IMPORTANT INFORMATION

Transcription

1 SERVICE MANUAL NUMBER 24 Tle of Contents IMPORTANT INFORMATION Section 1B - Mintennce MAINTENANCE 1 B Tools B-2 Luricnts / Selnts / Adhesives B-2 Mintennce Schedules B-3 Mintennce Intervls B-3 Engine nd Tune-Up Specifictions.... 1B-7 Fluid Cpcities B-11 Sterndrive Engines B-11 Inord nd Ski Engines B-11 Sterndrives B-11 Trnsmission B Hour Brek-In Period B-13 After Brek-in Period B-13 End of First Seson Checkup B-13 Specifictions B-14 Fuel Recommendtions B-14 Vpor locking B-14 Test For Alcohol Content In Gsoline 1B-16 Procedure B-16 Trnsmission Fluid B-16 Power Steering Fluid B-16 Coolnt for Closed Cooling System.... 1B-16 Crnkcse Oil B-17 Overfilled Crnkcse Oil B-17 Checking Engine Oil Level / Filling.. 1B-18 Chnging Oil nd Filter B-18 Chnging Wter Seprting Fuel Filter. 1B-19 MCM (Sterndrive) Models B-19 MIE (Inord nd Ski) Models B-20 Power Steering System B-21 Checking Fluid Level B-21 Engine Wrm B-21 Engine Cold B-21 Filling nd Bleeding B-22 Closed Cooling System B-23 Checking Coolnt Level B-23 Flushing System MCM (Sterndrive). 1B-24 Bot Out of Wter B-24 Bot In Wter B-25 Flushing System MIE (Inord nd Ski) B-26 Trnsmission Fluid B-27 Luriction B-28 Throttle Cle B-28 Shift Cle nd Trnsmission Linkge 1B-28 MCM (Sterndrive) Models B-28 MIE (Inord nd Ski) Models B-29 Engine Coupler/U-Joint Shft Splines 1B-30 Sterndrive Drive Shft Extension Models B-31 Strter Motor B-31 mie (Inord nd Ski) models B-31 Clening Flme Arrestor B-32 Top Mounted Flme Arrestor B-32 Blck Scorpion Flme Arrestor B-33 Serpentine Drive Belt B-34 Component Loction B-34 Inspection B-36 Replcing nd/or Adjusting Tension. 1B-36 Removl B-36 Instlltion nd Adjustment B-36 Ignition Timing B-37 Thunderolt V Models B-37 EFI/MPI Models B-38 Cold Wether or Extended Storge.... 1B-39 Precutions B-39 Power Pckge Lyup B-40 Drining Instructions B-42 Drining Sewter (Rw-Wter) Cooled Models B-42 Drining Sewter Section of Closed Cooled (Coolnt) Models B-48 Drining Sewter Section of Closed Cooled (Coolnt) Models B-50 Drining Sterndrive B-52 Recommissioning B OCTOBER 1999 Pge 1B-1

2 MAINTENANCE SERVICE MANUAL NUMBER 24 Tools Description Prt Numer Timing Light Quicksilver Scn Tool A2 Luricnts / Selnts / Adhesives Description Prt Numer Quicksilver Liquid Neoprene Quicksilver 2-4-C Mrine Luricnt With Teflon Loctite Pipe Selnt With Teflon Quicksilver U-Joint nd Giml Bering Grese A3 Otin Loclly A2 Pge 1B OCTOBER 1999

3 SERVICE MANUAL NUMBER 24 Mintennce Schedules MAINTENANCE Mintennce Intervls Mintennce intervls nd the tsks to e performed, s shown in this current schedule, or s found in previously printed schedules, re generlly sed on n verge oting ppliction nd environment. However, individul operting hits nd personl mintennce preferences cn hve n impct on the suggested intervls. In considertion of these fctors, Mercury MerCruiser hs djusted some mintennce intervls nd corresponding tsks to e performed. In some cses, this my llow for more individul tsks to e performed in single visit to the serving deler, rther thn multiple visits. Therefore, it is very importnt tht the ot owner nd servicing deler discuss the current Mintennce Schedule nd develop pproprite mintennce intervls to coincide with the individul operting hits, environment, nd mintennce requirements. Alwys disconnect ttery cles from ttery BEFORE working round electricl systems components to prevent injury to yourself nd dmge to electricl system should wire e ccidentlly shorted. Gs Sterndrive Routine Mintennce * Check crnkcse oil (intervl cn e extended sed on experience). If operting in slt, rchish or polluted wters, flush cooling system fter ech use. Check drive unit oil level, trim pump oil level nd power steering pump fluid level. Check wter pickups for deris or mrine growth. Check wter striner nd clen. Check coolnt level. Inspect drive unit nodes nd replce if 50 percent eroded. Inspect fuel pump sight tue nd hve pump replced if fuel is present. Check ttery connections nd fluid level. Luricte propeller shft nd the retorque nut (if operting in only freshwter, this mintennce my e extended to every four months). Operting in Sltwter Only: tret engine surfce with corrosion gurd. Clen ir filter every 50 hours of opertion. Ech Dy Strt Ech Dy End Weekly Every Two Months * Only perform mintennce which pplies to your prticulr power pckge Stndrd Models Horizon Models OCTOBER 1999 Pge 1B-3

4 MAINTENANCE SERVICE MANUAL NUMBER 24 Gs Sterndrive(Continued) Scheduled Mintennce * Annully Every 100 hours or Annully Every 200 hours or 3 yers Touch-up pint power pckge nd spry with corrosion gurd. Chnge crnkcse oil nd filter. Chnge drive unit oil nd retorque connection of giml ring to steering shft. Replce fuel filter(s). Check steering system nd remote control for loose, missing or dmged prts. Luricte cles nd linkges. Inspect U-joints, splines nd ellows. Check clmps. Check engine lignment. Luricte U-joints splines. Luricte giml ering nd engine coupler. Check continuity circuit for loose or dmged connections. Test MerCthode unit output on Brvo Models. Retorque engine mounts. Every 300 hours or 3 yers Every 2 yers Check sprk plugs, wires, distriutor cp nd ignition timing. Check nd djust idle speed. Clen flme rrestor nd crnkcse ventiltion hoses. Replce PCV vlve. Check electricl system for loose, dmged or corroded fsteners. Inspect condition nd tension of elts. Check cooling system nd exhust system hose clmps for tightness. Inspect oth systems for dmge or leks. Disssemle nd inspect sewter pump nd replce worn components. Clen sewter section of closed cooling system. Clen, inspect nd test pressure cp. Replce coolnt. * Only perform mintennce which pplies to your prticulr power pckge Stndrd Models Horizon Models Whichever Occurs First Intervl will e reduced if not using extended life coolnt. Luricte engine coupler every 50 hour if operted t idle for prolonged periods of time. Every 5 yers Pge 1B OCTOBER 1999

