Engine Type Fuel Type Combustion Cycle z or sterndrive with integral exhaust Diesel 4 stroke

Transcription

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 y meeting the ssocited stndrds, s mended: Recretionl Crft Propulsion Engines with the Requirements of Directive 94/25/EC s mended y 2003/44/EC Nme of engine mnufcturer: Volkswgen Antriessysteme Address: HMA E/1, PO 7962, Industriestrße Nord Town: Slzgitter Post Code: Country: Germny Nme of Authorized Representtive: Brunswick Mrine in EMEA Inc. Address: Prc Industriel de Petit Rechin Town: Verviers Post Code: 4800 Country: Belgium Nme of Notified Body for exhust emission ssessment: Interntionl Mrine Certifiction Institute (IMCI) Address: Rue Aé Cuypers 3 Town: Bruxelles Post Code: B 1040 Country: Belgium ID Numer: 0609 Nme of Notified Body for noise emission ssessment: Interntionl Mrine Certifiction Institute (IMCI) Address: Rue Aé Cuypers 3 Town: Bruxelles Post Code: B 1040 Country: Belgium ID Numer: 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 Comptiility Directive 2004/108/EC Description of Engines nd Essentil Requirements Engine Type Fuel Type Comustion Cycle z or sterndrive with integrl exhust Diesel 4 stroke Identifiction of Engines Covered y This Declrtion of Conformity Nme of engine model or engine fmily: Unique engine identifiction numer(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 230/260 TDI 230 6/TDI EXVWM007 TDI 4.2L 285/350 TDI 285 8/TDI EXVWM008 Essentil requirements Annex 1.B Exhust Emissions Stndrds Other normtive document/ method Technicl file B.1 engine identifiction EC Type exmintion certificte or type pprovl certificte numer Plese specify in more detil (* = mndtory stndrd) B.2 exhust emission requirements * *EN ISO :1996 B.3 durility 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 Mercury Mrine TDI 3.0L Diesel Sterndrive Models *8M * 90-8M

2 This declrtion of conformity is issued under the sole responsiility of the mnufcturer. I declre on ehlf of the engine mnufcturer tht the engine(s) mentioned ove complies (comply) with ll pplicle essentil requirements in the wy specified. Nme / function: Mrk Schwero, President Mercury Mrine Signture nd title: Dte nd plce of issue: My 16, 2012 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 Numer Trnsom Assemly Seril Numer (Sterndrive) Ger Rtio Sterndrive Unit Seril Numer Propeller Numer Pitch Dimeter Hull Identifiction Numer (HIN) Purchse Dte Bot Mnufcturer Bot Model Length The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury Diesel power pckge. When contcting Mercury Mrine out service, lwys specify model nd seril numers. 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 oligtion. Mercury Mrine, Fond du Lc, Wisconsin, USA. Printed in USA. 2013, Mercury Mrine 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, nd #1 On the Wter re registered trdemrks of Brunswick Corportion. Mercury Product Protection is registered service mrk of Brunswick Corportion. Welcome You hve selected one of the finest mrine power pckges ville. It incorportes numerous design fetures to ssure operting ese nd durility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny oting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. The Opertion, 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 Diesel products. We sincerely hope your oting will e plesnt! Mercury Mrine

3 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 est otin wrrnty coverge, importnt disclimers nd limittions of dmges, nd other relted informtion. Plese review this importnt informtion. Mercury Mrine products re designed nd mnufctured to comply with our own high qulity stndrds, pplicle industry stndrds nd regultions, s well s certin emissions regultions. At Mercury Mrine every engine is operted nd tested efore it is oxed for shipment to mke sure tht the product is redy for use. In ddition, certin Mercury Mrine products re tested in controlled nd monitored environment, for up to 10 hours of engine run time, in order to verify nd mke record of complince with pplicle stndrds nd regultions. All Mercury Mrine product, sold s new, receives the pplicle limited wrrnty coverge, whether the engine prticipted in one of the test progrms descried ove or not. 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 puliction, nd on your power pckge, dngers, wrnings, cutions, nd notices, ccompnied y the Interntionl Hzrd Symol!, my e used to lert the instller nd user to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. Oserve them crefully. These sfety lerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! 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 responsile for the correct nd sfe opertion of the ot, the equipment ord nd the sfety of ll occupnts ord. We strongly recommend tht the opertor red this Opertion, Mintennce nd Wrrnty Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories efore the ot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, irth defects or other reproductive hrm.

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5 TABLE OF CONTENTS Section 1 - Wrrnty Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Emission Control Wrrnty Informtion... 3 Importnt Informtion... 3 U.S. EPA Emissions Limited Wrrnty... 3 Emission Control System Components... 3 Wrrnty Policy Diesel Models... 3 TDI High Output Recretionl Use Limited Wrrnty... 3 Wht is Covered... 3 Durtion of Coverge... 4 High Output Rting... 4 Conditions Tht Must Be Met to Otin Wrrnty Coverge... 4 Wht Mercury Mrine Will Do... 4 How to Otin Wrrnty Coverge...4 Termintion of Coverge... 4 Wht Is Not Covered... 4 Light Duty Commercil Use Limited Wrrnty... 5 Products Included in this Coverge... 5 Durtion of Coverge... 5 Light Duty Commercil Rting...5 Conditions Tht Must Be Met to Otin Wrrnty Coverge... 6 Wht Mercury Mrine Will Do... 6 How to Otin Wrrnty Coverge...6 Termintion of Coverge... 6 Wht Is Not Covered 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 Otin Wrrnty Coverge... 7 Wht Mercury Will Do... 7 How to Otin Wrrnty Coverge...8 Wht Is Not Covered... 8 Trnsfer of Wrrnty... 8 Wrrnty Policy Austrli nd New Zelnd... 9 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 9 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...10 Termintion of Coverge Conditions Tht Must Be Met to Otin Wrrnty Coverge Wht Mercury Will Do How to Otin 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 Glol 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 Middle Est nd Afric Section 2 - Getting to Know Your Power Pckge Engine Component List Liter TDI Front View Components Liter TDI Strord View Components Liter TDI Port View Components Fetures nd Controls TDI 3.0 Liter Engine Fetures Lnyrd Stop Switch Instrumenttion VesselView SmrtCrft Speedometer, Tchometer, nd Digitl Guges System Link Digitl Guges Power Trim Single Engine Trim nd Triler Dul Engine Trim nd Triler...20 Power Trim nd MerCthode Overlod Protection Wrning Horn Signls Engine Gurdin System Controls Switches Emergency Stop Switch Lnyrd Stop Switch Remote Control Remote Control Function M eng APRIL 2013 Pge i

6 Digitl Throttle nd Shift Electricl System Overlod Protection Fuses Vessel Adpter Assemly (VAA) Fuse Replcement Identifiction Seril Numer Decl Plcement Engine Dt Lel Loction Brvo Sterndrive Seril Numer nd Identifiction Brvo Trnsom Seril Numer SeCore Equipped Drives SeCore Components nd Cstings Stinless Steel Fsteners Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsiility Section 3 - On The Wter Sfe Boting Suggestions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Bsic Bot Opertion Duty Cycle Rting Plesure Duty Rting TDI Opertion Chrt 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 Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump Protecting People In The Wter Protecting People in the Wter While You Are Cruising While Bot Is Sttionry High Speed nd High Performnce Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots with Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distriution (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...42 End of First Seson Checkup Section 4 - Specifictions Fuel Requirements Nonferrous Metls nd the Fuel System Winter Opertion nd Biodiesel Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions Fluid Specifictions Engine Fluid Cpcity 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 Responsiilities Deler Responsiilities Mintennce Replcement Prts Wrning Do It Yourself Mintennce Suggestions Inspection Mintennce Schedule (Sterndrive Models) Routine Mintennce Ech Dy Strt Ech Dy End Weekly Every Two Months Scheduled Mintennce Annully Every 100 Hours or Annully (Whichever Occurs First) Every 200 Hours or Annully (Whichever Occurs First) Every 500 Hours or 5 Yers (Whichever Occurs First) Pge ii 90-8M eng APRIL 2013

7 Every 1000 Hours or 5 Yers (Whichever Occurs First)...53 Every 2000 Hours or 5 Yers (Whichever Occurs First) Engine Oil Checking the Engine Oil Level Adding Engine Oil Chnging the Oil Filter Esy Engine Oil Drin System Sterndrive Ger Lue Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Assisted Steering Fluid Checking Filling Chnging Engine Coolnt Checking Filling Chnging Replcing the Engine Coolnt in the Closed Cooling System Drining the Closed Cooling System Filling the Closed Cooling System Air Filter Clening Removl Instlltion Wter Seprting Fuel Filter Drining Replcing Filling Purging the Fuel System Fuel System Priming Filling the Fuel System Winteriztion of Fuel System...71 Sewter System Sewter Pump Impeller Inspection Sterndrive Wter Inlets Check Flushing the Sewter System Sterndrive Models Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Corrosion Protection Generl Informtion Engine Corrosion Protection Components Removl Clening nd Inspection Instlltion Mintining Ground Circuit Continuity MerCthode Antifouling Pint Luriction Steering System Throttle Cle Shift Cle Trnsom Assemly Propeller Shft Engine Coupler Driveshft Extension Models Mintining Torques Giml Ring U olt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belt Drive Belt Filure Identifiction Bttery Bttery Precutions for Multiple Engines Alterntors Engine Control Unit (ECU) Btteries Bttery Switches...94 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 Section 7 - Trouleshooting Dignosing Electroniclly Controlled Fuel System Prolems Trouleshooting Chrts Strter Motor Will Not Crnk Engine, or Crnks Slow Engine Will Not Strt, or Is Hrd to Strt Engine Runs Rough, Misses, or Bckfires Poor Performnce 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 ut Sterndrive Unit Does Not Move) M eng APRIL 2013 Pge iii

8 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 Stolen Power Pckge Attention Required After Sumersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Prolem Contct Informtion for Mercury Mrine Customer Service Customer Service Literture English Lnguge Other Lnguges Ordering Literture United Sttes nd Cnd Outside the United Sttes nd Cnd Section 9 - Mintennce Log Mintennce Log Pge iv 90-8M eng APRIL 2013

9 Tle of Contents Section 1 - Wrrnty Section 1 - Wrrnty 1 Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Emission Control Wrrnty Informtion... 3 Importnt Informtion...3 U.S. EPA Emissions Limited Wrrnty... 3 Emission Control System Components... 3 Wrrnty Policy Diesel Models... 3 TDI High Output Recretionl Use Limited Wrrnty... 3 Wht is Covered... 3 Durtion of Coverge... 4 High Output Rting... 4 Conditions Tht Must Be Met to Otin Wrrnty Coverge... 4 Wht Mercury Mrine Will Do... 4 How to Otin Wrrnty Coverge... 4 Termintion of Coverge... 4 Wht Is Not Covered... 4 Light Duty Commercil Use Limited Wrrnty...5 Products Included in this Coverge... 5 Durtion of Coverge... 5 Light Duty Commercil Rting... 5 Conditions Tht Must Be Met to Otin Wrrnty Coverge... 6 Wht Mercury Mrine Will Do... 6 How to Otin Wrrnty Coverge... 6 Termintion of Coverge... 6 Wht Is Not Covered 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 Otin Wrrnty Coverge... 7 Wht Mercury Will Do... 7 How to Otin Wrrnty Coverge... 8 Wht Is Not Covered... 8 Trnsfer of Wrrnty... 8 Wrrnty Policy Austrli nd New Zelnd... 9 MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy... 9 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 Termintion of Coverge Conditions Tht Must Be Met to Otin Wrrnty Coverge Wht Mercury Will Do How to Otin Wrrnty Coverge Under This Limited Wrrnty Wht is Not Covered Expense of Climing This Limited Wrrnty Trnsfer of Wrrnty Austrli nd New Zelnd Policy Glol 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 Middle Est nd Afric M eng APRIL 2013 Pge 1

10 Section 1 - Wrrnty Wrrnty Informtion Wrrnty Registrtion United Sttes nd Cnd 1. To e eligile for wrrnty coverge, the product must e registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely sumit it to Mercury Mrine vi MercNET, E mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. 2. Wrrnty coverge is not effective until your product is registered with Mercury Mrine. 3. You my chnge your ddress t ny time, including t time of wrrnty clim, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril numer to Mercury Mrine s Wrrnty Registrtion Deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx NOTE: Registrtion lists must e mintined y Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act e required. 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 distriutor or Mrine Power Service Center responsile 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 numers, dte of sle, type of use nd the selling distriutor's nd deler's code numer, nme nd ddress. The distriutor 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 e given to you immeditely fter the crd hs een completely filled out y the selling distriutor or deler. This crd represents your fctory registrtion identifiction, nd should e retined y 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 distriutor or deler. If you receive plstic wrrnty registrtion crd, you my discrd the purchser's copy tht you received from the distriutor or deler when you purchsed the product. Ask your distriutor 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 Tle of Contents. IMPORTANT: Registrtion lists must e mintined y the fctory nd deler in some countries y lw. It is our desire to hve ALL products registered t the fctory should it ever e necessry to contct you. Mke sure your Mercury Mrine distriutor 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 The limited wrrnty is trnsferle to susequent purchser, ut 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 susequent owner, send or fx copy of the Bill of Sle or Purchse Agreement, new owner s nme, ddress, nd engine seril numer 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 y mil. There is no chrge for this service. Pge M eng APRIL 2013

11 Section 1 - Wrrnty For products purchsed outside the United Sttes nd Cnd, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Emission Control Wrrnty Informtion Importnt Informtion To identify the pplicle emission control wrrnty coverge for prticulr product, refer to the Emission Control Informtion lel ffixed to the engine. Engines designted s exempt from either Federl EPA or Cliforni emission control regultions re not covered y seprte emission control component wrrnty. The product's Mercury MerCruiser mnufcturer's wrrnty is not ffected y 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 oligtions creted y 40 CFR Prt 1042, Suprt 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, uilt, nd equipped so s to conform t the time of sle with pplicle 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 pplicle regultions. This emission relted wrrnty covers ll the components listed in the Emission Control System Components. Wrrnty clims my e denied for filures tht hve een cused y the owner's or opertor's improper mintennce or use, y ccidents for which Mercury Mrine hs no responsiility. 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. Cold strt enrichment system c. Intke vlves 2. Air induction system. Intke mnifold. Turochrger or superchrger systems c. Chrge ir cooler 3. Exhust system. Exhust mnifold. Exhust vlves 4. Miscellneous items used in ove systems. Hoses, clmps, fittings, tuing, seling gskets or devices, nd mounting hrdwre. Pulleys, elts, nd idlers c. Vcuum, temperture, check nd time sensitive vlves nd switches d. Sensors NOTE: The EPA emission relted wrrnty does not cover components whose filure would not increse n engine's emissions on ny regulted pollutnt. Wrrnty Policy Diesel Models TDI High Output Recretionl Use Limited Wrrnty Wht is Covered Mercury Mrine wrrnts ech new engine/drive pckge (Product) to e free of defects in mteril nd workmnship during the period descried following. 90-8M eng APRIL 2013 Pge 3

