Declaration of Conformity Mercury Diesel Sterndrive (VW)

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1 Declrtion of Conformity Mercury Diesel Sterndrive (VW) This sterndrive engine when instlled in ccordnce to Mercury Mrine's instructions complies with the requirements of the following directives by meeting the ssocited stndrds, s mended: Recretionl Crft Propulsion Engines with the Requirements of Directive 94/25/EC s mended by 2003/44/EC Nme of engine mnufcturer: Volkswgen Antriebssysteme Address: HMA E/1, PO 7962, Industriestrße Nord Town: Slzgitter Post Code: Country: Germny Nme of uthorized representtive: Brunswick Mrine in EMEA Inc. Address: Prc Industriel de Petit Rechin Town: Verviers Post Code:B 4800 Country: Belgium Nme of notified body for exhust emission ssessment: Interntionl Mrine Certifiction Institute (IMCI) Address: Rue Abbé Cuypers 3 Town: Bruxelles Post Code: B 1040 Country: Belgium ID Number: 0609 Nme of notified body for noise emission ssessment: Interntionl Mrine Certifiction Institute (IMCI) Address: Rue Abbé Cuypers 3 Town: Bruxelles Post Code: B 1040 Country: Belgium ID Number: 0609 Conformity ssessment module used for exhust emissions: B+C B+D B+E B+F G H Conformity ssessment module used for noise emissions: A A G H Other Community Directives pplied: Electromgnetic Comptibility Directive 2004/108/EC Description of Engines nd Essentil Requirements Engine Type Fuel Type Combustion Cycle z or sterndrive with integrl exhust Diesel 4 stroke Identifiction of Engines Covered by This Declrtion of Conformity Nme of engine model or engine fmily: Unique engine identifiction number(s) or engine fmily code(s) TDI 2.5L 100/120 TDI 100 5/TDI SE EXVWM003 TDI 2.5L 140/150/165 TDI 150 5/TDI D/TDI EXVWM004 TDI 3.0L 225/230/265 TDI 225 6/TDI 230 6/TDI EXVWM007 V6 TDI 100/230/260 TDI 3.0L 100/TDI 3.0L 230/TDI 3.0L 260 EXVWM007 TDI 4.2L 285/350 TDI 285 8/TDI EXVWM008 V8 TDI 335/370 TDI 4.2L 335/TDI 4.2L 370 EXVWM008 EC Type exmintion certificte or type pprovl certificte number 2013 Mercury Mrine TDI 4.2L Diesel Sterndrive Models 90-8M

2 Essentil requirements Annex 1.B Exhust Emissions Stndrds Other normtive document/ method Technicl file B.1 engine identifiction Plese specify in more detil (* = mndtory stndrd) B.2 exhust emission requirements * *EN ISO :1996 B.3 durbility B.4 owner's mnul ISO 8665:2006 Annex 1.C Noise Emissions C.1 Noise emission levels * *EN ISO C.2 Owner's mnul Owner's mnul This declrtion of conformity is issued under the sole responsibility of the mnufcturer. I declre on behlf of the engine mnufcturer tht the engine(s) mentioned bove complies (comply) with ll pplicble essentil requirements in the wy specified. Nme / function: Mrk Schwbero, President Mercury Mrine Signture nd title: Dte nd plce of issue: June 6, 2013 Fond du Lc, Wisconsin, USA Regultory contct: Regultions nd Product Sfety Deprtment Mercury Mrine W6250 W. Pioneer Rod Fond du Lc, WI USA 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 Propeller Number Pitch Dimeter Hull Identifiction Number (HIN) Purchse Dte Bot Mnufcturer Bot Model Length The seril numbers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Diesel power pckge. When contcting Mercury Mrine 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, USA. Welcome You hve selected one of the finest mrine power pckges vilble. It incorportes numerous design fetures to ensure operting ese nd durbility.

3 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. 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 Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Mercury Mrine; the terms of the wrrnty re set forth in the Wrrnty 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 do not 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 nd user to specil instructions concerning prticulr service or opertion tht my be hzrdous if performed incorrectly or crelessly. Observe them crefully. These sfety lerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! 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. 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. Copyright nd Trdemrk Informtion MERCURY MARINE. All rights reserved. Reproduction in whole or in prt without permission is prohibited.

4 Alph, Axius, Brvo One, Brvo Two, Brvo Three, Circle M with Wves Logo, K plnes, Mriner, MerCthode, MerCruiser, Mercury, Mercury with Wves Logo, Mercury Mrine, Mercury Precision Prts, Mercury Propellers, Mercury Rcing, MotorGuide, OptiMx, Quicksilver, SeCore, Skyhook, SmrtCrft, Sport Jet, Verdo, VesselView, Zero Effort, Zeus, #1 On the Wter nd We're Driven to Win re registered trdemrks of Brunswick Corportion. Pro XS is trdemrk of Brunswick Corportion. Mercury Product Protection is registered service mrk of Brunswick Corportion.

5 TABLE OF CONTENTS Section 1 - Wrrnty Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Outside United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty United Sttes nd Cnd... 2 Outside the United Sttes nd Cnd... 3 Diesel Duty Cycle Appliction Definitions... 3 Emission Control Wrrnty Informtion... 3 Importnt Informtion... 3 U.S. EPA Emissions Limited Wrrnty... 3 Emission Control System Components... 3 Wrrnty Policy Diesel Models... 4 TDI High Output Recretionl Use Limited Wrrnty... 4 TDI Light Duty Commercil Use Limited Wrrnty Yer Limited Wrrnty Aginst Corrosion Diesel Models (Recretionl Use Only)... 7 Wht Is Covered... 7 Durtion of Coverge... 7 Conditions Tht Must Be Met to Obtin Wrrnty Coverge... 7 Wht Mercury Will Do... 7 How to Obtin Wrrnty Coverge...7 Wht Is Not Covered... 8 Trnsfer of Wrrnty... 8 Wrrnty Policy Austrli nd New Zelnd... 8 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 8 Wht is Covered... 9 Gurntees Under Austrlin Consumer Lw... 9 Durtion of Coverge for This Limited Wrrnty... 9 Wrrnty Period for Recretionl Use... 9 Wrrnty Period for Commercil Use... 9 Trnsfer of Coverge...9 Termintion of Coverge... 9 Conditions Tht Must Be Met to Obtin Wrrnty Coverge Wht Mercury Will Do How to Obtin Wrrnty Coverge Under This Limited Wrrnty Wht is Not Covered Expense of Climing This Limited Wrrnty...11 Trnsfer of Wrrnty Austrli nd New Zelnd Policy Globl Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Outside United Sttes...12 Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Cnd...12 Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Austrli nd New Zelnd South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Outside of the South Pcific Asi Wrrnty Chrt MerCruiser Gs nd Diesel Outside of Asi Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Europe nd CIS...14 Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Middle Est nd Afric South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Outside South Afric...14 Section 2 - Getting to Know Your Power Pckge Fetures nd Controls TDI 4.2L Engine Description Identifiction Audio Wrning System Testing the Audio Wrning System Digitl Throttle nd Shift Instrumenttion VesselView SmrtCrft Speedometer, Tchometer, nd Digitl Guges System Link Digitl Guges Controls Switches Emergency Stop Switch Lnyrd Stop Switch Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition Digitl Throttle nd Shift Engine Electricl System Overlod Protection Fuses...21 Vessel Adpter Assembly Fuse Replcement Power Trim Single Engine Trim nd Triler...23 Dul Engine Trim nd Triler Power Trim nd MerCthode Overlod Protection Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsibility...25 Engine Components M eng DECEMBER 2013 Pge i

6 Section 3 - On The Wter Sfe Boting Recommendtions Crbon Monoxide Exposure Be Alert To Crbon Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Duty Cycle Bsic Bot Opertion Duty Cycle Rting Plesure Duty Rting Bsic Bot Opertion Opertion Chrt Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump Strting, Shifting, nd Stopping Before Strting the Engine Strting Cold Engine Engine Wrm Up Strting Wrm Engine Shifting Engine Shutdown (Stopping) Strting the Engine After Stopped While in Ger Trilering the Bot Protecting People In The Wter Protecting People in the Wter While Bot is in Opertion...37 While the Bot is Sttionry High Speed nd High Performnce Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots with Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection Brek In Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) Engine Brek In Hour Brek In Period After the 20 Hour Brek In Period...41 End of First Seson Checkup Section 4 - Specifictions Fuel Requirements Nonferrous Metls nd the Fuel System Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions Fluid Specifictions Engine Brvo Sterndrive Fluid Specifictions Diesel Power Steering nd Power Trim Fluids Approved Power Steering Fluids...46 Approved Power Trim Fluids Approved Pints Section 5 - Mintennce Owner nd Opertor Responsibilities Deler Responsibilities Mintennce Replcement Prts Wrning Inspection Routine Mintennce Strt of Seson Ech Dy Strt Ech Dy End Weekly End of Seson Scheduled Mintennce Once Yer or Every 200 Operting Hours (Whichever Occurs First) Mintennce Notice Every 5 Yers or 500 Hours (Whichever Occurs First) Every 5 Yers or 1,000 Operting Hours (Whichever Occurs First) Every 5 Yers or 2,000 Operting Hours (Whichever Occurs First) Engine Oil Checking Filling Drining Using the Esy Drin System, if Equipped Chnging Oil nd Filter Sterndrive Ger Lube Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Pge ii 90-8M eng DECEMBER 2013

7 Power Steering Fluid Checking Filling Chnging Engine Coolnt Checking the Coolnt Level Adding Coolnt Air Filter Removl Inspection nd Clening Instlltion Fuel Filter Drining Wter from the Filter Replcing the Filter Purging the Fuel System Fuel System Priming Fuel Tnk Clening nd Flushing Sewter System Sewter Pump Impeller Inspection Sterndrive Wter Inlets Check Flushing nd Drining the Sewter System Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Corrosion Protection Generl Informtion Scrificil Anode Antifouling Pint Lubriction Steering System Throttle Cble Shift Cble Trnsom Assembly Propeller Shft Engine Coupler Driveshft Extension Models Mintining Torques Gimbl Ring U bolt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belts Drive Belt Drive Belt Filure Identifiction Bttery Bttery Precutions for Multiple Engines Alterntors Engine Control Unit (ECU) Btteries Bttery Switches...79 Bttery Isoltors Genertors Section 6 - Storge Cold Wether (Freezing Temperture), Sesonl Storge, nd Extended Storge Prepring Your Power Pckge for Sesonl or Extended Storge Sesonl Storge Instructions Extended Storge Instructions Bttery Storge Recommissioning the Power Pckge Section 7 - Troubleshooting Troubleshooting Troubleshooting Chrts Strter Motor Will Not Crnk Engine, or Crnks Slow Engine Will Not Strt, or Is Hrd to Strt Engine Runs Rough, Misses, or Bckfires Poor Performnce No Fuel or Fulty Fuel Supply Engine Will Not Strt, Strter Does Not Turn Excessive Engine Temperture Insufficient Engine Temperture Low Engine Oil Pressure Bttery Will Not Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds Steering Wheel Turns Hrd or Jerky Power Trim Does Not Operte (Electric Motor Opertes but Sterndrive Unit Does Not Move) Power Trim Does Not Operte (Electric Motor Does Not Operte) Section 8 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service Service Awy From Home...92 Stolen Power Pckge Attention Required After Submersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Problem Contct Informtion for Mercury Mrine Customer Service M eng DECEMBER 2013 Pge iii

8 Customer Service Literture English Lnguge Other Lnguges Ordering Literture United Sttes nd Cnd Outside the United Sttes nd Cnd Section 9 - Mintennce Log Mintennce Log Pge iv 90-8M eng DECEMBER 2013

9 Tble of Contents Section 1 - Wrrnty Section 1 - Wrrnty 1 Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Outside United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty United Sttes nd Cnd...2 Outside the United Sttes nd Cnd... 3 Diesel Duty Cycle Appliction Definitions... 3 Emission Control Wrrnty Informtion... 3 Importnt Informtion...3 U.S. EPA Emissions Limited Wrrnty... 3 Emission Control System Components... 3 Wrrnty Policy Diesel Models... 4 TDI High Output Recretionl Use Limited Wrrnty... 4 TDI Light Duty Commercil Use Limited Wrrnty Yer Limited Wrrnty Aginst Corrosion Diesel Models (Recretionl Use Only)... 7 Wht Is Covered... 7 Durtion of Coverge... 7 Conditions Tht Must Be Met to Obtin Wrrnty Coverge... 7 Wht Mercury Will Do... 7 How to Obtin Wrrnty Coverge... 7 Wht Is Not Covered... 8 Trnsfer of Wrrnty... 8 Wrrnty Policy Austrli nd New Zelnd... 8 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 8 Wht is Covered... 9 Gurntees Under Austrlin Consumer Lw... 9 Durtion of Coverge for This Limited Wrrnty... 9 Wrrnty Period for Recretionl Use... 9 Wrrnty Period for Commercil Use... 9 Trnsfer of Coverge... 9 Termintion of Coverge... 9 Conditions Tht Must Be Met to Obtin Wrrnty Coverge Wht Mercury Will Do How to Obtin Wrrnty Coverge Under This Limited Wrrnty Wht is Not Covered Expense of Climing This Limited Wrrnty Trnsfer of Wrrnty Austrli nd New Zelnd Policy Globl Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Outside United Sttes Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Cnd Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Outside Austrli nd New Zelnd South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Outside of the South Pcific Asi Wrrnty Chrt MerCruiser Gs nd Diesel Outside of Asi Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Europe nd CIS Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Outside Middle Est nd Afric South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Outside South Afric M eng DECEMBER 2013 Pge 1

10 Section 1 - Wrrnty Wrrnty Informtion Wrrnty Registrtion United Sttes nd Cnd To be eligible for wrrnty coverge, the product must be registered with Mercury Mrine. At the time of sle, the selling deler should complete the wrrnty registrtion nd immeditely submit it to Mercury Mrine vi MercNET, e mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. A copy of the wrrnty registrtion should be provided to you by your selling deler. NOTE: Registrtion lists must be mintined by Mercury Mrine nd ny deler of Mercury Mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act be required. You my chnge your registered ddress t ny time, including t time of wrrnty clim, by clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Outside United Sttes nd Cnd For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Wrrnty Registrtion Outside the United Sttes nd Cnd 1. It is importnt tht your selling deler fills out the wrrnty registrtion crd completely nd mils it to the distributor or Mrine Power Service Center responsible for dministering the wrrnty registrtion nd clim progrm for your re. 2. 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. 3. 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, nd should be retined by you for future use when required. Should you ever require 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. 4. In some countries, the Mrine Power Service Center will issue you permnent (plstic) wrrnty registrtion crd 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. 5. For further informtion concerning the wrrnty registrtion crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. See Tble of Contents. IMPORTANT: Registrtion lists must be mintined by the fctory nd deler in some countries by lw. It is our desire to hve ALL products registered t the fctory should it ever be necessry to contct you. Mke sure your Mercury Mrine distributor or Mercury Mrine uthorized deler fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. Trnsfer of Wrrnty United Sttes nd Cnd 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 nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will record the new owner's informtion. Pge M eng DECEMBER 2013

