WARNING WARNING. Warranty Message

Transcription

1 Warranty Message The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information. WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard. Mercury Marine strongly recommend that the operator read this Operation, Maintenance & Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before using the boat. WARNING The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm. The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation. Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A. 2004, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Marathon, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, Cleaver, K-Planes, MerCathode, Quickleen, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation Mercury Marine HP1075 SCi Dry Sump

2 2

3 for your purchase of one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual. The Operation, Maintenance & Warranty Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water. Again, thank you for purchasing one of our Mercury Racing products. We sincerely hope your boating will be pleasant! Mercury Racing, N7480 County Road UU Fond du Lac, WI

4 a b b g h c f e d 0

5 IDENTIFICATION RECORD PLEASE RECORD THE FOLLOWING INFORMATION: a -Engine Model/Horsepower: b -Engine Serial Number 1 : c -Transom Assembly Serial Number: d -Sterndrive Serial Number & Gear Ratio 2 : e -Propeller Number/Pitch: f -Running rotation 3 : g -Hull Identification Number: h -Boat Model & Length: SERIAL NUMBERS The serial numbers are the manufacturer s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting your authorized Mercury Marine dealer about service, always specify model and serial numbers. 1 The engine Serial Number is printed on the center of the bell housing and stamped into the front of the port cylinder head along with the crankshaft number. 2 The gear ratio is stamped on the the bolt located next to the serial number label. 3 The running rotation is stamped on the back of the strut. 1

6 TABLE OF CONTENTS Page Warranty Information Warranty Registration Transfer Of Warranty Mercury RACING DIVISION 90 Day Limited Warranty... 8 Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products General Information Boater s Responsibilities Before Operating Your Boat Boat Horsepower Capacity High-Speed and High-Performance Boat Operation Lanyard Stop Switch Protecting People In The Water Carbon Monoxide Risk Wave And Wake Jumping Impact With Underwater Hazards Trailering Boat Safe Boating Suggestions Stolen Power Package Specifications Fuel Requirements Crankcase Oil Capacities Engine Specifications California Emissions Regulations Engine Break-in After Break-In Period Operation Instrumentation Warning System Electrical System Overload Protection Remote Controls (Console Mounted Zero Effort) Power Trim Starting, Shifting and Stopping Operation Chart

7 TABLE OF CONTENTS Page Operation Freezing Temperature Operation Drain Plug and Bilge Pump Launching And Boat Operation Care Conditions Affecting Operation Weight Distribution Bottom Of Boat Cavitation Ventilation Propeller Selection Conditions That Lower Engine Performance Maintenance Service Responsibilities Replacement Service Parts Do-It-Yourself Maintenance Suggestions Maintenance on High Horsepower Engines Maintenance Charts Checking Fluid Levels Changing Fluids Lubrication Propellers Seawater Pump Impeller Inspection Flushing Cooling System Cleaning Seawater (Raw Water) Section of Oil Cooler Drive Belts Corrosion and Corrosion Protection Battery Bottom of Boat Inspection and Maintenance Attention Required After Submersion Maintenance log Maintenance Log

8 TABLE OF CONTENTS Page Cold Weather or Extended Storage Power Package Lay-up Draining Instructions Battery Winter Storage Power Package Recommissioning Troubleshooting Engine Will Not Crank Engine Cranks but Will Not Start Engine Runs Rough, Hard to Start, Misses, and/or Backfires Poor Performance Insufficient Engine Temperature Excessive Engine Temperature Low Engine Oil Pressure Battery Will Not Come Up On Charge Power Trim Does Not Operate (Motor Doesn t Run) Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move) Remote Control Operates Hard, Binds, Has Excessive Free-Play or Makes Unusual Sounds Steering Wheel Turns Hard or Jerky Owner Service Assistance Owner service assistance Local Repair Service Service Away From Home Parts And Accessories Inquiries Service Assistance Ordering Literature United States and Canada Outside The United States and Canada

9 WARRANTY INFORMATION Warranty Registration UNITED STATES AND CANADA 1. It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately upon sale of the new product. 2. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer s code, name and address. The dealer also certifies that you are the original purchaser and user of the product. 3. Upon receipt of the Warranty Registration Card at the factory, you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification. It must be presented to the servicing dealer should warranty service be required. Warranty claims will not be accepted without presentation of this card. 4. A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed. Should your product need service during this period, present the temporary registration card to the dealer. He will attach it to your warranty claim form. 5. Because of your selling dealer s continuing personal interest in your satisfaction, the product should be returned to him for warranty service. 6. If your plastic card is not received within 30 days from date of new product sale, please contact your selling dealer. 7. The product warranty is not effective until the product is registered at the factory. NOTE: Registration lists must be maintained by factory and dealer on marine products sold in the United States, should notification under the Federal Boat Safety Act be required. 5

10 6 WARRANTY INFORMATION Warranty Registration OUTSIDE THE UNITED STATES AND CANADA 1. It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. 2. The Warranty Registration Card identifies your name and address, product model and serial number(s), date of sale, type of use and the selling distributor s/dealer s code number, name and address. The distributor/dealer also certifies that you are the original purchaser and user of the product. 3. A copy of the Warranty Registration Card, designated as the Purchaser s Copy, MUST be given to you immediately after the card has been completely filled out by the selling distributor/dealer. This card represents your factory registration identification, and should be retained by you for future use when required. Should you ever require warranty service on this product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form(s). 4. In some countries, the Marine Power Service Center will issue you a permanent (plastic) Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor/dealer. If you receive a plastic Warranty Registration Card, you may discard the Purchaser s Copy that you received from the distributor/dealer when you purchased the product. Ask your distributor/dealer if this plastic card program applies to you. 5. For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing, refer to the International Warranty. IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have ALL products registered at the factory should it ever be necessary to contact you. Make sure your dealer/distributor fills out the warranty registration card immediately and sends the factory copy to the Marine Power International Service Center for your area.

11 WARRANTY INFORMATION Mercury Racing Demonstrator Policy Mercury Racing products used by a dealer, boat builder, their representatives or agents for personal, recreational or promotional purposes, or products that accumulate more than 10 hours of demonstration run time MUST BE REGISTERED as a demonstrator by the dealer, boat builder or person(s) using those products.the Date of Sale will be the date the product was first put into service. Warranty coverage can be transferred to the retail customer by contacting Mercury Racing Technical Service. The retail purchaser of these products MUST be informed that the product was previously used and registered as a demonstrator along with the actual run time on the product. Transfer Of Warranty The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. DIRECT SALE BY OWNER The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI Attn: Warranty Registration Department A new Owner Warranty Registration Card will be issued with the new owner s name and address. Registration records will be changed on the factory computer registration file. There is no charge for this service. For products purchased outside the United States and Canada, contact the distributor in your country, or the Mercury Marine Service Office closest to you. 7

12 WARRANTY INFORMATION Mercury RACING DIVISION 90 Day Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for 90 days from either the date the product is first sold to a recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to a subsequent purchaser upon proper re-registration of the product. CONDITIONS THAT MUST BE MET IN ORDER TO OB- TAIN WARRANTY COVERAGE Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration information regarding recreational or commercial use of the product may void the warranty at the sole discretion of Mercury Marine. Routine maintenance outlined in the Operation and Maintenance Manual must be timely performed in order to obtain warranty coverage. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper maintenance. 8

13 WARRANTY INFORMATION Mercury RACING DIVISION 90 Day Limited Warranty WHAT MERCURY WILL DO Mercury s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured. HOW TO OBTAIN WARRANTY COVERAGE The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with that service. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercury. The warranty registration card is the only valid registration identification and must be presented to the dealer at the time warranty service is requested in order to obtain coverage. 9

