Declaration of Conformance Mercury MerCruiser

Transcription

1 NOTE: The following pplies to CE mrked products only. Declrtion of Conformnce Mercury MerCruiser This sterndrive or inbord engine when instlled in ccordnce to Mercury MerCruisers instructions complies with the requirements of the following directives by meeting the ssocited stndrds, s mended: Recretionl Crft Directive 94/25/EC; 2003/44/EC Applicble Requirement Owner s mnul (A.2.5) ISO Openings in Hull, Deck nd superstructure (A.3.4) ISO ; ISO Hndling chrcteristics (A.4) ISO 8665 Stndrds Applied Inbord Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469 Electricl System (A.5.3) ISO 10133; ISO 8846 Steering system (A.5.4) Exhust emission requirements (B.2) ISO 8178 Owner s mnul (B.4) ISO 8665 Noise emission levels (C.1) ISO Applicble portions of: ISO 10592, ISO 8848 nd ABYC P 17 Ignition protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031 Mercury MerCruiser declres tht our sterndrive or inbord engines without integrl exhust, when instlled in recretionl crft, in ccordnce with the mnufcturers supplied instructions, will meet the exhust emissions requirements of the directive mentioned bove. This engine must not be put into service until the recretionl crft in which it is to be instlled hs been declred in conformity, if so required, with the relevnt provision of the directive. Electromgnetic Comptibility Directive 89/336/EC, 92/31/EEC nd 93/68/EEC Generic emission stndrd EN Generic immunity stndrd EN Vehicles, bots nd internl combustion engine driven devices Rdio disturbnce chrcteristics Electrosttic dischrge testing SAE J551 (CISPR 12) EN ; EN ; EN The notified body responsible for surveillnce of the qulity system under Full Qulity Assurnce Module H of Directive 2003/44/EC is: Det Norske Verits Norwy Notified Body Number: 0575 This declrtion is issued under the sole responsibility of Mercury Mrine nd Mercury MerCruiser. Ptrick C. Mckey President Mercury Mrine, Fond du Lc, WI USA 2005 Mercury Mrine Crbureted Engines - Alph/Brvo Models

2 Identifiction Record Regultory contct: Engineering - Regultory MerCruiser 3003 N. Perkins Rd Stillwter, Oklhom USA (405) Plese record the following informtion: 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 Exhust Gs Emissions Certifiction Number 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. 2005, Mercury Mrine Mercury, Mercury Mrine, MerCruiser, Mercury MerCruiser, Mercury Rcing, Mercury Precision Prts, Mercury Propellers, Mriner, Quicksilver, #1 On The Wter, Alph, Brvo, Pro Mx, OptiMx, Sport Jet, K Plnes, MerCthode, RideGuide, SmrtCrft, Zero Effort, M with Wves logo, Mercury with Wves logo, nd SmrtCrft logo re ll registered trdemrks of Brunswick Corportion. Mercury Product Protection logo is registered service mrk of Brunswick Corportion. Welcome You hve selected one of the finest mrine power pckges vilble. It incorportes numerous design fetures to ssure operting ese nd durbility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny boting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul.

3 Wrrnty Messge 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 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, 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 indictes potentilly hzrdous sitution tht, if not voided, could result in deth or serious injury.! CAUTION CAUTION indictes potentilly hzrdous sitution tht, if not voided, my result in minor or moderte injury or property dmge. It my lso be used to lert ginst unsfe prctices. IMPORTANT: Indictes informtion or instructions tht re necessry for proper opertion nd/or mintennce.

4 ! 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. Cliforni Proposition 65 Wrning! 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 Trnsfer Of Wrrnty...2 Wrrnty Registrtion United Sttes And Cnd..2 Wrrnty Registrtion Outside The United Sttes And Cnd...2 Mercury, MerCruiser Limited Wrrnty United Sttes, Cnd nd Europe (Gsoline Fueled Products Only)...3 Mercury MerCruiser Limited Wrrnty (Confedertion of Independent Sttes, Middle-Est, nd Afric Yer Limited Wrrnty Aginst Corrosion (Worldwide)... 6 Wrrnty Coverge And Exclusions...7 Generl Exclusions From Wrrnty...8 Section 2 - Getting to Know Your Power Pckge Lnyrd Stop Switch...12 Instrumenttion...13 Remote Controls...14 Pnel Mount Fetures...14 Console Mount Fetures...15 Power Trim...15 Single Engine Trim/Triler...16 Dul Engine Trim/Triler...17 Electricl System Overlod Protection...17 Audio Wrning System...19 Testing The Audio Wrning System...19 Emissions Informtion...20 Emission Control Informtion Lbel...20 Owner Responsibility...21 Str Lbel...21 Section 3 - On The Wter Sfe Boting Suggestions...24 Be Alert To Crbon Monoxide Poisoning...25 Good Ventiltion...26 Poor Ventiltion...26 Bsic Bot Opertion...26 Lunching nd Bot Opertion...26 Opertion Chrt...27 Strting nd Stopping the Engine...27 Strting the Engine...27 Stopping the Engine...28 Strting Engine After Stopped While In Ger. 28 Throttle Only Opertion...28 Trilering the Bot...29 Freezing Temperture Opertion...29 Drin Plug nd Bilge Pump...29 Protecting People In The Wter...29 While You Are Cruising...29 While Bot Is Sttionry...29 High-Speed And High-Performnce Bot Opertion...30 Pssenger Sfety In Pontoon Bots And Deck Bots...30 Bots Hving An Open Front Deck...30 Bots With Front-Mounted, Rised Pedestl Fishing Sets...30 Wve And Wke Jumping...31 Impct With Underwter Hzrds...31 Drive Unit Impct Protection...32 Operting With Low Wter Inlets In Shllow Wter...32 Conditions Affecting Opertion...33 Weight Distribution (Pssengers nd Ger) Inside the Bot...33 Bottom Of Bot...33 Cvittion...33 Ventiltion...33 Elevtion And Climte...34 Propeller Selection...34 Getting Strted Hour Brek-In Period...34 After Brek-In Period...35 End of First Seson Checkup MAY 2005 Pge i

