90-864841060 506

NOTE: The following applies to CE marked products only.

Declaration of Conformance – Mercury MerCruiser

This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers’ instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement Standards Applied
Owner’s manual (A.2.5) ISO 10240
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093-1; ISO 9093-2
Handling characteristics (A.4) ISO 8665
Inboard Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO 10133
Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469
Electrical System (A.5.3) ISO 10133; ISO 8846

8.1S and 8.1 Horizon Inboard Models

Applicable portions of: ISO 10592, ISO 8848 and
Steering system (A.5.4)
ABYC P-17
Exhaust emission requirements (B.2) ISO 8178
Owner’s manual (B.4) ISO 8665
Noise emission levels (C.1) ISO 14509
Ignition-protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031

Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft
in which it is to be installed has been declared in conformity, if so required, with the
relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard EN 50081-1
Generic immunity standard EN 50082-1
Vehicles, boats and internal combustion engine
SAE J551 (CISPR 12)
driven devices - Radio disturbance characteristics
Electrostatic discharge testing EN 61000-6-2; EN 61000-4-2; EN61000-4-3

The notified body responsible for surveillance of the quality system under Full Quality Assurance
Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575

This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
© 2006 Mercury Marine

Patrick C. Mackey

President - Mercury Marine, Fond du Lac, WI USA

 Regulatory contact:
Engineering - Regulatory
MerCruiser
3003 N. Perkins Rd
Stillwater, Oklahoma 74075
USA
(405) 377-1200

Identification Record
Please record the following information:
Engine Model and Horsepower Engine Serial Number

Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number

The serial numbers are the manufacturer’s keys to numerous engineering details that apply
to your Mercury MerCruiser® power package. When contacting your Authorized Mercury
MerCruiser Dealer about service, always specify model and serial numbers.
The description and specifications contained herein were in effect at the time this guide
was approved for printing. Mercury Marine, whose policy is one of continuous
improvement, reserves the right to discontinue models at any time, or to change
specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
©2006, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury
Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort,
M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered
trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered
service mark of Brunswick Corporation.

Welcome
You have selected one of the finest marine power packages available. It incorporates
numerous design features to assure operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many
boating seasons. To ensure maximum performance and carefree use, we ask that you
thoroughly read this manual.
 The Operation, Maintenance and Warranty Manual contains specific instructions for using
and maintaining your product. We suggest that this manual remain with the product for
ready reference whenever you are on the water.
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your
boating will be pleasant!
Mercury MerCruiser

Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine;
the terms of the warranty are set forth in the Warranty Sections of this manual. The warranty
statement contains a description of what is covered, what is not covered, the duration of
coverage, how to best obtain warranty coverage, important disclaimers and limitations
of damages and other related information. Please review this important information.
Mercury Marine products are designed and manufactured to comply with our own high
quality standards, applicable industry standards and regulations, as well as certain
emissions regulations. At Mercury Marine every engine is operated and tested before it is
boxed for shipment to make sure that the product is ready for use. In addition, certain
Mercury Marine products are tested in a controlled and monitored environment, for up to
10 hours of engine run time, in order to verify and make a record of compliance with
applicable standards and regulations. All Mercury Marine product, sold as new, receives
the applicable limited warranty coverage, whether the engine participated in one of the test
programs described above or not.

Read This Manual Thoroughly

IMPORTANT: If you don’t understand any portion of this manual, contact your dealer for
a demonstration of actual starting and operating procedures.

Notice
Throughout this publication, and on your power package, WARNINGS and CAUTIONS,

accompanied by the International Hazard Symbol ! , may be used to alert the installer/
user to special instructions concerning a particular service or operation that may be
hazardous if performed incorrectly or carelessly. Observe them carefully.
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance
with these special instructions while performing the service, plus common sense operation,
are major accident prevention measures.

! WARNING
WARNING—indicates a potentially hazardous situation that, if not avoided, could result
in death or serious injury.

! CAUTION
CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury or property damage. It may also be used to alert against unsafe
practices.

IMPORTANT: Indicates information or instructions that are necessary for proper operation
and/or maintenance.
 ! WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the
equipment aboard and the safety of all occupants aboard. We strongly recommend that
the operator read this Operation, Maintenance and Warranty Manual and thoroughly
understand the operational instructions for the power package and all related accessories
before the boat is used.

