Gasoline Engines - Sterndrive MPI Models

Transcription

1 Gsoline Engines - Sterndrive MPI Models

2 Identifiction Record PLEASE RECORD THE FOLLOWING INFORMATION: Engine Model nd Horsepower Trnsom Assembly Seril Number (Sterndrive) Ger Rtio Engine Seril Number 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 Exhust Gs Emissions Certificte Number (Europe Only) The seril numbers re the mnufcturer s keys to numerous engineering detils, which pply to your Mercury MerCruiser power pckge. When contcting your uthorized 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. 2002, Mercury Mrine The following re registered trdemrks of Brunswick Corportion: AutoBlend, Jet-Prop, Mriner, Merc, MerCthode, MerCruiser, Mercury, Mercury Mrine, Quicksilver, RideGuide, Thruster nd Mercury Precision Prts

3 0002 Welcome! 0003 Wrrnty Messge 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! Consumer Affirs Deprtment 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.

4 0004 Red This Mnul Thoroughly NOTICE IF YOU DON T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. Throughout this publiction, nd on your power pckge, WARNINGS nd CAUTIONS, 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. WARNING WARNING - Hzrds or unsfe prctices which could result in severe personl injury or deth. CAUTION CAUTION - Hzrds or unsfe prctices which could result in minor personl injury or product or property dmge. IMPORTANT: - Indictes informtion or instructions tht re necessry for proper opertion nd/or mintennce. 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.

5 Wrrnty Informtion Owner Wrrnty Registrtion Interntionl Owner Registrtion Wrrnty Policies Mercury MerCruiser One Yer Limited Wrrnty (Gsoline Fueled Products Only) Yer Limited Wrrnty Aginst Corrosion (Worldwide) WARRANTY Trnsferble Wrrnty Direct Sle By Owner Mercury Product Protection Pln United Sttes And Cnd Only GETTING TO KNOW YOUR POWER PACKAGE Fetures And Controls Lnyrd Stop Switch Instrumenttion Remote Controls Power Trim Electricl System Overlod Protection 20 Audio Wrning System Engine Gurdin Strtegy ON THE WATER Sfe Boting Suggestions Be Alert To Crbon Monoxide Poisoning Bsic Bot Opertion Lunching And Bot Opertion Cre 30 Strting And Stopping The Engine.. 31 Strting Engine After Stopped While In Ger Trilering The Bot Freezing Temperture Opertion Drin Plug nd Bilge Pump Protecting People In The Wter While You Are Cruising While Bot Is Sttionry High-Speed And High-Performnce Bot Opertion Pssenger Sfety Messge Pontoon And Deck Bots Wve And Wke Jumping Impct With Underwter Hzrds Drive Unit Impct Protection Operting With Low Wter Inlets In Shllow Wter Conditions Affecting Opertion Weight Distribution (Pssengers And Ger) Inside The Bot Bottom Of Bot Cvittion Ventiltion Elevtion And Climte Propeller Selection Getting Strted Hour Brek-In Period After Brek-In Period End of First Seson Checkup MARCH 2002 Pge i

6 SPECIFICATIONS AND MAINTENANCE Specifictions Fuel Recommendtions Engine Oil Engine Specifictions Fluid Specifictions Owner/Opertor Responsibilities Deler Responsibilities Mintennce Do-It-Yourself Mintennce Suggestions Inspection Sterndrive Mintennce Chrt Mintennce Record Engine Oil Checking Filling Chnging Oil nd Filter Power Steering Pump Fluid Checking Filling Chnging Engine Coolnt - Closed Cooled Models Only Checking Filling Chnging Drive Unit Oil Checking Filling Chnging Power Trim Pump Fluid Checking Filling Chnging Bttery Multiple EFI Engine Bttery Precutions Flme Arrestor nd Relted Components Clening Positive Crnkcse Ventiltion Vlve PCV) Wter Seprting Fuel Filter Chnging In-line Fuel Filter Chnging Lubriction Steering System Throttle Cble Shift Cble - Typicl Sterndrive Unit nd Trnsom Assembly Engine Coupler Drive Shft Extension Models Propellers Alph Brvo One nd Two Brvo Three Serpentine Drive Belt Corrosion Protection Pinting Your Power Pckge Cold Wether Or Extended Storge Prepring Your Power Pckge For Storge Drining Instructions Identifiction Bot In Wter Bot Out Of The Wter All Models Flushing The Power Pckge Sterndrive Wter Pickups Alterntive Wter Pickups Power Pckge Recommissioning Emissions (Europe Only) Emissions Testing Instlling Test Probes Pge ii MARCH 2002

