NOTE: The following applies to CE marked products only.

Transcription

1 NOTE: The following pplies to CE mrked products only. Declrtion of Conformity 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 Propulsion Engines with the Requirements of Directive 94/25/EC s mended by 2003/44/EC 808 Nme of engine mnufcturer: Mercury Mrine MerCruiser Address: 3003 N. Perkins Rod Town: Stillwter, OK Post Code: Country: USA Nme of Authorized Representtive: Brunswick Mrine in EMEA Inc. Address: Prc Industriel de Petit Rechin Town: Verviers Post Code: 4800 Country: Belgium Nme of Notified Body for exhust emission ssessment: Det Norske Verits AS Address: Veritsveien 1 Town: Hovik Post Code: 1322 Country: Norwy ID Number: 0575 Conformity ssessment module used for exhust emissions: or engine type pproved ccording to: B+C B+D B+E B+F G H stge II of Directive 97/68/EC Directive 88/77/EC Conformity ssessment module used for noise emissions: A A G H Other Community Directives pplied: Electromgnetic Comptibility Directive 2004/108/EC Description of Engines nd Essentil Requirements Engine Type Fuel Type Combustion Cycle z or sterndrive without integrl exhust Diesel 2 stroke Inbord engine Petrol 4 stroke Identifiction of Engines Covered by This Declrtion of Conformity Nme of engine fmily Unique engine identifiction number: strting seril number EC Module H certificte number 3.0 TKS OW RCD-H TKS OW RCD-H-1 Essentil requirements Annex 1.B Exhust Emissions stndrds other normtive document/ method technicl file B.1 engine identifiction Plese specify in more detil (* = mndtory stndrd) B.2 exhust emission requirements * * EN ISO :1996 B.3 durbility B.4 owner's mnul ISO 8665: 1995 Annex 1.C Noise Emissions C.1 Noise emission levels * * EN ISO C.2 Owner's Mnul Owner's mnul 2008 Mercury Mrine 3.0 TKS Models * *

2 This declrtion of comformity is issued under the sole responsibility of the mnufcturer. I declre on behlf of the engine mnufcturer tht the engines will meet the exhust emission requirements of Directive 94/25/EC s mended by Directive 2003/44/ EC when instlled in recretionl crft, in ccordnce with the engine mnufcturer's supplied instructions nd tht these engines must not be put into service until the recretionl crft into which they re to be instlled hs been declred in conformity with the relevnt provisions of the bove mentioned Directives. Nme / function: Kevin Grodski, President, Mercury MerCuiser Signture nd title: 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: Dte nd plce of issue: July 24, 2008 Stillwter, Oklhom, USA 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. 2008, 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, VesselView, Zeus, Axius, Totl Commnd, M with Wves logo, Mercury with Wves logo, nd SmrtCrft logo re ll trdemrks or registered trdemrks of Brunswick Corportion. Mercury Product Protection logo is registered service mrk of Brunswick Corportion.

3 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. 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.

4 ! 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.

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...3 Mercury Product Protection Pln: United Sttes nd Cnd...3 Mercury MerCruiser Limited Wrrnty (Gsoline Fueled Products Only) Yer Limited Wrrnty Aginst Corrosion...6 Globl Wrrnty Chrts...7 Wrrnty for Consumer Applictions...7 Wrrnty for Commercil Applictions...7 Wrrnty for Government Applictions...7 Mercury Instlltion Qulity Certifiction Progrm..8 Emission Control Informtion Lbel...9 Owner Responsibility...10 Section 2 - Getting to Know Your Power Pckge Identifiction...12 Alph Sterndrive Decl Identifiction...12 Alph Trnsom Seril Number...12 Engine Seril Number Decl...13 Lnyrd Stop Switch...14 Instrumenttion...15 Remote Controls...16 Pnel Mount Fetures...16 Console Mount Fetures...17 Electricl System Overlod Protection Crbureted Engines...17 Audio Wrning System...20 Testing The Audio Wrning System...21 Power Trim...21 Single Engine Trim/Triler...22 Dul Engine Trim/Triler...22 Section 3 - On the Wter Sfe Boting Suggestions...24 Be Alert to Crbon Monoxide Poisoning...25 Good Ventiltion...25 Poor Ventiltion...26 Bsic Bot Opertion...26 Lunching nd Bot Opertion...26 Opertion Chrt...26 Strting nd Stopping the Engine...27 Strting the Engine...27 Stopping the Engine...28 Strting the Engine After It Hs Been Stopped While In Ger...28 Throttle Only Opertion...28 Trilering the Bot...28 Freezing Temperture Opertion...28 Drin Plug nd Bilge Pump...29 Protecting People in the Wter...29 While You Are Cruising...29 While Bot Is Sttionry...29 High Speed nd High Performnce Opertion...29 Pssenger Sfety in Pontoon Bots nd Deck Bots...29 Bots Hving An Open Front Deck...30 Bots With Front Mounted, Rised Pedestl Fishing Sets...30 Wve nd Wke Jumping...30 Impct with Underwter Hzrds...31 Drive Unit Impct Protection...32 Conditions Affecting Opertion...32 Weight Distribution (Pssengers nd Ger) Inside the Bot...32 The Bottom of the Bot...32 Cvittion...32 Ventiltion...32 Elevtion nd Climte...33 Propeller Selection...33 Getting Strted Hour Brek In Period...34 After Brek In Period...34 End of First Seson Checkup AUGUST 2008 Pge i

6 Section 4 - Specifictions Fuel Requirements...36 Fuel Rtings...36 Using Reformulted (Oxygented) Gsolines (USA Only)...36 Gsolines Contining Alcohol...36 Engine Oil...37 Engine Specifictions TKS Fluid Specifictions Sterndrives...38 Engine...38 Section 5 - Mintennce Owner/Opertor Responsibilities...40 Deler Responsibilities...40 Mintennce...40 Do It Yourself Mintennce Suggestions...41 Inspection...41 Mintennce Schedules...42 Routine Mintennce Scheduled Mintennce...42 Mintennce Log...43 Seled Crburetor Mixture Screw Engine Oil...44 Checking...44 Filling Chnging Oil nd Filter...46 Esy Engine Oil Drin System...46 Engine Oil Drin Pump Chnging Filter...47 Power Steering Fluid...47 Checking...47 Filling Chnging Engine Coolnt...48 Checking...48 Filling Chnging Drive Unit Oil Checking...50 Filling Chnging Power Trim Fluid Checking...52 Filling Chnging Clening The Flme Arrestor Positive Crnkcse Ventiltion Vlve (PCV) Chnging...54 Chnging the Wter Seprting Fuel Filter...54 Fuel Pump Sight Tube Inspection Lubriction...56 Steering System...56 Mnul Steering System...57 Throttle Cble...58 Shift Cble Typicl...58 Sterndrive Unit nd Trnsom Assembly Sterndrive U joint Shft Splines nd O rings (Sterndrive Unit Removed)...59 Engine Coupler Driveshft Extension Models...60 Propellers Propeller Repir Alph Propeller Removl Alph Propeller Instlltion Drive Belts...62 Checking...62 Replcing Front Mount Models...63 Power Steering Pump Drive Belt, if equipped...63 Alterntor Belt Replcing Side Mount Models...63 Power Steering Pump Drive Belt, if equipped...63 Alterntor Belt Flushing the Power Pckge...64 Flushing Attchments Sterndrive Wter Pickups Bttery...66 Corrosion Protection...67 Pinting Your Power Pckge...71 Pge ii AUGUST 2008

7 Section 6 - Storge Cold Wether or Extended Storge Prepring Power Pckge for Storge...74 Engine nd Fuel System Preprtion...75 Drining the Sewter System...76 Single Point Drin System...76 Drining the Sewter Section of Closed Cooled Models...78 Clering Clogged Blue Drin Hoses...80 Drining the Sterndrive...81 Bttery Storge...82 Power Pckge Recommissioning...82 Section 7 - Troubleshooting Strter Motor Will Not Crnk Engine, Or Crnks Slow...86 Engine Will Not Strt Or Is Hrd To Strt...86 Engine Runs Rough, Misses or Bckfires...86 Poor Performnce...86 Excessive Engine Temperture...87 Insufficient Engine Temperture...87 Low Engine Oil Pressure...87 Bttery Will Not Rechrge...87 Remote Control Is Difficult to Move, Hs Excessive Ply, or Mkes Unusul Sounds...88 Steering Wheel Jerks or Is Difficult to Turn...88 Power Trim Does Not Operte (Motor Does Not Operte)...88 Power Trim Does Not Operte (Motor Opertes but Sterndrive Unit Does Not Move)...88 Section 8 - Customer Assistnce Informtion Owner Service Assistnce...90 Locl Repir Service...90 Service Awy From Home...90 Stolen Power Pckge...90 Attention Required fter Submersion...90 Replcement Service Prts...90 Prts nd Accessories Inquiries...91 Resolving Problem...91 Mercury Mrine Service Offices...91 Ordering Literture...92 United Sttes nd Cnd...92 Outside The United Sttes nd Cnd AUGUST 2008 Pge iii

8 Pge iv AUGUST 2008

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... 3 Mercury Product Protection Pln: United Sttes nd Cnd... 3 Mercury MerCruiser Limited Wrrnty (Gsoline- Fueled Products Only) Yer Limited Wrrnty Aginst Corrosion... 6 Globl Wrrnty Chrts... 7 Wrrnty for Consumer Applictions...7 Wrrnty for Commercil Applictions...7 Wrrnty for Government Applictions...7 Mercury Instlltion Qulity Certifiction Progrm... 8 Emission Control Informtion Lbel... 9 Owner Responsibility AUGUST 2008 Pge 1