11 Section 1 - Wrrnty There is no chrge for this service. Outside the United Sttes nd Cnd For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Diesel Duty Cycle Appliction Definitions Continuous duty: This engine rting will llow for lod fctors bove 65% nd will llow the continuous use of full power. Medium duty: This engine rting will llow for lod fctors up to 50% nd is for pplictions tht use full power for 33% of engine run time (4 hours of full power for every 12 hours of engine run time) with the reminder t cruise speeds. Recretionl or light duty commercil: This engine rting will llow for lod fctors up to 40 percent nd will llow for the engine to use full power for 13% of engine run time (1 hour of full power for every 8 hours of engine run time) with the reminder t cruise speeds. Emission Control Wrrnty Informtion Importnt Informtion To identify the pplicble emission control wrrnty coverge for prticulr product, refer to the Emission Control Informtion lbel ffixed to the engine. Engines designted s exempt from either Federl EPA or Cliforni emission control regultions re not covered by seprte emission control component wrrnty. The product's Mercury MerCruiser mnufcturer's wrrnty is not ffected by the engine's designtion under Federl EPA or Cliforni emission control regultions. For list of typicl emission control relted engine components, refer to Emission Control System Components in the wrrnty section of your owner's mnul. U.S. EPA Emissions Limited Wrrnty Consistent with the obligtions creted by 40 CFR Prt 1042, Subprt B, Mercury Mrine provides n emission wrrnty of five yers or 500 hours of engine use whichever occurs first to the retil purchser, tht the engine is designed, built, nd equipped so s to conform t the time of sle with pplicble regultions under section 213 of the Clen Air Act, nd tht the engine is free from defects in mterils nd workmnship which cuse the engine to fil to conform with pplicble regultions. This emission relted wrrnty covers ll the components listed in the Emission Control System Components. Wrrnty clims my be denied for filures tht hve been cused by the owner's or opertor's improper mintennce or use, by ccidents for which Mercury Mrine hs no responsibility. Emission Control System Components The emission relted wrrnty covers ll components whose filure would increse n engine's emission of ny regulted component including the following list of components: 1. Fuel metering system. Pressure regultor or fuel injection system b. Cold strt enrichment system c. Intke vlves 2. Air induction system. Intke mnifold b. Turbochrger or superchrger systems c. Chrge ir cooler 3. Exhust system. Exhust mnifold b. Exhust vlves 4. Miscellneous items used in bove systems. 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. Sensors e. Electronic controls NOTE: The EPA emission relted wrrnty does not cover components whose filure would not increse n engine's emissions on ny regulted pollutnt. 90-8M eng DECEMBER 2013 Pge 3

12 Section 1 - Wrrnty Wrrnty Policy Diesel Models TDI High Output Recretionl Use Limited Wrrnty WHAT IS COVERED: Mercury Mrine wrrnts ech new engine/drive pckge (product) to be free of defects in mteril nd workmnship during the period described following. DURATION OF COVERAGE: 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. This Limited Wrrnty provides coverge for two (2) yers of use. Commercil use of the product voids the wrrnty. Commercil use includes ny work or employment relted use of the product, or ny use of the product tht genertes income during 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 term of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper registrtion of the product. HIGH OUTPUT RATING: A High Output Rting pplies to vrible lod pplictions where full power is limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion (the 7 hours out of 8 hours in which the engine is not operted t full power) must be t or below cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Full Power Engine Rted Speed (RPM) Cruise Speed (RPM) 3500 RPM 3.0L (V6) 3100 RPM 4000 RPM 3.0L (V6) 3600 RPM 4200 RPM 4.2L (V8) 3800 RPM This rting is for plesure (noncommercil) pplictions tht operte 500 hours or fewer per yer. CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: 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 predelivery inspection process 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 registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion, Mintennce nd Wrrnty mnul must be timely performed in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY MARINE 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 OBTAIN WARRANTY COVERAGE: Wrrnty clims must be mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge my be terminted if: The product ws repossessed from retil customer Purchsed t n uction Purchsed from slvge yrd Purchsed from n insurnce compny tht obtined the product s result of n insurnce clim Registered with incorrect informtion WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused by buse Dmge cused by bnorml use Dmge cused by the use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce nd Wrrnty mnul) Dmge cused by operting the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce nd Wrrnty mnul Pge M eng DECEMBER 2013

13 Dmge cused by neglect Dmge cused by n ccident Dmge cused by submersion Section 1 - Wrrnty Dmge cused by improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Dmge cused by improper service Dmge cused by the 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 Dmge cused by the use of fuels, oils, or lubricnts tht re not suitble for use with the product Altertion or removl of prts Dmge cused by 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 Dmge cused by running the engine out of wter Mounting the engine too high on the trnsom Dmge cused by operting the bot with the engine overtrimmed 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. TDI Light Duty Commercil Use Limited Wrrnty WHAT IS COVERED: Mercury Mrine wrrnts ech new engine/drive pckge (product) to be free of defects in mteril nd workmnship during the period described following. DURATION OF COVERAGE: The wrrnty period begins on the dte the product is first sold to light duty commercil use retil purchser or the dte on which the product is first put into service, whichever occurs first. This Limited Wrrnty provides coverge for one (1) yer or the number of hours of use, whichever occurs first, specific for the product stted horsepower. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of the wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cnnot be trnsferred. LIGHT DUTY COMMERCIAL RATING: Applies to vrible lod pplictions where full power is limited to one (1) hour out of every eight (8) hours of opertion. Reduced power opertion (the 7 hours out of 8 hours in which the engine is not operted t full power) must be t or below cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Engine Full Power Rted Speed (RPM) Mximum Cruise Speed RPM Mximum Hours Used 3.0L V6 100 hp (3000) L V6 230 hp (3500) L V6 230 hp (4000) L V6 260 hp (4000) L V8 335 hp (4200) L V8 370 hp (4200) M eng DECEMBER 2013 Pge 5

14 Section 1 - Wrrnty COMMERCIAL USE: Commercil use is defined s ny work or employment relted use of this product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. Light duty commercil use is not vilble in the United Sttes. Opertion of the product in excess of the light duty commercil specifictions will void the wrrnty. CONDITIONS THAT MUST BE MET TO OBTAIN WARRANTY COVERAGE: 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 predelivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Routine mintennce outlined in the Opertion, Mintennce nd Wrrnty mnul must be timely performed in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. WHAT MERCURY MARINE 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 OBTAIN WARRANTY COVERAGE: Wrrnty clims must be mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. TERMINATION OF COVERAGE: Wrrnty coverge my be terminted if: The product ws repossessed from retil customer Purchsed t n uction Purchsed from slvge yrd Purchsed from n insurnce compny tht obtined the product s result of n insurnce clim Registered with incorrect informtion WHAT IS NOT COVERED: This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused by buse Dmge cused by bnorml use Dmge cused by the use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce nd Wrrnty mnul) Dmge cused by operting the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce nd Wrrnty mnul Dmge cused by neglect Dmge cused by n ccident Dmge cused by submersion Dmge cused by improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Dmge cused by improper service Dmge cused by the 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 Dmge cused by the use of fuels, oils, or lubricnts tht re not suitble for use with the product Altertion or removl of prts Dmge cused by 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 Dmge cused by running the engine out of wter Mounting the engine too high on the trnsom Dmge cused by operting the bot with the engine overtrimmed Pge M eng DECEMBER 2013

15 Section 1 - Wrrnty 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 Diesel Models (Recretionl Use Only) Wht Is Covered Mercury Mrine wrrnts tht ech new recretionl use engine/drive pckge (Product) will not be rendered inopertive s direct result of corrosion for the period of time described in the following: Durtion of Coverge 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 reregistrtion of the product. Wrrnty coverge my be terminted for used product repossessed from retil customer, purchsed t n uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. Conditions Tht Must Be Met 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 Mercury Mrine specified predelivery 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. Wht Mercury Will Do 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. 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, 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. 90-8M eng DECEMBER 2013 Pge 7

16 Section 1 - Wrrnty Wht Is Not Covered 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; 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. 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. Trnsfer of Wrrnty 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 nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI 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 Mrine Power Service Center closest to you. Wrrnty Policy Austrli nd New Zelnd MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy This Limited Wrrnty is given by Mrine Power Interntionl Pty Ltd ACN of Bessemer Drive, Dndenong South, Victori 3175 Austrli (telephone (61) (3) ), e mil: merc_info@mercmrine.com. Pge M eng DECEMBER 2013

17 Wht is Covered Section 1 - Wrrnty Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described below. The benefits to the consumer given by the wrrnty re in ddition to other rights nd remedies of the consumer under lw in reltion to the goods or services to which the wrrnty reltes. Gurntees Under Austrlin Consumer Lw Our goods come with gurntees tht cnnot be excluded under the Austrlin Consumer Lw. You re entitled to replcement or refund for mjor filure nd compenstion for ny other resonbly foreseeble loss or dmge. You re lso entitled to hve the goods repired or replced if the goods fil to be of cceptble qulity nd the filure does not mount to mjor filure. Durtion of Coverge for This Limited Wrrnty You re only entitled to clim this Limited Wrrnty for defects which pper during the relevnt wrrnty period (see the following). Your clim must lso be received by us before the wrrnty period expires. MerCruiser Petrol Sterndrive nd Inbord Engines 2 yer product wrrnty 3 yer corrosion wrrnty 1 yer/500 hours product wrrnty light commercil MerCruiser SeCore 3 yer product wrrnty 4 yer corrosion wrrnty 1 yer/500 hours product wrrnty light commercil MerCruiser TowSport Engines 3 yer product wrrnty 3 yer corrosion wrrnty 1 yer/500 hours product wrrnty light commercil MerCruiser Diesel 2 yer product wrrnty 3 yer corrosion wrrnty 1 yer/500 hours product wrrnty light commercil 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. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this limited wrrnty beyond its originl expirtion dte. The wrrnty period is specific to the model covered. Refer to your model for the bse coverge period. 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 500 hours 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 to subsequent recretionl use customer upon proper registrtion of the product. Unexpired wrrnty coverge cnnot be trnsferred either to or from commercil use customer. Termintion of Coverge Wrrnty coverge under this Limited Wrrnty is terminted for used product obtined in ny of the following wys: Purchsed from n insurnce compny tht obtined the product s result of n insurnce clim Purchsed from slvge yrd 90-8M eng DECEMBER 2013 Pge 9

18 Section 1 - Wrrnty Repossession from retil customer Purchsed t n uction Conditions Tht Must Be Met to Obtin Wrrnty Coverge Wrrnty coverge under this Limited Wrrnty 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 predelivery 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 registered) 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, nd 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 Will Do Mercury Mrine's sole nd exclusive obligtion under this Limited 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 Under This Limited Wrrnty 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. A list of delers nd their contct detils is vilble t If the purchser cnnot deliver the product to such deler, written notice must be given to Mercury Mrine t the ddress shown bove. Mercury Mrine will then rrnge for the inspection nd ny covered repir. This Limited Wrrnty will not cover the purchser for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered by this limited wrrnty, the purchser shll py for ll relted lbor nd mteril nd ny other expenses ssocited with tht service, provided tht consumer will not be obligted to py where the service hs been crried out to remedy filure of n cceptble qulity gurntee which is binding on Mercury Mrine under the Austrlin Consumer Lw. 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 under this Limited Wrrnty. Wht is Not Covered This limited wrrnty does not cover the following: Operting the bot with the engine over trimmed 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. Refer to the Opertion, Mintennce, nd Wrrnty mnul. Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce, nd 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 tht cuses dmge to the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or lubricnts tht re not suitble for use with the product. Refer to the Opertion, Mintennce, nd 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 Pge M eng DECEMBER 2013

19 Section 1 - Wrrnty Running the engine out of wter Mounting the engine too high on the trnsom 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 this limited 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 limited 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 limited 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. Expense of Climing This Limited Wrrnty This Limited Wrrnty does not cover ny expenses you my incur climing the wrrnty. DISCLAIMERS AND LIMITATIONS EXCEPT FOR APPLICABLE GUARANTEES AND OTHER RIGHTS AND REMEDIES THAT A CONSUMER MAY HAVE UNDER THE AUSTRALIAN CONSUMER LAW OR OTHER LAW IN RELATION TO WHICH THE PRODUCTS RELATE, 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 LIMITED WARRANTY. Trnsfer of Wrrnty Austrli nd New Zelnd Policy 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 Agreement, new owner s nme, ddress, nd hull identifiction number (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. In Austrli nd New Zelnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment Brunswick Asi Pcific Group Privte Bg 1420 Dndenong South, Victori 3164 Austrli 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. You my chnge your ddress t ny time, including t the time of the wrrnty clim, by clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd hull identifiction number (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. 90-8M eng DECEMBER 2013 Pge 11

20 Section 1 - Wrrnty Globl Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord MerCruiser TowSport MerCruiser SeCore MerCruiser Inbord MPI, 8.2 H.O. MerCruiser Inbord horizon Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 3 yers 3 yers 4 yers 4 yers 1 yer 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not vilble t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside United Sttes For product purchsed outside of United Sttes, contct the distributor in your country, or the uthorized Mrine Power Service Center closest to you. Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord MerCruiser TowSport MerCruiser SeCore MerCruiser Inbord MPI, 8.2 H.O. MerCruiser Inbord horizon Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 3 yers 3 yers 4 yers 4 yers 1 yer 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not vilble t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Cnd For product purchsed outside of Cnd, contct the distributor in your country, or the uthorized Mrine Power Service Center closest to you. Pge M eng DECEMBER 2013