14 WARRANTY INFORMATION Mercury RACING DIVISION 90 Day Limited Warranty WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended rpm range (see the Operation, Maintenance and Warranty Manual), operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Operation, Maintenance and Warranty Manual, neglect, accident, submersion, improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product), improper service, use of an accessory or part not manufactured or sold by us, operation with fuels, oils or lubricants which are not suitable for use with the product (see the Operation, Maintenance and Warranty Manual), alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system, or damage to the product from insufficient cooling water caused by blockage of the cooling system by a foreign body, running the engine out of water, mounting the engine too high on the transom, or running the boat with the engine trimmed out too far. The commercial use of the product, defined as any work or employment related use of the product, or any income generating use of the product, even if such use is only occasional, will void the warranty. Use of the product for racing or other competitive activity, at any point, even by a prior owner of the product, voids the warranty. Expenses related to haul-out, launch, towing, storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or consequential damages are not covered by this warranty. Also, expenses associated with the removal and/or replacement of boat partitions or material caused by boat design for access to the product are not covered by this warranty. 10

15 WARRANTY INFORMATION Mercury RACING DIVISION 90 Day Limited Warranty No individual or entity, including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation, representation or warranty regarding the product, other than those contained in this limited warranty, and if made, shall not be enforceable against Mercury Marine. For additional information regarding events and circumstances covered by this warranty, and those that are not, see the Warranty Coverage section of the Operation, Maintenance and Warranty Manual, incorporated by reference into this warranty. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT- NESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DIS- CLAIMED. TO THE EXTENT THAT THEY CANNOT BE DIS- CLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURA- TION TO THE LIFE OF THE EXPRESSED WARRANTY. INCIDEN- TAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUN- TRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPE- CIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LE- GAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Warranty Against Corrosion (Worldwide) IMPORTANT: There is no corrosion failure warranty offered for the HP1075 SCi engine or power package. 11

16 WARRANTY INFORMATION Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage. The following information explains some of the types of services that are not covered by warranty. The provisions set forth following have been incorporated by reference into the Mercury Racing Division Three Year Limited Warranty Against Corrosion Failure, the Mercury Racing Division 90 Day and One Year Limited Warranties. Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship. Installation errors, accidents, normal wear, and a variety of other causes that affect the product are not covered. Warranty is limited to defects in material or workmanship, but only to retail customers that purchase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented. Should you have any questions concerning warranty coverage, contact your authorized dealer. They will be pleased to answer any questions that you may have. GENERAL EXCLUSIONS FROM WARRANTY 1 Corrosion damage incurred by your HP1075 SCi Mercury Racing product(s) is not covered under this warranty. 2 Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs, ignition components, carburetor or EFI settings, filters, belts, controls, and checking lubrication made in connection with normal services. 3 Damage caused by lack of maintenance. 4 Haul-out, launch, towing charges, and all related transportation charges and/or travel time, etc. 5 Additional service work requested by customer other than that necessary to satisfy the warranty obligation. 12

17 WARRANTY INFORMATION Warranty Coverage and Exclusions for Mercury Racing Outboard and Sterndrive Products 6 Labor performed by other than an authorized Mercury Marine dealer may be covered only under following circumstances: When performed on emergency basis (providing there are no authorized Mercury Marine dealers in the area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility). 7 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. 8 Engine noise does not necessarily indicate a serious engine problem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty. 9 Lower unit and/or propeller damage caused by striking a submerged object is considered a marine hazard. 10 Water in the starter motor. 11 Starter motors and/or armatures or field coil assembly, which are burned, or where lead is thrown out of commutator because of excess cranking. 12 Valve or valve seat grinding required because of wear. 13 Removal of the tamper proof seals without prior pre-approval from Mercury Racing. 13

18 GENERAL INFORMATION Boater s Responsibilities The boat driver is responsible for correct and safe operation of the boat and safety of its occupants and general public. It is strongly recommended that each operator (driver) read and understand this entire manual before operating the boat. Ensure at least one additional person on-board is instructed in the basics of starting, operating and boat handling in case the driver is unable to operate the boat. Before Operating Your Boat Read this manual carefully. Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage. If you have any questions, contact your dealer. This manual as well as safety labels posted on the engine package use safety alerts to draw your attention to special safety instructions that must be followed. WARNING WARNING indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a potentially hazardous situation that, If not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices. IMPORTANT: - Indicates information or instructions that are necessary for proper operation and/or maintenance. 14

19 GENERAL INFORMATION U.S. COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) XXX MAXIMUM WEIGHT CAPACITY XXX 1 2 Boat Horsepower Capacity 1 Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer. WARNING Overpowering a Boat Can Cause: Serious injury, death, or boat damage. Loss of Boat Control. Flotation Characteristics of Boat to be Altered from Placing Too Much Weight on Transom. Boat to Break Apart, Particularly Around the Transom Area. High-Speed and High-Performance Boat Operation 2 If you are not familiar with high-performance boat operation we recommend that you first request an orientation/demonstration ride with your dealer or an operator experienced with your boat/ sterndrive combination. Refer to the Guide to Hi-Performance Boat Operation booklet included in your literature packet. 15

20 GENERAL INFORMATION Lanyard Stop Switch WARNING Avoid serious injury or death. Should the operator fall out of the boat, the possibility of serious injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both ends of the stop switch lanyard to the stop switch and the operator. The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator s position (as in accidental ejection from the operator s position) to activate the switch. A lanyard stop switch can be installed as an accessory; generally on the dashboard or side adjacent to the operator s position. While activation of the lanyard stop switch will stop the engine immediately, a boat will continue to coast for some distance depending upon the velocity and degree of any turn at shut-down. However, the boat will not complete a full circle. While the boat is coasting, it can cause injury to anyone in the boat s path as seriously as the boat would when under power. 16

21 GENERAL INFORMATION Lanyard Stop Switch WARNING Avoid serious injury or death from deceleration forces resulting from in accidental stop switch activation. The boat operator should never leave the operator s station without first disconnecting the stop switch lanyard cord from themself. Accidental or unintended activation of the lanyard stop switch during normal operation is a possibility and could cause any, or all, of the following potentially hazardous situations: Occupants could be thrown forward due to unexpected loss of forward motion which is a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the gear case or propeller. Loss of power and directional control in heavy seas, strong current or high winds. Loss of control when docking. 17

22 GENERAL INFORMATION Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. Whenever a boat is moving (even coasting) even with the drive unit in neutral position, there is sufficient force by the water to rotate the propeller. This neutral propeller rotation can cause serious injury. WHILE BOAT IS STATIONARY Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat. WARNING Avoid serious injury or death. Stop your engine immediately whenever anyone in the water is near your boat to avoid striking them with a rotating propeller, a moving boat, a moving gear case, or any solid device rigidly attached to a moving boat or gear case. 18

23 NOTES 19

24 GENERAL INFORMATION Courtesy of ABYC 20

25 GENERAL INFORMATION Carbon Monoxide Risk WARNING Avoid serious injury or death. Prolonged exposure to carbon monoxide in a sufficient concentration can lead to unconsciousness, brain damage, or death. Avoid the combination of a running engine and poor ventilation. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless and is present in the exhaust fumes of all internal combustion engines. Early symptoms of carbon monoxide poisoning which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea. INSUFFICIENT FRESH AIR FLOW Under certain conditions, enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although rare, on a very calm day, swimmers and passengers in an open stationary boat with a running engine, or near a running engine may be exposed to a hazardous level of carbon monoxide. Insufficient Air Flow Could Occur If: While boat is stationary 1 Boat moored in a confined space with the engine running. 2 Boat is moored close to another boat with its engine running. While boat is moving 3 Running the boat with the trim angle of the bow too high. 4 Running the boat with no forward hatches open (station wagon effect). SUFFICIENT FRESH AIR FLOW 5 Example of desired air flow through the boat. Ventilate passenger area, open side curtains, or forward hatches to remove carbon monoxide fumes. 21

26 GENERAL INFORMATION Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water. The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat. There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also steer sharply to one side. WARNING Avoid serious injury or death from wave or wake jumping. Occupants can be thrown within or out of a boat when jumping a wave or wake. Instruct all occupants to get low and grasp boat hand holds if a wave or wake jump occurs. 22