! WARNING
California Proposition 65 Warning
The engine exhaust from this product contains chemicals known to the state of California
to cause cancer, birth defects or other reproductive harm.
 TABLE OF CONTENTS

Section 1 - Warranty

Transfer Of Warranty...............................................2 Mercury MerCruiser Limited Warranty (Confederation

Warranty Registration United States And Canada. .2 of Independent States, Middle-East, and Africa......5
Warranty Registration Outside The United States And 3 Year Limited Warranty Against Corrosion
Canada....................................................................2 (Worldwide).............................................................6
Mercury, MerCruiser Limited Warranty United States, Warranty Coverage And Exclusions........................7
Canada and Europe (Gasoline Fueled Products General Exclusions From Warranty....................8
Only)........................................................................3

Section 2 - Getting to Know Your Power Package

Lanyard Stop Switch..............................................12 Console Mount Features- Dual Engine..........20

Instrumentation......................................................13 Synchronizing Dual Engines..........................20
System View.....................................................13 Dual Helm Station Transfer............................21
Digital Gauges..................................................14 Synchronizing Dual Helms Prior To Station
Analog Gauges.................................................14 Transfer........................................................22
Remote Controls (Non-DTS Models).....................15 Zero Effort Features.......................................22
Remote Controls............................................15 Electrical System Overload Protection..................22
Panel Mount Features..................................15 Audio Warning System..........................................24
Console Mount Features..............................16 Testing The Audio Warning System.................24
Zero Effort Features.......................................16 Engine Guardian Strategy.....................................24
Remote Controls (DTS Models)............................17 Transmission Guardian Strategy...........................25
Remote Controls............................................17 Warning Horn Signals............................................25
Panel Mount Features....................................17 Emissions Information...........................................26
Console Mount Features - Single Engine.......18 Emission Control Information Label...............26
Slim Binnacle Console Mount Features - Single Owner Responsibility...................................27
Engine............................................................19 Star Label.......................................................27

Section 3 - On The Water

Safe Boating Suggestions.....................................30 Starting and Stopping the Engine...................35

Be Alert To Carbon Monoxide Poisoning..............31 Starting the Engine.......................................35
Good Ventilation...............................................32 Stopping the Engine.....................................36
Poor Ventilation ...............................................32 Throttle Only Operation..................................37
Basic Boat Operation (Non-DTS Models)..............32 Freezing Temperature Operation...................37
Launching and Boat Operation.......................32 Drain Plug and Bilge Pump............................38
Operation Chart............................................33 Protecting People In The Water............................38
Starting and Stopping the Engine...................33 While You Are Cruising.....................................38
Starting the Engine.......................................33 While Boat Is Stationary...................................38
Stopping the Engine.....................................34 High-Speed And High-Performance Boat
Throttle Only Operation..................................34 Operation...............................................................38
Freezing Temperature Operation...................34 Passenger Safety In Pontoon Boats And Deck
Drain Plug and Bilge Pump............................34 Boats.....................................................................39
Basic Boat Operation (DTS Models).....................34 Boats Having An Open Front Deck...................39
Launching and Boat Operation.......................34 Boats With Front-Mounted, Raised Pedestal
Operation Chart............................................35 Fishing Seats....................................................39

90-864841060 MAY 2006 Page i

 Wave And Wake Jumping....................................40 Ventilation..................................................... 42
Impact With Underwater Hazards........................ 40 Elevation And Climate...................................42
Conditions Affecting Operation............................. 41 Getting Started..................................................... 42
Weight Distribution (Passengers and Gear) 20-Hour Break-In Period............................... 42
Inside the Boat.............................................. 41 After Break-In Period.....................................42
Bottom Of Boat..............................................41 End of First Season Checkup....................... 43
Cavitation...................................................... 41

Section 4 - Specifications

Cruising RPM....................................................... 46 Engine Oil.............................................................47

Fuel Requirements...............................................46 Engine Specifications...........................................48
Fuel Ratings.....................................................46 Fluid Specifications.............................................. 49
Using Reformulated (Oxygenated) Gasolines Transmission................................................... 49
(USA Only).......................................................46 Engine..............................................................49
Gasolines Containing Alcohol..........................46

Section 5 - Maintenance

Owner/Operator Responsibilities.......................... 52 Engine Oil Drain Pump............................... 57