6 Section 4 - Specifictions Fuel Requirements...38 Fuel Rtings...38 Using Reformulted (Oxygented) Gsolines (USA Only)...38 Gsolines Contining Alcohol...38 Engine Oil...39 Engine Specifictions...40 Fluid Specifictions...40 Sterndrives...40 Engine...40 Section 5 - Mintennce Owner/Opertor Responsibilities...44 Deler Responsibilities...44 Mintennce...44 Do It Yourself Mintennce Suggestions...45 Inspection...45 Mintennce Schedule - Sterndrive Models...46 Routine Mintennce...46 Ech Dy Strt...46 Ech Dy End...46 Weekly...46 Every Two Months or 50 Hours...46 Scheduled Mintennce...46 Every 100 Hours or Annully (Whichever Occurs First)...46 Every 200 Hours or 3 Yers...46 Every 300 Hours or 3 Yers...47 Every 5 Yers...47 Mintennce Log...47 Seled Crburetor Mixture Screw...48 Engine Oil...48 Checking...48 Filling...48 Chnging Oil nd Filter...49 Esy Engine Oil Drin System...49 Engine Oil Drin Pump...50 Chnging Filter...50 Power Steering Fluid...51 Checking...51 Filling...51 Chnging...51 Engine Coolnt...51 Checking...51 Filling...52 Chnging...53 Drive Unit Oil...53 Checking...53 Filling...54 Chnging...55 Power Trim Fluid...57 Checking...57 Filling...57 Chnging...58 Clening The Flme Arrestor...58 Positive Crnkcse Ventiltion Vlve (PCV)...58 Chnging...58 Chnging Wter Seprting Fuel Filter...59 Lubriction...60 Steering System...60 Throttle Cble...62 Shift Cble - Typicl...62 Sterndrive Unit nd Trnsom Assembly...63 Sterndrive U-joint Shft Splines And O-rings (Sterndrive Unit Removed)...63 Engine Coupler...63 Driveshft Extension Models...64 Propellers...65 Propeller Repir...65 Alph Propeller Removl...65 Alph Propeller Instlltion...65 Brvo One Propeller Removl...66 Brvo One Propeller Instlltion...66 Brvo Two Propeller Removl...67 Brvo Two Propeller Instlltion...68 Brvo Three Propeller Removl...69 Brvo Three Propeller Instlltion...70 Serpentine Drive Belt...72 Checking...72 Replcing Belt nd/or Adjusting Tension...72 Flushing the Power Pckge...73 Flushing Attchments...74 Sterndrive Wter Pickups...75 Alterntive Wter Pickups...76 Bttery...78 Corrosion Protection...79 Pinting Your Power Pckge...83 Pge ii MAY 2005

7 Section 6 - Storge Cold Wether or Extended Storge...86 Prepring Power Pckge for Storge...86 Engine nd Fuel System Preprtion Drining the Sewter System Drin System Identifiction...88 Air Actuted Single Point Drin System...88 Three Point Mnul Drin System Air Actuted Single Point Drin System Bot in the Wter Bot out of the Wter Three Point Mnul Drin System Bot in the Wter Bot out of the Wter Drining the Sterndrive...95 Power Pckge Recommissioning Bttery Storge...96 Section 7 - Troubleshooting Strter Motor Will Not Crnk Engine, Or Crnks Slow...98 Engine Will Not Strt Or Is Hrd To Strt Engine Runs Rough, Misses And/Or Bckfires Poor Performnce Excessive Engine Temperture...99 Insufficient Engine Temperture...99 Low Engine Oil Pressure Bttery Will Not Come Up On Chrge Remote Control Opertes Hrd, Binds, Hs Excessive Free-ply Or Mkes Unusul Sounds 100 Steering Wheel Turns Hrd Or Jerky Power Trim Does Not Operte (Motor Does Not Operte) Power Trim Does Not Operte (Motor Opertes But Sterndrive Unit Does Not Move) Section 8 - Customer Assistnce Informtion Owner Service Assistnce Locl Repir Service Service Awy From Home Stolen Power Pckge Attention Required After Submersion Replcement Service Prts Prts And Accessories Inquiries Resolving A Problem Mercury Mrine Service Offices Ordering Literture United Sttes nd Cnd Outside The United Sttes nd Cnd MAY 2005 Pge iii

8 Pge iv MAY 2005

9 Tble of Contents Section 1 - Wrrnty Wrrnty 1 Trnsfer Of Wrrnty... 2 Wrrnty Registrtion United Sttes And Cnd... 2 Wrrnty Registrtion Outside The United Sttes And Cnd... 2 Mercury, MerCruiser Limited Wrrnty United Sttes, Cnd nd Europe (Gsoline Fueled Products Only)... 3 Mercury MerCruiser Limited Wrrnty (Confedertion of Independent Sttes, Middle-Est, nd Afric Yer Limited Wrrnty Aginst Corrosion (Worldwide)... 6 Wrrnty Coverge And Exclusions... 7 Generl Exclusions From Wrrnty MAY 2005 Pge 1

10 Wrrnty Trnsfer Of Wrrnty The limited wrrnty is trnsferble to subsequent purchser, but only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the subsequent owner, send or fx copy of the bill of sle or purchse greement, new owner s nme, ddress nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product by mil. There is no chrge for this service. For products purchsed outside the United Sttes nd Cnd, contct the distributor in your country, or the Mrine Power Service Center closest to you. Wrrnty Registrtion United Sttes And Cnd 1. You my chnge your ddress t ny time, including t time of wrrnty clim, by clling Mercury Mrine or sending letter or fx with your nme, old ddress, new ddress, nd engine seril number to Mercury Mrine s wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx NOTE: Registrtion lists must be mintined by Mercury Mrine nd ny deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Sfety Act be required. 2. To be eligible for wrrnty coverge, the product must be registered with Mercury Mrine. At the time of sle, the deler should complete the wrrnty registrtion nd immeditely submit it to Mercury Mrine vi MercNET, E mil, or mil. Upon receipt of this wrrnty registrtion, Mercury Mrine will record the registrtion. 3. Upon processing the wrrnty registrtion, Mercury Mrine will send registrtion verifiction by mil to the purchser of the product. If this registrtion verifiction is not received within 30 dys, plese contct your selling deler immeditely. Wrrnty coverge is not effective until your product is registered with Mercury Mrine. Wrrnty Registrtion Outside The United Sttes And Cnd 1. It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the distributor or Mrine Power Service Center responsible for dministering the wrrnty registrtion/clim progrm for your re. Pge MAY 2005

11 Wrrnty 2. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril numbers, dte of sle, type of use nd the selling distributor's/deler's code number, nme nd ddress. The distributor/deler lso certifies tht you re the originl purchser nd user of the product. 3. A copy of the Wrrnty Registrtion Crd, designted s the Purchser's Copy, MUST be given to you immeditely fter the crd hs been completely filled out by the selling distributor/deler. This crd represents your fctory registrtion identifiction, nd should be retined by you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the Wrrnty Registrtion Crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim forms. 4. In some countries, the Mrine Power Service Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter receiving the Fctory Copy of the Wrrnty Registrtion Crd from your distributor/deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser's Copy tht you received from the distributor/deler when you purchsed the product. Ask your distributor/deler if this plstic crd progrm pplies to you. IMPORTANT: Registrtion lists must be mintined by the fctory nd deler in some countries by lw. It is our desire to hve ALL products registered t the fctory should it ever be necessry to contct you. Mke sure your deler/distributor fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. 5. For further informtion concerning the Wrrnty Registrtion Crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. Mercury, MerCruiser Limited Wrrnty United Sttes, Cnd nd Europe (Gsoline Fueled Products Only) WHAT IS COVERED: Mercury Mrine wrrnts its new products to be free of defects in mteril nd workmnship during the period described below. DURATION OF COVERAGE: This Limited Wrrnty provides coverge for either two (2) yers from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. 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 wrrnt coverge cnnot be trnsferred either to or from commercil use customer MAY 2005 Pge 3

12 Wrrnty CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: 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. Routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke future wrrnty coverge contingent on proof of proper mintennce. WHAT MERCURY WILL DO: Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: 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. WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion nd Mintennce Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion nd Mintennce Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt which dmges the Mercury Product nd ws not mnufctured or sold by us, jet pump impellers nd liners, opertion with fuels, oils or lubricnts which re not suitble for use with the product (see the Opertion nd Mintennce Mnul), ltertion or removl of prts, or 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. Pge MAY 2005