12 Section 1 - Wrrnty Durtion of Coverge The wrrnty period egins 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 or 1000 hours of use, whichever occurs first. 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 which 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 eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one recretionl use customer to susequent recretionl use customer upon proper re registrtion of the product. High-Output Rting A High Output Rting pplies to vrile 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 e t or elow cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): Full Power Engine Rted Speed (RPM) Cruise Speed Reduction from Engine Rted Speed (RPM) 4000 RPM 3.0 L (V6) 400 RPM 4200 RPM 4.2 L (V8) 400 RPM This rting is for plesure (non commercil) pplictions tht operte 500 hours or fewer per yer. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or susequent chnge of use from recretionl to commercil (unless properly re registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion, Mintennce, & Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Wht Mercury Mrine Will Do Mercury Mrine s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured 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 oligtion to modify products previously mnufctured. How to Otin Wrrnty Coverge Wrrnty clims must e mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Termintion of Coverge Wrrnty coverge my e terminted for used product otined in ny of the following wys: Repossession from retil customer Purchse t uction Purchse from slvge yrd Purchse from n insurnce compny tht otined the product s result of n insurnce clim Inccurte wrrnty registrtion informtion Wht Is Not Covered This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Anorml use Pge M eng APRIL 2013

13 Section 1 - Wrrnty Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce & Wrrnty mnul) Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce & Wrrnty mnul Neglect Accident Sumersion 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 y Mercury Mrine nd tht dmges the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or luricnts tht re not suitle for use with the product (see the Opertion, Mintennce & Wrrnty mnul) Altertion or removl of prts Wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Running the engine out of wter Mounting the engine too high on the trnsom Operting the ot with the engine over trimmed Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even y 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 y this wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y 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 e enforcele 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. Light Duty Commercil Use Limited Wrrnty Products Included in this Coverge Mercury Mrine wrrnts ech new engine/drive pckge (Product) to e free of defects in mteril nd workmnship during the period s descried in the following. Durtion of Coverge The wrrnty period egins 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 500 hours of use, whichever occurs first. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of the wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cnnot e trnsferred. Light-Duty Commercil Rting Light duty commercil pplies to vrile 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 e t or elow cruise speed. Cruise speed is dependnt on the engine's mximum engine rted speed (RPM): 90-8M eng APRIL 2013 Pge 5

14 Section 1 - Wrrnty Full Power Engine Rted Speed (RPM) Cruise Speed Reduction from Engine Rted Speed (RPM) 4000 RPM 3.0 L (V6) 400 RPM 4200 RPM 4.2 L (V8) 400 RPM This rting is for plesure (non commercil) pplictions tht operte 500 hours or fewer per yer. 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. Opertion of the product in excess of the light duty commercil specifictions will void the wrrnty. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Routine mintennce outlined in the Opertion, Mintennce, & Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Wht Mercury Mrine Will Do Mercury Mrine s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured 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 oligtion to modify products previously mnufctured. How to Otin Wrrnty Coverge Wrrnty clims must e mde through Mercury Mrine uthorized repir fcility. The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Termintion of Coverge Wrrnty coverge my e terminted for used product otined in ny of the following wys: Repossession from retil customer Purchse t uction Purchse from slvge yrd Purchse from n insurnce compny tht otined the product s result of n insurnce clim Inccurte wrrnty registrtion informtion Wht Is Not Covered This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Anorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce & Wrrnty mnul) Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce & Wrrnty mnul Neglect Accident Sumersion 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 y Mercury Mrine nd tht dmges the Mercury product Pge M eng APRIL 2013

15 Section 1 - Wrrnty Jet pump impellers nd liners Opertion with fuels, oils, or luricnts tht re not suitle for use with the product (see the Opertion, Mintennce & Wrrnty mnul) Altertion or removl of prts Wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused y lockge of the cooling system y foreign ody Running the engine out of wter Mounting the engine too high on the trnsom Operting the ot with the engine over trimmed Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even y 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 y this wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y 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 e enforcele 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 e rendered inopertive s direct result of corrosion for the period of time descried 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 eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred to susequent (noncommercil use) purchser upon proper reregistrtion of the product. Wrrnty coverge my e terminted for used product repossessed from retil customer, purchsed t n uction, from slvge yrd, or from n insurnce compny tht otined the product s result of n insurnce clim. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wrrnty coverge is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute 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 ecomes ville upon proper registrtion of the product y the uthorized deler. Corrosion prevention devices specified in the Opertion, Mintennce & Wrrnty mnul must e in use on the ot, nd routine mintennce outlined in the Opertion, Mintennce & Wrrnty mnul must e timely performed (including without limittion the replcement of scrificil nodes, use of specified luricnts, 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 oligtion 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 oligtion to modify products previously mnufctured. 90-8M eng APRIL 2013 Pge 7

16 Section 1 - Wrrnty How to Otin Wrrnty Coverge The customer must provide Mercury with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y 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 e 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 y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. Wht Is Not Covered This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, use 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 y 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 trnsferle to susequent purchser, ut 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 susequent owner, send or fx copy of the ill of sle or purchse greement, new owner s nme, ddress nd engine seril numer 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 y mil. There is no chrge for this service. For products purchsed outside the United Sttes nd Cnd, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Pge M eng APRIL 2013

17 Wrrnty Policy Austrli nd New Zelnd MerCruiser Limited Wrrnty Austrli nd New Zelnd Policy Section 1 - Wrrnty This Limited Wrrnty is given y Mrine Power Interntionl Pty Ltd ACN of Bessemer Drive, Dndenong South, Victori 3175 Austrli (telephone (61) (3) ), e mil: merc_info@mercmrine.com. Wht is Covered Mercury Mrine wrrnts its new products to e free of defects in mteril nd workmnship during the period descried elow. The enefits to the consumer given y 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 e excluded under the Austrlin Consumer Lw. You re entitled to replcement or refund for mjor filure nd compenstion for ny other resonly foreseele loss or dmge. You re lso entitled to hve the goods repired or replced if the goods fil to e of cceptle 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 e received y us efore the wrrnty period expires. MerCruiser Petrol Sterndrive nd Inord 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 Tow Sport 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 egins 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 eyond its originl expirtion dte. The wrrnty period is specific to the model covered. Refer to your model for the se coverge period. Wrrnty Period for Commercil Use The wrrnty period egins 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 eyond its originl expirtion dte. 90-8M eng APRIL 2013 Pge 9

18 Section 1 - Wrrnty Trnsfer of Coverge Unexpired wrrnty coverge cn e trnsferred to susequent recretionl use customer upon proper registrtion of the product. Unexpired wrrnty coverge cnnot e trnsferred either to or from commercil use customer. Termintion of Coverge Wrrnty coverge under this Limited Wrrnty is terminted for used product otined in ny of the following wys: Purchsed from n insurnce compny tht otined the product s result of n insurnce clim Purchsed from slvge yrd Repossession from retil customer Purchsed t n uction Conditions Tht Must Be Met to Otin Wrrnty Coverge Wrrnty coverge under this Limited Wrrnty is ville only to retil customers tht purchse from deler uthorized y Mercury Mrine to distriute the product in the country in which the sle occurred, nd then only fter the predelivery inspection process specified y Mercury Mrine is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use or susequent chnge of use from recretionl to commercil (unless properly registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce must e performed ccording to the mintennce schedule in the Opertion, Mintennce, nd Wrrnty mnul in order to otin 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 oligtion 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 oligtion to modify products previously mnufctured. How to Otin Wrrnty Coverge Under This Limited Wrrnty The customer must provide Mercury Mrine with resonle opportunity to repir nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde y delivering the product for inspection to Mercury Mrine deler uthorized to service the product. A list of delers nd their contct detils is ville t If the purchser cnnot deliver the product to such deler, written notice must e given to Mercury Mrine t the ddress shown ove. 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 y this limited wrrnty, the purchser shll py for ll relted lor nd mteril nd ny other expenses ssocited with tht service, provided tht consumer will not e oligted to py where the service hs een crried out to remedy filure of n cceptle qulity gurntee which is inding on Mercury Mrine under the Austrlin Consumer Lw. The purchser shll not, unless requested y Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge under this Limited Wrrnty. Wht is Not Covered This limited wrrnty does not cover the following: Operting the ot with the engine over trimmed Routine mintennce items Adjustments Norml wer nd ter Dmge cused y use Anorml 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 Sumersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Pge M eng APRIL 2013

19 Section 1 - Wrrnty Use of n ccessory or prt tht ws not mnufctured or sold y Mercury Mrine tht cuses dmge to the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or luricnts tht re not suitle 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 y lockge of the cooling system y foreign ody 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 y 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 y this limited wrrnty. Also, expenses ssocited with the removl or replcement of ot prtitions or other mteril in order to gin ccess to the product re not covered y this limited wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs een given uthority y 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 e enforcele 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 trnsferle to susequent purchser, ut 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 susequent owner, send or fx copy of the Bill of Sle or Purchse Agreement, new owner s nme, ddress, nd hull identifiction numer (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 y mil. There is no chrge for this service. You my chnge your ddress t ny time, including t the time of the wrrnty clim, y clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd hull identifiction numer (HIN) to Mercury Mrine s Wrrnty Registrtion Deprtment. 90-8M eng APRIL 2013 Pge 11

20 Section 1 - Wrrnty Glol Wrrnty Chrts United Sttes Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord MerCruiser TowSport MerCruiser SeCore MerCruiser Inord MPI, 8.2 H.O. MerCruiser Inord horizon Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yers 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 yer Not ville 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 distriutor in your country, or the uthorized Mrine Power Service Center closest to you. Cnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord MerCruiser TowSport MerCruiser SeCore MerCruiser Inord MPI, 8.2 H.O. MerCruiser Inord horizon Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yers 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 yer Not ville 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 distriutor in your country, or the uthorized Mrine Power Service Center closest to you. Pge M eng APRIL 2013

21 Section 1 - Wrrnty Austrli nd New Zelnd Wrrnty Chrt MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Stndrd Limited Wrrnty 2 yers 3 yers MerCruiser SeCore 3 yers 4 yers MerCruiser TowSport 3 yers 3 yers Mercury Diesel Sterndrive nd Inord 2 yer 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 distriutor 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 Inord Mercury Diesel Sterndrive nd Inord 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 distriutor 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 Inord Mercury Diesel Sterndrive nd Inord 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 distriutor 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 Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 2 yers 3 yers 3 yers 3 yers 4 yers 3 yers 2 yers Not ville t time of printing Stndrd Limited Corrosion Wrrnty 3 yers Commercil Appliction Contct the Mrine Power Service Center closest to you 90-8M eng APRIL 2013 Pge 13

22 Section 1 - Wrrnty Outside Europe nd CIS For products purchsed outside of Europe nd CIS regions, contct the distriutor 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 Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yers 2 yers 3 yers 2 yers 3 yers 4 yers 1 yers Not ville 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 distriutor in your country, or the Mrine Power Service Center closest to you. South Afric Wrrnty Chrts MerCruiser Gs nd Diesel Product MerCruiser Sterndrive nd Inord Horizon, Scorpion, SeCore Mercury Diesel Sterndrive nd Inord Stndrd Limited Wrrnty Instlltion Qulity Certifiction Wrrnty 1 yers 2 yers 3 yers 2 yers 3 yers 4 yers 1 yer Not ville 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 distriutor in your country, or the Mrine Power Service Center closest to you. Pge M eng APRIL 2013

23 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tle of Contents Engine Component List Liter TDI Front View Components Liter TDI Strord View Components Liter TDI Port View Components Fetures nd Controls TDI 3.0 Liter Engine Fetures...17 Lnyrd Stop Switch Instrumenttion VesselView SmrtCrft Speedometer, Tchometer, nd Digitl Guges System Link Digitl Guges Power Trim Single Engine Trim nd Triler Dul Engine Trim nd Triler Power Trim nd MerCthode Overlod Protection Wrning Horn Signls Engine Gurdin System Controls Switches Emergency Stop Switch...23 Lnyrd Stop Switch Remote Control...25 Remote Control Function Digitl Throttle nd Shift Electricl System Overlod Protection Fuses Vessel Adpter Assemly (VAA) Fuse Replcement Identifiction Seril Numer Decl Plcement...27 Engine Dt Lel Loction...27 Brvo Sterndrive Seril Numer nd Identifiction Brvo Trnsom Seril Numer SeCore Equipped Drives SeCore Components nd Cstings Stinless Steel Fsteners Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) Owner Responsiility M eng APRIL 2013 Pge 15

24 Section 2 - Getting to Know Your Power Pckge Engine Component List 3.0 Liter TDI Front View Components p o n m c d i h e g f - Ger luriction monitor - Engine control module cover c - Engine oil dipstick d - Engine coolnt expnsion tnk e - Power steering oil reservoir f - Chrge ir cooler (intercooler) g - Scrificil node h - Sewter inlet connection i - Sewter pump j - Sewter cooling system drin screw k - Closed cooling system drin screw l - Het exchnger m - Alterntor n - Wter in fuel sensor o - Fuel filter with wter sensor p - Mnul fuel primer l k j Liter TDI Strord View Components h i j k - Engine control module cover - Ger luriction monitor c - Mnul fuel primer d - Fuel filter with wter sensor e - Wter in fuel sensor f - Motor mount g - Strter h - Air filter i - Turochrger j - Oil filter k - Oil fill cp c d g f e Pge M eng APRIL 2013

25 3.0 Liter TDI Port View Components Section 2 - Getting to Know Your Power Pckge k j l m c d - Oil filter - Air filter c - Turochrger d - Exhust pipe e - Sewter cooling drin screw f - Power steering/gerox oil cooler g - Motor mount h - Power steering pump i - Chrge ir cooler (intercooler) j - Oil fill cp k - Power steering oil reservoir l - Engine coolnt expnsion tnk m - Engine control module cover i Fetures nd Controls TDI 3.0 Liter Engine Fetures The Mercury Diesel 3.0 Liter 6 cylinder engine hs the following fetures: Four stroke diesel engine Common ril direct injection 6 cylinders (90 V ngle) 3.0 liter displcement (183.1 cid) Crnkshft mounted on four erings 4 vlves per cylinder Hydruliclly djusted ucket tppets Forced feed circultory engine luriction with gered oil pump nd replcele oil filter in min flow Dry ir filter Turochrged with vrile turine geometry Two seprte cooling circuits Sewter cooled circuit runs through the oil cooler, the min het exchnger, nd the exhust mnifold. Closed cooling circuit runs coolnt s closed pressurized system through the engine lock, oil cooler, exhust collector, nd fter reching the operting temperture, through the min het exchnger. Refer to Specifictions for dditionl detils. Lnyrd Stop Switch h g f The purpose of lnyrd stop switch is to turn off the engine when the opertor moves fr enough wy from the opertor's position (s in ccidentl ejection from the opertor's position) to ctivte the switch. Some remote control units re equipped with lnyrd stop switch. A lnyrd stop switch cn e instlled s n ccessory, generlly on the dshord or side djcent to the opertor's position. IMPORTANT: Mercury MerCruiser recommends the instlltion of lnyrd stop switch to turn off the engine in the event of ccidentl ejection from the opertor's position of the vessel. e M eng APRIL 2013 Pge 17

26 Section 2 - Getting to Know Your Power Pckge The lnyrd is cord, usully cm (4 5 feet) in length when stretched out, with n element on one end mde to e inserted into the switch, nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. - Lnyrd cord - Lnyrd stop switch Instrumenttion VesselView Your power pckge my e connected to SmrtCrft VesselView disply. VesselView 7 is comprehensive ot informtion center tht cn disply informtion for up to four gsoline or diesel engines. It continuously monitors nd reports sic operting dt including detiled informtion such s sewter temperture nd depth, trim sttus, ot speed nd steering ngle, nd the sttus of fuel, oil, wter, nd wste tnks. VesselView cn e fully integrted with vessel s glol positioning system (GPS) or other NMEA comptile device to provide up to the minute nvigtion, speed, nd fuel to destintion informtion. VesselView 4 nd 7 re equipped with mico SD crd port tht llows n uthorized OEM or delership to import the personlity configurtion. It cn lso e use y 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 e 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 y VesselView. The instrument pckge my disply: Engine RPM Bot speed Coolnt temperture Oil pressure Bttery voltge Fuel consumption Engine operting hours Pge M eng APRIL 2013