Dealer Responsibilities.........................................52 Changing Filter............................................ 58
Maintenance.........................................................52 Transmission Fluid............................................... 58
Do It Yourself Maintenance Suggestions............. 53 Checking While the Engine is Warm............... 58
Inspection.............................................................53 Checking While Engine is Cold........................59
Maintenance Schedule - Inboard Models.............54 Changing......................................................... 59
Routine Maintenance.......................................54 Engine Coolant.....................................................59
Each Day Start............................................54 Checking..........................................................59
Each Day End.............................................54 Filling............................................................... 60
Weekly........................................................ 54 Changing ........................................................ 60
Every Two Months or 50 Hours.................. 54 Cleaning The Flame Arrestor............................... 60
Scheduled Maintenance..................................54 Changing Water Separating Fuel Filter................61
After the Initial 20 Hour Break-in.................54 Serpentine Drive Belt........................................... 63
Every 100 Hours or Annually (Whichever Checking..........................................................63
Occurs First)............................................... 54 Replacing.........................................................64
Every 300 Hours or 3 Years........................ 54 Flushing the Seawater System—Inboard
Every 5 Years............................................. 55 Models..................................................................65
Maintenance Log..................................................55 The Boat out of the Water—Inboard Models. 65
Engine Oil.............................................................55 The Boat in the Water—Inboard Models.......66
Checking..........................................................56 Battery..................................................................68
Filling............................................................... 56 Multiple EFI Engine Battery Precautions....... 68
Changing Oil and Filter....................................57

Section 6 - Storage

Cold Weather or Extended Storage..................... 70 Air Actuated Single Point Drain System...... 72
Preparing Power Package for Storage.......... 70 Manual Drain System.................................. 73
Engine and Fuel System Preparation......... 71 Air Actuated Single Point Drain System........73
Draining the Seawater System.............................71 Boat in the Water........................................ 73
Drain System Identification........................... 72 Boat out of the Water..................................75

Page ii 90-864841060 MAY 2006

 Manual Drain System.....................................77 Battery Storage...................................................... 78
Boat in the Water.........................................77 Power Package Recommissioning........................78
Boat out of the Water...................................78

Section 7 - Troubleshooting

Diagnosing EFI Problems......................................82 Excessive Engine Temperature............................. 83

Diagnosing DTS Problems....................................82 Insufficient Engine Temperature............................ 84
Engine Guardian System....................................... 82 Low Engine Oil Pressure.......................................84
Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Come Up On Charge...................84
Slow.......................................................................82 Remote Control Operates Hard, Binds, Has
Engine Will Not Start Or Is Hard To Start..............82 Excessive Free-play Or Makes Unusual Sounds. .84
Engine Runs Rough, Misses And/Or Backfires.....83 Steering Wheel Turns Hard Or Jerky....................84
Poor Performance.................................................83

Section 8 - Customer Assistance Information

Owner Service Assistance..................................... 86 Parts And Accessories Inquiries..................87

Local Repair Service.........................................86 Resolving A Problem........................................87
Service Away From Home................................86 Mercury Marine Service Offices........................87
Stolen Power Package.....................................86 Ordering Literature................................................88
Attention Required After Submersion...............86 United States and Canada................................88
Replacement Service Parts..............................86 Outside The United States and Canada...........88

90-864841060 MAY 2006 Page iii

Page iv 90-864841060 MAY 2006
 Warranty

Section 1 - Warranty 1
Table of Contents
Transfer Of Warranty............................................ 2 Mercury MerCruiser Limited Warranty
Warranty Registration United States And Canada (Confederation of Independent States, Middle-East,
.............................................................................. 2 and Africa.............................................................. 5
Warranty Registration Outside The United States 3 Year Limited Warranty Against Corrosion
And Canada.......................................................... 2 (Worldwide)........................................................... 6
Mercury, MerCruiser Limited Warranty United Warranty Coverage And Exclusions..................... 7
States, Canada and Europe (Gasoline Fueled General Exclusions From Warranty ............... 8
Products Only)...................................................... 3

90-864841060 MAY 2006 Page 1

Warranty

Transfer Of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder
of the unused portion of the limited warranty. This will not apply to products used for
commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or
purchase agreement, new owner’s name, address and engine serial number to Mercury
Marine’s warranty registration department. In the United States and Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax 920-929-5893
Upon processing the transfer of warranty, Mercury Marine will send registration verification
to the new owner of the product by mail.
There is no charge for this service.
For products purchased outside the United States and Canada, contact the distributor in
your country, or the Marine Power Service Center closest to you.