13 Wrrnty 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. Mercury MerCruiser Limited Wrrnty (Confedertion of Independent Sttes, Middle Est, nd Afric WHAT IS COVERED: Mercury Mrine wrrnts its products to be free of defects in mteril nd workmnship during the period described below. DURATION OF COVERAGE: 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 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 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: 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. Routine mintennce outlined in the Opertion nd Mintennce Mnul must be timely performed in order to mintin wrrnty coverge. Mercury Mrine reserves the right to mke wrrnty coverge contingent on proof of proper mintennce. WHAT MERCURY WILL DO: Mercury s sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified remnufctured 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 MAY 2005 Pge 5

14 Wrrnty HOW TO OBTAIN WARRANTY COVERAGE: 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 lbornd 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. WHAT IS NOT COVERED: This limited wrrnty does not cover routine mintennce items, tune ups, djustments, norml wer nd ter, dmge cused by buse, bnorml use, use of propeller or ger rtio tht does not llow the engine to run in its recommended RPM rnge (see the Opertion nd Mintennce Mnul), opertion of the product in mnner inconsistent with the recommended opertion/duty cycle section of the Opertion nd Mintennce Mnul, neglect, ccident, submersion, improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product), improper service, use of n ccessory or prt 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, or wter entering the engine through the fuel intke, ir intke or exhust system, or dmge to the product from insufficient cooling wter cused by blockge of the cooling system by foreign body, running the engine out of wter, mounting the engine too high on the trnsom, or running the bot with the engine trimmed out too fr. Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit, t ny point, even by prior owner of the product, voids the wrrnty. Expenses relted to hul out, lunch, towing, storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges re not covered by this wrrnty. Also, expenses ssocited with the removl nd/or replcement of bot prtitions or mteril cused by bot design for ccess to the product re not covered by this wrrnty. No individul or entity, including Mercury Mrine uthorized delers, hs been given uthority by Mercury Mrine to mke ny ffirmtion, representtion or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not be enforceble ginst Mercury Mrine. DISCLAIMERS AND LIMITATIONS: THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. 3 Yer Limited Wrrnty Aginst Corrosion (Worldwide) WHAT IS COVERED: Mercury Mrine wrrnts tht ech new Mercury, Mriner, Mercury Rcing, Sport Jet, M 2 Jet Drive, Trcker by Mercury Mrine Outbord, MerCruiser Inbord or sterndrive engine (Product) will not be rendered inopertive s direct result of corrosion for the period of time described below. Pge MAY 2005

15 Wrrnty DURATION OF COVERAGE: 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 or replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty beyond its originl expirtion dte. Unexpired wrrnty coverge cn be trnsferred to subsequent (non commercil use) purchser upon proper re registrtion of the product. CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE: 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. WHAT MERCURY WILL DO: Mercury's sole nd exclusive obligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n obligtion to modify products previously mnufctured. HOW TO OBTAIN WARRANTY COVERAGE: 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. WHAT IS NOT COVERED: This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge, corrosion which cuses purely cosmetic dmge, buse or improper service; corrosion to ccessories, instruments, steering systems; corrosion to fctory instlled jet drive unit; dmge due to mrine growth; product sold with less thn one yer limited Product wrrnty; replcement prts (prts purchsed by 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 the wrrnty period, even if the product is only occsionlly used for such purposes. Wrrnty Coverge And Exclusions The purpose of this section is to help eliminte some of the more common misunderstndings regrding wrrnty coverge. The following informtion explins some of the types of services tht re not covered by wrrnty. The provisions set forth following hve been incorported by reference into the Three Yer Limited Wrrnty Aginst Corrosion Filure, the Interntionl Limited Outbord Wrrnty, nd the United Sttes nd Cnd Limited Outbord Wrrnty MAY 2005 Pge 7

16 Wrrnty Keep in mind tht wrrnty covers repirs tht re needed within the wrrnty period becuse of defects in mteril nd workmnship. Instlltion errors, ccidents, norml wer, nd vriety of other cuses tht ffect the product re not covered. Wrrnty is limited to defects in mteril or workmnship, but only when the consumer sle is mde in the country to which distribution is uthorized by us. Should you hve ny questions concerning wrrnty coverge, contct your uthorized deler. They will be plesed to nswer ny questions tht you my hve. Generl Exclusions From Wrrnty 1. Minor djustments nd tune ups, including checking, clening or djusting sprk plugs, ignition components, crburetor settings, filters, belts, controls, nd checking lubriction mde in connection with norml services. 2. Fctory instlled jet drive units Specific prts excluded from the wrrnty re: The jet drive impeller nd jet drive liner dmged by impct or wer, nd wter dmged drive shft berings s result of improper mintennce. 3. Dmge cused by neglect, lck of mintennce, ccident, bnorml opertion or improper instlltion or service. 4. Hul out, lunch, towing chrges, removl nd/or replcement of bot prtitions or mteril becuse of bot design for necessry ccess to the product, ll relted trnsporttion chrges nd/or trvel time, etc. Resonble ccess must be provided to the product for wrrnty service. Customer must deliver product to n uthorized deler. 5. Additionl service work requested by customer other thn tht necessry to stisfy the wrrnty obligtion. 6. Lbor performed by other thn n uthorized deler my be covered only under following circumstnces: When performed on emergency bsis (providing there re no uthorized delers in the re who cn perform the work required or hve no fcilities to hul out, etc., nd prior fctory pprovl hs been given to hve the work performed t this fcility). 7. All incidentl nd/or consequentil dmges (storge chrges, telephone or rentl chrges of ny type, inconvenience or loss of time or income) re the owner's responsibility. 8. Use of other thn Mercury Precision or Quicksilver prts when mking wrrnty repirs. 9. Oils, lubricnts or fluids chnged s mtter of norml mintennce is customer's responsibility unless loss or contmintion of sme is cused by product filure tht would be eligible for wrrnty considertion. 10. Prticipting in or prepring for rcing or other competitive ctivity or operting with rcing type lower unit. 11. Engine noise does not necessrily indicte serious engine problem. If dignosis indictes serious internl engine condition which could result in filure, condition responsible for noise should be corrected under the wrrnty. 12. Lower unit nd/or propeller dmge cused by striking submerged object is considered mrine hzrd. 13. Wter entering engine through the fuel intke, ir intke or exhust system or submersion. 14. Filure of ny prts cused by lck of cooling wter, which results from strting motor out of wter, foreign mteril blocking inlet holes, motor being mounted too high or trimmed too fr out. Pge MAY 2005

17 Wrrnty 15. Use of fuels nd lubricnts which re not suitble for use with or on the product. Refer to the Mintennce section. 16. Our limited wrrnty does not pply to ny dmge to our products cused by the instlltion or use of prts nd ccessories which re not mnufctured or sold by us. Filures which re not relted to the use of those prts or ccessories re covered under wrrnty if they otherwise meet the terms of the limited wrrnty for tht product MAY 2005 Pge 9