27 Section 2 - Getting to Know Your Power Pckge SmrtCrft tchometer nd speedometer - Tchometer - 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 prolems on its LCD disply. For sic opertion informtion on the SmrtCrft instrument pckge nd for detils on the wrning functions monitored y the system, refer to the mnul provided with your guge pckge. System Link Digitl Guges Some instrumenttion pckges include guges tht ugment the informtion provided y VesselView nd the SmrtCrft tchometer nd speedometer. The owner nd opertor should e fmilir with ll the instruments nd their functions on the ot. Hve your ot deler explin the guges nd norml redings tht pper on your ot. The following types of digitl guges my e included with your power pckge. c d System Link digitl guges Item Guge Indictes Oil pressure guge Engine oil pressure Voltmeter Bttery voltge c Wter temperture guge Engine operting temperture d Fuel guge Quntity of fuel in tnk Power Trim Power trim llows the opertor to djust the sterndrive ngle while underwy to provide the idel ot ngle for vrying lod nd wter conditions. Also, the trilering feture llows the opertor to rise nd lower the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM engine speed), nd shllow wter opertion.! WARNING Excessive trim cn cuse serious injury or deth t high speeds, nd single rm trim systems do not provide trim out limiting device or trim indictor. Use cution when trimming with single rm trim system nd never trim out eyond the unit's side support flnges while the ot is underwy or t engine speeds ove 1200 RPM. 90-8M eng APRIL 2013 Pge 19

28 Section 2 - Getting to Know Your Power Pckge For est performnce trim the sterndrive so tht the ot ottom is t 3 5 ngle to the wter. 3-5 mc79528 Trimming the sterndrive up (out) cn: Generlly increse top speed Increse clernce over sumerged ojects or shllow ottom Cuse the ot to ccelerte nd plne off slower In excess, cuse ot porpoising (ouncing) or propeller ventiltion Cuse engine overheting if trimmed up (out) to point where ny cooling wter intke holes re ove the wter line mc78529 Trimming the sterndrive down (in) cn: Help the ot ccelerte nd plne off quicker Generlly improve the ride in choppy wter In most cses, reduce ot speed If in excess, lower the ow of some ots to point t which they egin to plow with their ow in the wter while on plne. This cn result in n unexpected turn in either direction clled ow steering or over steering if ny turn is ttempted or if significnt wve is encountered. mc79530 Single Engine Trim nd Triler Single engine pplictions hve utton tht cn e pressed to trim the sterndrive unit up (out) or down (in). To rise the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM), nd shllow wter opertion push the trim utton to rise the sterndrive to the full up (out) position. Some controls lso hve triler utton tht trims the sterndrive to position suitle for triler purposes only. Dul Engine Trim nd Triler NOTICE If using externl tie rs, rising or lowering the drives independently of ech other cn dmge the drive nd steering systems. If using n externl tie r, rise nd lower ll drives together s unit. Pge M eng APRIL 2013

29 Section 2 - Getting to Know Your Power Pckge Dul engine pplictions my hve single integrl utton to operte oth sterndrives simultneously or my hve seprte uttons for ech sterndrive. Some controls lso hve triler utton tht trims the sterndrives to position suitle for triler purposes only. Power Trim nd MerCthode Overlod Protection If n electricl overlod on the electricl system occurs, fuse will open (low). Find nd correct the cuse efore replcing the fuse. NOTE: If you must operte the engine in n emergency, turn off nd disconnect ll ccessories from the engine nd instrumenttion wiring if you cnnot find nd correct the cuse for the electricl overlod or excessive current drw. Replce the fuse. If the fuse urns out, the electricl overlod hs not een eliminted. Further checks must e mde on the electricl system. Contct your Mercury Diesel uthorized repir fcility. 1. The power trim system is protected from overlod y 110 mp fuse nd 20 mp in line fuse on the power trim pump mp in line fuse holder mp fuse There re severl different Quicksilver MerCthode systems ville. Ech hs fuse connected to the positive (+) terminl on the controller. If the fuse is open (lown), the system will not operte, resulting in loss of corrosion protection. Replce the fuse with one of the sme mp rting. - MerCthode - Red/purple wire c - Fuse c Wrning Horn Signls When the key switch is turned to the on position, the horn will turn on for moment s test to indicte the horn is working. There re two types of wrning horns to lert the opertor of n ctive prolem within the engine s operting system. 1. Continuous six second eep: Indictes criticl engine condition. Depending on the condition, the Engine Gurdin system my engge nd protect the engine y limiting power. You should return to port immeditely nd contct your servicing deler. 90-8M eng APRIL 2013 Pge 21

30 Section 2 - Getting to Know Your Power Pckge 2. Intermittent short eeps for six seconds: Indictes noncriticl engine condition. This condition does not require immedite ttention. You my continue using your ot, however, depending on the nture of the prolem, the engine s power my e limited y the Engine Gurdin system to protect the engine. You should contct your servicing deler t your erliest convenience. It is importnt to note tht in either of the ove scenrios, the horn will only sound one time. If you key the engine off nd restrt it, the horn will sound gin, one time, if the fult is still present. A few of the noncriticl conditions indicted y the intermittent short eeps for six seconds cn e corrected y the opertor. These opertor correctle conditions re s follows: Wter in the fuel filter. Refer to Mintennce Wter Seprting Fuel Filter. Cooling system (wter pressure or engine temperture) prolem. Stop the engine nd check the wter intke holes in the lower unit for ostruction. Low engine oil level. Refer to Fuel nd Oil Checking nd Adding Engine Oil. Engine Gurdin System The Engine Gurdin system monitors the criticl sensors on the engine for ny erly indictions of prolems. Engine Gurdin is functionl whenever your engine is operting, so you never hve to e concerned out whether or not you re protected. The system will respond to prolem y sounding the wrning horn for six seconds nd/or reducing engine power in order to provide engine protection. If Engine Gurdin hs een ctivted, reduce the engine speed. The prolem will need to e identified nd corrected. The system must e reset efore the engine will operte t higher speeds. Moving the throttle lever ck to the idle position will reset the Engine Gurdin system. If the Engine Gurdin system hs determined the reset hs not corrected the prolem, Engine Gurdin will remin ctivted, limiting the throttle. The prolem must e identified nd corrected efore Engine Gurdin will llow the engine to rech norml operting RPM. 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 e operted. The engine will not operte with the key switch in the "ACC" position. "ON" In the "ON" position, ll electricl circuits nd instrumenttion receive power. The engine cn e strted with n optionl strt stop switch. "START" Turn the key to the strt position nd relese to strt the engine. NOTE: The key cn only e removed with the key switch in the "OFF" position Pge M eng APRIL 2013

31 Section 2 - Getting to Know Your Power Pckge Dul Engine Strt Stop Switch A strt stop switch is optionl equipment. The strt stop switch works in conjunction with the key switch. There is one strt stop switch for ech engine. Ech utton on multi engine strt stop switch functions independently. The key switch must e in the run position to strt stopped engine with the strt stop switch. Pressing strt stop switch utton when n engine is running will shut down the corresponding engine Bilge Blower Toggle Switch Opertes the ilge lower, if equipped. ON OFF Emergency Stop Switch An emergency stop (E stop) switch is used to turn off the engines in n emergency sitution, such s person overord or tngled propeller. When ctivted, n E stop switch interrupts the power supply to the engine nd trnsmission. If the ot is equipped with n E stop switch, the E stop switch turns off ll of the engines. Typicl E-stop switch Activtion of n E stop switch stops the engine, or engines, immeditely, ut the ot cn continue to cost for some distnce depending upon the velocity nd degree of ny turn t shutdown. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We recommend instructing other occupnts on proper strting nd operting procedures should they need to operte the engine in n emergency. Accidentl or unintended ctivtion of the switch during norml opertion is lso possile, which cn cuse ny or ll of the following potentilly hzrdous situtions: M eng APRIL 2013 Pge 23

32 Section 2 - Getting to Know Your Power Pckge Occupnts cn e thrown forwrd due to unexpected loss of forwrd motion, nd pssengers in the front of the ot could e ejected over the ow nd possily struck y the propulsion or steering components. The opertor cn lose power nd directionl control in hevy ses, strong current, or high winds. The opertor cn lose control of the vessel when docking. Restrting n engine using the key switch or strt utton fter n E stop shutdown without first turning the key switch to the off position for t lest 30 seconds will restrt the engine ut cuse fult codes to e set. Unless you re in potentilly hzrdous sitution, turn the key switch off nd wit t lest 30 seconds efore restrting the engine or engines. If fter restrting, some fult codes re still eing displyed, contct your uthorized Mercury Diesel repir fcility. Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor's position (s in ccidentl ejection from the opertor's position). c RUN OFF - Stop switch - Lnyrd c - Clips to the opertor Accidentl ejections, such s flling overord, re more likely to occur in: low sided sport ots ss ots high performnce ots Accidentl ejections cn lso occur from: poor operting prctices sitting on the set or gunwle t plning speeds stnding t plning speeds operting t plning speeds in shllow or ostcle infested wters relesing your grip on the steering wheel tht is pulling in one direction consuming lcohol or drugs high speed oting mneuvers The lnyrd is cord usully etween 122 nd 152 cm (4 nd 5 ft) in length when stretched out, with n element on one end mde to e inserted into the switch nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, ut the ot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the ot will not complete full circle. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We strongly recommend tht other occupnts e instructed on proper strting nd operting procedures should they e required to operte the engine in n emergency (if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd. Accidentl or unintended ctivtion of the switch during norml opertion is lso possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y the propulsion or steering components. Loss of power nd directionl control in hevy ses, strong current, or high winds. Loss of control when docking Pge M eng APRIL 2013

33 ! WARNING Section 2 - Getting to Know Your Power Pckge Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor. Remote Control Remote Control Function Opertion of the throttle nd shift re controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse the engine RPM. Pull the control hndle ck from neutrl with quick firm motion to the first detent for reverse ger nd continue pulling ck to increse the engine RPM. The remote control hndle must e in the neutrl position to strt the engine. c d - Neutrl - Increse engine RPM c - Forwrd ger d - Reverse ger 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. Electricl System Overlod Protection! 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. Fuses Fuses protect individul circuits from n overlod. If n electricl overlod occurs, fuse will urn out. Find nd correct the cuse for the electricl overlod efore replcing the fuse. Alwys replce urned out fuse with fuse tht is the sme current rting. Never instll higher current rted fuse. Identifying urned out fuse - Good fuse - Burned out fuse Two fuses re locted on the engine. To ccess these fuses, remove the two screws securing the engine control module cover. Be certin to replce n open fuse only with one of the sme current rting. 90-8M eng APRIL 2013 Pge 25

34 Section 2 - Getting to Know Your Power Pckge The remining fuses re locted in the vessel dpter ssemly (refer to your ot owner's mnul for loction) nd on the rer side of the control unit of the individul instrumenttion. Engine Control Module - 25 mp fuse - 15 mp fuse Vessel Adpter Assemly (VAA) Fuse Replcement NOTE: Refer to your ot owner's mnul for the loction of the vessel dpter ssemly (VAA). The key for the VAA ws provided long with the ignition keys. 1. Verify the ignition key is off nd the lnyrd switch is off. 2. Insert the key into the lock nd turn it 1/4 turn to the right to unlock it. Vessel dpter ssemly - Locked - Unlocked Lift the cover. A decl on the cover identifies components nd fuses inside the VAA. f e d c - Helm power 5 mp fuse - 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 open fuse with new fuse of the sme current rting Close nd lock the cover to prevent wter intrusion nd n ccidentl short circuit. Pge M eng APRIL 2013

35 Identifiction Seril Numer Decl Plcement Section 2 - Getting to Know Your Power Pckge Three sets of engine, trnsom ssemly, nd sterndrive seril numer decl strips re provided with ech power pckge. One set should e used for ech of the following: Engine specifiction decl Wrrnty registrtion crd Opertion, Mintennce, nd Wrrnty Mnul identifiction pge. Engine Dt Lel Loction The engine dt lel is locted on top of the electricl ox Engine specifiction nd seril numer decl - Engine dt lel (not seen on top of the electricl ox) M eng APRIL 2013 Pge 27

36 Section 2 - Getting to Know Your Power Pckge Brvo Sterndrive Seril Numer nd Identifiction The Brvo sterndrive seril numer, ger rtio, model numer, nd r code re emedded in the ground plte on the port side of the sterndrive. Brvo sterndrive informtion on ground plte The seril numer is lso stmped s permnent reference on the sterndrive csting inside the ck cover Brvo Trnsom Seril Numer Brvo sterndrive seril numer stmping The Brvo trnsom seril numer is stmped in the U olt plte of the Brvo trnsom ssemly. Brvo trnsom ssemly U-olt plte - Trnsom ssemly seril numer Pge M eng APRIL 2013

37 Section 2 - Getting to Know Your Power Pckge The seril numer is lso stmped on the giml housing. This is used s permnent reference for Mercury Diesel uthorized repir fcilities. Giml housing with seril numer stmping - Trnsom ssemly seril numer SeCore Equipped Drives SeCore Components nd Cstings Mercury MerCruiser SeCore power pckges re equipped with dditionl stinless steel components nd prticulr luminum cstings with specil cotings. Do not replce SeCore components with non SeCore. Use only the specified Mercury MerCruiser SeCore components nd cstings on these power pckges. Stinless Steel Fsteners SeCore models re equipped with dditionl stinless steel fsteners to mximize corrosion resistnce in sltwter environments. Stinless steel fsteners re suject to glling when instlled without luriction. Glling cn result in fstener destruction, improper clmp lods, or oth. Glled fsteners my pper to torque properly, ut still hve incorrect clmp lods. Apply luricnt 2 4 C with PTFE or n equivlent, on the threds of stinless steel fsteners during instlltion to void glling. Luricte t lest the first 8 mm (1/4 in.) of the threds efore instlltion. Tue Ref No. Description Where Used Prt No C with PTFE Threds of stinless steel fsteners A M eng APRIL 2013 Pge 29

38 Section 2 - Getting to Know Your Power Pckge Emissions Informtion Exhust Gs Emissions Certificte (Europe Only) A tmper resistnt lel is ffixed to the engine t time of mnufcture. In ddition to the required exhust gs emissions certificte numer, the lel lists the engine seril numer, 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. Botuilders nd delers my not remove the lel or the prt it is ffixed to efore sle. If modifictions re necessry, contct Mercury Diesel out the vilility of replcement decls efore proceeding. xxxxxxxxx x.x xxxxxxxxx x x Owner Responsiility 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. Pge M eng APRIL 2013

39 Tle of Contents Section 3 - On The Wter Section 3 - On The Wter Sfe Boting Suggestions Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Sty Cler of Exhust Ares Good Ventiltion Poor Ventiltion Bsic Bot Opertion Duty Cycle Rting Plesure Duty Rting TDI Opertion Chrt Strting, Shifting, nd Stopping Before Strting the Engine...36 Strting Cold Engine Engine Wrm Up Strting Wrm Engine...37 Shifting Engine Shutdown (Stopping) Strting the Engine After Stopped While in Ger Trilering the Bot Freezing Temperture nd Cold Wether Opertion Drin Plug nd Bilge Pump Protecting People In The Wter Protecting People in the Wter While You Are Cruising While Bot Is Sttionry High Speed nd High Performnce Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots with Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Bottom of Bot Cvittion Ventiltion Elevtion nd Climte Propeller Selection...41 Brek In Initil Brek In Procedure Sterndrive 10 Hour Brek In Period (New or With Replcement Gers)...42 Engine Brek In Hour Brek In Period After the 20 Hour Brek In Period End of First Seson Checkup M eng APRIL 2013 Pge 31