27 GENERAL INFORMATION Impact With Underwater Hazards CAUTION Avoid impact damage or injury from striking a floating or underwater object. Control boat speed when driving in waters known to have floating or underwater obstacles. Boat speed should be kept to a minimum planing speed of 24 to 40 km/h (15 to 25 mph). Reduce speed and proceed with caution whenever you re driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bottom. The VI drive hydraulic trim system does not have a impact protection feature. 23

28 GENERAL INFORMATION Impact With Underwater Hazards Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could result in the following: The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat. A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat. Impact damage to the sterndrive and/or boat. After striking a submerged object, stop engine as soon as possible and inspect the sterndrive unit for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury Marine dealer for a thorough inspection and necessary repair. The boat should also be checked for any hull fractures, transom fractures, water leaks. Operating a damaged sterndrive could cause additional damage to other parts of the power package, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds. WARNING Avoid serious injury or death from loss of boat control. Continued boating with major impact damage can result in sudden component failure with or without subsequent impacts. Have the power package thoroughly inspected and any necessary repairs made. Trailering Boat Boat can be trailered with drive unit in UP or DOWN position. Adequate road clearance is required between road and gear housing skeg when trailering with drive unit in DOWN position. If adequate road clearance is a problem, place drive unit in full UP position. 24

29 GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course. Courses are offered in the U.S.A. by (1) The US Coast Guard Auxiliary, (2) The Power Squadron, (3) The Red Cross and (4) your state or provincial boating law enforcement agency. Inquiries may be made to the Boating Hotline, or the Boat US Foundation information number BOAT. We strongly recommend that all powerboat operators attend one of these courses. You should also review the NMMA Sources of Waterway Information booklet. It lists regional sources of safety, cruising and local navigation and is available at no charge by writing to: Sources of Waterway Information National Marine Manufacturers Association 410 N. Michigan Avenue Chicago, IL U.S.A. Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made. Check safety equipment on-board. Here are suggestions of the types of safety equipment to carry when boating: a. Approved fire extinguisher; paddle or oar. b. Signal devices: flashlight, rockets or flares, flag and whistle or horn. c. Spare propeller, thrust hubs and an appropriate wrench. d. Tools for necessary minor repairs; first aid kit and book. e. Anchor, extra anchor line; water-proof storage containers. f. Manual bilge pump and extra drain plugs; compass and map or chart of area. g. Spare operating equipment; batteries, bulbs, fuses, etc. h. Transistor radio and drinking water. 25

30 GENERAL INFORMATION Safe Boating Suggestions Know signs of weather change and avoid foul weather and rough-sea boating. Tell someone where you are going and when you expect to return. Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Just shifting the drive unit into neutral is not sufficient. Use personal flotation devices. Federal Law requires that there be a U. S. Coast Guard approved, wearable-type life jacket (personal flotation device), correctly sized and readily accessible for every person on-board, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat. Prepare other boat operators. Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard. Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). When in doubt, contact your dealer or the boats manufacturer. Know your boat s operating and loading limitations. Make sure everyone in the boat is properly seated. Don t allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes backs of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a person to be thrown overboard or into the boat. Never be under the influence of alcohol or drugs while boating (it is the law). They impair your judgment and greatly reduce your ability to react quickly. 26

31 GENERAL INFORMATION Safe Boating Suggestions Know your boating area and avoid hazardous locations. Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operators view when operating the boat above idle or planing transition speed. Watch the other guy, the water and your wake. Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h (25 mph) will overtake a fallen skier in 5 seconds who was 61 m (200 ft) in front of you. Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator s side of the boat while returning to attend the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water. Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents. Usually a boating accident must be reported if (1) there is loss of life or probable loss of life, (2) there is personal injury requiring medical treatment beyond first aid, (3) there is damage to boats or other property where the damage value exceeds $ or (4) there is complete loss of the boat. Seek further assistance from local law enforcement. Stolen Power Package If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This Stolen Power Package information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen engines. 27

32 Fuel Requirements SPECIFICATIONS CAUTION Use of improper gasoline can seriously damage your engine. Engine damage resulting from use of improper gasoline is considered misuse of engine, will not be covered under the Mercury Racing limited warranty. Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness. OCTANE REQUIREMENTS FOR YOUR ENGINE (UNITED STATES AND CANADA) FUEL TYPE Unleaded premium 1 MINIMUM POSTED OCTANE (R+M)/2=92 OCTANE REQUIREMENTS FOR YOUR ENGINE (OUTSIDE THE UNITED STATES AND CANADA) FUEL TYPE Unleaded premium 1-2 MINIMUM POSTED OCTANE RON*=98 *Research Octane Number 1 The use of premium unleaded fuels with octane ratings higher than (R+M) 2=92 are acceptable to use but will not give any increase in performance or durability. 2 Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the combustion chambers. 28

33 Fuel Requirements SPECIFICATIONS USING REFORMULATED (OXYGENATED) FUELS (USA ONLY) This type of fuel is required in certain areas of the US. The two types of oxygenates used in these fuels are alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol. These reformulated fuels are acceptable for use in your Mercury Marine engine. GASOLINES CONTAINING ALCOHOL If the fuel in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects. Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat s fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boats fuel system components (fuel tanks, fuel lines, and fittings). 29

34 Fuel Requirements SPECIFICATIONS FUEL CONTAINING ALCOHOL MAY INCREASE: Corrosion of metal parts. Deterioration of rubber or plastic parts. Fuel permeation through rubber fuel lines. Starting and operating difficulties and decrease in performance. IMPORTANT: Because of possible adverse effects of alcohol in fuel, it is recommended that only alcohol-free gasoline be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required. CAUTION When operating a Mercury Marine engine on fuel containing alcohol, avoid storaging fuel in the fuel tank for long periods. Long periods of storage, common to boats, create unique problems. In cars, alcohol-blend fuels are normally consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components. 30

35 Crankcase Oil OIL RECOMMENDATIONS SPECIFICATIONS PREFERRED OILS API CLASSIFICATION Mercury 4-cycle Marine Engine Oil 25W40 SJ, SL, CF-2, CH-4 OTHER RECOMMENDATIONS IF PREFERRED OILS ARE NOT AVAILABLE Premium multi-viscosity 20W-50 commercial oil CG-4, CH-4, CI-4 Premium multi-viscosity 15W-40 commercial oil CG-4, CH-4. CI-4 Oil filter should always be changed with oil IMPORTANT OIL PRACTICES Do Not Use Non-detergent oils Oils containing solid additives Multi-viscosity oils other than the ones recommended Low quality oils Do Not Mix Straight weight and multi-viscosity oils Different brands of oils, straight weight or multi-viscosity Different weights of straight weight or different weights of multiviscosity oils. 31

36 SPECIFICATIONS TEMPERATURE/OIL VISCOSITY CHART Multi-viscosity Oil SJ, SL, CF-2, CF-4, CG-4, CH-4, CI-4 Mercury/Quicksilver 25W 40 Premium Multi-Viscosity 20W 50 F C Capacities Model Oil reservoir capacity with new filter 1 Seawater cooling system 2 Transmission fluid capacity 1 Approximately 15.2 liter (16 U.S. qt.) 19 liter (20 U.S. qt.) Approximately 1.9 liter (2.0 U.S. qt.) 1 Refer to Changing Fluids for the correct procedure to avoid overfilling. 2 Seawater cooling system capacity information is for winterization use only. Drive Type VI Dry Sump liter (U.S. qt.) Transom Bearing Cavity (Close Couple Models Only) 4 (4.25) 0.47 liter (0.5 U.S. qt.) liter (U.S. qt.) to add per 2.5 cm (1 in.) of spacer none 32

