: On V6 models the PCV vlve is non serviceble nd is n internl component of the vlve cover. Pge JUNE 2007

75 Section 5 - Mintennce 1. Remove the PCV vlve from the port vlve cover. b - PCV vlve b - Hose mc Disconnect the PCV vlve from the hose nd discrd the vlve. 3. Instll new PCV vlve in the vlve cover nd reconnect the hose. 4. Ensure the PCV vlve is tightly seted in the vlve cover. Chnging Wter Seprting Fuel Filter GEN II Models! WARNING Fuel is flmmble nd explosive. Ensure 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 before ttempting to strt the engine nd wipe up ny spilled fuel immeditely. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends tht the engine be shut off for 12 hours prior to filter removl. 2. Close fuel supply vlve, if equipped. 3. Wrp the wter seprting fuel filter with cloth to help ctch ny fuel spills or spry. 4. Remove nd discrd the wter seprting fuel filter nd seling ring from the mounting brcket. 5. Cot the seling ring on the new filter with engine oil. Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Filter seling ring K JUNE 2007 Pge 67

76 Section 5 - Mintennce 6. Thred filter onto the mounting brcket nd tighten securely by hnd. Do not use filter wrench. b c Fuel filter mounting brcket b - Seling ring c - Fuel filter GEN III Models 7. Open fuel supply vlve, if equipped. 8. Ensure tht engine comprtment is properly ventilted. 9. Supply cooling wter to the engine. 10. Strt the engine. Check for gsoline leks round the fuel filter ssembly. If leks exist, stop the engine immeditely. Recheck the filter instlltion, wipe up ny spilled fuel, nd properly ventilte the engine comprtment. If leks continue, stop engine immeditely nd contct your uthorized Mercury MerCruiser deler. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends tht the engine be shut off for 12 hours prior to filter removl. 2. Close fuel supply vlve, if equipped. 3. Disconnect the Cool Fuel Module hrness from the engine wiring hrness. 4. Turn the key switch to the strt position nd llow the strter to operte for 5 seconds. 5. Turn key switch to off position. Pge JUNE 2007