Warranty Registration United States And Canada

1. You may change your address at any time, including at time of warranty claim, by calling
Mercury Marine or sending a letter or fax with your name, old address, new address,
and engine serial number to Mercury Marine’s warranty registration department. Your
dealer can also process this change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax 920-929-5893
NOTE: Registration lists must be maintained by Mercury Marine and any dealer on marine
products sold in the United States, should a safety recall notification under the Federal
Safety Act be required.
2. To be eligible for warranty coverage, the product must be registered with Mercury
Marine. At the time of sale, the dealer should complete the warranty registration and
immediately submit it to Mercury Marine via MercNET, E-mail, or mail. Upon receipt of
this warranty registration, Mercury Marine will record the registration.
3. Upon processing the warranty registration, Mercury Marine will send registration
verification by mail to the purchaser of the product. If this registration verification is not
received within 30 days, please contact your selling dealer immediately. Warranty
coverage is not effective until your product is registered with Mercury Marine.

Warranty Registration Outside The United States And Canada

1. It is important that your selling dealer fills out the Warranty Registration Card completely
and mails it to the distributor or Marine Power Service Center responsible for
administering the warranty registration/claim program for your area.

Page 2 90-864841060 MAY 2006

 Warranty

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

Mercury, MerCruiser Limited Warranty United States, Canada and

Europe (Gasoline Fueled Products Only)
WHAT IS COVERED: Mercury Marine warrants its new products to be free of defects in
material and workmanship during the period described below.
DURATION OF COVERAGE: This Limited Warranty provides coverage for either two (2)
years from the date the product is first sold to a recreational use retail purchaser, or the
date on which the product is first put into service, whichever occurs first. Commercial users
of these products receive warranty coverage of either one (1) year from the date of first
retail sale, or the accumulation of 500 hours of operation, whichever occurs first.
Commercial use is defined as any work or employment related use of the product, or any
use of the product which generates income, for any part of the warranty period, even if the
product is only occasionally used for such purposes. The repair or replacement of parts,
or the performance of service under this warranty, does not extend the life of this warranty
beyond its original expiration date. Unexpired warranty coverage can be transferred from
one recreational use customer to a subsequent recreational use customer upon proper re–
registration of the product. Unexpired warrant coverage cannot be transferred either to or
from a commercial use customer.

90-864841060 MAY 2006 Page 3

Warranty

CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE:

Warranty coverage is available only to retail customers that purchase from a Dealer
authorized by Mercury Marine to distribute the product in the country in which the sale
occurred, and then only after the Mercury Marine specified pre–delivery inspection process
is completed and documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Routine maintenance outlined in the
Operation and Maintenance Manual must be timely performed in order to maintain warranty
coverage. Mercury Marine reserves the right to make future warranty coverage contingent
on proof of proper maintenance.
WHAT MERCURY WILL DO: Mercury’s sole and exclusive obligation under this warranty
is limited to, at our option, repairing a defective part, replacing such part or parts with new
or Mercury Marine certified remanufactured parts, or refunding the purchase price of the
Mercury product. Mercury reserves the right to improve or modify products from time to
time without assuming an obligation to modify products previously manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with
a reasonable opportunity to repair, and reasonable access to the product for warranty
service. Warranty claims shall be made by delivering the product for inspection to a Mercury
dealer authorized to service the product. If purchaser cannot deliver the product to such a
dealer, written notice must be given to Mercury. We will then arrange for the inspection and
any covered repair. Purchaser in that case shall pay for all related transportation charges
and/or travel time. If the service provided is not covered by this warranty, purchaser shall
pay for all related labor and material, and any other expenses associated with that service.
Purchaser shall not, unless requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be presented to the dealer at the
time warranty service is requested in order to obtain coverage.
WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance
items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal
use, use of a propeller or gear ratio that does not allow the engine to run in its recommended
RPM range (see the Operation and Maintenance Manual), operation of the product in a
manner inconsistent with the recommended operation/duty cycle section of the Operation
and Maintenance Manual, neglect, accident, submersion, improper installation (proper
installation specifications and techniques are set forth in the installation instructions for the
product), improper service, use of an accessory or part which damages the Mercury
Product and was not manufactured or sold by us, jet pump impellers and liners, operation
with fuels, oils or lubricants which are not suitable for use with the product (see the
Operation and Maintenance Manual), alteration or removal of parts, or water entering the
engine through the fuel intake, air intake or exhaust system, or damage to the product from
insufficient cooling water caused by blockage of the cooling system by a foreign body,
running the engine out of water, mounting the engine too high on the transom, or running
the boat with the engine trimmed out too far.. Use of the product for racing or other
competitive activity, or operating with a racing type lower unit, at any point, even by a prior
owner of the product, voids the warranty.
Expenses related to haul out, launch, towing, storage, telephone, rental, inconvenience,
slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other
type of incidental or consequential damages are not covered by this warranty. Also,
expenses associated with the removal and/or replacement of boat partitions or material
caused by boat design for access to the product are not covered by this warranty.
No individual or entity, including Mercury Marine authorized dealers, has been given
authority by Mercury Marine to make any affirmation, representation or warranty regarding
the product, other than those contained in this limited warranty, and if made, shall not be
enforceable against Mercury Marine.