40 Section 3 - On The Wter Sfe Boting Suggestions In order to sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl oting regultions nd restrictions, nd lso consider the following suggestions. Mercury Mrine strongly recommends tht ll powerot opertors complete oting sfety course. Courses re offered in the U.S.A. y the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil oting lw enforcement gency. Inquiries my e mde to the Boting Hotline or the Bot U.S. Foundtion. Know nd oey ll nuticl rules nd lws of the wterwys. Perform sfety checks nd required mintennce. Follow regulr schedule nd verify ll repirs re properly completed. Check sfety equipment on ord. Here re some suggestions of the types of sfety equipment to crry when oting: Approved fire extinguishers Pddle or or Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Rdio equipment Tools necessry for minor repirs First id kit nd instructions Anchor nd extr nchor line Wterproof storge continers Mnul ilge pump nd extr drin plugs Spre operting equipment, tteries, uls, nd fuses Drinking wter Compss nd mp or chrt of the re Wtch for signs of wether chnge nd void foul wether nd rough se oting. Tell someone where you re going nd when you expect to return. Pssenger ording. Stop the engine whenever pssengers re ording, unloding, or re ner the ck (stern) of the ot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl lw requires tht there e U.S. Cost Gurd pproved, werle type life jcket (personl flottion device), correctly sized nd redily ccessile for every person ord, plus throwle cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the ot. Prepre other ot opertors. Instruct t lest one person ord in the sics of strting nd operting the engine nd hndling the ot in cse the driver ecomes disled or flls overord. Do not overlod your ot. Most ots re rted nd certified for mximum lod (weight) cpcities (refer to your ot cpcity plte). Know your ot s operting nd loding limittions. Know if your ot will flot if it is full of wter. When in dout, contct your uthorized Mercury Mrine deler/distriutor or the ot mnufcturer. Verify ot occupnts re properly seted. Do not llow nyone to sit or ride on ny prt of the ot tht ws not intended for such use. This includes the cks of sets, gunwles, trnsom, ow, decks, rised fishing sets, nd ny rotting fishing set; nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of ot control or sudden ot movement could cuse person to e thrown overord or into the ot. Verify tht ll pssengers hve proper set nd re in it efore ny ot movement. Never e under the influence of lcohol or drugs while oting. It is the lw. Alcohol or drugs impirs your judgment nd gretly reduces your ility to rect quickly. Know your oting re nd void hzrdous loctions. Be lert. The opertor of the ot is responsile y lw to mintin proper lookout y sight nd hering. The opertor must hve n unostructed view prticulrly to the front. No pssengers, lod, or fishing sets should lock the opertor's view when operting the ot ove idle or plning trnsition speed. Wtch out for others, keep your eyes on the the wter, nd e wre of your wke. Never drive your ot directly ehind wter skier in cse the skier flls. Your ot trveling t 40 km/h (25 mph) will overtke fllen skier who ws 61 m (200 ft) in front of you in five seconds. Wtch fllen skiers. When using your ot for wterskiing or similr ctivities, lwys keep fllen or down skier on the opertor s side of the ot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never ck up to the skier or nyone in the wter. Pge M eng APRIL 2013

41 Section 3 - On The Wter Report ccidents. Bot opertors re required y lw to file oting ccident report with their stte oting lw enforcement gency when their ot is involved in certin oting ccidents. A oting ccident must e reported if 1) there is loss of life or prole loss of life, 2) there is personl injury requiring medicl tretment eyond first id, 3) there is dmge to ots or other property where the dmge vlue exceeds US $ or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. Cron Monoxide Exposure Be Alert To Cron Monoxide Poisoning Cron monoxide (CO) is dedly gs tht is present in the exhust fumes of ll internl comustion engines, including the engines tht propel ots, nd the genertors tht power ot ccessories. By itself, CO is odorless, colorless, nd tsteless, ut if you cn smell or tste engine exhust, you re inhling CO. Erly symptoms of cron monoxide poisoning, which re similr to the symptoms of sesickness nd intoxiction, include hedche, dizziness, drowsiness, nd nuse.! WARNING Inhling engine exhust gses cn result in cron monoxide poisoning, which cn led to unconsciousness, rin dmge, or deth. Avoid exposure to cron monoxide. Sty cler from exhust res when engine is running. Keep the ot well ventilted while t rest or underwy. Sty Cler of Exhust Ares Engine exhust gses contin hrmful cron monoxide. Avoid res of concentrted engine exhust gses. When engines re running, keep swimmers wy from the ot, nd do not sit, lie, or stnd on swim pltforms or ording ldders. While underwy, do not llow pssengers to e positioned immeditely ehind the ot (pltform drgging, tek/ody surfing). This dngerous prctice not only plces person in n re of high engine exhust concentrtion, ut lso sujects them to the possiility of injury from the ot propeller. Good Ventiltion Ventilte the pssenger re, open side curtins or forwrd htches to remove fumes. Exmple of desired ir flow through the ot: Poor Ventiltion Under certin running or wind conditions, permnently enclosed or cnvs enclosed cins or cockpits with insufficient ventiltion my drw in cron monoxide. Instll one or more cron monoxide detectors in your ot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry ot tht contins or is ner running engine my e exposed to hzrdous level of cron monoxide. 90-8M eng APRIL 2013 Pge 33

42 Section 3 - On The Wter 1. Exmples of poor ventiltion while the ot is sttionry: - Operting the engine when the ot is moored in confined spce - Mooring close to nother ot tht hs its engine operting 2. Exmples of poor ventiltion while the ot is moving: Operting the ot with the trim ngle of the ow too high - Operting the ot with no forwrd htches open (sttion wgon effect) Bsic Bot Opertion IMPORTANT: Alwys check to ensure the ilge drin plug is instlled efore lunching the ot. Duty Cycle Rting IMPORTANT: Dmge cused y improper ppliction or filure to operte the power pckge within the specified operting prmeters will not e covered y the Mercury Diesel Limited Wrrnty. It is the responsiility of the ot mnufcturer or the instlling deler to ensure tht the power pckge is properly pplied. In ll cses, the power pckge must e 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 e pplied in ccordnce with recommendtions indicted in the pproprite pplictions mnul. Use of Mercury Diesel engines in other thn the pplictions indicted y 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 pplictions include plesure crft such s silots, ski ots, runouts, speedots, nd other plning hulls. Appliction must conform to the Plesure Crft/Recretionl duty cycle shown (EPA Mode Numer Cycle 5 Duty Cycle). EPA Mode Numer 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%) Pge M eng APRIL 2013

43 TDI Opertion Chrt Section 3 - On The Wter Strting Procedure After Strting While Underwy Stopping nd Shutdown Open the engine htch. Air out the ilge completely. Turn the ttery switch on, if equipped. Turn on nd run the engine comprtment ilge lower, if equipped, for five minutes. Check for leks: fuel, oil, wter, fluid, etc. Open the fuel shut off vlve, if equipped. Open the secock, if equipped. Prime the fuel injection system, if necessry. Turn the key switch to the run position nd check tht the lights nd indictor lmps come on. Turn the key switch to the strt position. Relese the key when the engine strts. Check tht the chrge indictor nd oil pressure indictor lmps re off fter engine strts. Wrm up the engine t fst idle RPM for severl minutes. Oserve ll guges nd indictor lmps to check the condition of the engine. If not norml, stop the engine. Check for fuel, oil, wter, fluid, nd exhust leks, etc. Check the shift nd throttle control opertion. Check the steering opertion. Verify there re no fults. Strting, Shifting, nd Stopping! WARNING Frequently oserve ll guges nd indictor lmps to monitor engine condition. Listen for the udio lrm. Shift the remote control lever to the neutrl position. Run the engine t idle RPM for severl minutes to llow the turochrger nd engine to cool. Turn the key switch to the off position. Turn the ttery switch off, if equipped. Close the fuel shut off vlve, if equipped. Close the secock, if equipped. Flush the sewter cooling circuit, if operting in sltwter, rckish wter, or polluted wter. Vpors cn ignite nd cuse n explosion, resulting in engine dmge or severe personl injury. Do not use voltile strting ids such s ether, propne, or gsoline in the engine ir intke system.! WARNING Fuel vpors trpped in the engine comprtment my e n irritnt, cuse difficulty rething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment efore servicing the power pckge. 90-8M eng APRIL 2013 Pge 35

44 Section 3 - On The Wter Before Strting the Engine NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. IMPORTANT: Oserve the following efore strting: Provide wter to the sewter pickup pump. 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 Schedule nd Opertion Chrt. Perform ny other necessry checks s indicted y your Mercury Diesel uthorized repir fcility or specified in your ot owner s mnul. Strting Cold Engine IMPORTANT: Check the fluid levels efore strting the engine. Refer to Mintennce. 1. Turn on nd run the engine comprtment ilge lower (if equipped) for five minutes. Or, open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Plce the sterndrive in the full down (in) position. 3. Plce the control hndle in neutrl. NOTE: The fuel delivery pump is equipped with priming lever to ssist in filling the fuel filter or fuel system. The fuel delivery pump priming lever cn e moved up nd down repetedly in the event tht the hnd pump nd primer plunger on the fuel filter heder is not used to fill the system. 4. If the engine hs not een run for period of time nd will not redily strt with the stndrd strting procedure, use the hnd pump nd primer plunger locted on the fuel filter heder. Move the primer plunger (or the priming lever on the fuel delivery pump) up nd down four or five strokes. Attempt to strt the engine following the norml procedure. 5. Turn the key switch to the "RUN" position. Oserve the indictor lmp for the glow plugs, if equipped. When the cylinder temperture is gret enough to sustin comustion, the indictor lmp will go off nd the engine cn e strted. 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. 6. Turn the key switch to the "START" position. Relese the key nd llow the switch to return to the "RUN" position when the engine strts. IMPORTANT: Within seconds fter strting the engine, the oil pressure should exceed 10 psi (69 kp) minimum. If the oil pressure does not meet these minimum limits, stop the engine then locte nd correct the prolem. If you re unle to determine the prolem, see your Mercury Diesel uthorized repir fcility. 7. Ensure tht the chrge indictor nd oil pressure wrning lmps re off. 8. Ensure tht ll instrumenttion is functioning properly nd indicting norml redings. 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 e wrmed up efore pplying full lod. The wrm up period provides time for the luricting oil to estlish film etween moving prts. NOTICE Engine wer cused y incresed friction nd limited oil flow is gretest when n engine is cold. Decrese engine wer y llowing the engine coolnt temperture to rech norml operting rnge efore hrd ccelertion or pplying full throttle. 3. After the engine hs reched operting temperture:. The oil pressure should e within the rnge specified. Refer to Specifictions Engine Specifictions. Stop the engine if the oil pressure is not within the rnge specified. Pge M eng APRIL 2013

45 . Check the fuel system for lekge from the injection pump, fuel pipes, fuel filter, or fuel lines. Section 3 - On The Wter 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 prolems found, or see your Mercury Diesel uthorized repir fcility if you re unle to determine the prolem. Strting Wrm Engine 1. Run the engine comprtment ilge lower for five minutes. Otherwise, open the engine htch to ir out the ilge efore ttempting to strt the engine. 2. Plce the remote control hndle in neutrl. 3. Turn the key switch to the "RUN" position. 4. Turn the key switch to the "START" position nd relese the key when the engine strts. Ensure tht the chrge indictor nd oil pressure wrning lmps turn off. 5. Ensure tht ll the instrumenttion functions properly nd indictes norml redings. Shifting NOTICE Shifting into ger t engine speeds ove 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. Ensure tht the remote control shift lever is in Neutrl. 2. To shift the sterndrive, move the remote control shift lever with firm, quick motion forwrd to shift to forwrd ger, or ckwrd to shift to reverse. 3. After shifting the sterndrive, dvnce the throttle to the desired setting. IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, see the following procedure: 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 ove 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 turochrger erings. Idle the engine for severl minutes efore shutdown. 2. Operte the engine t idle speed for severl minutes to llow the turochrger nd engine to cool. 3. Turn key switch to the "OFF" position. Strting the Engine After Stopped While in Ger IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, see the following procedure: 1. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting ove idle RPM when the engine stopped. 2. After the hndle returns to the neutrl detent position, resume norml strting procedures. Trilering the Bot Your ot cn e trilered with the sterndrive in the up (out) or down (in) position. Adequte clernce is required etween the rod nd sterndrive when trnsporting. If dequte rod clernce is prolem, plce the sterndrive in full triler position nd support it with n optionl triler kit, which is ville from your Mercury Mrine uthorized repir fcility. 90-8M eng APRIL 2013 Pge 37

46 Section 3 - On The Wter Freezing Temperture nd Cold Wether Opertion IMPORTANT: If the ot is operted during periods of freezing temperture, tke precutions to prevent freezing dmge to the power pckge. Dmge cused y freezing is not covered y Mercury Diesel Limited Wrrnty. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or efore ny length of storge in freezing tempertures. If the ot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing ck into the cooling system. If the ot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the ot reminding the opertor to open the secock or unplug nd reconnect the wter inlet hose efore strting the engine. In order to operte the engine in tempertures of 0 C (32 F) or lower, oserve the following instructions: At the end of ech dily opertion, completely drin the sewter section of the cooling system to protect ginst dmge y freezing. At the end of ech dily opertion, drin the wter from the wter seprtor, if equipped. Fill the fuel tnk t end of dily opertion to prevent condenstion. Use the required permnent type ntifreeze solution to protect components ginst dmge y freezing. Be sure to use proper cold wether luriction oil, nd e sure the crnkcse contins sufficient mount. Mke certin tht the ttery is of sufficient size nd is fully chrged. Check tht ll other electricl equipment is in optimum condition. At tempertures of 20 C ( 4 F) nd elow, use coolnt heter to improve cold strting. If operting in rctic tempertures of 29 C ( 20 F) or lower, consult your Mercury Diesel uthorized repir fcility for informtion out specil cold wether equipment nd precutions. Refer to Section 6 for cold wether or extended storge relted informtion. Drin Plug nd Bilge Pump The engine comprtment in your ot is nturl plce for wter to collect. For this reson, ots re normlly equipped with drin plug or ilge pump. It is very importnt to check these items on regulr sis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will e dmged if sumerged. Dmge cused y sumersion is not covered y the wrrnty. Protecting People In The Wter While You Are Cruising It is very difficult for person in the wter to tke quick ction to void ot heding in their direction, even t slow speeds Alwys slow down nd exercise extreme cution ny time you re oting in n re where there might e people in the wter. Whenever ot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force y the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. While Bot Is Sttionry! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. Shift into neutrl nd shut off the engine efore llowing people to swim or e in the wter ner your ot. Pge M eng APRIL 2013

47 High Speed nd High Performnce Section 3 - On The Wter If your ot is high speed or high performnce ot with which you re unfmilir, we recommend tht you never operte it t its high speed cpility without first requesting n initil orienttion nd demonstrtion ride with your deler or n opertor experienced with your ot. For dditionl informtion, refer to the High Performnce Bot Opertion ooklet ( R2) from your uthorized Mercury Diesel repir fcility. Pssenger Sfety in Pontoon Bots nd Deck Bots Whenever the ot is in motion, oserve the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in ot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of ot direction, could throw them over the front of ot. Flling over the front of the ot etween the two pontoons will position them to e run over. Bots Hving n Open Front Deck No one should ever e on the deck in front of the ril while the ot is in motion. Keep ll pssengers ehind the front ril or enclosure. Persons on the front deck could esily e thrown overord or persons dngling their feet over the front edge could get their legs cught y wve nd pulled into the wter. mc ! WARNING Sitting or stnding in n re of the ot not designed for pssengers t speeds ove idle cn cuse serious injury or deth. Sty ck from the front end of deck ots or rised pltforms nd remin seted while the ot is in motion. Bots with Front-Mounted, Rised-Pedestl Fishing Sets Elevted fishing sets re not intended for use when the ot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Any unexpected, sudden reduction in ot speed could result in the elevted pssenger flling over the front of the ot. mc Wve nd Wke Jumping! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts eing thrown within or out of the ot. Avoid wve or wke jumping whenever possile. mc M eng APRIL 2013 Pge 39