37 Engine Specifications Model Displacement SPECIFICATIONS 9.1 liter (557 cid) Crankshaft horsepower 1075 Crankshaft Kilowatts 802 Maximum WOT 1 Idle rpm in gear Idle rpm out of gear Fuel pump pressure at key up Fuel rail pressure at WOT Minimum oil stable idle rpm (HOT) Minimum oil 2000 rpm (HOT) Minimum oil WOT rpm (HOT) Boost pressure (Max.) Engine oil temperature (Maximum allowable) Coolant thermostat 6000 RPM 800 RPM 825 RPM 400 kpa (58 psi) 498 kpa (72 psi) Minimum kpa (14.5 psi) Minimum kpa (22 psi) Minimum kpa (54.5 psi) 0.9 bar ( rpm 140 C ( rpm 70 C (158 F) Minimum block water WOT rpm 138 kpa (20 psi) Maximum block water WOT rpm 250 kpa (36.5 psi) Fuel requirements Refer to fuel or oil requirements in Oil requirements the Specifications section 1 The engine is equipped with a built-in 6250 rpm rev limiter. The engine is performing normally if it will not exceed this rpm. 33

38 Engine Specifications Model Spark Plug Type Spark Plug Gap SPECIFICATIONS NGK BR9ECS (Only) 0.75 mm (0.030 in.) Firing Order Inlet valve lash setting Exhaust valve lash setting Ignition timing Electrical system Alternator Recommended battery rating Hot mm (0.020 in.) Cold mm (0.016 in.) Hot mm (0.020 in.) Cold mm (0.016 in.) PCM controlled 12-Volt Negative ( ) Ground 65 Amps / 917 Watts Minimum 750 cca, 950 mca, or 180 Ah a a -Front of engine and boat b -Firing order

39 SPECIFICATIONS California Emissions Regulations An emission certification label, showing emission levels and engine specifications directly related to emissions, is placed on the engine at the time of manufacture. EMISSION CONTROL INFORMATION THIS ENGINE IS RATED AT GREATER THAN 500 HP (CRANKSHAFT) AND IS THEREFORE EXEMPT FROM CALIFORNIA EMISSIONS REGULATIONS FOR SPARK IGNITION MARINE ENGINES. 35

40 OPERATION Engine Break-in CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. Do not exceed 5000 rpm. 1 HR. BREAK-IN PROCEDURE 5 HR. BREAK-IN PROCEDURE Allow engine to warm-up for 3-5 minutes. Do not exceed 3/4 throttle. Avoid full throttle acceleration from IDLE speed. Always vary throttle setting. Run engine the majority of time between rpm. Frequently check engine oil level at reservoir sight tube. Add oil if needed. It is normal for oil consumption to be high during break-in period. After Break-In Period To help extend the life of your power package, Mercury Marine recommends the following: AFTER 5 HR. BREAK-IN Use a propeller that allows the engine to operate at or near the top of the maximum rpm range (See Specifications section) when at full throttle with a normal boat load. Do not advance the throttle until the engine runs smoothly at idle and water temperature reaches a minimum of 54 C (130 F). Do not operate at full throttle until the engine oil temperature reaches 60 C (140 F). Follow the maintenance schedule in this manual. 36

41 Instrumentation OPERATION Mercury Racing requires that the following critical engine functions be monitored: Oil pressure Oil temperature System voltage Engine rpm Water temperature Guardian fault messages The use of Smart Craft instrumentation will display all of the above critical engine functions as well as others not listed. Smart Craft instrumentation will also display information about power train sensor faults and Guardian activation. Warning System CAUTION Avoid engine damage. Do not operate the engine after a continous horn is heard, EXCEPT TO AVOID A HAZARDOUS SITUATION. ENGINE GUARDIAN SYSTEM The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. The system responds to a problem by emitting a continuous or intermittent horn and, under certain circumstances, reduces engine power to provide engine protection. When the key switch is turned ON, the system monitors horn beeps once to verify horn operation. 37

42 Warning System ENGINE GUARDIAN SYSTEM OPERATION If the Propulsion Control Module (PCM) detects a fault signal from an engine sensor, it records a fault code. 1. The horn warning can be stopped by turning the engine off. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem. 2. On restart, if the beeping stops, see your authorized Mercury Marine dealer to diagnose and clear the fault.. NOTE: The following Table lists only the possible problem areas and not specific error codes recorded by the PCM. Use a Digital Diagnostic Terminal (DDT) or Computer Diagnostic System (CDS) to extract specific problem codes from the PCM. 38

43 Warning System ENGINE GUARDIAN SYSTEM Problem Battery range high or low Low Seawater Pressure Boost Valve Error Low Oil Pressure Oil Temperature Overheat Engine Overspeed Reverse Overspeed Neutral Overspeed Coolant Overheat Horn 3 Beeps-1.5 Sec. Long OPERATION Monitor Display Guardian Activated Engine Power Reduced By Yes Yes 100% down to 5% Steady Horn Yes Yes 100% down to 15% Steady Horn Yes Yes 70% Steady Horn Yes Yes 100% down to 15% 5 Beeps-3 Sec. Long Yes Yes 100% down to 15% Steady Horn Yes No Rev limit with no power loss 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long Yes No Rev limit with no power loss Yes No Rev limit with no power loss Steady Horn Yes Yes 100% down to 15% PCM Error Steady Horn Yes Yes Forced Idle Coil Pack 5 Beeps-3 Yes No Failure Sec. Long Fuel Injector Failure Fuel Pump Failure 5 Beeps-3 Sec. Long 5 Beeps-3 Sec. Long Yes No Yes Yes 70% 39

44 Warning System ENGINE GUARDIAN SYSTEM OPERATION Problem Idle Air Control Failure Transmission Overtemp Knock Sensor Failure Oil Pressure Sensor Failure Oil Temperature Sensor Failure Crankshaft Sensor Problem Cam Sensor 40 MAP Sensor Error Fuel Pressure Sensor Failure Block Pressure Sensor Failure Charge Temperature Sensor Failure Horn 5 Beeps-3 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long Monitor Display Yes Yes Guardian Activated No No Engine Power Reduced By Yes Yes 70% Yes Yes No No Steady Horn Yes Yes 70% 3 Beeps-1.5 Sec. Long 5 Beeps-3 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long Yes Yes 70% Yes No RPM limit to 5150 Yes Yes No No Yes Yes 70%

45 Warning System ENGINE GUARDIAN SYSTEM OPERATION Problem CAN Bus Problem Coolant Temperature Sensor Throttle Position Sensor Low Sensor Power Horn 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long 3 Beeps-1.5 Sec. Long Monitor Display Guardian Activated Engine Power Reduced By Yes Yes 70% or Forced Idle Yes No Yes Yes 70% Yes Yes 70% 41

46 OPERATION b c a d f b e d c 1 a -50 amp circuit breaker b -Fuse pack 5-15 amp c -Fuse pack amp d -Engine electrical panel e -14 pin boat harness connector f -PCM 03 42

47 OPERATION Electrical System Overload Protection 1 If an electrical overload occurs, a fuse or circuit breader opens. Locate and correct the problem before replacing the fuse or resetting circuit breaker. a -A circuit breaker protects the engine wiring harness and instrumentation power lead. Reset by pushing the reset button. In an emergency, if you cannot locate and correct the cause of the high current draw, and you must operate the engine; perform the following: Turn OFF or disconnect all accessories connected to the engine and instrumentation wiring and reset the circuit breaker. If the breaker remains open, electrical overload is still present. Inspect the electrical system. b -Four fuses are located at the upper rear of the engine containing 5 and 15 amp fuses. c -Four fuses are located at the upper rear of the engine containing 20 and 25 amp fuses. Fuse Holder (b) Fuse Holder (c) 5 amp A-Red/Grn 25 amp A-Red/Blk Hour Meter B-Red/Orn Fuel pump B-Red/Pnk 15 amp C-Red 20 amp C-Red/Grn CAN/Main Re- IAC boost bypass mote D-Red/PPL D-Red/Blu 15 amp E-Red 20amp E-Red/Grn Constant Coil Power Power F-Red/Blu F-Red/Yel 5 amp G-PPL 20-amp G-Red/Grn Accessories H-PPL/Wht Fuel Injectors H-Red/Wht 43

48 OPERATION 2 3 a d 4 b c e f Electrical System Overload Protection 2 The power trim system is protected by a 10 amp fuse in the power trim red (Hot) wire. 3 A 90 amp fuse is located on the starter. 4 Analog gauges (if used) are protected with a 5 amp fuse. a -Helm harness connection b -Fuse (5 Amp) c -Relay d -Ground e -Fused 12v (5 Amp maximum) f -Switched 12v 44