7 Dignosing EFI Problems Troubleshooting Chrts Strter Motor Will Not Crnk Engine, Or Crnks Slow Engine Will Not Strt, Or Is Hrd To Strt Engine Runs Rough, Misses And/Or Bckfires Poor Performnce Excessive Engine Temperture Insufficient Engine Temperture TROUBLESHOOTING Low Engine Oil Pressure Bttery Will Not Come Up On Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free-ply Or Mkes Unusul Sounds Steering Wheel Turns Hrd Or Jerky 126 Power Trim Does Not Operte (Motor Doesn t Operte) Power Trim Does Not Operte (Motor Opertes But Sterndrive Unit Does Not Move) CUSTOMER ASSISTANCE INFORMATION Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Submersion 130 Replcement Service Prts Resolving A Problem Mercury Mrine Service Offices Customer Service Literture English Lnguge Other Lnguges Andre sprog Andere tlen Muut kielet Autres lngues Andere Sprchen Altre lingue Andre språk Outros Idioms Otros idioms Andr språk Allej gl ssej Ordering Literture United Sttes nd Cnd Outside The United Sttes nd Cnd MARCH 2002 Pge iii

8 THIS PAGE IS INTENTIONALLY BLANK Pge iv MARCH 2002

9 Tble of Contents WARRANTY WARRANTY 1 Wrrnty Informtion Owner Wrrnty Registrtion Interntionl Owner Registrtion Wrrnty Policies Mercury MerCruiser One Yer Limited Wrrnty (Gsoline Fueled Products Only) Yer Limited Wrrnty Aginst Corrosion (Worldwide) Trnsferble Wrrnty Direct Sle By Owner Mercury Product Protection Pln United Sttes And Cnd Only MARCH 2002 Pge 1

10 WARRANTY 0005 Wrrnty Informtion Owner Wrrnty Registrtion UNITED STATES AND CANADA ONLY It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the fctory immeditely upon sle of the new product. It identifies 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. Upon receipt of the Wrrnty Registrtion Crd t the fctory, you will be issued plstic Owner Wrrnty Registrtion Crd which is your only vlid registrtion identifiction. It must be presented to the servicing deler should wrrnty service be required. Wrrnty clims will not be ccepted without presenttion of this crd. A temporry Owner Wrrnty Registrtion Crd will be presented to you when you purchse the product. It is vlid only for 30 dys from dte of sle while your plstic Owner Wrrnty Registrtion Crd is being processed. Should your product need service during this period, present the temporry registrtion crd to the deler. He will ttch it to your wrrnty clim form. Becuse of your selling deler s continuing personl interest in your stisfction, the product should be returned to him for wrrnty service. If your plstic crd is not received within 30 dys from dte of new product sle, plese contct your selling deler. The product wrrnty is not effective until the product is registered t the fctory. NOTICE: Registrtion lists must be mintined by fctory nd deler on mrine products sold in the United Sttes, should notifiction under the Federl Bot Sfety Act be required. Pge MARCH 2002

11 Interntionl Owner Registrtion OUTSIDE THE UNITED STATES AND CANADA WARRANTY It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the distributor or Mrine Power Service Center responsible for dministering the wrrnty registrtion/clim progrm for your re. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril number(s), dte of sle, type of use nd the selling distributor s/deler s code number, nme nd ddress. The distributor/deler lso certifies tht you re the originl purchser nd user of the product. A copy of the Wrrnty Registrtion Crd, designted s the Purchser s Copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor/deler. This crd represents your fctory registrtion identifiction, nd should be retined by you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the Wrrnty Registrtion Crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim form(s). In some countries, the Mrine Power Service Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter receiving the Fctory Copy of the Wrrnty Registrtion Crd from your distributor/deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser s Copy tht you received from the distributor/deler when you purchsed the product. Ask your distributor/deler if this plstic crd progrm pplies to you. For further informtion concerning the Wrrnty Registrtion Crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. Refer to Tble of Contents. IMPORTANT: Registrtion lists must be mintined by the fctory nd deler in some countries by lw. It is our desire to hve ALL products registered t the fctory should it ever be necessry to contct you. Mke sure your deler/distributor fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re MARCH 2002 Pge 3