48 Section 3 - On The Wter Operting recretionl ots over wves nd wkes is nturl prt of oting. However, when this ctivity is done with enough speed to force the ot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the ot reenters the wter. The primry concern is the ot chnging direction while in the midst of the jump. In such cses the lnding my cuse the ot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to e thrown out of their sets or out of the ot. There is nother less common hzrdous result from llowing your ot to lunch off of wve or wke. If the ow of your ot pitches down fr enough while irorne, upon wter contct it my penetrte under the wter surfce nd sumrine for n instnt. This will ring the ot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The ot my lso veer shrply to one side. Impct with Underwter Hzrds Reduce speed nd proceed with cution when operting in shllow wter or in res where the wters re suspected of hving underwter ostcles tht could e struck y the drive components, rudder, or the ot ottom. mc IMPORTANT: To help reduce injury or impct dmge from striking floting or underwter oject, control the ot speed. Under these conditions, ot speed should e kept to mximum of 24 to 40 km/h (15 to 25 mph). The following demonstrte some, ut not ll, exmples of wht cn hppen if the ot strikes n oject: The ot could move suddenly in new direction. A shrp chnge in direction or turn cn throw occupnts out of their sets or out of the ot. A rpid reduction in speed. This will cuse occupnts to e thrown forwrd, even out of the ot. Impct dmge to the underwter drive components, rudder, or ot. Keep in mind tht one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the ot speed. Bot speed should e kept to minimum plning speed when driving in wters known to hve underwter ostcles. After striking sumerged oject, stop the engine s soon s possile nd inspect the drive system for ny roken or loose prts. If dmge is present or suspected, the power pckge should e tken to Mercury Diesel uthorized repir fcility for thorough inspection nd ny necessry repir. The ot should e checked for hull frctures, trnsom frctures, nd wter leks. Operting with dmged drive components, rudder, or ot ottom could cuse dmge to other prts of the power pckge, or could ffect control of the ot. If continued opertion is necessry, do so t gretly reduced speeds.! WARNING Operting ot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Shifting weight to the rer (stern): Generlly increses speed nd engine RPM Cuses ow to ounce in choppy wter Increses dnger of following wve splshing into the ot when coming off plne At extremes, cn cuse the ot to porpoise Shifting weight to the front (ow): Improves ese of plning Improves rough wter ride Pge M eng APRIL 2013

49 Section 3 - On The Wter At extremes, cn cuse the ot to veer ck nd forth (ow steer) Bottom of Bot To mintin mximum speed, ensure tht the ot ottom is: Clen, free of rncles nd mrine growth Free of distortion, nerly flt where it contcts wter Stright nd smooth, fore nd ft Mrine vegettion my ccumulte when the ot is docked. This growth must e removed efore opertion; it my clog wter inlets nd cuse the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter oject, such s ger housing or propeller. Cvittion increses propeller speed while reducing ot speed. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other deris sngged on the propeller Bent propeller lde Rised urrs or shrp edges on the propeller Ventiltion Ventiltion is cused y surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in ot speed. Air ules strike the propeller lde nd cuse erosion of the lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Excessive ventiltion is usully cused y: The drive unit eing trimmed out too fr A missing propeller diffuser ring A dmged propeller or ger housing, tht llows exhust gses to escpe etween 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 e cused y: High elevtions High tempertures Low rometric pressures High humidity For you to hve optimum engine performnce under chnging wether conditions, it is essentil tht the engine e propped to llow the engine to operte t or ner the top end of the specified mximum RPM rnge with norml ot lod during your norml oting wether conditions. In most cses, the recommended RPM cn e chieved y 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 responsiility of the ot mnufcturer nd the selling deler to equip the power pckge with the correct propellers. IMPORTANT: Be sure tht the propeller eing used does not llow the engine to run ginst the limiter, s significnt loss in performnce will result. NOTE: Use n ccurte service tchometer to verify RPM. Select propeller tht will llow the engine power pckge to operte t the rted engine RPM with full lod. If full throttle opertion is elow the rted engine RPM, the propeller must e chnged to prevent loss of performnce nd possile engine dmge. On the other hnd, operting n engine ove the rted engine RPM will cuse higher thn norml wer or dmge. After initil propeller selection, the following common prolems my require tht the propeller e chnged to lower pitch: Wrmer wether nd greter humidity cuse n RPM loss (not s significnt on these models). 90-8M eng APRIL 2013 Pge 41

50 Section 3 - On The Wter Operting in higher elevtion cuses n RPM loss (not s significnt on these models). Operting with dmged propeller or dirty ot ottom cuses n RPM loss. Operting with incresed lod (dditionl pssengers, pulling skiers). For etter ccelertion, such s is needed for wter skiing, use the next lower pitch propeller. Do not operte t full throttle when using the lower pitch propeller ut not pulling skiers. Brek In Initil Brek In Procedure It is especilly importnt tht the following procedure e used on new diesel engines. This rek in procedure llows the proper seting of the pistons nd rings, which gretly reduces the likelihood of prolems. IMPORTANT: It is recommended tht the ot not e ccelerted hrd until this procedure hs een completed. IMPORTANT: Never operte the strter motor longer thn 15 seconds t time to void overheting the strter motor. If the engine does not strt, wit 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 e used on new sterndrives nd reuilt sterndrives with new replcement gers. This rek in procedure llows the proper seting of the sterndrive gers nd relted components, which gretly reduces the likelihood of prolems. Avoid full throttle strts. Do not operte t ny 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 e shifted into forwrd ger minimum of 10 times during rek in, with run in time t moderte RPM fter ech shift. Engine Brek In 20-Hour Brek-In Period IMPORTANT: The first 20 hours of opertion is the engine rek in period. Correct rek in is essentil to otin minimum oil consumption nd mximum engine performnce. During this rek in period, the following rules must e oserved: Do not operte elow 1500 RPM for extended periods of time for the first 10 hours. Shift into ger s soon s possile fter strting, nd dvnce the throttle ove 1500 RPM if conditions permit sfe opertion. Do not operte t 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 permissile (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 rek in period. At the end of the 20 hour rek 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 powernd for fully loded ot. Refer to Specifictions nd Mintennce. Never operte t wide open throttle for prolonged periods. Opertion t 3/4 throttle nd elow 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 sis, contct the deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. Pge M eng APRIL 2013

51 Tle of Contents Section 4 - Specifictions Section 4 - Specifictions Fuel Requirements Nonferrous Metls nd the Fuel System Winter Opertion nd Biodiesel Diesel Fuel in Cold Wether Antifreeze/Coolnt Engine Oil Engine Specifictions Fluid Specifictions Engine Fluid Cpcity Brvo Sterndrive Fluid Specifictions Diesel Power Steering nd Power Trim Fluids Approved Power Steering Fluids Approved Power Trim Fluids Approved Pints M eng APRIL 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 ots equipped with these engines, unless provisions hve een mde to exclude gsoline vpors from the engine comprtment (REF: 33 CFR).! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement efore further engine opertion.! WARNING This engine requires diesel fuel. Mixing gsoline, gsohol, or lcohol nd diesel fuel cn cuse serious injury or deth due to fire or explosion. Never mix gsoline, gsohol, or lcohol with diesel fuel. IMPORTANT: Use of improper or wter contminted diesel fuel cn seriously dmge your engine. Use of improper fuel is considered misuse of the engine, nd dmge cused therey will not e covered y the wrrnty. Grde 2 D diesel fuel is required, must meet ASTM Stndrds D975 (or fuel rted Diesel DIN EN 590), nd hve minimum cetne rting of 51. The cetne numer is mesure of the ignition qulity of diesel fuel. Incresing the cetne numer will not improve overll engine performnce, ut it my e necessry to rise the cetne rting for low temperture or high ltitude use. A lower cetne numer could cuse hrd strting nd slower wrm up, nd could increse engine noise nd exhust emissions. NOTE: If your engine suddenly ecomes noisy fter fill up, you possily received sustndrd fuel with low cetne rting. On 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 erings, 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 e used in the fuel system components. The use of items such s copper lines, rss nipples, or glvnized tnks my result in n engine power loss or filure of the injection nozzles. Winter Opertion nd Biodiesel Biodiesel fuel up to 7% my e used. Diesel Fuel in Cold Wether Unltered diesel fuels thicken nd gel in cold tempertures unless treted. Virtully ll diesel fuels re climtized to llow their use in the prticulr region for tht time of the yer. If it ecomes necessry to further tret diesel fuel, it is the owner/opertor's responsiility to dd commercil stndrd rnd of 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 suitle to the lowest temperture to which the engine will e exposed. Diesel engines re high compression engines tht operte t higher tempertures thn typicl insternl comustion engines. Therefore, the closed cooling system nd engine, including relted cooling pssges, must remin s clen s possile to provide dequte engine cooling. To ensure proper cooling, we recommend filling the closed cooling section of the cooling system with low silicte formul of ethylene glycol ntifreeze in solution with deionized wter. Common tp wter or softened wter contins unwnted minerls tht cn leve lrge deposits in the system tht restrict the cooling system efficiency. A low silicte formul prevents the ntifreeze from seprting nd forming silicte geltin. This geltin cn lock pssges in the engine nd het exchnger, cusing the engine to overhet. Pge M eng APRIL 2013

53 Section 4 - Specifictions Only premixed, coolnt should e dded to the closed cooling system. Additives nd inhiitors introduced into cceptle coolnt solutions will form protective film on the internl pssges nd provide protection ginst internl cooling system erosion. Do not drin the closed cooling section for storge. The closed cooling section should e kept filled yer round with n cceptle ntifreeze/coolnt solution to void rust forming on the internl surfces. If the engine will e exposed to freezing tempertures, ensure tht the closed cooling section is filled with properly mixed ntifreeze/coolnt solution to protect the engine nd closed cooling system to the lowest temperture to which they will e exposed. NOTE: It is recommended tht 50/50 solution of coolnt (ntifreeze) nd deionized, purified wter e used. A 50/50 solution will provide freeze protection to 35 C ( 31 F). Decresing the solution to 40/60 will provide freeze protection to 25 C ( 13 F). Even in the wrmest climtes, never decrese the solution elow 40/60. Incresing the solution to 60/40 will provide freeze protection to 50 C ( 58 F). IMPORTANT: The ntifreeze/coolnt used in these mrine engines must e low silicte ethylene glycol, contining specil dditives, nd deionized, purified wter. Using other types of engine coolnt my cuse fouling of the het exchngers nd overheting of the engine. Do not comine different types of coolnts without knowing tht they re comptile. Refer to the coolnt mnufcturer's instructions. The cceptle ntifreeze/coolnts is listed in the following tle. Refer to Section 5 Mintennce for respective chnge intervls. Description Avilility Prt Numer Mrine Engine Coolnt Worldwide 8M Engine Oil NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. The recommended Mercury Diesel oil is ny 5W 30 weight oil tht meets the VW Stndrd / We strongly recommend the use of: Description Where Used Prt Numer Quicksilver 5W 30 Diesel Oil 4.0 L (4.2 US qt) Quicksilver 5W 30 Diesel Oil 1.0 L (1.1 US qt) Engine Specifictions Engine crnkcse 8M M Engine type Displcement Engine weight Description Specifictions 90 V6 cylinder diesel 3.0 L (183.1 cid) 330 kg (727.5 l) Firing order Bore Stroke 83 mm (3.267 in.) 91.4 mm (3.598 in.) Rted engine RPM 4000 Idle RPM in neutrl (engine t norml operting temperture) 640 ± 25 Rted engine horsepower Chrge ir pressure t 4000 RPM kw (230.0 hp) kw (260.0 hp) r (14.5 psi) r (21.7 psi) 90-8M eng APRIL 2013 Pge 45

54 Section 4 - Specifictions Oil pressure (minimum) Description Specifictions 640 RPM (idle) 1.8 r (26.0 psi) 2000 RPM 4.0 r (58.0 psi) Thermostt temperture Wter 70 C (158 F) Cooling system type Overpressure vlve opening Coolnt temperture (mximum) Coolnt specifiction Oil temperture (mximum) Oil volume difference etween minimum nd mximum mrkings on the dipstick Electricl system Alterntor rting Recommended ttery rting* Twin circuit cooling system: Closed cooling system with seprte expnsion tnk, thermostt controlled Het exchnge system cooled with sewter/freshwter impeller pump r ( psi) 105 C (221 F) 50% wter nd 50% ntifreeze (lilc colored) 135 C (275 F) 1.3 L (1.4 US qt) 12 volt negtive ( ) ground 2160 W, 12 V 750 CCA, 950 MCA, or 180 mah *Bttery mnufcturers my rte nd test their tteries to different stndrds. MCA, CCA, Ah, nd reserve cpcity (RC) re the rtings recognized y Mercury Mrine. Mnufcturers tht use stndrds different thn these, such s equivlent MCA, do not meet Mercury Mrine ttery requirements. Fluid Specifictions Engine Fluid Cpcity IMPORTANT: It my e necessry to djust the fluid levels depending on instlltion ngle nd cooling systems (het exchnger nd fluid lines). All models Cpcity Fluid type Prt Numer Engine oil with filter 8.0 L (8.45 US qt) 5W 30 8M Closed cooling system 9.0 L (9.5 US qt) Brvo Sterndrive Fluid Specifictions Diesel Mrine Engine Coolnt (lilc colored) 8M Sterndrive Model Brvo One X Diesel Brvo Two X Diesel Brvo Three X Diesel Fluid Cpcity includes the Sterndrive nd the Ger Lue Monitor 2736 ml (92.5 oz) 3209 ml (108.5 oz) 2972 ml (100.5 oz) Fluid Type Fluid Prt Numer High Performnce Ger Luricnt K01 Power Steering nd Power Trim Fluids Approved Power Steering Fluids Description Prt Numer Power Trim nd Steering Fluid A1 Dextron III Automtic Trnsmission Fluid Otin Loclly Pge M eng APRIL 2013

55 Section 4 - Specifictions Approved Power Trim Fluids Description Prt Numer Power Trim nd Steering Fluid A1 SAE Engine Oil 30W Otin loclly SAE Engine Oil 40W Otin loclly Approved Pints Description Prt Numer Mercury Light Gry Primer Mercury Phntom Blck Q 1 Mercury Diesel White 8M M eng APRIL 2013 Pge 47

