Ignition protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031

Transcription

1 NOTE: The following pplies to CE mrked products only. Declrtion of Conformnce Mercury MerCruiser This sterndrive or inbord engine when instlled in ccordnce to Mercury MerCruisers instructions complies with the requirements of the following directives by meeting the ssocited stndrds, s mended: Recretionl Crft Directive 94/25/EC; 2003/44/EC Applicble Requirement Owner s mnul (A.2.5) ISO Openings in Hull, Deck nd superstructure (A.3.4) ISO ; ISO Hndling chrcteristics (A.4) ISO 8665 Stndrds Applied Inbord Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469 Electricl System (A.5.3) ISO 10133; ISO 8846 Steering system (A.5.4) Exhust emission requirements (B.2) ISO 8178 Owner s mnul (B.4) ISO 8665 Noise emission levels (C.1) ISO Applicble portions of: ISO 10592, ISO 8848 nd ABYC P 17 Ignition protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 Mercury MerCruiser declres tht our sterndrive or inbord engines without integrl exhust, when instlled in recretionl crft, in ccordnce with the mnufcturers supplied instructions, will meet the exhust emissions requirements of the directive mentioned bove. This engine must not be put into service until the recretionl crft in which it is to be instlled hs been declred in conformity, if so required, with the relevnt provision of the directive. Electromgnetic Comptibility Directive 89/336/EC, 92/31/EEC nd 93/68/EEC Generic emission stndrd EN Generic immunity stndrd EN Vehicles, bots nd internl combustion engine driven devices Rdio disturbnce chrcteristics Electrosttic dischrge testing SAE J551 (CISPR 12) EN ; EN ; EN The notified body responsible for surveillnce of the qulity system under Full Qulity Assurnce Module H of Directive 2003/44/EC is: Det Norske Verits Norwy Notified Body Number: 0575 This declrtion is issued under the sole responsibility of Mercury Mrine nd Mercury MerCruiser. Kevin Grodzki President Mercury MerCruiser, Stillwter, OK, 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: Mercury Mrine Tow Sports/Inbord MPI Inbord Models *8M * 90-8M

2 Engine Model nd Horsepower Engine Seril Number Trnsom Assembly Seril Number (Sterndrive) Ger Rtio Sterndrive Unit Seril Number Trnsmission Model (Inbord) Ger Rtio Trnsmission Seril Number Propeller Number Pitch Dimeter Hull Identifiction Number (HIN) Purchse Dte Bot Mnufcturer Bot Model Length The seril numbers re the mnufcturer s keys to numerous engineering detils tht pply to your Mercury MerCruiser power pckge. When contcting your Authorized Mercury MerCruiser Deler bout service, lwys specify model nd seril numbers. The description nd specifictions contined herein were in effect t the time this guide ws pproved for printing. Mercury Mrine, whose policy is one of continuous improvement, reserves the right to discontinue models t ny time, or to chnge specifictions or designs, without notice nd without incurring obligtion. Mercury Mrine, Fond du Lc, Wisconsin, U.S.A. Printed in U.S.A. 2009, Mercury Mrine Mercury, Mercury Mrine, MerCruiser, Mercury MerCruiser, Mercury Rcing, Mercury Precision Prts, Mercury Propellers, Mriner, Quicksilver, #1 On The Wter, Alph, Brvo, Brvo Two, Pro Mx, OptiMx, Sport Jet, K Plnes, MerCthode, RideGuide, SmrtCrft, Zero Effort, M with Wves logo, Mercury with Wves logo, VesselView, nd SmrtCrft logo re ll registered trdemrks of Brunswick Corportion. Mercury Product Protection logo is registered service mrk of Brunswick Corportion. Welcome You hve selected one of the finest mrine power pckges vilble. It incorportes numerous design fetures to ssure operting ese nd durbility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny boting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. The Opertion, Mintennce nd Wrrnty Mnul contins specific instructions for using nd mintining your product. We suggest tht this mnul remin with the product for redy reference whenever you re on the wter. Thnk you for purchsing one of our Mercury MerCruiser products. We sincerely hope your boting will be plesnt! Mercury MerCruiser Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Mercury Mrine; the terms of the wrrnty re set forth in the Wrrnty Sections of this mnul. The wrrnty sttement contins description of wht is covered, wht is not covered, the durtion of coverge, how to best obtin wrrnty coverge, importnt disclimers nd limittions of dmges nd other relted informtion. Plese review this importnt informtion. Mercury Mrine products re designed nd mnufctured to comply with our own high qulity stndrds, pplicble industry stndrds nd regultions, s well s certin emissions regultions. At Mercury Mrine every engine is operted nd tested before it is boxed for shipment to mke sure tht the product is redy for use. In ddition, certin Mercury Mrine products re tested in controlled nd monitored environment, for up to 10 hours of engine run time, in order to verify nd mke record of complince with pplicble stndrds nd regultions. All Mercury Mrine product, sold s new, receives the pplicble limited wrrnty coverge, whether the engine prticipted in one of the test progrms described bove or not. Red This Mnul Thoroughly IMPORTANT: If you don t understnd ny portion of this mnul, contct your deler for demonstrtion of ctul strting nd operting procedures.

3 Notice Throughout this publiction, nd on your power pckge, dngers, wrnings, cutions, nd notices, ccompnied by the Interntionl Hzrd Symbol!, my be used to lert the instller/user to specil instructions concerning prticulr service or opertion tht my be hzrdous if performed incorrectly or crelessly. Observe them crefully. These Sfety Alerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.! DANGER Indictes hzrdous sitution which, if not voided, will result in deth or serious injury.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. IMPORTANT: Identifies informtion essentil to the successful completion of the tsk. NOTE: Indictes informtion tht helps in the understnding of prticulr step or ction.! WARNING The opertor (driver) is responsible for the correct nd sfe opertion of the bot, the equipment bord nd the sfety of ll occupnts bord. We strongly recommend tht the opertor red this Opertion, Mintennce nd Wrrnty Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories before the bot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, birth defects or other reproductive hrm.

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5 TABLE OF CONTENTS Section 1 - Wrrnty Wrrnty Registrtion United Sttes nd Cnd...2 Wrrnty Registrtion Outside the United Sttes nd Cnd..2 Trnsfer of Wrrnty...2 Mercury Product Protection Pln...3 United Sttes And Cnd Only...3 Mercury MerCruiser Limited Wrrnty (Gsoline Fueled Products Only)...3 Wht Is Covered...3 Stndrd Coverge...3 Horizon Sterndrive nd Inbord Models, nd MX 6.2 Blck Scorpion Tow Sport Model Coverge...3 Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge...3 Wht Mercury Will Do...3 How To Obtin Wrrnty Coverge...4 Wht Is Not Covered Yer Limited Wrrnty Aginst Corrosion (Worldwide)...4 Wht Is Covered...4 Durtion Of Coverge...4 Condition Tht Must Be Met In Order To Obtin Wrrnty Coverge...5 Wht Mercury Will Do...5 How To Obtin Wrrnty Coverge...5 Wht Is Not Covered...5 Mercury Instlltion Qulity Certifiction Progrm...5 Cliforni Emissions Limited Wrrnty...6 Wht Is Covered...6 Durtion of Coverge...6 How to Obtin Wrrnty Coverge...7 Wht Mercury Will Do...7 Wht Is Not Covered...7 Disclimers nd Limittions...7 Cliforni Emission Control Wrrnty Sttement...7 Your Wrrnty Rights nd Obligtions...7 Mnufcturer's Wrrnty Coverge...8 Owner's Wrrnty Responsibilities...8 Emission Certifiction Str Lbel...8 Section 2 - Getting to Know Your Power Pckge Lnyrd Stop Switch...12 Instrumenttion...13 System View...13 Digitl Guges...13 Anlog Guges...13 Remote Controls (Non DTS Models)...14 Remote Controls...14 Pnel Mount Fetures...14 Console Mount Fetures...15 Zero Effort Fetures...15 Remote Controls (DTS Models)...15 Remote Controls...15 Pnel Mount Fetures...16 Console Mount Fetures Single Engine...17 Slim Binncle Console Mount Fetures Single Engine..17 Console Mount Fetures Dul Engine...18 Synchronizing Dul Engines...18 Dul Helm Sttion Trnsfer...19 Synchronizing Dul Helms Prior To Sttion Trnsfer...19 Zero Effort Fetures...20 Electricl System Overlod Protection...20 Audio Wrning System...21 Testing The Audio Wrning System...22 Engine Gurdin Strtegy...22 Trnsmission Gurdin Strtegy...22 Wrning Horn Signls...22 Emissions Informtion...23 Emission Control Informtion Lbel...23 Owner Responsibility...23 Str Lbel...24 Section 3 - On The Wter Sfe Boting Suggestions...26 Be Alert to Crbon Monoxide Poisoning...27 Good Ventiltion...27 Poor Ventiltion...27 Bsic Bot Opertion (Non DTS Models)...28 Lunching nd Bot Opertion...28 Opertion Chrt...28 Strting nd Stopping the Engine...28 Strting the Engine...28 Stopping the Engine...29 Throttle Only Opertion...29 Freezing Temperture Opertion...29 Drin Plug nd Bilge Pump...29 Bsic Bot Opertion (DTS Models)...29 Lunching nd Bot Opertion...29 Opertion Chrt...29 Strting nd Stopping the Engine...30 Strting the Engine...30 Stopping the Engine...31 Throttle Only Opertion...31 Freezing Temperture Opertion...31 Drin Plug nd Bilge Pump...31 Protecting People in the Wter...32 While You Are Cruising...32 While Bot Is Sttionry...32 High Speed nd High Performnce Opertion M NOVEMBER 2010 Pge i

6 Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck...32 Bots With Front Mounted, Rised Pedestl Fishing Sets...32 Wve nd Wke Jumping...33 Impct with Underwter Hzrds Conditions Affecting Opertion...34 Weight Distribution (Pssengers nd Ger) Inside the Bot...34 The Bottom of the Bot Cvittion Ventiltion...34 Elevtion nd Climte Getting Strted Hour Brek In Period After Brek In Period...35 End of First Seson Checkup...35 Section 4 - Specifictions Cruising RPM Fuel Requirements Fuel Rtings...38 Using Reformulted (Oxygented) Gsolines (USA Only)38 Gsolines Contining Alcohol...38 Engine Oil...39 Engine Specifictions Tow Sports Models...39 Inbord Models...40 Fluid Specifictions...41 Engine...41 Trnsmission Section 5 - Mintennce Owner/Opertor Responsibilities...44 Deler Responsibilities...44 Mintennce...44 Do It Yourself Mintennce Suggestions...44 Inspection Mintennce Schedule Inbord Models...45 Routine Mintennce...45 Ech Dy Strt...45 Ech Dy End Weekly Every Two Months or 50 Hours...45 Scheduled Mintennce After the Initil 20 Hour Brek In Period Every 100 Hours or Annully (Whichever Occurs First) Every 300 Hours or 3 Yers...46 Mintennce Log...46 Engine Oil...47 Checking...47 Filling Chnging Oil nd Filter...48 Esy Engine Oil Drin System...48 Engine Oil Drin Pump...48 Chnging Filter...49 Trnsmission Fluid Checking While the Engine is Wrm Checking While Engine is Cold...49 Chnging Engine Coolnt...50 Checking...50 Filling Chnging Clening the Flme Arrestor...51 Positive Crnkcse Ventiltion Vlve (PCV) Chnging...52 Chnging Wter Seprting Fuel Filter GEN II Models GEN III Models In line Fuel Filter...55 Lubriction...56 Throttle Cble...56 Trnsmission Linkge Serpentine Drive Belt...58 Checking...58 Replcing Belt nd/or Adjusting Tension...58 Flushing The Power Pckge Tow Sports...59 The Bot Out of the Wter...59 The Bot In the Wter...60 Bttery Multiple EFI Engine Bttery Precutions...62 Section 6 - Storge Cold Wether or Extended Storge Prepring Power Pckge for Storge...64 Engine nd Fuel System Preprtion Drining the Sewter System...65 Drin System Identifiction...65 Air Actuted Single Point Drin System...65 Three Point Mnul Drin System Air Actuted Single Point Drin System...66 Bot in the Wter Bot out of the Wter Three Point Mnul Drin System Bot in the Wter Bot out of the Wter Bttery Storge...71 Recommissioning the Power Pckge...71 Pge ii 90-8M NOVEMBER 2010

7 Section 7 - Troubleshooting Dignosing EFI Problems...74 Dignosing DTS Problems...74 Engine Gurdin System...74 Strter Motor Will Not Crnk Engine, Or Crnks Slow...74 Engine Will Not Strt or Is Hrd to Strt...74 Engine Runs Rough, Misses, or Bckfires...75 Poor Performnce...75 Excessive Engine Temperture...75 Insufficient Engine Temperture...75 Low Engine Oil Pressure...76 Bttery Will Not Rechrge...76 Remote Control Is Difficult to Move, Hs Excessive Ply, or Mkes Unusul Sounds...76 Steering Wheel Jerks or Is Difficult to Turn...76 Section 8 - Customer Assistnce Informtion Owner Service Assistnce...78 Locl Repir Service...78 Service Awy From Home...78 Stolen Power Pckge...78 Attention Required fter Submersion...78 Replcement Service Prts...78 Prts nd Accessories Inquiries...78 Resolving Problem...78 Mercury Mrine Service Offices...79 Ordering Literture...79 United Sttes nd Cnd...79 Outside the United Sttes nd Cnd M NOVEMBER 2010 Pge iii

8 Pge iv 90-8M NOVEMBER 2010

9 Tble of Contents Section 1 - Wrrnty Section 1 - Wrrnty 1 Wrrnty Registrtion United Sttes nd Cnd... 2 Wrrnty Registrtion Outside the United Sttes nd Cnd... 2 Trnsfer of Wrrnty... 2 Mercury Product Protection Pln... 3 United Sttes And Cnd Only... 3 Mercury MerCruiser Limited Wrrnty (Gsoline Fueled Products Only)... 3 Wht Is Covered... 3 Stndrd Coverge... 3 Horizon Sterndrive nd Inbord Models, nd MX 6.2 Blck Scorpion Tow Sport Model Coverge... 3 Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge... 3 Wht Mercury Will Do... 3 How To Obtin Wrrnty Coverge... 4 Wht Is Not Covered Yer Limited Wrrnty Aginst Corrosion (Worldwide)... 4 Wht Is Covered... 4 Durtion Of Coverge... 4 Condition Tht Must Be Met In Order To Obtin Wrrnty Coverge... 5 Wht Mercury Will Do... 5 How To Obtin Wrrnty Coverge... 5 Wht Is Not Covered... 5 Mercury Instlltion Qulity Certifiction Progrm... 5 Cliforni Emissions Limited Wrrnty... 6 Wht Is Covered... 6 Durtion of Coverge... 6 How to Obtin Wrrnty Coverge... 7 Wht Mercury Will Do... 7 Wht Is Not Covered... 7 Disclimers nd Limittions... 7 Cliforni Emission Control Wrrnty Sttement... 7 Your Wrrnty Rights nd Obligtions... 7 Mnufcturer's Wrrnty Coverge... 8 Owner's Wrrnty Responsibilities... 8 Emission Certifiction Str Lbel M NOVEMBER 2010 Pge 1