21 Section 1 - Wrrnty Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord Stndrd Limited Wrrnty 2 yers 3 yers MerCruiser SeCore 3 yers 4 yers MerCruiser TowSport 3 yers 3 yers Mercury Diesel Sterndrive nd Inbord 2 yers 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Austrli nd New Zelnd For product purchsed outside of Austrli nd New Zelnd, contct the distributor in your country, or the uthorized Mrine Power Service Center closest to you. South Pcific Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty 2 yers 3 yers 2 yers 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside of the South Pcific For product purchsed outside of the South Pcific, contct the distributor in your country, or the uthorized Mrine Power Service Center closest to you. Asi Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Gsoline Sterndrive nd Inbord Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty 1 yer 3 yers 1 yer 3 yers Stndrd Limited Corrosion Wrrnty Commercil Appliction Contct the Mrine Power Service Center closest to you Outside of Asi For product purchsed outside of the Asin region, contct the distributor in your country, or the Mrine Power Service Center closest to you. Europe nd the Confedertion of Independent Sttes (CIS) Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 2 yers 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not vilble t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you 90-8M eng DECEMBER 2013 Pge 13

22 Section 1 - Wrrnty Outside Europe nd CIS For products purchsed outside of Europe nd CIS regions, contct the distributor in your country, or the Mrine Power Service Center closest to you. Middle Est nd Afric (excluding South Afric) Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not vilble t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside Middle-Est nd Afric For products purchsed outside of Middle Est nd Afric regions, contct the distributor in your country, or the Mrine Power Service Center closest to you. South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inbord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inbord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yer 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not vilble t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you Outside South Afric For products purchsed outside of South Afric, contct the distributor in your country, or the Mrine Power Service Center closest to you. Pge M eng DECEMBER 2013

23 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tble of Contents Fetures nd Controls TDI 4.2L Engine Description Identifiction...16 Audio Wrning System Testing the Audio Wrning System Digitl Throttle nd Shift Instrumenttion VesselView SmrtCrft Speedometer, Tchometer, nd Digitl Guges System Link Digitl Guges Controls Switches Emergency Stop Switch...20 Lnyrd Stop Switch Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition Digitl Throttle nd Shift Engine Electricl System Overlod Protection Fuses Vessel Adpter Assembly Fuse Replcement Power Trim Single Engine Trim nd Triler Dul Engine Trim nd Triler Power Trim nd MerCthode Overlod Protection Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsibility Engine Components M eng DECEMBER 2013 Pge 15

24 Section 2 - Getting to Know Your Power Pckge Fetures nd Controls TDI 4.2L Engine Description Four stroke V8 diesel engine 4.2 liter displcement (252 cid) Common ril direct fuel injection Chin driven overhed cm hydrulic vlvetrin Pressurized engine lubriction with replceble oil filter Dry ir filter Vrible geometry turbochrgers Twin cooling circuits, utilizing sewter cooling nd closed circuit cooling Refer to Engine Specifictions for dditionl detils. Refer to Engine Components for the loctions of engine components referenced in this mnul. Identifiction The seril numbers re the mnufcturer's keys to numerous engineering detils tht pply to your Mercury Mrine power pckge. When contcting Mercury Mrine bout service, lwys specify model nd seril numbers. Audio Wrning System Your Mercury Diesel power pckge my be equipped with n udio wrning system. The udio 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: The engine oil pressure is too low The coolnt temperture is too hot Wter in fuel Low coolnt level 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 Pge M eng DECEMBER 2013

25 Section 2 - Getting to Know Your Power Pckge If the lrm sounds, stop the engine immeditely if you re not in hzrdous sitution. Investigte the cuse nd correct it, if possible. If you cnnot determine the cuse, consult your Mercury Diesel uthorized repir fcility. Testing the Audio Wrning System 1. Turn the ignition switch to the "RUN" or 1 position; do not strt the engine. 2. Push the udio test switch toggle lever down nd hold it. 3. Listen for the lrm. The lrm will sound if the system is functioning correctly. Digitl Throttle nd Shift Digitl Throttle nd Shift (DTS) operting instructions re provided in seprte mnul. Refer to Mercury Diesel's SmrtCrft nd DTS Opertor's Mnul. Instrumenttion VesselView Your power pckge my be connected to SmrtCrft VesselView disply. VesselView 7 is comprehensive bot informtion center tht cn disply informtion for up to four gsoline or diesel engines. It continuously monitors nd reports bsic operting dt including detiled informtion such s sewter temperture nd depth, trim sttus, bot speed nd steering ngle, nd the sttus of fuel, oil, wter, nd wste tnks. VesselView cn be fully integrted with vessel s globl positioning system (GPS) or other NMEA comptible device to provide up to the minute nvigtion, speed, nd fuel to destintion informtion. VesselView 4 nd 7 re equipped with micro SD crd port tht llows n uthorized OEM or delership to import the personlity configurtion. It cn lso be use by the owner to import pictures or grphics. When more thn one VesselView is used, either s triple or qud engine ppliction for multiple helms, the sme mico SD crd cn be used to downlod those configurtions. VesselView Refer to your VesselView opertions mnul for detiled instructions on how to operte this disply. SmrtCrft Speedometer, Tchometer, nd Digitl Guges The SmrtCrft instrument pckge ugments the informtion provided by VesselView. The instrument pckge my disply: Engine RPM Bot speed Coolnt temperture Oil pressure Bttery voltge Fuel consumption Engine operting hours M eng DECEMBER 2013 Pge 17

26 Section 2 - Getting to Know Your Power Pckge b SmrtCrft tchometer nd speedometer - Tchometer b - Speedometer c - LCD disply c The SmrtCrft instrument pckge lso ids in identifying the fult codes ssocited with the engine udio wrning system. The SmrtCrft instrument pckge displys criticl engine lrm dt nd other potentil problems on its LCD disply. For bsic opertion informtion on the SmrtCrft instrument pckge nd for detils on the wrning functions monitored by the system, refer to the mnul provided with your guge pckge. System Link Digitl Guges Some instrumenttion pckges include guges tht ugment the informtion provided by VesselView nd the SmrtCrft tchometer nd speedometer. The owner nd opertor should be fmilir with ll the instruments nd their functions on the bot. Hve your bot deler explin the guges nd norml redings tht pper on your bot. The following types of digitl guges my be included with your power pckge. b c d System Link digitl guges Item Guge Indictes Oil pressure guge Engine oil pressure b Voltmeter Bttery voltge c Wter temperture guge Engine operting temperture d Fuel guge Quntity of fuel in tnk Pge M eng DECEMBER 2013

27 Section 2 - Getting to Know Your Power Pckge Controls Switches Four Position Key Switch "OFF" In the "OFF" position, ll electricl circuits re off. The engine will not operte with the key switch in the "OFF" position. "ACC" In the "ACC" position, ny ccessories connected to the electricl circuits cn be operted. The engine will not operte with the key switch in the "ACC" position. "ON" In the "ON" position, ll electricl circuits nd instrumenttion receive power. The engine cn be strted with n optionl strt stop switch. "START" Turn the key to the strt position nd relese to strt the engine. NOTE: The key cn only be removed with the key switch in the "OFF" position Dul Engine Strt Stop Switch A strt stop switch is optionl equipment. The strt stop switch works in conjunction with the key switch. There is one strt stop switch for ech engine. Ech button on multi engine strt stop switch functions independently. The key switch must be in the "ON" position to strt stopped engine with the strt stop switch. Pressing strt stop switch button when n engine is running will shut down the corresponding engine Bilge Blower Toggle Switch Opertes the bilge blower, if equipped. ON OFF M eng DECEMBER 2013 Pge 19

28 Section 2 - Getting to Know Your Power Pckge Emergency Stop Switch An emergency stop (E stop) switch is used to turn off the engines in n emergency sitution, such s person overbord or tngled propeller. When ctivted, n E stop switch interrupts the power supply to the engine nd trnsmission. If the bot is equipped with n E stop switch, the E stop switch turns off ll of the engines. Typicl E-stop switch Activtion of n E stop switch stops the engine, or engines, immeditely, but the bot cn continue to cost for some distnce depending upon the velocity nd degree of ny turn t shutdown. 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 recommend instructing other occupnts on proper strting nd operting procedures should they need to operte the engine in n emergency. Accidentl or unintended ctivtion of the switch during norml opertion is lso possible, which cn cuse ny or ll of the following potentilly hzrdous situtions: Occupnts cn be thrown forwrd due to unexpected loss of forwrd motion, nd pssengers in the front of the bot could be ejected over the bow nd possibly struck by the propulsion or steering components. The opertor cn lose power nd directionl control in hevy ses, strong current, or high winds. The opertor cn lose control of the vessel when docking. Restrting n engine using the key switch or strt button fter n E stop shutdown without first turning the key switch to the off position for t lest 30 seconds will restrt the engine but cuse fult codes to be set. Unless you re in potentilly hzrdous sitution, turn the key switch off nd wit t lest 30 seconds before restrting the engine or engines. If fter restrting, some fult codes re still being displyed, contct your uthorized Mercury Diesel repir fcility. Lnyrd Stop Switch A lnyrd switch is designed to shut down the engine in the event the opertor unexpectedly moves wy from the helm, s my hppen in n ccidentl ejection. The lnyrd is connected to the opertor's personl flottion device or wrist. A decl ner the lnyrd stop switch reminds the opertor to ttch the lnyrd to his or her personl flottion device or wrist b ATTACH LANYARD RUN OFF - Lnyrd cord clip b - Lnyrd decl c - Lnyrd stop switch c 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: Pge M eng DECEMBER 2013

29 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 Crelessness cused by consuming lcohol or drugs High speed boting mneuvers Section 2 - Getting to Know Your Power Pckge The lnyrd is cord usully between 122 nd 152 cm (4 nd 5 ft) long 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 opertor's norml position. The opertor cn shorten the lnyrd by wrpping the lnyrd round his wrist, or by tying 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 its velocity. While the bot is costing, it cn cuse injury to nyone in the bot's pth s it would under power. Instruct ll pssengers on the proper strting nd operting procedures should they be required to operte the bot in n emergency.! 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. 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. Keep the Lnyrd Stop Switch nd Lnyrd Cord in Good Operting Condition Before ech use, ensure tht the lnyrd stop switch works properly. Strt the engine, nd then stop it by pulling the lnyrd cord. If the engine does not stop, hve the switch repired before operting the bot. Before ech use, inspect the lnyrd cord to ensure tht it is in good working condition nd tht there re no breks, cuts, or wer to the cord. Check tht the clips on the ends of the cord re in good condition. Replce ny dmged or worn lnyrd cords. Digitl Throttle nd Shift Digitl Throttle nd Shift (DTS) operting instructions re provided in seprte mnul. Refer to Mercury Diesel's SmrtCrft nd DTS Opertor's Mnul. Engine Electricl System Overlod Protection Fuses! CAUTION Filure to protect wiring with n pproprite fuse cn dmge the wiring nd strt fire. When instlling ny ccessories, we recommend using Mercury ccessory kit. Alwys use the pproprite fuse to protect wiring. Individul circuits re protected by fuses. If n electricl overlod occurs, fuse will burn out. Find nd correct the cuse for the electricl overlod before replcing the fuse. 90-8M eng DECEMBER 2013 Pge 21

30 Section 2 - Getting to Know Your Power Pckge Two fuses re locted on the top of the engine. Remove the engine cover to ccess these fuses. Be certin to replce n open fuse only with one of the sme rting. b - 15 mp fuse b - 25 mp fuse The remining fuses re locted in the vessel dpter ssembly (refer to your bot owner's mnul for loction) nd on the rer side of the control unit of the individul instrumenttion. Vessel Adpter Assembly Fuse Replcement NOTE: Refer to your bot owner's mnul for the loction of the vessel dpter ssembly (VAA). The key for the VAA ws provided long with the ignition keys. 1. Turn the ignition switch to the "OFF" position Unlock nd open the cover of the vessel dpter ssembly. 3. Determine which fuse belongs to the filed circuit using the illustrtion below. f e d c b - Helm power 5 mp fuse b - EFP 1 mp fuse c - Feture A 1 mp fuse d - T.15 5 mp fuse e - Feture B 1 mp fuse f - Min power 10 mp fuse 4. Replce the blown fuse with new fuse of the sme rting. 5. Close nd lock the cover of the VAA. Power Trim Power trim llows the opertor to djust the sterndrive ngle while underwy to provide the idel bot ngle for vrying lod nd wter conditions. Also, the trilering feture llows the opertor to rise nd lower the sterndrive for trilering, beching, lunching, low speed (below 1200 RPM engine speed), nd shllow wter opertion.! WARNING Excessive trim cn cuse serious injury or deth t high speeds, nd single rm trim systems do not provide trim out limiting device or trim indictor. Use cution when trimming with single rm trim system nd never trim out beyond the unit's side support flnges while the bot is underwy or t engine speeds bove 1200 RPM Pge M eng DECEMBER 2013

31 For best performnce, trim the sterndrive so tht the bot bottom is t 3 5 ngle to the wter. Section 2 - Getting to Know Your Power Pckge 3-5 mc79528 Trimming the sterndrive up (out) cn: Generlly increse top speed Increse clernce over submerged objects or shllow bottom Cuse the bot to ccelerte nd plne off slower In excess, cuse bot porpoising (bouncing) or propeller ventiltion Cuse engine overheting if trimmed up (out) to point where ny cooling wter intke holes re bove the wter line mc78529 Trimming the sterndrive down (in) cn: Help the bot ccelerte nd plne off quicker Generlly improve the ride in choppy wter In most cses, reduce bot speed If in excess, lower the bow of some bots to point t which they begin to plow with their bow in the wter while on plne. This cn result in n unexpected turn in either direction clled bow steering or over steering if ny turn is ttempted or if significnt wve is encountered. mc79530 Single Engine Trim nd Triler Single engine pplictions hve button tht cn be pressed to trim the sterndrive unit up (out) or down (in). To rise the sterndrive for trilering, beching, lunching, low speed (below 1200 RPM), nd shllow wter opertion push the trim button to rise the sterndrive to the full up (out) position. Some controls lso hve triler button tht trims the sterndrive to position suitble for triler purposes only. Dul Engine Trim nd Triler NOTICE If using externl tie brs, rising or lowering the drives independently of ech other cn dmge the drive nd steering systems. If using n externl tie br, rise nd lower ll drives together s unit. 90-8M eng DECEMBER 2013 Pge 23