56 Section 4 - Specifictions Notes: Pge M eng APRIL 2013

57 Tle of Contents Section 5 - Mintennce Section 5 - Mintennce Owner nd Opertor Responsiilities Deler Responsiilities Mintennce Replcement Prts Wrning Do It Yourself Mintennce Suggestions Inspection Mintennce Schedule (Sterndrive Models) Routine Mintennce Ech Dy Strt Ech Dy End Weekly Every Two Months Scheduled Mintennce Annully Every 100 Hours or Annully (Whichever Occurs First) Every 200 Hours or Annully (Whichever Occurs First) Every 500 Hours or 5 Yers (Whichever Occurs First) Every 1000 Hours or 5 Yers (Whichever Occurs First) Every 2000 Hours or 5 Yers (Whichever Occurs First) Engine Oil Checking the Engine Oil Level...53 Adding Engine Oil Chnging the Oil Filter Esy Engine Oil Drin System...56 Sterndrive Ger Lue Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Power Assisted Steering Fluid Checking Filling Chnging Engine Coolnt Checking Filling Chnging Replcing the Engine Coolnt in the Closed Cooling System Drining the Closed Cooling System Filling the Closed Cooling System Air Filter Clening Removl Instlltion Wter Seprting Fuel Filter Drining Replcing Filling Purging the Fuel System Fuel System Priming Filling the Fuel System Winteriztion of Fuel System Sewter System Sewter Pump Impeller Inspection Sterndrive Wter Inlets Check Flushing the Sewter System Sterndrive Models Checking the Sewter Pickups Clening the Sewter Striner, if Equipped Corrosion Protection Generl Informtion Engine Corrosion Protection Components Removl Clening nd Inspection Instlltion Mintining Ground Circuit Continuity MerCthode Antifouling Pint Luriction Steering System Throttle Cle Shift Cle Trnsom Assemly Propeller Shft Engine Coupler Driveshft Extension Models Mintining Torques Giml Ring U olt Nuts Engine Mounts Propellers Brvo Sterndrive Propeller Removl Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Propeller Instlltion Brvo One Models Brvo Three Drive Belt Drive Belt Filure Identifiction Bttery Bttery Precutions for Multiple Engines Alterntors Engine Control Unit (ECU) Btteries Bttery Switches Bttery Isoltors Genertors M eng APRIL 2013 Pge 49

58 Section 5 - Mintennce Owner nd Opertor Responsiilities It is the opertor's responsiility to perform ll sfety checks, to ensure tht ll luriction nd mintennce instructions re complied with for sfe opertion, nd to return the unit to Mercury Diesel uthorized repir fcility for periodic checkup. Norml mintennce service nd replcement prts re the responsiility of the owner or opertor nd re not covered y the terms of the wrrnty. Individul operting hits nd usge contriute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependility nd will keep your overll operting expenses t minimum. See your Mercury Diesel uthorized repir fcility for service ids. Deler Responsiilities In generl, deler's responsiilities to the customer include predelivery inspection nd preprtion: Before delivery, mking certin tht the Mercury Diesel power pckge is in proper operting condition. Mking ll necessry djustments for mximum efficiency. Explining nd demonstrting the opertion of the power pckge nd the ot. Providing copy of the Predelivery Inspection Checklist. Filling out the Wrrnty Registrtion Crd completely nd miling it to the fctory immeditely upon sle of the new product. All power pckges must e 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 descried 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 efore removing ny components or opening ny fluid hoses.! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components.! WARNING Fuel vpors trpped in the engine comprtment my e n irritnt, cuse difficulty rething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment efore servicing the power pckge. IMPORTANT: Refer to Mintennce Schedule for complete listing of ll scheduled mintennce to e performed. Some tsks cn e done y the owner or opertor, while others should e performed y 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 suitle 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 efore eginning work. Disconnect the ttery, if servicing ny electricl components. Alwys disconnect the negtive ( ) led first nd reconnect it lst. Pge M eng APRIL 2013

59 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. Do It Yourself Mintennce Suggestions Present dy mrine equipment, such s your Mercury Diesel power pckge, re highly technicl pieces of mchinery. Specil fuel delivery systems provide greter fuel economies, ut lso re more complex for the untrined mechnic. If you re one of those persons who likes to do it yourself, here re some suggestions for you. Do not ttempt ny repirs unless you re wre of the Cutions, Wrnings, nd procedures required. Your sfety is our concern. If you ttempt to service the product yourself, we suggest you order the service mnul for tht model. The service mnul outlines the correct procedures to follow. It is written for the trined mechnic, so there my e procedures you do not understnd. Do not ttempt repirs if you do not understnd the procedures. There re specil tools nd equipment tht re required to perform some repirs. Do not ttempt these repirs unless you hve these specil tools nd equipment. You cn cuse dmge to the product in excess of the cost deler would chrge you. Also, if you prtilly disssemle n engine or drive ssemly nd re unle to repir it, the deler's mechnic must ressemle the components nd test to determine the prolem. This will cost you more thn tking it to the deler immeditely upon hving prolem. It my e very simple djustment to correct the prolem. Do not telephone the deler, service office, or the fctory to ttempt for them to dignose prolem or to request the repir procedure. It is difficult for them to dignose prolem over the telephone. Your locl Mercury Diesel uthorized repir fcility is there to service your power pckge. They hve qulified fctory trined mechnics. It is recommended you hve the Mercury Diesel uthorized repir fcility do periodic mintennce checks on your power pckge. Hve them winterize it in the fll nd service it efore the oting seson. This will reduce the possiility of ny prolems occurring during your oting seson when you wnt troule free oting plesure. Inspection Inspect your power pckge often nd t regulr intervls to help mintin operting performnce nd to identify potentil prolems efore they occur. The entire power pckge should e checked crefully, including ll ccessile engine prts. 1. Check for loose, dmged, or missing prts, hoses, nd clmps; tighten or replce s necessry. 2. Check electricl connections nd leds for dmge. 3. Remove nd inspect the propeller. If it is dly nicked, ent, or crcked, contct your Mercury Diesel uthorized repir fcility. 4. Repir nicks nd corrosion dmge on power pckge exterior finish. Contct your Mercury Diesel uthorized repir fcility. Mintennce Schedule (Sterndrive Models) Routine Mintennce Ech Dy Strt Check the engine oil level. Check the engine coolnt level. Check the power ssisted steering fluid level. Check the sterndrive ger luricnt level in the ger lue monitor. Ech Dy End If operting in sltwter, rckish wter, or polluted wter, flush the sewter section of the cooling system fter ech use. Drin ny wter from the fuel filter fter ech use if operting in freezing tempertures. 90-8M eng APRIL 2013 Pge 51

60 Section 5 - Mintennce Weekly Drin ny wter from the fuel filter. Check the trim pump fluid level. Check the sewter inlets for deris or mrine growth. Check nd clen the sewter striner. Inspect the nodes nd replce if they re 50% eroded. Inspect the ir filter. Every Two Months Check the ttery connections nd fluid level. Luricte the propeller shft nd torque the propeller nut (if operting in only freshwter, this mintennce my e extended to every four months). Spry the engine surfces with Corrosion Gurd if operting in sltwter, rckish wter, or polluted wters. Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Engine surfces Inspect the ir filter every two months or every 20 hours, whichever occurs first. Ensure tht the guges nd the wiring connections re secure. Clen the guges every two months or every 50 hours, whichever occurs first. If operting in sltwter, the intervl is reduced to every 25 hours or 30 dys whichever occurs first. Scheduled Mintennce Annully Touch up the power pckge with pint nd spry with Corrosion Gurd. Tue Ref No. Description Where Used Prt No. 120 Corrosion Gurd Engine surfces Every 100 Hours or Annully (Whichever Occurs First) Chnge the sterndrive ger lue. Torque the giml ring U olt locknuts. Check the steering system nd the remote control for loose, missing, or dmged prts. Luricte the cles nd linkges. Inspect the sterndrive U joints nd luricte the splines. Inspect the ellows, the exhust tue, nd check the clmps for tightness. Inspect the giml ering nd luricte the engine coupler every 50 hours if operted t idle for prolonged periods of time Check the continuity circuit for loose or dmged connections. If equipped with MerCthode, test the unit output. See your uthorized deler. Check the electricl system for loose, dmged, or corroded fsteners. Driveshft extension models: Inspect the driveshft U joints, trnsom end (tilstock) erings, nd engine end (output) erings for wer. See your uthorized deler. Luricte the throttle nd shift linkge if pplicle Every 200 Hours or Annully (Whichever Occurs First) Visul inspection for leks Chnge the engine oil nd filter. Replce the fuel wter seprtor filter Check the power steering fluid level Check the closed cooling fluid condition nd level Inspect the ir filter element nd clen if necessry Check the condition of lterntor nd power steering pump ried V elt Check the condition of the fuel injection pump elt. See your uthorized deler. Clen the sewter filter. Pge M eng APRIL 2013

61 Inspect the sewter pump nd replce the impeller if necessry. See your uthorized deler. Inspect the scrificil node nd replce if necessry Every 500 Hours or 5 Yers (Whichever Occurs First) Inspect nd clen the turochrger intercooler core s required. Every 1000 Hours or 5 Yers (Whichever Occurs First) Clen the fuel tnk Inspect nd clen, s required, the pipe undles of the het exchnger. Every 2000 Hours or 5 Yers (Whichever Occurs First) Replce the fuel injection pump elt. See your uthorized deler. Engine Oil Checking the Engine Oil Level NOTICE Section 5 - Mintennce With the engine running, the crnkshft journls or rod journls my strike nd rek the dipstick, resulting in dmge to internl engine components. Stop the engine completely efore removing or inserting the dipstick. 1. Stop the engine nd llow five minutes for the oil to drin into the pn. 2. Remove the dipstick, wipe it clen, nd instll it into the dipstick tue. Verify tht the dipstick is completely inserted into the tue. 3. Remove the dipstick nd oserve the oil level. The oil level must e etween the mrks on the dipstick. If necessry, dd oil No oil required - Oil my e dded ut not to exceed rnge "" c - Oil must e dded ut not to exceed rnge "" c Adding Engine Oil IMPORTANT: When filling or dding oil to the engine, lwys use the dipstick to determine how much oil is required. Do not overfill the engine with oil. 90-8M eng APRIL 2013 Pge 53

62 Section 5 - Mintennce 1. Remove the oil fill cp. - Oil fill cp Add the specified oil to ring the oil level up to, ut not over, the mximum mrk on the dipstick. - No oil required - Oil my e dded ut not to exceed rnge "" c - Oil must e dded ut not to exceed rnge "" c NOTE: If the engine will e running for n extended period of time (10 12 hours), the oil level must e in the middle of the MIN nd MAX mrkings indicted on the dipstick. Engine oil (with filter) 3.0 L TDI Fluid Type Cpcity 5W 30 tht meets VW / specifictions Volume difference etween the minimum nd mximum mrkings on the dipstick 3. Instll the oil fill cp. Chnging the Oil Filter NOTICE 8.0 Liter (8.45 US qt) 1.3 Liter (1.4 US qt) Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Refer to the Mintennce Schedule for the chnge intervl. You should chnge the engine oil efore plcing the ot in storge. IMPORTANT: Chnge the engine oil when the engine is wrm from opertion. Wrm oil flows more freely, crrying wy more impurities. Use only recommended engine oil. Refer to Specifictions. 1. Remove the top engine cover. Pge M eng APRIL 2013

63 2. Remove the cover of the oil filter so tht the return vlve opens, llowing the oil to return to the oil sump. Section 5 - Mintennce - Oil filter cover 3. Seprte the oil filter element from the oil filter cover. 4. Clen the cover with clen cloth. 5. Replce the seling O rings. 6. Apply clen oil to the new seling O rings. c Filter cover - O ring c - Oil filter element d - Pin with O ring d Instll the new oil filter element into the filter housing. IMPORTANT: When instlling the oil filter element, ensure tht the pin on the lower end of the filter element is ligned with the hole in the housing. - Hole Instll the cover onto the filter element. Tighten the cover to the specified torque. Description Nm l in. l ft Oil filter element cover Clen up ny spilled oil nd dispose of s directed y locl uthorities. 10. Remove the oil fill cp nd dd the required mount of oil to the engine. IMPORTANT: When dding oil to the engine, lwys use the dipstick to determine how much oil is required. 90-8M eng APRIL 2013 Pge 55

64 Section 5 - Mintennce Esy Engine Oil Drin System NOTE: The ot must e out of wter to perform this procedure. 1. Loosen the oil filter to vent the system. 2. Allow sufficient time for the oil to drin from the filter down into the engine lock. 3. Remove the ilge drin plug. 4. Pull tether through the ilge drin. c f d e Bilge drin plug - Tether c - Clip d - Oil drin hose plug e - Oil drin hose f - Bilge drin flnge 5. Plce the oil drin hose in suitle continer. 6. Remove the drin plug from the oil drin hose. 7. After oil hs drined completely, instll the drin plug in the oil drin hose. 8. Push the hose through ilge drin nd instll the plug. 9. Replce the engine oil filter. See Chnging the Oil Filter. Sterndrive Ger Lue NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking NOTE: The ger lue level will fluctute during opertion. The ger lue level should e checked with the engine cold, efore strting. Pge M eng APRIL 2013

65 Section 5 - Mintennce Check the ger lue monitor to determine the ger lue level. Keep the ger lue level within the recommended operting rnge. Refer to Filling. Ger lue level shown is t the correct operting rnge - "ADD" mrk - "OPERATING RANGE" mrk Filling IMPORTANT: If more thn 59 ml (2 fl oz) of High Performnce Ger Lue is required to fill the ger lue monitor, sel my e leking. Dmge to the sterndrive my occur due to lck of luriction. Contct your Mercury Diesel uthorized repir fcility. 1. If the ger lue level is elow or ner the "ADD" mrk, the specified ger lue must e dded. 2. Remove the ger lue monitor cp. 3. Fill the ger lue monitor with the specified ger lue so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Ger lue monitor K01 4. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll the cp. Do not overtighten. - Ger lue monitor cp NOTE: When filling the entire sterndrive, refer to Chnging. 90-8M eng APRIL 2013 Pge 57

66 Section 5 - Mintennce Chnging 1. Remove the ger lue monitor from the rcket. - Ger lue monitor rcket - Ger lue monitor nd cp c - Retining strp c Empty the contents of the ger lue monitor into suitle continer. 3. Instll the ger lue monitor in the rcket. 4. Brvo One X Models:. Remove the propeller.. Lower the sterndrive to the full down (in) position. c. Remove the ger lue fill nd drin plug nd the seling wshers. d. Drin the ger lue into suitle continer. - Fill nd drin plug - Seling wsher mc Brvo Three X Models:. Plce the sterndrive in the full trim limit out position.. Remove the fill nd drin plug nd the seling wshers. Pge M eng APRIL 2013

67 Section 5 - Mintennce c. Drin the ger lue into suitle continer Brvo Two X - Fill nd drin plug - Seling wsher Brvo Three X 6. Remove the vent plug nd seling wsher. Allow the ger lue to drin completely. - Vent plug - Seling wsher IMPORTANT: If ny wter drins from the fill nd drin plug hole, or if the ger lue ppers milky, the sterndrive is leking nd should e checked immeditely y your Mercury Diesel uthorized repir fcility. 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 lue until n ir free strem of lue flows from the vent plug hole. IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lue in the sterndrive. Tue Ref No. Description Where Used Prt No High Performnce Ger Lue 9. Instll the vent plug nd seling wsher. Sterndrive unit K Continue to pump ger lue into the drive through the fill nd drin plug hole until the ger lue ppers in the ger lue monitor. 90-8M eng APRIL 2013 Pge 59

68 Section 5 - Mintennce 11. Fill the ger lue monitor so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Sterndrive Model Brvo One X Diesel Brvo One XR Brvo Two X Diesel Brvo Three X Diesel Brvo Three XR Fluid Cpcity includes the Sterndrive nd the Ger Lue Monitor 2736 ml (92.5 oz) 3209 ml (108.5 oz) 2972 ml (100.5 oz) Fluid Type High Performnce Ger Lue 12. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll. Do not overtighten. - Ger lue monitor cp Fluid Prt Numer A Remove the pump from the sterndrive fill nd drin plug hole. Pge M eng APRIL 2013

69 Section 5 - Mintennce 14. Quickly instll the seling wsher nd the fill nd drin plug. Tighten the plug to the specified torque. mc All Brvo models shown - Fill nd drin plug - Seling wsher Description Nm l in l ft Fill nd drin plug Instll the sterndrive propeller. Refer to Propellers. 16. Check the level of the ger lue monitor fter the first use. IMPORTANT: The ger lue monitor level will chnge while the product is in use. Alwys check the ger lue 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 APRIL 2013 Pge 61