5 SERVICE MANUAL NUMBER 24 Gs Inord Routine Mintennce * MAINTENANCE Check crnkcse oil (intervl cn e extended sed on experience). If operting in slt, rckish or polluted wters, flush cooling system fter ech use. Check trnsmission fluid. Check wter pickups for deris or mrine growth. Check wter striner nd clen. Check coolnt level. Ech Dy Strt Ech Dy End Weekly Every Two Months * Only perform mintennce which pplies to your prticulr power pckge Stndrd Models Horizon Models OCTOBER 1999 Pge 1B-5

6 MAINTENANCE SERVICE MANUAL NUMBER 24 Gs Inord(Continued) Scheduled Mintennce * Annully Every 100 hours or Annully Every 200 hours or 3 yers Every 300 hours or 3 yers Every 2 yers Every 5 yers Touch-up pint power pckge nd spry with corrosion gurd. Chnge crnkcse oil nd filter. Chnge trnsmission fluid. Replce fuel filter(s). Check steering system nd remote control for loose, missing or dmged prts. Luricte cles nd linkges. Retorque engine mounts. Check sprk plugs, wires, distriutor cp nd ignition timing. Check nd djust idle speed. Clen flme rrestor nd crnkcse ventiltion hoses. Replce PCV vlve. Check electricl system for loose, dmged or corroded fsteners. Inspect condition nd tension of elts. Check cooling system nd exhust system hose clmps for tightness. Inspect oth systems for dmge or leks. Disssemle nd inspect sewter pump nd replce worn components. Clen sewter section of closed cooling system. Clen, inspect nd test pressure cp. Replce coolnt. Check engine-to-propeller shft lignment. * Only perform mintennce which pplies to your prticulr power pckge Stndrd Models Horizon Models Whichever Occurs First Intervl will e reduced if not using extended life coolnt. Per OEM Pge 1B OCTOBER 1999

7 SERVICE MANUAL NUMBER 24 Engine nd Tune-Up Specifictions MAINTENANCE MCM (Sterndrive) Model MCM 5.0L ALPHA BRAVO MCM 5.7L ALPHA BRAVO Propshft Horsepower (SAV1 Rting) Propshft Kilowtts (SAV1 Rting) Numer of Cylinders V-8 Displcement 305 cid (5.0 l) 350 cid (5.7 l) Bore / Stroke - in. (mm) 3.74 x 3.48 (95 x 88.4) 4.0 x 3.48 (101.6 x 88.4) Compression Rtio 9.4:1 Compression Pressure Minimum 100 psi (690 kp) 7 Idle rpm In Neutrl rpm 5 Mximum rpm (t WOT) rpm Oil Pressure (t 2000 rpm) Minimum 30 psi (207 kp) Minimum Oil Pressure (t Idle) Minimum 4 psi (28 kp) Fuel Pressure (1800 rpm) 3-7 psi (21-48 kp) Electricl System 12 V Negtive ( ) Ground Alterntor Rting 55 or 65 mp 8 Minimum Bttery Requirements 375 cc / 475 mc / 90 Ah Firing Order AC - MR43LTS Sprk Plug Type Chmpion - RS12YC NGK - BPR6EFS Sprk Plug Gp.045 in. (1.1 mm) Timing (t idle rpm) 4 10 BTDC Preliminry Idle Mixture 1 1/4 Turns Thermostt 160 F (71 C) 1 Power Rted in Accordnce with NMMA (Ntionl Mrine Mnufcturers Assocition) rting procedures. 2 Power Rted in Accordnce with SAV1 rting procedures. This rting procedure is used to certify tht the engine complies with Stge 1 Bodensee nd Swiss Regultions. Horsepower differences shown result from differences in test rpm, llowle test tolernces, nd/or instlltion of specil kit components. 3 Mesured using n ccurte service tchometer with engine t norml operting temperture. 4 Timing must e set using specil procedure s outlined in the pproprite section of this mnul. Timing cnnot e properly set using the conventionl method. 5 A specil procedure must e followed to djust idle rpm. Consult your Authorized Mercury MerCruiser Deler efore ttempting this procedure. 6 Idle speed on EFI models is not djustle. 7 Minimum recorded compression in ny one cylinder should not e less thn 70 percent of the highest recorded cylinder. 8 Seril Numer Brek 65Amp strts t OL nd up OCTOBER 1999 Pge 1B-7

8 MAINTENANCE SERVICE MANUAL NUMBER 24 Engine nd Tune-Up Specifictions (Continued) MCM (Sterndrive) (continued) Model Propshft Horsepower (SAV1 Rting) Propshft Kilowtts (SAV1 Rting) MCM 5.0L EFI ALPHA BRAVO MCM 5.7L EFI ALPHA BRAVO Numer of Cylinders V-8 MCM 350 MAG MPI ALPHA BRAVO ( ) (205 2 ) Displcement 305 cid (5.0 l) 350 cid (5.7 l) Bore / Stroke - in. (mm) 3.74 x 3.48 (95 x 88.4) 4.0 x 3.48 (101.6 x 88.4) Compression Rtio 9.4:1 Compression Pressure Minimum 100 psi (690 kp) 7 Idle rpm In Neutrl rpm 6 Mximum rpm (t WOT) rpm Oil Pressure (t 2000 rpm) Minimum 30 psi (207 kp) Minimum Oil Pressure (t Idle) Minimum 4 psi (28 kp) Fuel Pressure (1800 rpm) 30 psi (207 kp) Electricl System 12 V Negtive ( ) Ground Alterntor Rting 55 or 65 mp 8 Minimum Bttery Requirements 550 cc / 700 mc / 120 Ah Firing Order Sprk Plug Type Sprk Plug Gp Timing (t idle rpm) 5 AC - MR43LTS Chmpion - RS12YC NGK - BPR6EFS.045 in (1.1 mm) 8 BTDC Thermostt 160 F (71 C) 1 Power Rted in Accordnce with NMMA (Ntionl Mrine Mnufcturers Assocition) rting procedures. 2 Power Rted in Accordnce with SAV1 rting procedures. This rting procedure is used to certify tht the engine complies with Stge 1 Bodensee nd Swiss Regultions. Horsepower differences shown result from differences in test rpm, llowle test tolernces, nd/or instlltion of specil kit components. 3 Mesured using n ccurte service tchometer with engine t norml operting temperture. 4 Timing must e set using specil procedure s outlined in the pproprite section of this mnul. Timing cnnot e properly set using the conventionl method. 5 A specil procedure must e followed to check or djust idle rpm. Consult your Authorized Mercury MerCruiser Deler efore ttempting this procedure. 6 Idle speed on EFI models is not djustle. 7 Minimum recorded compression in ny one cylinder should not e less thn 70 percent of the highest recorded cylinder. 8 Seril Numer Brek 65Amp strts t OL nd up. Pge 1B OCTOBER 1999