32 Section 2 - Getting to Know Your Power Pckge Dul engine pplictions my hve single integrl button to operte both sterndrives simultneously or my hve seprte buttons for ech sterndrive. Some controls lso hve triler button tht trims the sterndrives to position suitble for triler purposes only. Power Trim nd MerCthode Overlod Protection If n electricl overlod on the electricl system occurs, fuse will open (blow). Find nd correct the cuse before replcing the fuse. NOTE: If you must operte the engine in n emergency, turn off nd disconnect ll ccessories from the engine nd instrumenttion wiring if you cnnot find nd correct the cuse for the electricl overlod or excessive current drw. Replce the fuse. If the fuse burns out, the electricl overlod hs not been eliminted. Further checks must be mde on the electricl system. Contct your Mercury Diesel uthorized repir fcility. 1. The power trim system is protected from overlod by 110 mp fuse nd 20 mp in line fuse on the power trim pump mp in line fuse holder b mp fuse b There re severl different Quicksilver MerCthode systems vilble. Ech hs fuse connected to the positive (+) terminl on the controller. If the fuse is open (blown), the system will not operte, resulting in loss of corrosion protection. Replce the fuse with one of the sme mp rting. - MerCthode b - Red/purple wire c - Fuse c b Pge M eng DECEMBER 2013

33 Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Section 2 - Getting to Know Your Power Pckge A tmper resistnt lbel is ffixed to the engine t time of mnufcture. In ddition to the required exhust gs emissions certificte number, the lbel lists the engine seril number, engine fmily, mximum RPM, engine power, nd weight. Note tht the exhust gs 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 Diesel bout the vilbility of replcement decls before proceeding. xxxxxxxxx x.x xxxxxxxxx x x Owner Responsibility The owner or opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow exhust gs emission levels to exceed their predetermined fctory specifictions. 90-8M eng DECEMBER 2013 Pge 25

34 Section 2 - Getting to Know Your Power Pckge Engine Components b c d e f g h i Exhust outlet b - Turbochrger c - Oil filter d - Engine oil filler cp e - Scrificil node (hidden) f - Intercooler g - Sewter pump h - Het exchnger i - Strter Pge M eng DECEMBER 2013

35 Section 2 - Getting to Know Your Power Pckge c d e f g b h i Engine oil dipstick b - Coolnt resevoir c - Coolnt reservoir cp d - Ribbed V belt e - Alterntor f - Fuses g - Air filter h - Fuel injection pump drive belt (hidden) NOTE: The fuel injection pump drive belt is locted t the rer of the engine nd is protected by cover. Refer to your Mercury Diesel uthorized repir fcility for servicing. i - Electronic control units 90-8M eng DECEMBER 2013 Pge 27

36 Section 2 - Getting to Know Your Power Pckge Notes: Pge M eng DECEMBER 2013

37 Tble of Contents Section 3 - On The Wter Section 3 - On The Wter Sfe Boting Recommendtions Crbon Monoxide Exposure Be Alert To Crbon Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Duty Cycle Bsic Bot Opertion Duty Cycle Rting Plesure Duty Rting Bsic Bot Opertion Opertion Chrt Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump...34 Strting, Shifting, nd Stopping Before Strting the Engine...34 Strting Cold Engine Engine Wrm Up Strting Wrm Engine...36 Shifting Engine Shutdown (Stopping) Strting the Engine After Stopped While in Ger Trilering the Bot Protecting People In The Wter Protecting People in the Wter While Bot is in Opertion While the Bot is Sttionry High Speed nd High Performnce Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots with Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection...40 Brek In Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers)...40 Engine Brek In Hour Brek In Period After the 20 Hour Brek In Period End of First Seson Checkup M eng DECEMBER 2013 Pge 29

38 Section 3 - On The Wter Sfe Boting Recommendtions 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. We recommend tht ll powerbot opertors complete boting sfety course. In the U.S., the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil boting lw enforcement gency provide courses. For more informtion in the U.S., cll the Bot U.S. Foundtion t BOAT (2628). Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment onbord. 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 Rdio Pddle or or Spre propeller, thrust hubs, nd n pproprite wrench First id kit nd instructions Wterproof storge continers Spre operting equipment, btteries, bulbs, nd fuses Compss nd mp or chrt of the re Personl flottion device (one per person onbord) 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 onbord, 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 one person onbord 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. Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot's cpcity plte). Know your bot's operting nd loding limittions. Know if your bot will flot if it is full of wter. When in doubt, contct your uthorized Mercury Mrine 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. Pssengers should not sit or ride 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 operte bot while under the influence of lcohol or drugs. It is the lw. Alcohol or drugs cn impir your judgment nd gretly reduce your bility to rect quickly. Know your boting re nd void hzrdous loctions. Pge M eng DECEMBER 2013

39 Be lert. Section 3 - On The Wter 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 opertor's 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. Your bot trveling t 40 km/h (25 mph) will overtke fllen skier who is 61 m (200 ft) in front of you in five seconds. Wtch fllen skiers. When using your bot for wterskiing 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 ccident 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 $500.00, or 4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement. Crbon Monoxide Exposure Be Alert To Crbon Monoxide Poisoning Crbon monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl combustion engines, including the engines tht propel bots, nd the genertors tht power bot ccessories. By itself, CO is odorless, colorless, nd tsteless, but if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of crbon monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse.! WARNING Inhling engine exhust gses cn result in crbon monoxide poisoning, which cn led to unconsciousness, brin dmge, or deth. Avoid exposure to crbon monoxide. Sty cler from exhust res when engine is running. Keep the bot well ventilted while t rest or underwy. Sty Cler of Exhust Ares Engine exhust gses contin hrmful crbon monoxide. Avoid res of concentrted engine exhust gses. When engines re running, keep swimmers wy from the bot, nd do not sit, lie, or stnd on swim pltforms or bording ldders. While underwy, do not llow pssengers to be positioned immeditely behind the bot (pltform drgging, tek/body surfing). This dngerous prctice not only plces person in n re of high engine exhust concentrtion, but lso subjects them to the possibility of injury from the bot propeller. Good Ventiltion Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the bot: M eng DECEMBER 2013 Pge 31

40 Section 3 - On The Wter Poor Ventiltion Under certin running or wind 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 running engine my be exposed to hzrdous level of crbon monoxide. 1. Exmples of poor ventiltion while the bot is sttionry: b - Operting the engine when the bot is moored in confined spce b - Mooring close to nother bot tht hs its engine operting 2. Exmples of poor ventiltion while the bot is moving: b Operting the bot with the trim ngle of the bow too high b - Operting the bot with no forwrd htches open (sttion wgon effect) Duty Cycle Bsic Bot Opertion IMPORTANT: Dmge cused by improper ppliction or filure to operte the power pckge within the specified operting prmeters will not be covered by the Mercury Diesel Limited Wrrnty. Duty Cycle Rting It is the responsibility of the bot mnufcturer or the instlling deler to ensure tht the power pckge is properly pplied. In ll cses, the power pckge must be equipped with the ger rtio tht llows the engine to operte t wide open throttle (WOT) t the rted engine RPM. The power pckge must lso be pplied in ccordnce with recommendtions indicted in the pproprite pplictions mnul. Use of Mercury Diesel engines in other thn the pplictions indicted by the following informtion nd in the pproprite pplictions mnul requires written pprovl from n uthorized Mercury Diesel ppliction engineer. Plesure Duty Rting The plesure duty rting pplies to recretionl plning crft used exclusively for plesure nd recretion. Typicl plesure crft include silbots, ski bots, runbouts, speedbots, nd other plning hulls. Appliction must conform to the Plesure Crft/Recretionl duty cycle shown in the following tble. Pge M eng DECEMBER 2013

41 Section 3 - On The Wter EPA Mode Number Cycle 5 Duty Cycle Modes Engine speed (percent of WOT) Idle Engine power (percent of totl) Time t given mode (percent of totl operting time) Chrt showing full power opertion is limited to mximum of 1 of 12 hours 1 - Mode 1: 1.0 hour (8%) 2 - Mode 2: 1.5 hours (13%) 3 - Mode 3: 2.0 hours (17%) 4 - Mode 4: 4.0 hours (32%) 5 - Mode 5: 3.5 hours (30%) Bsic Bot Opertion Opertion Chrt Strting Procedure After Strting While Underwy Stopping nd Shut Down Open the engine htch. Air out the bilge completely. Turn the bttery switch on, if equipped. Turn on nd run the engine comprtment bilge blower, if equipped, for five minutes. Check for leks: fuel, oil, wter, fluid, etc. Open the fuel shut off vlve, if equipped. Open the secock, if equipped. Prime the fuel injection system, if necessry. Turn the key switch to "START" position. Relese the key when the engine strts. Wrm up the engine t fst idle RPM for severl minutes. Observe ll instrumenttion to monitor the condition of the engine. If not norml, stop the engine. Check for fuel, oil, wter, fluid, nd exhust leks, etc. Check shift nd throttle control opertion. Check steering opertion. Frequently review ll instrumenttion to monitor engine condition. Listen for the udio lrm. Shift the remote control lever to the neutrl position. Run the engine t idle RPM for severl minutes to llow the turbochrger nd engine to cool. Turn the key switch to "OFF" position. Turn the bttery switch off, if equipped. Close the fuel shut off vlve, if equipped. Close the secock, if equipped. Flush the sewter cooling circuit, if operting in sltwter, brckish wter, or polluted wter. 90-8M eng DECEMBER 2013 Pge 33

42 Section 3 - On The Wter Freezing Temperture nd Cold Wether Opertion IMPORTANT: If the bot is operted during periods of freezing temperture, tke precutions to prevent freezing dmge to the power pckge. Dmge cused by freezing is not covered by the Mercury Mrine Limited Wrrnty. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or before ny length of storge in freezing tempertures. If the bot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing bck into the cooling system. If the bot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the bot reminding the opertor to open the secock or unplug nd connect the wter inlet hose before strting the engine. In order to operte the engine in tempertures of 0 C (32 F) or lower, observe the following instructions: At the end of ech dily opertion, completely drin the sewter section of the cooling system to protect ginst dmge by freezing. At the end of ech dily opertion, drin the wter from the wter seprtor, if equipped. Fill the fuel tnk t the end of dily opertion to prevent condenstion. Use the required permnent type ntifreeze solution to protect components ginst dmge by freezing. Use proper cold wether lubriction oil; ensure tht the crnkcse contins sufficient mount. Mke certin tht the bttery is of sufficient size nd is fully chrged. Check tht ll other electricl equipment is in optimum condition. At tempertures of 20 C ( 4 F) nd below, use coolnt heter nd mrine ppliction bilge ir heter to improve cold strting. If operting in rctic tempertures of 29 C ( 20 F) or lower, consult your Mercury Diesel uthorized repir fcility for informtion bout specil cold wether equipment nd precutions. Refer to Section 6 for cold wether or extended storge relted informtion. 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 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 wrrnty. Strting, Shifting, nd Stopping! WARNING Vpors cn ignite nd cuse n explosion, resulting in engine dmge or severe personl injury. Do not use voltile strting ids such s ether, propne, or gsoline in the engine ir intke system.! WARNING Fuel vpors trpped in the engine comprtment my be n irritnt, cuse difficulty brething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment before servicing the power pckge. Before Strting the Engine NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. Pge M eng DECEMBER 2013

43 IMPORTANT: Observe the following before strting: Verify sewter pickup is open. Section 3 - On The Wter Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit one minute to llow the strter motor to cool; then, repet the strting procedure. Ensure tht the engine crnkcse is filled to the correct level with the proper grde of oil for the previling temperture. Refer to Specifictions Engine Oil. Ensure tht ll electricl connections re secure. Check ll items listed in the mintennce schedules nd Opertion Chrt. Perform ny other necessry checks s indicted by your Mercury Diesel uthorized repir fcility or specified in your bot owner s mnul. Strting Cold Engine IMPORTANT: Check the fluid levels before strting the engine. Refer to the Mintennce Schedule. Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit one minute to llow the strter motor to cool; then, repet the strting procedure. 1. Run the engine comprtment bilge blower for five minutes, or open the engine htch to ir out the bilge before ttempting to strt the engine. 2. Plce the sterndrive in the full down (in) position. 3. Plce the control hndle in neutrl. 4. If the engine hs not been run for long period of time nd will not redily strt with the stndrd strting procedure, proceed s follows. 5. Turn the ignition switch to the "ON" position nd the fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit for five seconds. repet this step six times. 6. Strt the engine. IMPORTANT: Within seconds fter strting the engine, the oil pressure should exceed minimum of 10 psi (69 kp). If the oil pressure is below the minimum specifiction, stop the engine then locte nd correct the problem. If you re unble to determine the problem, see your Mercury Diesel uthorized repir fcility. NOTICE Engging the strter motor while the engine is operting cn dmge the strter motor or flywheel. Do not engge the strter motor continully for longer thn 15 seconds. Do not engge the strter motor when the engine is operting. 7. Verify tht the chrge indictor nd oil pressure wrning lmps re off. 8. Verify tht ll instrumenttion is functioning properly nd indicting norml redings. 9. Allow the engine to rech norml operting temperture before demnding power from the engine. Engine Wrm Up 1. After strting the engine, verify tht ll instrumenttion is functioning properly. 2. Operte the engine t RPM until the engine temperture is within the norml operting rnge. It is importnt tht ny engine be wrmed up before pplying full lod. The wrm up period provides time for the lubricting oil to estblish film between moving prts. NOTICE Engine wer cused by incresed friction nd limited oil flow is gretest when n engine is cold. Decrese engine wer by llowing the engine coolnt temperture to rech norml operting rnge before hrd ccelertion or pplying full throttle. 3. After the engine hs reched operting temperture:. The oil pressure should be within the rnge specified. Refer to Specifictions Engine Specifictions. Stop the engine if the oil pressure is not within the rnge specified. b. Check the fuel system for lekge from the injection pump, fuel pipes, fuel filter, or fuel lines. c. Check the engine nd drive system for oil lekge. Specificlly inspect the oil filter, oil lines, oil line connectors, nd oil pn. d. Check for coolnt leks. Check the coolnt hoses nd connection pipes of the het exchnger, fluid coolers, ftercooler, wter pump, nd drin fittings for leks. 4. Correct ny problems found, or see your Mercury Diesel uthorized repir fcility if you re unble to determine the problem. 90-8M eng DECEMBER 2013 Pge 35