49 NOTES 45

50 OPERATION

51 OPERATION Remote Controls (Console Mounted Zero Effort) 1 Throttle Control Lever(s) - Control the throttle by moving the longer control lever(s) or, to increase speed, push the control lever forward. Detents give the movement of the lever a notched, precise feel. The detents also help hold the lever at the desired engine RPM to reduce operator fatigue. CAUTION Never shift the unit into or out of gear unless the engine is at idle RPM. 2 Shift Control Lever(s) - Control shifting by moving the shorter control lever(s). This control shifts the unit into gear with full lever movement. Move the lever forward to engage the forward gear. Move lever backward to engage reverse gear. Place the lever in the center position to shift to neutral. Shifting should occur only with the engine at idle speed. Always move to the desired gear position with a quick, firm motion. The control handle should be adjusted by your dealer to engage forward, reverse, and neutral when the lever is at the appropriate detent. 3 Power Trim Switch - See Power Trim section for detailed power trim operating procedures. 47

52 OPERATION

53 OPERATION Power Trim Power Trim allows the operator to adjust the drive angle while underway to provide the ideal boat angle for varying load and water conditions. CAUTION Use extreme caution when operating with the drive unit raised. Mercury Marine recommends manual indicators to help keep the operator aware of the drive position. 1 In most cases, best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the water. 2 Trimming Drive Unit up/out Can: Generally increase top speed. Increase clearance over submerged objects or a shallow bottom. Cause the boat to accelerate and plane off slower. In excess, cause boat porpoising (bouncing) or propeller ventilation. 3 Trimming Drive Unit down/in Can: Help the boat accelerate and plane off quicker. Generally improve the ride in choppy water. In most cases, reduce boat speed. If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction, called bow steering or over steering. if any turn is attempted or if a significant wave is encountered. 49

54 OPERATION a b 1 a b

55 Power Trim OPERATION POWER TRIM OPERATION IMPORTANT: If the power trim button is held depressed after the drive unit(s) reaches the end of upward travel, an internal circuit breaker opens and the pump stops. Should this happen, release the button and allow the trim pump motor to cool for about one minute, at which time the circuit breaker will reset and power trim operation may be resumed. CAUTION Avoid damage to the sterndrive(s) or tie bar(s). Evenly raise and lower sterndrives equipped with tie bars to prevent tie bar twisting or sterndrive damage. CAUTION The VI drive does not have a trim limit switch. Depressing the trim or trailer buttons allows the drive to be tilted to its full extension without stopping at a preset trim limit. The drive s position should be monitored with the trim gauge(s). 1 Power trim switch in handle (can control up to 3 drives): a -Raise the drive unit: Press (top) up/out on trim switch until the drive unit(s) reaches the desired trim position. b -Lower the drive unit: Press (bottom) down/in on trim switch until drive unit(s) reaches the desired position. 2 Console mounted power trim switch (One switch per drive): NOTE: On multiple engine installations, the individual trim switches can be used to fine tune the drives by setting each drive unit to the desired trim angle. Then use the single trim switch in the handle to control the trim of all drive units simultaneously. a -Raise drive unit: Press (top) up/out on trim switch until the drive unit reaches the desired trim position. This switch can also be used to bring the drive to a trailering position. b -Lower Drive Unit: Press (bottom) down/in on trim switch until the drive unit reaches the desired position. 51

56 OPERATION Starting, Shifting and Stopping WARNING Before starting the engine, operate the bilge blower for at least five minutes to remove any explosive fumes from engine compartment. If boat is not equipped with a bilge blower, open the engine hatch and leave it open while starting the engine. NEW ENGINES OR ENGINES COMING OUT OF STORAGE See Power Package Recommissioning. IMPORTANT: Observe the following: Do not start the engine without supplying water to the seawater pickup pump (to prevent pump or engine damage). Do not operate the starter motor continuously for more than 30 seconds. Never shift the drive unit unless the engine is at idle RPM. Perform the following as appropriate: Check all items listed in Operation Chart. Perform any other necessary checks, as indicated by your dealer, or specified in your boat owner s manual. Place the drive unit in full the down/in position. Place the control handle in neutral. COLD OR WARM ENGINE EFI engines require no throttle advance to start. The boat can be operated after the engine has started and is idling smoothly. NOTE: Engines that have not been started for extended periods or have had fuel filter changes may not stay running on the first few initial attempts to start. Do not advance the throttle to keep the engine running. Continue to restart the engine until it idles smoothly which means the fuel system is primed. Allow the engine to warm up to 54 C (130 F) before advancing the throttle. 52

57 OPERATION Starting, Shifting and Stopping IMPORTANT: If the engine has not been operated for more than 24 hours, Mercury Marine recommends priming the engine oil system. 1 If the engine has not been operated for more than 24 hours, deactivate the lanyard stop switch so that the engine will not start and crank the engine until oil pressure is indicated on the oil pressure gauge. 2 Turn the key switch to ON and wait 10 seconds to allow the fuel pump to prime the system. 3 Start the engine. Release the key when the engine starts and allow the switch to return to the ON position. 4 Check the oil pressure gauge immediately after the engine starts. If oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause. 5 If the engine is cold, allow the engine to run for 3 minutes. 6 After the engine has warmed up, check the water temperature gauge to ensure that the engine temperature is not abnormally high. If it is, stop the engine immediately and determine cause. 7 Ensure that the charging system is functioning correctly. 8 Observe the power package for fuel, oil, water, and exhaust leaks. 9 To shift the drive unit into gear, move the control/shift lever with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting the drive unit, advance the throttle to the desired setting. 10 To shift the drive unit out of gear, move the control/shift lever to neutral and allow the engine to drop to idle speed. If the engine has been operating at high speed for a long period of time, allow the engine to cool by running at idle speed for 3 to 5 minutes. 11 Turn key switch to OFF. 53

58 OPERATION Operation Chart Before Starting Open the engine hatch Turn battery switch ON, if equipped Operate bilge blowers, if equipped Open fuel shut off valve Open seacock Perform all other checks specified by your dealer and/or boat builder After Starting Observe all gauges to check condition of engine. If not normal, stop engine Check for fuel, oil, water, fluid and exhaust leaks, etc. Check shift and throttle control operation. Check steering operation While Underway Observe all gauges to monitor engine condition Freezing Temperature Operation After Stopping Shift to Neutral. Turn ignition key OFF Turn battery switch OFF, if equipped Close fuel valve. Close seacock Flush cooling system if in saltwater area IMPORTANT: If operating the boat during periods of freezing temperatures, take precautions to prevent freezing damage to power package. Damage caused by freezing is not covered by the Mercury Racing Limited Warranty. 54

59 OPERATION Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug and/or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package. Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. Launching And Boat Operation Care CAUTION During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat may enter the water rapidly and at a steep angle. This may force water through the exhaust system into the cylinders. The more weight on the transom, the more likely this is to occur. Slowing down rapidly or stopping suddenly may cause a following wave to swamp the transom. In this instance, water may enter the cylinders through the exhaust system. When backing up rapidly, the same situation may occur as stated in the preceding paragraph. In any of the situations described in the preceding caution, water entering the engine could cause severe damage to internal parts. Refer to Attention Required After Submersion in the General Information section of this manual. 55

60 CONDITIONS AFFECTING OPERATION Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) may: Increase speed and engine RPM. Cause the boat to porpoise. Cause the bow to bounce in choppy water. Increase the danger of a following wave splashing into the boat when coming off plane. Shifting weight to front (bow) may: Improve ease of planing. Improve rough water ride. Cause the boat to veer back and forth (bow steer). Bottom Of Boat To maintain maximum speed, ensure that the bottom of the boat is: Clean and free of barnacles and marine growth. Free of distortion and nearly flat where it contacts the water. Straight and smooth both fore and aft. Marine vegetation may accumulate when the boat is docked, clogging water inlets and causing the engine to overheat. This growth must be removed before operation. 56