9 SERVICE MANUAL NUMBER 24 Engine nd Tune-Up Specifictions (Continued) MAINTENANCE MIE (Inord nd Ski) Propshft Horsepower (SAV1 Rting) Model MIE 5.7L MIE 350 MAG MPI (290 2 ) Propshft Kilowtts (SAV1 Rting) ( ) Numer of Cylinders V-8 Displcement 350 cid (5.7 l) Bore / Stroke - in. (mm) 4.00 x 3.48 in. (101.6 x 88.4) Compression Rtio 9.4:1 Compression Pressure 100 psi (690 kp) 7 Idle rpm In Neutrl rpm rpm 6 Mximum rpm (t WOT) rpm rpm 3 Oil Pressure (t 2000 rpm) Minimum 30 psi (207 kp) Minimum Oil Pressure (t Idle) 4 psi (28 kp) Fuel Pressure (1800 rpm) 3-7 psi (21-48 kp) 30 psi (207 kp) Electricl System 12 V Negtive ( ) Ground Alterntor Rting 55 or 65 mp 8 Minimum Bttery Requirements 375 cc/475 mc/90 Ah 550 cc/700 mc/120 Ah Firing Order AC - MR43LTS Sprk Plug Type Chmpion - RSY9C NGK - BPR6EFS Sprk Plug Gp.045 in. (1.1 mm) Timing (t idle rpm) 3 10 BTDC 4 8 BTDC 4 Preliminry Idle Mixture 1 1/4 Turns Does Not Apply Thermostt 160 F (71 C) 1 Power Rted in Accordnce with NMMA (Ntionl Mrine Mnufcturers Assocition) rting procedures. 2 Power Rted in Accordnce with SAV1 rting procedures. This rting procedure is used to certify tht the engine complies with Stge 1 Bodensee nd Swiss Regultions. Horsepower differences shown result from differences in test rpm, llowle test tolernces, nd/or instlltion of specil kit components. 3 Mesured using n ccurte service tchometer with engine t norml operting temperture. 4 Timing must e set using specil procedure s outlined in the pproprite section of this mnul. Timing cnnot e properly set using the conventionl method. 5 A specil procedure must e followed to djust idle rpm. Consult your Authorized Mercury MerCruiser Deler efore ttempting this procedure. 6 Idle speed on EFI models is not djustle. 7 Minimum recorded compression in ny one cylinder should not e less thn 70 percent of the highest recorded cylinder. 8 Seril Numer Brek 65Amp strts t OL nd up OCTOBER 1999 Pge 1B-9

10 MAINTENANCE SERVICE MANUAL NUMBER 24 Engine nd Tune-Up Specifictions (Continued) SKI (Inord) Model 5.7L SKI 350 MAG MPI SKI BLACK SCORPION SKI Propshft HorsePower (SAV1 Rting) Propshft Kilowtts (SAV1 Rting) Numer of Cylinders V-8 Displcement 350 cid (5.7 l) Bore / Stroke - in. (mm) 4.00 x 3.48 in. (101.6 x 88.4 mm) Compression Rtio 9.4:1 Compression Pressure Minimum100 psi (690 kp) 7 Idle rpm In Neutrl rpm rpm 6 Mximum rpm (t WOT) Oil Pressure (t 2000 rpm) Minimum 30 psi (207 kp) Minimum Oil Pressure (t Idle) 4 psi (28 kp) Fuel Pressure (1800 rpm) 3-7 psi (21-48 kp) 30 psi (207 kp) Electricl System 12 V Negtive ( ) Ground Minimum Bttery Requirements 375 cc / 475 mc / 90 Ah 550 cc / 700 mc / 120 Ah Firing Order AC - MR43LTS Sprk Plug Type NGK - BPR6EFS Chmpion - RS12YC Sprk Plug Gp.045 in. (1.1 mm) Timing (t idle rpm) 10 BTDC 4 8 BTDC 4 Preliminry Idle Mixture 1 1/4 Turns Does Not Apply Thermostt 160 F (71 C) 1 Power Rted in Accordnce with NMMA (Ntionl Mrine Mnufcturers Assocition) rting procedures. 2 Power Rted in Accordnce with SAV1 rting procedures. This rting procedure is used to certify tht the engine complies with Stge 1 Bodensee nd Swiss Regultions. Horsepower differences shown result from differences in test rpm, llowle test tolernces, nd/or instlltion of specil kit components. 3 Mesured using n ccurte service tchometer with engine t norml operting temperture. 4 Timing must e set using specil procedure s outlined in the pproprite section of this mnul. Timing cnnot e properly set using the conventionl method. 5 A specil procedure must e followed to djust idle rpm. Consult your Authorized Mercury MerCruiser Deler efore ttempting this procedure. 6 Idle speed on EFI models is not djustle. 7 Minimum recorded compression in ny one cylinder should not e less thn 70 percent of the highest recorded cylinder. 8 Seril Numer Brek 65Amp strts t OL nd up. Pge 1B OCTOBER 1999

11 SERVICE MANUAL NUMBER 24 Fluid Cpcities MAINTENANCE Sterndrive Engines Inord nd Ski Engines NOTICE Unit Of Mesurement: U.S. Qurts (Liters) All cpcities re pproximte fluid mesures. Model MCM 305 cid / 5.0L nd 350 cid / 5.7L Crnkcse Oil (With Filter) (5.25) Sewter Cooling System 2 15 (14.1) Closed Cooling System 20 (19) 1 Alwys use dipstick to determine exct quntity of oil or fluid required. 2 Sewter Cooling System cpcity informtion is for winteriztion use only. IMPORTANT: It my e necessry to djust oil levels depending on instlltion ngle nd cooling systems (het exchnger nd fluid lines). Model 350 cid / 5.7L Crnkcse Oil (With Filter) (5.25) Sewter Cooling System 2 15 (14.1) Closed Cooling System 20 (19) 1 Alwys use dipstick to determine exct quntity of oil or fluid required. Sterndrives 2 Sewter Cooling System cpcity informtion is for winteriztion use only. NOTICE Unit Of Mesurement: U.S. Fluid Ounces (Milliliters) All cpcities re pproximte fluid mesures. Model ALPHA ONE Drive Unit Oil Cpcity (With Ger Lue Monitor) 64 (1892) Model Drive Unit Oil Cpcity (With Ger Lue Monitor) BRAVO ONE BRAVO TWO BRAVO THREE BLACK- HAWK 88 (2603) 104 (3076) 96 (2839) 80 (2365) OCTOBER 1999 Pge 1B-11