10 Section 1 - Wrrnty Wrrnty Registrtion United Sttes nd Cnd 1. You my chnge your ddress t ny time, including t time of wrrnty clim, by clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril number to Mercury Mrine s Wrrnty Registrtion Deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx NOTE: Registrtion lists must be mintined by Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act be required. 2. To be eligible for wrrnty coverge, the product must be registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely submit it to Mercury Mrine vi MercNET, E mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. 3. Upon processing the wrrnty registrtion, Mercury Mrine will send registrtion verifiction by mil to the purchser of the product. If this registrtion verifiction is not received within 30 dys, plese contct your selling deler immeditely. Wrrnty coverge is not effective until your product is registered with Mercury Mrine. Wrrnty Registrtion Outside the United Sttes nd Cnd 1. It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the distributor or Mrine Power Service Center responsible for dministering the wrrnty registrtion/clim progrm for your re. 2. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril numbers, dte of sle, type of use nd the selling distributor's/deler's code number, nme nd ddress. The distributor/deler lso certifies tht you re the originl purchser nd user of the product. 3. A copy of the Wrrnty Registrtion Crd, designted s the Purchser's Copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor/deler. This crd represents your fctory registrtion identifiction nd should be retined by you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the Wrrnty Registrtion Crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim forms. 4. In some countries, the Mrine Power Service Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter receiving the Fctory Copy of the Wrrnty Registrtion Crd from your distributor/deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser's Copy tht you received from the distributor/deler when you purchsed the product. Ask your distributor/deler if this plstic crd progrm pplies to you. IMPORTANT: Registrtion lists must be mintined by the fctory nd deler in some countries by lw. It is our desire to hve ALL products registered t the fctory should it ever be necessry to contct you. Mke sure your deler/distributor fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. 5. For further informtion concerning the Wrrnty Registrtion Crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. Trnsfer of Wrrnty The limited wrrnty is trnsferble to subsequent purchser, but only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the subsequent owner, send or fx copy of the bill of sle or purchse greement, new owner s nme, ddress nd engine seril number to Mercury Mrine s Wrrnty Registrtion Deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product by mil. There is no chrge for this service. Pge M NOVEMBER 2010

11 Section 1 - Wrrnty For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Mercury Product Protection Pln United Sttes And Cnd Only (Certin performnce products, triple engine instlltions, nd commercil pplictions re excluded.) The Mercury Product Protection Pln provides coverge ginst unexpected mechnicl nd electricl brekdowns tht my occur beyond the stndrd limited wrrnty. The optionl Mercury Product Protection Pln is the only Fctory Pln vilble for your engine. One, two, three, four or five yer term plns cn be purchsed up to 12 months fter the originl engine registrtion dte. See your prticipting Mercury MerCruiser deler for complete progrm detils. Mercury MerCruiser Limited Wrrnty (Gsoline Fueled Products Only) Wht Is Covered Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described following. Stndrd Coverge This Limited Wrrnty provides coverge for either one (1) yer from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Products instlled by n IQ Certified Instller receive one (1) yer of dditionl coverge. Commercil users of these products receive wrrnty coverge of 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 or employment relted use of the 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. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper re registrtion of the product. Unexpired wrrnty coverge cnnot be trnsferred either to or from commercil use customer. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. Horizon Sterndrive nd Inbord Models, nd MX 6.2 Blck Scorpion Tow Sport Model Coverge This Limited Wrrnty provides coverge for either three (3) yers from 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. An dditionl one (1) yer is dded to the recretionl user if the product is instlled by n IQS certified instller. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper re registrtion of the product. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. Conditions Tht Must Be Met In Order To Obtin Wrrnty Coverge Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or subsequent 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 nd Mintennce Mnul must be timely performed in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Wht Mercury Will Do Mercury's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. 90-8M NOVEMBER 2010 Pge 3

12 Section 1 - Wrrnty How To Obtin Wrrnty Coverge The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. Wht Is Not Covered This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion nd Mintennce Mnul), opertion of the product in mnner inconsistent with the recommended opertion/ duty cycle section of the Opertion nd Mintennce Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt which dmges the Mercury product nd ws not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion nd Mintennce Mnul), ltertion or removl of prts, wter entering the engine through the fuel intke, ir intke or exhust system or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body, running the engine out of wter, mounting the engine too high on the trnsom, or running the bot with the engine trimmed out too fr. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Yer Limited Wrrnty Aginst Corrosion (Worldwide) Wht Is Covered Mercury Mrine wrrnts tht ech new Mercury, Mriner, Mercury Rcing, Sport Jet, M 2 Jet Drive, Trcker by Mercury Mrine Outbord, MerCruiser Inbord or Sterndrive engine (Product) will not be rendered inopertive s direct result of corrosion for the period of time described below. Durtion Of Coverge This limited corrosion wrrnty provides coverge for three (3) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir nd replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent (noncommercil use) purchser upon proper re registrtion of the product. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht obtined the product s result of n insurnce clim. Pge M NOVEMBER 2010

13 Condition Tht Must Be Met In Order To Obtin Wrrnty Coverge Section 1 - Wrrnty Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Corrosion prevention devices specified in the Opertion nd Mintennce Mnul must be in use on the bot, nd routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed (including without limittion the replcement of scrificil nodes, use of specified lubricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. Wht Mercury Will Do Mercury's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. How To Obtin Wrrnty Coverge The customer must provide Mercury with resonble opportunity to repir, nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must be given to Mercury. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. Wht Is Not Covered This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, buse or improper service; corrosion to ccessories, instruments, steering systems; corrosion to fctory instlled jet drive unit; dmge due to mrine growth; product sold with less thn one yer limited Product wrrnty; replcement prts (prts purchsed by the Customer); products used in commercil ppliction. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of wrrnty period, even if the product is only occsionlly used for such purposes. Mercury Instlltion Qulity Certifiction Progrm Mercury MerCruiser products instlled by Mercury Instlltion Qulity Certified Mnufcturer re Instlltion Qulity certified products nd my receive n dditionl one (1) yer of limited wrrnty coverge. The Instlltion Qulity Certifiction progrm ws developed to recognize MerCruiser botbuilder customers who hve chieved higher mnufcturing stndrds. It is the first nd only comprehensive mnufcturer instlltion certifiction progrm in the industry. The progrm hs three gols: 1. To enhnce overll product qulity. 90-8M NOVEMBER 2010 Pge 5

14 Section 1 - Wrrnty 2. To improve the bot ownership experience. 3. To enhnce overll customer stisfction. The certifiction process is designed to review ll fcets of mnufcturing nd engine instlltion. The progrm is composed of design, mnufcturing nd instlltion review stges with which builders must comply. Certifiction pplies leding edge methodologies to crete: Efficiencies nd best prctices specific to engine instlltion. World clss ssembly nd component specifictions. Efficient instlltion processes. Industry stndrd end of line test procedures Bot builders tht successfully complete the progrm nd meet ll certifiction requirements ern Instlltion Qulity System Certified Mnufcturer sttus nd receive n dditionl one (1) yer of Mercury limited fctory wrrnty coverge on ll MerCruiser powered bots tht re registered on nd fter the bot builder's certifiction dte for ll worldwide registrtions. Mercury hs designted section of our Website to promote the Instlltion Qulity Certifiction Progrm nd communicte its benefits to consumers. For current list of MerCruiser powered bot brnds tht hve erned Instlltion Qulity Certifiction, visit Cliforni Emissions Limited Wrrnty NOTE: Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer The Cliforni Air Resources Bord hs promulgted ir emissions regultions for inbord nd sterndrive engines. The regultions pply to ll inbord nd sterndrive engines tht were mnufctured for the 2003 model yer nd lter. Mercury Mrine, in complince with those regultions, provides this limited wrrnty for the emission control systems (see the components of the emission control system listed following), nd further wrrnts tht the inbord or sterndrive engine ws designed, built, nd equipped to conform with ll pplicble regultions dopted by the Cliforni Air Resources Bord pursunt to its uthority in Chpters 1 nd 2, Prt 5, Division 26 of the Helth nd Sfety Code. For informtion regrding the limited wrrnty for the non emissions relted components of the inbord or sterndrive engine, plese see the limited wrrnty sttement for your engine. Wht Is Covered NOTE: Your deler will register your engine for wrrnty coverge for you. The wrrnty registrtion process is not relted in ny wy to the process of obtining license, title or registrtion from stte boting uthorities. You should sk your deler to updte your wrrnty registrtion informtion to reflect chnge of ddress or trnsfer of ownership. (This chnge my be mde t ny time.) Refer to the Wrrnty Registrtion informtion in your owners mnul or to your deler for more informtion. Mercury Mrine wrrnts the components of the emissions control systems (see the components of the emission control system listed following) of its new, 2003 model yer nd lter Cliforni certified inbord nd sterndrive engines, registered to Cliforni resident, to be free from defects in mteril or workmnship tht cuse the filure of wrrnted prt to be identicl in ll mteril respects to tht prt s described in the ppliction of Mercury Mrine for certifiction from the Cliforni Air Resources Bord, for the period of time, nd under the conditions identified below. The cost to dignose wrrnty filure is covered if the wrrnty clim is pproved. Dmge to other engine components cused by the filure of wrrnted prt will lso be repired under wrrnty. Durtion of Coverge NOTE: Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer 2003 This limited wrrnty provides coverge for the components of the emissions control systems. Specific emission control relted prts on new inbord or sterndrive engines re wrrnted for 3 yers or 480 hours, whichever first occurs, from either the dte the product is first sold, or first put into service, whichever occurs first. Emission relted norml mintennce items such s sprk plugs nd filters, tht re on the wrrnted prts list re wrrnted up to their first required replcement intervl only. Refer to Emission Control System Components nd Mintennce Schedule. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent purchser. Refer to Trnsfer of Wrrnty. Pge M NOVEMBER 2010

15 How to Obtin Wrrnty Coverge Section 1 - Wrrnty The customer must provide Mercury with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury deler uthorized to service the product. If purchser cnnot deliver the product to such deler, plese notify Mercury Mrine nd Mercury will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered by this wrrnty, purchser shll py for ll relted lbor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested by Mercury, ship the product or prts of the product directly to Mercury. Wht Mercury Will Do Mercury Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our expense nd t our option, repiring or replcing defective prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. Wht Is Not Covered This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended wide open throttle RPM rnge (see Specifictions), opertion of the product in mnner inconsistent with the recommended opertion procedures, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see Specifictions), ltertion or removl of prts. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. Non wrrnty mintennce, replcement, or repir of emission control devices nd systems my be performed by ny mrine engine repir estblishment or individul. The use of non Mercury prts for non wrrnty mintennce or repirs will not be grounds for disllowing other wrrnty work. The use of dd on (s defined t section 1900 (b)(1) nd (b)(10) of Title 13 of the Cliforni Code of Regultions) or modified prts not exempted by the Cliforni Air Resources Bord my be grounds for disllowing wrrnty clim, t the discretion of Mercury Mrine. Filures of wrrnted prts cused by the use of non exempted dd on or modified prt will not be covered. Disclimers nd Limittions DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. If you hve ny questions regrding your wrrnty rights nd responsibilities, refer to Owner Service Assistnce for contct informtion. Cliforni Emission Control Wrrnty Sttement Your Wrrnty Rights nd Obligtions NOTE: Mercury Mrine does not estblish model yers for the Mercury MerCruiser product line. In order to comply with CARB wrrnty regultions, nd for tht limited purpose only, model yer shll hve the sme mening s clendr yer. As n exmple, 2003 model yer products refers to products mnufctured during clendr yer The Cliforni Air Resources Bord is plesed to explin the emission control system wrrnty on your 2003 model yer nd lter inbord or sterndrive engine. In Cliforni, new inbord nd sterndrive engines must be designed, built nd equipped to meet the Stte's stringent nti smog stndrds. Mercury Mrine must wrrnt the emission control system on your inbord or sterndrive engine for the periods of time listed below provided there hs been no buse, neglect or improper mintennce of your inbord or sterndrive engine. Your emission control system my include prts such s the crburetor or fuel injection system, the ignition system, nd ctlytic converter. Also included my be hoses, belts, connectors nd other emission relted ssemblies. 90-8M NOVEMBER 2010 Pge 7

16 Section 1 - Wrrnty Where wrrntble condition exists, Mercury Mrine will repir your inbord or sterndrive engine t no cost to you; including dignosis, prts nd lbor. Mnufcturer's Wrrnty Coverge Select emission control prts from 2009 nd lter (inbord or sterndrive) engines re wrrnted for 3 yers or 480 hours, whichever first occurs. However, wrrnty coverge bsed on the hourly period is only permitted for engines tht re equipped with hour meters s defined in s 2441()(13) or their equivlent. If ny emission relted prt on your engine is defective under wrrnty, the prt will be repired or replced by Mercury Mrine. Owner's Wrrnty Responsibilities As the inbord or sterndrive engine owner, you re responsible for the performnce of the required mintennce listed in your owner's mnul. Mercury Mrine recommends tht you retin ll receipts covering mintennce on your inbord or sterndrive engine, but Mercury Mrine cnnot deny wrrnty solely for the lck of receipts or your filure to ensure the performnce of ll scheduled mintennce. As the inbord or sterndrive engine owner, you should however be wre tht Mercury Mrine my deny you wrrnty coverge if your inbord or sterndrive engine or prt hs filed due to buse, neglect, improper mintennce or unpproved modifictions. You re responsible for presenting your inbord or sterndrive engine to Mercury Mrine deler uthorized to service the product s soon s problem exists. The wrrnty repirs will be completed in resonble mount of time, not to exceed 30 dys. If you hve ny questions regrding your wrrnty rights nd responsibilities, refer to Owner Service Assistnce for contct informtion. Emission Certifiction Str Lbel Your bot is lbeled on the hull with one of the following str lbels.the Symbol for Clener Mrine Engines Mens: Clener Air nd Wter for helthier lifestyle nd environment. Better Fuel Economy burns up to percent less gs nd oil thn conventionl crbureted two stroke engines, sving money nd resources. Longer Emission Wrrnty Protects consumer for worry free opertion. Pge M NOVEMBER 2010

17 Section 1 - Wrrnty One Str - Low emission mc The one str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2001 exhust emission stndrds. Engines meeting these stndrds hve 75% lower emissions thn conventionl crbureted two stroke engines. These engines re equivlent to the U.S. EPA's 2006 stndrds for mrine engines. Two Strs - Very Low emission FO IDA mc The two str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2004 exhust emission stndrds. Engines meeting these stndrds hve 20% lower emissions thn One Str Low Emission engines. Three Strs - Ultr Low emission A SS D mc The three str lbel identifies engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2008 exhust emission stndrds or the Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emission engines. Four Strs - Super Ultr Low emission RN F T mc The Four Str lbel identifies engines tht meet the Air Resources Bord's Sterndrive nd Inbord mrine engine 2009 exhust emission stndrds. Personl Wtercrft nd Outbord mrine engines my lso comply with these stndrds. Engines meeting these stndrds hve 90% lower emissions thn One Str Low Emission engines. 90-8M NOVEMBER 2010 Pge 9

18 Section 1 - Wrrnty Notes: Pge M NOVEMBER 2010

19 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tble of Contents Lnyrd Stop Switch Instrumenttion System View Digitl Guges Anlog Guges Remote Controls (Non DTS Models) Remote Controls...14 Pnel Mount Fetures Console Mount Fetures Zero Effort Fetures...15 Remote Controls (DTS Models) Remote Controls...15 Pnel Mount Fetures...16 Console Mount Fetures Single Engine...17 Slim Binncle Console Mount Fetures Single Engine...17 Console Mount Fetures Dul Engine...18 Synchronizing Dul Engines...18 Dul Helm Sttion Trnsfer...19 Synchronizing Dul Helms Prior To Sttion Trnsfer Zero Effort Fetures...20 Electricl System Overlod Protection Audio Wrning System Testing The Audio Wrning System Engine Gurdin Strtegy Trnsmission Gurdin Strtegy Wrning Horn Signls Emissions Informtion Emission Control Informtion Lbel...23 Owner Responsibility Str Lbel M NOVEMBER 2010 Pge 11

20 Section 2 - Getting to Know Your Power Pckge Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor's position (s in ccidentl ejection from the opertor's position). c b RUN - Stop switch b - Lnyrd c - Clips to the opertor Accidentl ejections, such s flling overbord, re more likely to occur in: low sided sport bots bss bots high performnce bots Accidentl ejections cn lso occur from: poor operting prctices sitting on the set or gunwle t plning speeds stnding t plning speeds operting t plning speeds in shllow or obstcle infested wters relesing your grip on the steering wheel tht is pulling in one direction consuming lcohol or drugs high speed boting mneuvers The lnyrd is cord usully between 122 nd 152 cm (4 nd 5 ft) in length when stretched out, with n element on one end mde to be inserted into the switch nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t rest condition s short s possible to minimize the likelihood of lnyrd entnglement with nerby objects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, but the bot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the bot will not complete full circle. While the bot is costing, it cn cuse injury to nyone in the bot's pth s seriously s the bot would when under power. We strongly recommend tht other occupnts be instructed on proper strting nd operting procedures should they be required to operte the engine in n emergency (e.g. if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the bot, stop the engine immeditely to reduce the possibility of serious injury or deth from being struck by the bot. Alwys properly connect the opertor to the stop switch using lnyrd. Accidentl or unintended ctivtion of the switch during norml opertion is lso possibility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could be thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the bot who could be ejected over the bow nd possibly struck by the propulsion or steering components. Loss of power nd directionl control in hevy ses, strong current or high winds. Loss of control when docking.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The bot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor Pge M NOVEMBER 2010