10 Section 1 - Wrrnty Wrrnty Registrtion: United Sttes nd Cnd To ensure tht your wrrnty coverge begins promptly, your selling deler should fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product. The Wrrnty Registrtion Crd identifies the nme nd ddress of the originl purchser, product model nd seril number(s), dte of sle, type of use nd selling deler s code, nme, nd ddress. The deler lso certifies tht you re the originl purchser nd user of the product. A temporry Owner Wrrnty Registrtion Crd will be presented to you when you purchse the product. Upon receipt of the Wrrnty Registrtion Crd t the fctory, Mercury MerCruiser will send you n owner resource guide tht includes your wrrnty registrtion confirmtion. If you do not receive your owner resource guide within 60 dys from dte of new product sle, plese contct your selling deler. Becuse of your selling deler s ongoing interest in your stisfction, the product should be returned to him for wrrnty service. The product wrrnty is not effective until the product is registered t the fctory. NOTE: Registrtion lists must be mintined by the fctory nd deler on mrine products sold in the United Sttes in the event tht sfety recll notifiction under the Federl Bot Sfety Act is required. You my chnge your ddress t ny time, including t time of wrrnty clim, by clling Mercury MerCruiser or sending letter or fx to Mercury MerCruiser s wrrnty registrtion deprtment with your nme, old ddress, new ddress, nd engine seril number. Your deler cn lso process this chnge of informtion. United Sttes customers or delers my contct: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Cndin customers or delers my contct: Mercury Mrine Cnd Limited 2395 Medowpine Blvd. Mississug, ON Cnd, L5N 7W6 Fx Wrrnty Registrtion: Outside the United Sttes nd Cnd To ensure tht your wrrnty coverge begins promptly, your selling deler should fill out the wrrnty registrtion crd completely nd mil it to the distributor responsible for dministering the wrrnty registrtion nd clim progrm for your re. Pge AUGUST 2008

11 Trnsfer of Wrrnty Section 1 - Wrrnty The wrrnty registrtion crd identifies your nme nd ddress, product model nd seril numbers, dte of sle, type of use, nd the selling distributor s nd deler s code number, nme, nd ddress. The distributor or deler lso certifies tht you re the originl purchser nd user of the product. A copy of the wrrnty registrtion crd, designted s the purchser s copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor or deler. This crd represents your fctory registrtion identifiction. Keep the crd; if you ever need 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. In some countries, the distributor will issue permnent (plstic) wrrnty registrtion crd to you within 30 dys fter receiving the fctory copy of the wrrnty registrtion crd from your distributor or deler. If you receive plstic wrrnty registrtion crd, you my discrd the purchser s copy tht you received from the distributor or deler when you purchsed the product. Ask your distributor or deler if this plstic crd progrm pplies to you. For further informtion concerning the wrrnty registrtion crd nd its reltionship to wrrnty clim processing, refer to the Interntionl Wrrnty. See Tble of Contents. NOTE: Registrtion lists must be mintined by the fctory nd deler on mrine products sold in the United Sttes in the event of sfety recll notifiction under the Federl Bot Sfety Act. 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 mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx In Cnd mil to: Mercury Mrine Cnd Limited 2395 Medowpine Blvd. Mississug, ON Cnd, L5N 7W6 Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product by mil. There is no chrge for this service. For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the distributor closest to you. Mercury Product Protection Pln: United Sttes nd Cnd (Certin performnce products, triple engine instlltions, nd commercil pplictions re excluded.) AUGUST 2008 Pge 3

12 Section 1 - Wrrnty 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) 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. Durtion of Coverge Wrrnty Period for Recretionl Use The wrrnty period begins on the dte the product is first sold to recretionl use retil purchser or the dte on which the product is first put into service, whichever occurs first. Products instlled by n Instlltion Qulity Certified Instller receive one (1) yer of dditionl wrrnty coverge. 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. The wrrnty period is specific to the model covered; see your model for the bse coverge period: Coverge for Horizon Inbord Models, nd Vzer 100 Sterndrive Models The Limited Wrrnty for Horizon Inbord Models nd Vzer 100 Models is four (4) yers when instlled by n Instlltion Qulity Certified Instller or three (3) yers for non certified instlltions.. Coverge for SeCore Sterndrive Models The Limited Wrrnty for SeCore Sterndrive Models is four (4) yers when instlled by n Instlltion Qulity Certified Instller or three (3) yers for non certified instlltions. Coverge for Tow Sports Inbord Models The Limited Wrrnty for ll Tow Sports Inbord models is three (3) yers when instlled by n Instlltion Qulity Certified Instller or two (2) yers for non certified instlltions. Coverge for All Other Models The Limited Wrrnty for ll other Gsoline Sterndrive nd Inbord models except those described bove is two (2) yers when instlled by n Instlltion Qulity Certified Instller or one (1) yer for non certified instlltions. Wrrnty Period for Commercil Use The wrrnty period begins on the dte the product is first sold to commercil use retil purchser or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge for either one (1) yer from the dte of first retil sle or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work relted or employment relted use of the product, or ny use of the product tht genertes income for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Trnsfer of Coverge Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper reregistrtion of the product. Unexpired wrrnty coverge cnnot be trnsferred either to or from commercil use customer. Termintion of Coverge Wrrnty coverge is terminted for used product obtined in ny of the following wys: Repossession from retil customer Purchse t uction Purchse from slvge yrd Purchse from n insurnce compny tht obtined the product s result of n insurnce clim Pge AUGUST 2008

13 Section 1 - Wrrnty 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 pre delivery inspection process specified by Mercury Mrine is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use or subsequent chnge of use from recretionl to commercil (unless properly reregistered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce must be performed ccording to the mintennce schedule in the Opertion, Mintennce & Wrrnty mnul in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Wht Mercury Mrine Will Do Mercury Mrine's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury Mrine product. Mercury Mrine reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. How to Obtin Wrrnty Coverge The customer must provide Mercury Mrine with resonble opportunity to repir nd resonble ccess to the product for wrrnty service. Wrrnty clims shll be mde by delivering the product for inspection to Mercury Mrine deler uthorized to service the product. If the purchser cnnot deliver the product to such deler, written notice must be given to Mercury Mrine. Mercury Mrine will then rrnge for the inspection nd ny covered repir. The purchser in tht cse shll py for ll relted trnsporttion chrges nd trvel time. If the service provided is not covered by this wrrnty, the purchser shll py for ll relted lbor nd mteril nd ny other expenses ssocited with tht service. The purchser shll not, unless requested by Mercury Mrine, ship the product or prts of the product directly to Mercury Mrine. Proof of registered ownership must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. Wht Is Not Covered This limited wrrnty does not cover the following: Routine mintennce items Adjustments Norml wer nd ter Dmge cused by buse Abnorml use Use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion, Mintennce & Wrrnty mnul) Opertion of the product in mnner inconsistent with the recommended opertion nd duty cycle section of the Opertion, Mintennce & Wrrnty mnul Neglect Accident Submersion Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Improper service Use of n ccessory or prt tht ws not mnufctured or sold by Mercury Mrine nd tht dmges the Mercury product Jet pump impellers nd liners Opertion with fuels, oils, or lubricnts tht re not suitble for use with the product (see the Opertion, Mintennce & Wrrnty mnul) Altertion or removl of prts Wter entering the engine through the fuel intke, ir intke, or exhust system or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body Running the engine out of wter Mounting the engine too high on the trnsom Operting the bot with the engine over trimmed AUGUST 2008 Pge 5

14 Section 1 - Wrrnty Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny point, even by previous owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl or replcement of bot prtitions or other mteril in order to gin ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty. If such ffirmtion, representtion, or wrrnty is mde, it shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Yer Limited Wrrnty Aginst Corrosion 3-YEAR LIMITED WARRANTY AGAINST CORROSION Wht Is Covered Durtion of Coverge 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. 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. Condition Tht Must Be Met in Order to Obtin Wrrnty Coverge Wht Mercury Will Do How to Obtin Wrrnty Coverge Wht Is Not Covered 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, Mintennce & Wrrnty mnul must be in use on the bot, nd routine mintennce outlined in the Opertion, Mintennce & Wrrnty mnul must be timely performed (including without limittion the replcement of scrificil nodes, use of specified lubricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. 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. 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. Pge AUGUST 2008

15 Globl Wrrnty Chrts Section 1 - Wrrnty 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. Wrrnty for Consumer Applictions Engine Model 3.0 TKS Region The Americs (excluding Brzil) Brzil Europe, Middle Est, Afric Austrli, New Zelnd Stndrd Fctory Limited Wrrnty by Certifiction Sttus of Bot Mnufcturer Not Certified 1 yer 2 yers Instlltion Qulity Certified 2 yers 3 yers 2 yers Consumer Limited Corrosion Wrrnty 3 yers 2 yers 3 yers Jpn 1 yer 1 yer 1 yer South Pcific 2 yers 2 yers 2 yers Other Asi 1 yer 1 yer 1 yer Wrrnty for Commercil Applictions Engine Model 3.0 TKS Region Stndrd Fctory Limited Wrrnty by Certifiction Sttus of Bot Mnufcturer Not Certified Instlltion Qulity Certified Commercil Limited Corrosion Wrrnty The Americs (excluding Brzil) 1 yer 1 yer 1 yer Brzil 2 yers 2 yers 2 yers Europe, Middle Est, Afric Austrli, New Zelnd Jpn South Pcific Other Asi 1 yer or 500 hours 1 yer or 500 hours 1 yer or 500 hours Wrrnty for Government Applictions Engine Model 3.0 TKS Region Stndrd Fctory Limited Wrrnty by Certifiction Sttus of Bot Mnufcturer Not Certified Instlltion Qulity Certified Government Limited Corrosion Wrrnty The Americs (excluding Brzil) 1 yer 1 yer 3 yers Brzil 2 yers 2 yers 2 yers Europe, Middle Est, Afric Austrli, New Zelnd Jpn South Pcific Other Asi 1 yer or 500 hours 1 yer or 500 hours 3 yers 1 yer or 500 hours AUGUST 2008 Pge 7