12 MAINTENANCE SERVICE MANUAL NUMBER 24 Fluid Cpcities (Continued) Trnsmission NOTICE Unit Of Mesurement: U.S. Qurts (Liters) All cpcities re pproximte fluid mesures. NOTE: Alwys use dipstick to determine exct quntity of fluid required. Mke nd Model Cpcity Fluid Type Moil 424 or Velvet Drive Dexron III Automtic Trnsmission Fluid 71C In-Line 1-1/2 (1.33) 1 Do Not Mix! Velvet Drive Moil 424 or 72 Series 3 (2.75) 1 Dexron III Automtic Trnsmission Fluid V-Drive Do Not Mix! 5000A 2-1/2 (2.4) 5000V 3 (2.75) 1 Dexron III Automtic Trnsmission Fluid Wlter V-Drive Model RV-36 3/4 (0.5) 1 SAE 30 Hevy Duty Motor Exxon Sprtn, EP-68 Ger Oil, APG-80 Ger Oil ZF (Hurth) 630V 4-1/4 (4.0) 630A 3-1/4 (3.0) Dexron III Automtic Trnsmission Fluid 800A 5-3/4 (5.5) 1 Fluid should e circulted nd then rechecked. Add dditionl fluid s necessry. Pge 1B OCTOBER 1999

13 SERVICE MANUAL NUMBER Hour Brek-In Period MAINTENANCE 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 first 10 hours. Shift into ger s soon s possile fter strting nd dvnce throttle ove 1500 rpm if conditions permit sfe opertion. After Brek-in Period Do not operte t one speed consistently for extended periods. Do not exceed 3/4 throttle during first 10 hours. During next 10 hours, occsionl opertion t full throttle is permissile (5 minutes t time mximum). Avoid full throttle ccelertion from IDLE speed. Do not operte t full throttle until engine reches norml operting temperture. To help extend the life of your Mercury MerCruiser power pckge, the following recommendtions should e considered; Use propeller tht llows the engine to operte t or ner the top of the mximum rpm rnge (refer to Specifictions section) when t full throttle with norml ot lod. Opertion t 3/4 throttle setting or lower is recommended. Refrin from prolonged opertion t mximum (full throttle) rpm. End of First Seson Checkup At the end of the first seson of opertion, n Authorized Mercury MerCruiser Deler should e contcted to discuss nd/or perform vrious scheduled mintennce items. If you re in n re where the product is operted continuously (yer-round opertion), you should contct your deler t the end of the first 100 hours of opertion, or once yerly, whichever occurs first OCTOBER 1999 Pge 1B-13

14 MAINTENANCE SERVICE MANUAL NUMBER 24 CA261 Specifictions Fuel Recommendtions FUEL RATINGS CA291 IMPORTANT: Use of improper gsoline cn dmge your engine seriously. Engine dmge resulting from use of improper gsoline is considered misuse of engine, nd dmge cused therey will not e covered under the limited wrrnty. Mercury MerCruiser engines will operte stisfctorily when using mjor rnd of unleded gsoline s follows: USA nd Cnd - hving posted pump Octne Rting of 87 (R+M)/2 minimum. Premium gsoline [92 (R+M)/2 Octne] is lso cceptle. DO NOT use leded gsoline. Outside USA nd Cnd - hving posted pump Octne Rting of 90 RON minimum. Premium gsoline (98 RON) is lso cceptle. If unleded gsoline is not ville, use mjor rnd of leded gsoline. USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY) VAPOR LOCKING This type of gsoline is required in certin res of the USA. The two types of oxygentes used in these fuels is Alcohol (Ethnol) or Ether (MTBE or ETBE). If Ethnol is the oxygente tht is used in the gsoline in your re, refer to Gsolines Contining Alcohol. These Reformulted Gsolines re cceptle for use in your Mercury MerCruiser engine. Fuels contining lcohol nd winter grde fuels will ggrvte vpor lock prolems. A vpor lock condition cn e identified y the following prolems: Engine strts nd, upon dvncing throttle, shuts off nd will not restrt. If engine does restrt, it shuts off when dvncing throttle. Engine is difficult to restrt fter operting the ot nd then leving the engine off for 1 to 3 hours. Other fctors my comine to increse vpor locking. These fctors include ut re not limited to: ir temperture fuel tnk loction fuel supply system engine coolnt temperture temperture nd vcuum of fuel to engine engine comprtment ir temperture nd ventiltion Other conditions should e ruled out efore treting the prolem s vpor locking. Pge 1B OCTOBER 1999

15 SERVICE MANUAL NUMBER 24 MAINTENANCE CA618 GASOLINES CONTAINING ALCOHOL If the gsoline in your re contins either methnol (methyl lcohol) or ethnol (ethyl lcohol), you should e wre of certin dverse effects tht cn occur. These dverse effects re more severe with methnol. Incresing the percentge of lcohol in the fuel cn lso worsen these dverse effects. Some of these dverse effects re cused ecuse the lcohol in the gsoline cn sor moisture from the ir, resulting in seprtion of the wter/lcohol from the gsoline in the fuel tnk. The fuel system components on your Mercury MerCruiser engine will withstnd up to 10% lcohol content in the gsoline. We do not know wht percentge your ot s fuel system will withstnd. Contct your ot mnufcturer for specific recommendtions on the ots fuel system components (fuel tnks, fuel lines, nd fittings). Be wre tht gsolines contining lcohol my cuse incresed: Corrosion of metl prts. Deteriortion of ruer or plstic prts. Fuel permetion through ruer fuel lines. Strting nd operting difficulties. WARNING FIRE AND EXPLOSION HAZARD: Fuel lekge from ny prt of fuel system cn e fire nd explosion hzrd which cn cuse serious odily injury or deth. Creful periodic inspection of entire fuel system is mndtory, prticulrly fter storge. All fuel components including fuel tnks, whether plstic metl or fierglss, fuel lines, fittings, fuel filters nd cruretors/fuel injection components should e inspected for lekge, softening, hrdening, swelling or corrosion. Any sign of lekge or deteriortion requires replcement efore further engine opertion. Becuse of possile dverse effects of lcohol in gsoline, it is recommended tht only lcohol-free gsoline e used where possile. If only fuel contining lcohol is ville, or if the presence of lcohol is unknown, incresed inspection frequency for leks nd normlities is required. IMPORTANT: When operting Mercury MerCruiser engine on gsoline contining lcohol, storge of gsoline in the fuel tnk for long periods should e voided. Long periods of storge, common to ots, crete unique prolems. In crs lcohol-lend fuels normlly re consumed efore they cn sor enough moisture to cuse troule, ut ots often sit idle long enough for phse seprtion to tke plce. In ddition, internl corrosion my tke plce during storge if lcohol hs wshed protective oil films from internl components OCTOBER 1999 Pge 1B-15