Page 4 90-864841060 MAY 2006

 Warranty

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 Warranty (Confederation of Independent

States, Middle-East, and Africa
WHAT IS COVERED: Mercury Marine warrants its products to be free of defects in material
and workmanship during the period described below.
DURATION OF COVERAGE: This Limited Warranty provides coverage for either one (1)
year from the date the product is first sold to a recreational use retail purchaser, or the date
on which the product is first put into service, whichever occurs first. Commercial users of
these products receive warranty coverage for either one (1) year from the date of first retail
sale, or the accumulation of 500 hours of operation, whichever occurs first. Commercial
use is defined as any work or employment related use of the product, or any use of the
product which generates income, for any part of the warranty period, even if the product is
only occasionally used for such purposes. The repair or replacement of parts, or the
performance of service under this warranty, does not extend the life of this warranty beyond
its original expiration date. Unexpired warranty coverage can be transferred from one
recreational use customer to a subsequent recreational use customer upon proper
re-registration of the product. Unexpired warranty coverage cannot be transferred either
to or from a commercial use customer.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE:
Warranty coverage is available only to retail customers that purchase from a Dealer
authorized by Mercury Marine to distribute the product in the country in which the sale
occurred, and then only after the Mercury Marine specified pre–delivery inspection process
is completed and documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Routine maintenance outlined in the
Operation and Maintenance Manual must be timely performed in order to maintain warranty
coverage. Mercury Marine reserves the right to make warranty coverage contingent on
proof of proper maintenance.
WHAT MERCURY WILL DO: Mercury’s sole and exclusive obligation under this warranty
is limited to, at our option, repairing a defective part, replacing such part or parts with new
or Mercury Marine certified remanufactured parts, or refunding the purchase price of the
Mercury product. Mercury reserves the right to improve or modify products from time to
time without assuming an obligation to modify products previously manufactured.

90-864841060 MAY 2006 Page 5

Warranty

HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with
a reasonable opportunity to repair, and reasonable access to the product for warranty
service. Warranty claims shall be made by delivering the product for inspection to a Mercury
dealer authorized to service the product. If purchaser cannot deliver the product to such a
dealer, written notice must be given to Mercury. We will then arrange for the inspection and
any covered repair. Purchaser in that case shall pay for all related transportation charges
and/or travel time. If the service provided is not covered by this warranty, purchaser shall
pay for all related laborand material, and any other expenses associated with that service.
Purchaser shall not, unless requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be presented to the dealer at the
time warranty service is requested in order to obtain coverage.
WHAT IS NOT COVERED: This limited warranty does not cover routine maintenance
items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal
use, use of a propeller or gear ratio that does not allow the engine to run in its recommended
RPM range (see the Operation and Maintenance Manual), operation of the product in a
manner inconsistent with the recommended operation/duty cycle section of the Operation
and Maintenance Manual, neglect, accident, submersion, improper installation (proper
installation specifications and techniques are set forth in the installation instructions for the
product), improper service, use of an accessory or part not manufactured or sold by us, jet
pump impellers and liners, operation with fuels, oils or lubricants which are not suitable for
use with the product (see the Operation and Maintenance Manual), alteration or removal
of parts, or water entering the engine through the fuel intake, air intake or exhaust system,
or damage to the product from insufficient cooling water caused by blockage of the cooling
system by foreign body, running the engine out of water, mounting the engine too high on
the transom, or running the boat with the engine trimmed out too far.
Use of the product for racing or other competitive activity, or operating with a racing type
lower unit, at any point, even by a prior owner of the product, voids the warranty.
Expenses related to haul out, launch, towing, storage, telephone, rental, inconvenience,
slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other
type of incidental or consequential damages are not covered by this warranty. Also,
expenses associated with the removal and/or replacement of boat partitions or material
caused by boat design for access to the product are not covered by this warranty.
No individual or entity, including Mercury Marine authorized dealers, has been given
authority by Mercury Marine to make any affirmation, representation or warranty regarding
the product, other than those contained in this limited warranty, and if made, shall not be
enforceable against Mercury Marine.
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 Year Limited Warranty Against Corrosion (Worldwide)

WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury
Racing, Sport Jet, M2 Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard
or sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion
for the period of time described below.

Page 6 90-864841060 MAY 2006

 Warranty

DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three
(3) years from either the date the product is first sold, or the date on which the product is
first put into service, whichever occurs first. The repair or replacement of parts, or the
performance of service under this warranty does not extend the life of this warranty beyond
its original expiration date. Unexpired warranty coverage can be transferred to subsequent
(non-commercial use) purchaser upon proper re-registration of the product.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY
COVERAGE: Warranty coverage is available only to retail customers that purchase from
a Dealer authorized by Mercury Marine to distribute the product in the country in which the
sale occurred, and then only after the Mercury Marine specified pre-delivery inspection
process is completed and documented. Warranty coverage becomes available upon
proper registration of the product by the authorized dealer. Corrosion prevention devices
specified in the Operation and Maintenance Manual must be in use on the boat, and routine
maintenance outlined in the Operation and Maintenance Manual must be timely performed
(including without limitation the replacement of sacrificial anodes, use of specified
lubricants, and touch-up of nicks and scratches) in order to maintain warranty coverage.
Mercury Marine reserves the right to make warranty coverage contingent upon proof of
proper maintenance.
WHAT MERCURY WILL DO: Mercury's sole and exclusive obligation under this warranty
is limited to, at our option, repairing a corroded part, replacing such part or parts with new
or Mercury Marine certified re-manufactured parts, or refunding the purchase price of the
Mercury product. Mercury reserves the right to improve or modify products from time to
time without assuming an obligation to modify products previously manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury with
a reasonable opportunity to repair, and reasonable access to the product for warranty
service. Warranty claims shall be made by delivering the product for inspection to a Mercury
dealer authorized to service the product. If purchaser cannot deliver the product to such a
dealer, written notice must be given to Mercury. We will then arrange for the inspection and
any covered repair. Purchaser in that case shall pay for all related transportation charges
and/or travel time. If the service provided is not covered by this warranty, purchaser shall
pay for all related labor and material, and any other expenses associated with that service.
Purchaser shall not, unless requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be presented to the dealer at the
time warranty service is requested in order to obtain coverage.
WHAT IS NOT COVERED: This limited warranty does not cover electrical system
corrosion; corrosion resulting from damage, corrosion which causes purely cosmetic
damage, abuse or improper service; corrosion to accessories, instruments, steering
systems; corrosion to factory installed jet drive unit; damage due to marine growth; product
sold with less than a one year limited Product warranty; replacement parts (parts purchased
by customer); products used in a commercial application. Commercial use is defined as
any work or employment related use of the product, or any use of the product which
generates income, for any part of the warranty period, even if the product is only
occasionally used for such purposes.

Warranty Coverage And Exclusions

The purpose of this section is to help eliminate some of the more common
misunderstandings regarding warranty coverage. The following information explains some
of the types of services that are not covered by warranty. The provisions set forth following
have been incorporated by reference into the Three Year Limited Warranty Against
Corrosion Failure, the International Limited Outboard Warranty, and the United States and
Canada Limited Outboard Warranty.