18 Wrrnty Notes: Pge MAY 2005

19 Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tble of Contents Lnyrd Stop Switch Instrumenttion Remote Controls Pnel Mount Fetures Console Mount Fetures Power Trim Single Engine Trim/Triler Dul Engine Trim/Triler Electricl System Overlod Protection Audio Wrning System Testing The Audio Wrning System Emissions Informtion Emission Control Informtion Lbel...20 Owner Responsibility Str Lbel MAY 2005 Pge 11

20 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 feet) 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 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. Pge MAY 2005

21 Instrumenttion 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 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. 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) MAY 2005 Pge 13

22 Getting to Know Your Power Pckge Remote Controls Your bot my be equipped with Mercury Precision Prts or Quicksilver remote controls. All controls my not hve ll fetures shown. Consult your deler for description nd/or demonstrtion of your remote control. Pnel Mount Fetures 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 MAY 2005

23 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. 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 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.! CAUTION Never trim the sterndrive unit up\out using the triler 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 MAY 2005 Pge 15

24 Getting to Know Your Power Pckge 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 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 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. Pge MAY 2005

25 Getting to Know Your Power Pckge Some controls lso hve triler button tht trims the sterndrive to position suitble for triler purposes only. Dul Engine Trim/Triler! CAUTION Avoid twisting or binding dul engine tie brs. Dmge to the tie br nd sterndrives could occur. Alwys 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 sterndrives to position suitble for triler purposes only. Electricl System Overlod Protection 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. 1. A circuit breker provides protection for engine wiring hrness nd the instrumenttion power led. Reset by pushing the red "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 mc MAY 2005 Pge 17

26 Getting to Know Your Power Pckge 3. 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 The power trim system is protected from overlod by 110 mp fuse nd 20 mp spde fuse on the power trim pump. b mp spde fuse b mp fuse 5. The Quicksilver Three Button Power Trim Control Pnel is further protected by 20 mp in line fuse. mc Pge MAY 2005

27 Getting to Know Your Power Pckge 6. A 20 mp fuse is locted ner the TKS module on the crburetor. This fuse provides protection to the wiring of the TKS module if n electricl overlod occurs. 7. 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: Engine oil pressure too low Engine temperture too hot 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 void hzrdous sitution. If the lrm sounds, stop the engine immeditely. Investigte cuse nd correct it, if possible. If the cuse cnnot be determined, contct your uthorized Mercury MerCruiser deler. Testing The Audio Wrning System 1. Turn the ignition switch to the "ON" position without crnking the engine. 2. Listen for the udio lrm. The lrm will sound if the system is functioning correctly MAY 2005 Pge 19

28 Getting to Know Your Power Pckge Emissions Informtion Emission Control Informtion Lbel A tmper resistnt Emission Control Informtion lbel is ffixed in visible loction to the engine t time of mnufcture by Mercury MerCruiser. In ddition to the required emissions sttement, the lbel lists the engine seril number, fmily, FEL (emission level), dte of mnufcture (month, yer), nd the engine displcement. Plese note tht the low emissions certifiction will not ffect the fit, function, or performnce of the engines. Botbuilders nd delers my not remove the lbel or the prt it is ffixed to before sle. If modifictions re necessry, contct Mercury MerCruiser bout the vilbility of replcement decls before proceeding. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# OMXXXXXXXX D.O.M. JAN FAMILY XXXXX_XXXXXX DISP X.XL FEL. XX.X g/kw-hr Emission Control Lbel Non CE Mrked "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "FEL." Fmily Emission Limit "D.O.M." Dte of Mnufcture "DISP" Piston Displcement EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# OMXXXXXX D.O.M. Dec 2004 FAMILY XXXXX XXXXXX FEL. XX.X g/kw-hr DISP. X.XL Emission Control Lbel CE Mrked "SERIAL#" Engine Seril Number "FAMILY" Engine Fmily "FEL." Fmily Emission Limit "D.O.M." Dte of Mnufcture "DISP" Piston Displcement Pge MAY 2005

29 OWNER RESPONSIBILITY Str Lbel Getting to Know Your Power Pckge CE When this mrk is present in the lower right corner of the Emission Control Informtion Lbel, on the engine, the Declrtion of Conformnce pplies. Refer to the front pge of this Mnul for further informtion. The owner/opertor is required to hve routine engine mintennce performed to mintin emission levels within prescribed certifiction stndrds. The owner/opertor is not to modify the engine in ny mnner tht would lter the horsepower or llow emissions levels to exceed their predetermined fctory specifictions. Beginning Jnury 1, 2003, one Three Str lbel will be included with ech fctory certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp nd below) will hve Three Str Ultr Low Emission rting. The Three Str lbel identifies tht these engines meet the Cliforni Air Resources Bord's Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emissions engines. The Three Str lbel will be ffixed on the left side of the hull s shown. XX 1234 XX b mc Recommended loction b - Secondry loction MAY 2005 Pge 21

30 Getting to Know Your Power Pckge One Str Low emission Two Strs Very Low emission mc The one str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2001 exhust emission stndrds. Engines meeting these stndrds hve 75% lower emissions thn conventionl crbureted two stroke engines. These engines re equivlent to the U.S. EPA's 2006 stndrds for mrine engines. FO IDA mc The two str lbel identifies personl wtercrft, outbord, sterndrive nd inbord engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2004 exhust emission stndrds. Engines meeting these stndrds hve 20% lower emissions thn One Str Low Emission engines. Three Strs Ultr Low emission A SS D mc The three str lbel identifies engines tht meet the Air Resources Bord's Personl Wtercrft nd Outbord mrine engine 2008 exhust emission stndrds or the Sterndrive nd Inbord mrine engine 2003 exhust emission stndrds. Engines meeting these stndrds hve 65% lower emissions thn One Str Low Emission engines. Four Strs Super Ultr Low emission RN F T mc The Four Str lbel identifies engines tht meet the Air Resources Bord's Sterndrive nd Inbord mrine engine 2009 exhust emission stndrds. Personl Wtercrft nd Outbord mrine engines my lso comply with these stndrds. Engines meeting these stndrds hve 90% lower emissions thn One Str Low Emission engines. Pge MAY 2005

31 Tble of Contents Section 3 - On The Wter 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 Engine After Stopped While In Ger...28 Throttle Only Opertion...28 Trilering the Bot...29 Freezing Temperture Opertion...29 Drin Plug nd Bilge Pump...29 Protecting People In The Wter While You Are Cruising While Bot Is Sttionry High-Speed And High-Performnce Bot Opertion Pssenger Sfety In Pontoon Bots And Deck Bots Bots Hving An Open Front Deck Bots With Front-Mounted, Rised Pedestl Fishing Sets 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 nd Ger) Inside the Bot...33 Bottom Of Bot...33 Cvittion...33 Ventiltion...33 Elevtion And Climte...34 Propeller Selection...34 Getting Strted Hour Brek-In Period...34 After Brek-In Period...35 End of First Seson Checkup MAY 2005 Pge 23

32 On The Wter Sfe Boting Suggestions In order 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. 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. 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. Pge MAY 2005