21 Instrumenttion System View Section 2 - Getting to Know Your Power Pckge Smrt Crft SELECT System View HOME 5650 Your power pckge my be connected to the Mercury SC5000 SmrtCrft System View disply. The disply monitors nd reports informtion rnging from bsic operting dt to engine lrm dt. The SC5000 System View Disply is comprehensive bot informtion center. System View llows the bot opertor to receive welth of criticl opertionl informtion, displyed clerly nd instntly t the helm on the LCD disply. The System View continuously monitors nd reports informtion rnging from bsic operting dt to detiled vessel environment informtion. System View displys wter temperture nd depth, engine trim sttus, bot speed, steering ngle, system preventive mintennce reminders nd systems dignostics. System View lso cn be fully integrted with the bot's GPS, if equipped, to provide up to the minute loction, course, speed, nd fuel to destintion informtion. When problem is detected with the engine or system, the System View will lert the opertor to the potentil problem by displying the lrm messge in the informtion window, locted t the bottom of the view screen. If the problem cn cuse immedite engine dmge, the Engine Gurdin System will respond to the problem by limiting engine power. Immeditely reduce throttle speed to idle. Refer to the System View Opertion Mnul for further explntion of the problem nd the correct ction to tke. Digitl Guges A Mercury SmrtCrft System instrument pckge cn be purchsed for this product. A few of the functions the instrument pckge will disply re engine RPM, coolnt temperture, oil pressure, bttery voltge, fuel consumption nd engine operting hours. The SmrtCrft Instrument pckge will lso id in Engine Gurdin dignostics. The SmrtCrft Instrument pckge will disply criticl engine lrm dt nd potentil problems. Refer to the mnul with your guge pckge for the wrning functions monitored nd bsic opertion of the SmrtCrft Instrument pckge. Anlog Guges The following is brief explntion of the instrumenttion typiclly found on some bots. The owner/opertor should be fmilir with ll instruments nd their functions. Becuse of the lrge vriety of instrumenttion nd mnufcturers, you should hve your bot deler explin the prticulr guges nd norml redings for your bot KPH MPH X 1000 R P M L OIL H b c d e FUEL CRUISELOG BATT C TEMP H - Speedometer b - Tchometer c - Oil pressure guge d - Voltmeter e - Wter temperture guge f - Fuel guge g - Hour meter h - Bilge blower switch i - Ignition switch f g h i M NOVEMBER 2010 Pge 13

22 Section 2 - Getting to Know Your Power Pckge Speedometer: Indictes bot speed. Tchometer: Indictes engine RPM. Oil Pressure Guge: Indictes engine oil pressure. Voltmeter: Indictes bttery voltge. Wter Temperture Guge: Indictes engine operting temperture. Fuel Guge: Indictes quntity of fuel in tnk. Hour meter: Records engine operting time. Bilge Blower Switch: Opertes bilge blower. Ignition Switch: Allows opertor to strt nd stop engine. Remote Controls (Non DTS Models) Remote Controls Your bot my be equipped with Mercury Precision Prts or Quicksilver remote controls. All controls my not hve ll fetures shown. Consult your deler for description nd/or demonstrtion of your remote control. Pnel Mount Fetures b e - Neutrl lock button b - Throttle only button c - Lnyrd stop switch d - Control hndle tension djustment screw e - Control hndle c d Neutrl Lock Button - Prevents ccidentl shift nd throttle enggement. Neutrl lock button must be pushed in to move the control hndle out of neutrl. Throttle Only Button - Allows engine throttle dvncement without shifting the engine. This is done by disengging the shift mechnism from the control hndle. The throttle only button cn be depressed only when the remote control hndle is in the neutrl position, nd should only be used to ssist in strting the engine. Lnyrd Stop Switch - Turns the ignition off whenever the opertor (when ttched to the lnyrd) moves fr enough wy from the opertor's position to ctivte the switch. Refer to Lnyrd Stop Switch for informtion on the use of this switch. Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Control Hndle Tension Adjustment Screw - (not visible) This screw is used to djust the effort required to move the remote control hndle. Refer to instructions provided with remote control for complete djustment instructions. Pge M NOVEMBER 2010

23 Section 2 - Getting to Know Your Power Pckge Console Mount Fetures - Throttle Only Button b - Control Hndle b Throttle Only Button - Allows engine throttle dvncement without shifting the engine. This is done by disengging the shift mechnism from the control hndle. The throttle only button cn be depressed only when the remote control hndle is in the neutrl position. Control Hndles - Opertion of the the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick firm motion to the first detent for forwrd ger nd continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Control Hndle Tension Adjustment Screw - (not visible) This screw is used to djust the effort required to move the remote control hndle. Refer to instructions provided with remote control for complete djustment instructions. Zero Effort Fetures b b - Shift ever b - Throttle lever Shift Lever - Shift functions re controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its ft position. Shift into neutrl by moving the shift lever to its center position. Shift into forwrd by moving the shift lever to its forwrd position. Throttle Lever - Throttle functions re controlled by the movement of the throttle lever. Increse the RPM by moving the throttle lever forwrd. Achieve Wide Open Throttle (WOT) by plcing the throttle lever in its full forwrd position. Decrese RPM by moving the throttle lever bck. Achieve minimum RPM (idle) by plcing the throttle lever in its full ft position. Remote Controls (DTS Models) Remote Controls IMPORTANT: Your bot must be equipped with Mercury Mrine electronic remote control. Strt in ger protection is provided by this control system nd prevents the engine from strting when the control is ctuted in forwrd or reverse. Refer to the Mercury Precision Prts/Quicksilver Accessories Guide. 90-8M NOVEMBER 2010 Pge 15

24 Section 2 - Getting to Know Your Power Pckge The Digitl Throttle nd Shift System (DTS) required to operte this engine pckge provides strt nd stop functions, throttle control, shift control, strt in ger protection, nd emergency lnyrd stop functions. The DTS system works with specilized helm components such s commnd module kit nd electronic remote control. Consult your deler for description nd/or demonstrtion of your remote control. Pnel Mount Fetures c b d e f - g + - Lnyrd stop switch b - Control hndle c - Shift lock d - Trim/tilt switch e - Throttle only button f - Detent tension djustment screw g - Control hndle friction djustment screw Lnyrd Stop Switch - Turns the ignition off whenever the opertor (when ttched to the lnyrd) moves fr enough wy from the opertor's position to ctivte the switch. Refer to Lnyrd Stop Switch for informtion on the use of this switch. Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Shift Lock - Pressing the shift lock llows the engine to shift. The shift lock must lwys be pressed when moving the control hndle out of the neutrl position. Throttle Only Button - Allows engine throttle dvncement without shifting the engine. The throttle only button cn be depressed only when the remote control is in the neutrl position, nd should only be used to ssist in strting or wrming up the engine. Strt/Stop Button - Allows the bot opertor to strt or stop the engine without using the ignition key. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Pge M NOVEMBER 2010

25 Section 2 - Getting to Know Your Power Pckge Console Mount Fetures Single Engine c - + d g b f e h Control hndle b - Active light c - Neutrl light d - Select key e - Arrow trckpd f - Throttle only/sttion select key g - Detent tension djustment h - Control hndle friction djustment screw Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Active Light - The ctive light is illuminted to show the remote control is ctive nd redy for use. Neutrl Light - The neutrl light is illuminted when the engine is in neutrl ger position. Select Key - Selects System View on screen options nd confirms dt entries. Arrow Trckpd - Nvigtes through System View on screen function messges. Throttle Only/Sttion Select Key - Allows engine throttle dvncement without shifting the engine. The throttle only/sttion select button lso llows the bot opertor to select which remote control is in control of the engine opertion when operting with multiple helms. Refer to Dul Helm Sttion Trnsfer. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Slim Binncle Console Mount Fetures Single Engine b c START STOP d e f + g Control hndle b - Active light c - Neutrl light d - Strt/stop button e - Throttle only/sttion select key f - Detent tension djustment g - Control hndle friction djustment screw 90-8M NOVEMBER 2010 Pge 17

26 Section 2 - Getting to Know Your Power Pckge Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Active Light - The ctive light is illuminted to show the remote control is ctive nd redy for use. Neutrl Light - The neutrl light is illuminted when the engine is in neutrl ger position. Strt/Stop Button - Allows the bot opertor to strt or stop the engine without using the ignition key. Throttle Only/Sttion Select Key - Allows engine throttle dvncement without shifting the engine. The throttle only/sttion select button lso llows the bot opertor to select which remote control is in control of the engine opertion when operting with multiple helms. Refer to Dul Helm Sttion Trnsfer. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Console Mount Fetures Dul Engine - Control hndles b - Active light c - Neutrl light d - Select key e - Arrow trckpd f - Sync light g - Throttle only/sttion select key h - Detent tension djustment i - Control hndle friction djustment screw Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing bck to increse speed. Active Light - The ctive light is illuminted to show the remote control is ctive nd redy for use. Neutrl Light - The neutrl light is illuminted when the engine is in neutrl ger position. Select Key - Selects System View on screen options nd confirms dt entries. Arrow Trckpd - Nvigtes through System View on screen function messges. Sync Light - The sync light is illuminted when the RPM of the two engines re being synchronized by the DTS system. Throttle Only/Sttion Select Key - Allows engine throttle dvncement without shifting the engine. The throttle only/sttion select button lso llows the bot opertor to select which remote control is in control of the engine opertion when operting with multiple helms. Refer to Dul Helm Sttion Trnsfer. Detent Tension Adjustment Screw - This screw cn be djusted to increse or decrese the effort required to move the control hndle out of the detent positions (cover must be removed). Turning the screw clockwise will increse tension. Control Hndle Friction Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed). This will help prevent unwnted motion of the hndle in rough wter. Turn the screw clockwise to increse tension nd counterclockwise to decrese tension. Synchronizing Dul Engines b ACTIVE c THROTTLE ONLY STATION SELECT g SYNC d f e h The uto synchronizing feture, when engged, will utomticlly djust the port engine speed to mtch the speed of the strbord engine. Synchronizing of engines will utomticlly engge when the speed of both engines re over 900 RPM for two seconds nd remote control hndles re positioned within 5 of ech other. - + i Pge M NOVEMBER 2010

27 Section 2 - Getting to Know Your Power Pckge Auto Synchronizing will sty engged up to 95% throttle opening. The Sync light will turn on when the engines re synchronized. ACTIVE THROTTLE ONLY STAT ION SELECT To disengge, move one or both control hndles until they re more thn 5 prt, reduce engine speed below 900 RPM, or increse engine speed beyond 95%. Dul Helm Sttion Trnsfer The throttle only/sttion select button llows the bot opertor to select which remote control is in control of the engine opertion. The ctive light is illuminted t the remote control sttion tht is in control of the engine. SYNC! WARNING Avoid serious injury or deth from loss of bot control. The bot opertor should never leve the ctive sttion while engine is in ger. Helm trnsfer should only be ttempted while both sttions re mnned. One person helm trnsfer should only be performed while engine is in neutrl. NOTE: Idle position is preferred when doing sttion trnsfer. If conditions do not llow the remote control to be plced t idle position, sttion trnsfer cn be done while in ger. NOTE: Pressing nd relesing sttion select button t new sttion llows the engine control to be trnsferred to the new sttion. The control will utomticlly strt djusting engine RPM nd ger position to mtch the control hndle setting t the new sttion. Adjust control hndles to the desired throttle nd ger position. 1. Plce ctive remote control lever to idle position. 2. Proceed to the inctive helm sttion nd position remote control lever to the idle position. 3. Press throttle only/sttion select button once. The "ACTIVE" light will illuminte to indicte the remote control sttion is in control of the engine Active light b - Throttle only/sttion select button ACTIVE THROTTLE ONLY STATION SELECT 4. The ctive light will switch off t the originl remote control sttion. Synchronizing Dul Helms Prior To Sttion Trnsfer b Pressing the sttion select button nd holding it in llows the bot opertor 10 seconds to mtch up the control hndle settings t the new sttion with the hndle settings tht re t the old (to be inctive) sttion. If the hndles re not mtched, the neutrl light will flsh. The light blinks fster s the hndles re nering mtch position. Once the light stys on continuously, the hndles re mtched nd the button cn be relesed. Trnsfer process is complete nd the new sttion is now in control. If the button is held for over 10 seconds, the sttion trnsfer is cncelled. ACTIVE THROTTLE ONLY STAT ION SELECT SYNC 3433 b 90-8M NOVEMBER 2010 Pge 19

28 Section 2 - Getting to Know Your Power Pckge Zero Effort Fetures b - Shift ever b - Throttle lever Shift Lever - Shift functions re controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its ft position. Shift into neutrl by moving the shift lever to its center position. Shift into forwrd by moving the shift lever to its forwrd position. Throttle Lever - Throttle functions re controlled by the movement of the throttle lever. Increse the RPM by moving the throttle lever forwrd. Achieve Wide Open Throttle (WOT) by plcing the throttle lever in its full forwrd position. Decrese RPM by moving the throttle lever bck. Achieve minimum RPM (idle) by plcing the throttle lever in its full ft position. Electricl System Overlod Protection If n electricl overlod occurs, fuse will blow or the circuit breker will trip open. Find nd correct the cuse before replcing the fuse or resetting the circuit breker. NOTE: In n emergency, when the engine must be operted nd the cuse for the high current drw cnnot be locted nd corrected, turn off or disconnect ll ccessories connected to the engine nd instrumenttion wiring. Reset the circuit breker. If the breker remins open, the electricl overlod hs not been eliminted. Further checks must be mde on the electricl system. Contct your uthorized deler. 1. A circuit breker protects the engine wiring hrness nd the instrumenttion power led. Test the circuit breker by pushing the red button. If the circuit breker is functioning properly, the yellow lever will pper. Reset fter testing, or if tripped, by pushing the yellow lever bck into the housing. b Yellow lever style circuit breker-typicl - Yellow lever shown tripped b - Red test button Pge M NOVEMBER 2010

29 Section 2 - Getting to Know Your Power Pckge 2. A 90 mp fuse is locted on the lrge post of the strter solenoid. This fuse protects the engine wiring hrness if n electricl overlod occurs. mc Four fuses re locted on the port side of the engine. These fuses protect the min power, fuel pump, ignition, nd ccessory circuits A 20 mp fuse my be locted in the ignition switch "I" terminl led to protect the electricl system. Check for blown fuse if the ignition key is turned to the "START" position nd nothing hppens (nd circuit breker is not tripped). mc Audio Wrning System Your Mercury MerCruiser power pckge my be equipped with n Audio Wrning System. The Audio Wrning System will not protect the engine from dmge. It is designed to wrn the opertor tht problem hs occurred. The udio wrning system will sound with continuous horn if one of the following occurs: Engine oil pressure too low Engine temperture too hot Sewter pressure too low 90-8M NOVEMBER 2010 Pge 21