16 Section 1 - Wrrnty 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. 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 Pge AUGUST 2008

17 Emission Control Informtion Lbel Section 1 - Wrrnty 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, STD (emission stndrd/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. NOTE: When the CE 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. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # FAMILY STD. XXXXXXXX XXXXXXXXXXXX XX.X g/kw-hr D.O.M. DISP MMM YYYY X.XL Emission Control Lbel Cliforni Emissions Complint "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "STD." Emissions Stndrd "D.O.M." Dte of Mnufcture "DISP" Piston Displcement EMISSION CONTROL INFORMATION NOT FOR SALE IN CALIFORNIA REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # FAMILY STD. XXXXXXXX XXXXXXXXXXXX XX.X g/kw-hr D.O.M. DISP MMM YYYY X.XL Emission Control Lbel Not for Sle in Cliforni "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "STD." Emissions Stndrd "D.O.M." Dte of Mnufcture "DISP" Piston Displcement AUGUST 2008 Pge 9

18 Section 1 - Wrrnty Owner Responsibility The opertor must hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. The opertor my not modify the engine in ny mnner tht lters the horsepower or llows emissions levels to exceed their fctory specifictions. Pge AUGUST 2008

19 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tble of Contents Identifiction Alph Sterndrive Decl Identifiction...12 Alph Trnsom Seril Number...12 Engine Seril Number Decl...13 Lnyrd Stop Switch Instrumenttion Remote Controls Pnel Mount Fetures Console Mount Fetures Electricl System Overlod Protection-Crbureted Engines Audio Wrning System Testing The Audio Wrning System Power Trim Single Engine Trim/Triler Dul Engine Trim/Triler AUGUST 2008 Pge 11

20 Section 2 - Getting to Know Your Power Pckge Identifiction The seril numbers re the mnufcture's keys to numerous engineering detils which pply to your MerCruiser power pckge. When contcting MerCruiser bout service, lwys specify model nd seril numbers. Alph Sterndrive Decl Identifiction The Drive Seril No. is locted on the port side of the lph sterndrive. The Drive Rtio is locted on the strbord side of the lph sterndrive. b Alph sterndrive - Drive ger rtio decl (strbord) b - Seril number decl (port) Alph Trnsom Seril Number The trnsom seril number is locted on the top of the trnsom ssembly. Alph trnsom ssembly seril number Pge AUGUST 2008

21 Engine Seril Number Decl Section 2 - Getting to Know Your Power Pckge The seril number decl is locted on the ft portion of the strbord side of the block, ner the strter motor The engine, trnsom, nd drive seril numbers re lso locted on the engine identifiction plte. b c - Engine seril number b - Trnsom seril number c - Drive seril number AUGUST 2008 Pge 13

22 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). b RUN c - 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. Pge AUGUST 2008

23 Instrumenttion Section 2 - Getting to Know Your Power Pckge 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. 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 R P M L OIL H BATT C TEMP H b c d e FUEL CRUISELOG TRIM f g h i j Speedometer b - Tchometer c - Oil pressure guge d - Voltmeter e - Wter temperture guge Speedometer: Indictes bot speed. Tchometer: Indictes engine RPM. Oil Pressure Guge: Indictes engine oil pressure. Voltmeter: Indictes bttery voltge. f - Fuel guge g - Hour meter h - Bilge blower switch i - Ignition switch j - Power trim guge 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. Power Trim Guge: Indictes sterndrive unit ngle (trim up/out nd down/in) AUGUST 2008 Pge 15

24 Section 2 - Getting to Know Your Power Pckge Remote Controls Pnel Mount Fetures 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. e f b c d mc Neutrl lock button b - Throttle only button c - Lnyrd stop switch d - Control hndle tension djustment screw e - Control hndle f - Trim/tilt button Neutrl Lock Button - Prevents ccidentl shift nd throttle enggement. Neutrl lock button must be pushed into 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. Trim/Tilt Button - Refer to Power Trim. Pge AUGUST 2008

25 Section 2 - Getting to Know Your Power Pckge Console Mount Fetures d c b b c d mc Throttle Only Button b - Control Hndle c - Power Trim Switch d - Triler Switch 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. Power Trim Switch - See Power Trim section for detiled power trim operting procedures. Triler Switch - Used to rise drive unit for trilering, lunching, beching or shllow wter opertion. See Power Trim for detiled triler switch opertion. Electricl System Overlod Protection Crbureted Engines If n electricl overlod occurs, fuse will blow or the circuit breker will trip open. The cuse must be found nd corrected 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 AUGUST 2008 Pge 17

26 Section 2 - Getting to Know Your Power Pckge 1. A circuit breker provides protection for the engine wiring hrness nd the instrumenttion power led. The circuit breker cn be tested by pushing the red button. If the circuit breker is functioning properly, the yellow lever will pper. Reset the yellow lever 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 2. A 90 mp fuse is locted on the lrge post of the strter solenoid. This fuse is designed to protect the engine wiring hrness if n electricl overlod occurs. mc Pge AUGUST 2008

27 Section 2 - Getting to Know Your Power Pckge 3. A 15 mp ccessory fuse is locted on the rer of the engine. This fuse protects the ccessory circuits. A 20 mp fuse is locted on the top of the engne to protect the TKS circuit. 4. 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 AUGUST 2008 Pge 19

28 Section 2 - Getting to Know Your Power Pckge 5. The power trim system is protected from overlod by 110 mp fuse nd 20 mp spde fuse on the power trim pump. The trim pump my lso hve n in line circuit protection device in the power trim positive led ner the bttery switch or bttery connection. b mp spde fuse b mp fuse 6. The Quicksilver Three Button Power Trim Control Pnel is further protected by 20 mp in line fuse. mc The Quicksilver MerCthode System hs 20 mp in line fuse in the wire which connects to the positive (+) terminl on controller. If the fuse is blown, the system will not operte resulting in loss of corrosion protection. mc79977 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: Pge AUGUST 2008

29 Section 2 - Getting to Know Your Power Pckge Engine oil pressure too low Engine temperture too hot Sterndrive oil level 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 Power Trim 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. Power trim llows the opertor to djust the sterndrive ngle while underwy, to provide the idel bot ngle for vrying lod nd wter conditions. Also, the trilering feture llows the opertor to rise nd lower the sterndrive unit for trilering, beching, lunching, low speed (below 1200 RPM engine speed) nd shllow wter opertion.! WARNING Excessive trim cn cuse serious injury or deth t high speeds. Use cution when trimming the sterndrive, nd never trim out beyond the gimbl ring support flnges while the bot is underwy or t engine speeds bove 1200 RPM. For best performnce trim the sterndrive unit so tht the bot bottom is t 3 5 ngle to the wter. 3-5 mc79528 Trimming sterndrive unit up/out cn: Generlly increse top speed Increse clernce over submerged objects or shllow bottom Cuse bot to ccelerte nd plne off slower In excess, cuse bot porpoising (bouncing) or propeller ventiltion AUGUST 2008 Pge 21

30 Section 2 - Getting to Know Your Power Pckge Cuse engine overheting if trimmed up/out to point where ny cooling wter intke holes re bove the wter line mc78529 Trimming sterndrive unit down/in cn: Help the bot ccelerte nd plne off quicker Generlly improve the ride in choppy wter In most cses, reduce bot speed If in excess, lower the bow of some bots to point t which they begin to plow with their bow in the wter while on plne. This cn result in n unexpected turn in either direction clled bow steering or over steering if ny turn is ttempted or if significnt wve is encountered. mc79530 Single Engine Trim/Triler Dul Engine Trim/Triler Single engine pplictions will hve button tht cn be pressed to trim the sterndrive unit up or down. To rise the sterndrive unit for trilering, beching, lunching, low speed (below 1200 rpm), nd shllow wter opertion push the trim button to rise the sterndrive unit to the full up/ out position. Some controls lso hve triler button tht trims the sterndrive to position suitble for triler purposes only. NOTICE If using externl tie brs, rising or lowering the drives independently of ech other cn dmge the drive nd steering systems. If using n externl tie br, rise nd lower ll drives together s unit. Dul engine pplictions my hve single integrl button to operte both sterndrive units simultneously or my hve seprte buttons for ech sterndrive unit. Some controls lso hve triler button tht trims the sterndrives to position suitble for triler purposes only. Pge AUGUST 2008

31 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 Lunching nd Bot Opertion...26 Opertion Chrt Strting nd Stopping the Engine...27 Strting the Engine Stopping the Engine Strting the Engine After It Hs Been Stopped While In Ger...28 Throttle-Only Opertion...28 Trilering the Bot...28 Freezing Temperture Opertion...28 Drin Plug nd Bilge Pump...29 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 An Open Front Deck Bots With Front-Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping Impct with Underwter Hzrds Drive Unit Impct Protection Conditions Affecting Opertion Weight Distribution (Pssengers nd Ger) Inside the Bot...32 The Bottom of the Bot...32 Cvittion...32 Ventiltion...32 Elevtion nd Climte...33 Propeller Selection...33 Getting Strted Hour Brek-In Period...34 After Brek-In Period...34 End of First Seson Checkup AUGUST 2008 Pge 23

32 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. Pge AUGUST 2008

33 Section 3 - On the Wter 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. 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 Good Ventiltion 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. Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes AUGUST 2008 Pge 25

34 Section 3 - On the Wter 1. Exmple of desired ir flow through the bot. Poor Ventiltion mc 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: - Operting the engine when the bot is moored in confined spce b mc b - Mooring close to nother bot with its engine operting 2. Exmples of poor ventiltion while bot is moving: - Operting the bot with the trim ngle of the bow too high b mc b - Operting the bot with no forwrd htches open (sttion wgon effect) Bsic Bot Opertion Lunching nd Bot Opertion IMPORTANT: Instll bilge drin plug prior to lunching bot. OPERATION CHART 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. Pge AUGUST 2008