12 WARRANTY 0006 Wrrnty Policies Mercury MerCruiser One Yer Limited Wrrnty (Gsoline Fueled Products Only) WHAT IS COVERED DURATION OF COVERAGE Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described below. This Limited Wrrnty provides coverge for either one (1) yer from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. Commercil users of these products receive wrrnty coverge of either one (1) yer from the dte of first retil sle, or the ccumultion of 500 hours of opertion, whichever occurs first. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product which genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred from one recretionl use customer to subsequent recretionl use customer upon proper re-registrtion of the product. Unexpired wrrnty coverge cnnot be trnsferred either to or from commercil use customer. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE WHAT MERCURY WILL DO Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre-delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or subsequent chnge of use from recretionl to commercil (unless properly re-registered) my void the wrrnty t the sole discretion of Mercury Mrine. Routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed in order to obtin wrrnty coverge. Mercury Mrine reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re-mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. Pge MARCH 2002

13 HOW TO OBTAIN WARRANTY COVERAGE WHAT IS NOT COVERED WARRANTY 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. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion nd Mintennce Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion nd Mintennce Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt which dmges the Mercury product nd ws not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion nd Mintennce Mnul), ltertion or removl of prts, wter entering the engine through the fuel intke, ir intke or exhust system or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body, running the engine out of wter, mounting the engine too high on the trnsom, or running the bot with the engine trimmed out too fr. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul-out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY MARCH 2002 Pge 5

14 WARRANTY Yer Limited Wrrnty Aginst Corrosion (Worldwide) WHAT IS COVERED DURATION OF COVERAGE 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. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE WHAT MERCURY WILL DO Wrrnty coverge is vilble only to retil customers tht purchse from Deler uthorized by Mercury Mrine to distribute the product in the country in which the sle occurred, nd then only fter the Mercury Mrine specified pre-delivery inspection process is completed nd documented. Wrrnty coverge becomes vilble upon proper registrtion of the product by the uthorized deler. Corrosion prevention devices specified in the Opertion nd Mintennce Mnul must be in use on the bot, nd routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed (including without limittion the replcement of scrificil nodes, use of specified lubricnts, nd touch-up of nicks nd scrtches) in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. 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. Pge MARCH 2002

15 HOW TO OBTAIN WARRANTY COVERAGE WHAT IS NOT COVERED WARRANTY 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. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must be presented to the deler t the time wrrnty service is requested in order to obtin coverge. 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 MARCH 2002 Pge 7

16 WARRANTY 0008 Trnsferble Wrrnty Direct Sle By Owner 0009 The product 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. The second owner cn be registered s the new owner nd retin the unused portion of the limited wrrnty by sending the former owner s plstic Owner Wrrnty Registrtion Crd nd copy of the bill of sle to show proof of ownership. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI A new Owner Wrrnty Registrtion Crd will be issued with the new owner s nme nd ddress. Registrtion records will be chnged on the fctory computer registrtion file. There is no chrge for this service. Outside the United Sttes nd Cnd, plese contct the distributor in your country, or the Mrine Power Interntionl Service Center closest to you, for the trnsferble wrrnty procedure tht would pply to you. Mercury Product Protection Pln United Sttes And Cnd Only (Certin performnce products, triple engine instlltions, nd commercil pplictions re excluded.) The Mercury Product Protection Pln provides coverge ginst unexpected mechnicl nd electricl brekdowns tht my occur beyond the stndrd limited wrrnty. The optionl Mercury Product Protection Pln is the only Fctory Pln vilble for your engine. Two, three or four - 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. Pge MARCH 2002