33 On The Wter Most bots re rted nd certified for mximum lod (weight) cpcities (refer to your bot cpcity plte). Know your bot's operting nd loding limittions. Know if your bot will flot if full of wter. When in doubt, contct your uthorized Mercury MerCruiser deler or the bot mnufcturer. Ensure tht everyone in the bot is properly seted. Do not llow nyone to sit or ride on ny prt of the bot tht ws not intended for such use. This includes the bcks of sets, gunwles, trnsom, bow, decks, rised fishing sets nd ny rotting fishing set; nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of bot control or sudden bot movement could cuse person to be thrown overbord or into the bot. Ensure tht ll pssengers hve proper set nd re in it before ny bot movement. Never be under the influence of lcohol or drugs while boting (it is the lw). They impir your judgment nd gretly reduce your bility to rect quickly. Know your boting re nd void hzrdous loctions. Be lert. The opertor of the bot is responsible by lw to mintin proper lookout by sight nd hering. The opertor must hve n unobstructed view prticulrly to the front. No pssengers, lod or fishing sets should block the opertors view when the bot is bove idle or plning trnsition speed. Wtch out for others, the wter nd your wke. Never drive your bot directly behind wter skier in cse the skier flls. As n exmple, your bot trveling t 40 km/h (25 MPH) will overtke fllen skier who ws 61 m (200 ft.) in front of you in 5 seconds. Wtch fllen skiers. When using your bot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor's side of the bot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never bck up to the skier or nyone in the wter. Report ccidents. Bot opertors re required by lw to file Boting Accident Report with their stte boting lw enforcement gency when their bot is involved in certin boting ccidents. A boting ccident must be reported if 1) there is loss of life or probble loss of life, 2) there is personl injury requiring medicl tretment beyond first id, 3) there is dmge to bots or other property where the dmge vlue exceeds $ or 4) there is complete loss of the bot. Seek further ssistnce from locl lw enforcement. Be Alert To Crbon Monoxide Poisoning Crbon monoxide is present in the exhust fumes of ll internl combustion engines including the outbords, sterndrives nd inbord engines tht propel bots, s well s the genertors tht power vrious bot ccessories. Crbon monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of crbon monoxide poisoning, which should not be confused with sesickness or intoxiction, include hedche, dizziness, drowsiness nd nuse.! WARNING 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 MAY 2005 Pge 25

34 On The Wter Good Ventiltion Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes. 1. Exmple of desired ir flow through the bot. 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.! 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. 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. Pge MAY 2005

35 On The Wter 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. 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.! CAUTION Overheting from insufficient cooling wter will cuse engine nd drive system dmge. Ensure tht there is sufficient wter lwys vilble t wter inlet holes during opertion.! WARNING Explosive gsoline fumes collect in the engine comprtment. Avoid injury or property dmge, operte the bilge blower for t lest 5 minutes prior to strting the engine. If the bot is not equipped with bilge blower, open the engine htch nd leve it open while strting the engine. 3. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. Allow engine to wrm up (6 10 minutes on first strt of the dy). The engine will normlly idle t RPM nd then return to norml idle RPM of pproximtely 750 RPM MAY 2005 Pge 27

36 On The Wter STOPPING THE ENGINE NOTE: If the engine hs not run for long period of time it my require couple of ttempts while the fuel bowl refills. 4. If engine does not strt fter 3 ttempts:. Push the throttle only button nd position the remote control hndle/throttle lever to the 1/4 throttle position. b. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. 5. If engine does not strt fter step 4:. Move the remote control hndle/throttle lever to full throttle position, then return to 1/4 throttle. b. Turn ignition key to "START". Relese key when engine strts nd llow switch to return to "ON" position. 6. Inspect the power pckge for fuel, oil, wter nd exhust leks. 7. Move control hndle with firm, quick motion forwrd to shift to forwrd ger, or bckwrd to shift to reverse. After shifting, dvnce throttle to desired setting.! CAUTION Avoid dmge to the drive system. Shifting the drive system t RPMs greter thn engine idle speed my cuse internl dmge to the drive system. Shift the drive system only when the engine is t idle RPM. 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 Engine After 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. Pge MAY 2005

37 Trilering the Bot On The Wter 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. Drin Plug nd Bilge Pump The engine comprtment in your bot is nturl plce for wter to collect. For this reson, bots re normlly equipped with drin plug nd/or bilge pump. It is very importnt to check these items on regulr bsis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will be dmged if submerged. Dmge cused by submersion is not covered by the Mercury MerCruiser Limited Wrrnty. 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. ob00311 Alwys slow down nd exercise extreme cution ny time you re boting in n re where there might be people in the wter. Whenever bot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force by the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. While Bot Is Sttionry! WARNING Stop your engine immeditely whenever nyone in the wter is ner your bot. Serious injury to the person in the wter is likely if contcted by rotting propeller, moving bot, moving gercse, or ny solid device rigidly ttched to moving bot or gercse. Shift into neutrl nd shut off the engine before llowing people to swim or be in the wter ner your bot MAY 2005 Pge 29

38 On The Wter High Speed And High Performnce Bot 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 And Deck Bots Whenever the bot is in motion, observe the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in bot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of bot direction, could throw them over the front of bot. Flling over the front of the bot between the two pontoons will position them to be run over. Bots Hving 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 Avoid serious injury or deth from flling over the front end of pontoon or deck bot nd being run over. Sty bck from the front end of the deck 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. mc Pge MAY 2005

39 On The Wter Wve And Wke Jumping! WARNING Avoid serious injury or deth from being thrown within or out of bot when it lnds fter jumping wve or wke. Avoid wve or wke jumping whenever possible. Instruct ll occupnts tht if wke or wve jump occurs, get low nd hng on to bot hnd hold. mc Operting recretionl bots over wves nd wkes is nturl prt of boting. However, when this ctivity is done with enough speed to force the bot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the bot re enters the wter. The primry concern is the bot chnging direction while in the midst of the jump. In such cses the lnding my cuse the bot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to be thrown out of their sets or out of the bot. There is nother less common hzrdous result from llowing your bot to lunch off of wve or wke. If the bow of your bot pitches down fr enough while irborne, upon wter contct it my penetrte under the wter surfce nd submrine for n instnt. This will bring the bot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The bot my lso veer shrply to one side. Impct With Underwter Hzrds Reduce speed nd proceed with cution whenever you're driving bot in shllow wter or in res where the wters re suspected of hving underwter obstcles tht could be struck by the underwter drive components, rudder or the bot bottom. 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 MAY 2005 Pge 31

40 On The Wter Drive Unit Impct Protection 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 Avoid serious injury or deth from loss of bot control. Continued boting with mjor impct dmge cn result in sudden component filure with or without subsequent impcts. Hve the power pckge thoroughly inspected nd ny necessry repirs mde. 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. Operting With Low Wter Inlets In Shllow Wter - Low Wter Inlets mc Pge MAY 2005

41 On The Wter! CAUTION Serious engine dmge could occur by filing to follow these instructions. Snd, silt or mud could be sucked into the wter inlets restricting or shutting off the wter supply to the engine. Extreme cre should be exercised when operting bot equipped with low wter inlets while mneuvering in shllow wter. Also, void beching bot with the engine operting. 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) Bottom Of 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 permits the propeller to speed up, but the bot speed to reduce. 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: Drive unit trimmed out too fr. A missing propeller diffuser ring. A dmged propeller or ger housing, which llows exhust gses to escpe between propeller nd ger housing. Drive unit instlled too high on trnsom MAY 2005 Pge 33