35 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. Flush cooling system if in sltwter. Open secock, if equipped. Drin bilge. Close the drin system. Plce sterndrive unit in full down/in position. 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 STARTING THE ENGINE NOTE: Only perform those functions pplicble to your power pckge. 1. Check ll items listed in the Opertion Chrt. 2. Plce the remote control hndle in neutrl. 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.! 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 the engine to wrm up (6 10 minutes on the first strt of the dy). NOTE: If the engine hs not run for long period of time it my require couple of ttempts. 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 AUGUST 2008 Pge 27

36 Section 3 - On the Wter STOPPING THE ENGINE 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 gercse. Shifting into ger when the engine is not running cn cuse mislign the clutch, preventing proper shifting. Alwys shift the gercse into ger when the engine is operting t idle. If you must shift while the engine is not operting, rotte the propeller shft in the pproprite direction during shifting. 1. 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. Strting the Engine After It Hs Been Stopped While In Ger IMPORTANT: Avoid stopping the engine if the sterndrive unit is in ger. If the engine does stop, refer to the following procedure: 1. Push nd pull repetedly on the remote control hndle until hndle returns to the neutrl/idle position. This my tke severl tries if the power pckge ws operting bove idle RPM when the engine stopped. 2. After the hndle returns to the neutrl/idle position, resume norml strting procedures. 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. Trilering the Bot Your bot cn be trilered with the sterndrive unit in the up or down position. Adequte clernce is required between the rod nd sterndrive when trnsporting. If dequte rod clernce is problem, plce the sterndrive unit in full triler position nd support it with n optionl triler kit which is vilble from your uthorized Mercury MerCruiser deler. 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. Pge AUGUST 2008

37 Drin Plug nd Bilge Pump Section 3 - On the Wter 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. 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. While Bot Is Sttionry 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 ! 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 AUGUST 2008 Pge 29

38 Section 3 - On the Wter Bots Hving An 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. Any unexpected, sudden reduction in bot speed could result in the elevted pssenger flling over the front of the bot. Wve nd Wke Jumping! WARNING mc 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. Pge AUGUST 2008

39 Section 3 - On the Wter 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. mc 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. 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 AUGUST 2008 Pge 31

40 Section 3 - On the Wter Drive Unit Impct Protection The power trim hydrulic system is designed to provide impct protection for the sterndrive unit. If submerged object is struck while the bot is moving forwrd, the hydrulic system will cushion the kickup of the sterndrive unit s it clers the object, reducing dmge to the unit. After the sterndrive unit hs clered the object, the hydrulic system llows the sterndrive unit to return to its originl operting position, preventing loss of steering control nd engine overspeed. Use extreme cution when operting in shllow wter or where underwter objects re known to be present. No impct protection is provided in reverse; use extreme cre to prevent striking submerged objects while operting in reverse. IMPORTANT: Impct protection system cnnot be designed to ensure totl protection from impct dmge under ll conditions. 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 Cvittion Ventiltion 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 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 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: Pge AUGUST 2008

41 Drive unit trimmed out too fr. A missing propeller diffuser ring. Section 3 - On the Wter 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: Higher elevtions Higher tempertures Low brometric pressures High humidity 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. Propeller Selection IMPORTANT: The engines covered in this mnul re equipped with n RPM rev limiter tht is set to n upper RPM limit. This limit, which is slightly bove the norml operting rnge of the engine, helps prevent dmge from excessive engine RPM. Once the RPM returns to the recommended operting RPM rnge, norml engine opertion resumes. The bot mnufcturer nd the selling deler re responsible for equipping the power pckge with the correct propeller. Refer to Mercury Mrine's web pge Select propeller tht will llow the engine power pckge to operte t or ner the top end of the recommended WOT operting RPM rnge with norml lod. If full throttle opertion is below the recommended rnge, the propeller must be chnged to prevent loss of performnce nd possible engine dmge. On the other hnd, operting n engine bove the recommended operting RPM rnge will cuse higher thn norml wer nd dmge. After initil propeller selection, the following common problems my require tht the propeller be chnged to lower pitch. Wrmer wether nd greter humidity cuse loss of RPM. Operting in higher elevtion cuses loss of RPM. Operting with dirty bot bottom cuses loss of RPM. Operting with incresed lod (dditionl pssengers, pulling skiers) cuses loss of RPM. For better ccelertion, such s is needed for wter skiing, use the next lower pitch propeller. When not pulling skiers, do not operte t full throttle when using the lower pitch propeller AUGUST 2008 Pge 33

42 Section 3 - On the Wter 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, the following recommendtions should be considered; Ensure tht propeller llows the engine to operte t or ner the top of the specified WOT RPM rnge (Refer to Specifictions nd Mintennce) when t full throttle with norml bot lod. Opertion t 3/4 throttle setting or lower is recommended. Refrin from prolonged opertion t WOT RPM. Chnge the engine oil nd oil filter. Refer to Mintennce. Chnge the sterndrive lube or 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. Pge AUGUST 2008

43 Tble of Contents Section 4 - Specifictions Section 4 - Specifictions Fuel Requirements Fuel Rtings Using Reformulted (Oxygented) Gsolines (USA Only)...36 Gsolines Contining Alcohol Engine Oil Engine Specifictions TKS...37 Fluid Specifictions Sterndrives Engine AUGUST 2008 Pge 35

44 Section 4 - Specifictions Fuel Requirements Fuel Rtings 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 ny resulting dmge will not be covered under the limited wrrnty. 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 91 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 lcohol (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 mixture 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 the 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 the 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 AUGUST 2008

45 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. 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. 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 recommend using the following oil: Appliction All MerCruiser engines Recommended Oil Mercury MerCruiser Full Synthetic Engine Oil, 20W 40, NMMA FC W rted If the Mercury MerCruiser Full Synthetic, 20W 40 oil is unvilble, you cn use the following lubricnts, listed in order of recommendtion: 1. Mercury/Quicksilver 25W 40 Synthetic Blend, NMMA FC W rted 4 cycle MerCruiser oil 2. Mercury/Quicksilver 25W 40, NMMA FC W rted 4 cycle MerCruiser oil 3. Other recognized brnds of NMMA FC W rted 4 cycle oils 4. A good grde, stright weight detergent utomotive oil per the operting chrt below. NOTE: We do not recommend 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. Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rted ORDER OF PREFERENCE MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rted 4-cycle MerCruiser oil Mercury/Quicksilver 25W-40, NMMA FC-W rted 4-cycle MerCruiser oil Other recognized brnds of NMMA FC-W rted oils SAE40W SAE30W SAE 20W 0 C (32 F) AIR TEMPERATURE 10 C (50 F) Engine Specifictions 3.0 TKS NOTE: Performnce specifictions re obtined nd corrected in ccordnce with SAE J1228/ISO 8665 Crnkshft Power. All mesurements re tken with the engine t norml operting temperture. RPM rnge is mesured using n ccurte service tchometer with the engine t norml operting tempertures. Oil pressure must be checked with the engine t norml operting temperture AUGUST 2008 Pge 37

46 Section 4 - Specifictions NOTE: Oil pressure specifictions re for reference nd my vry. Propshft power 101 kw (135 hp) Displcement 3.0 L (181 cid) Alterntor mperge Hot 72 A Cold 65 A WOT RPM Rev limiter 4950 Idle in neutrl 700 Minimum oil pressure At 2000 RPM 207 kp (30 psi) At idle 28 kp (4 psi) Thermostt Sewter cooled models Models with closed cooling 71 C (160 F) Timing t idle 2 ATDC Firing order Minimum bttery rting 375 CCA, 475 MCA, 90 Ah AC MR43LTS Sprk plug type Chmpion RS12YC NGK BPR6EFS Sprk plug gp 0.9 mm (0.045 in.) Fluid Specifictions Sterndrives NOTE: Oil cpcity includes the drive lube monitor. Model Cpcity Fluid Type Alph One 1892 ml (64 oz) High Performnce Ger Lubricnt Engine IMPORTANT: All cpcities re pproximte fluid mesures. 3.0 TKS Cpcity Fluid Type Engine oil (with filter) 3.8 L (4 US qt) Sewter cooling system 9 L (8.5 US qt) Closed cooling system 9 L (8.5 US qt) Mercury Full Synthetic MerCruiser 20W 40, NMMA FC W rted oil. Propylene glycol nd purified wter Mercury Extended Life Coolnt Antifreeze or extended life ethylene glycol 5/100 ntifreeze mixed 50/50 with purified wter Pge AUGUST 2008

47 Tble of Contents Section 5 - Mintennce Section 5 - Mintennce Owner/Opertor Responsibilities Deler Responsibilities Mintennce Do-It-Yourself Mintennce Suggestions Inspection Mintennce Schedules Routine Mintennce...42 Scheduled Mintennce...42 Mintennce Log Seled Crburetor Mixture Screw Engine Oil Checking Filling Chnging Oil nd Filter Esy Engine Oil Drin System Engine Oil Drin Pump Chnging Filter Power Steering Fluid Checking Filling Chnging Engine Coolnt Checking Filling Chnging Drive Unit Oil Checking Filling Chnging Power Trim Fluid Checking Filling Chnging Clening The Flme Arrestor Positive Crnkcse Ventiltion Vlve (PCV) Chnging Chnging the Wter-Seprting Fuel Filter Fuel Pump Sight Tube Inspection Lubriction Steering System...56 Mnul Steering System...57 Throttle Cble...58 Shift Cble - Typicl...58 Sterndrive Unit nd Trnsom Assembly Sterndrive U-joint Shft Splines nd O-rings (Sterndrive Unit Removed)...59 Engine Coupler...59 Driveshft Extension Models...60 Propellers Propeller Repir...61 Alph Propeller Removl...61 Alph Propeller Instlltion...61 Drive Belts Checking Replcing - Front Mount Models Power Steering Pump Drive Belt, if equipped Alterntor Belt Replcing - Side Mount Models Power Steering Pump Drive Belt, if equipped Alterntor Belt Flushing the Power Pckge Flushing Attchments Sterndrive Wter Pickups Bttery Corrosion Protection Pinting Your Power Pckge AUGUST 2008 Pge 39