17 THIS PAGE IS INTENTIONALLY BLANK WARRANTY MARCH 2002 Pge 9

18 WARRANTY THIS PAGE IS INTENTIONALLY BLANK Pge MARCH 2002

19 GETTING TO KNOW YOUR POWER PACKAGE GETTING TO KNOW YOUR POWER PACKAGE Tble of Contents Fetures And Controls Lnyrd Stop Switch Instrumenttion Remote Controls Power Trim Electricl System Overlod Protection 20 Audio Wrning System Engine Gurdin Strtegy MARCH 2002 Pge 11

20 GETTING TO KNOW YOUR POWER PACKAGE 0010 Fetures And Controls 0011 Lnyrd Stop Switch The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor s position (s in ccidentl ejection from the opertor s position). c b 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 Some remote control units re equipped with lnyrd stop switch, if your remote control is not equipped with lnyrd stop switch one cn be instlled on the dshbord or side djcent to the opertor s position. The lnyrd is cord usully 4-5 ft ( m) long 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 it s short s possible to minimize the likelihood of entnglement with nerby objects. It stretches to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor s position. To shorten the lnyrd, wrp it round the opertor s wrist or leg, or tie knot in the lnyrd. Pge MARCH 2002

21 GETTING TO KNOW YOUR POWER PACKAGE 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 Avoid contct with the bot hull nd propeller from ccidentl ejection. Personl injury or deth could occur. Alwys properly connect both ends of the lnyrd stop switch. 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 ger cse or propeller. Loss of power nd directionl control in hevy ses, strong current or high winds. Loss of control when docking. WARNING Avoid brupt decelertion of the bot from lnyrd stop switch ctivtion. Bot dmge nd personl injury or deth could occur. NEVER leve the opertor s sttion with the engine operting nd in ger MARCH 2002 Pge 13

22 GETTING TO KNOW YOUR POWER PACKAGE Instrumenttion 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 Speedometer: Indictes bot speed. 2. Tchometer: Indictes engine rpm. 3. Oil Pressure Guge: Indictes engine oil pressure. 4. Bttery Meter: Indictes bttery voltge. 5. Wter Temperture Guge: Indictes engine operting temperture. 6. Fuel Guge: Indictes quntity of fuel in tnk. 7. Hour Meter: Records engine operting time. 8. Bilge Blower Switch: Opertes bilge blower. 9. Ignition Switch: Allows opertor to strt nd stop engine. 10. Power Trim Guge: Indictes sterndrive unit ngle (trim up/out nd down/in). Sterndrive Models only SMARTCRAFT PRODUCT A Mercury SmrtCrft System instrument pckge cn be purchsed for this product. A few of the functions the instrument pckge will disply re engine rpm, coolnt temperture, wter pressure, bttery voltge, fuel consumption nd engine operting hours. The SmrtCrft Instrument pckge will lso id in Engine Gurdin dignostics. The SmrtCrft Instrument pckge will disply criticl engine lrm dt nd potentil problems. Refer to the Mercury SmrtCrft Opertor s Supplement ( ) for the wrning functions monitored nd bsic opertion of the SmrtCrft Instrument pckge. Pge MARCH 2002

23 0014 Remote Controls GETTING TO KNOW YOUR POWER PACKAGE 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 PANEL MOUNTED Neutrl Lock Button - Prevents ccidentl shift nd throttle enggement. Neutrl lock button must be pushed IN to move the control hndle out of NEUTRAL. 2. 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 NEUTRAL position, nd should only be used to ssist in strting the engine. 3. 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. 4. Control Hndle Throttle Friction Screw - This screw (locted behind the bezel cover) cn be djusted to increse or decrese the tension on the control hndle. This will help prevent slipping of the remote control hndle. Turn screw clockwise to increse tension nd counterclockwise to decrese tension. Adjust to tension desired. 5. Control Hndle - Opertion of the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from NEUTRAL with quick firm motion to the first detent for FORWARD ger. Continue pushing forwrd to increse speed. Pull the control hndle bck from NEUTRAL with quick firm motion to the first detent for REVERSE ger nd continue pushing bck to increse speed. 6. Trim/Tilt Button (if equipped) - Refer to Power Trim MARCH 2002 Pge 15