90-864841060 MAY 2006 Page 7

Warranty

Keep in mind that warranty covers repairs that are needed within the warranty period
because of defects in material and workmanship. Installation errors, accidents, normal
wear, and a variety of other causes that affect the product are not covered.
Warranty is limited to defects in material or workmanship, but only when the consumer sale
is made in the country to which distribution is authorized by us.
Should you have any questions concerning warranty coverage, contact your authorized
dealer. They will be pleased to answer any questions that you may have.
General Exclusions From Warranty
1. Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs,
ignition components, carburetor settings, filters, belts, controls, and checking
lubrication made in connection with normal services.
2. Factory installed jet drive units - Specific parts excluded from the warranty are: The jet
drive impeller and jet drive liner damaged by impact or wear, and water damaged drive
shaft bearings as a result of improper maintenance.
3. Damage caused by neglect, lack of maintenance, accident, abnormal operation or
improper installation or service.
4. Haul out, launch, towing charges, removal and/or replacement of boat partitions or
material because of boat design for necessary access to the product, all related
transportation charges and/or travel time, etc. Reasonable access must be provided to
the product for warranty service. Customer must deliver product to an authorized
dealer.
5. Additional service work requested by customer other than that necessary to satisfy the
warranty obligation.
6. Labor performed by other than an authorized dealer may be covered only under
following circumstances: When performed on emergency basis (providing there are no
authorized dealers in the area who can perform the work required or have no facilities
to haul out, etc., and prior factory approval has been given to have the work performed
at this facility).
7. All incidental and/or consequential damages (storage charges, telephone or rental
charges of any type, inconvenience or loss of time or income) are the owner's
responsibility.
8. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.
9. Oils, lubricants or fluids changed as a matter of normal maintenance is customer's
responsibility unless loss or contamination of same is caused by product failure that
would be eligible for warranty consideration.
10. Participating in or preparing for racing or other competitive activity or operating with a
racing type lower unit.
11. Engine noise does not necessarily indicate a serious engine problem. If diagnosis
indicates a serious internal engine condition which could result in a failure, condition
responsible for noise should be corrected under the warranty.
12. Lower unit and/or propeller damage caused by striking a submerged object is
considered a marine hazard.
13. Water entering engine through the fuel intake, air intake or exhaust system or
submersion.
14. Failure of any parts caused by lack of cooling water, which results from starting motor
out of water, foreign material blocking inlet holes, motor being mounted too high or
trimmed too far out.

Page 8 90-864841060 MAY 2006

 Warranty

15. Use of fuels and lubricants which are not suitable for use with or on the product. Refer
to the Maintenance section.
16. Our limited warranty does not apply to any damage to our products caused by the
installation or use of parts and accessories which are not manufactured or sold by us.
Failures which are not related to the use of those parts or accessories are covered
under warranty if they otherwise meet the terms of the limited warranty for that product.

90-864841060 MAY 2006 Page 9

Warranty

Notes:

Page 10 90-864841060 MAY 2006

 Getting to Know Your Power Package

Section 2 - Getting to Know Your Power Package

Table of Contents
Lanyard Stop Switch........................................... 12 Console Mount Features- Dual Engine.........20 2
Instrumentation................................................... 13 Synchronizing Dual Engines.........................20
System View ................................................ 13 Dual Helm Station Transfer...........................21
Digital Gauges .............................................. 14 Synchronizing Dual Helms Prior To Station
Analog Gauges ............................................ 14 Transfer .................................................. 22
Remote Controls (Non-DTS Models).................. 15 Zero Effort Features......................................22
Remote Controls...........................................15 Electrical System Overload Protection............... 22
Panel Mount Features ............................ 15 Audio Warning System....................................... 24
Console Mount Features ........................ 16 Testing The Audio Warning System ............. 24
Zero Effort Features......................................16 Engine Guardian Strategy.................................. 24
Remote Controls (DTS Models).......................... 17 Transmission Guardian Strategy........................ 25
Remote Controls...........................................17 Warning Horn Signals......................................... 25
Panel Mount Features...................................17 Emissions Information........................................ 26
Console Mount Features - Single Engine.....18 Emission Control Information Label..............26
Slim Binnacle Console Mount Features - Single Owner Responsibility ............................. 27
Engine...........................................................19 Star Label......................................................27

90-864841060 MAY 2006 Page 11

Getting to Know Your Power Package

Lanyard Stop Switch

The purpose of a lanyard stop switch is to turn off the engine when the operator moves
outside the operator's position (as in accidental ejection from the operator's position).