48 Section 5 - Mintennce Owner/Opertor Responsibilities Deler Responsibilities Mintennce 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. 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.! 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 the complete listing of ll scheduled mintennce to be performed. Some items should be performed only by n uthorized Mercury MerCruiser deler only. 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. Pge AUGUST 2008

49 Section 5 - Mintennce Mintennce Point Color Codes Yellow Blck Brown Blue Engine oil Drive lube Power steering fluid Rw wter flush Do It Yourself Mintennce Suggestions Inspection 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. 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. 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 AUGUST 2008 Pge 41

50 Section 5 - Mintennce Mintennce Schedules Routine Mintennce NOTE: Only perform mintennce tht pplies to your prticulr power pckge. Tsk Intervl Ech dy strt Ech dy end Weekly Every two months or 50 hours Mintennce to Be Performed Check the engine oil level. (You cn extend this intervl bsed on experience with the product.) Check the sterndrive ger lube level. Check the trim pump oil level. Check the power ssisted steering pump or the compct hydrulic steering fluid level, depending on the steering system of your model. If operting in sltwter, brckish wter, or polluted wter, flush the sewter section of the cooling system fter ech use. Check the wter inlets for debris or mrine growth. Check nd clen the sewter striner, if equipped. Check the coolnt level. Inspect the sterndrive nodes nd replce if 50% eroded. Lubricte the propeller shft nd retorque the nut. (If operting only in freshwter, you cn extend the intervl to every four months.) If operting in sltwter, brckish wter, or polluted wter, pply Corrosion Gurd to the power pckge. Check the bttery connections nd the fluid level. Ensure tht the guges nd the wiring connections re secure. Clen the guges. (If operting in sltwter, reduce this intervl to every 25 hours or 30 dys, whichever occurs first.) Scheduled Mintennce NOTE: Only perform mintennce which pplies to your prticulr power pckge. Tsk Intervl After the initil 20 hour brek in period Every 50 hours or 2 months (whichever occurs first) Chnge the engine oil nd filter. Mintennce to Be Performed All Brvo models except 496 : Lubricte the engine coupler (lubricte the engine coupler every 50 hours if operted t idle for prolonged periods of time). Pge AUGUST 2008

51 Section 5 - Mintennce Tsk Intervl Every 100 hours or nnully (whichever occurs first) Every 150 hours or nnully (whichever occurs first) Every 300 hours or 3 yers Every 5 yers Mintennce to Be Performed Touch up the pint on the power pckge. Chnge the engine oil nd filter. Chnge the sterndrive ger lube. On models with closed cooling, check the coolnt level nd ntifreeze concentrtion for dequte freeze protection. Correct if necessry. Refer to the Specifictions section. Tighten the connection of the gimbl ring to the steering shft to specifictions. Replce the wter seprting fuel filter. Check the steering system nd the remote control for loose, missing, or dmged prts. Lubricte the cbles nd the linkges. Check the continuity circuit for loose or dmged connections. Test the MerCthode unit output if equipped. Clen the flme rrestor, IAC muffler, nd the crnkcse ventiltion hoses. Inspect the PCV vlve, if equipped. Inspect the condition nd the tension of the belts. Driveshft extension models: Lubricte the driveshft U joints, nd tilstock input nd output berings. All Brvo models except 496: Lubricte the engine coupler. Check the engine mounts for tightness nd torque if necessry. Check the electricl system for loose, dmged, or corroded fsteners. Inspect the condition of the sprk plugs, sprk plug wires, nd the distributor cp nd rotor, if equipped. Replce s necessry. 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. On models with closed cooling, clen the sewter section of the closed cooling system. Clen, inspect, nd test the pressure cp. Inspect the exhust system components. If the pckge ws equipped with wter shutters (flpper vlves), verify tht they re not missing or worn. Check the engine lignment. Inspect the U joints, the splines, the bellows, nd check the clmps. Lubricte the U joint splines nd cross bering, if equipped with grese fitting. Inspect the gimbel bering for roughness. Replce if necessry. See your certified Mercury MerCruiser deler. Vzer models, Alph models, nd 496 MAG Brvo models only: Lubricte the engine coupler. Replce the coolnt/nitifreeze. Replce every two yers if not using extended life coolnt/ntifreeze. 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 AUGUST 2008 Pge 43

52 Section 5 - Mintennce Dte Mintennce Performed Engine Hours Seled Crburetor Mixture Screw Engine Oil IMPORTANT: Chnging the mixture setting on this engine cn ffect the exhust emissions level nd void the emissions certifiction. Do not djust or remove the mixture settings or remove the mixture screw sels. See your uthorized Mercury deler or emissions testing gency. 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. Pge AUGUST 2008

53 Section 5 - Mintennce NOTE: Ensure tht dipstick is instlled with oil level indiction mrks fcing the rer of the engine (flywheel end). - Dipstick tube 7150 Filling 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. 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 7519 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. Engine Model Cpcity Fluid Type 3.0 TKS 3.8 L (4 US qt) Mercury Full Synthetic MerCruiser Oil 20W AUGUST 2008 Pge 45

54 Section 5 - Mintennce Chnging Oil nd Filter 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). EASY ENGINE OIL DRAIN 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 - Bilge drin plug b - Tether c - Clip d e d - Oil drin hose plug e - Oil drin hose f - Bilge drin flnge 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 DRAIN 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. Pge AUGUST 2008

55 5. Remove the pump. 6. Instll the dipstick. CHANGING FILTER 1. Remove nd discrd oil filter. 2. Cot seling ring on new filter with engine oil nd instll. Section 5 - Mintennce 3. Tighten oil filter securely (following filter mnufcturer's instructions). Do not overtighten. 4. Remove oil fill cp. Power Steering Fluid 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. Engine Model Cpcity Fluid Type 3.0 TKS 3.8 L (4 US qt) Mercury Full Synthetic MerCruiser Oil 20W 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. Checking 1. Stop the engine nd center the sterndrive unit. 2. Remove the fill cp/dipstick nd observe the level.. Proper fluid level with engine t norml operting temperture should be within the wrm rnge AUGUST 2008 Pge 47

56 Section 5 - Mintennce b. Proper fluid level with engine cold should be within the cold rnge. b c Power steering pump fill cp/ dipstick b - Cold rnge c - Wrm rnge Filling 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contct your uthorized Mercury MerCruiser deler. 1. Remove the fill cp/dipstick nd observe the level. 2. Add Quicksilver Power Trim nd Steering Fluid or Dexron III Automtic Trnsmission Fluid (ATF) to bring the fluid level up to the proper level. Tube Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power steering system K01 3. Reinstll the fill cp/dipstick. Chnging Power steering fluid does not require chnging unless it becomes contminted with wter or debris. Contct your uthorized Mercury MerCruiser deler. 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. Pge AUGUST 2008

57 1. Remove the cp from the thermostt housing nd observe the fluid level. Section 5 - Mintennce - Thermostt housing cp The coolnt level in the thermostt housing 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 thermostt housing. 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. Tube Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/ Coolnt Closed Cooling System K1 Filling NOTICE Using propylene glycol ntifreeze in the closed cooling system cn dmge the cooling system or the engine. Fill the closed cooling system with n ethylene glycol ntifreeze solution suitble to the lowest temperture to which the engine will be exposed. 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 AUGUST 2008 Pge 49

58 Section 5 - Mintennce 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 Closed Cooling System K1 3. Instll the fill cp onto the coolnt recovery bottle. Chnging Contct your uthorized Mercury MerCruiser deler. Drive Unit 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 Filling NOTE: Oil level will fluctute during opertion. Oil level should be checked with the engine cold, before strting. 1. Check the ger lube oil level. Keep the oil level within the recommended operting rnge. If ny wter is visible t the bottom of the monitor or ppers t the oil fill/drin plug nd/or if oil ppers discolored, contct your uthorized Mercury MerCruiser deler immeditely. Both conditions my indicte wter lek somewhere in the sterndrive unit. IMPORTANT: If more thn 59 ml (2 fl. oz.) of High Performnce Ger Lubricnt is required to fill the monitor, sel my be leking. Dmge to the sterndrive unit my occur due to lck of lubriction. Contct your uthorized Mercury MerCruiser deler. 1. Remove the ger lube monitor cp. 2. Fill the monitor with the specified fluid so tht the oil level is in the operting rnge. Do not overfill. Tube Ref No. Description Where Used Prt No. 87 High Performnce Ger Lubricnt Ger lube monitor K01 3. Replce the cp. NOTE: When filling the entire sterndrive unit refer to Chnging instructions, following. Pge AUGUST 2008

59 Section 5 - Mintennce Chnging 1. Remove the ger lube monitor from the brcket. - Ger lube monitor Empty the contents into suitble continer. 3. Instll the ger lube monitor in the brcket. 4. Plce the sterndrive unit in full trim limit out position, remove the oil fill/drin screw nd seling wsher nd drin the oil. b - Oil fill\drin screw 7160 b - Seling wsher 5. Remove the oil vent screw nd seling wsher. Allow the oil to drin completely. b Oil vent screw b - Seling wsher IMPORTANT: If ny wter drined from the oil fill/drin hole, or if the oil ppers milky, the sterndrive unit is leking nd should be checked immeditely by your uthorized Mercury MerCruiser deler AUGUST 2008 Pge 51