24 GETTING TO KNOW YOUR POWER PACKAGE 0016 CONSOLE MOUNTED CAUTION Avoid possible bot nd power pckge dmge. Never shift unit into or out of ger unless throttle lever is t idle rpm. IMPORTANT: Bots equipped with dul power pckges my hve both shift levers on one control nd both throttle levers on the other control Shift Lever - shifts unit into ger with full lever movement. Move lever forwrd to shift to FORWARD ger. Move lever bckwrd to shift to REVERSE ger. Lever in full verticl position shifts to NEUTRAL. 2. Throttle Lever - llows engine rpm to be incresed or decresed. 3. FRICTION Screw - djusts control hndle friction so motor speed cn be set nd driver does not hve to hold hndle. Turn screw clockwise to increse friction. Do not thred screw ll the wy out. 4. DETENT Screw - controls the effort needed to move control hndle out of NEUTRAL. To increse tension, turn screw clockwise; to decrese, turn screw counterclockwise. Do not thred screw ll the wy out. Pge MARCH 2002

25 GETTING TO KNOW YOUR POWER PACKAGE CONSOLE MOUNTED 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 NEUTRAL position, nd should only be used to ssist in strting the engine. 2. Control Hndle Tension Adjustment Screw - This screw cn be djusted to increse or decrese the tension on the control hndle (cover must be removed to djust). This will help prevent slipping of the remote control hndle. Turn screw clockwise to increse tension nd counterclockwise to decrese tension. Adjust to tension desired. 3. Control Hndles - Opertion of the the shift nd throttle re controlled by the movement of the control hndle. Push the control hndle forwrd from NEUTRAL with quick firm motion to the first detent for FORWARD ger nd continue pushing forwrd to increse speed. Pull the control hndle bck from NEUTRAL with quick firm motion to the first detent for REVERSE ger nd continue pushing bck to increse speed. 4. Power Trim Switch - See Power Trim section for detiled power trim operting procedures. 5. Triler Switch - Used to rise drive unit for trilering, lunching, beching or shllow wter opertion. See Power Trim for detiled triler switch opertion MARCH 2002 Pge 17

26 GETTING TO KNOW YOUR POWER PACKAGE 0169 Power Trim 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 Power Trim system Trilering feture llows the opertor to rise nd lower the sterndrive unit for trilering, beching, lunching nd low speed (below 1200 rpm engine speed), shllow wter opertion. CAUTION Never trim the sterndrive unit UP/OUT using TRAILER switch while bot is underwy t engine speeds bove 1200 rpm. Use extreme cution when operting with sterndrive unit rised. Severe dmge to the sterndrive unit my result if unit is rised beyond the gimbl ring support flnges t engine speeds bove 1200 rpm. For best performnce trim the sterndrive unit so tht the bot bottom is t 3-5 degree ngle to the wter. 3-5 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 Cuse engine overheting if trimmed UP/OUT to point where ny cooling wter intke holes re bove the wter line Pge MARCH 2002

27 Trimming sterndrive Unit DOWN/IN Cn: Help the bot ccelerte nd plne off quicker GETTING TO KNOW YOUR POWER PACKAGE 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 SINGLE ENGINE TRIM/TRAILER 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 nd low speed (below 1200 rpm), 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 DUAL ENGINE TRIM/TRAILER CAUTION Avoid twisting or binding dul engine tie brs. Dmge to the tie br nd sterndrives could occur. ALWAYS rise or lower the sterndrive units evenly. 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 drives to position suitble for triler purposes only MARCH 2002 Pge 19

28 GETTING TO KNOW YOUR POWER PACKAGE 0018 Electricl System Overlod Protection 0019 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 Mercury MerCruiser deler A red circuit breker provides protection for engine wiring hrness nd the instrumenttion power led. Reset by pushing the RESET button IN. 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. 3. Three fuses re locted on the port side of the engine. These fuses control vrious EFI circuits. 4. The min power nd fuel pump relys re locted next to the fuses nd control voltge to the engine with the ignition key in the ON position. 5. 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). Pge MARCH 2002