70 Section 5 - Mintennce 2. Oserve the fluid level. The fluid level must e etween the "MIN" nd "MAX" lines on the reservoir Reservoir - "MIN" nd "MAX" lines 3. Fill s necessry with the specified fluid. Refer to Filling. Filling Tue Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid 1. If the fluid level is elow the "MIN" line, the specified fluid must e dded. 2. Remove the fill cp from the reservoir. NOTE: Fill cp is vented. Power trim pump K01 Power trim pump reservoir shows the fluid level is elow "MIN" line - Fill cp ssemly - Fill cp instlled 7701 Pge M eng APRIL 2013

71 Section 5 - Mintennce 3. Add the specified fluid to ring the fluid level to within the "MIN" nd "MAX" lines on the reservoir Reservoir - "MIN" nd "MAX" lines Tue Ref No. Description Where Used Prt No Instll the fill cp. Chnging Power Trim nd Steering Fluid Power trim fluid does not require chnging unless it ecomes contminted with wter or deris. Power Assisted Steering Fluid The power steering fluid level should e checked t regulr intervls. Power trim pump K01 IMPORTANT: Do not leve the steering wheel t full lock for longer thn 15 seconds with the engine running. The power steering fluid will het up considerly when the steering wheel is t full lock nd could cuse dmge to 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 e reduced momentrily. Checking 1. Center the sterndrive nd stop the engine. 2. Remove the fill cp nd dipstick from the fluid reservoir nd oserve the level IMPORTANT: If fluid is not visile in the fluid reservoir, see your Mercury Diesel uthorized repir fcility. Filling 1. Remove the fill cp/dipstick nd wipe it with clen cloth. 2. Instll the fill cp/dipstick completely into the power steering fluid reservoir. 90-8M eng APRIL 2013 Pge 63

72 Section 5 - Mintennce 3. Remove the fill cp/dipstick from the reservoir nd oserve the fluid level. If the fluid level is within rnge, no fluid should e dded. If the fluid level is within rnge "", fluid my e dded ut should not exceed the mximum level in rnge "". If the oil level is within rnge "c", fluid must e dded. There is sufficient fluid when the fluid level is within rnge "". NOTE: If high steering lods re expected for prolonged period of opertion (10 12 hours), the fluid level should e in the middle of the min/mx mrkings of the dipstick. - No fluid required - Oil my e dded, ut do not exceed rnge "" c - Oil must e dded, ut do not exceed ove "" c 4. Add the specified fluid to ring the fluid level up to the proper level. Tue Ref No. Description Where Used Prt No Instll the fill cp/dipstick. Chnging Dexron III Automtic Trnsmission Fluid Power-ssisted steering system Otin Loclly Power ssisted steering fluid does not require chnging unless it ecomes contminted. See your Mercury Diesel uthorized repir fcility. Engine Coolnt 50641! CAUTION A sudden loss of pressure cn cuse hot coolnt to oil nd dischrge violently resulting in serious injury from urns. Allow the engine to cool down efore removing the coolnt pressure cp. Checking IMPORTANT: Check the engine coolnt efore strting the engine. 1. Stop the engine nd llow the engine to cool. 2. Remove the pressure cp from the coolnt expnsion tnk. 3. The coolnt level must e ove the minimum mrk nd elow the mximum mrk on the coolnt expnsion tnk. - Pressure cp - Mximum mrk c - Minimum mrk c Pge M eng APRIL 2013

73 Section 5 - Mintennce IMPORTANT: The coolnt level is monitored y sensor. If the coolnt level is low, fult will e recorded, indicted on SmrtCrft gge, nd wrning tone will e ctivted. 4. If the coolnt level is low:. Inspect the coolnt recovery system for leks.. Inspect the O ring in the pressure cp for dmge nd replce if necessry. - Pressure cp - Over pressure vlve c - O ring c c. The pressure cp mintins pressure on the cooling system nd my not e holding pressure properly. To hve the cp tested, contct your Mercury Diesel uthorized repir fcility. d. Refer to Filling nd dd the specified coolnt s necessry. IMPORTANT: When instlling the pressure cp, e sure to tighten it securely until it clicks to prevent coolnt loss. 5. If the coolnt level is correct, instll the pressure cp nd tighten securely until it clicks. Filling 1. Allow the engine to cool. 2. Remove the pressure cp from the coolnt expnsion tnk. 3. If the coolnt is low in the coolnt expnsion tnk, dd the specified coolnt s necessry to ring the level etween the minimum mrk nd the mximum mrk. - Pressure cp - Mximum mrk c - Minimum mrk c Description Cpcity Prt Numer Mrine Engine Coolnt 9.0 Liter (9.5 US qt) 8M IMPORTANT: When instlling the pressure cp, e sure to tighten it securely until the cp clicks to prevent coolnt loss. 4. Instll the pressure cp. Tighten it securely until the cp clicks. Chnging Chnge (replce) the engine coolnt t the prescried intervl. Refer to Replcing the Engine Coolnt in the Closed Cooling System. 90-8M eng APRIL 2013 Pge 65

74 Section 5 - Mintennce Replcing the Engine Coolnt in the Closed Cooling System Drining the Closed Cooling System NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. NOTE: For instructions on drining the sewter section, refer to Flushing nd Drining the Sewter System in this section. IMPORTANT: Oserve the following points: Ensure tht the engine is s level s possile to promote complete drining of the cooling system. The closed cooling section must e filled yer round with the required coolnt. If the engine will e exposed to freezing tempertures, ensure tht the closed cooling section is filled with solution of ethylene glycol ntifreeze nd wter properly mixed to protect the engine to the lowest temperture to which it will e exposed. Do not use propylene glycol ntifreeze in the closed cooling section of the engine.! CAUTION A sudden loss of pressure cn cuse hot coolnt to oil nd dischrge violently resulting in serious injury from urns. Allow the engine to cool down efore removing the coolnt pressure cp. 1. Allow the engine to cool. 2. Remove the pressure cp from the expnsion tnk coolnt reservoir. 3. Loosen the closed cooling het exchnger drin screw pproximtely two turns, nd llow the contents to drin into n pproprite continer. - Closed cooling system drin screw - Sewter system drin screw 4. If required, clen the closed cooling system. See your Mercury Diesel uthorized repir fcility. 5. Fill the system with the specified coolnt. Refer to Filling the Closed Cooling System. Filling the Closed Cooling System IMPORTANT: Use only the specified coolnt. Description Cpcity Prt Numer Mrine Engine Coolnt 9.0 Liter (9.5 US qt) 8M Verify tht the closed cooling het exchnger drin screw is tight. Pge M eng APRIL 2013

75 Section 5 - Mintennce 2. Remove the pressure cp from the expnsion tnk coolnt reservoir. - Pressure cp - Mximum mrk c - Minimum mrk c 3. Slowly dd the coolnt to the expnsion tnk. Allow the entrpped ir to escpe. 4. When coolnt cnnot e dded, supply the sewter pump with wter. NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. 5. Do not instll the pressure cp. Strt nd operte the engine t idle for pproximtely two minutes. 6. Add coolnt if necessry to mintin the coolnt t the specified level on the expnsion tnk. 7. Allow the engine to wrm up, Add coolnt if necessry to mintin the coolnt t the specified level on the expnsion tnk. 9. Inspect the O ring in the pressure cp for dmge nd replce if necessry. - Pressure cp - Over pressure vlve c - O ring c Instll the pressure cp fter the engine hs reched norml operting temperture (with the thermostt fully open) nd the coolnt level remins constnt. 11. Oserve the temperture guge nd check the engine for coolnt leks. If the temperture guge indictes the presence of excessive temperture or coolnt is leking, stop the engine immeditely nd inspect for the cuse. 12. After the first opertion, llow the engine to cool. 13. Remove the pressure cp nd dd the specified coolnt to the level indicted on the expnsion tnk. 14. Instll nd securely tighten the pressure cp. 90-8M eng APRIL 2013 Pge 67

76 Section 5 - Mintennce Air Filter Clening Removl 1. Loosen the screw securing the ir filter to the intke mnifold nd remove the ir filter. - Air filter - Screw c - Intke mnifold c 50680! CAUTION Using compressed ir cn cuse serious injury. Alwys wer eye protection when working with compressed ir to prevent injury from ruptured hoses or flying deris. 2. Use compressed ir to low out the filter from the inside towrds the outside. Do not exceed the ir pressure specifiction. - Air filter - Compressed ir nozzle Air Filter Clening Mximum ir pressure 2.0 r (29 psi) IMPORTANT: Do not use petroleum products for clening the ir filter s the filter element my e dmged. 3. For clening the ir filter, purchse K&N filter rechrging kit Follow the procedures contined in the rechrging kit. Instlltion 1. Instll the ir filter onto the intke mnifold. Pge M eng APRIL 2013

77 Section 5 - Mintennce 2. Tighten the ir filter ttching screw securely. - Air filter - Screw c - Intke mnifold Wter Seprting Fuel Filter! WARNING Fuel is flmmle nd explosive. Ensure tht the key switch is off nd the lnyrd is positioned so tht the engine cnnot strt. Do not smoke or llow sources of sprk or open flme in the re while servicing. Keep the work re well ventilted nd void prolonged exposure to vpors. Alwys check for leks efore ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. NOTICE Wter entering the fuel injection system will cuse corrosion nd rusting of the injectors nd other components, disling the fuel injection system. Check dily for wter in the wter seprting fuel filter nd hve the engine inspected immeditely if there is evidence of wter in the fuel system. IMPORTANT: Use suitle continer to collect fuel. Clen up ny spills immeditely nd dispose of fuel in sfe mnner in ccordnce with ll locl, federl, nd interntionl regultions. The engine mounted wter seprting fine element fuel filter is equipped with wter in fuel sensor tht should lert the opertor when wter is present in the filter. This fuel filter needs to e replced t specified intervls or whenever wter is detected in the fuel, whichever comes first. The opertor my e lerted tht the wter in fuel sensor hs detected wter in the fuel, if the ot is equipped with the proper instrumenttion: Instrument notifiction (if equipped) Indictor lmp (if equipped) When the engine is equipped with remote mounted primry filter, it should e drined or replced t specified intervls, or whenever wter is detected in the engine mounted fuel filter. Drining The engine mounted wter seprting fuel filter cn e drined of wter nd sediment y removing the wter in fuel sending unit locted on the ottom of the filter. NOTE: To ensure complete drining in wrm wether, drin the filter efore strting dily opertions. In cold wether, where there is possiility tht the condensed wter will freeze, drin the filter shortly fter the end of dily opertions. NOTE: Plce suitle continer under the fuel filter to ctch contminted fuel or wter. Dispose of fuel nd old filters in sfe mnner in ccordnce with ll locl, federl, nd interntionl regultions. 1. Plce suitle continer under the wter seprting fine element fuel filter. 2. Disconnect the wter in fuel sensor hrness connector. 3. Remove the wter in fuel sensor from the ottom of the filter. 4. Unscrew the leed screw. 5. Drin the filter until the fuel is free of deris nd wter. c M eng APRIL 2013 Pge 69

78 Section 5 - Mintennce 6. Instll the wter in fuel sensor nd tighten securely. 7. Connect the wter in fuel hrness connector. 8. Instll the leed screw nd tighten securely. 9. Push on the primer pump on top of the fuel filter until incresed resistnce is felt. Incresed resistnce will indicte the fuel system hs een filled with fuel. - Primer pump - Bleed screw c - Fine element fuel filter d - Wter in fuel sensor c Replcing! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components. IMPORTANT: The fine element fuel filter cnnot e clened nd reused. It must e replced. 1. Disconnect oth ttery cles from the ttery. 2. Disconnect the wter in fuel sensor hrness connector. 3. Plce suitle continer under the wter seprting fine element fuel filter. 4. Unscrew the fine element fuel filter nd empty the fuel contents into the continer. 5. Remove the wter in fuel sensor nd O ring from the fuel filter. 6. Instll the wter in fuel sensor with O ring into the new fuel filter. Tighten securely. 7. Fill the new fuel filter with clen diesel fuel. NOTE: After replcing the fine element fuel filter nd filling it with fuel, it is not necessry to leed the fuel system. 8. Apply clen diesel fuel to the new fuel filter seling O ring. 9. Instll the new fine element fuel filter onto the filter rcket nd tighten y hnd. 10. Connect the wter in fuel sensor hrness connector. 11. After chnging the fine element fuel filter, push on the primer pump on the filter housing until incresed resistnce is felt. The fuel system hs then een filled. 12. Visully check the fuel system for leks. 13. Connect the ttery cles. 14. Strt nd operte the engine. Check the filter connection for fuel leks. If leks exist, recheck filter instlltion. If leks continue, stop the engine immeditely nd contct your Mercury Diesel uthorized repir fcility. Filling d A plunger type of primer pump is locted on the fuel filter rcket nd is used to: Fill the fuel filter when drining or chnging the fine element fuel filter. Fill the fuel system on the engine if the system ws run dry. Prime the fuel system if the engine hs not een run for n extended period. NOTE: Follow this procedure fter instlling new filter if it hs not een prefilled or if the fuel hs een drined from the filter when checking for wter. 1. Loosen the leed screw on the fuel filter rcket. Pge M eng APRIL 2013

79 Section 5 - Mintennce 2. Move the primer pump up nd down repetedly until the filter is full nd the strem of fuel flowing from the leed screw contins no ir ules. 3. Securely tighten the leed screw. - Primer pump - Bleed screw c - Fine element fuel filter d - Wter in fuel sensor c d Purging the Fuel System IMPORTANT: The fuel line must e purged efore the engine is put into opertion. 1. Loosen the leed screw on top of the fuel filter rcket. 2. Use suitle continer to collect fuel while purging the system. Clen up ny spills immeditely nd dispose of the fuel in sfe mnner ccording with ll locl, federl, nd interntionl regultions. 3. Move the hnd pump on top of the fuel filter rcket up nd down repetedly. The filter is full when n ir free strem of fuel flows from the leed screw port. - Hnd pump - Bleed screw nd sel Instll the leed screw with the sel nd securely tighten. Fuel System Priming Prime the engine if it hs not een run for n extended period or if the engine will not strt. 1. Move the hnd pump/primer plunger on the fine element fuel filter rcket up nd down severl times. 2. Strt the engine. Filling the Fuel System NOTE: Follow this procedure if the fuel system ws run dry or if prt of the fuel system ws drined for service function. 1. Move the hnd pump/primer plunger on the fine element fuel filter rcket up nd down severl times to fill the fuel filter. 2. Check the filter for fuel leks. Ensure tht the leed screw on the fuel filter rcket is closed. Winteriztion of Fuel System 1. Fill the fuel tnk to prevent condenstion from forming. 90-8M eng APRIL 2013 Pge 71

80 Section 5 - Mintennce 2. Inspect the fuel system for leks. 3. Drin the wter from the circultion filter. 4. Replce the fine element fuel filter. Sewter System Sewter Pump Impeller Inspection The sewter pump impeller must e inspected (nd replced, if necessry) t the intervl specified y the mintennce schedule. It is recommended this tsk e performed t Mercury Diesel uthorized repir fcility. 1. Close the secock. 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 c d e f - Sewter pump - Impeller c - Protective cp d - O ring e - Cover f - Screw (4) 4. Use suitle puller to remove the impeller from the impeller shft. 5. Inspect the impeller for dmge. The impeller must e replced if there re ny signs of dmge. NOTE: Keep n extr impeller onord the ot t ll times. 6. Luricte 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 l in. l ft Sewter pump cover screws Open the secock. 11. Strt the engine nd check the cooling system for leks. Sterndrive Wter Inlets Check Otin piece of wire the pproprite size to insert into the wter inlets holes. 2. Insert the wire in nd out of the sterndrive wter inlets to ensure tht they re open nd to remove deris or mrine growth. Do not scrpe the sterndrive pint. Pge M eng APRIL 2013