60 Section 5 - Mintennce 6. Lower the sterndrive unit so tht the propeller shft is level. Fill the sterndrive unit, through the oil fill/drin hole, with specified ger lubricnt until n ir free strem of lubricnt flows from oil vent hole. Tube Ref No. Description Where Used Prt No. 87 High Performnce Ger Lubricnt Sterndrive unit K01 Power Trim Fluid IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lubricnt in sterndrive unit. 7. Instll the oil vent screw nd seling wsher. 8. Continue to pump ger lubricnt into the drive through the oil fill/drin hose until the ger lubricnt ppers in the ger lube monitor. 9. Fill the monitor so tht the oil level is in the operting rnge. Do not overfill. Ensure tht the rubber gsket is inside the cp nd instll. Do not overtighten. NOTE: Oil cpcity includes ger lube monitor. Model Cpcity Fluid Type Alph One 1892 ml (64 oz) High Performnce Ger Lubricnt 10. Remove the pump from the oil fill/drin hole. Quickly instll the seling wsher nd oil fill/drin screw. Tighten securely. 11. Recheck the oil level fter the first use. IMPORTANT: Oil level in the ger lube monitor will rise nd fll during sterndrive opertion; lwys check the oil level when the sterndrive is cool nd the engine is shut down. Checking IMPORTANT: Check the oil level with the sterndrive unit in the full down/in position only. 1. Plce the sterndrive unit in full down/in position. 2. Remove the fill cp from the reservoir. b c Fill cp b - Reservoir fill neck c - "MIN" nd "MAX" lines 3. Observe the oil level. Level must be between the "MIN" nd "MAX" lines on the reservoir. NOTE: Fill cp is vented. Pge AUGUST 2008

61 Section 5 - Mintennce 4. Fill s necessry with the specified fluid. Tube Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power trim pump K01 Filling 1. Remove the fill cp from the reservoir. 2. Add lubricnt to bring level to the bottom of the filler neck. Tube Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power trim pump K01 3. Instll the cp. Chnging Power trim fluid does not require chnging unless it becomes contminted with wter or debris. Contct your uthorized Mercury MerCruiser deler. Clening The Flme Arrestor! WARNING Fuel is flmmble nd explosive. Ensure 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. Disconnect nd remove the crnkcse ventiltion hose from the fitting on the flme rrestor nd vlve cover. 2. Remove the flme rrestor. b c Flme rrestor b - Flme rrestor nut nd wsher c - Crnkcse ventiltion hose 3. Clen the flme rrestor with wrm wter nd mild detergent AUGUST 2008 Pge 53

62 Section 5 - Mintennce 4. Inspect the flme rrestor for holes, crcks or deteriortion. Replce if necessry. 5. Allow the flme rrestor to ir dry completely before use. 6. Clen the crnkcse ventiltion hose with wrm wter nd mild detergent. Dry with compressed ir or llow to ir dry completely. 7. Inspect the crnkcse ventiltion hose for crcks or deteriortion. Replce if necessry. 8. Instll the flme rrestor, seling wsher, nd locknut. Torque the flme rrestor locknut. Description Nm lb. in. lb. ft. Flme rrestor nut Connect the crnkcse ventiltion hose to the fitting on the flme rrestor nd vlve cover. Positive Crnkcse Ventiltion Vlve (PCV) CHANGING IMPORTANT: Use only 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. 1. Remove the PCV vlve. 2. Disconnect the PCV vlve from the hose nd discrd the vlve. b - PCV vlve b - Hose 3. Instll new PCV vlve in the vlve cover nd reconnect the hose. 4. Ensure the PCV vlve is tightly seted in the vlve cover. Chnging the Wter Seprting Fuel Filter! WARNING Fuel is flmmble nd explosive. Ensure 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. Pge AUGUST 2008

63 2. Close fuel supply vlve, if equipped. Section 5 - Mintennce 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 40 Filter seling ring K01 6. Thred filter onto brcket nd tighten securely by hnd. Do NOT use filter wrench. b c Fuel filter bse b - Seling ring c - Fuel filter 7. Open fuel supply vlve, if equipped. 8. Ensure tht engine comprtment is properly ventilted. 9. Supply cooling wter to the engine. 10. 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 the engine immeditely nd contct your uthorized Mercury MerCruiser deler. Fuel Pump Sight Tube Inspection 1. The engine fuel pump is equipped with sight tube which gives visible evidence of ruptured fuel pump diphrm. IMPORTANT: If fuel is visible in tube, the fuel pump should be replced by your Authorized Mercury MerCruiser Deler immeditely. - Sight tube AUGUST 2008 Pge 55

64 Section 5 - Mintennce Lubriction Steering System! WARNING Incorrect cble lubriction cn cuse hydrulic lock, leding to serious injury or deth from loss of bot control. Completely retrct the end of the steering cble before pplying lubricnt. NOTE: If steering cble does not hve grese fitting, inner wire of cble cnnot be gresed. 1. If Steering Cble Hs Grese Fittings: Turn steering wheel until steering cble is fully retrcted into cble housing. Apply pproximtely 3 pumps of grese from typicl hnd operted grese gun. - Steering cble grese fitting 6221 Tube Ref No. Description Where Used Prt No. 34 Specil Lubricnt 101 Steering cble grese fitting Q02 2. Turn steering wheel until steering cble fully extended. Lightly lubricte the exposed prt of cble. - Extended steering cble 6222 Tube Ref No. Description Where Used Prt No. 34 Specil Lubricnt 101 Steering cble Q02 Pge AUGUST 2008

65 Section 5 - Mintennce 3. Lubricte the steering pin. - Steering pin mc Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Steering pin K01 4. On dul engine bots: Lubricte the tie br pivot points. Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie br pivot points K01 5. Upon first strting engine, turn steering wheel severl times to strbord nd then port to ensure tht the steering system opertes properly before getting underwy. Mnul Steering System 1. Inspect the bushings for debris nd lubricte the bushings Bushings Tube Ref No. Description Where Used Prt No. 34 Specil Lubricnt 101 Steering cble end bushings Q AUGUST 2008 Pge 57

66 Section 5 - Mintennce Throttle Cble 1. Lubricte the pivot points nd the guide contct surfces Pivot points Tube Ref. No. Description Where Used Prt No. Shift Cble Typicl Synthetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cble pivot points & guide contct surfces 1. Lubricte the pivot points nd the guide contct surfces K01 b - Pivot points mc79736 b - Guide contct surfces Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cble pivot points & guide contct surfces K01 Pge AUGUST 2008

67 Sterndrive Unit nd Trnsom Assembly Section 5 - Mintennce 1. Lubricte gimbl bering by pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun. - Gimbl bering grese fitting mc Tube Ref No. Description Where Used Prt No. 42 U-joint nd Gimbl Bering Grese 2. For propeller shft lubriction, refer to Propellers. Gimbl bering A1 Sterndrive U joint Shft Splines nd O rings (Sterndrive Unit Removed) 1. Cot sterndrive U joint O rings nd driveshft splines with grese. - U joint O rings (3) b b - Driveshft splines Tube Ref No. Description Where Used Prt No. 91 Engine Coupler Spline Grese 2. For propeller shft lubriction, refer to Propellers. Engine Coupler Driveshft splines nd U-joint O-rings A 1 1. Lubricte engine coupler splines through grese fittings on coupler by pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun AUGUST 2008 Pge 59

68 Section 5 - Mintennce NOTE: If the bot is operted t idle for prolonged periods of time, coupler should be lubricted in the Alph Models every 150 hours Alph drive coupler - Engine coupler grese fitting Tube Ref No. Description Where Used Prt No. 91 Engine Coupler Spline Grese Coupler A 1 NOTE: Alph Models Your power pckge is equipped with seled engine coupler nd Perm Lube U joints. The seled coupler nd shft splines cn be lubricted without removing the sterndrive unit. The Perm Lube U joints do not require lubriction. Driveshft Extension Models 1. Lubricte the trnsom end grese fitting nd engine end grese fitting by pplying pproximtely pumps of grese from typicl hnd operted grese gun. 2. Lubricte the driveshft grese fittings by pplying pproximtely 3 4 pumps of grese from typicl hnd operted grese gun. c b - Driveshft grese fittings b - Trnsom end grese fitting c - Engine end grese fitting Tube Ref No. Description Where Used Prt No. 42 U-joint nd Gimbl Bering Grese Trnsom end grese fitting, engine end grese fitting, driveshft grese fittings A1 Pge AUGUST 2008

69 Section 5 - Mintennce Propellers Propeller Repir Some dmged propellers cn be repired. Contct your uthorized Mercury MerCruiser deler. Alph Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the bot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce block of wood between the propeller blde nd the nti ventiltion plte. 1. Plce wood block between propeller blde nd nti ventiltion plte to prevent rottion. Strighten bent tbs on tb wsher. 2. Turn propeller shft nut counterclockwise to remove nut. 3. Slide tb wsher, drive sleeve, propeller nd thrust hub off propeller shft. Alph Propeller Instlltion NOTICE Operting the engine with loose propeller cn dmge the propeller, the drive, or drive components. Alwys tighten the propeller nut or nuts to specifiction nd check for tightness periodiclly nd t the required mintennce intervl. IMPORTANT: If reusing tb wsher, crefully inspect tbs for crcks or other dmge. Replce tb wsher if condition is questionble. d b c e g f Propeller shft b - Thrust hub c - Flo Torq II drive hub d - Propeller e - Drive sleeve f - Locking tb wsher g - Propeller nut 1. Apply liberl cot of one of the following lubricnts to the propeller shft. Tube Ref No. Description Where Used Prt No. 34 Specil Lubricnt 101 Propeller shft Q AUGUST 2008 Pge 61