29 GETTING TO KNOW YOUR POWER PACKAGE The Power Trim System is protected from overlod by 110 mp fuse nd 20 mp in-line fuse on the power trim pump. 7. The Quicksilver Three-Button Power Trim Control Pnel is further protected by 20 mp in-line fuse. 8. 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 MARCH 2002 Pge 21

30 GETTING TO KNOW YOUR POWER PACKAGE 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: 1. Engine Oil Pressure Too Low 2. Engine Temperture Too Hot The udio wrning system will sound with n intermittent horn if the following occurs: 3. Sterndrive Oil Level Too Low CAUTION Opertion of the engine fter the udio wrning system lrm hs sounded could result in dmge to the power pckge. Do not operte engine once the lrm hs sounded EXCEPT TO AVOID A HAZARDOUS SITUATION. If the lrm sounds, stop the engine immeditely. Investigte cuse nd correct it, if possible. If cuse cnnot be determined, consult your uthorized Mercury MerCruiser deler TESTING THE AUDIO WARNING SYSTEM 1. Turn the ignition switch to the ON position without crnking the engine. 2. Listen for the udio lrm. The lrm will sound if the system is functioning correctly. Pge MARCH 2002

31 0021 Engine Gurdin Strtegy GETTING TO KNOW YOUR POWER PACKAGE IMPORTANT: Bot speed could be reduced to idle nd my not respond to the throttle. Engine Gurdin Strtegy is designed to help reduce the potentil for engine dmge by reducing engine power when potentil problem is sensed by the ECM. Engine Gurdin monitors: Oil Pressure Coolnt Temperture Sewter Pressure Engine Overspeed Also the Engine Gurdin Strtegy will reduce engine power to 90 percent of mximum if ny sensor on the power pckge fils. For exmple, if the wter inlet becomes prtilly blocked, Engine Gurdin Strtegy will reduce the vilble power level of the engine to help prevent dmge from decresed wter flow to the engine. If the debris psses through nd full wter flow is restored, engine power levels re restored to norml. To void possible recurrence of the problem you should contct n uthorized Mercury MerCruiser deler. The ECM stores the fult nd with this informtion the technicin will be ble to more rpidly dignose problems MARCH 2002 Pge 23

32 GETTING TO KNOW YOUR POWER PACKAGE THIS PAGE IS INTENTIONALLY BLANK Pge MARCH 2002

33 Tble of Contents ON THE WATER ON THE WATER Sfe Boting Suggestions Be Alert To Crbon Monoxide Poisoning Bsic Bot Opertion Lunching And Bot Opertion Cre 30 Strting And Stopping The Engine.. 31 Strting Engine After Stopped While In Ger Trilering The Bot Freezing Temperture Opertion Drin Plug nd Bilge Pump Protecting People In The Wter While You Are Cruising While Bot Is Sttionry High-Speed And High-Performnce Bot Opertion Pssenger Sfety Messge Pontoon And Deck Bots Wve And Wke Jumping Impct With Underwter Hzrds Drive Unit Impct Protection Operting With Low Wter Inlets In Shllow Wter Conditions Affecting Opertion Weight Distribution (Pssengers And Ger) Inside The Bot Bottom Of Bot Cvittion Ventiltion Elevtion And Climte Propeller Selection Getting Strted Hour Brek-In Period After Brek-In Period End of First Seson Checkup MARCH 2002 Pge 25

34 ON THE WATER 0022 Sfe Boting Suggestions In order to sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl boting regultions nd restrictions nd lso consider the following suggestions. Know nd obey ll nuticl rules nd lws of the wterwys. Mercury MerCruiser strongly recommends tht ll powerbot opertors complete boting sfety course. Courses re offered in the U.S.A. by: The U.S. Cost Gurd Auxiliry, The Power Squdron, The Red Cross nd your stte or provincil boting lw enforcement gency. Inquiries my be mde to the Boting Hotline t or the Bot U.S. Foundtion t BOAT. You should lso review the NMMA Sources of Wterwy Informtion booklet. It lists regionl sources of sfety, cruising nd locl nvigtion nd is vilble t no chrge by writing to: Sources of Wterwy Informtion Ntionl Mrine Mnufcturers Assocition 410 N. Michign Avenue Chicgo, IL U.S.A. 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 Pge MARCH 2002