44 Section 3 - On The Wter Strting Wrm Engine 1. Run the engine comprtment bilge blower for five minutes, or open the engine htch to ir out the bilge before ttempting to strt the engine. 2. Move the remote control hndle to the "NEUTRAL" position. 3. Turn the key switch to the "ON" position. 4. Turn the key switch to the "START" position nd relese the key when the engine strts. Verify tht the chrge indictor nd oil pressure wrning lmps turn off. 5. Verify tht the instrumenttion functions properly nd norml redings re indicted. Shifting NOTICE Shifting into ger t engine speeds bove idle will dmge the gercse. Shifting into ger when the engine is not running cn 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. Verify tht the remote control shift lever is in neutrl. 2. To shift the sterndrive, move the remote control shift lever with firm, quick motion forwrd to shift to forwrd ger, or bckwrd to shift into reverse. 3. After shifting the sterndrive, dvnce the throttle to the desired setting. IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, proceed to steps 4 nd 5: 4. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting bove idle RPM when the engine stopped. 5. After the hndle returns to the neutrl detent position, resume norml strting procedures. Engine Shutdown (Stopping) 1. Plce the remote control lever in neutrl. NOTICE Immeditely stopping the engine fter high lod opertion cn dmge the turbochrger berings. Idle the engine for severl minutes before shutdown. 2. Operte the engine t idle speed for severl minutes to llow the turbochrger nd engine to cool. 3. Turn the key switch to the "OFF" position or press the strt stop switch button if equipped. Strting the Engine After Stopped While in Ger IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, see the following procedure: 1. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting bove idle RPM when the engine stopped. 2. After the hndle returns to the neutrl detent position, resume norml strting procedures. Trilering the Bot Your bot cn be trilered with the sterndrive unit in the up or down position. Adequte clernce is required between the rod nd sterndrive when trnsporting. If dequte rod clernce is problem, plce the sterndrive unit in full triler position nd support it with n optionl triler kit, vilble t your Mercury Diesel uthorized repir fcility. Pge M eng DECEMBER 2013

45 Section 3 - On The Wter Protecting People In The Wter While Bot is in Opertion People in the wter cnnot tke quick ction to void bot heding in their direction Approch slowly nd exercise extreme cution when boting in res where people my be in the wter. When bot is moving 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. While the Bot is Sttionry! 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 down the engine before llowing people in the wter ner the bot. High Speed nd High Performnce If your bot is 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 the High Performnce Bot Opertion booklet ( R2) from your uthorized Mercury Diesel repir fcility. Pssenger Sfety in Pontoon Bots nd 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 n Open Front Deck No one should ever be on the deck in front of the ril while the bot is in motion. Keep ll pssengers behind the front ril 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. 90-8M eng DECEMBER 2013 Pge 37

46 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. mc Wve nd Wke Jumping! WARNING 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 reenters 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 when operting in shllow wter or in res where the wters re suspected of hving underwter obstcles tht could be struck by the drive components, rudder, or the bot bottom. mc IMPORTANT: To help reduce injury or impct dmge from striking floting or underwter object, control the bot speed. Under these conditions, bot speed should be kept to mximum of 24 to 40 km/h (15 to 25 mph). The following demonstrte some, but not ll, exmples of wht cn hppen if the bot strikes n object: The bot could move suddenly in new direction. A shrp chnge in direction or turn cn throw occupnts 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, or bot. Keep in mind tht one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the bot speed. Bot speed should be kept to minimum plning speed when driving in wters known to hve underwter obstcles. Pge M eng DECEMBER 2013

47 Section 3 - On The Wter 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 Mercury Diesel uthorized repir fcility for thorough inspection nd ny necessry repir. The bot should be checked for hull frctures, trnsom frctures, nd wter leks. Operting with dmged drive components, rudder, or bot bottom could cuse 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 the 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 the 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, ensure tht the bot bottom is: Clen, free of brncles nd mrine growth Free of distortion, nerly flt where it contcts 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 wter inlets nd cuse the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter object, such s ger housing or propeller. Cvittion increses propeller speed while reducing bot speed. 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 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: The drive unit being trimmed out too fr A missing propeller diffuser ring A dmged propeller or ger housing, tht llows exhust gses to escpe between the propeller nd ger housing The drive unit instlled too high on trnsom Elevtion nd Climte Elevtion nd climte chnges ffect the performnce of your power pckge. Loss of performnce cn be cused by: High elevtions High tempertures Low brometric pressures High humidity 90-8M eng DECEMBER 2013 Pge 39

48 Section 3 - On The Wter 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, the recommended RPM cn be chieved by chnging to lower pitch propeller. Propeller Selection NOTICE Operting the engine with the wrong propeller instlled cn limit power, increse fuel consumption, overhet the engine, or cuse internl powerhed dmge. Choose propeller tht llows the engine to operte t the specified wide open throttle RPM. It is the responsibility of the bot mnufcturer nd the selling deler to equip the power pckge with the correct propellers. IMPORTANT: Be sure tht the propeller being used does not llow the engine to run ginst the limiter, s significnt loss in performnce will result. NOTE: Use n ccurte service tchometer to verify RPM. Select propeller tht will llow the engine power pckge to operte t the rted engine RPM with full lod. If full throttle opertion is below the rted engine RPM, the propeller must be chnged to prevent loss of performnce nd possible engine dmge. On the other hnd, operting n engine bove the rted engine RPM will cuse higher thn norml wer or dmge. After initil propeller selection, the following common problems my require tht the propeller be chnged to lower pitch: Wrmer wether nd greter humidity cuse n RPM loss (not s significnt on these models). Operting in higher elevtion cuses n RPM loss (not s significnt on these models). Operting with dmged propeller or dirty bot bottom cuses n RPM loss. Operting with incresed lod (dditionl pssengers, pulling skiers). For better ccelertion, such s is needed for wter skiing, use the next lower pitch propeller. Do not operte t full throttle when using the lower pitch propeller but not pulling skiers. Brek In Initil Brek In Procedure It is especilly importnt tht the following procedure be used on new diesel engines. This brek in procedure llows the proper seting of the pistons nd rings, which gretly reduces the likelihood of problems. IMPORTANT: It is recommended tht the bot not be ccelerted hrd until this procedure hs been completed. IMPORTANT: Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit pproximtely 60 seconds to llow the strter motor to cool; then, repet the strting procedure. 1. See the pproprite Strting, Shifting, nd Stopping section, nd strt the engine. Operte the engine t fst idle until it hs reched norml operting temperture. 2. Operte the engine in ger for three minutes t : 1200 RPM, 2400 RPM, nd 3000 RPM. 3. Operte the engine in ger for three minutes t: 1500 RPM, 2800 RPM, nd 3400 RPM. 4. Operte the engine in ger for three minutes t : 1800 RPM, 3000 RPM, nd mximum rted full throttle RPM. Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) It is importnt tht the following procedure be used on new sterndrives nd rebuilt sterndrives with new replcement gers. This brek in procedure llows the proper seting of the sterndrive gers nd relted components, which gretly reduces the likelihood of problems. Avoid full throttle strts. Do not operte t ny constnt speed for n extended period of time. Do not exceed 75% throttle during the first five hours. During the next five hours, operte t intermittent full throttle. The sterndrive should be shifted into forwrd ger minimum of 10 times during brek in, with run in time t moderte RPM fter ech shift. Engine Brek In 20-Hour Brek-In Period IMPORTANT: The first 20 hours of opertion 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: Pge M eng DECEMBER 2013

49 Section 3 - On The Wter 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 ny constnt speed for n extended period of time. Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occsionl opertion t full throttle is permissible (in five minute intervls). Avoid full throttle ccelertion from n idle. Do not operte t full throttle until the engine reches norml operting temperture. Check engine oil level frequently. Add oil s needed. High oil consumption is norml during the brek in period. At the end of the 20 hour brek in period, chnge the engine oil nd filter s specified. Refer to Specifictions nd Mintennce. After the 20-Hour Brek-In Period To help extend the life of the power pckge, Mercury Diesel recommends the following: Select propeller tht functions efficiently throughout the recommended engine powerbnd for fully loded bot. Refer to Specifictions nd Mintennce. Never operte t wide open throttle for prolonged periods. Opertion t 3/4 throttle nd below is recommeneded. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized Mercury Diesel repir fcility regrding scheduled mintennce items. If the product is operted on continuous, or yer round bsis, contct the deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. 90-8M eng DECEMBER 2013 Pge 41

50 Section 3 - On The Wter Notes: Pge M eng DECEMBER 2013

51 Tble of Contents Section 4 - Specifictions Section 4 - Specifictions Fuel Requirements Nonferrous Metls nd the Fuel System Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions Fluid Specifictions Engine...46 Brvo Sterndrive Fluid Specifictions Diesel Power Steering nd Power Trim Fluids Approved Power Steering Fluids Approved Power Trim Fluids Approved Pints M eng DECEMBER 2013 Pge 43

52 Section 4 - Specifictions Fuel Requirements! WARNING Filure to comply with regultions cn result in injury from fire or explosion. Electricl system components on this engine re not rted s externl ignition protected (EIP). Do not store or use gsoline on bots equipped with these engines, unless provisions hve been mde to exclude gsoline vpors from the engine comprtment (REF: 33 CFR).! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement before further engine opertion.! WARNING This engine requires diesel fuel. Mixing gsoline, gsohol, or lcohol nd diesel fuel cn cuse serious injury or deth due to fire or explosion. Never mix gsoline, gsohol, or lcohol with diesel fuel. IMPORTANT: Use of improper or wter contminted diesel fuel cn seriously dmge your engine. Use of improper fuel is considered misuse of the engine, nd dmge cused thereby will not be covered by the wrrnty. Mercury diesels re required to use Grde No. 2 D ULSD (ultr low sulphur diesel) fuel meeting ASTM Stndrds D975 (or fuel rted Diesel DIN EN 590), nd hving minimum cetne rting of 40. BIODIESEL: The blend of diesel fuel used my not contin more thn 7% biodiesel fuel. Use of LSD or blends of ULSD fuel contining more thn 7% biodiesel fuel my result in fuel system degrdtion, injection nozzle clogging, hrd strting, incresed oil chnge intervls, or excessive exhust smoke. The cetne number is mesure of the ignition qulity of diesel fuel. Incresing the cetne number will not improve overll engine performnce, but it my be necessry to rise the cetne rting for low temperture or high ltitude use. A lower cetne number could cuse hrd strting nd slower wrm up, nd could increse engine noise nd exhust emissions. NOTE: If your engine suddenly becomes noisy fter fill up, you possibly received substndrd fuel with low cetne rting. On intermittent use engines, high sulphur content diesel fuel will gretly increse: Corrosion on metl prts Deteriortion of elstomer nd plstic prts Excessive wer of internl engine prts, prticulrly berings, nd corrosion nd extensive dmge to other engine prts Difficulty strting nd operting the engine Nonferrous Metls nd the Fuel System Nonferrous metls must not be used in the fuel system components. The use of items such s copper lines, brss nipples, or glvnized tnks my result in n engine power loss or filure of the injection nozzles. Diesel Fuel in Cold Wether Unltered diesel fuels thicken nd gel in cold tempertures unless treted. Virtully ll diesel fuels re climtized to llow their use in the prticulr region for tht time of the yer. If it becomes necessry to further tret diesel fuel, it is the owner/opertor's responsibility to dd commercil stndrd brnd of nti gel diesel fuel dditive, following tht product's directions. Antifreeze/Coolnt NOTICE Using propylene glycol ntifreeze in the closed cooling system cn dmge the cooling system or the engine. Fill the closed cooling system with n ethylene glycol ntifreeze solution suitble to the lowest temperture to which the engine will be exposed. Diesel engines re high compression engines tht operte t higher tempertures thn typicl insternl combustion engines. Therefore, the closed cooling system nd engine, including relted cooling pssges, must remin s clen s possible to provide dequte engine cooling. To ensure proper cooling, we recommend filling the closed cooling section of the cooling system with low silicte formul of ethylene glycol ntifreeze in solution with deionized wter. Common tp wter or softened wter contins unwnted minerls tht cn leve lrge deposits in the system tht restrict the cooling system efficiency. A low silicte formul prevents the ntifreeze from seprting nd forming silicte geltin. This geltin cn block pssges in the engine nd het exchnger, cusing the engine to overhet. Pge M eng DECEMBER 2013

53 Section 4 - Specifictions Only premixed, coolnt should be dded to the closed cooling system. Additives nd inhibitors introduced into cceptble coolnt solutions will form protective film on the internl pssges nd provide protection ginst internl cooling system erosion. Do not drin the closed cooling section for storge. The closed cooling section should be kept filled yer round with n cceptble ntifreeze/coolnt solution to void rust forming on the internl surfces. If the engine will be exposed to freezing tempertures, ensure tht the closed cooling section is filled with properly mixed ntifreeze/coolnt solution to protect the engine nd closed cooling system to the lowest temperture to which they will be exposed. NOTE: It is recommended tht 50/50 solution of coolnt (ntifreeze) nd deionized, purified wter be used. A 50/50 solution will provide freeze protection to 35 C ( 31 F). Decresing the solution to 40/60 will provide freeze protection to 25 C ( 13 F). Even in the wrmest climtes, never decrese the solution below 40/60. Incresing the solution to 60/40 will provide freeze protection to 50 C ( 58 F). IMPORTANT: The ntifreeze/coolnt used in these mrine engines must be low silicte ethylene glycol, contining specil dditives, nd deionized, purified wter. Using other types of engine coolnt my cuse fouling of the het exchngers nd overheting of the engine. Do not combine different types of coolnts without knowing tht they re comptible. Refer to the coolnt mnufcturer's instructions. The cceptble ntifreeze/coolnts is listed in the following tble. Refer to Section 5 Mintennce for respective chnge intervls. Description Avilbility Prt Number Mrine Engine Coolnt Worldwide 8M 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. Engine oil must be 5W 30 viscosity, nd meet VW Stndrd / We strongly recommend the use of: Description Where Used Prt Number 5W 30 (1 L) Engine crnkcse 8M W 30 (4 L) Engine crnkcse 8M Engine Specifictions Engine type Displcement Description Specifiction V8 diesel 4.2 L (252 cid) Firing order Bore Stroke Rted engine RPM (refer to Conditions Affecting Opertion Propeller Selection for dditionl informtion) Idle RPM in neutrl (engine t norml operting temperture) Oil pressure t ny engine temperture 83.0 mm (3.27 in.) 95.5 mm (3.75 in.) Refer to Performnce Curve nd Dt Sheet TDI (vilble t RPM 750 RPM kp (22 45 psi) 3800 RPM kp (50 80 psi) Thermostt Wter 70 C (158 F) Coolnt temperture C ( F) Electricl system Bttery* 12 volt negtive ( ) ground 750 CCA, 950 MCA, or 180 mah 90-8M eng DECEMBER 2013 Pge 45