61 Cavitation CONDITIONS AFFECTING OPERATION Cavitation occurs when water flow cannot follow the contour of a fast-moving, underwater object, such as a gear housing or propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housing or propeller. Common causes of cavitation are: Weeds or other debris snagged on propeller or gear housing. Bent propeller blade or damaged gear housing skeg. Raised burrs or sharp edges on propeller or gear housing. Ventilation Ventilation occurs when surface air or exhaust gases surround the propeller, causing propeller speed-up (slippage) and a decrease in boat speed. Excessive ventilation is annoying and usually caused by: A drive unit trimmed out too far. A damaged propeller or gear housing, allowing exhaust gases to escape between propeller and gear housing. A drive unit installed too high on the transom. 57

62 CONDITIONS AFFECTING OPERATION Propeller Selection IMPORTANT: Choosing the correct propeller allows the engine to run at its specified maximum wide-open-throttle rpm. Use an accurate service tachometer to verify engine operating rpm. It is the boat manufacturer and/or the selling dealer s responsibility to equip the power package with the correct propeller(s). Specified engine wide-open-throttle (WOT) and operating rpm range are listed in Specifications. IMPORTANT: All Mercury Racing engines have a rpm revlimiter that is set to an upper (or limited) rpm. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine rpm. Once the rpm drops into the recommended operating rpm range, normal engine operation resumes. Select a propeller that allows the engine to operate in the upper half of the recommended full throttle rpm range with the boat normally loaded (refer to specifications). If full throttle operation is below the recommended range, change the propeller to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range causes higher than normal wear or damage. Generally, there is a rpm change between propeller pitches. RPM loss may require changing to a lower pitch propeller due to the following conditions: Operating in warmer weather and greater humidity. Operating in a higher elevation. Operating with a damaged propeller or dirty boat bottom. Operating with increased load (additional passengers, pulling skiers, etc.). 58

63 CONDITIONS AFFECTING OPERATION Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems. Above sea level elevations High temperature. Low barometric pressure. High humidity. The conditions listed above reduce air density to the engine which in turn reduces the following: Boost pressure on supercharged engines Horsepower and torque throughout the rpm range Peak rpm Cranking compression EXAMPLE: An engine running at an elevation of 2,438 m (8,000 ft) will have over a 30% power loss while engine power on a hot and humid day can be reduced by as much as 14%. These losses apply to both normally aspirated and supercharged engines Compensating for power robbing conditions: Switch to a lower pitch propeller. Change the gear ratio. Some boat performance can be regained by dropping to a lower pitch propeller, but engine performance will remain lower. In some cases, a gear ratio reduction may be more beneficial. To optimize engine performance, prop the engine to allow it to allow operation at or near the top end of the recommended maximum rpm range at wide open throttle with a normal boat load. Other advantages to propeller or gear ratio changes: Reduces the possibility of detonation. Enhances overall reliability and durability of the engine. 59

64 Service Responsibilities MAINTENANCE OWNER/OPERATOR RESPONSIBILITIES It is the owner/operator s responsibility to perform the following: Perform all safety checks. Make sure lubrication and maintenance instructions are complied with for safe operation. Return the unit to an authorized Mercury Marine dealer for a periodic checkup. Normal maintenance service and replacement parts. Proper maintenance and care of your power package will ensure optimum performance and dependability, and will keep your overall operating expenses at a minimum. See your authorized Mercury Marine dealer for service aids. DEALER RESPONSIBILITIES In general, a dealer s responsibilities to the customer include predelivery inspection and preparation. These include: Completing a Warranty Registration Card and mailing it to the factory immediately upon sale of the new product. Properly equipping the boat. Making certain that the Mercury Marine power package and other equipment are in proper operating condition prior to delivery. Making all necessary adjustments for maximum efficiency. Familiarizing the customer with the on-board equipment. Explaining and demonstrating the operation of the power package and boat. Providing you with a copy of a Predelivery Inspection Checklist prior to delivery. 60

65 MAINTENANCE Replacement Service Parts WARNING Electrical, ignition and fuel system components on Mercury Marine gasoline power packages are designed and manufactured to comply with US Coast Guard rules and regulations to minimize risks of fire or explosion. Use of replacement electrical, ignition or fuel system components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. When servicing the electrical, ignition, and fuel systems, it is extremely important that all components are properly installed and tightened. If not, any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks, if they existed. Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in fresh and saltwater environments. These conditions require numerous special parts. Care should be exercised when replacing marine engine parts, as specifications are quite different from those of the standard automotive engine. For example, one of the most important, and probably the least suspected special replacement part, is the cylinder head gasket. Since saltwater is highly corrosive, the steel-type automotive head gasket cannot be used. A marine engine head gasket uses special materials to resist corrosive action. Since marine engines must be capable of running at or near maximum rpm much of the time, special valve springs, valve lifters, pistons, bearings, camshafts and other heavy-duty moving parts are required for long life and peak performance. These are but a few of the many special modifications that are required in Mercury Marine engines to provide long life and dependable performance. 61

66 MAINTENANCE Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. Present-day marine equipment, such as your Mercury Marine power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but are more complex for the untrained mechanic. Do not attempt any repairs that are not covered in this manual unless you are aware of the precautions (Cautions and Warnings) and procedures required. Your safety is of our concern. If you attempt to service the product yourself, we suggest you order the service manual for that model. This manual outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don t understand. Do not attempt repairs if you do not understand the procedures. Special tools and equipment may be required to perform some repairs. Do not attempt these repairs unless you have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would charge you. Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer s mechanic must reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately upon having a problem. It may be a very simple adjustment to correct the problem. Do not telephone the dealer, service office or the factory to attempt for them to diagnose a problem or request the repair procedure. It is difficult for them to diagnose a problem over the telephone. Your authorized Mercury Marine dealer is there to service your power package. They have qualified factory-trained mechanics. Mercury Marine recommends that you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble-free boating pleasure. 62

67 MAINTENANCE Do-It-Yourself Maintenance Suggestions WARNING Avoid Injury or Electrical System Damage. Always disconnect battery cables from battery before working around electrical system components. IMPORTANT: Refer to Maintenance Charts (on following pages) for complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner/operator, while others should be performed by an authorized Mercury Marine dealer. Before attempting maintenance or repair procedures not covered in this manual, Mercury Marine recommends purchasing a Mercury Marine Service Manual. Servicing High Horsepower Engines All high performance engines require frequent maintenance and inspection schedules due to the extreme duty cycles and related stress these products endure. Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastrophic engine failure and increased owner expense. 63

68 Maintenance Charts MAINTENANCE SCHEDULED MAINTENANCE Interval After every use Check every 3 hours of operation Every 15 hours of operation Task Cooling system - Flush Engine oil - (reservoir) Check level Power steering fluid - Check level Sterndrive unit oil - Check level Transmission fluid - Check level Battery - Check level and inspect for damage Power trim pump oil - Check level Anodes - Inspect for erosion Seawater pickups - Check for marine growth or debris VI SSM Tie bar mounting bracket nuts. Tighten nuts to 102 Nm (75 lb-ft) Check exhaust header mounting bolts for tightness Engine oil and filter - Change Check and adjust valve clearance 64

69 Maintenance Charts MAINTENANCE SCHEDULED MAINTENANCE Interval Every 25 hours of operation or every 90 days, whichever occurs first. Task Propeller shaft - Lubricate Propeller nut - Retighten Anodes - Inspect for erosion Flame arrestor - Clean Sterndrive - Inspect and clean Sterndrive oil filter and oil - Change oil and filter after first 25 hours. Change oil and filter every 200 hrs. thereafter. 65

70 Maintenance Charts MAINTENANCE SCHEDULED MAINTENANCE Interval Every 50 hours of operation or once a year, whichever occurs first. Task Perform 25 hour maintenance items VI SSM Tie bar mounting bracket nuts. Tighten nuts to 102 Nm (75 lb-ft) Lubricate and inspect universal joint cross bearings Lubricate drive input shaft Tighten drive mounting nuts 136 Nm (100 lb-ft) Change transmission fluid Inspect condition and tension of all drive belts Inspect cooling system hoses and clamps Inspect exhaust system condition and tighten clamps Inspect electrical system for loose or damaged wires 66