16 MAINTENANCE SERVICE MANUAL NUMBER 24 Test For Alcohol Content In Gsoline PROCEDURE Trnsmission Fluid The following is n cceptle nd widely used field procedure for the detection of lcohol in gsoline. Use ny smll trnsprent ottle or tue tht cn e cpped nd is, or cn e, provided with grdutions or mrk t out 1/3 full. A pencil mrk on piece of dhesive tpe my e used. 1. Fill the continer with wter to the mrk. 2. Add fuel lmost to fill the continer, leving some ir spce, then cp the continer. The proportions of fuel to wter re not criticl, ut there should e 2 to 3 times s much fuel s wter. 3. Shke continer vigorously nd llow it to sit upright for 3 to 5 minutes. If the volume of wter ppers to hve incresed, lcohol is present. If you re not sure, there is no need for concern. If the dividing line etween wter nd fuel ecomes cloudy, use the middle of the cloudy nd. Velvet Drive - Dexron IIl Wlter V-Drive - SAE 30 Hevy Duty Motor, Exxon Sprtn EP-68 Ger Oil or APG-80 Ger Oil. Hurth - Dexron IIl Power Steering Fluid Use Quicksilver Power Trim nd Steering Fluid, or utomtic trnsmission Fluid (ATF) Dexron IIl. Coolnt for Closed Cooling System CAUTION Alcohol or Methnol se ntifreeze or plin wter, re not recommended for use in fresh wter section of cooling system t ny time. We recommend tht the coolnt section of closed cooling system e filled with Extended Life Ethylene Glycol 5/100 Antifreeze/Coolnt mixed 50/50 with purified wter. In res where the possiility of freezing does not exist, it is permissile to use solution of rust inhiitor nd wter (mixed to mnufcturer s recommendtions). If ny non-comptile coolnt is dded to this coolnt, coolnt must e chnged every 2 yers or 400 hours, whichever occurs first. All coolnts other thn Extended Life 5/100 Ethylene Glycol Antifreeze/Coolnt must e chnged every 2 yers or 400 hours, whichever occurs first. Mercury MerCruiser V-8 engines cn use ny type of permnent ntifreeze or ny rnd ntifreeze solution tht meets GM specifiction 1825M. Pge 1B OCTOBER 1999

17 SERVICE MANUAL NUMBER 24 CA693 Crnkcse Oil MAINTENANCE To help otin optimum engine performnce nd to provide mximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Mrine Engine Oil. This oil is specil lend of 25-weight nd 40-weight oils for mrine engines. If not ville, good grde, stright weight, detergent utomotive oil of correct viscosity, with n API clssifiction of SH,CF/CF-2, my e used. In those res where Quicksilver 4-Cycle 25W-40 Mrine Engine Oil or recommended stright weight oil re not ville, multiviscosity 20W-40 (SH, CF/CF-2) or, s second ut less preferle choice, 20W-50, with API service rtings of SH, CF/CF-2 my e used. IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other thn Quicksilver 25W-40 or good qulity 20W-40 or 20W-50), synthetic oils, low qulity oils or oils tht contin solid dditives re specificlly not recommended. The chrt elow is guide to crnkcse oil selection. The oil filter should lwys e chnged with oil. Quicksilver 4-Cycle Mrine Engine Oil SAE 40W SAE 30W SAE 20W 32 F 0 C 50 F 10 C AIR TEMPERATURE Overfilled Crnkcse Oil Overfilled crnkcses (oil level eing too high ) cn cuse fluctution or drop in oil pressure nd rocker rm cltter on Mercury MerCruiser engines. The over-full condition results in the engine crnkshft splshing nd gitting the oil, cusing it to fom (ecome erted). The erted oil cuses the hydrulic vlve lifters to leed down. This, in turn, results in rocker rm cltter nd loss of engine performnce, due to the vlves not opening properly. Cre must e tken when checking engine oil level. Oil level must e mintined etween the ADD mrk nd the FULL mrk on the dipstick. To ensure tht you re not getting flse reding, mke sure the following steps re done efore checking the oil level. Bot t rest in the wter, or If ot is on triler, rise or lower ow until the ot is setting t the pproximte ngle tht it would e if setting t rest in the wter. Allow sufficient time for oil to drin into the crnkcse if engine hs just een run or oil hs just een dded OCTOBER 1999 Pge 1B-17

18 MAINTENANCE SERVICE MANUAL NUMBER 24 Checking Engine Oil Level / Filling IMPORTANT: ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN MAINTENANCE SCHEDULE CHART. It is norml for n engine to use certin mount of oil in the process of luriction nd cooling of the engine. The mount of oil consumption is gretly dependent upon engine speed, with consumption eing highest t wide-open-throttle nd decresing sustntilly s engine speed is reduced. 1. Stop engine nd llow ot to come to rest. 2. Allow oil to drin ck into oil pn - pproximtely 5 minutes. 3. Remove dipstick. 4. Wipe clen nd reinstll. Push dipstick ll the wy into dipstick tue. 5. Remove dipstick nd note the oil level. 6. Oil level must e etween the FULL or OP RANGE nd ADD mrks. 7. If oil level is elow ADD mrk, proceed to Steps 8. nd Remove oil filler cp from vlve rocker rm cover. 9. Add required mount of oil to ring level up to, ut not over, the FULL mrk on dipstick. Chnging Oil nd Filter 1. Strt engine nd run until it reches norml operting tempertures. IMPORTANT: Chnge oil when engine is wrm from opertion, s it flows more freely, crrying wy more impurities. 2. Stop engine. 3. Remove drin plug from oil pn or from oil drin hose. NOTE: If drin plug is not ccessile ecuse of ot construction, oil my e removed through dipstick tue, using Quicksilver Crnkcse Oil Pump. (See Quicksilver Accessory Guide.) 4. After oil hs drined completely, reinstll drin plug (if removed) nd tighten securely. 5. Remove nd discrd oil filter nd its seling ring. 6. Cot seling ring on new filter with engine oil, nd instll. Tighten filter securely (following filter mnufcturer s instructions). Do not overtighten. 7. Fill crnkcse with oil. See Specifictions for type of oil nd quntity. 8. Strt engine nd check for leks. Pge 1B OCTOBER 1999

19 SERVICE MANUAL NUMBER 24 Chnging Wter Seprting Fuel Filter MAINTENANCE WARNING Be creful when chnging wter seprting fuel filter. Gsoline is extremely flmmle nd highly explosive under certin conditions. Be sure ignition key is OFF. Do not smoke or llow sprk or open flme in re when chnging fuel filter. Wipe up ny spilled fuel immeditely. WARNING Mke sure no fuel leks exist efore closing engine htch. CAUTION The electric fuel pump nd fctory instlled wter seprting fuel filter hve een crefully designed to function properly together. Do not instll dditionl fuel filters nd/or wter seprting fuel filters etween fuel tnk nd engine. The instlltion of dditionl filters my cuse: Fuel Vpor Locking Difficult Wrm-Strting Piston Detontion Due to Len Fuel Mixture Poor Driveility MCM (Sterndrive) Models 1. Unsnp ltch nd slide top nd ottom cover pieces from round the wter seprting fuel filter nd rcket Fuel Filter Cover NOTE: Top nd ottom cover pieces re formed with groove on ech side tht slides round the rckets outer edges OCTOBER 1999 Pge 1B-19