54 Section 4 - Specifictions Alterntor Description Specifiction 120 A *Bttery mnufcturers my rte nd test their btteries to different stndrds. MCA, CCA, Ah, nd Reserve Cpcity (RC) re the rtings recognized by Mercury Mrine. Mnufcturers tht use stndrds different thn these, such s equivlent MCA, do not meet Mercury Mrine bttery requirements. Fluid Specifictions IMPORTANT: All cpcities re pproximte fluid mesures. Engine 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 Prt Number Engine oil (with filter) 9.5 L (10.0 US qt) 5W 30 4 cycle Diesel Engine Oil (1 L) 8M W 30 4 cycle Diesel Engine Oil (4 L) 8M Closed cooling system 15.0 L (15.8 US qt) Mrine Engine Coolnt 8M Hydrulic oil Hydrulic oil K01 Brvo Sterndrive Fluid Specifictions Diesel Sterndrive Model Fluid Cpcity includes the Sterndrive nd the Ger Lube Monitor Fluid Type Fluid Prt Number Brvo One XR 2736 ml (92 1/2 oz) High Performnce Ger Brvo Three XR 2972 ml (100 1/2 oz) Lubricnt A1 Power Steering nd Power Trim Fluids Approved Power Steering Fluids Description Prt Number Power Trim nd Steering Fluid A1 Dextron III Automtic Trnsmission Fluid Obtin Loclly Approved Power Trim Fluids Description Prt Number Power Trim nd Steering Fluid A1 SAE Engine Oil 30W Obtin loclly SAE Engine Oil 40W Obtin loclly Approved Pints Description Prt Number Mercury Light Gry Primer Mercury Phntom Blck Q 1 Diesel White 8M Pge M eng DECEMBER 2013

55 Tble of Contents Section 5 - Mintennce Section 5 - Mintennce Owner nd Opertor Responsibilities Deler Responsibilities Mintennce Replcement Prts Wrning Inspection Routine Mintennce Strt of Seson Ech Dy Strt Ech Dy End Weekly End of Seson Scheduled Mintennce Once Yer or Every 200 Operting Hours (Whichever Occurs First) Mintennce Notice Every 5 Yers or 500 Hours (Whichever Occurs First) Every 5 Yers or 1,000 Operting Hours (Whichever Occurs First) Every 5 Yers or 2,000 Operting Hours (Whichever Occurs First) Engine Oil Checking Filling Drining Using the Esy Drin System, if Equipped Chnging Oil nd Filter Sterndrive Ger Lube Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Steering Fluid Checking Filling Chnging Engine Coolnt Checking the Coolnt Level Adding Coolnt Air Filter Removl Inspection nd Clening Instlltion Fuel Filter Drining Wter from the Filter Replcing the Filter Purging the Fuel System Fuel System Priming Fuel Tnk Clening nd Flushing Sewter System Sewter Pump Impeller Inspection Sterndrive Wter Inlets Check Flushing nd Drining the Sewter System...65 Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Corrosion Protection Generl Informtion Scrificil Anode Antifouling Pint Lubriction Steering System Throttle Cble Shift Cble Trnsom Assembly Propeller Shft Engine Coupler Driveshft Extension Models Mintining Torques Gimbl Ring U bolt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belts Drive Belt Drive Belt Filure Identifiction Bttery Bttery Precutions for Multiple Engines Alterntors Engine Control Unit (ECU) Btteries Bttery Switches Bttery Isoltors Genertors M eng DECEMBER 2013 Pge 47

56 Section 5 - Mintennce Owner nd Opertor Responsibilities 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 Mercury Diesel uthorized repir fcility for periodic checkup. Norml mintennce service nd replcement prts re the responsibility of the owner or opertor nd re not covered by 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 Mercury Diesel uthorized repir fcility for service ids. Deler Responsibilities Below is list of Mercury Diesel deler predelivery inspection nd preprtion responsibilities: Verify tht the power pckge is in proper operting condition. Mke ny necessry djustments for mximum efficiency. Explin nd demonstrte the opertion of the power pckge nd the bot. Provide copy of the Predelivery Inspection Checklist. Fill out the wrrnty registrtion crd completely nd mil it to the fctory immeditely upon sle of the new product. All power pckges must be registered for wrrnty purposes. Mintennce! WARNING Neglect or improper mintennce, repirs, or inspections of the power pckge cn result in product dmge or serious injury or deth. Perform ll procedures s described in this mnul. If you re not fmilir with proper mintennce or service procedures, consign the work to n uthorized Mercury Mrine deler.! WARNING Accidentl engine strting cn cuse serious injury or deth. Remove the key from the ignition switch nd engge the lnyrd stop or E stop switch to prevent the engine from strting when performing service or mintennce on the power pckge.! WARNING Engine components nd fluids re hot nd cn cuse serious injury or deth. Allow the engine to cool before removing ny components or opening ny fluid hoses.! 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 Mintennce Schedule for complete listing of ll scheduled mintennce to be performed. Some tsks cn be done by the owner or opertor, while others should be performed by n uthorized Mercury Diesel repir fcility. Before ttempting mintennce or repir procedures not covered in this mnul, we recommended tht you purchse the pproprite Mercury Diesel service mnul nd red it thoroughly. Before performing ny mintennce on your Mercury Diesel engine: Protect yourself with suitble work clothing nd personl protection equipment. Stop the engine, remove the ignition key, nd press the emergency stop switch. Move the throttle to the neutrl position. Allow the engine to cool. Ventilte the engine comprtment for t lest five minutes before beginning work. Disconnect the bttery, if servicing ny electricl components. Alwys disconnect the negtive ( ) led first nd reconnect it lst. Pge M eng DECEMBER 2013

57 Section 5 - Mintennce Replcement Prts Wrning! WARNING Avoid fire or explosion hzrd. Electricl, ignition, nd fuel system components on Mercury Mrine products comply with federl nd interntionl stndrds to minimize risk of fire or explosion. Do not use replcement electricl or fuel system components tht do not comply with these stndrds. When servicing the electricl nd fuel systems, properly instll nd tighten ll components. Inspection Inspect your power pckge often nd t regulr intervls to help mintin operting performnce nd to identify potentil problems before they occur. The entire power pckge should be checked crefully, including ll ccessible engine prts. 1. Check for loose, dmged, or missing prts, hoses, nd clmps; tighten or replce s necessry. 2. Check electricl connections nd leds for dmge. 3. Remove nd inspect the propeller. If it is bdly nicked, bent, or crcked, contct your Mercury Diesel uthorized repir fcility. 4. Repir nicks nd corrosion dmge on power pckge exterior finish. Contct your Mercury Diesel uthorized repir fcility. Routine Mintennce Strt of Seson Inspect the power pckge for leks nd dmge. Inspect the ccessory drive belts, hoses, nd power steering pump (if pplicble). Inspect the fuel injection pump drive belt condition. Verify tht the secock opertes properly. Check the chrge, connections, nd condition of the bttery. Chrge or replce the bttery s necessry. Check ll fluid nd lubricnt levels, nd djust them s necessry. Inspect the nodes nd replce them if they re 50% eroded. Ech Dy Strt Inspect the power pckge for leks nd dmge. Check the engine oil level nd djust it s necessry. Check the engine coolnt level nd djust it s necessry. Check the condition of the fuel filter. Drin wter from the filter s necessry. Check the sewter striner nd clen it s necessry. Check the drive lubricnt level (if pplicble), nd djust it s necessry. Check the reverse gerbox lubricnt level nd djust it s necessry, where pplicble. Clen the guges. Inspect the ir filter for discolortion nd contminnts. Ech Dy End If operting in sltwter, brckish wter, or polluted wter, flush the sewter section of the cooling system. Drin ny wter from the fuel filter, if operting in freezing tempertures. Weekly Inspect the power pckge for leks nd dmge. Drin ny wter from the fuel filter. Check the trim pump fluid level, if pplicble. Check the sewter inlets for debris or mrine growth. Check nd clen the sewter striner. Inspect the nodes, nd replce them if they re 50% eroded. Inspect the ir filter for discolortion nd contminnts. End of Seson Inspect the power pckge for leks or dmge. 90-8M eng DECEMBER 2013 Pge 49

58 Section 5 - Mintennce Chnge the engine oil nd filter. Check the coolnt level nd djust it s necessry. Check the sewter pump impeller nd replce it s necessry. Check the ir filter element nd clen it s necessry. Check nd clen the sewter striner. Inspect the nodes nd replce them if they re 50% eroded. Clen the engine nd replce worn or dmged components. Flush, drin, nd winterize the sewter cooling system, if the climte requires it. Fill the fuel tnk with fresh fuel. Scheduled Mintennce Once Yer or Every 200 Operting Hours (Whichever Occurs First) Inspect the power pckge for leks nd dmge. Check the chrge, connections, nd condition of the bttery. Chrge or replce the bttery s necessry. Chnge the engine oil nd filter element. Drin ny wter nd chnge the fuel filter. Check the power steering hydrulic oil level (if pplicble), nd djust it s necessry. Inspect the coolnt level nd djust it s necessry. Inspect the ir filter element nd clen it s necessry. Inspect the ccessory drive belts, hoses, nd power steering pump, where pplicble. Inspect the fuel injection pump drive belt condition. Inspect nd clen the sewter striner. Inspect the sewter pump nd chnge the impeller s necessry. Inspect the nodes nd replce them if they re 50% eroded. Verify tht the guges nd the wiring connections re secure. Mintennce Notice IMPORTANT: Due to the risk of dmging equipment if they re performed incorrectly, we highly recommended tht the following scheduled mintennce items be performed only by Mercury Diesel uthorized repir fcility. Every 5 Yers or 500 Hours (Whichever Occurs First) In ddition to the Once Yer or Every 200 Operting Hours intervl: Clen the intercooler core. Every 5 Yers or 1,000 Operting Hours (Whichever Occurs First) In ddition to the Once Yer or Every 200 Operting Hours intervl: Clen the fuel tnk. Check the het exchnger pipe bundles. Remove nd clen them s necessry: Every 5 Yers or 2,000 Operting Hours (Whichever Occurs First) In ddition to the Once Yer or Every 200 Operting Hours nd Every 5 Yers or 1,000 Operting Hours intervls: Replce the fuel injection pump drive belt. 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. Pge M eng DECEMBER 2013

59 Section 5 - Mintennce Checking NOTICE With the engine running, the crnkshft journls or rod journls my strike nd brek the dipstick, resulting in dmge to internl engine components. Stop the engine completely before removing or inserting the dipstick. 1. If it becomes necessry to check the engine oil level during opertion, stop the engine nd llow five minutes for the oil to drin into the pn. 2. Remove the dipstick, wipe it clen, nd insert the dipstick bck into the dipstick tube. 3. Remove the dipstick nd check the oil level. The oil level must be between the indictor mrks on the dipstick. If necessry, dd oil s follows. b b Dipstick indictor mrks - Do not dd oil b - Sfe operting rnge c - Add oil c Filling IMPORTANT: Do not overfill the engine with oil. When filling the engine with oil lwys use the dipstick to determine how much oil is required. 1. Remove the oil fill cp. c Oil fill cp 2. Add oil to bring the level up to, but not over, the mximum mrk on the dipstick. Description Cpcity Fluid Type Engine oil (with filter) 9.5 L (10.0 US qt) SAE 5W 30 meeting VW Spec Instll the oil fill cp. Drining Using the Esy Drin System, if Equipped NOTE: The bot must be out of the wter to perform this procedure. 1. Remove the bot from the wter M eng DECEMBER 2013 Pge 51

60 Section 5 - Mintennce 2. Loosen the oil filter to vent the oil system. b c f d e Bilge drin plug b - Tether c - Clip d - Oil drin hose plug e - Oil drin hose f - Bilge drin flnge 3. Remove the bilge drin plug. 4. Pull the tether through the bilge drin. 5. Plce the oil drin hose in suitble continer. 6. Remove the drin plug from the oil drin hose. 7. After the oil hs drined completely, instll the drin plug in the oil drin hose. 8. Push the oil drin hose through bilge drin nd instll the bilge drin plug. Chnging Oil nd Filter Refer to the Mintennce Schedule for the chnge intervl. You should chnge the engine oil before plcing the bot in storge. IMPORTANT: Chnge the engine oil when the engine is wrm from opertion. Wrm oil flows more freely, crrying wy more impurities. Use only the recommended engine oil. Refer to Specifictions. 1. Strt nd run the engine until norml operting temperture is chieved. 2. Stop the engine nd wit pproximtely five minutes for the oil to drin into the oil pn. 3. Drin the oil from the engine into suitble continer. Dispose of ll wste oil s directed by locl uthorities. 4. Plce suitble continer under the oil filter housing to contin ny oil lekge tht my occur. Use n pproprite socket to loosen the oil filter protective cp. 5. Remove the protective cp nd filter element. b e c d Oil filter nd housing - Protective cp b - O ring (lrge) c - Filter element d - Trnsfer tube O ring (smll) e - Oil filter housing Disconnect nd discrd the old filter element. 7. Discrd the old O ring from the protective cp. 8. Apply smll mount of engine oil to the lrge O ring nd instll the O ring in the protective cp. 9. Apply smll mount of engine oil to the smll O ring nd instll it onto the filter element trnsfer tube. Pge M eng DECEMBER 2013

61 Section 5 - Mintennce 10. Push the filter element onto the protective cp until it is locked. Listen for click. 11. Instll the protective cp with the new filter element into the oil filter housing. IMPORTANT: When instlling the filter element into the oil filter housing, be sure to lign the trnsfer tube on the filter element with the orifice in the bottom of the filter housing to void dmging the filter element. IMPORTANT: Overtightening the protective cp will cuse deformtion resulting in oil lekge. 12. Thred the protective cp into the filter housing until the seling surfce contcts the housing. Tighten the protective cp to the specified torque. Description Nm lb in. lb ft Protective cp Remove the oil fill cp nd fill the engine with new oil. Refer to Filling. IMPORTANT: When filling the engine with oil, lwys use the dipstick to determine how much oil is required. 14. Strt the engine nd check for leks. Sterndrive Ger Lube 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 NOTE: The ger lube level will fluctute during opertion. The ger lube level should be checked with the engine cold, before strting. Check the ger lube monitor to determine the ger lube level. Keep the ger lube level within the recommended operting rnge. Refer to Filling. b Ger lube level shown is t the correct operting rnge - "ADD" mrk b - "OPERATING RANGE" mrk Filling IMPORTANT: If more thn 59 ml (2 fl oz) of High Performnce Ger Lube is required to fill the ger lube monitor, sel my be leking. Dmge to the sterndrive my occur due to lck of lubriction. Contct your Mercury Diesel uthorized repir fcility. 1. If the ger lube level is below or ner the "ADD" mrk, the specified ger lube must be dded. 2. Remove the ger lube monitor cp. 90-8M eng DECEMBER 2013 Pge 53