30 Section 2 - Getting to Know Your Power Pckge The udio wrning system will sound with n intermittent beeping if the following occurs: Trnsmission fluid temperture too hot Trnsmission pressure too low NOTICE A continuous horn indictes criticl fult. Operting the engine during criticl fult cn dmge components. If the wrning horn emits continuous beep, do not operte the engine unless voiding hzrdous sitution. If the lrm sounds, stop the engine immeditely. Investigte cuse nd correct it, if possible. If the cuse cnnot be determined, contct your uthorized Mercury MerCruiser deler. Testing The Audio Wrning System 1. Turn the ignition switch to the "ON" position without crnking the engine. 2. Listen for the udio lrm. The lrm will sound if the system is functioning correctly. Engine Gurdin Strtegy IMPORTANT: Bot speed could be reduced to idle nd my not respond to the throttle. Engine Gurdin Strtegy is designed to help reduce the potentil for engine dmge by reducing engine power when potentil problem is sensed by the ECM. Engine Gurdin monitors: Oil pressure Coolnt temperture Sewter pressure Engine overspeed Exhust Mnifold Temperture [8.1 liter (496 cid) engines only] Also the Engine Gurdin Strtegy will reduce engine power to 90 percent of mximum if ny sensor on the power pckge fils. For exmple, if the wter inlet becomes prtilly blocked, Engine Gurdin Strtegy will reduce the vilble power level of the engine to help prevent dmge from decresed wter flow to the engine. If the debris psses through nd full wter flow is restored, engine power levels re restored to norml. To void possible recurrence of the problem you should contct n uthorized deler. The ECM stores the fult nd with this informtion the technicin will be ble to more rpidly dignose problems. Trnsmission Gurdin Strtegy IMPORTANT: Bot speed could be reduced to idle nd my not respond to the throttle. Trnsmission Gurdin is MerCruiser DTS feture tht protects trnsmissions from clutch dmge. Trnsmission Gurdin monitors the clutch pck pressure in forwrd nd reverse gers. If the trnsmission fluid pressure drops below predetermined level, Trnsmission Gurdin lowers the engine torque nd speed to prevent clutch slippge. To void possible recurrence of the problem, you should contct n uthorized deler. The ECM stores the fult nd with this informtion the technicin will be ble to more rpidly dignose problems. Wrning Horn Signls Most fults will cuse the wrning horn circuit to ctivte. How the wrning horn ctivtes depends on how serious the problem is. There re four wrning horn sttes: Cution horn signl vries with product line nd clibrtion. Miniml gurdin. Wrning horn signl vries with product line nd clibrtion. Severe horn is beeping constntly. Criticl horn is beeping constntly nd gurdin will be t forced idle. In ddition, depending on the guge pckge, there will be wrning icons nd fult messges on the dsh mounted guges. Pge M NOVEMBER 2010

31 Emissions Informtion Emission Control Informtion Lbel Section 2 - Getting to Know Your Power Pckge A tmper resistnt Emission Control Informtion lbel is ffixed in visible loction to the engine t time of mnufcture by Mercury MerCruiser. In ddition to the required emissions sttement, the lbel lists the engine seril number, fmily, FEL (emission level), dte of mnufcture (month, yer), nd the engine displcement. Plese note tht the low emissions certifiction will not ffect the fit, function, or performnce of the engines. Botbuilders nd delers my not remove the lbel or the prt it is ffixed to before sle. If modifictions re necessry, contct Mercury MerCruiser bout the vilbility of replcement decls before proceeding. "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "FEL." Fmily Emission Limit "D.O.M." Dte of Mnufcture "DISP" Piston Displcement EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# OMXXXXXXXX D.O.M. JAN FAMILY XXXXX_XXXXXX DISP X.XL FEL. XX.X g/kw-hr Emission Control Lbel - Non CE Mrked EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# FAMILY FEL. OMXXXXXX XXXXX XXXXXX XX.X g/kw-hr D.O.M. DISP. Dec 2004 X.XL "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "FEL." Fmily Emission Limit "D.O.M." Dte of Mnufcture "DISP" Piston Displcement Emission Control Lbel - CE Mrked CE When this mrk is present in the lower right corner of the Emission Control Informtion Lbel, on the engine, the Declrtion of Conformnce pplies. Refer to the front pge of this Mnul for further informtion. Owner Responsibility The owner/opertor is required to hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. The owner/opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow emissions levels to exceed their predetermined fctory specifictions. 90-8M NOVEMBER 2010 Pge 23

32 Section 2 - Getting to Know Your Power Pckge Str Lbel Beginning Jnury 1, 2003, one Three Str lbel will be included with ech fctory certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp nd below) will hve Three Str Ultr Low Emission rting. The Three Str lbel identifies tht these engines meet the Cliforni Air Resources Bord's Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emissions engines. The Three Str lbel will be ffixed on the left side of the hull s shown. XX 1234 XX - Recommended loction b - Secondry loction b mc79531 One Str - Low emission mc The one str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2001 exhust emission stndrds. Engines meeting these stndrds hve 75% lower emissions thn conventionl crbureted two stroke engines. These engines re equivlent to the U.S. EPA's 2006 stndrds for mrine engines. Two Strs - Very Low emission FO IDA mc The two str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2004 exhust emission stndrds. Engines meeting these stndrds hve 20% lower emissions thn One Str Low Emission engines. Three Strs - Ultr Low emission A SS D mc The three str lbel identifies engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2008 exhust emission stndrds or the Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emission engines. Four Strs - Super Ultr Low emission RN F T mc The Four Str lbel identifies engines tht meet the Air Resources Bord's Sterndrive nd Inbord mrine engine 2009 exhust emission stndrds. Personl Wtercrft nd Outbord mrine engines my lso comply with these stndrds. Engines meeting these stndrds hve 90% lower emissions thn One Str Low Emission engines. Pge M NOVEMBER 2010

33 Tble of Contents Section 3 - On The Wter Section 3 - On The Wter Sfe Boting Suggestions Be Alert to Crbon Monoxide Poisoning Good Ventiltion Poor Ventiltion Bsic Bot Opertion (Non DTS Models) Lunching nd Bot Opertion...28 Opertion Chrt Strting nd Stopping the Engine...28 Strting the Engine Stopping the Engine Throttle Only Opertion...29 Freezing Temperture Opertion...29 Drin Plug nd Bilge Pump...29 Bsic Bot Opertion (DTS Models) Lunching nd Bot Opertion...29 Opertion Chrt Strting nd Stopping the Engine...30 Strting the Engine Stopping the Engine Throttle Only Opertion...31 Freezing Temperture Opertion...31 Drin Plug nd Bilge Pump...31 Protecting People in the Wter While You Are Cruising While Bot Is Sttionry High Speed nd High Performnce Opertion Pssenger Sfety in Pontoon Bots nd Deck Bots Bots Hving n Open Front Deck Bots With Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot...34 The Bottom of the Bot...34 Cvittion...34 Ventiltion...34 Elevtion nd Climte...34 Getting Strted Hour Brek In Period...35 After Brek In Period...35 End of First Seson Checkup M NOVEMBER 2010 Pge 25

34 Section 3 - On The Wter Sfe Boting Suggestions To sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl boting regultions nd restrictions nd consider the following suggestions. Know nd obey ll nuticl rules nd lws of the wterwys. We recommend tht ll powerbot opertors complete boting sfety course. In the US, the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil boting lw enforcement gency provide courses. For more informtion in the US, cll the Bot U.S. Foundtion t BOAT (2628). Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment on bord. Here re some suggestions of the types of sfety equipment to crry when boting: Approved fire extinguishers Signl devices: flshlight, rockets or flres, flg nd whistle or horn Tools necessry for minor repirs Anchor nd extr nchor line Mnul bilge pump nd extr drin plugs Drinking wter Trnsistor rdio Pddle or or Spre propeller, thrust hubs, nd n pproprite wrench First id kit nd instructions Wter proof storge continers Spre operting equipment, btteries, bulbs nd fuses Compss nd mp or chrt of the re Personl flottion device (1 per person on bord) Wtch for signs of wether chnge nd void foul wether nd rough-se boting. Tell someone where you re going nd when you expect to return. Pssenger bording. Stop the engine whenever pssengers re bording, unloding or re ner the bck (stern) of the bot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl Lw requires tht there be U. S. Cost Gurd pproved life jcket (personl flottion device), correctly sized nd redily ccessible for every person on bord, plus throwble cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the bot. Prepre other bot opertors. Instruct t lest 1 person on bord in the bsics of strting nd operting the engine nd bot hndling in cse the driver becomes disbled or flls overbord. Do not overlod your bot. Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot cpcity plte). Know your bot's operting nd loding limittions. Know if your bot will flot if full of wter. When in doubt, contct your uthorized Mercury MerCruiser deler or the bot mnufcturer. Ensure tht everyone in the bot is properly seted. Do not llow nyone to sit or ride on ny prt of the bot tht ws not intended for such use. This includes the bcks of sets, gunwles, trnsom, bow, decks, rised fishing sets nd ny rotting fishing set; nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of bot control or sudden bot movement could cuse person to be thrown overbord or into the bot. Ensure tht ll pssengers hve proper set nd re in it before ny bot movement. Never be under the influence of lcohol or drugs while boting (it is the lw). They impir your judgment nd gretly reduce your bility to rect quickly. Know your boting re nd void hzrdous loctions. Be lert. Pge M NOVEMBER 2010

35 Section 3 - On The Wter The opertor of the bot is responsible by lw to mintin proper lookout by sight nd hering. The opertor must hve n unobstructed view prticulrly to the front. No pssengers, lod or fishing sets should block the opertors view when the bot is bove idle or plning trnsition speed. Wtch out for others, the wter nd your wke. Never drive your bot directly behind wter skier in cse the skier flls. As n exmple, your bot trveling t 40 km/h (25 MPH) will overtke fllen skier who ws 61 m (200 ft.) in front of you in 5 seconds. Wtch fllen skiers. When using your bot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the bot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never bck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required by lw to file Boting Accident Report with their stte boting lw enforcement gency when their bot is involved in certin boting ccidents. A boting ccident must be reported if 1) there is loss of life or probble loss of life, 2) there is personl injury requiring medicl tretment beyond first id, 3) there is dmge to bots or other property where the dmge vlue exceeds $ or 4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement. Be Alert to Crbon Monoxide Poisoning Crbon monoxide is present in the exhust fumes of ll internl combustion engines including the outbords, sterndrives nd inbord engines tht propel bots, s well s the genertors tht power vrious bot ccessories. Crbon monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of crbon monoxide poisoning, which should not be confused with sesickness or intoxiction, include hedche, dizziness, drowsiness nd nuse.! WARNING Crbon monoxide poisoning cn led to unconsciousness, brin dmge, or deth. Keep the bot well ventilted while t rest or underwy nd void prolonged exposure to crbon monoxide. Good Ventiltion Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes. 1. Exmple of desired ir flow through the bot. mc Poor Ventiltion Under certin conditions, permnently enclosed or cnvs enclosed cbins or cockpits with insufficient ventiltion my drw in crbon monoxide. Instll one or more crbon monoxide detectors in your bot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry bot tht contins or is ner n operting engine my be exposed to hzrdous level of crbon monoxide. 1. Exmples of poor ventiltion while bot is sttionry: b mc Operting the engine when the bot is moored in confined spce b - Mooring close to nother bot with its engine operting 90-8M NOVEMBER 2010 Pge 27

36 Section 3 - On The Wter 2. Exmples of poor ventiltion while bot is moving: b mc Operting the bot with the trim ngle of the bow too high b - Operting the bot with no forwrd htches open (sttion wgon effect) Bsic Bot Opertion (Non DTS Models) Lunching nd Bot Opertion IMPORTANT: Instll bilge drin plug prior to lunching bot. Opertion Chrt Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Instll bilge drin plug. Open engine htch. Turn bttery switch on. Observe ll guges to check condition of engine. If not norml, stop engine. Check for fuel, oil, wter, fluid nd exhust leks. Check shift nd throttle control opertion. Observe ll guges to check condition of engine. If not norml, stop engine. Listen for the udio lrm. Turn ignition key to the "OFF" position. Turn bttery switch to the "OFF" position. Close fuel shut off vlve. Operte bilge blowers. Check steering opertion. Close secock, if equipped. Open fuel shut off vlve. Open secock, if equipped. Close the drin system. Check the engine oil. Perform ll other checks specified by your deler nd/or bot builder. Listen for Audio Wrning Alrm to sound when the ignition switch is in the "ON" position. Strting nd Stopping the Engine NOTE: Only perform those functions pplicble to your power pckge. Strting the Engine 1. Check ll items listed in the Opertion Chrt. 2. Plce the remote control hndle in neutrl. NOTICE Flush cooling system if in sltwter. Drin bilge. 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.! WARNING Explosive fumes contined in the engine comprtment cn cuse serious injury or deth from fire or explosion. Before strting the engine, operte the bilge blower or vent the engine comprtment for t lest five minutes. 3. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. Allow engine to wrm up (6 10 minutes on first strt of the dy). Pge M NOVEMBER 2010

37 Section 3 - On The Wter 4. If engine does not strt fter 3 ttempts:. Push the throttle only button nd position the remote control hndle/throttle lever to the 1/4 throttle position. b. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. 5. If engine does not strt fter step 4:. Move the remote control hndle/throttle lever to full throttle position, then return to 1/4 throttle. b. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. 6. Inspect the power pckge for fuel, oil, wter nd exhust leks. 7. Move control hndle with firm, quick motion forwrd to shift to forwrd ger, or bckwrd to shift to reverse. After shifting, dvnce throttle to desired setting. NOTICE Shifting into ger t engine speeds bove idle will dmge the drive system. Shift the drive into ger only when the engine is operting t idle. Stopping the Engine 1. Move the remote control hndle to neutrl/idle nd llow the engine to slow to idle speed. If engine hs been operted t high speed for long period of time, llow the engine to cool t idle speed for 3 to 5 minutes. 2. Turn ignition key to the "OFF" position. Throttle Only Opertion 1. Refer to Remote Controls section for remote control fetures. 2. Move the control lever to the idle/neutrl position. 3. Depress nd hold the throttle only button, nd move the control lever to the idle/forwrd or idle/reverse position. 4. Advncing the control lever beyond the idle/forwrd or idle/reverse position will cuse engine speed to increse. IMPORTANT: Moving the control lever bck to the idle/neutrl position will disengge the throttle only button nd llow the engine to shift into ger. 5. Throttle only mode is dectivted by moving the control lever to the idle/neutrl position. Moving the control lever from the idle/neutrl position to the idle/forwrd or idle/reverse position without pressing the throttle only button will shift the unit into the chosen ger. Freezing Temperture Opertion IMPORTANT: If the bot is operted during periods of freezing temperture, precutions must be tken to prevent freeze dmge to the power pckge. Dmge cused by freezing is not covered by Mercury MerCruiser Limited Wrrnty. Drin Plug nd Bilge Pump The engine comprtment in your bot is nturl plce for wter to collect. For this reson, bots re normlly equipped with drin plug nd/or bilge pump. It is very importnt to check these items on regulr bsis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will be dmged if submerged. Dmge cused by submersion is not covered by the Mercury MerCruiser Limited Wrrnty. Bsic Bot Opertion (DTS Models) Lunching nd Bot Opertion IMPORTANT: Instll bilge drin plug prior to lunching bot. Opertion Chrt Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Instll bilge drin plug. Observe ll guges to check condition of engine. If not norml, stop engine. Observe ll guges to check condition of engine. If not norml, stop engine. Turn ignition key to the "OFF" position. Open engine htch. Check for fuel, oil, wter, fluid nd exhust leks. Listen for the udio lrm. Turn bttery switch to the "OFF" position. 90-8M NOVEMBER 2010 Pge 29