42 On The Wter Elevtion And 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 Getting Strted 20 Hour Brek In Period IMPORTANT: The engines covered in this mnul re equipped with n RPM rev limiter tht is set to n upper (or limited) RPM mount. This limit is slightly bove the norml operting rnge of the engine nd is designed to help prevent dmge from excessive engine RPM. Once the RPM returns to the recommended operting RPM rnge, norml engine opertion resumes. It is the responsibility of the bot mnufcturer nd/or the selling deler to equip 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/or 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. 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. Pge MAY 2005

43 Do not operte t one speed consistently for extended periods. On The Wter 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 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 MAY 2005 Pge 35

44 On The Wter Notes: Pge MAY 2005

45 Tble of Contents Section 4 - Specifictions Specifictions Fuel Requirements Fuel Rtings Using Reformulted (Oxygented) Gsolines (USA Only)...38 Gsolines Contining Alcohol Engine Oil Engine Specifictions Fluid Specifictions Sterndrives Engine MAY 2005 Pge 37

46 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 dmge cused thereby 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 90 RON minimum. Premium gsoline (98 RON) is lso cceptble. If unleded gsoline is not vilble, use mjor brnd of leded gsoline. Using Reformulted (Oxygented) Gsolines (USA Only) This type of gsoline is required in certin res of the USA. The 2 types of oxygentes used in these fuels is Alcohol (Ethnol) or Ether (MTBE or ETBE). If Ethnol is the oxygente tht is used in the gsoline in your re, refer to Gsolines Contining Alcohol. These Reformulted Gsolines re cceptble for use in your Mercury MerCruiser engine. Gsolines Contining Alcohol If the gsoline in your re contins either methnol (methyl lcohol) or ethnol (ethyl lcohol), you should be wre of certin dverse effects tht cn occur. These dverse effects re more severe with methnol. Incresing the percentge of lcohol in the fuel cn lso worsen these dverse effects. Some of these dverse effects re cused becuse the lcohol in the gsoline cn bsorb moisture from the ir, resulting in seprtion of the wter/lcohol from the gsoline in the fuel tnk. The fuel system components on your Mercury MerCruiser engine will withstnd up to 10% lcohol content in the gsoline. We do not know wht percentge your bot's fuel system will withstnd. Contct your bot mnufcturer for specific recommendtions on the bot's fuel system components (fuel tnks, fuel lines, nd fittings). Be wre tht gsolines contining lcohol my cuse incresed: Corrosion of metl prts Deteriortion of rubber or plstic prts Fuel permetion through rubber fuel lines Strting nd operting difficulties! WARNING FIRE AND EXPLOSION HAZARD: Fuel lekge from ny prt of the fuel system cn be fire nd explosion hzrd which cn cuse serious bodily injury or deth. Creful periodic inspection of entire fuel system is mndtory, prticulrly fter storge. All fuel components should be inspected for lekge, softening, hrdening, swelling or corrosion. Any sign of lekge or deteriortion requires replcement before further engine opertion. Becuse of possible dverse effects of lcohol in gsoline, it is recommended tht only lcohol free gsoline be used where possible. If only fuel contining lcohol is vilble, or if the presence of lcohol is unknown, incresed inspection frequency for leks nd bnormlities is required. Pge MAY 2005

47 Specifictions IMPORTANT: When operting Mercury MerCruiser engine on gsoline contining lcohol, storge of gsoline in the fuel tnk for long periods should be voided. Long periods of storge, common to bots, crete unique problems. In crs lcohol blend fuels normlly re consumed before they cn bsorb enough moisture to cuse trouble, but bots often sit idle long enough for phse seprtion to tke plce. In ddition, internl corrosion my tke plce during storge if lcohol hs wshed protective oil films from internl components. Engine Oil To help obtin optimum engine performnce nd to provide mximum protection, we strongly recommend the use of the following oils listed in the order of recommendtion: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC W rted, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC W rted oil. 3. A NMMA FC W rted oil. 4. MerCruiser / Quicksilver 4 cycle 25W40, non FC W rted oil. 5. A good grde stright weight detergent utomotive oil per the operting chrt below. NOTE: The use of non detergent oils, multi viscosity oils (other thn s specified), non FC W rted synthetic oils, low qulity oils or oils tht contin solid dditives re specificlly not recommended MAY 2005 Pge 39

48 Specifictions Engine Specifictions Models 4.3L 5.0L 5.7L Horsepower Kilowtts Displcement 4.3 L (262 cid) 5.0 L (305 cid) 5.7 L (350 cid) Specified WOT RPM Rnge Idle RPM in Neutrl Minimum Oil Idle 4. Minimum Oil kp 2000 RPM 4. (30 70 psi) 28 kp (4 psi) kp (30 60 psi) Thermostt, 71 C (160 F) Idle BTDC Firing Order Electricl System Alterntor Rting Hot Operting Amps Alterntor Rting Cold Operting Amps Recommended Bttery Rting (Minimum) Sprk Plug Type Sprk Plug Gp 12 Volt Negtive ( ) Ground 65 mp 72 mp 375 CCA, 475 MCA, or 90 Ah AC MR43LTS or AC (Pltinum) 1.14 mm (0.045 in.) Fluid Specifictions Sterndrives NOTE: Oil cpcity includes ger lube monitor. Model Cpcity Fluid Type Alph One Brvo One Brvo Two Brvo Three 1892 ml (64 oz.) 2736 ml (92 1/2 oz.) 3209 ml (108 1/2 oz.) 2972 ml (100 1/2 oz.) High Performnce Ger Lubricnt Engine IMPORTANT: All cpcities re pproximte fluid mesures. IMPORTANT: It my be necessry to djust oil levels depending on instlltion ngle nd cooling systems (het exchnger nd fluid lines). 1. Performnce obtined nd corrected in ccordnce with SAE J1228/ISO 8665 Crnkshft Power. 2. Mesured using n ccurte service tchometer with the engine t norml operting tempertures 3. A specil procedure must be followed to djust idle rpm. Consult your Authorized Mercury MerCruiser Deler before ttempting this procedure. 4. Oil pressure must be checked with the engine t norml operting temperture. Pge MAY 2005

49 4.3L (262 CID) Models Cpcity Fluid Type Engine Oil (With Filter) liters (4 U.S. qt.) Specifictions Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 Sewter Cooling System liters (15 U.S. qt.) Propylene Glycol nd Purified Wter Closed Cooling System 5.0L (305 CID) nd 5.7L (350 CID) Models Engine Oil (With Filter) liters (20 U.S. qt.) Cpcity 4.25 liters (4.5 U.S. qt.) Mercury Extended Life Coolnt/Antifreeze or Extended Life Ethylene Glycol 5/100 Coolnt/Antifreeze mixed 50/50 with Purified Wter Fluid Type Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 Sewter Cooling System liters (21 U.S. qt.) Propylene Glycol nd Purified Wter 1. Alwys use the dipstick to determine the exct quntity of oil or fluid required. 2. Sewter cooling system cpcity informtion is for winteriztion use only MAY 2005 Pge 41