62 Section 5 - Mintennce 3. Fill the ger lube monitor with the specified ger lube so tht the ger lube level is in the operting rnge. Do not overfill. c b Ger lube monitor - Ger lube level t the "ADD" mrk b - Ger lube level t the "OPERATING RANGE" mrk c - Ger lube monitor cp Tube Ref No. Description Where Used Prt No. 87 High Performnce Ger Lube Ger lube monitor K01 4. Ensure tht the rubber gsket is inside the ger lube monitor cp nd instll the cp. Do not overtighten. - Ger lube monitor cp NOTE: When filling the entire sterndrive, refer to Chnging. Chnging Remove the ger lube monitor from the brcket. b - Ger lube monitor brcket b - Ger lube monitor nd cp c - Retining strp c Empty the contents of the ger lube monitor into suitble continer. 3. Instll the ger lube monitor in the brcket. 4. Brvo One X Models:. Remove the propeller. b. Lower the sterndrive to the full down (in) position. c. Remove the ger lube fill nd drin plug nd seling wsher. Pge M eng DECEMBER 2013

63 Section 5 - Mintennce d. Drin the ger lube into suitble continer. - Fill nd drin plug b - Seling wsher b mc Brvo Three X Models:. Plce the sterndrive in full trim limit out position. b. Remove the fill nd drin plug nd seling wsher. c. Drin the ger lube into suitble continer. b b Brvo Two X - Fill nd drin plug b - Seling wsher Brvo Three X 6. Remove the vent plug nd seling wsher. Allow the ger lube to drin completely. b - Vent plug b - Seling wsher IMPORTANT: If ny wter drins from the fill nd drin plug hole, or if the ger lube ppers milky, the sterndrive is leking nd should be checked immeditely by your Mercury Diesel uthorized repir fcility. 7. Lower the sterndrive so tht the propeller shft is level. 8. Fill the sterndrive through the fill nd drin plug hole with the specified ger lube until n ir free strem of lube flows from the vent plug hole. IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lube in the sterndrive. 90-8M eng DECEMBER 2013 Pge 55

64 Section 5 - Mintennce Tube Ref No. Description Where Used Prt No. 87 High Performnce Ger Lube Sterndrive unit K01 9. Instll the vent plug nd seling wsher. 10. Continue to pump ger lube into the drive through the fill nd drin plug hole until the ger lube ppers in the ger lube monitor. 11. Fill the ger lube monitor so tht the ger lube level is in the operting rnge. Do not overfill. c b Ger lube monitor - Ger lube level t the "ADD" mrk b - Ger lube level t the "OPERATING RANGE" mrk c - Ger lube monitor cp Sterndrive Model Brvo One X Diesel Brvo One XR Brvo Three X Diesel Brvo Three XR Fluid Cpcity includes the Sterndrive nd the Ger Lube Monitor 2736 ml (92 1/2 oz) 2972 ml (100 1/2 oz) Fluid Type High Performnce Ger Lube 12. Ensure tht the rubber gsket is inside the ger lube monitor cp nd instll. Do not overtighten. - Ger lube monitor cp Fluid Prt Number A Remove the pump from the sterndrive fill nd drin plug hole. Pge M eng DECEMBER 2013

65 Section 5 - Mintennce 14. Quickly instll the seling wsher nd the fill nd drin plug. Tighten the plug to the specified torque. b b mc All Brvo models shown - Fill nd drin plug b - Seling wsher b Description Nm lb in lb ft Fill nd drin plug Instll the sterndrive propeller. Refer to Propellers. 16. Check the level of the ger lube monitor fter the first use. Refer to Mintining Fluid Levels. IMPORTANT: The ger lube monitor level will chnge while the product is in use. Alwys check the ger lube level when the sterndrive is cool nd the engine is not running. Power Trim Fluid Checking IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only. 1. Plce the sterndrive in full down (in) position. 90-8M eng DECEMBER 2013 Pge 57

66 Section 5 - Mintennce 2. Observe the fluid level. The fluid level must be between the "MIN" nd "MAX" lines on the reservoir. b Reservoir b - "MIN" nd "MAX" lines 3. Fill s necessry with the specified fluid. Refer to Filling. Filling Tube Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power trim pump K01 1. If the fluid level is below the "MIN" line, the specified fluid must be dded. 2. Remove the fill cp from the reservoir. NOTE: The fill cp is vented. b Power trim pump reservoir shows the fluid level is below "MIN" line - Fill cp ssembly b - Fill cp instlled 7701 Pge M eng DECEMBER 2013

67 3. Add the specified fluid to bring the fluid level to within the "MIN" nd "MAX" lines on the reservoir. Section 5 - Mintennce b Reservoir b - "MIN" nd "MAX" lines Tube Ref No. Description Where Used Prt No. 4. Instll the fill cp. Chnging 114 Power Trim nd Steering Fluid Power trim pump K01 Power trim fluid does not require chnging unless it becomes contminted with wter or debris. Contct your Mercury Diesel uthorized repir fcility. Power Steering Fluid The power steering fluid level should be checked t regulr intervls. IMPORTANT: Do not leve the steering wheel t full lock longer thn 15 seconds with the engine running. The power steering fluid will het up considerbly when the steering wheel is t full lock nd could dmge the power steering system. When the steering wheel is t full lock, power steering pump noise will increse s the pump is under full lod nd the engine idle RPM will be reduced momentrily. Checking 1. Center the sterndrive nd stop the engine. 2. Remove the fill cp nd dipstick from the fluid reservoir nd observe the level. - Fill cp b - Power steering fluid reservoir b IMPORTANT: If fluid is not visible in the fluid reservoir, see your Mercury Diesel uthorized repir fcility. Filling Remove the fill cp/dipstick nd wipe it with clen cloth. 90-8M eng DECEMBER 2013 Pge 59

68 Section 5 - Mintennce 2. Screw the fill cp/dipstick completely into the power steering fluid reservoir. 3. Remove the fill cp/dipstick from the reservoir nd observe the fluid level. If the fluid level is within rnge, no fluid should be dded. If the fluid level is within rnge b, fluid my be dded but should not exceed the mximum level in rnge. If the oil level is within rnge c, fluid must be dded. There is sufficient fluid when the fluid level is within rnge b. NOTE: If high steering lods re going to be encountered for prolonged period of opertion (10 12 hours), the fluid level should be t lest in the middle of the min/mx mrkings of the dipstick. - No fluid required b - Oil my be dded, but do not exceed bove rnge c - Oil must be dded, but do not exceed bove rnge b c Add the specified fluid to bring the fluid level up to the proper level. Tube Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power-ssisted steering system K01 28 Dexron III Automtic Trnsmission Fluid 5. Instll the fill cp/dipstick. Chnging Power-ssisted steering system Obtin Loclly Power ssisted steering fluid does not require chnging unless it becomes contminted. See your Mercury Diesel uthorized repir fcility. Engine Coolnt! CAUTION A sudden loss of pressure cn cuse hot coolnt to boil nd dischrge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolnt pressure cp. b - Coolnt minimum level ("min" mrk) b - Coolnt mximum level For proper engine opertion, the coolnt must lwys be mintined t the correct level within the closed cooling system. With the engine cold, the level should lwys be between the minimum nd mximum level mrks on the coolnt expnsion tnk. The coolnt level is monitored by sensor. The disply window on the tchometer will wrn the user of low coolnt level condition. An udible wrning will lso sound. A visul inspection of the coolnt level within the coolnt expnsion tnk should be performed regulrly. Pge M eng DECEMBER 2013

69 Checking the Coolnt Level IMPORTANT: Check the engine coolnt before strting the engine. 1. Allow the engine to cool. 2. Verify tht the coolnt level is bove the "min" mrk on the coolnt expnsion tnk. 3. If the coolnt level is below the "min" mrk: Section 5 - Mintennce. Inspect the closed cooling system for leks. If ny leks re found, contct your Mercury Diesel uthorized repir fcility for further dignosis nd repir. b. Refer to Adding Coolnt nd dd the specified coolnt s necessry. Adding Coolnt 1. Allow the engine to cool. 2. Cover the cp on the coolnt expnsion tnk with cloth nd crefully remove the cp (counterclockwise). IMPORTANT: If the specified coolnt is not immeditely vilble, dd only wter nd restore the proper coolnt/wter rtio with the specified coolnt s soon s possible. Do not dd ny coolnt other thn the specified coolnt. 3. Add the specified coolnt s necessry to bring the level to the minimum level ("min" mrk) but no higher thn the coolnt mximum level. Description Where Used Prt Number Mrine Engine Coolnt Closed cooling system 8M Instll the cp nd tighten securely to prevent coolnt loss. Air Filter Removl 1. Remove the crnkcse ventiltion hoses. 2. Remove the smll clmps from the turbochrger inlets. 3. Remove the lrge clmps from the ir filter. 4. Remove the tension springs from the ir filter ssembly. 5. Remove the rubber side covers from the ir filter element. c b 5 d Air filter mounting - Crnkcse ventiltion hoses b - Smll clmps c - Lrge clmps d - Tension springs e - Rubber side covers e d e b c Inspection nd Clening NOTICE Do not use fuel, thinner, or other clening gents for clening the ir filter element. Use only the recommended products in the clening kit. Filure to use the correct products cn dmge the ir filter element. 1. Inspect the ir filter for dmge. 2. Using compressed ir, not exceeding 2.0 br (29 psi), blow debris from the ir filter from the inside, towrd the outside of the filter. 3. For clening the ir filter, purchse K&N filter rechrging kit Follow the procedures contined in rechrging kit. 4. Replce the ir filter s needed. 90-8M eng DECEMBER 2013 Pge 61

70 Section 5 - Mintennce Instlltion 1. Instll the rubber side covers onto the ir filter element. 2. Align the mrks s shown by the rrows in the ir filter mounting illustrtion. 3. Instll the tension springs. 4. Instll the lrge clmps onto the rubber side covers. Tighten the fsteners to retin the boots. 5. Plce the smll clmps onto the smll openings on the rubber side covers. 6. Gently compress the rubber side covers towrd the center of the ir filter element nd instll the filter ssembly onto the turbochrger inlets. 7. Tighten the smll clmps to retin the filter ssembly. 8. Instll the crnkcse ventiltion hoses. Fuel Filter NOTICE Wter entering the fuel injection system will cuse corrosion nd rusting of the injectors nd other components, disbling the fuel injection system. Check dily for wter in the wter seprting fuel filter nd hve the engine inspected immeditely if there is evidence of wter in the fuel system. IMPORTANT: Use suitble continer to collect fuel. Clen up ny spills immeditely nd dispose of fuel nd old filters in sfe mnner in ccordnce with ll locl, federl, nd interntionl regultions. This remote mounted fuel filter nd lift pump ssembly is equipped with wter in fuel sensor to lert the opertor when wter is present in the filter. This filter needs to be replced t specified intervls, refer to Routine Mintennce, or whenever wter is detected in the fuel, whichever occurs first. d c e d - Wter in fuel sensor b - Cnnister nut (hidden) c - Cnnister d - Fuel line fittings e - Power connector b Drining Wter from the Filter 1. Plce suitble continer under the fuel filter ssembly. 2. Remove the drin plug from the bottom of the ssembly. 3. Drin the filter until the fuel is clen in ppernce. 4. Instll the drin plug nd tighten securely. Replcing the Filter! 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. IMPORTANT: The fuel filter cnnot be clened nd reused. It must be replced. Be sure to replce the filter with filter of the sme specifictions to eliminte possible dmge to the fuel system components. 1. Disconnect both bttery cbles from the bttery. 2. Disconnect the wter in fuel sensor from the wiring hrness. 3. Plce suitble continer under the fuel filter ssembly. 4. Remove the cnnister from the ssembly. 5. Pull up on the fuel filter to remove it from the cnnister Pge M eng DECEMBER 2013

71 Section 5 - Mintennce 6. Replce the O ring. 7. Insert the new fuel filter into the cnnister. The filter will snp into plce. 8. Lubricte the new O ring round the cnnister with clen diesel fuel. NOTE: Do not fill the cnister with fuel. 9. Instll the cnnister onto the upper portion of the fuel filter ssembly nd hnd tighten it. 10. Connect the wter in fuel sensor to the wiring hrness. 11. Connect the bttery cbles to the bttery, connecting the negtive ( ) cble lst. 12. Ensure the fuel tnk is filled with fuel. 13. Turn the ignition switch to the "ON" position. The fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit five seconds. Repet this step six times. 14. Strt the engine nd let it idle for pproximtely seconds then shut the engine off. 15. Wit few seconds nd repet step 13 two more times. 16. Check fuel filter nd connections for leks. IMPORTANT: If leks exist, check the connections nd verify tht ll connections nd the cnnister re properly seted. If leks continue, stop the engine immeditely nd contct your Mercury Diesel uthorized repir fcility. Purging the Fuel System! WARNING The fuel injection pump genertes pressure in excess of kp (2000 psi), which is high enough to penetrte or cut the skin. Do not use your fingers to feel for fuel leks nd wer personl protective equipment when servicing the fuel system. NOTE: It is possible tht the engine will not strt if the fuel system hs not been completely purged of ir. 1. Ensure tht the fuel tnk is filled with fuel. 2. Turn the ignition switch to the "ON" position. The fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit five seconds. Repet this step six times. 3. Strt the engine nd let it idle for pproximtely seconds, then shut the engine off. 4. Wit few seconds nd repet step 3 two more times. Fuel System Priming NOTE: Follow this procedure if the fuel system ws run dry or if prt of the fuel system ws drined for service function. 1. Turn the ignition switch to the "ON" position nd the fuel pump will run for five seconds. Turn the ignition switch to the "OFF" position nd wit five seconds. Repet this step six times. 2. Strt the engine. Fuel Tnk Clening nd Flushing IMPORTANT: Diesel fuel should not be left in the tnk during winter storge, s n ccumultion of rust, sludge nd wx residue will form. Refer to the bot mnufcturer's instructions nd clen the fuel tnk t specified intervls. Unless specified otherwise, flush nd clen the diesel fuel tnk every 1000 hours or five yers, whichever occurs first. Sewter System Sewter Pump Impeller Inspection The sewter pump impeller must be inspected (nd replced, if necessry) t the intervl specified by the mintennce schedule. It is recommended this tsk be performed t Mercury Diesel uthorized repir fcility. 1. Close the secock. 90-8M eng DECEMBER 2013 Pge 63