70 Section 5 - Mintennce Tube Ref No. Description Where Used Prt No. 94 Anti-Corrosion Grese Propeller shft Q C Mrine Lubricnt with Teflon Propeller shft A 1 2. Slide thrust hub onto propeller shft, with stepped side towrd propeller hub. 3. Instll Flo Torq II Drive Hub into propeller. NOTE: The drive sleeve is tpered nd will slide fully into the propeller s the nut is tightened nd properly torqued. 4. Align splines nd plce propeller on propeller shft. 5. Instll drive sleeve nd locking tb wsher. 6. Instll nd torque the propeller nut. Description Nm lb in. lb ft Propeller nut (minimum) Bend three tbs on the tb wsher down into the grooves in spline wsher. After the first use, bend the three tbs stright nd retorque the propeller nut. Bend tbs bck down into spline wsher. Check propeller t lest fter 20 hours of opertion. Do not operte with loose propeller. Drive Belts! 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. b d c Power steering pump pulley b - Wter circulting pump pulley c - Crnkshft pulley d - Alterntor pulley 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 6 mm (1/4 in.) deflection, with moderte thumb pressure, on the belt t the loction tht hs the longest distnce between two pulleys. Pge AUGUST 2008

71 Replcing Front Mount Models POWER STEERING PUMP DRIVE BELT, IF EQUIPPED 1. Loosen power steering pump ttching bolts nd mounting bolts. Section 5 - Mintennce 2. Pivot power steering pump towrd engine, s required, until belt cn be removed. 3. Instll new drive belt on pulleys. Adjust tension. d c b Power steering belt b - Spcer block c - Alterntor d - Alterntor belt Description Deflection 6 mm ( 1/4 inches) ALTERNATOR BELT 1. Remove the power steering belt, if equipped. 2. Remove the two port side, front engine mount brcket ssembly screws nd wshers. 3. Remove the spcer block between the brcket ssembly nd the engine block. It my be necessry to tpe gently on the spcer to llow removl. 4. Loosen the lterntor. Remove nd replce the lterntor belt. 5. Replce the spcer block between the brcket ssembly nd the engine block. Instll the two screws using the flt nd lockwshers removed previously. Torque the two spcer block screws. Description Nm lb. in. lb. ft. Spcer block screws Instll power steering belt, if equipped. Adjust tension of both drive belts. Description Deflection 6 mm ( 1/4 inches) Replcing Side Mount Models POWER STEERING PUMP DRIVE BELT, IF EQUIPPED 1. Loosen power steering pump ttching bolts nd mounting bolts. 2. Pivot power steering pump towrd engine, s required, until belt cn be removed AUGUST 2008 Pge 63

72 Section 5 - Mintennce 3. Instll new drive belt on pulleys. Adjust the tension to the specifiction following. b c - Power steering belt b - Alterntor belt c - Alterntor ALTERNATOR BELT Description Deflection 1. Remove power steering pump drive belt, if equipped. 6 mm ( 1/4 inches) 2. Loosen the lterntor. Remove nd replce the lterntor belt. 3. Instll power steering belt, if equipped. Move the power steering brce to its originl position nd djust tension of both drive belts. Description Deflection Flushing the Power Pckge Flushing Attchments 6 mm ( 1/4 inches) Your bot comes equipped with through the sterndrive wter pickups. See Sterndrive Wter Pickups (following) for the flushing procedure. Consult your uthorized Mercury MerCruiser deler for further explntion. IMPORTANT: Alph engines with the sterndrive wter inlet blocked off t the gimbl housing, nd using through the hull wter inlet, need supply of cooling wter vilble to both the sterndrive nd to the engine during opertion Flushing Device Q 2 Attches to the wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine Pge AUGUST 2008

73 Sterndrive Wter Pickups Section 5 - Mintennce This Mercury MerCruiser sterndrive is equipped with side wter pickups. Side pickups require the flushing ttchment (44357Q 2) Side Pickup NOTE: Flushing is needed only for slty, brckish, minerl lden, or polluted wter pplictions. Flushing is recommended fter ech outing for best results. NOTICE Flushing the engine with the bot in the wter cn cuse sewter to flow into the engine, resulting in engine dmge. Close the secock before flushing the engine. Keep the secock closed until strting the engine. 1. On sewter cooled models: Proceed to Step 5. or Step 6. NOTE: Closed cooled models re equipped with het exchnger on the side of the engine. 2. If flushing the cooling system with the bot in the wter:. Rise the sterndrive to triler position. b. Instll the pproprite flushing ttchment over the wter inlet holes in the ger housing. c. Lower sterndrive to full down/in position. 3. If flushing the cooling system with the bot out of the wter:. Lower sterndrive to full down/in position.! 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. b. Remove propeller. c. Instll the pproprite flushing ttchment over the wter inlet holes in the ger housing. 4. Connect hose between flushing ttchment nd wter source. 5. With sterndrive in norml operting position, open the wter source completely. 6. Plce the remote control in the neutrl idle speed position nd strt engine AUGUST 2008 Pge 65

74 Section 5 - Mintennce Bttery 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. 7. Depress the throttle only button nd slowly dvnce the throttle until the engine reches 1300 RPM (± 100 RPM). 8. Observe the wter temperture guge to ensure tht the engine is operting in the norml rnge. 9. Operte engine with sterndrive in neutrl for bout 10 minutes or until dischrge wter is cler. 10. Slowly return throttle to idle speed position. 11. Stop engine. 12. Shut off wter nd remove flushing ttchment. 13. This step is only required if the bot is to be stored in the wter. After the flush procedure is completed, remove the sewter inlet hose from the thermostt housing nd plug the hose to prevent wter from siphoning into the bot. This prevents sewter from contminting the engine flush. 14. Tg the ignition switch with n pproprite tg requiring the sewter inlet hose to be reconnected prior to operting engine. 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. Pge AUGUST 2008

75 Corrosion Protection NOTICE Section 5 - Mintennce Wshing the MerCthode ssembly cn dmge components nd led to rpid corrosion. Do not use ny clening equipment such s brushes or high pressure wshers to clen the MerCthode ssembly. c b - MerCthode reference electrode b - Do not pint 6211 c - Do not pressure wsh Whenever two or more dissimilr metls (like those found on the sterndrive) re submerged in conductive solution, such s sltwter, polluted wter or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow between metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This is known s glvnic corrosion nd, if not controlled, it will in time cuse the need for replcement of power pckge components exposed to wter. Refer to the Mrine Corrosion Protection Guide ( ) AUGUST 2008 Pge 67

76 Section 5 - Mintennce Mercury MerCruiser power pckges re equipped with nodes to help protect them from glvnic corrosion under moderte conditions. However, for severe conditions (i.e. when using stinless steel propeller, docking/mooring in res with rpid wter flow, etc.), it is recommended tht Quicksilver Anti Corrosion Anode Kit nd/or MerCthode System be instlled (some models hve MerCthode System s stndrd equipment) Gercse nodic plte 2 - Ventiltion plte node 3 - Gimbl mounted nodic block 4 - MerCthode System 5 - Anode kit 6 - Trim cylinder nodes 7 - Bering crrier nodes (Alph only) 8 - Propshft Anode (Brvo III stndrd) IMPORTANT: Replce scrificil nodes if eroded 50 percent or more. The following scrificil nodes re instlled t different loctions on your power pckge. These nodes help protect ginst glvnic corrosion by scrificing its metl to be slowly eroded insted of the metl components on the power pckge. Pge AUGUST 2008

77 Gercse Anodic Plte Mounted on the underside of the lower gercse. Section 5 - Mintennce - Anode Ventiltion Plte Anode Mounted on the front of the gercse. - Anode Drive Mounted Anodic Block (if equipped) Mounted to underside of gimbl housing MerCthode System Electrode ssembly replces Anodic block. System should be tested to ensure dequte output. The test should be performed where bot is moored, using Quicksilver Reference Electrode nd Test Meter. Contct your uthorized Mercury MerCruiser deler AUGUST 2008 Pge 69

78 Section 5 - Mintennce IMPORTANT: To ensure tht the MerCthode reference electrode is not dmged, do not pint or pressure wsh. b - MerCthode controller 6206 b - MerCthode ssembly Anode Kit (if equipped) Mounted to the bot trnsom Trim Cylinder Anodes Mounted on ech trim cylinder. - Trim cylinder nodes 7460 Pge AUGUST 2008

79 Section 5 - Mintennce Bering Crrier Anode (Alph) Locted in front of the propeller, between the front side of the propeller nd the ger housing. b Bering crrier node b - Screws In ddition to the corrosion protection devices, the following steps should be tken to inhibit corrosion: 1. Pint your power pckge, refer to Pinting Your Power Pckge. 2. Spry power pckge components on inside of bot nnully with Corrosion Gurd to protect finish from dulling nd corrosion. Externl power pckge components my lso be spryed. 3. All lubriction points, especilly steering system, shift nd throttle linkges, should be kept well lubricted. 4. Flush cooling system periodiclly, preferbly fter ech use. Pinting Your Power Pckge IMPORTANT: Corrosion dmge tht results from the improper ppliction of nti fouling pint will not be covered by the limited wrrnty. 1. Pinting Bot Hull or Bot Trnsom: Anti fouling pint my be pplied to bot hull nd bot trnsom but you must observe the following: IMPORTANT: Do NOT pint nodes or MerCthode System reference electrode nd node, s this will render them ineffective s glvnic corrosion inhibitors. IMPORTANT: If nti fouling protection is required for bot hull or bot trnsom, copper or tin bse pints, if not prohibited by lw, cn be used. If using copper or tin bsed nti fouling pints, observe the following: AUGUST 2008 Pge 71