35 ON THE WATER 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, werble-type 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 one person on bord in the bsics of strting nd operting the engine nd bot hndling in cse the driver becomes disbled or flls overbord. Do not overlod your bot. Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot cpcity plte). Know your bot s operting nd loding limittions. Know if your bot will flot if full of wter. When in doubt, contct your uthorized Mercury MerCruiser deler or the bot mnufcturer. Ensure tht everyone in the bot is properly seted. Do not llow nyone to sit or ride on ny prt of the bot tht ws not intended for such use. This includes the bcks of sets, gunwles, trnsom, bow, decks, rised fishing sets nd ny rotting fishing set; nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of bot control or sudden bot movement could cuse person to be thrown overbord or into the bot. Ensure tht ll pssengers hve proper set nd re in it before ny bot movement. Never be under the influence of lcohol or drugs while boting (it is the lw). They impir your judgment nd gretly reduce your bility to rect quickly MARCH 2002 Pge 27

36 ON THE WATER 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 operting the bot 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 25 MPH (40 km/h) will overtke fllen skier who ws 61 m (200 ft) in front of you in 5 seconds. Wtch fllen skiers. When using your bot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor s side of the bot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never bck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required by lw to file Boting Accident Report with their stte boting lw enforcement gency when their bot is involved in certin boting ccidents. A boting ccident must be reported if (1) there is loss of life or probble loss of life, (2) there is personl injury requiring medicl tretment beyond first id, (3) there is dmge to bots or other property where the dmge vlue exceeds $ or (4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement Be Alert To Crbon Monoxide Poisoning Crbon monoxide is present in the exhust fumes of ll internl combustion engines including the outbords, sterndrives nd inbord engines tht propel bots, s well s the genertors tht power vrious bot ccessories. Crbon monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of crbon monoxide poisoning, which should not be confused with sesickness or intoxiction, include hedche, dizziness, drowsiness nd nuse. WARNING Avoid prolonged exposure to crbon monoxide. Crbon monoxide poisoning cn led to unconsciousness, brin dmge or deth. Ensure tht the bot, while t rest or underwy, is well ventilted. Pge MARCH 2002

37 0024 GOOD VENTILATION ON THE WATER Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes. 1. Exmple of desired ir flow through the bot. Courtesy of ABYC 0025 POOR VENTILATION 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. 2. Exmples of poor ventiltion while bot is sttionry: b Courtesy of ABYC -Operting the engine when the bot is moored in confined spce. b-mooring close to nother bot with its engine operting. 3. Exmples of poor ventiltion while bot is moving: b Courtesy of ABYC -Operting the bot with the trim ngle of the bow too high. b-operting the bot with no forwrd htches open (sttion wgon effect) MARCH 2002 Pge 29

38 ON THE WATER 0026 Bsic Bot Opertion 0027 Lunching And Bot Opertion Cre CAUTION To void possible ingestion of wter tht cn dmge engine components: Do NOT turn the ignition key off when the engine is bove idle speed. When lunching your bot from steep rmp, enter the wter slowly OPERATION CHART Do NOT use the lnyrd stop switch to shut off the engine bove idle speed. When coming off plne, if lrge following wve my roll over the bot s trnsom, pply short, light burst of throttle to minimize the wve ction ginst the stern of the bot. Do NOT come off plne quickly, shift into reverse nd shut off engine. Opertion Chrt BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Open engine htch. 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 OFF position. Turn bttery switch ON. Check for fuel, oil, wter, fluid nd exhust leks. Listen for the udio lrm. Turn bttery switch to OFF position. Operte bilge blowers. Check shift nd throttle control opertion. Close fuel shut off vlve. Open fuel shutoff vlve. Check steering opertion. Close secock. Open secock. Flush cooling system if in sltwter. Close the drin system. Drin bilge. Plce sterndrive unit in full DOWN/IN position. 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. Pge MARCH 2002