72 Section 5 - Mintennce 2. Remove the four screws on the front side of the sewter pump nd remove the cover. Discrd the O ring. Sewter pump cover screws 3. Mrk the direction of rottion of the impeller nd remove the protective cp from the middle of the impeller b c d e f - Sewter pump b - Impeller c - Protective cp d - O ring e - Cover f - Screw (4) 4. Use suitble puller to remove the impeller from the impeller shft. 5. Inspect the impeller for dmge. The impeller must be replced if there re ny signs of dmge. NOTE: Keep n extr impeller onbord the bot t ll times. 6. Lubricte the impeller with silicone spry or glycerine. 7. Push the impeller onto the shft nd press the protective cp into the impeller. 8. Insert new O ring into its groove. 9. Instll the cover onto the housing nd secure the cover with the four screws. Tighten the screws to the specified torque. Description Nm lb in. lb ft Sewter pump cover screws Open the secock. 11. Strt the engine nd check the cooling system for leks. Sterndrive Wter Inlets Check Obtin piece of wire the pproprite size to insert into the wter inlets holes. 2. Insert the wire in nd out of the sterndrive wter inlets to ensure tht they re open nd to remove debris or mrine growth. Do not scrpe the sterndrive pint. Pge M eng DECEMBER 2013

73 Section 5 - Mintennce 3. Remove the wire from the sterndrive nd retin for periodic wter inlet checks. - Dul wter pickup wter inlets b - Side pickup wter inlets Flushing nd Drining the Sewter System 1. Close the secock. 2. Open nd clen the sewter filter. 3. Fill the sewter filter with fresh wter nd operte the engine t idle. IMPORTANT: Keep the sewter filter filled with fresh wter while the engine is running. 4. Operte the engine until the wter drining from the engine runs cler to ensure tht ll sludge nd slt residues re flushed wy. 5. Switch off the engine. 6. Replce the cover on the sewter filter. 7. Attch suitble hose to the sewter cooling system drin screw. b Het exchnger drin screws - Closed cooling system drin screw b - Sewter cooling system drin screw b Open the drin screw nd llow the wter to drin into suitble continer. 9. When the drining is complete, remove the hose nd close the drin screw. 10. Be certin to open the secock prior to bot opertion. 90-8M eng DECEMBER 2013 Pge 65

74 Section 5 - Mintennce Checking the Sewter Pickups Verify tht the wter inlet holes for the sewter pickup re clen nd unobstructed Typicl through-the-hull sewter pickup - Wter inlet holes Typicl through-the-trnsom sewter pickup Clening the Sewter Striner, if Equipped NOTICE An open sewter striner or secock during some service or mintennce procedures cn introduce wter into the bot, cusing dmge or sinking the bot. Alwys close the wter supply from the sewter pump, wter inlet, or secock when performing service or mintennce on the cooling system. 1. With the engine off, close the secock, if equipped, or remove nd plug the sewter inlet hose. 2. Remove the screws, wshers, nd cover. 3. Remove the striner, drin plug, nd seling wsher. 4. Clen ll the debris from the striner housing. Flush both the striner nd housing with clen wter. 5. Check the cover gsket nd replce when dmged or if it leks. 6. Reinstll the striner, drin plug, nd seling wsher.! CAUTION Sewter leking from the sewter striner could cuse excess wter in the bilge, dmging the engine or cusing the bot to sink. Do not overtighten the cover screws, or the cover my wrp nd introduce sewter into the bilge. Pge M eng DECEMBER 2013

75 Section 5 - Mintennce 7. Instll the sel nd cover using the screws nd wshers. Do not overtighten the cover screws. b f - Screws nd wshers b - Cover with glss c - Striner d - Housing e - Drin plug nd seling wsher f - Sel c d e 8. Open the secock, if equipped, or remove the plug nd reconnect the sewter inlet hose. 9. Upon first strting the engine, check for leks or ir in the system tht would indicte n externl lek. Corrosion Protection Generl Informtion When two or more dissimilr metls re submerged in conductive solution of sltwter, polluted wter, or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow between metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This erosion is known s glvnic corrosion nd, if it is not controlled, it will eventully cuse the need for replcement of power pckge components exposed to wter. To help control the effects of glvnic corrosion, Mercury Diesel power pckges come with severl scrificil nodes nd other corrosion protection devices. For more comprehensive explntion of corrosion nd corrosion protection refer to the Mrine Corrosion Protection Guide. IMPORTANT: Replce scrificil nodes if they re eroded 50% or more. Mercury Diesel strongly recommends voiding the use of nodes from other mnufcturers. Refer to your Mercury Diesel uthorized repir fcility for dditionl informtion. Scrificil Anode The scrificil node in the cooling system must be checked s specified by the mintennce schedule. The node is locted t the bck of the chrge ir cooler. b - Scrificil node b - Length of new node = 20 mm (0.79 in.) c - Bck of the chrge ir cooler c 1. Close the secock. 2. Plce suitble continer cpble of holding pproximtely L ( US qt) of liquid in position to cpture the escping sewter. 3. Remove the scrificil node. 4. Inspect the node. If the node is less thn 10 mm (0.39 in.), it hs eroded more thn 50% nd must be replced M eng DECEMBER 2013 Pge 67

76 Section 5 - Mintennce 5. Instll the node into the bck of the chrge ir cooler. 6. Open the secock. 7. Strt the engine nd check for leks. Antifouling Pint IMPORTANT: Corrosion dmge tht results from the improper ppliction of nti fouling pint is not covered by the limited wrrnty. In some res it my be dvisble to pint the bottom of the bot to help prevent mrine growth. Contct Mercury Diesel uthorized repir fcility for recommendtions for your bot. Lubriction Steering System! WARNING Incorrect cble lubriction cn cuse hydrulic lock, leding to serious injury or deth from loss of bot control. Completely retrct the end of the steering cble before pplying lubricnt. NOTE: If the steering cble does not hve grese fitting, the inner wire of the cble cnnot be gresed. 1. If the steering cble hs grese fittings, turn the steering wheel until the steering cble is fully retrcted into the cble housing. Apply pproximtely three pumps of grese from typicl hnd operted grese gun. - Steering cble grese fitting 6221 Tube Ref No. Description Where Used Prt No C with PTFE Steering cble grese fitting A 1 2. Turn the steering wheel until the steering cble is fully extended. Lightly lubricte the exposed prt of the cble. - Extended steering cble 6222 Tube Ref No. Description Where Used Prt No C with PTFE Steering cble A 1 Pge M eng DECEMBER 2013

77 Section 5 - Mintennce 3. Lubricte the steering pin. - Steering pin mc Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Steering pin K01 4. On dul engine bots: Lubricte the tie br pivot points. Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie br pivot points K01 5. Upon first strting the engine, turn the steering wheel severl times to strbord nd then port to ensure tht the steering system opertes properly before getting underwy. Throttle Cble The throttle control system for the TDI 4.2L engine is electronic nd requires no mintennce. See your Mercury Diesel uthorized repir fcility for dignosis or repir. Shift Cble The shift control system for the TDI 4.2L engine is electronic nd requires no mintennce. See your Mercury Diesel uthorized repir fcility for dignosis or repir. Trnsom Assembly Lubricte the gimbl bering by pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun. - Gimbl bering grese insert Tube Ref No. Description Where Used Prt No. Extreme Grese Gimbel bering grese insert 8M Propeller Shft NOTE: Refer to Propeller Removl. Lubricte the sterndrive propeller shft by pplying coting of one of the following lubricnts to the propeller shft. 90-8M eng DECEMBER 2013 Pge 69

78 Section 5 - Mintennce Apply generous coting of one of the following lubricnts to the propeller shft Propeller shft Tube Ref No. Description Where Used Prt No. Extreme Grese Propeller shft 8M C with PTFE Propeller shft A 1 Engine Coupler IMPORTANT: These engines re equipped with seled engine coupler. The seled coupler nd the shft splines cn be lubricted without removing the sterndrive unit. Lubricte the engine coupler splines through the grese fitting on the coupler by pplying pproximtely 8 10 pumps of Extreme Grese from typicl hnd operted grese gun. NOTE: On Brvo equipped models, if the bot is operted t idle for prolonged periods, the coupler should be lubricted every 50 hours. Coupler shown seprted for clrity Tube Ref No. Description Where Used Prt No. Extreme Grese Engine coupler nd shft splines 8M Pge M eng DECEMBER 2013

79 Driveshft Extension Models Section 5 - Mintennce 1. Lubricte the trnsom end grese fitting nd engine end grese fitting by pplying pproximtely pumps of grese from typicl hnd operted grese gun. 2. Lubricte the driveshft grese fittings by pplying pproximtely 3 4 pumps of grese from typicl hnd operted grese gun. c b Driveshft grese fittings b - Trnsom end grese fitting c - Engine end grese fitting Tube Ref No. Description Where Used Prt No. Mintining Torques Extreme Grese Gimbl Ring U bolt Nuts NOTE: The gimbl ring is component of the trnsom ssembly. Tighten the gimbl ring U bolt nuts to the specified torque. Trnsom end grese fitting, engine end grese fitting, driveshft grese fittings 8M b - Trnsom ssembly b - Gimbl ring U bolt nuts Description Nm lb in. lb ft Gimbl ring U bolt nuts for 3/8 in. U bolt Gimbl ring U bolt nuts for 7/16 in. U bolt M eng DECEMBER 2013 Pge 71

80 Section 5 - Mintennce Engine Mounts Loosen the rer engine mount bolts 1 to 1 1/2 turns. Tighten the rer engine mount bolts to the specified torque. - Rer engine mount b - Trnsom plte mount c - Rer engine mount bolt c b Description Nm lb in. lb ft Rer engine mount bolts Propellers Brvo Sterndrive Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the bot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce block of wood between the propeller blde nd the nti ventiltion plte. Brvo One Models 1. Strighten the bent tbs of the tb wsher on the propeller shft. b c d e - Propeller b - Tb wsher c - Drive sleeve dpter d - Tb bent down e - Propeller nut 4750 Pge M eng DECEMBER 2013

81 Section 5 - Mintennce 2. Plce block of wood between the propeller blde nd the sterndrive's nti ventiltion plte. - Wood block b - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise nd remove the nut. 4. Slide the propeller nd the ttching hrdwre from the propeller shft. b c d e f g Brvo One models - Propeller shft splines b - Forwrd thrust hub c - Flo Torque II drive hub d - Propeller e - Drive sleeve dpter f - Tb wsher g - Propeller nut 5301 Brvo Two Models 1. Strighten the bent tbs of the tb wsher on the propeller shft. b c d e - Propeller b - Tb wsher c - Drive sleeve dpter d - Tb bent down e - Propeller nut Plce block of wood between the propeller blde nd the sterndrive's nti ventiltion plte. - Wood block b - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise to remove the nut. 90-8M eng DECEMBER 2013 Pge 73

82 Section 5 - Mintennce 4. Slide the propeller nd ttching hrdwre from the propeller shft. b c d f Brvo Two - Propeller shft splines b - Forwrd thrust hub c - Propeller d - Spline wsher e - Tb wsher f - Propeller nut e 8566 Brvo Three Models 1. Plce block of wood between the propeller blde nd the sterndrive's nti ventiltion plte. 2. Remove the bolt nd wshers securing the propeller shft node. 3. Remove the propeller shft node. c b - Propeller b - Propeller shft nut c - Propeller shft node d - Propeller shft node screw e - Flt wsher f - Str wsher d f e Turn the ft propeller shft nut counterclockwise to remove the nut. 5. Slide the propeller nd thrust hub off of the propeller shft. 6. Using the propeller nut tool, turn the front propeller shft nut counterclockwise nd remove the nut. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Slide the propeller nd the thrust hub off the propeller shft. g i h j b c d e f 5304 Brvo Three - Aft propeller nut b - Aft propeller c - Aft propeller thrust hub d - Front propeller nut e - Front propeller f - Front propeller thrust hub g - Propeller shft node screw h - Flt wsher i - Str wsher j - Propeller shft node Pge M eng DECEMBER 2013

83 Section 5 - Mintennce Brvo Sterndrive Propeller Instlltion! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the bot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce block of wood between the propeller blde nd the nti ventiltion plte. - Wood block b - Propeller c - Propeller nut under socket Brvo One Models IMPORTANT: Use the correct rottion propeller. The propeller rottion must mtch the direction of rottion of the propeller shft. 1. Liberlly cot the propeller shft spline with one of the following lubricnts. Tube Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Instll the propeller with the ttching hrdwre s shown. 3. Tighten the propeller nut to the specified torque. b c d e f g Typicl Brvo One models - Propeller shft splines b - Forwrd thrust hub c - Flo Torque II drive hub d - Propeller e - Drive sleeve dpter f - Tb wsher g - Propeller nut NOTE: The propeller torque stted is minimum torque vlue. Description Nm lb in. lb ft Brvo One propeller nut Then lign tbs with grooves 4. Models equipped with the tb wsher: Continue to tighten the propeller nut until the three tbs on the tb wsher lign with the grooves on the spline wsher M eng DECEMBER 2013 Pge 75

84 Section 5 - Mintennce 5. Bend the three tbs down into the grooves. b c d e - Propeller b - Tb wsher c - Drive sleeve dpter d - Tb bent down e - Propeller nut 4750 Brvo Three 1. Liberlly cot the propeller shft spline with one of the following lubricnts. Tube Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Slide the forwrd thrust hub onto the propeller shft with the tpered side towrd the propeller hub. 3. Align splines nd plce front propeller on propeller shft. 4. Instll the front propeller locknut nd tighten to the specified torque using the propeller nut tool. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Description Nm lb in. lb ft Brvo Three front propeller nut Slide the ft thrust hub onto the propeller shft with the tpered side towrd the propeller hub. 6. Align the splines nd instll the ft propeller. 7. Instll the propeller nut nd torque. NOTE: The propeller torque stted is minimum torque vlue. Description Nm lb in. lb ft Brvo Three rer propeller nut Pge M eng DECEMBER 2013

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