71 Maintenance Charts MAINTENANCE SCHEDULED MAINTENANCE Interval Every 50 hours of operation or once a year, whichever occurs first. Every 50 to 70 hours of operation Every 100 Hours of operation or once yearly, whichever occurs first. Every 100 to 120 hours of operation Every 200 Hours Task Replace high pressure fuel filter element Inspect steering system components and lubricate pivot points Replace water separating fuel filter Inspect throttle and shift components for wear and proper adjustment Inspect all valve train components for wear, particularly the valve lifters. Perform 25 and 50 hour maintenance items Seawater pickup pump - Disassemble and Inspect Engine alignment - Check Inspect all rotating and reciprocating components for wear. Replace components as needed. Sterndrive oil and filter - After the initial 25 hour oil and filter change, change the oil and filter every 200 hrs. 67

72 MAINTENANCE 1 Checking Fluid Levels CHECKING ENGINE OIL (RESERVOIR) Oil consumption is greatly dependant upon engine speed, with consumption being highest at wide-open-throttle and decreasing substantially as engine speed is reduced. It is not uncommon for big block high performance engines to use up to 1 quart of oil in 1-5 hours if the engine is operated continuously at the upper end of the RPM range. 1 With the engine at idle, observe the oil reservoir sight tube. 2 Oil level in the reservoir sight tube should be approximately even with the bottom of the reservoir split ring. IMPORTANT: Do not overfill engine oil. NOTE: If the engine is not operated for a period of time (several days or longer), a certain amount of oil may drain from the reservoir back into the engine oil pan. When the engine is started this oil will be pumped back into the reservoir. 68

73 NOTES 69

74 MAINTENANCE a b c d e

75 Checking Fluid Levels MAINTENANCE CHECKING DRIVE UNIT OIL NOTE: Oil level will fluctuate during operation. Check the oil level with a cold engine before starting. IMPORTANT: If more than 59 ml (2 fl oz) of gear lube is required, a seal may be leaking. Damage to drive unit may occur due to lack of lubrication. Contact your authorized Mercury Marine dealer for service. Fill Dry Sump drive and transom input shaft housing with TORCO MTF Gear Lube. Tube Description Where Used Part Number 132 TORCO MTF Gear Oil Transom Input Shaft Reservoir and Dry Sump Drive CAUTION The input shaft housing must be filled with lubricant on driveline models. 3 Check the input shaft housing oil level on driveline models as follows: Remove the reservoir level pipe plug (c). The oil level should be even with the bottom of the hole. If low, fill the input shaft housing (b) through the top fill pipe plug hole (a) until oil flows from the reservoir level plug hole (c). Reinstall the reservoir level pipe plug and the top fill plug. 4 Check drive unit oil level as follows: Remove the drive vent plug (d). The oil level should be even with the bottom of the hole. If low, remove the drain/fill plug and sealing washer (e) from the gearcase and fill until oil comes out of the top vent plug (d) opening. Install the drive vent plug (d). Remove the filler tube and quickly install the drain/fill plug and sealing washer (e). Recheck the oil level at the vent plug (d). 71

76 MAINTENANCE b c a

77 Checking Fluid Levels MAINTENANCE CHECKING POWER TRIM PUMP FLUID Place the drive unit in the full down/in position. 5 Remove the fill/vent screw (a). Wipe clean and re-insert back into the pump, but do not thread it into place. Remove it again and note the oil level, which must be between the Add (c) and Full (b) marks on the dipstick. If necessary, add Power Trim and Steering Fluid or SAE 10W-30 motor oil through the fill/vent hole to bring the oil level up to the Full mark on the dipstick. Do not overfill. Tube Description Where Used Part Number 114 Power Trim and Steering Fluid Trim Pump A1 Raise and lower the drive unit 6 to 10 times to purge air from the system. Re-check the oil level. IMPORTANT: Loosen the fill/vent screw 1-1/2 turns after seating to vent the pump reservoir. Failure to loosen the screw could result in damage to the pump. Re-install the fill/vent screw until it seats, then loosen it 1-1/2 turns to vent the pump. 73

78 MAINTENANCE

79 Checking Fluid Levels MAINTENANCE CHECKING TRANSMISSION FLUID LEVEL IMPORTANT: The first time the transmission fluid is checked, the boat should be on a trailer or in a sling with the engine level. Add fluid until the dipstick reads full, then put the boat in the water and recheck the fluid level. Mark the dipstick at the new fluid level and use this mark when checking the fluid with the boat in the water. 6 Operate the engine for at least two minutes at idle, shifting the transmission from forward to reverse several times. NOTE: If the engine has not been run for more than two weeks, fluid can drain out of the transmission pistons and change the fluid level by as much as one quart. 7 Shut the engine off and check the dipstick level. The fluid level should be up to the full mark on the dipstick or the mark established when the boat was first run. Add Automatic Transmission Fluid Type F or FA through the dipstick tube as necessary. Reinstall the dipstick and push down to tighten. Tube Description Where Used Part Number 166 ATF Type F or FA Transmission Obtain Locally 8 Do not use the transmission expansion bottle as a fluid reservoir. IMPORTANT: Only use the bottle for fluid expansion and overflow. 75

80 MAINTENANCE (2) (7) b 5 8 a 76

81 Changing Fluids MAINTENANCE CHANGING CRANKCASE OIL (RESERVOIR) AND FILTERS 1 Place a sufficiently sized container, 19 liters (20 U.S. qt.) below the oil reservoir. 2 Remove the plug from the reservoir bottom and let the oil drain. 3 Loosen the oil pump mounting bolts and remove the belt. Using an electric drill, manually turn the oil pump pulley (clockwise) to discharge any remaining engine oil into the reservoir to be drained. 4 Drain the vent canister into a suitable container. 5 To replace the spin on the oil filter: Loosen the filter retaining clamp (a) and slide it off the filter. Place a container under the filter to catch oil. Remove the spin on the oil filter by turning it counter-clockwise. Coat the new filter sealing ring with oil and install it hand tight. Do not over tighten. Install the filter retaining clamp (a) so that the clasp of the retaining clamp is against the stop screw (b) to secure the filter during operation. Tighten the clamp. IMPORTANT: The screen style filter element must always be returned to its original orientation (correct side up) to prevent the oil from flowing through it in the wrong direction. 6 Remove the cover of the Oberg screen style filter and mark the element so it can be returned to its original orientation with the correct side up. Clean the element with solvent. Reassemble the filter assembly, making sure that the screen is installed with the up side in the proper orientation. NOTE: Engine to reservoir oil line lengths affect total oil capacity and will vary with each installation 7 Install the bottom oil reservoir plug and tighten securely. 77

82 Changing Fluids MAINTENANCE CHANGING CRANKCASE OIL (RESERVOIR) AND FILTERS 8 Begin by filling the oil reservoir with 11.4 liters (12 U.S. qt.) of oil. 9 Using an electric drill motor, manually turn the oil pump pulley (clockwise) to prime the engine oiling system until reaching an oil pressure of 276 kpa (40 psi). 10 Add any additional oil to the reservoir to bring the oil level to approximately 25.4 mm (1 in.) below the bottom of the reservoir split ring. 11 Install the oil pump belt and tighten the pump mounting fasteners. Tension the oil pump belt to specifications. NOTE: Engine oil level in the reservoir will increase as the engine oil temperature increases. 12 Start the engine and observe the engine oil level in the reservoir. The oil level should be even with the bottom of the reservoir split ring. Shut off the engine if it is necessary to add oil. 13 Operate the engine at idle and monitor the oil pressure and oil level at the reservoir sight tube. 78