50 Specifictions Notes: Pge MAY 2005

51 Tble of Contents Section 5 - Mintennce Mintennce Owner/Opertor Responsibilities Deler Responsibilities Mintennce Do It Yourself Mintennce Suggestions Inspection Mintennce Schedule - Sterndrive Models Routine Mintennce Ech Dy Strt Ech Dy End Weekly Every Two Months or 50 Hours Scheduled Mintennce Every 100 Hours or Annully (Whichever Occurs First)...46 Every 200 Hours or 3 Yers Every 300 Hours or 3 Yers Every 5 Yers 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 Wter Seprting Fuel Filter Lubriction Steering System...60 Throttle Cble...62 Shift Cble - Typicl...62 Sterndrive Unit nd Trnsom Assembly Sterndrive U-joint Shft Splines And O-rings (Sterndrive Unit Removed)...63 Engine Coupler...63 Driveshft Extension Models...64 Propellers Propeller Repir...65 Alph Propeller Removl...65 Alph Propeller Instlltion...65 Brvo One Propeller Removl...66 Brvo One Propeller Instlltion...66 Brvo Two Propeller Removl...67 Brvo Two Propeller Instlltion...68 Brvo Three Propeller Removl...69 Brvo Three Propeller Instlltion...70 Serpentine Drive Belt Checking Replcing Belt nd/or Adjusting Tension Flushing the Power Pckge Flushing Attchments Sterndrive Wter Pickups Alterntive Wter Pickups Bttery Corrosion Protection Pinting Your Power Pckge MAY 2005 Pge 43

52 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 Avoid injury or deth nd product dmge from n electricl shock, fire or explosion. Alwys disconnect both bttery cbles from the bttery before servicing the power pckge.! WARNING Fuel vpors cn be present in the engine comprtment. Avoid injury or power pckge dmge cused by fuel vpors or explosion. Alwys ventilte the engine comprtment prior to servicing the power pckge. IMPORTANT: Refer to the mintennce schedule for complete listing of ll scheduled mintennce to be performed. Some listings cn be done by owner/opertor, while others should be performed by n uthorized Mercury MerCruiser deler. Before ttempting mintennce or repir procedures not covered in this mnul, it is recommended tht Mercury MerCruiser Service Mnul be purchsed nd red thoroughly. NOTE: Mintennce points re color coded for ese of identifiction. See the decl on engine for identifiction. Mintennce Point Color Codes Blue Coolnt Pge MAY 2005

53 Mintennce Mintennce Point Color Codes Yellow Ornge Blck Brown Engine Oil Fuel Ger Lube Oil (Sterndrive models only) Trnsmission (Inbord models only) 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 MAY 2005 Pge 45

54 Mintennce Mintennce Schedule Sterndrive Models Routine Mintennce EACH DAY START EACH DAY END WEEKLY NOTE: Only perform mintennce which pplies to your prticulr power pckge. Check the crnkcse oil (intervl cn be extended bsed on experience). Check the drive unit oil level, the trim pump oil level, nd the power steering pump or compct hydrulic steering fluid level. If operting in slt, brckish or polluted wters, flush the cooling system fter ech use. Check the wter inlets for debris or mrine growth. Check the sewter striner nd clen. Check the coolnt level. Inspect the drive unit nodes nd replce if 50 percent eroded. EVERY TWO MONTHS OR 50 HOURS Scheduled Mintennce Lubricte the propeller shft nd retorque the nut (if operting in only freshwter, this mintennce my be extended to every four months). Operting in sltwter or brckish or polluted wter only: tret the power pckge with Corrosion Gurd. Check the bttery connections nd the fluid level. Ensure tht the guges nd the wiring connections re secure. Clen the guges. 1. NOTE: Only perform mintennce which pplies to your prticulr power pckge. EVERY 100 HOURS OR ANNUALLY (WHICHEVER OCCURS FIRST) Touch up the pint on the power pckge. Chnge the crnkcse oil nd filter. Chnge the drive unit oil Retorque the connection of the gimbl ring to the steering shft. Replce the wter seprting fuel filter element. Check the steering system nd the remote control for loose, missing or dmged prts. Lubricte the cbles nd the linkges. Check the continuity circuit for loose or dmged connections. Test the MerCthode unit output on Brvo Models. NOTE: On V6 models the PCV vlve is non serviceble nd is n internl component of the vlve cover ssembly. Clen the flme rrestor, IAC muffler (MPI engines), 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. EVERY 200 HOURS OR 3 YEARS Inspect the U joints, the splines nd the bellows. Check the clmps. Check the engine lignment. Lubricte the U joint splines nd cross bering, if equipped with grese fitting. 1. If operting in sltwter, intervl is reduced to every 25 hours or 30 dys whichever occurs first. Pge MAY 2005

55 EVERY 300 HOURS OR 3 YEARS Lubricte the gimbl bering nd the engine coupler. 2. Check the engine mount for tightness nd retorque if necessry. Check the distributor cp, if equipped. Check the electricl system for loose, dmged, or corroded fsteners. Mintennce Check the cooling system nd the exhust system hose clmps for tightness. Inspect both systems for dmge or leks. Disssemble nd inspect the sewter pump nd replce worn components. Clen the sewter section of the closed cooling system. Clen, inspect, nd test the pressure cp. Inspect the exhust system components nd verify tht the flpper vlves re not missing or worn, if equipped. EVERY 5 YEARS Mintennce Log Replce the coolnt (every two yers if extended life ntifreeze coolnt is not being used). Record ll mintennce performed on your power pckge here. Be sure to sve ll work orders nd receipts. Dte Mintennce Performed Engine Hours 2. Lubricte the engine coupler every 50 hours if operted t idle for prolonged periods of time MAY 2005 Pge 47

56 Mintennce Seled Crburetor Mixture Screw! CAUTION Do not remove mixture screw sels nd/or ttempt to djust fuel mixture setting. Tmpering with the mixture setting on this engine could ffect the exhust emissions level, thus voiding the emissions certifiction. These sels should only be removed by n uthorized deler or emissions testing gency. Engine Oil! CAUTION ENVIRONMENTAL HAZARD! Dischrge of oil or oil wste into the environment is restricted by lw. Do not spill oil or oil wste into the environment when using or servicing your bot. Contin nd dispose of oil or oil wste s defined by locl uthorities. Checking 1. Stop the engine. Allow pproximtely 5 minutes for the oil to drin into the oil pn. The bot must be t rest in the wter. 2. Remove the dipstick. Wipe clen nd reinstll fully into the dipstick tube. Wit 60 seconds to llow trpped ir to vent. NOTE: Ensure tht dipstick is instlled with oil level indiction mrks fcing the rer of the engine (flywheel end). - Dipstick tube 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. Pge MAY 2005

57 Mintennce 1. Remove oil fill cp Oil fill cp 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 Engine Oil Cpcity Fluid type 4.3L (262 cid) 3.8 liters (4 U.S. qt.) 5.0L (305 cid) 4.25 liters (4.5 U.S. qt.) 5.7L (350 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W 40 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. 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 MAY 2005 Pge 49