38 Section 3 - On The Wter Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Turn bttery switch on. Check shift nd throttle control opertion. Close fuel shut off vlve. Operte bilge blowers. Check steering opertion. Close secock, if equipped. Open fuel shut off vlve. Open secock, if equipped. Close the drin system. Check the engine oil. Perform ll other checks specified by your deler nd/or bot builder. Listen for Audio Wrning Alrm to sound when the ignition switch is in the "ON" position. Strting nd Stopping the Engine NOTE: Perform only those functions pplicble to your power pckge. Strting the Engine 1. Check ll items listed in the Opertion Chrt. 2. Plce the remote control hndle in neutrl. NOTICE Flush cooling system if in sltwter. Drin bilge. 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.! WARNING Explosive fumes contined in the engine comprtment cn cuse serious injury or deth from fire or explosion. Before strting the engine, operte the bilge blower or vent the engine comprtment for t lest five minutes. NOTE: MerCruiser DTS models re equipped with SmrtStrt. The SmrtStrt feture incorportes push button strting. Rther thn holding the strt button or key switch to strt the engine nd then relesing it when the engine strts, SmrtStrt completely controls the strting process. When the strt button is pushed, the DTS system signls the engine PCM to strt the engine. If the engine does not strt, the strting process times out fter few seconds or when the engine reches 400 RPM. Attempting to strt the engine with the engine lredy running will turn the engine off. 3. Turn ignition key to "RUN" position. 4. Turn the ignition key switch to the "START" position then relese, or depress the strt/stop button nd relese. If the engine is cold, llow the engine to operte t idle for 6 10 minutes or until the engine temperture reches 60 C (140 F). 5. If the engine does not strt fter three ttempts:. Push the throttle only button nd position the remote control hndle or throttle lever to the 1/4 throttle position. b. Turn the ignition key to "strt." Relese key when the engine strts nd llow the switch to return to the "on" position. 6. If the engine does not strt fter step 5:. Move the remote control hndle.throttle lever to the full throttle position, then return to 1/4 throttle. b. Turn the ignition key to "START." Relese key when the engine strts nd llow the switch to return to the "on" position. 7. Inspect the power pckge for fuel, oil, wter, nd exhust leks. 8. Move the control hndle with firm, quick motion forwrd to shift to forwrd ger, or bckwrd to shift to reverse. After shifting, dvnce throttle to desired setting. NOTICE Shifting into ger t engine speeds bove idle will dmge the drive system. Shift the drive into ger only when the engine is operting t idle. Pge M NOVEMBER 2010

39 Stopping the Engine Section 3 - On The Wter 1. Move the remote control hndle to neutrl/idle nd llow the engine to slow to idle speed. If engine hs been operted t high speed for long period of time, llow the engine to cool t idle speed for 3 to 5 minutes. 2. The engine cn be stopped by ny one of the following 4 methods:. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop nd the control system will be dectivted. b. Depress the strt/stop button, if equipped. The engine will stop nd the control system will remin ctive. c. Momentrily move the ignition key switch to the "START" position, then relese immeditely. The control system will recognize tht the engine is running nd will stop the engine. The control system will remin ctive. Moving the ignition key switch to the "START" position gin will issue strt request to the control system nd the control system will strt the engine, if pproprite. d. Activte the lnyrd stop switch, if equipped. The engine will stop, but the control system will remin ctive. The control system will not llow the engine to strt if the lnyrd stop switch is ctivted. Throttle Only Opertion NOTE: When operting in throttle only (neutrl) mode, the DTS Control System will not llow the engine speed to increse bove 3500 RPM. Zero effort remote controls: Zero effort remote controls hve seperte throttle control nd shift control levers. Advncing the throttle control lever beyond the idle position while the shift control lever is in the neutrl position will cuse engine speed to increse, but only up to the mximum neutrl engine speed of 3500 RPM.! WARNING The Digitl Throttle nd Shift (DTS) Zero Effort control cn shift the engine or trnsmission t speeds greter thn idle, cusing unexpected bot movement, which my result in injury, deth, or property dmge due to loss of bot control. Alwys plce the throttle control lever in the idle position before moving the shift control lever into forwrd or reverse ger position. Pnel Mount nd Console Mount Remote Controls: Pnel mount nd console mount remote controls re equipped with throttle only button. To ctivte throttle only mode: 1. Refer to Remote Controls section for remote control fetures. 2. Move the control lever to the idle/neutrl position. 3. Depress the throttle only button, nd move the control lever to the idle/forwrd or idle/reverse position. The DTS control system will sound two beeps on the udio wrning horn to indicte throttle only mode is ctive. On console mount remote controls, the neutrl light will begin to blink. 4. Advncing the control lever beyond the idle/forwrd or idle/reverse position will cuse engine speed to increse. IMPORTANT: Moving the control lever bck to the idle/neutrl position will dectivte the throttle only mode nd llow the engine to shift into ger. 5. Throttle only mode is dectivted by moving the control lever to the idle/neutrl position. Moving the control lever from the idle/neutrl position to the idle/forwrd or idle/reverse position without pressing the throttle only button will shift the unit into the chosen ger. Freezing Temperture Opertion IMPORTANT: If the bot is operted during periods of freezing temperture, precutions must be tken to prevent freeze dmge to the power pckge. Dmge cused by freezing is not covered by Mercury MerCruiser Limited Wrrnty. Drin Plug nd Bilge Pump The engine comprtment in your bot is nturl plce for wter to collect. For this reson, bots re normlly equipped with drin plug nd/or bilge pump. It is very importnt to check these items on regulr bsis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will be dmged if submerged. Dmge cused by submersion is not covered by the Mercury MerCruiser Limited Wrrnty. 90-8M NOVEMBER 2010 Pge 31

40 Section 3 - On The Wter Protecting People in the Wter While You Are Cruising It is very difficult for person in the wter to tke quick ction to void bot heding in their direction, even t slow speeds Alwys slow down nd exercise extreme cution ny time you re boting in n re where there might be people in the wter. Whenever bot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force by the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. While Bot Is Sttionry! WARNING A spinning propeller, moving bot, or ny solid device ttched to the bot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your bot. Shift into neutrl nd shut off the engine before llowing people to swim or be in the wter ner your bot. High Speed nd High Performnce Opertion If your bot is considered high speed or high performnce bot with which you re unfmilir, we recommend tht you never operte it t its high speed cpbility without first requesting n initil orienttion nd demonstrtion ride with your deler or n opertor experienced with your bot. For dditionl informtion, refer to Hi-Performnce Bot Opertion booklet ( R2) from your deler, distributor or Mercury Mrine. Pssenger Sfety in Pontoon Bots nd Deck Bots Whenever the bot is in motion, observe the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in bot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of bot direction, could throw them over the front of bot. Flling over the front of the bot between the two pontoons will position them to be run over. Bots Hving n Open Front Deck No one should ever be on the deck in front of the fence while the bot is in motion. Keep ll pssengers behind the front fence or enclosure. Persons on the front deck could esily be thrown overbord or persons dngling their feet over the front edge could get their legs cught by wve nd pulled into the wter. mc ! WARNING Sitting or stnding in n re of the bot not designed for pssengers t speeds bove idle cn cuse serious injury or deth. Sty bck from the front end of deck bots or rised pltforms nd remin seted while the bot is in motion. Bots With Front Mounted, Rised Pedestl Fishing Sets Elevted fishing sets re not intended for use when the bot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Pge M NOVEMBER 2010

41 Section 3 - On The Wter Any unexpected, sudden reduction in bot speed could result in the elevted pssenger flling over the front of the bot. mc Wve nd Wke Jumping! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts being thrown within or out of the bot. Avoid wve or wke jumping whenever possible. mc Operting recretionl bots over wves nd wkes is nturl prt of boting. However, when this ctivity is done with enough speed to force the bot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the bot re enters the wter. The primry concern is the bot chnging direction while in the midst of the jump. In such cses the lnding my cuse the bot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to be thrown out of their sets or out of the bot. There is nother less common hzrdous result from llowing your bot to lunch off of wve or wke. If the bow of your bot pitches down fr enough while irborne, upon wter contct it my penetrte under the wter surfce nd submrine for n instnt. This will bring the bot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The bot my lso veer shrply to one side. Impct with Underwter Hzrds Reduce speed nd proceed with cution whenever you're driving bot in shllow wter or in res where the wters re suspected of hving underwter obstcles tht could be struck by the underwter drive components, rudder or the bot bottom. IMPORTANT: The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter object is control the bot speed. Under these conditions, bot speed should be kept to mximum speed of 24 to 40 km/h (15 to 25 MPH). Striking floting/underwter object my result in n infinite number of situtions. Some of these situtions could result in the following: The bot could move suddenly in new direction. Such shrp chnge in direction or turn cn cuse occupnts to be thrown out of their sets or out of the bot. A rpid reduction in speed. This will cuse occupnts to be thrown forwrd, even out of the bot. Impct dmge to the underwter drive components, rudder nd/or bot M NOVEMBER 2010 Pge 33

42 Section 3 - On The Wter Keep in mind, one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the bot speed. Bot speed should be kept to minimum plning speed when driving in wters known to hve underwter obstcles. After striking submerged object, stop the engine s soon s possible nd inspect the drive system for ny broken or loose prts. If dmge is present or suspected, the power pckge should be tken to n uthorized Mercury MerCruiser deler for thorough inspection nd necessry repir. The bot should be checked for hull frctures, trnsom frctures nd wter leks. Operting with dmged underwter drive components, rudder or bot bottom could cuse dditionl dmge to other prts of the power pckge, or could ffect control of the bot. If continued opertion is necessry, do so t gretly reduced speeds.! WARNING Operting bot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot Shifting weight to rer (stern): Generlly increses speed nd engine RPM Cuses bow to bounce in choppy wter Increses dnger of following wve splshing into the bot when coming off plne At extremes, cn cuse the bot to porpoise Shifting weight to front (bow): Improves ese of plning Improves rough wter ride At extremes, cn cuse the bot to veer bck nd forth (bow steer) The Bottom of the Bot To mintin mximum speed, the bot bottom should be: Clen, free of brncles nd mrine growth Free of distortion; nerly flt where it contcts the wter Stright nd smooth, fore nd ft Mrine vegettion my ccumulte when the bot is docked. This growth must be removed before opertion; it my clog the wter inlets nd cuse the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter object, such s ger housing or propeller. Cvittion increses propeller speed while reducing bot speed. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other debris sngged on the propeller Bent propeller blde Rised burrs or shrp edges on the propeller Ventiltion Ventiltion is cused by surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in bot speed. Air bubbles strike the propeller blde nd cuse erosion of the blde surfce. If llowed to continue, eventul blde filure (brekge) will occur. Excessive ventiltion is usully cused by: Drive unit trimmed out too fr A missing propeller diffuser ring A dmged propeller or ger housing, which llows exhust gses to escpe between propeller nd ger housing Drive unit instlled too high on trnsom Elevtion nd Climte Elevtion nd climte chnges will ffect the performnce of your power pckge. Loss of performnce cn be cused by: Pge M NOVEMBER 2010

43 Higher elevtions Higher tempertures Low brometric pressures High humidity Section 3 - On The Wter For you to hve optimum engine performnce under chnging wether conditions, it is essentil tht the engine be propped to llow the engine to operte t or ner the top end of the specified mximum RPM rnge with norml bot lod during your norml boting wether conditions. In most cses, recommended RPM cn be chieved by chnging to lower pitch propeller. Getting Strted 20 Hour Brek In Period IMPORTANT: The first 20 hours of opertion is the engine brek in period. Correct brek in is essentil to obtin minimum oil consumption nd mximum engine performnce. During this brek in period, the following rules must be observed: Do not operte below 1500 RPM for extended periods of time for the first 10 hours. Shift into ger s soon s possible fter strting nd dvnce the throttle bove 1500 rpm if conditions permit sfe opertion. Do not operte t one speed consistently for extended periods. Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occsionl opertion t full throttle is permissible (5 minutes t time mximum). Avoid full throttle ccelertion from idle speed. Do not operte t full throttle until the engine reches norml operting temperture. Frequently check engine oil level. Add oil s needed. It is norml for oil consumption to be high during the brek in period. After Brek In Period To help extend the life of your Mercury MerCruiser power pckge, follow these recommendtions: Ensure tht propeller llows the engine to operte t or ner the top of the specified WOT RPM rnge. Refer to Specifictions nd Mintennce. Operte the engine t 3/4 throttle or lower. Refrin from prolonged opertion t wide open throttle RPM. Chnge the engine oil nd oil filter. Refer to Mintennce. Chnge the trnsmission oil nd filter. Refer to Mintennce (ZF Trnsmission models). 1. End of First Seson Checkup At the end of the first seson of opertion, contct n uthorized Mercury MerCruiser deler to discuss nd/or perform scheduled mintennce items. If you re in n re where the product is operted continuously, yer round, you should contct your deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. 1. Require fluid nd filter chnge fter the first 25 hours nd then every 100 hours. 90-8M NOVEMBER 2010 Pge 35

44 Section 3 - On The Wter Notes: Pge M NOVEMBER 2010

45 Tble of Contents Section 4 - Specifictions Section 4 - Specifictions Cruising RPM Fuel Requirements Fuel Rtings Using Reformulted (Oxygented) Gsolines (USA Only) Gsolines Contining Alcohol Engine Oil Engine Specifictions Tow Sports Models Inbord Models Fluid Specifictions Engine Trnsmission M NOVEMBER 2010 Pge 37

46 Section 4 - Specifictions Cruising RPM Modern inbord engines operte t higher engine speeds thn those produced just few yers go. This incresed RPM long with better brething is lrgely responsible for the significnt increse in horsepower of these new engines. Along with the higher WOT RPM comes higher cruising RPM. This higher RPM is criticl for optimum performnce nd efficiency. The mterils nd design of the new engines llow these higher speeds without durbility penlty. In fct, over propping the bot to reduce the cruising RPM to previous levels will increse the susceptibility to engine dmge from detontion nd pre ignition. The recommended cruising RPM rnges re: Cruising RPM for Pek Efficiency Model RPM Rnge 350 MAG MPI MAG MPI Horizon MX 6.2L MPI Fuel Requirements IMPORTANT: Use of improper gsoline cn dmge your engine. Engine dmge resulting from the use of improper gsoline is considered misuse of the engine, nd dmge cused thereby will not be covered under the limited wrrnty. Fuel Rtings Mercury MerCruiser engines will operte stisfctorily when using mjor brnd of unleded gsoline meeting the following specifictions: USA nd Cnd hving posted pump Octne Rting of 87 (R+M)/2 minimum. Premium gsoline [92 (R+M)/2 Octne] is lso cceptble. Do not use leded gsoline. Outside USA nd Cnd hving posted pump Octne Rting of 90 RON minimum. Premium gsoline (98 RON) is lso cceptble. If unleded gsoline is not vilble, use mjor brnd of leded gsoline. Using Reformulted (Oxygented) Gsolines (USA Only) This type of gsoline is required in certin res of the USA. The 2 types of oxygentes used in these fuels is Alcohol (Ethnol) or Ether (MTBE or ETBE). If Ethnol is the oxygente tht is used in the gsoline in your re, refer to Gsolines Contining Alcohol. These Reformulted Gsolines re cceptble for use in your Mercury MerCruiser engine. Gsolines Contining Alcohol If the gsoline in your re contins either methnol (methyl lcohol) or ethnol (ethyl lcohol), you should be wre of certin dverse effects tht cn occur. These dverse effects re more severe with methnol. Incresing the percentge of lcohol in the fuel cn lso worsen these dverse effects. Some of these dverse effects re cused becuse the lcohol in the gsoline cn bsorb moisture from the ir, resulting in seprtion of the wter/lcohol from the gsoline in the fuel tnk. The fuel system components on your Mercury MerCruiser engine will withstnd up to 10% lcohol content in the gsoline. We do not know wht percentge your bot's fuel system will withstnd. Contct your bot mnufcturer for specific recommendtions on the bot's fuel system components (fuel tnks, fuel lines, nd fittings). Be wre tht gsolines contining lcohol my increse: Corrosion of metl prts Deteriortion of rubber or plstic prts Fuel permetion through rubber fuel lines Difficulty strting nd operting the engine! WARNING Fuel lekge is fire or explosion hzrd, which cn cuse serious injury or deth. Periodiclly inspect ll fuel system components for leks, softening, hrdening, swelling, or corrosion, prticulrly fter storge. Any sign of lekge or deteriortion requires replcement before further engine opertion. Becuse of possible dverse effects of lcohol in gsoline, we recommend only lcohol free gsoline when possible. If the only fuel vilble contins lcohol or if you do not know whether the fuel contins lcohol, inspect for leks nd bnormlities more frequently. Pge M NOVEMBER 2010