20 MAINTENANCE SERVICE MANUAL NUMBER Remove wter seprting fuel filter nd seling ring from mounting rcket nd discrd Fuel Filter -Seling Ring 3. Cot seling ring on new filter with motor oil. 4. Thred filter onto rcket nd tighten securely y hnd. Do not use filter wrench. 5. Strt nd run engine. 6. Check filter connection for gsoline leks. If leks exist, recheck filter instlltion. 7. Instll cover pieces round fuel filter. Be certin top prt of cover ltches to lower prt. MIE (Inord nd Ski) Models 1. Remove wter seprting fuel filter nd seling ring from mounting rcket nd discrd. 2. Cot seling ring on new filter with motor oil. 3. Thred filter onto rcket nd tighten securely y hnd. Do not use filter wrench. 4. Strt nd run engine. 5. Check filter connection for gsoline leks. If leks exist, recheck filter instlltion. Pge 1B OCTOBER 1999

21 SERVICE MANUAL NUMBER 24 Power Steering System MAINTENANCE Checking Fluid Level ENGINE WARM 1. Stop engine. Position drive unit so tht it is stright ck. 2. Remove fill cp / dipstick from power steering pump nd note fluid level. c-fill Cp / Dipstick d- Power Steering Pump 3. Level should e etween the FULL HOT mrk nd ADD mrk on dipstick Engine Cold Proper Fluid Level with Engine Wrm 4. If level is elow ADD mrk, ut fluid is still visile in pump reservoir, dd required mount of Quicksilver Power Trim nd Steering Fluid or utomtic trnsmission fluid (ATF) Dexron III through fill cp opening, to ring level up to FULL HOT mrk on dipstick. DO NOT OVERFILL. 5. If fluid is not visile in reservoir, lek exists in the power steering system. Find cuse nd correct. 1. With engine stopped, position drive unit so tht it is stright ck. 2. Remove fill cp / dipstick from power steering pump nd note fluid level. 3. Level should e etween FULL COLD mrk nd ottom of dipstick OCTOBER 1999 Pge 1B Proper Fluid Level with Engine Cold 4. If level is elow ottom of dipstick, ut fluid is still visile in pump reservoir, dd required mount of Quicksilver Power Trim nd Steering Fluid or utomtic Dexron III trnsmission fluid (ATF), through fill cp opening, to ring level up to FULL COLD mrk on dipstick. DO NOT OVERFILL. If fluid is not visile in reservoir, lek exists in the power steering system. Find cuse nd correct.

22 MAINTENANCE SERVICE MANUAL NUMBER 24 Filling nd Bleeding IMPORTANT: Power steering system must e filled exctly s explined in the following to e sure tht ll ir is led from the system. All ir must e removed, or fluid in pump my fom during opertion nd e dischrged from pump reservoir. Fomy fluid lso my cuse power steering system to ecome spongy, which my result in poor ot control. 1. With engine stopped, position drive unit so tht it is stright ck. 2. Remove fill cp / dipstick from power steering pump. 3. Add Quicksilver Power Trim nd Steering Fluid or Dexron III utomtic trnsmission fluid (ATF), s required, to ring level up to FULL COLD mrk on dipstick. IMPORTANT: Use only Quicksilver Power Trim nd Steering Fluid or Dexron IIl utomtic trnsmission fluid (ATF), in power steering system. 4. Turn steering wheel ck nd forth to end of trvel in ech direction severl times. 5. Recheck fluid level nd dd fluid, if necessry. 6. Instll vented fill cp. Tighten securely. CAUTION DO NOT operte engine without wter eing supplied to sewter pickup pump, or pump impeller my e dmged nd susequent overheting dmge to engine my result. 7. Strt engine nd run t fst idle ( rpm) until engine reches norml operting temperture. During this time, turn steering wheel ck nd forth to end of trvel in ech direction severl times. 8. Position drive unit so tht it is stright ck nd stop engine. 9. Remove fill cp from pump. 10. Allow ny fom in pump reservoir to disperse. 11. Check fluid level nd dd fluid, s required, to ring level up to FULL HOT mrk on dipstick. DO NOT OVERFILL. 12. Reinstll fill cp. Tighten securely. IMPORTANT: Drive unit must e positioned stright ck nd power steering fluid must e hot to ccurtely check fluid level. 13. If fluid is still fomy (in Step 5), repet Steps 7. through 12. until fluid does not fom nd level remins constnt. Pge 1B OCTOBER 1999

23 SERVICE MANUAL NUMBER 24 Closed Cooling System MAINTENANCE Checking Coolnt Level CAUTION Allow engine to cool down efore removing pressure cp. Sudden loss of pressure could cuse hot coolnt to oil nd dischrge violently. After engine hs cooled, turn cp 1/4 turn to llow ny pressure to escpe slowly, then push down nd turn cp ll the wy off. 1. Coolnt level in het exchnger should e full (to ottom of filler neck). IMPORTANT: When reinstlling pressure cp, e sure to tighten it until it contcts on filler neck. 2. Coolnt level should e etween the ADD nd FULL mrks on coolnt recovery reservoir with the engine t norml operting temperture. -Coolnt Recovery Reservoir OCTOBER 1999 Pge 1B-23

24 MAINTENANCE SERVICE MANUAL NUMBER 24 Flushing System MCM (Sterndrive) BOAT OUT OF WATER If engine is operted in slty, polluted or minerl-lden wter, flush sewter cooling system (preferly fter ech use) to reduce corrosion nd prevent the ccumultion of deposits in the system. Thoroughly flush the sewter cooling system prior to storge. NOTE: For dditionl protection ginst freezing nd rust to the exhust mnifolds nd other components, mixture of ntifreeze nd wter cn e run through the engine during Power Pckge Lyup. 1. Instll flushing ttchment over wter pickup holes in ger housing s shown. 2. Attch wter hose etween the flushing ttchment nd wter tp. -Flushing Attchment - Hose WARNING When flushing, e certin the re round propeller is cler, nd no one is stnding nery. To void possile injury, remove propeller. CAUTION Do not run engine ove 1500 rpm when flushing. Suction creted y sewter pickup pump my collpse flushing hose, cusing engine to overhet. CAUTION Wtch temperture guge on dsh to ensure tht engine does not overhet Prtilly open wter tp (pproximtely 1/2 mximum cpcity). DO NOT use full wter pressure. 4. Plce remote control in neutrl, idle speed position, nd strt engine. 5. Operte engine t idle speed in neutrl for 10 minutes, or until dischrge wter is cler, then stop engine. 6. Shut off wter tp. Remove wter hose nd flushing ttchment. Pge 1B OCTOBER 1999