80 Section 5 - Mintennce Avoid ny electricl interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCthode System nd the pint by llowing minimum of 40 mm (1 1/2 in.) unpinted re on trnsom of the bot round these items. b - Pinted bot trnsom 5578 b - Unpinted Are on Trnsom 2. Pinting Sterndrive Unit or Trnsom Assembly: Sterndrive unit nd trnsom ssembly should be pinted with good qulity mrine pint or n nti fouling pint tht does not contin copper, tin, or ny other mteril tht could conduct electricl current. Do not pint drin holes, nodes, MerCthode system, nd items specified by bot mnufcturer. Pge AUGUST 2008

81 Tble of Contents Section 6 - Storge Section 6 - Storge Cold Wether or Extended Storge Prepring Power Pckge for Storge...74 Engine nd Fuel System Preprtion...75 Drining the Sewter System Single Point Drin System...76 Drining the Sewter Section of Closed Cooled Models...78 Clering Clogged Blue Drin Hoses...80 Drining the Sterndrive...81 Bttery Storge Power Pckge Recommissioning AUGUST 2008 Pge 73

82 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 cold wether. 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. IMPORTANT: In order to run the engine s required in the reminder of the storge preprtion procedure, wter must be supplied to the engine s described in the flushing procedure. 4. Provide cooling wter to the engine s done in the previous step. 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. 8. Drin the engine sewter cooling system. Refer to Drining the Sewter System. Pge AUGUST 2008

83 NOTICE Section 6 - Storge 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 cold wether. 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. Ensure tht the sterndrive vent holes nd wter drin holes nd pssges re unobstructed nd open (refer to Drining Instructions). 10. For dditionl ssurnce ginst freezing nd rust, fter drining, fill the 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. NOTICE The universl joint bellows my develop set when stored in rised or up position, cusing the bellows to fil when returned to service nd llowing wter to enter the bot. Store the sterndrive in the full down position. 11. Store bot with drive unit in full down/in position. 12. Store the bttery ccording to the mnufcturer's instructions. ENGINE AND FUEL SYSTEM PREPARATION! WARNING Fuel is flmmble nd explosive. Ensure 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. Prepre crbureted fuel system for extended storge s follows:. Strt engine. b. Provide cooling wter to the engine s done in the previous step. c. Remove flme rrestor ssembly. d. Close the fuel shut off vlve, if equipped. Disconnect nd plug the fuel inlet fitting if not equipped with fuel shut off vlve. e. While operting engine t fst idle (1300 RPM), fog internl surfces of induction system nd combustion chngers by sprying pproximtely 227 g (8 oz.) of Mercury/Quicksilver Storge Sel or SAE 20W engine oil into crburetor bores. f. Spry the remining 57 g (2 oz.) of Storge Sel (or oil) rpidly into crburetor, just s the engine begins to stll, due to lck of fuel. Allow engine to stop AUGUST 2008 Pge 75

84 Section 6 - Storge Tube Ref No. Description Where Used Prt No. 119 Storge Sel Rust Inhibitor Crburetor K01 g. Turn ignition key to "OFF" position. 2. Refer to Flushing the Power Pckge nd ppropritely remove the wter supply the the sewter pickup pump. 3. Clen the flme rrestor nd crnkcse ventiltion hoses nd reinstll. 4. Lubricte ll items listed in the Lubriction section. 5. On models with closed cooling systems: Test coolnt to ensure tht it will withstnd the lowest temperture expected during storge. 6. Service btteries ccording to the mnufcturer's instructions. 7. Clen the outside of the engine nd repint ny res required with Mercury/ Quicksilver Light Gry Primer nd Phntom Blck Pint. After pint hs dried, wipe down the outside of the engine with Corrosion Gurd. Tube Ref No. Description Where Used Prt No. 120 Corrosion Gurd Outside of engine For sterndrive unit ly up, refer to pproprite Mercury MerCruiser sterndrive service mnul. 9. Replce the fuel filter. Refer to the Mintennce section for proper procedure. 10. Chnge the oil nd oil filter. 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. IMPORTANT: The engine must not be operting t ny point during the drining procedure. Single Point Drin System! CAUTION Disconnecting the blue drin hoses cn cuse serious burns due to hot wter. Check ll hose connections before operting the engine nd never disconnect the hoses until the engine hs hd suffient time to cool. NOTICE If the bot is t rest in the wter with the engine off, n open secock or wter inlet hose could introduce wter into the engine's cooling system or the bot. Keep the secock or wter inlet hose plugged until redy to strt the engine. Attch tg to the ignition switch or steering wheel to inform others of the wter inlet connection. IMPORTANT: Do not strt or operte engine t ny point in this procedure. Pge AUGUST 2008

85 Section 6 - Storge 1. If drining with the bot in the wter, close the secock (if equipped) or remove nd plug the wter inlet hose. If drining with the bot out of the wter, plce the bot on level surfce to ensure complete drining of the system. 2. Turn on the bilge pump. 3. Push the quick connect fitting relese buttons nd remove the blue drin hoses from the brcket. b - Relese button b - Blue drin hoses 4. Pull the T hndle until the hose guide is in contct with the quick connect fittings. - T hndle b 7183 b - Hose guide 5. Push down on the T hndle to force the blue drin hoses below their connection points on the block. 6. Ensure wter is drining from blue drin hoses. If wter is not drining from ll blue drin hoses, refer to Clering Clogged Drin Hoses. 7. Leve the blue drin hoses disconnected until ll wter hs drined from the engine. 8. Pull the T hndle until the quick connect fittings on the blue drin hoses re within rech. 9. Instll the quick connect fittings on the brcket. Pull on the blue drin hoses to ensure they re firmly connected. 10. Push down on the T hndle until seted. 11. Turn off the bilge pump. 12. If the bot ws drined in the wter, prior to operting the engine open the secock (if equipped) or unplug nd reconnect the wter inlet hose. IMPORTANT: The next time the engine is strted, visully inspect tht the blue drin hoses re connected nd not leking AUGUST 2008 Pge 77

86 Section 6 - Storge Drining the Sewter Section of Closed Cooled Models 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 cold wether. 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. 1. If drining with the bot in the wter, close the secock (if equipped) or remove nd plug the wter inlet hose. If drining with the bot out of the wter, plce the bot on level surfce to ensure complete drining of the system. 2. Remove the drin plug from the following loctions:. Aft (rer) drin plug from the het exchnger. - Het exchnger drin plug 7184 b. Bottom of exhust mnifold. - Exhust mnifold drin plug Clen out the drin holes with stiff piece of wire until the entire system is drined. NOTE: It my be necessry to lift or bend hoses to llow wter to drin completely. Pge AUGUST 2008

87 Section 6 - Storge 4. Remove nd lower the hose from the wter inlet to the power steering cooler (if equipped), or the wter inlet to the het exchnger. b Power steering cooler, if equipped b - Wter inlet to het exchnger hose 5. Ensure the ger housing wter vent nd drin holes, speedometer pitot hole, nd trim tb cvity vent nd drin holes re open nd unobstructed. c d b Ger housing vent holes b - Trim tb cvity drin holes c - Ger housing drin hole d - Speedometer pitot hole 6. Crnk the engine over slightly with the strter motor to purge ny wter trpped in sewter pickup pump. Do not llow the engine to strt AUGUST 2008 Pge 79

88 Section 6 - Storge 7. After the cooling system hs been drined completely, pply selnt to the ft het exchnger plug. - Het exchnger drin plug 7184 Tube Ref No. Description Where Used Prt No. 19 Perfect Sel Aft het exchnger plug Prior to lunching the bot or strting the engine, instll the drin plugs, reconnect the hoses, nd tighten ll hose clmps securely. 9. If the bot ws drined in the wter, open the secock (if equipped) or unplug nd reconnect the wter inlet hose prior to operting the engine. Clering Clogged Blue Drin Hoses! CAUTION Disconnecting the blue drin hoses cn cuse serious burns due to hot wter. Check ll hose connections before operting the engine nd never disconnect the hoses until the engine hs hd suffient time to cool. 1. If the engine cn be strted proceed to Step 2. If the engine cnnot be strted, proceed to Step If one hose is flowing freely, reconnect it to the brcket. 3. Ensure the clogged blue drin hose is in the correct position below its connection point on the block. 4. Turn on the bilge pump nd supply wter to the wter inlets. If the bot is out of the wter, instll the flushing ttchment nd open the wter source fully to provide mximum wter flow. - Flushing ttchment 7358 Pge AUGUST 2008

89 Section 6 - Storge Flushing Device Q 2 Attches to the wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine Strt the engine nd llow it to operte t idle until the obstruction is clered from the hose or for pproximtely 1 minute, whichever occurs first. 6. Check for wter drining from the blue drin hose. If fter 1 minute of idling, the blue drin hose is still clogged, proceed to Step 7. If wter is drining, shut off the engine nd continue with Step 3 of Single Point Drin System. 7. Shut off the engine. Disconnect the wter source if connected to flush device. 8. Attch the femle end of the wter hose dpter fitting to wter supply Drining the Sterndrive Hose Adpter Fitting ( ) 9. Attch the clogged blue drin hose to the mle end of the wter hose dpter fitting. 10. Fully open the wter supply nd llow it to run for 1 minute. 11. Turn off the wter supply. Disconnect the wter hose dpter from the blue drin hose nd the wter hose. 12. Push down on the T hndle to force the blue drin hoses down below their connection points on the block. 13. Check for wter drining from the blue drin hose. If the blue drin hose is still clogged, shut off the bilge pump nd rettch the blue drin hoses following the steps below. The unit will need to be serviced by n uthorized Mercury MerCruiser deler.. Pull the T hndle until the quick connect fittings on the blue drin hoses re within rech. b. Instll the quick connect fittings on the brcket. Pull on the blue drin hoses to ensure they re firmly connected. c. Push down on the T hndle until seted. 14. If wter is drining from the blue drin hose, continue with Step 4 of Single Point Drin System. NOTE: This procedure is needed only for slty, brckish, minerl lden, or polluted wter pplictions; nd for freezing tempertures or extended storge AUGUST 2008 Pge 81