47 Section 4 - Specifictions IMPORTANT: When operting Mercury MerCruiser engine on gsoline contining lcohol, do not store the gsoline in the fuel tnk for long periods. Wheres crs normlly consume lcohol blend fuels before they cn bsorb enough moisture to cuse trouble, bots often sit idle long enough for phse seprtion to tke plce. In ddition, internl corrosion my tke plce during storge if lcohol hs wshed protective oil films from internl components. Engine Oil To help obtin optimum engine performnce nd to provide mximum protection, we strongly recommend the use of the following oils listed in the order of recommendtion: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC W rted, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC W rted oil. 3. A NMMA FC W rted oil. 4. MerCruiser / Quicksilver 4 cycle 25W40, non FC W rted oil. 5. A good grde stright weight detergent utomotive oil per the operting chrt below. NOTE: The use of non detergent oils, multi viscosity oils (other thn s specified), non FC W rted synthetic oils, low qulity oils or oils tht contin solid dditives re specificlly not recommended. MerCruiser/ Quicksilver Synthetic Blend, NMMA FC-W rted, 4-cycle oil ORDER OF PREFERENCE MerCruiser / Quicksilver 25W40 NMMA FC-W rted oil A NMMA FC-W rted oil MerCruiser / Quicksilver 4-cycle 25W40, non FC-W rted oil SAE40W SAE30W SAE 20W 32 F 0 C AIR TEMPERATURE 50 F 10 C 8082 Engine Specifictions Tow Sports Models Models 350 MAG MPI Tow Sports MX 6.2 MPI Tow Sports Horsepower Kilowtts Displcement 5.7 L (350cid) 6.2 L (377cid) Specified WOT RPM Rnge Idle RPM in Neutrl Performnce obtined nd corrected in ccordnce with SAE J1228/ISO 8665 Crnkshft Power. 2. Mesured using n ccurte service tchometer with the engine t norml operting tempertures. 3. Idle speed nd timing on EFI models re not djustble 90-8M NOVEMBER 2010 Pge 39

48 Section 4 - Specifictions Minimum Oil Idle 4. Minimum Oil 2000 RPM 4. Models 350 MAG MPI Tow Sports MX 6.2 MPI Tow Sports 41 kp (6 psi) 124 kp (18 psi) Thermostt, sewter cooled models 71 C (160 F) Thermostt, closed cooled models 77 C (170 F) Idle 3. Not Adjustble Firing Order Electricl System Alterntor Rting Hot Operting Amps Alterntor Rting Cold Operting Amps Recommended Bttery Rting (Minimum) 12 Volt Negtive ( ) Ground 65 mp 72 mp 750 CCA, 950 MCA, or 180 Ah Sprk Plug Type AC Pltinum (AC ) Sprk Plug Gp Inbord Models 1.5 mm (0.060 in.) Models 350 MAG MPI 350 MAG MPI Horizon MX 6.2 MPI MX 6.2 MPI Horizon Horsepower Kilowtts Displcement 5.7 L (350 cid) 6.2 L (377 cid) Specified WOT RPM Rnge Idle RPM in Neutrl Minimum Oil Idle 8. Minimum Oil 2000 RPM kp (6 psi) 124 kp (18 psi) Thermostt, sewter cooled models 71 C (160 F) Thermostt, closed cooled models 77 C (170 F) Idle 7. Not Adjustble Firing Order Electricl System Alterntor Rting Hot Operting Amps Alterntor Rting Cold Operting Amps Recommended Bttery Rting (DTS Models) (Minimum) Recommended Bttery Rting (Non DTS Models) (Minimum) 12 Volt Negtive ( ) Ground 65 mp 72 mp 750 CCA, 950 MCA, or 180 Ah 800 CCA, 1000 MCA, or 190 Ah Sprk Plug Type AC Pltinum (AC ) Sprk Plug Gp 1.5 mm (0.060 in.) 4. Oil pressure must be checked with the engine t norml operting temperture. 5. Performnce obtined nd corrected in ccordnce with SAE J1228/ISO 8665 Crnkshft Power. 6. Mesured using n ccurte service tchometer with the engine t norml operting tempertures. 7. Idle speed nd timing on EFI models re not djustble 8. Oil pressure must be checked with the engine t norml operting temperture. Pge M NOVEMBER 2010

49 Fluid Specifictions Section 4 - Specifictions Engine IMPORTANT: All cpcities re pproximte fluid mesures. IMPORTANT: It my be necessry to djust oil levels depending on instlltion ngle nd cooling systems (het exchnger nd fluid lines). All Models Cpcity Fluid Type Engine Oil (With Filter) liters (4.5 U.S qts) Quicksilver Synthetic Blend, NMMA FC W rted, 4 cycle oil Sewter Cooling System liters (21 U.S. qts) Propylene Glycol nd Purified Wter Closed Cooling System Trnsmission 19 liters (20 U.S. qts) Mercury Extended Life Coolnt/Antifreeze or Extended Life Ethylene Glycol 5/100 Antifreeze/Coolnt mixed 50/50 with Purified Wter Model Cpci Fluid Type 5000A 5000V 71C In Line 71C Ger Reduction 71C Remote V Drive 3 72C In Line 72C Ger Reduction 72C Remote V Drive 3 72C V Drive 63A 63V 45C Tow Sports 45C Remote V Drive 3. 45C In Line 2.84L (3 qts) 3.30L (3 1/2 qts) 1.66L (1 3/4 qts) 2.84L (3 qts) 1.66L (1 3/4 qts) 1.66L (1 3/4 qts) 1.66L (1 3/4 qts) 1.66L (1 3/4 qts) 3.79L (4 qts) 4.00L (4 1/2 qts) 4.00L (4 1/2 qts) 1.77L (60 oz) 1.90L (64 oz) 1.94L (66 oz) Dexron III Automtic Trnsmission Fluid Dexron III Automtic Trnsmission Fluid Dexron III Automtic Trnsmission Fluid Dexron III Automtic Trnsmission Fluid 1. Alwys use the dipstick to determine the exct quntity of oil or fluid required. 2. Sewter Cooling System cpcity informtion is for winteriztion use only. 3. Wlters V Drive pplictions hve 2 fluid service points, the trnsmission nd the v drive ger box. Refer to the Wlters owner's mnul for cpcity nd intervls. 90-8M NOVEMBER 2010 Pge 41

50 Section 4 - Specifictions Notes: Pge M NOVEMBER 2010

51 Tble of Contents Section 5 - Mintennce Section 5 - Mintennce Owner/Opertor Responsibilities Deler Responsibilities Mintennce Do It Yourself Mintennce Suggestions Inspection Mintennce Schedule Inbord Models Routine Mintennce Ech Dy Strt Ech Dy End Weekly Every Two Months or 50 Hours Scheduled Mintennce After the Initil 20 Hour Brek In Period Every 100 Hours or Annully (Whichever Occurs First) Every 300 Hours or 3 Yers Mintennce Log Engine Oil Checking Filling Chnging Oil nd Filter Esy Engine Oil Drin System Engine Oil Drin Pump Chnging Filter Trnsmission Fluid Checking While the Engine is Wrm Checking While Engine is Cold Chnging Engine Coolnt Checking Filling Chnging Clening the Flme Arrestor Positive Crnkcse Ventiltion Vlve (PCV)...52 Chnging Chnging Wter Seprting Fuel Filter GEN II Models GEN III Models In line Fuel Filter Lubriction Throttle Cble...56 Trnsmission Linkge...56 Serpentine Drive Belt Checking Replcing Belt nd/or Adjusting Tension Flushing The Power Pckge Tow Sports The Bot Out of the Wter The Bot In the Wter Bttery Multiple EFI Engine Bttery Precutions M NOVEMBER 2010 Pge 43

52 Section 5 - Mintennce Owner/Opertor Responsibilities It is the opertor's responsibility to perform ll sfety checks, to ensure tht ll lubriction nd mintennce instructions re complied with for sfe opertion nd to return the unit to n uthorized Mercury MerCruiser deler for periodic checkup. Norml mintennce service nd replcement prts re the responsibility of the owner/opertor nd s such, re not considered defects in workmnship or mteril within the terms of the wrrnty. Individul operting hbits nd usge contribute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependbility nd will keep your overll operting expenses t minimum. See your uthorized Mercury MerCruiser deler for service ids. Deler Responsibilities In generl, deler's responsibilities to the customer include predelivery inspection nd preprtion such s: Ensure tht the bot is properly equipped. Prior to delivery, mke certin tht the Mercury MerCruiser power pckge nd other equipment re in proper operting condition. Mke ll necessry djustments for mximum efficiency. Fmilirize the customer with the on bord equipment. Explin nd demonstrte the opertion of the power pckge nd bot. Provide you with copy of Predelivery Inspection Checklist. Your selling deler should fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product. Mintennce! WARNING Performing service or mintennce without first disconnecting the bttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the bttery cbles from the bttery before mintining, servicing, instlling, or removing engine or drive components.! WARNING Fuel vpors trpped in the engine comprtment my be n irritnt, cuse difficulty brething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment before servicing the power pckge. IMPORTANT: Refer to the mintennce schedule for complete listing of ll scheduled mintennce to be performed. Wheres you cn perform some items, others should be performed only by n uthorized Mercury MerCruiser deler. Before ttempting mintennce or repir procedures not covered in this mnul, we recommend tht you purchse Mercury MerCruiser service mnul nd red it thoroughly. NOTE: Mintennce points re color coded for ese of identifiction. See the decl on engine for identifiction. Mintennce Point Color Codes Blue Yellow Ornge Blck Brown Coolnt Engine oil Fuel Ger lube oil (sterndrive models only) Trnsmission (inbord models only) Do It Yourself Mintennce Suggestions Present dy mrine equipment, such s your Mercury MerCruiser power pckge, re highly technicl pieces of mchinery. Electronic ignition nd specil fuel delivery systems provide greter fuel economies, but lso re more complex for the untrined mechnic. If you re one of those persons who likes to do it yourself, here re some suggestions for you. Do not ttempt ny repirs unless you re wre of the Cutions, Wrnings nd procedures required. Your sfety is our concern. Pge M NOVEMBER 2010

53 Section 5 - Mintennce If you ttempt to service the product yourself, we suggest you order the service mnul for tht model. The service mnul outlines the correct procedures to follow. It is written for the trined mechnic, so there my be procedures you don't understnd. Do not ttempt repirs if you do not understnd the procedures. There re specil tools nd equipment tht re required to perform some repirs. Do not ttempt these repirs unless you hve these specil tools nd/or equipment. You cn cuse dmge to the product in excess of the cost deler would chrge you. Also, if you prtilly disssemble n engine or drive ssembly nd re unble to repir it, the deler's mechnic must ressemble the components nd test to determine the problem. This will cost you more thn tking it to the deler immeditely upon hving problem. It my be very simple djustment to correct the problem. Do not telephone the deler, service office or the fctory to ttempt for them to dignose problem or to request the repir procedure. It is difficult for them to dignose problem over the telephone. Your uthorized deler is there to service your power pckge. They hve qulified fctory trined mechnics. It is recommended you hve the deler do periodic mintennce checks on your power pckge. Hve them winterize it in the fll nd service it before the boting seson. This will reduce the possibility of ny problems occurring during your boting seson when you wnt trouble free boting plesure. Inspection Inspect your power pckge often, nd t regulr intervls, to help mintin its top operting performnce nd correct potentil problems before they occur. The entire power pckge should be checked crefully, including ll ccessible engine prts. Check for loose, dmged or missing prts, hoses nd clmps; tighten or replce s necessry. Check plug leds nd electricl leds for dmge. Remove nd inspect the propeller. If bdly nicked, bent or crcked, contct your uthorized Mercury MerCruiser deler. Repir nicks nd corrosion dmge on power pckge exterior finish. Contct your uthorized Mercury MerCruiser deler. Mintennce Schedule Inbord Models Routine Mintennce NOTE: Only perform mintennce which pplies to your prticulr power pckge. Ech Dy Strt Check the crnkcse oil (intervl cn be extended bsed on experience). Check the trnsmission fluid level. Ech Dy End If operting in slt, brckish or polluted wters, flush the cooling system fter ech use. Weekly Check the wter inlets for debris or mrine growth. Check the sewter striner nd clen. Check the coolnt level. Check the trnsmission fluid. Every Two Months or 50 Hours Operting in sltwter or brckish or polluted wter only: tret the power pckge with Corrosion Gurd. Check the bttery connections nd the fluid level. Ensure tht the guges nd the wiring connections re secure. Clen the guges. 1. Scheduled Mintennce NOTE: Only perform mintennce which pplies to your prticulr power pckge. After the Initil 20 Hour Brek-In Period To help extend the life of your Mercury MerCruiser power pckge, we recommend the following: Chnge the engine oil nd filter Chnge the trnsmission oil nd filter on inbord models. NOTE: ZF Mrine requires the trnsmission to be chnged to preserve the wrrnty. 1. If operting in sltwter, intervl is reduced to every 25 hours or 30 dys whichever occurs first. 90-8M NOVEMBER 2010 Pge 45

54 Section 5 - Mintennce Every 100 Hours or Annully (Whichever Occurs First) Touch up the pint on the power pckge. Chnge the crnkcse oil nd filter. Chnge the trnsmission fluid (ZF Trnsmission Models) 2. Replce the wter seprting fuel filter element. Check the steering system nd the remote control for loose, missing or dmged prts. Lubricte the cbles nd the linkges. Inspect the condition of the belts. Clen the flme rrestor, IAC muffler 3., nd the crnkcse ventiltion hoses. Inspect the PCV vlve, if equipped. Every 300 Hours or 3 Yers Check the engine mount for tightness nd retorque if necessry. Check the distributor cp, if equipped. Check the electricl system for loose, dmged, or corroded fsteners. Check the cooling system nd the exhust system hose clmps for tightness. Inspect both systems for dmge or leks. Disssemble nd inspect the sewter pump nd replce worn components. Clen the sewter section of the closed cooling system. Clen, inspect, nd test the pressure cp. Inspect the exhust system components nd verify tht the flpper vlves re not missing or worn, if equipped. Mintennce Log Record ll mintennce performed on your power pckge here. Be sure to sve ll work orders nd receipts. Dte Mintennce Performed Engine Hours 2. Require fluid nd filter chnge fter the first 25 hours nd then every 100 hours. 3. Contct your uthorized Mercury MerCruiser deler to replce the IAC muffler. Pge M NOVEMBER 2010

55 Section 5 - Mintennce Engine Oil NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted by lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your bot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking 1. Stop the engine. Allow pproximtely 5 minutes for the oil to drin into the oil pn. The bot must be t rest in the wter. 2. Remove the dipstick. Wipe clen nd reinstll fully into the dipstick tube. Wit 60 seconds to llow trpped ir to vent. NOTE: Ensure tht dipstick is instlled with oil level indiction mrks fcing the rer of the engine (flywheel end). - Dipstick tube IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK rnge mrk on the dipstick. 3. Remove the dipstick nd observe the oil level. Oil level must be between full or OK rnge nd dd. Reinstll dipstick into dipstick tube. Filling IMPORTANT: Do not overfill the engine with oil. IMPORTANT: Alwys use the dipstick to determine the exct quntity of oil or fluid required. 1. Remove oil fill cp Oil fill cp 6077 IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK rnge mrk on the dipstick. 2. Add the specified engine oil to bring the level up to, but not over, the full or OK rnge mrk on the dipstick. Recheck oil level. 3. Replce the fill cp. 90-8M NOVEMBER 2010 Pge 47

56 Section 5 - Mintennce Models Cpcity Fluid Type Engine Oil (With Filter) Chnging Oil nd Filter 4.25 liters (4.5 U.S. Qurt) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 Refer to the Mintennce schedule for the chnge intervl. Engine oil should be chnged before plcing the bot in storge. IMPORTANT: Chnge engine oil when the engine is wrm from opertion. Wrm oil flows more freely, crrying wy more impurities. Use only recommended engine oil (refer to Specifictions). Esy Engine Oil Drin System NOTE: Bot must be out of wter to perform this procedure. 1. Loosen the oil filter to vent the system. 2. Remove the bilge drin plug. 3. Pull tether through the bilge drin. b c f d e Binge drin plug b - Tether c - Clip d - Oil drin hose plug e - Oil drin hose f - Bilge drin flnge 4. Plce the oil drin hose in suitble continer. 5. Remove the drin plug from the oil drin hose. 6. After oil hs drined completely, instll the drin plug in the oil drin hose. 7. Push the hose through bilge drin nd instll the plug. Engine Oil Drin Pump 1. Loosen the oil filter to vent the system. 2. Remove the dipstick. 3. Instll the oil pump onto the dipstick tube. b c mc Typicl oil pump b - Dipstick tube c - Oil drin hose 4. Insert the hose end of the crnkcse oil pump onto n pproprite continer nd, using the hndle, pump until the crnkcse is empty. 5. Remove the pump. Pge M NOVEMBER 2010