25 SERVICE MANUAL NUMBER 24 BOAT IN WATER MAINTENANCE 1. Rise drive unit to full UP position. 2. Instll flushing ttchment over wter pickup holes in ger housing s shown. 3. Attch wter hose etween the flushing ttchment nd wter tp. -Flushing Attchment - Hose 4. Lower drive unit to full IN position CAUTION Do not run engine ove 1500 rpm when flushing. Suction creted y sewter pickup pump my collpse flushing hose, cusing engine to overhet. CAUTION Wtch temperture guge on dsh to ensure tht engine does not overhet. 5. Prtilly open wter tp (pproximtely 1/2 mximum cpcity). DO NOT use full wter pressure. 6. Plce remote control in neutrl, idle speed position, nd strt engine. 7. Operte engine t idle speed in neutrl for 10 minutes, then stop engine. 8. Shut off wter tp. 9. Rise drive unit to full UP position. 10. Remove wter hose nd flushing ttchment OCTOBER 1999 Pge 1B-25

26 MAINTENANCE SERVICE MANUAL NUMBER 24 Flushing System MIE (Inord nd Ski) CAUTION If ot is in the wter, secock, if so equipped, must remin closed until engine is to e re-strted, to prevent wter from flowing ck into cooling system nd/or ot. If ot is not fitted with secock, wter inlet hose must e left disconnected nd plugged (to prevent wter from flowing ck into cooling system nd/or ot). As precutionry mesure, ttch tg to the ignition switch or steering wheel of the ot with the wrning: Open secock or reconnect wter inlet hose efore strting engine. IMPORTANT: If secock is to e instlled for this purpose, vlve used must hve n internl cross-sectionl re equl to or greter thn wter inlet hose to prevent restricting wter flow during norml opertion. A 1-1/4 in. (32 mm), or lrger, rss ll vlve or gte vlve is recommended. 1. If ot is in wter, close secock, if so equipped, or disconnect nd plug sewter inlet hose to prevent sewter from entering ot. 2. Remove inlet hose from sewter pickup pump. 3. Using n dptor, connect wter hose from wter tp to sewter pump inlet. 4. Prtilly open wter tp (pproximtely 1/3 mximum). Do not use full wter pressure. 5. Plce the remote control lever in neutrl position nd strt engine. WARNING When flushing, e certin the re round propeller is cler, nd no one is stnding nery. To void possile injury, remove propeller. CAUTION Do not run engine ove 1500 rpm when flushing. Suction creted y sewter pickup pump my collpse flushing hose, cusing engine to overhet. CAUTION Wtch temperture guge on dsh to ensure tht engine does not overhet. 6. Operte engine t idle speed in neutrl for 10 minutes, or until dischrge wter is cler. Stop engine. 7. Shut off wter tp. Remove wter hose nd dptor from pump inlet nd reconnect wter inlet hose. Be sure to tighten hose clmp securely. IMPORTANT: If ot is in the wter, do not open wter inlet vlve until engine is to e restrted to prevent contminted wter from flowing ck into engine. If ot is not fitted with vlve, leve wter inlet hose disconnected nd plugged. Pge 1B OCTOBER 1999

27 SERVICE MANUAL NUMBER 24 Trnsmission Fluid MAINTENANCE NOTE: Due to the vrious instlltion ngles nd oil cooler set-ups, it my e necessry to djust oil level. WARNING Do not remove dipstick with engine running. Hot oil cn cuse urns. CAUTION Clen round the re of the dipstick efore removing. Smll prticles of dirt cn cuse dmge to internl components nd cuse vlves to stick. IMPORTANT: DO NOT llow fluid level to drop elow the ottom line TRANSMISSION WARM TRANSMISSION COLD The trnsmission should e t operting temperture (190 mximum) to get n ccurte oil level reding. Oil will expnd when heted. Oil will drin ck from the cooler. Expnsion nd drin-ck cn significntly ffect oil level. 1. When the trnsmission is t operting temperture, plce selector lever in neutrl. 2. Shut off engine. 3. Crefully remove dipstick nd wipe clen. 4. Immeditely insert clen dipstick nd red oil level. NOTE: Oil level must e checked immeditely fter engine shut-down to prevent n incorrect reding. Oil drins ck into the trnsmission from the cooler nd cooler lines. 5. Add or remove oil s necessry until the oil is t the required mrk. NOTE: For ese of checking the oil prior to engine strt-up, cold oil level mrk cn e mde. To find the cold oil level mrk, the oil level must first e set ccording to the wrm oil level checking procedure. 1. Let the ot sit overnight. Insert clen dipstick nd red level. 2. Put mrk on the dipstick t the cold oil level. NOTE: You cn use the new mrk to check the oil level when cold. If oil level djustment is needed, dd oil to the new mrk. This procedure cn e performed y the uilder, deler or owner to ese fluid checking procedure OCTOBER 1999 Pge 1B-27

28 MAINTENANCE SERVICE MANUAL NUMBER 24 Luriction Throttle Cle 1. Luricte pivot points nd guide contct surfces with SAE 30W motor oil Brrel Crureted Models EFI Models -Pivot Points - Guide Contct Surfce Shift Cle nd Trnsmission Linkge MCM (STERNDRIVE) MODELS Luricte pivot points nd guide contct surfces with SAE 30W motor oil Typicl Shift Cle -Pivot Points - Guide Contct Surfce Pge 1B OCTOBER 1999

29 SERVICE MANUAL NUMBER 24 MIE (INBOARD AND SKI) MODELS MAINTENANCE 1. Luricte pivot points nd guide contct surfces with SAE 30W motor oil Typicl Shift Cle -Pivot Points - Guide Contct Surfce 2. Luricte detent ll nd holes in lever with SAE 30W motor oil Typicl In-Line Trnsmission -Poppet Bll Loctions OCTOBER 1999 Pge 1B-29

30 MAINTENANCE SERVICE MANUAL NUMBER 24 Engine Coupler/U-Joint Shft Splines NOTE: Engine coupler nd shft splines re gresed with Quicksilver Engine Coupler Spline Grese, A4; universl joints re gresed with Quicksilver 2-4-C Mrine Luricnt. NOTE: Refer to Mercury MerCruiser Sterndrive Service Mnul for sterndrive unit removl nd instlltion, if necessry. IMPORTANT: Sterndrive Unit does not hve to e removed to grese coupler. 1. Luricte engine coupler splines through grese fitting on coupler y pplying pproximtely 8-10 pumps of grese from typicl hnd-operted grese gun Alph Drive Coupler Brvo Drive Coupler -Grese Fitting - Quicksilver Engine Coupler Spline Grese Typicl Brvo Drive -Quicksilver Engine Coupler Spline Grese Pge 1B OCTOBER 1999

31 SERVICE MANUAL NUMBER 24 Sterndrive Drive Shft Extension Models MAINTENANCE Strter Motor Trnsom End -Grese Fitting Engine End MIE (INBOARD AND SKI) MODELS WARNING When performing the following procedure, e sure to oserve the following: Be sure tht engine comprtment is well ventilted nd tht no gsoline vpors re present to void the possiility of fire. Be sure to ground coil high-tension wire to lock. Filure to ground coil wire my cuse dmge to ignition coil in ddition to eing sfety hzrd. Sty cler of ll moving prts. 1. Remove ignition coil high-tension wire from distriutor cp tower nd ground it to engine lock with jumper wire. While crnking engine with strter motor, luricte strter motor front ushing through oil cover with motor oil or its equivlent. Reinstll coil high-tension wire. 2. Remove plstic plug from flywheel housing. Luricte strter motor shft with motor oil through hole in flywheel housing. Reinstll plstic plug. -Grese Fitting OCTOBER 1999 Pge 1B-31