58 Mintennce 2. Remove the bilge drin plug. 3. Pull tether through the bilge drin. 4. Plce the oil drin hose in suitble continer. 5. Remove the drin plug from the oil drin hose. 6. After oil hs drined completely, instll the drin plug in the oil drin hose. 7. Push the hose through bilge drin nd instll the plug. ENGINE OIL 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. 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. 3. Tighten oil filter securely (following filter mnufcturer's instructions). Do not overtighten. 4. Remove oil fill cp. IMPORTANT: Alwys use dipstick to determine exctly how much oil is required. 5. Add recommended engine oil to bring level up to the bottom of the OK rnge on the dipstick. 6. With the bot t rest in the wter, check the oil level nd dd specified fluid to bring the oil level up to, but not over, the full or OK rnge. NOTE: Adding 0.95 liters (1 qurt) of engine oil will rise the level from the dd mrk to the top of the OK rnge. Engine Model Engine Oil Cpcity Fluid type 4.3L (262 cid) 3.8 liters (4 U.S. qt.) 5.0L (305 cid) 4.25 liters (4.5 U.S. qt.) 5.7L (350 cid) Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil 25W Strt the engine, run the engine for three minutes, nd check for leks. Stop the engine. Allow pproximtely 5 minutes for the oil to drin into the oil pn. The bot must be t rest in the wter. Pge MAY 2005

59 Mintennce Power Steering Fluid 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. b. Proper fluid level with engine cold should be within the cold rnge. b c Power steering pump 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 A1 Chnging 3. Reinstll the fill cp/dipstick. Power steering fluid does not require chnging unless it becomes contminted with wter or debris. Contct your uthorized Mercury MerCruiser deler. Engine Coolnt Checking! WARNING Allow the engine to cool down before removing the coolnt pressure cp. A sudden loss of pressure could cuse hot coolnt to boil nd dischrge violently. After the engine hs cooled, turn the cp 1/4 turn to llow ny pressure to escpe slowly, then push down nd turn the cp ll the wy off MAY 2005 Pge 51

60 Mintennce 1. Remove the cp from the het exchnger nd observe the fluid level. - Het exchnger cp The coolnt level in the het exchnger should be t the bottom of the filler neck. If the coolnt level is low, contct your uthorized Mercury MerCruiser deler. 3. Instll the cp onto the het exchnger. IMPORTANT: When reinstlling the pressure cp, be sure to tighten it until it sets on the filler neck. 4. With the engine t norml operting temperture, check the coolnt level in the coolnt recovery bottle. 5. The coolnt level should be between the "ADD" nd "FULL" mrks. 6. Add the specified fluid s necessry Tube Ref No. Description Where Used Prt No. 122 Extended Life Antifreeze/ Coolnt Closed Cooling System K1 Filling! CAUTION Alcohol or Methnol bsed ntifreeze or plin wter, re not recommended for use in the coolnt section of the Closed Cooling System t ny time.! CAUTION Overheting from insufficient cooling wter will cuse engine nd drive system dmge. Ensure tht there is sufficient wter lwys vilble t wter inlet holes during opertion. Pge MAY 2005

61 Mintennce! CAUTION Air trpped in the closed cooling section of n engine cooling system cn cuse the engine to overhet resulting in engine dmge. To minimize the possibility of trpping ir when initilly filling the closed cooling system, position 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 Chnging 3. Instll the fill cp onto the coolnt recovery bottle. Contct your uthorized Mercury MerCruiser deler. Drive Unit Oil! CAUTION ENVIRONMENTAL HAZARD! Dischrge of oil or oil wste into the environment is restricted by lw. Do not spill oil or oil wste into the environment when using or servicing your bot. Contin nd dispose of oil or oil wste s defined by locl uthorities. Checking NOTE: Oil level will fluctute during opertion. Oil level should be checked with the engine cold, before strting MAY 2005 Pge 53

62 Mintennce 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 Sewter cooled models - Ger lube monitor 6105 Closed cooled models Filling 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 A1 3. Replce the cp. NOTE: When filling the entire sterndrive unit refer to Chnging instructions, following. Pge MAY 2005

63 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. Brvo One Models: Remove the propeller, lower the sterndrive unit to the full down/in position, remove the oil fill/drin screw nd seling wsher nd drin the oil. - Oil fill/drin screw b mc b - Seling wsher MAY 2005 Pge 55

64 Mintennce 5. All Other Models: 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 mc b - Seling wsher 6. Remove the oil vent screw nd seling wsher. Allow the oil to drin completely. b - Oil vent screw mc 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. 7. 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 A1 IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lubricnt in sterndrive unit. 8. Instll the oil vent screw nd seling wsher. 9. Continue to pump ger lubricnt into the ger lube monitor circuit until the ger lubricnt ppers in the ger lube monitor. 10. 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. Pge MAY 2005

65 Mintennce Alph One Brvo One Brvo Two Brvo Three Power Trim Fluid Model Cpcity Fluid Type 1892 ml (64 oz.) 2736 ml (92 1/2 oz.) 3209 ml (108 1/2 oz.) 2972 ml (100 1/2 oz.) High Performnce Ger Lubricnt 11. Remove the pump from the oil fill/drin hole. Quickly instll the seling wsher nd oil fill/drin screw. Tighten securely. 12. Reinstll the propeller. Refer to Propellers. 13. 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. 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 A1 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 A MAY 2005 Pge 57

66 Mintennce Chnging 3. Instll the cp. 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 Avoid gsoline fire or explosion. Gsoline is extremely flmmble nd highly explosive under certin conditions. Be creful when clening flme rrestor; ensure tht ignition is off. Do not smoke or llow sources of sprk or open flme in re when clening flme rrestor. 1. Disconnect nd remove the crnkcse ventiltion hose from the fitting on the flme rrestor nd vlve cover. 2. Remove the flme rrestor. d e b c - Locknut b - Seling wsher c - Typicl crburetor d - Crnkcse ventiltion hose e - Flme rrestor 3. Clen the flme rrestor with wrm wter nd mild detergent. 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. Pge MAY 2005

67 Mintennce NOTE: On V6 models the PCV vlve is non serviceble nd is n internl component of the vlve cover. 1. Remove the PCV vlve from the port vlve cover. b - PCV vlve b - Hose mc Disconnect the PCV vlve from the hose nd discrd the vlve. 3. Instll new PCV vlve in the vlve cover nd reconnect the hose. 4. Ensure the PCV vlve is tightly seted in the vlve cover. Chnging Wter Seprting Fuel Filter! WARNING Avoid serious injury or deth from gsoline fire or explosion; gsoline is extremely flmmble nd highly explosive under certin conditions. When servicing the fuel system components ensure tht the engine is cool, the ignition switch is in the off position, nd tht the lnyrd stop switch, if equipped, is in the off position. Do not smoke or llow sprk or open flme in the re. Wipe up ny spilled fuel immeditely. Ensure tht no fuel leks exist before closing the engine htch. 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends tht the engine be shut off for 12 hours prior to filter removl. 2. Close fuel supply vlve, if equipped. 3. Wrp the wter seprting fuel filter with cloth to help ctch ny fuel spills or spry. 4. Remove nd discrd the wter seprting fuel filter nd seling ring from the mounting brcket. 5. Cot the seling ring on the new filter with engine oil. Tube Ref. No. Description Where Used Prt No. Synthetic Blend MerCruiser Engine Oil SAE25W 40 Filter seling ring K MAY 2005 Pge 59

68 Mintennce 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 engine immeditely nd contct your uthorized Mercury MerCruiser deler. Lubriction Steering System! CAUTION Do not grese the steering cble while its extended. Hydrulic lock could occur nd cuse loss of steering control. 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 A1 Pge MAY 2005