57 Section 5 - Mintennce 6. Instll the dipstick. Chnging Filter 1. Remove nd discrd oil filter In-line exhust - Oil filter V-drive exhust 2. Cot seling ring on new filter with engine oil nd instll. 3. Tighten oil filter securely (following filter mnufcturer's instructions). Do not overtighten. 4. Remove oil fill cp. IMPORTANT: Alwys use dipstick to determine exctly how much oil is required. 5. Add recommended engine oil to bring level up to the bottom of the OK rnge on the dipstick. 6. With the bot t rest in the wter, check the oil level nd dd specified fluid to bring the oil level up to, but not over, the full or OK rnge. NOTE: Adding 0.95 liters (1 qurt) of engine oil will rise the level from the dd mrk to the top of the OK rnge. Models Cpcity Fluid Type Engine Oil (With Filter) 4.25 liters (4.5 U.S. Qurt) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W Strt the engine, run the engine for three minutes, nd check for leks. Stop the engine. Allow pproximtely 5 minutes for the oil to drin into the oil pn. The bot must be t rest in the wter. Trnsmission Fluid Checking While the Engine is Wrm 1. Velvet Drive Trnsmissions Stop the engine nd immeditely check fluid level by turning T hndle counterclockwise, to remove dipstick. Fluid level should be up to full mrk. If low, dd specified fluid through dipstick tube on trnsmissions. 2. ZF Mrine Trnsmissions Stop the engine nd remove the dipstick to check level. If fluid is below top (full) line, dd specified fluid through dipstick hole. Do not overfill. Reinstll dipstick with cp fully seted. 3. Wlter V Drive Trnsmissions Stop the engine nd remove the dipstick to check the level. If the fluid is below the top (full) line, dd the specified fluid through the brether elbow. Do not overfill. Reinstll the dipstick with the cp fully seted. Checking While Engine is Cold NOTE: Cold fluid level check: To ese checking the fluid level, the dipstick cn be mrked or scribed with cold level mrk. 1. Follow the procedure for the wrm fluid level check, then llow the bot to sit overnight. IMPORTANT: Be sure to push the dipstick ll the wy down into the dipstick tube when checking the fluid level. 2. Remove the dipstick, wipe clen nd reinsert. 3. Remove the dipstick, observe the fluid level nd mrk the cold fluid level. 4. Reinstll the dipstick, tighten the T hndle securely. Do not overtighten. Chnging Contct your uthorized Mercury MerCruiser deler. 90-8M NOVEMBER 2010 Pge 49

58 Section 5 - Mintennce Engine Coolnt Checking! CAUTION A sudden loss of pressure cn cuse hot coolnt to boil nd dischrge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolnt pressure cp. 1. Remove the cp from the het exchnger nd observe the fluid level. - Het exchnger cp 2. The coolnt level in the het exchnger should be t the bottom of the filler neck. If the coolnt level is low, contct your uthorized Mercury MerCruiser deler. 3. Instll the cp onto the het exchnger. IMPORTANT: When reinstlling the pressure cp, be sure to tighten it until it sets on the filler neck. 4. With the engine t norml operting temperture, check the coolnt level in the coolnt recovery bottle. 5. The coolnt level should be between the "ADD" nd "FULL" mrks Add the specified fluid s necessry. Filling Tube Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/ Coolnt NOTICE Closed Cooling System K1 Using propylene glycol ntifreeze in the closed cooling system cn dmge the cooling system or the engine. Fill the closed cooling system with n ethylene glycol ntifreeze solution suitble to the lowest temperture to which the engine will be exposed. Pge M NOVEMBER 2010

59 Section 5 - Mintennce 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. NOTICE Air trpped in the closed cooling system cn cuse the engine to overhet, resulting in engine dmge. Minimize the possibility of trpping ir when initilly filling the closed cooling system by positioning the bot so tht the front of the engine is higher thn the rer of the engine. NOTE: Add coolnt only when engine is t norml operting temperture. 1. Remove the fill cp from the coolnt recovery bottle. 2. Fill to the "FULL" line with the specified coolnt. Tube Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/ Coolnt 3. Instll the fill cp onto the coolnt recovery bottle. Chnging Contct your uthorized Mercury MerCruiser deler. Clening the Flme Arrestor! WARNING Closed Cooling System K1 Fuel is flmmble 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 before ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. 1. Remove the engine cover. 2. Disconnect nd remove the crnkcse ventiltion hose from the fitting on the flme rrestor nd vlve cover. 90-8M NOVEMBER 2010 Pge 51

60 Section 5 - Mintennce 3. Remove the flme rrestor. b c d e 6110 f - Engine cover knob b - Engine cover c - Nuts, flme rrestor d - Cover mount brcket e - Flme rrestor f - Crnkcse ventiltion hose 4. Clen the flme rrestor with wrm wter nd mild detergent. 5. Inspect the flme rrestor for holes, crcks, or deteriortion. Replce if necessry. 6. Allow the flme rrestor to ir dry completely before use. 7. Clen the crnkcse ventiltion hose with wrm wter nd mild detergent. Dry with compressed ir or llow to ir dry completely. 8. Inspect the crnkcse ventiltion hose for crcks or deteriortion. Replce if necessry. 9. Instll the flme rrestor nd flme rrestor brcket. Torque the flme rrestor brcket nuts to specifiction. Description Nm lb in. lb ft Flme rrestor brcket nut Connect the crnkcse ventiltion hose to the fitting on the flme rrestor nd vlve cover. 11. Instll the engine cover. Positive Crnkcse Ventiltion Vlve (PCV) Chnging NOTE: We recommend the use of Mercury MerCruiser replcement prts to ensure complince with emission regultions. NOTE: On V6 models the PCV vlve is non serviceble nd is n internl component of the vlve cover. Pge M NOVEMBER 2010

61 Section 5 - Mintennce 1. Remove the PCV vlve from the port vlve cover. - PCV vlve b - Hose b mc Disconnect the PCV vlve from the hose nd discrd the vlve. 3. Instll new PCV vlve in the vlve cover nd reconnect the hose. 4. Ensure tht the PCV vlve is tightly seted in the vlve cover. Chnging Wter Seprting Fuel Filter! WARNING Fuel is flmmble 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 before ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. GEN II Models 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends tht the engine be shut off for 12 hours prior to filter removl. 2. Close fuel supply vlve, if equipped. 3. Wrp the wter seprting fuel filter with cloth to help ctch ny fuel spills or spry. 4. Remove nd discrd the wter seprting fuel filter nd seling ring from the mounting brcket. 5. Cot the seling ring on the new filter with engine oil. Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W Thred filter onto the mounting brcket nd tighten securely by hnd. Do not use filter wrench. b - Fuel filter mounting brcket b - Seling ring c - Fuel filter Filter seling ring K01 c Open fuel supply vlve, if equipped. 8. Ensure tht engine comprtment is properly ventilted. 9. Supply cooling wter to the engine. 90-8M NOVEMBER 2010 Pge 53

62 Section 5 - Mintennce 10. Strt the engine. Check for gsoline leks round the fuel filter ssembly. If leks exist, stop the engine immeditely. Recheck the filter instlltion, wipe up ny spilled fuel, nd properly ventilte the engine comprtment. If leks continue, stop engine immeditely nd contct your uthorized Mercury MerCruiser deler. GEN III Models 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends tht the engine be shut off for 12 hours prior to filter removl. 2. Close fuel supply vlve, if equipped. 3. Disconnect the Cool Fuel Module hrness from the engine wiring hrness. 4. Turn the key switch to the strt position nd llow the strter to operte for 5 seconds. 5. Turn key switch to off position. 6. Loosen ech filter ssembly retining screw until the screw is disengged from the Cool Fuel Module. Do not remove the filter ssembly retining screws from the filter cp. b c d f e g h - Cool Fuel Module b - Cool Fuel Module hrness c - Filter cp d - Filter ssembly retining screw e - Fuel filter element f - Filter cup g - Cool Fuel Module filter reservoir h - O ring 7. Unset the filter ssembly by grsping the filter ssembly hndle nd pulling upwrd. Do not remove the filter ssembly from the Cool Fuel Module t this time. 8. Allow ny fuel tht my be in the filter ssembly to drin out through the bottom of the filter ssembly nd into the Cool Fuel Module filter reservoir. 9. Remove the filter cup from the filter cp by grsping the filter cp nd rotting it in clockwise direction while holding the filter cup sttionry. 10. Remove the used wter seprting fuel filter element from the filter cup, plce it in clen, pproved continer. 11. Dispose of ny wter or debris tht my be in the filter cup. 12. Instll new wter seprting fuel filter element into the filter cup. Push the element into the cup until completely seted. 13. Instll new O ring on the filter cup Attch the filter cp to the filter cup by grsping the filter cp nd rotting it in counter clockwise direction while holding the filter cup sttionry, until the filter cp locks securely into plce. 15. Instll the fuel filter ssembly slowly into the Cool Fuel Module to prevent spilling fuel, nd lign the screws retined in the filter cp with the screw holes in the Cool Fuel Module. Tighten the filter ssembly retining screws until hnd tight. 16. Ensure tht the filter cp is firmly seted ginst the Cool Fuel Module nd torque ech filter ssembly retining screw. Description Nm lb. in. lb. ft. Filter ssembly retining screw 6 53 Pge M NOVEMBER 2010

63 17. Open fuel supply vlve, if equipped. 18. Reconnect the Cool Fuel Module hrness to the engine wiring hrness. 19. Supply cooling wter to the engine. 20. Properly ventilte the engine comprtment. Section 5 - Mintennce 21. Strt the engine. Check for gsoline leks round the fuel filter ssembly. If leks exist, stop the engine immeditely. Recheck the filter instlltion, clen spilled fuel nd properly ventilte the engine comprtment. If leks continue, stop engine immeditely nd contct your uthorized Mercury MerCruiser deler. In line Fuel Filter! WARNING Fuel is flmmble 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 before ttempting to strt the engine, nd wipe up ny spilled fuel immeditely. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends tht the engine be shut off for 12 hours prior to filter removl. 2. Close fuel supply vlve, if equipped. 3. Wrp the wter seprting fuel filter with cloth to help ctch ny fuel spills or spry. 4. Remove nd discrd the in line fuel filter. 5. Select pproprite size connector for the fuel line nd instll the connector on the new filter. 6. Apply selnt to the mle pipe threds on the connectors. Tube Ref No. Description Where Used Prt No. 9 Loctite 567 PST Pipe Selnt 7. Torque ech connector using bckup wrench on the hex fitting nerest to the connector. b - Connector b - Hex fitting Mle threds Description Nm lb. in. lb. ft. Connectors Insert filter into mounting clip. c b - Connectors b - In line filter c - Mounting clip 9. Instll nd torque screw nd wsher through the mounting clip into the stringer M NOVEMBER 2010 Pge 55

64 Section 5 - Mintennce Description Nm lb. in. lb. ft. Mounting clip screw Insert the hoses onto the brb fittings nd fsten using hose clmps. b Fuel line stringer clips b - Fuel line Description Nm lb. in. lb. ft. Hose clmps Open fuel supply vlve, if equipped. 12. Ensure tht engine comprtment is properly ventilted. 13. Supply cooling wter to the engine. 14. Strt the engine. Check for gsoline leks round the fuel filter ssembly. If leks exist, stop the engine immeditely. Recheck the filter instlltion, clen spilled fuel nd properly ventilte the engine comprtment. If leks continue, stop engine immeditely nd contct your uthorized Mercury MerCruiser deler. Lubriction Throttle Cble 1. Lubricte the pivot points nd the guide contct surfces. b - Pivot points b - Guide contct surfces 5577 Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Trnsmission Linkge IMPORTANT: The poppet bll must be centered in the detent hole for ech F N R position. Throttle cble pivot points & guide contct surfces K01 Pge M NOVEMBER 2010

65 Section 5 - Mintennce 1. Lubricte the detent bll nd the holes in the shift lever In-Line Trnsmission Tube Ref. No. Description Where Used Prt No. 2. Lubricte the shift cble pivot points. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Detent bll nd shift lever holes K01 - Pivot points 5935 Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cble pivot points K M NOVEMBER 2010 Pge 57

66 Section 5 - Mintennce Serpentine Drive Belt! WARNING Inspecting the belts with the engine running my cuse serious injury or deth. Turn off the engine nd remove the ignition key before djusting tension or inspecting belts. - Idler pulley b - Circulting pump pulley c - Crnkshft pulley d - Alterntor pulley e - Sewter pump pulley e c b d 6089 Checking 1. Inspect the drive belt for proper tension nd for the following: Excessive wer Crcks NOTE: Minor, trnsverse crcks (cross the belt width) my be cceptble. Longitudinl crcks (in the direction of belt length) tht join trnsverse crcks re NOT cceptble. Frying Glzed surfces Proper tension 13 mm (1/2 in.) deflection, with moderte thumb pressure, on the belt t the loction tht hs the longest distnce between two pulleys. mc Replcing Belt nd/or Adjusting Tension IMPORTANT: If belt is to be reused, it should be instlled in the sme direction of rottion s before. NOTE: Belt deflection is to be mesured on the belt t the loction tht hs the longest distnce between two pulleys. 1. Loosen the 16 mm (5/8 in.) locking nut on the djustment stud. 2. Turn the djustment stud nd loosen the belt. 3. If new serpentine drive belt is required, remove the old belt nd instll new belt onto the pulleys. 4. Put wrench on the djustment stud 16 mm (5/8 in.) locking nut. 5. Use 8 mm (5/16 in.) socket nd tighten djusting the stud to djust the belt deflection. 6. Using one of the 2 methods following, check for correct deflection.. Push down with moderte thumb pressure on the longest stretch of belt. Proper deflection is 13 mm (1/2 in.). Pge M NOVEMBER 2010

67 NEWTONE Section 5 - Mintennce b. Attch the Kent Moore Belt Tension Guge to the belt. The guge hs different rnges for new nd used belts. b COLOR GUIDE for NEWTONE PATENT Kent Moore Tension Guge b - Serpentine belt 7. While holding the djustment stud t the correct belt tension, tighten the 16 mm (5/8 in.) locking nut mm (1/16 in.) djusting stud b - 16 mm (5/8 in.) locking nut b 8. Operte the engine for short period of time nd recheck the belt djustment. Flushing The Power Pckge Tow Sports The Bot Out of the Wter IMPORTANT: Flushing the power pckge is most effective when performed with the bot out of the wter. IMPORTANT: Flushing is needed If the engine pckge hs been operted in slty, brckish, minerl lden or polluted wter. For best results flushing is recommended fter ech outing nd before cold wether nd extended storge.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the bot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce block of wood between the propeller blde nd the nti ventiltion plte. 1. Models with Wlter V-Drive Trnsmissions: Close the secock, if equipped, nd then disconnect the sewter inlet hose from the trnsmission sewter inlet fitting. b. If not equipped with secock, disconnect the sewter inlet hose from the trnsmission sewter inlet fitting nd plug the sewter inlet hose c. Using pproprite connector, connect the flushing wter hose to the trnsmission sewter inlet fitting. d. Proceed to step M NOVEMBER 2010 Pge 59