83 MAINTENANCE Changing Fluids CHANGING TRANSMISSION OIL 1 Place a suitable container (approximately 2.8 liter [3 qts]) under the transmission lower fitting. 2 Remove both the upper and lower transmission-to-oil-cooler lines and drain. 3 Remove the check valve assembly from the lower fitting and drain the transmission fluid. 4 Reinstall the check valve assembly and the upper and lower oil lines. 5 Fill the transmission through the dipstick tube with approximately 1.9 liters (2 qts) of Type F or FA transmission fluid. Tube Description Where Used Part Number 166 ATF Type F or FA Transmission Obtain Locally 6 Start the engine and let it run for at least two minutes at idle, shifting the transmission from forward to reverse several times. 7 Stop the engine and check the transmission oil level with the dipstick. If addition oil is required, add it through the dipstick tube to bring the level up to the full mark. 79

84 MAINTENANCE 1 a b 2 a 132 b 80

85 Changing Fluids MAINTENANCE CHANGING DRIVE UNIT OIL (DRY SUMP) IMPORTANT: Fill the dry sump drive and transom input shaft housing with TORCO MTF Gear Lube. Tube Description Where Used Part Number 132 TORCO MTF Gear Oil Transom Input Shaft Reservoir and Dry Sump Drive DRIVELINE MODELS ONLY 1 Place a container below the input shaft housing and remove the bottom pipe plug. a -Input shaft housing b -Oil drain pipe plug WARNING Avoid damage to the input shaft housing. Do Not Overfill the input shaft housing reservoir or damage to transom components could occur. 2 Fill the input shaft housing through the top pipe plug hole (a) until oil flows from oil level pipe plug hole (b). Install the pipe plugs (a & b) into the input shaft housing and tighten securely. a -Fill pipe plug hole (fill through here) b -Oil level pipe plug hole 81

86 MAINTENANCE a b 82

87 Changing Fluids MAINTENANCE ALL MODELS 1 Place the drive unit in a position so that the propshaft is level. 2 Remove the upper oil level plug and sealing washer from the gearcase. a -Oil Level Plug IMPORTANT: If water drains from the gearcase, or if gear lube appears milky; the drive unit is leaking. Have the unit checked immediately by your authorized Mercury Marine dealer. 3 Remove the lower fill/drain plug and sealing washer from the gearcase and allow the oil to drain into a suitable container. b -Fill/Drain plug and sealing washer 4 Fill the drive unit through the lower fill/drain hole until oil comes out of the top oil level plug opening. Tube Description Where Used Part Number 132 TORCO MTF Gear Oil Transom Input Shaft Reservoir and Dry Sump Drive 5 Install the upper oil level plug and sealing washer Remove filler tube and quickly install the lower fill/drain plug and sealing washer. 83

88 MAINTENANCE F N R

89 Lubrication MAINTENANCE Lubricate the following grease fittings with Optimal PD-2. 1 Engine Driveshaft. 2 Transmission shift lever - Lubricate poppet ball. Tube Description Where Used Part Number 133 Optimal PD-2 Engine drive shaft, Transmission shift lever Lubricate pivot points with SAE 25W40 motor oil. 3 Shift cable. 4 Throttle linkage and cable - Lubricate cable and swivels. Tube Description Where Used Part Number 79 MerCruiser 4-cycle 25W 40 Engine Oil Shift Cable and Throttle Linkage A1 85

90 MAINTENANCE

91 MAINTENANCE Propellers WARNING Avoid serious injury or death. Place the remote control in neutral and remove the ignition key from the switch before removing and/or installing the propeller. Place a block of wood between the anti-ventilation plate and the propeller to protect hands from propeller blades and to prevent the propeller from rotating when removing the propeller nut. CAUTION Avoid propeller/sterndrive damage or injury. Periodically check propeller nut for tightness during boating season. A minimum of 136 Nm (100 lb-ft) torque is required. REMOVAL 1 Place a wood block between the propeller blade and the antiventilation plate to prevent rotation. Straighten bent tabs on tab washer. 2 Turn the propeller shaft nut counter-clockwise to remove the nut. 3 Slide washer, continuity washer, and propeller off propeller shaft. Some damaged propellers can be repaired. See your dealer. INSTALLATION 4 Apply a liberal coat of Anti-Corrosion Grease to propeller shaft. Tube Description Where Used Part Number 94 Anti-Corrosion Grease Propshaft A1 5 Align splines and install propeller, washer and propeller nut. 6 Place wood block between the propeller blade and anti-ventilation plate to prevent rotation and tighten the propeller nut. After first use, retighten propeller nut. Check propeller at least every 20 hours of operation. Do not operate with a loose propeller. Description Nm lb-in. lb-ft Propeller nut

92 MAINTENANCE 1 Seawater Pump Impeller Inspection Seawater Pump Impeller service should be performed by an authorized Mercury Marine dealer. 1 The seawater pump impellers (3 in one pump assembly) should be inspected whenever insufficient seawater flow is suspected. The two rear impellers supply the engine with water and the front impeller supplies the charge air cooler (CAC). The impellers supplying the engine should be inspected if the engine operating temperature exceeds the normal range. The charge air cooler impeller should be inspected if the discharge stream for the charge air cooler is less than normal. Consult your boat owners manual for the location of the charge air cooler discharge location. 88

93 MAINTENANCE Flushing Cooling System WARNING Avoid possible death or serious injury. Always remove the propeller before flushing the cooling system. CAUTION Do not operate the engine above 1500 rpm when flushing. Suction created by the seawater pickup pump may collapse the flushing hose, causing the engine or drive unit or both to overheat. Watch the temperature gauge on the dash to ensure that the engine does not overheat. To prevent silt and salt buildup in the cooling system, flush with freshwater. 1 Install a flushing hose from a water tap to the flushing connector. Consult your boat owners manual for the location of the flushing connector. 2 Completely open the water tap. Place the remote control in neutral position and start the engine. Operate the engine at idle speed, in neutral, for about 10 minutes or until discharge water is clear. Stop the engine, shut off the water, and remove the flushing hose. 89

94 MAINTENANCE a b b 1 c d a 3712 Cleaning Seawater (Raw Water) Section of Oil Cooler ENGINE COOLERS 1 Transmission/Power Steering Cooler - (Starboard side) 1. Loosen the inlet and outlet water hose clamps (a) and remove the hoses from the cooler (c). 2. Remove the two clamps (d) that retain the cooler and lift the cooler away from the engine to gain access to the end plate fasteners. 3. Remove the end plates and gaskets (b). 4. Clean the cooler with a suitable brush and flush passages with fresh water. 5. Inspect the end plate gaskets and replace if necessary. 6. Install the gaskets and end plates. Tighten screws securely. 7. Re-install the cooler on its bracket and tighten clamps securely. 8. Re-install the inlet and outlet water hoses onto the cooler and tighten clamps securely. 9. Start the engine and check all hoses for leaks. 2 Engine Oil Coolers - Cleaning of the engine oil coolers should be performed by an authorized Mercury Marine dealer. 90

95 MAINTENANCE Drive Belts WARNING Avoid possible serious injury or death. Make sure engine is shut off and ignition key is removed before inspecting belts. Periodically inspect all of the following drive belts for condition and tension. See your authorized Mercury Marine dealer for replacement or tension adjustments. a b c d 1 f e rmc22 1 Seawater Pump/Alternator Drive Belt Description N lb Seawater pump/alternator belt a -Sea pump pulley b -Seawater pump/alternator drive belt c -Crankshaft pulley d -Idler pulley e -Alternator pulley (adjust belt tension here) f -Tensioner gauge 91

96 Drive Belts MAINTENANCE d a f b c 2 e Power Steering Pump Drive Belt Description N lb Power steering pump belt a -Power steering pump pulley (adjust belt tension here) b -Idler pulley c -Tensioner gauge d -Power steering pump drive belt e -Crankshaft pulley f -Recirculating pump pulley 92

97 MAINTENANCE Drive Belts a b c 3 rmc21 3 Oil Pump Belt - Belt should twist 1/4 turn. a -Crankshaft pulley b -Oil pump drive belt c -Oil pump (Adjust belt tension here) a a e d b c 4 rmc23 4 Supercharger Belt - Self tensioning a -Supercharger pulley b -Supercharger drive belt c -Crankshaft pulley d -Idler pulleys e -Belt tensioner 93