81 Section 5 - Mintennce 3. Remove the wire from the sterndrive nd retin for periodic wter inlet checks. - Dul wter pickup wter inlets - Side pickup wter inlets Flushing the Sewter System Sterndrive Models Flushing the sewter system with fresh wter is needed only for pplictions operting in sltwter, rckish wter, polluted wter, or wter with high minerl content to void slt or silt uildup. For est results we recommend flushing the sewter system fter ech outing. After ech opertion in sltwter nd efore storge, the sewter cooling system must e flushed. 1. If flushing the sewter system with the ot out of the wter:. Lower the sterndrive to the full down (in) position.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte.. Remove the propeller. Refer to Propellers NOTICE Operting the engine out of the wter t high speeds cretes suction, which cn collpse the wter supply hose nd overhet the engine. Do not operte the engine ove 1400 RPM out of the wter nd without sufficient cooling wter supply. c. Instll the pproprite flushing ttchment over the wter inlet holes in the ger housing Dul wter pickup Side pickup d. Connect flushing hose from wter tp to the flushing ttchment. IMPORTANT: Do not use full wter tp pressure. IMPORTANT: Engines with the sterndrive wter inlet locked off t the giml housing nd using through hull or through trnsom wter inlet need supply of cooling wter ville to oth the sterndrive nd to the engine during opertion. 90-8M eng APRIL 2013 Pge 73

82 Section 5 - Mintennce e. Using n pproprite dpter, connect second flushing hose from wter tp to the sewter inlet hose connected to the sewter pump inlet. c - Adpter - Flushing hose c - Wter tp d - Sewter inlet hose d If flushing the sewter system with the ot in the wter: NOTICE Disconnecting the sewter inlet hose will cuse wter to enter the ilge resulting in engine dmge. Close the secock efore disconnecting the sewter inlet hose. Plug the sewter inlet hose immeditely fter disconnecting it.. Close the secock, if equipped, or disconnect nd plug the sewter inlet hose. c Secock - Sewter inlet hose c - Plug Pge M eng APRIL 2013

83 Section 5 - Mintennce. Using n pproprite dpter, connect flushing hose from wter tp to the sewter inlet hose connected to the sewter pump inlet. c - Adpter - Flushing hose c - Wter tp d - Sewter inlet hose d c. Instll the pproprite flushing ttchment over the wter inlet holes in the ger housing. d. Connect flushing hose from wter tp to the flushing ttchment. e. Lower the sterndrive to the full down (in) position. IMPORTANT: Engines with the sterndrive wter inlet locked off t the giml housing nd using through hull or through trnsom sewter pickup, need supply of cooling wter ville to oth the sterndrive nd to the engine during opertion. 3. Prtilly open the wter source to out 1/2 mximum. Do not use full wter pressure. 4. Plce the remote control in neutrl, idle speed position nd strt the engine. NOTICE Operting the engine out of the wter t high speeds cretes suction, which cn collpse the wter supply hose nd overhet the engine. Do not operte the engine ove 1400 RPM out of the wter nd without sufficient cooling wter supply. 5. Operte the engine t idle speed in neutrl for out ten minutes or until the dischrge wter is cler. 6. Oserve the wter temperture guge to ensure tht the engine is operting in the norml rnge. 7. Stop the engine. 8. Shut off the wter tp. 9. Remove the sterndrive flushing ttchment. 10. Remove the dpter from the sewter pump inlet hose connection. 11. If flushing the cooling system with the ot in the wter:. To prevent wter from siphoning into the ot or engine, do not open the secock or reconnect the wter inlet hose t this time.. Plce n pproprite tg on the key switch stting tht the secock must e opened or the sewter inlet hose must e reconnected efore operting the engine. 12. If flushing the cooling system with the ot out of the wter, reconnect the sewter inlet hose. Tighten the hose clmps securely. 90-8M eng APRIL 2013 Pge 75

84 Section 5 - Mintennce Checking the Sewter Pickups Verify the wter inlet holes for the sewter pickup re clen nd unostructed 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 ot, cusing dmge or sinking the ot. Alwys close the wter supply from the sewter pump, wter inlet, or secock when performing service or mintennce on the cooling system. 1. With the engine off, close the secock, if equipped, or remove nd plug the sewter inlet hose. 2. Remove the screws, wshers, nd cover. 3. Remove the striner, drin plug, nd seling wsher. 4. Clen ll the deris from the striner housing. Flush oth 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 ilge, dmging the engine or cusing the ot to sink. Do not overtighten the cover screws, or the cover my wrp nd introduce sewter into the ilge. Pge M eng APRIL 2013

85 Section 5 - Mintennce 7. Instll the sel nd cover using the screws nd wshers. Do not overtighten the cover screws. f - Screws nd wshers - 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 sumerged in conductive solution of sltwter, polluted wter, or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow etween metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This erosion is known s glvnic corrosion nd, if it is not controlled, it will eventully cuse the need for replcement of power pckge components exposed to wter. To help control the effects of glvnic corrosion, Mercury 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. Engine Corrosion Protection Components The engine is equipped with scrificil node locted on the intercooler end cover to ssist in protecting the engine nd the sewter cooling system from corrosion. Removl 1. Allow the engine to cool NOTICE Filure to close the sewter inlet or secock when removing or replcing the node plugs cn led to wter dmge. Close the secock or remove nd plug the sewter inlet hose to prevent wter from entering the node plug holes. 2. With the engine off, close the secock, if equipped, or remove nd plug sewter inlet hose. 3. Drin the sewter system. Refer to Flushing nd Drining the Sewter System. 90-8M eng APRIL 2013 Pge 77

86 Section 5 - Mintennce 4. Remove the node ssemly. - Intercooler - Anode plug c - Anode length 20 mm (0.79 in.) c Clening nd Inspection Inspection nd replcement intervl will vry ccording to the condition of the sewter nd the mode of engine opertion. NOTE: Use sndpper, fier rush, or clening pd, remove the deposits from the surfce of the node efore trying to determine the mount of erosion. Do not use mild steel rush which might leve deposits tht could ccelerte corrosion. 1. Remove the deposits. 2. Inspect nd mesure the node. Compre the mesurements to the specifictions for new scrificil node nd replce the node ssemly when deteriorted 50%. NOTE: Scrificil nodes re ville only s n ssemly. Replce oth the plug nd node s unit. - Anode plug - Scrificil node c - Length d - Dimeter e - Seling wsher Scrificil node mesurements (new) Length Dimeter 3. Discrd the seling wsher. Instlltion 1. Instll new seling wsher on the node ssemly. - Anode ssemly - Seling wsher 20.0 mm (0.79 in.) 9.9 mm (0.390 in.) Pge M eng APRIL 2013

87 Section 5 - Mintennce 2. Instll the node ssemly with the wsher into the intercooler end cover nd tighten securely. - Anode 3. Unplug nd connect the sewter inlet hose, or open the secock if equipped. NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. 4. Ensure tht the sewter pickup pump is supplied cooling wter. 5. Strt the engine nd check for leks Mintining Ground Circuit Continuity The trnsom ssemly nd sterndrive re equipped with ground wire circuit to ensure good electricl continuity etween the engine, trnsom ssemly, nd sterndrive components. Good continuity is essentil for the node nd the MerCthode system to function effectively. Inspect ll ground circuit components for loose connections nd roken or frying wires. Models equipped with seprte ground wire must hve the wire connected etween the engine flywheel housing nd the trnsom plte. - Engine flywheel housing olt - Ground wire c - Inner trnsom plte grounding screw c M eng APRIL 2013 Pge 79

88 Section 5 - Mintennce Models equipped with trnsom hrness must connect its ground wire to the grounding screw on the giml housing. d - Giml housing grounding screw - Trnsom hrness ground wire to engine hrness c - Trnsom plte grounding stud nd nut d - Grounding wire giml housing to trnsom plte c Steering lever - Torx screw c - Continuity wire c c d Brvo model shown, Alph similr - Trim cylinder to giml ring ground wire (2) - Giml housing to giml ring ground wire c - Giml ring to ell housing ground wire d - Screw c - MerCthode - Continuity wshers c - Hydrulic mnifold Pge M eng APRIL 2013

89 Section 5 - Mintennce c Brvo sterndrive shown, Alph sterndrive similr - Sterndrive - Ground wsher c - Ground plte (lter model) Ground wsher shown inside node cvity of Brvo Three ger housing, other models similr c U joint ellows ground clip - Exhust ellows ground clip c - Exhust tue ground clip MerCthode If the ot is equipped with MerCthode system, the system should e tested to ensure tht it is providing dequte output to protect the underwter metl prts on the ot. The test should e mde where the ot is moored, using Reference Electrode nd Test Meter. Reference Electrode T 1 Senses nd electricl current in the wter when testing the MerCthode system. Use to check hull potentil Refer to the pproprite Mercury MerCruiser sterndrive service mnul for testing procedures. Antifouling Pint IMPORTANT: Corrosion dmge tht results from the improper ppliction of nti fouling pint is not covered y the limited wrrnty. 90-8M eng APRIL 2013 Pge 81

90 Section 5 - Mintennce In some res it my e dvisle to pint the ottom of the ot to help prevent mrine growth. Contct Mercury Diesel uthorized repir fcility for recommendtions for your ot. Luriction Steering System! WARNING Incorrect cle luriction cn cuse hydrulic lock, leding to serious injury or deth from loss of ot control. Completely retrct the end of the steering cle efore pplying luricnt. NOTE: If the steering cle does not hve grese fitting, the inner wire of the cle cnnot e gresed. 1. If the steering cle hs grese fittings, turn the steering wheel until the steering cle is fully retrcted into the cle housing. Apply pproximtely three pumps of grese from typicl hnd operted grese gun. - Steering cle grese fitting 6221 Tue Ref No. Description Where Used Prt No C with PTFE Steering cle grese fitting A 1 2. Turn the steering wheel until the steering cle is fully extended. Lightly luricte the exposed prt of the cle. - Extended steering cle 6222 Tue Ref No. Description Where Used Prt No C with PTFE Steering cle A 1 Pge M eng APRIL 2013

91 Section 5 - Mintennce 3. Luricte the steering pin. - Steering pin mc Tue Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W On dul engine ots: Luricte the tie r pivot points. Steering pin K01 Tue Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie r pivot points K01 5. Upon first strting the engine, turn the steering wheel severl times to strord nd then port to ensure tht the steering system opertes properly efore getting underwy. Throttle Cle Luricte the pin nd throttle cle surfces with oil. Throttle cle luriction - Pin - Throttle cle Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Bll pin nd throttle cle end contct surfces Otin Loclly 90-8M eng APRIL 2013 Pge 83

92 Section 5 - Mintennce Shift Cle 1. Luricte the pivot points nd guide contct surfces Typicl sterndrive model shift cle - Pivot points - Guide contct surfce Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Shift cle pivot points nd guide contct surfces Otin Loclly Trnsom Assemly Luricte the giml ering y pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun. - Giml ering grese insert Tue Ref No. Description Where Used Prt No. Extreme Grese Gimel ering grese insert 8M Propeller Shft NOTE: Refer to Propeller Removl. Luricte the sterndrive propeller shft y pplying coting of one of the following luricnts to the propeller shft. Pge M eng APRIL 2013

93 Section 5 - Mintennce Apply generous coting of one of the following luricnts to the propeller shft Propeller shft Tue 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 e luricted without removing the sterndrive unit. 1. Luricte the engine coupler splines through the grese fitting on the coupler y pplying pproximtely 8 10 pumps of Extreme Grese from typicl hnd operted grese gun. NOTE: If the ot is operted t idle for prolonged periods of time, the coupler should e luricted on Brvo models every 50 hours. Coupler shown seprted for clrity - Grese fitting Tue Ref No. Description Where Used Prt No. Driveshft Extension Models Extreme Grese Engine coupler nd shft splines 8M Luricte the trnsom end grese fitting nd engine end grese fitting y pplying pproximtely pumps of grese from typicl hnd operted grese gun. 90-8M eng APRIL 2013 Pge 85

94 Section 5 - Mintennce 2. Luricte the driveshft grese fittings y pplying pproximtely 3 4 pumps of grese from typicl hnd operted grese gun. c Driveshft grese fittings - Trnsom end grese fitting c - Engine end grese fitting Tue Ref No. Description Where Used Prt No. Extreme Grese Mintining Torques Giml Ring U olt Nuts NOTE: The giml ring is component of the trnsom ssemly. Tighten the giml ring U olts to the specified torque. Trnsom end grese fitting, engine end grese fitting, driveshft grese fittings 8M Trnsom ssemly - Giml ring U olt nuts Description Nm l in. l ft Giml ring U olt nuts for 3/8 in. U olt Giml ring U olt nuts for 7/16 in. U olt Pge M eng APRIL 2013

95 Engine Mounts Loosen the rer engine mount olts 1 to 1 1/2 turns. Tighten the rer engine mount olts to the specified torque. Section 5 - Mintennce - Rer engine mount - Trnsom plte mount c - Rer engine mount olt c Description Nm l in. l ft Rer engine mount olts Propellers Brvo Sterndrive Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. Brvo One Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut M eng APRIL 2013 Pge 87

96 Section 5 - Mintennce 2. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise nd remove the nut. 4. Slide the propeller nd the ttching hrdwre from the propeller shft. c d e f g Brvo One models - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut Brvo Two Models 1. Strighten the ent ts of the t wsher on the propeller shft c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket 3. Turn the propeller shft nut counterclockwise to remove the nut. Pge M eng APRIL 2013

97 Section 5 - Mintennce 4. Slide the propeller nd ttching hrdwre from the propeller shft. c d f Brvo Two - Propeller shft splines - Forwrd thrust hu c - Propeller d - Spline wsher e - T wsher f - Propeller nut e 8566 Brvo Three Models 1. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. 2. Remove the olt nd wshers securing the propeller shft node. 3. Remove the propeller shft node. c - Propeller - Propeller shft nut c - Propeller shft node d - Propeller shft node screw e - Flt wsher f - Str wsher d f e Turn the ft propeller shft nut counterclockwise to remove the nut. 5. Slide the propeller nd thrust hu off of the propeller shft. 6. Using the propeller nut tool, turn the front propeller shft nut counterclockwise nd remove the nut. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Slide the propeller nd the thrust hu off the propeller shft. g i h j c d e f 5304 Brvo Three - Aft propeller nut - Aft propeller c - Aft propeller thrust hu d - Front propeller nut e - Front propeller f - Front propeller thrust hu g - Propeller shft node screw h - Flt wsher i - Str wsher j - Propeller shft node 90-8M eng APRIL 2013 Pge 89

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

99 Section 5 - Mintennce 5. Bend the three ts down into the grooves. c d e - Propeller - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut 4750 Brvo Three 1. Lierlly cot the propeller shft spline with one of the following luricnts. Tue Ref No. Description Where Used Prt No C with PTFE Propeller shft splines A 1 Extreme Grese Propeller shft splines 8M Slide the forwrd thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 3. Align splines nd plce front propeller on propeller shft. 4. Instll the front propeller locknut nd tighten to the specified torque using the propeller nut tool. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Description Nm l in. l ft Brvo Three front propeller nut Slide the ft thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 6. Align the splines nd instll the ft propeller. 7. Instll the propeller nut nd torque. NOTE: The propeller torque stted is minimum torque vlue. Description Nm l in. l ft Brvo Three rer propeller nut M eng APRIL 2013 Pge 91