32 MAINTENANCE SERVICE MANUAL NUMBER 24 Clening Flme Arrestor WARNING Avoid gsoline fire or explosion. Gsoline is extremely flmmle nd highly explosive under certin conditions. Be creful when clening flme rrestor nd crnkcse ventiltion hoses. Be sure tht ignition is OFF. DO NOT smoke or llow sources of sprk or open flme in re when clening flme rrestor nd crnkcse ventiltion hoses. WARNING Avoid gsoline fire or explosion. Gsoline is extremely flmmle nd highly explosive under certin conditions. NEVER use gsoline s clening solvent. Top Mounted Flme Arrestor 1. Remove crnkcse ventiltion hose from fitting on side of flme rrestor housing. 2. Remove flme rrestor Erly Brcket Models Lter Throttle Body Stud Models Erly Clmp Models Horizon Models -Flme Arrestor 3. Clen flme rrestor in solvent. Blow dry with compressed ir. 4. Clen crnkcse ventiltion hose in solvent. Blow dry with compressed ir. 5. Inspect crnkcse ventiltion hose for crcks or deteriortion nd replce if necessry. 6. Reinstll flme rrestor nd nd crnkcse ventiltion hose. 7. Reinstll flme rrestor screws nd tighten securely. Pge 1B OCTOBER 1999

33 SERVICE MANUAL NUMBER 24 Blck Scorpion Flme Arrestor 1. Remove clmp or nut, s pplicle. 2. Remove crnkcse ventiltion hose. 3. Remove flme rrestor. MAINTENANCE c Erlier Style Flme Arrestor -Flme Arrestor -Clmp c -Vent Hose c Lter Style Flme Arrestor -Flme Arrestor -Nut c -Vent Hose 4. Clen flme rrestor in solvent. Blow dry with compressed ir. 5. Clen crnkcse ventiltion hoses in solvent. Blow dry with compressed ir. 6. Inspect crnkcse ventiltion hoses for crcks or deteriortion, nd replce if necessry. 7. Instll flme rrestor nd relted components. 8. Tighten clmp or nut securely OCTOBER 1999 Pge 1B-33

34 MAINTENANCE SERVICE MANUAL NUMBER 24 Serpentine Drive Belt Component Loction WARNING Avoid possile serious injury. Mke sure engine is shut off nd ignition key is removed efore inspecting elt. IMPORTANT: MIE ENGINES ONLY: The rckets nd wshers on the 3 idler pulleys must e in certin order or the elt will come off of the serpentine elt. All pulleys re referenced s though you were stnding in front of the engine looking t the elt. Upper Right Idler Pulley Brcket Stud: Stud is threded into the cylinder hed. From the cylinder hed is nut, flt wsher, the lifting eye rcket, the oil cooler rcket, the idler pulley rcket nd then nut. Upper Left Idler Pulley Brcket Bolt: From the cylinder hed is n idler pulley rcket, flt wsher, the het exchnger rcket, flt wsher nd the hed of the olt. Lower Idler Pulley Brcket Bolt: From the cylinder lock is n idler pulley rcket nd then the hed of the olt. Pge 1B OCTOBER 1999

35 SERVICE MANUAL NUMBER 24 MAINTENANCE NOTE: Some models will hve components rrnged in different order. All configurtions re not shown. Checking, replcing nd djustment procedures re the sme. d e c Typicl Inord Model -Idler Pulley -Sewter Pump Pulley c -Crnkshft Pulley d-circulting Pump Pulley e -Alterntor Pulley e d c Typicl Sterndrive Model -Idler Pulley -Sewter Pump Pulley c -Crnkshft Pulley d-circulting Pump Pulley e -Alterntor Pulley OCTOBER 1999 Pge 1B-35

36 MAINTENANCE SERVICE MANUAL NUMBER 24 Inspection 1. Inspect drive elt for the following: Excessive wer Crcks NOTE: Minor, trnsverse crcks (cross the elt width) my e cceptle. Longitudinl crcks (in direction of elt length) tht join trnsverse crcks re NOT cceptle. Frying Glzed surfces Frying -Crcks Replcing nd/or Adjusting Tension REMOVAL 1. Loosen 5/8 in. locking nut on djustment stud. 2. Turn djustment stud nd loosen elt. 3. Remove drive elt. INSTALLATION AND ADJUSTMENT 4. Instll drive elt on pulleys. 5. Adjust tension y loosening 5/8 in. locking nut on djustment stud. Leve wrench on djustment stud. NOTE: Belt deflection is to e mesured on the elt t the loction tht hs the longest distnce etween two (2) pulleys. Proper tension is 1/4 in. (6 mm) deflection with moderte thum pressure. 6. Use 5/16 in. socket nd tighten djusting stud until the correct deflection of the elt is otined t loction specified ove. Pge 1B OCTOBER 1999

37 SERVICE MANUAL NUMBER 24 MAINTENANCE 7. While holding djustment stud t the correct elt tension, tighten 5/8 in. locking nut. 8. Run engine for short period of time nd recheck elt djustment. Ignition Timing -5/8 in. Locking Nut -5/16 in Adjusting Stud 7490 Thunderolt V Models 1. Connect timing light to numer 1 sprk plug wire. 2. Connect shop tchometer to the engine. IMPORTANT: Before strting the engine, connect jumper wire from the igniton timing led to good ground. This hs to e done efore the ignition key is turned ON to lock the igniton module into Bse Timing Mode. 3. Before strting the engine, connect jumper wire from timing led to good ground. NOTE: The PUR/WHT timing led is locted towrds the front of the engine ner the fuel line or ner the distriutor, s equipped for your model. 4. Strt engine nd run t 1300 rpm until it reches norml operting temperture. 5. Disconnect throttle cle from the cruretor. 6. With engine t idle rpm, djust the ceuretor idle rpm screw to the specified engine idle rpm. 7. With the engine still t idle rpm, check the ignition timing. If incorrect, rotte the distriutor until timing is correct. Torque clmping screw to 18 l-ft (25 Nm). 8. Adjust the idle mixture screw. Inwrd is LEAN, outwrd is RICH. 9. Recheck ignition timing. 10. Stop engine. Remove timing light, jumper wire nd shop tchometer. IMPORTANT: Timing jumper wire hs to e removed or the ignition module will sty locked in the Bse Timing Mode nd it will not e le to dvnce the ignition timing correctly when the engine rpm is incresed. 11. Adjust nd reinstll throttle cle. Open nd close remote control throttle lever to mke sure tht the cruretor s throttle lever returns ginst the rpm djusting screw every time OCTOBER 1999 Pge 1B-37