68 Section 5 - Mintennce 2. All other models:. Close the secock, if equipped, nd then disconnect the sewter inlet hose from the sewter pump inlet fitting.. b. If not equipped with secock, disconnect the sewter inlet hose from the sewter pump nd plug the hose c. Using suitble dpter, connect the flushing hose from the wter source to the wter inlet of the sewter pump. d. Proceed to step 3. NOTICE Flushing the engine when it is not operting will result in wter collecting in the exhust system, dmging the engine. Do not supply flush wter for more thn 15 seconds without the engine operting. 3. Completely open the wter source to provide mximum wter supply. 4. Plce the remote control in the neutrl idle speed position. 5. Immeditely 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 bove 1400 RPM out of the wter nd without sufficient cooling wter supply. 6. Depress the throttle only button nd slowly dvnce the throttle until the engine reches 1300 RPM (± 100 RPM). 7. Observe the wter temperture guge to ensure tht the engine is operting in the norml rnge. 8. Operte the engine with the trnsmission in neutrl for minimum of 10 minutes. 9. For power pckges operted in slty, brckish, minerl lden or polluted wter: Continue to operte the engine until the dischrge wter is cler. 10. Slowly return the throttle to idle speed position. NOTICE Flushing the engine when it is not operting will result in wter collecting in the exhust system, dmging the engine. Do not supply flush wter for more thn 15 seconds without the engine operting. 11. Stop the engine. 12. Immeditely shut off the supply wter nd remove the flushing ttchment. 13. Instll the wter inlet hose to the sewter inlet of the sewter pump or V Drive wter inlet. 14. Tighten hose clmp securely. 15. Attch to the next engine, if equipped, nd repet procedure. The Bot In the Wter IMPORTANT: Flushing the power pckge is most effective when performed with the bot out of the wter. IMPORTANT: Flushing is needed If the engine pckge hs been operted in slty, brckish, minerl lden or polluted wter. For best results flushing is recommended fter ech outing nd before cold wether nd extended storge. NOTICE Disconnecting the sewter inlet hose will cuse wter to enter the bilge resulting in engine dmge. Close the secock before disconnecting the sewter inlet hose. Plug the sewter inlet hose immeditely fter disconnecting it. Pge M NOVEMBER 2010

69 Section 5 - Mintennce 1. Models with Wlter V-Drive Trnsmissions:. Close the secock, if equipped, nd then disconnect the sewter inlet hose from the trnsmission sewter inlet fitting. NOTICE Disconnecting the sewter inlet hose will cuse wter to enter the bilge resulting in engine dmge. Close the secock before disconnecting the sewter inlet hose. Plug the sewter inlet hose immeditely fter disconnecting it. b. If not equipped with secock, disconnect the sewter inlet hose from the trnsmission sewter inlet fitting nd immeditely plug the sewter inlet hose to prevent wter from siphoning into the engine or bot c. Using suitble dpter, connect the flushing wter hose to the trnsmission sewter inlet fitting. d. Proceed to step 3 2. All other models:. Close the secock, if equipped, nd then disconnect the sewter inlet hose from the sewter pump inlet fitting. NOTICE Disconnecting the sewter inlet hose will cuse wter to enter the bilge resulting in engine dmge. Close the secock before disconnecting the sewter inlet hose. Plug the sewter inlet hose immeditely fter disconnecting it. b. If not equipped with secock, disconnect the sewter inlet hose from the sewter pump inlet fitting nd immeditely plug the sewter inlet hose to prevent wter from siphoning into the engine or bot c. Using suitble dpter, connect the flushing hose from the wter source to the wter inlet of the sewter pump. d. Proceed to step 3. NOTICE Flushing the engine when it is not operting will result in wter collecting in the exhust system, dmging the engine. Do not supply flush wter for more thn 15 seconds without the engine operting. 3. Completely open the wter source to provide mximum wter supply. 4. Plce the remote control in the neutrl idle speed position. 5. Immeditely strt the engine. 90-8M NOVEMBER 2010 Pge 61

70 Section 5 - Mintennce 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 bove 1400 RPM out of the wter nd without sufficient cooling wter supply. 6. Depress the throttle only button nd slowly dvnce the throttle until the engine reches 1300 RPM (± 100 RPM). 7. Observe the wter temperture guge to ensure tht the engine is operting in the norml rnge. 8. Operte the engine with the trnsmission in neutrl for minimum of 10 minutes. 9. For power pckges operted in slty, brckish, minerl lden or polluted wter: Continue to operte the engine until the dischrge wter is cler. 10. Slowly return the throttle to idle speed position. NOTICE Flushing the engine when it is not operting will result in wter collecting in the exhust system, dmging the engine. Do not supply flush wter for more thn 15 seconds without the engine operting. 11. Stop the engine. 12. Immeditely shut off the wter supply nd remove the flushing ttchment. 13. Remove the flushing connector from the wter inlet. 14. Tg the ignition switch with n pproprite tg requiring the secock to be opened or the sewter inlet hose to be reconnected prior to operting the engine. 15. Repet the flushing procedure on the next engine, if equipped. Bttery Refer to specific instructions nd wrnings ccompnying your bttery. If this informtion is not vilble, observe the following precutions when hndling bttery.! WARNING Rechrging wek bttery in the bot, or using jumper cbles nd booster bttery to strt the engine, cn cuse serious injury or product dmge from fire or explosion. Remove the bttery from the bot nd rechrge in ventilted re wy from sprks or flmes.! WARNING An operting or chrging bttery produces gs tht cn ignite nd explode, sprying out sulfuric cid, which cn cuse severe burns. Ventilte the re round the bttery nd wer protective equipment when hndling or servicing btteries. Multiple EFI Engine Bttery Precutions Alterntors: Alterntors re designed to chrge the bttery tht supplies electricl power to the engine tht the lterntor is mounted on. When btteries for 2 different engines re connected, one lterntor will supply ll of the chrging current for both btteries. Normlly, the other engine's lterntor will not be required to supply ny chrging current. EFI Electronic Control Module (ECM): The ECM requires stble voltge source. During multiple engine opertion, n onbord electricl device my cuse sudden drin of voltge t the engine's bttery. The voltge my go below the ECM's minimum required voltge. Also, the lterntor on the other engine my now strt chrging. This could cuse voltge spike in the engine's electricl system. In either cse, the ECM could shut off. When the voltge returns to the rnge tht the ECM requires, the ECM will reset itself, nd the engine will operte normlly. The ECM shuts off nd resets itself so quickly tht the engine my only seem to hve n ignition miss. Btteries: Bots with multi engine EFI power pckges require ech engine be connected to its own bttery. This ensures tht the engine's ECM hs stble voltge source. Bttery Switches: Bttery switches should lwys be positioned so ech engine is operting off of its own bttery. Do not operte engines with switches in both or ll position. In n emergency, nother engine's bttery cn be used to strt n engine with ded bttery. Bttery Isoltors: Isoltors cn be used to chrge n uxiliry bttery used for powering ccessories in the bot. They should not be used to chrge the bttery of nother engine in the bot unless the type of isoltor is specificlly designed for this purpose. Genertors: The genertors bttery should be considered nother engine's bttery. Pge M NOVEMBER 2010

71 Tble of Contents Section 6 - Storge Section 6 - Storge Cold Wether or Extended Storge Prepring Power Pckge for Storge...64 Engine nd Fuel System Preprtion Drining the Sewter System Drin System Identifiction...65 Air Actuted Single Point Drin System Three Point Mnul Drin System Air Actuted Single Point Drin System...66 Bot in the Wter Bot out of the Wter Three Point Mnul Drin System...70 Bot in the Wter Bot out of the Wter Bttery Storge Recommissioning the Power Pckge M NOVEMBER 2010 Pge 63

72 Section 6 - Storge Cold Wether or Extended Storge IMPORTANT: Mercury MerCruiser strongly recommends tht this service should be performed by n uthorized Mercury MerCruiser deler. Dmge cused by freezing tempertures IS NOT covered by the Mercury MerCruiser Limited Wrrnty. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or before ny length of storge in freezing tempertures. If the bot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing bck into the cooling system. If the bot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. NOTE: As precutionry mesure, ttch tg to the key switch or steering wheel of the bot reminding the opertor to open the secock or unplug nd reconnect the wter inlet hose before strting the engine. IMPORTANT: Mercury MerCruiser requires tht propylene glycol ntifreeze, mixed to the mnufcturers instructions, be used in the sewter section of the cooling system for freezing tempertures or extended storge. Mke sure tht the propylene glycol ntifreeze contins rust inhibitor nd is recommended for use in mrine engines. Be certin to follow the propylene glycol mnufcturer's recommendtions. Prepring Power Pckge for Storge 1. Fill the fuel tnks with fresh gsoline (tht does not contin lcohol) nd sufficient mount of Quicksilver Gsoline Stbilizer for Mrine Engines to tret the gsoline. Follow instructions on the continer. 2. If the bot is to be plced in storge with fuel contining lcohol in fuel tnks (if fuel without lcohol is not vilble): Fuel tnks should be drined s low s possible nd Mercury/Quicksilver Gsoline Stbilizer for Mrine Engines dded to ny fuel remining in the tnk. Refer to Fuel Requirements for dditionl informtion. 3. Flush the cooling system. Refer to the Mintennce section. 4. For dditionl ssurnce ginst freezing nd rust, fter drining, fill the sewter cooling system with propylene glycol mixed to the mnufcturer's recommendtion to protect engine to the lowest temperture to which it will be exposed during freezing tempertures or extended storge. 5. Operte the engine sufficiently to bring it up to norml operting temperture nd llow fuel with Mercury/Quicksilver Gsoline Stbilizer to circulte through the fuel system. Shut off the engine. 6. Chnge the oil nd oil filter. 7. Prepre the engine nd fuel system for storge. Refer to Engine nd Fuel System Preprtion. Perform this opertion. 8. Drin the engine sewter cooling system. Refer to Drining the Sewter System. NOTICE Wter trpped in the sewter section of the cooling system cn cuse corrosion or freeze dmge. Drin the sewter section of the cooling system immeditely fter opertion or before ny length of storge in freezing tempertures. If the bot is in the wter, keep the secock closed until restrting the engine to prevent wter from flowing bck into the cooling system. If the bot is not fitted with secock, leve the wter inlet hose disconnected nd plugged. 9. Store the bttery ccording to the mnufcturer's instructions. Engine nd Fuel System Preprtion! WARNING Fuel is flmmble 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 before ttempting to strt the engine, nd wipe up ny spilled fuel immeditely.! WARNING Fuel vpors trpped in the engine comprtment my be n irritnt, cuse difficulty brething, or my ignite resulting in fire or explosion. Alwys ventilte the engine comprtment before servicing the power pckge. 1. In 23 liter (6 U.S.gl.) remote fuel tnk mix:. 19 liter (5 U.S. gl) regulr unleded 87 octin (90 RON) gsoline b liter (2 U.S. qts.) Premium Plus 2 Cycle TC W3 Outbord Oil Pge M NOVEMBER 2010

73 Section 6 - Storge c. 150 ml (5 ounces) Fuel System Tretment nd Stbilizer or 30 ml (1 ounce) Fuel System Tretment nd Stbilizer Concentrte Tube Ref No. Description Where Used Prt No Premium Plus 2-cycle TC- W3 Outbord Oil Fuel System Tretment & Stbilizer Fuel system K01 Fuel system K01 2. Allow the engine to cool down. IMPORTANT: Immeditely wipe up ny fuel spills or sprys. 3. Close the fuel shut off vlve, if equipped. Disconnect nd plug the fuel inlet fitting if not equipped with fuel shut off vlve. 4. Connect the remote fuel tnk (with the fogging mixture) to the fuel inlet fitting. IMPORTANT: Supply cooling wter to the engine. 5. Strt nd operte the engine t 1300 rpm for 5 minutes. 6. After specified operting time is complete, slowly return throttle to idle rpm nd shut engine off. IMPORTANT: Ensure tht some fogging mixture remins in the engine. Do not llow the engines fuel system to become completely dry. 7. Replce the wter seprting fuel filter element. Refer to Section 5 for proper procedure. Drining the Sewter System! CAUTION Wter cn enter the bilge when the drin system is open, dmging the engine or cusing the bot to sink. Remove the bot from the wter or close the secock, disconnect nd plug the sewter inlet hose, nd ensure the bilge pump is opertionl before drining. Do not operte the engine with the drin system open. IMPORTANT: Only drin the sewter section of the closed cooling system. IMPORTANT: The bot must be s level s possible to ensure complete drining of the cooling system. Your power pckge is equipped with drin system. Refer to Drin System Identifiction to determine which instructions pply to your power pckge. IMPORTANT: The engine must not be operting t ny point during the drining procedure. Drin System Identifiction Air Actuted Single Point Drin System b c c b d 6124 d 6125 Closed Cooled Models - Blue drin plug loction b - Blue ir pump c - Air mnifold d - Green indictors Sewter Cooled Models 90-8M NOVEMBER 2010 Pge 65

74 Section 6 - Storge Three Point Mnul Drin System - Blue drin plug 6126 Air Actuted Single Point Drin System Bot in the Wter NOTE: This procedure is written for the ir pump tht is ttched to the engine. However, ny ir source cn be used. 1. Close the secock (if equipped) or remove nd plug the wter inlet hose. 2. Remove the ir pump from the engine. 3. Ensure tht the lever on top of the pump is flush with the hndle (horizontl). 4. Instll the ir pump on the ctutor fitting. 5. Pull lever on ir pump (verticl) to lock pump on the fitting. c e d - Actutor fitting b - Green indictors c - Mnul relese vlve d - Air pump e - Lever (locking) b Pump ir into the system until both green indictors extend nd wter drins from both sides of the engine. The port side will begin drining before the strbord side. Pge M NOVEMBER 2010

75 Section 6 - Storge 7. Immeditely remove the blue drin plug from the side of the thermostt housing or the het exchnger. This must be removed within 30 seconds to properly vent the cooling system. b c c b d 6124 d 6125 Closed Cooled Models - Blue drin plug loction b - Blue ir pump c - Air mnifold d - Green indictors Sewter Cooled Models 8. Verify tht wter is drining from ech opening. If not, use the Three Point Mnul Drin System instructions. - Port side drin loction b - Strbord side drin loction b Allow the system to drin for minimum of five minutes. Pump ir s necessry to keep the green indictors extended. 10. Crnk the engine over slightly with the strter motor to purge ny wter trpped in the sewter pump. Do not llow engine to strt. 11. Reinstll the blue drin plug in the thermostt housing or het exchnger. 12. Remove the ir pump from the ir mnifold nd return it to the mounting brcket. 13. Mercury MerCruiser recommends leving the drin system open while trnsporting the bot or while performing other mintennce. This helps ensure tht ll wter is drined. 90-8M NOVEMBER 2010 Pge 67

76 Section 6 - Storge 14. Before lunching the bot, pull up on the mnul relese vlve. Verify tht the green indictors re no longer extended. - Green indictors 15. Open the secock, if equipped, or unplug nd reconnect the wter inlet hose prior to operting the engine. Bot out of the Wter NOTE: This procedure is written for the ir pump tht is ttched to the engine. However, ny ir source cn be used. 1. Plce the bot on lever surfce to ensure complete drining of system. 2. Remove the ir pump from the engine. 3. Ensure tht the lever on top of the pump is flush with the hndle (horizontl). 4. Instll the ir pump on the ctutor fitting. 5. Pull lever on ir pump (verticl) to lock pump on the fitting. c 6135 e d - Actutor fitting b - Green indictors c - Mnul relese vlve d - Air pump e - Lever (locking) b 8293 Pge M NOVEMBER 2010

77 Section 6 - Storge 6. Pump ir into the system until both green indictors extend nd wter drins from both sides of the engine. The port side will begin drining before the strbord side. b c c b d 6124 d 6125 Closed Cooled Models - Blue drin plug loction b - Blue ir pump c - Air mnifold d - Green indictors Sewter Cooled Models 7. Verify tht wter is drining from ech opening. If not, use the Three Point Mnul Drin System instructions. - Port side drin loction b - Strbord side drin loction b Allow the system to drin for minimum of five minutes. Pump ir s necessry to keep the green indictors extended. 9. Crnk the engine over slightly with strter motor to purge ny wter trpped in the sewter pump. Do not llow engine to strt. 10. Remove the ir pump from the ir mnifold nd return it to the mounting brcket. 11. Mercury MerCruiser recommends leving the drin system open while trnsporting the bot or while performing other mintennce. This helps ensure tht ll wter is drined. 12. Before lunching the bot, pull up on the mnul relese vlve. Verify tht the green indictors re no longer extended. - Green indictors M NOVEMBER 2010 Pge 69