RUN a
b

74608
a - Stop switch c - Clips to the operator
b - Lanyard

Accidental ejections, such as falling overboard, are more likely to occur in:
• low sided sport boats
• bass boats
• high performance boats
Accidental ejections can also occur from:
• poor operating practices
• sitting on the seat or gunwale at planing speeds
• standing at planing speeds
• operating at planing speeds in shallow or obstacle infested waters
• releasing your grip on the steering wheel that is pulling in one direction
• consuming alcohol or drugs
• high speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when
stretched out, with an element on one end made to be inserted into the switch and a snap
on the other end for attaching to the operator. The lanyard is coiled to make its at-rest
condition as short as possible to minimize the likelihood of lanyard entanglement with
nearby objects. Its stretched-out length is made to minimize the likelihood of accidental
activation should the operator choose to move around in an area close to the normal
operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the
operator's wrist or leg, or tie a knot in the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will
continue to coast for some distance depending upon the velocity and degree of any turn
at shut down. However, the boat will not complete a full circle. While the boat is coasting,
it can cause injury to anyone in the boat's path as seriously as the boat would when under
power.
We strongly recommend that other occupants be instructed on proper starting and
operating procedures should they be required to operate the engine in an emergency (e.g.
if the operator is accidentally ejected).

! WARNING
Avoid contact with the boat hull and propeller from accidental ejection. Personal injury or
death could occur. Always properly connect both ends of the lanyard stop switch.

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 Getting to Know Your Power Package

Accidental or unintended activation of the switch during normal operation is also a

possibility. This could cause any, or all, of the following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward motion, a
particular concern for passengers in the front of the boat who could be ejected over the
bow and possibly struck by the propulsion or steering components.
• Loss of power and directional control in heavy seas, strong current or high winds.
• Loss of control when docking.

! WARNING
Avoid abrupt deceleration of the boat from lanyard stop switch activation. Boat damage
and personal injury or death could occur. Never leave the operator's station with the
engine operating and in gear.

Instrumentation
System View

Smart Craft SELECT

System View

HOME

5650

Your power package may be connected to the Mercury SC5000 SmartCraft System View
display. The display monitors and reports information ranging from basic operating data to
engine alarm data.
The SC5000 System View Display is a comprehensive boat information center. System
View allows the boat operator to receive a wealth of critical operational information,
displayed clearly and instantly at the helm on the LCD display. The System View
continuously monitors and reports information ranging from basic operating data to detailed
vessel environment information. System View displays water temperature and depth,
engine trim status, boat speed, steering angle, system preventive maintenance reminders
and systems diagnostics. System View also can be fully integrated with the boat's GPS, if
equipped, to provide up to the minute location, course, speed, and fuel-to-destination
information.
When a problem is detected with the engine or system, the System View will alert the
operator to the potential problem by displaying the alarm message in the information
window, located at the bottom of the view screen.
If the problem can cause immediate engine damage, the Engine Guardian System will
respond to the problem by limiting engine power. Immediately reduce throttle speed to idle.
Refer to the System View Operation Manual for further explanation of the problem and the
correct action to take.

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Getting to Know Your Power Package

Digital Gauges
A Mercury SmartCraft System instrument package can be purchased for this product. A
few of the functions the instrument package will display are engine RPM, coolant
temperature, oil pressure, battery voltage, fuel consumption and engine operating hours.
The SmartCraft Instrument package will also aid in Engine Guardian diagnostics. The
SmartCraft Instrument package will display critical engine alarm data and potential
problems.
Refer to the manual with your gauge package for the warning functions monitored and
basic operation of the SmartCraft Instrument package.
Analog Gauges
The following is a brief explanation of the instrumentation typically found on some boats.
The owner/operator should be familiar with all instruments and their functions. Because of
the large variety of instrumentation and manufacturers, you should have your boat dealer
explain the particular gauges and normal readings for your boat.

50 60 4
3 5
90
80 100
40 70 110 70 2 6
60
50 120 C H
30 40
L H 10 16
30 1 7
KPH
20
80 X 1000
10 0 8 BATT TEMP
MPH RPM OIL

a b c d e

0
4
4
4
0 0 0 0 0
CRUISELOG
FUEL

f g h i 17352

a- Speedometer f- Fuel gauge

b- Tachometer g- Hour meter
c- Oil pressure gauge h- Bilge blower switch
d- Voltmeter i- Ignition switch
e- Water temperature gauge

Speedometer: Indicates boat speed.

Tachometer: Indicates engine RPM.
Oil Pressure Gauge: Indicates engine oil pressure.
Voltmeter: Indicates battery voltage.
Water Temperature Gauge: Indicates engine operating temperature.
Fuel Gauge: Indicates quantity of fuel in tank.
Hour meter: Records engine operating time.
Bilge Blower Switch: Operates bilge blower.
Ignition Switch: Allows operator to start and stop engine.

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 Getting to Know Your Power Package

Remote Controls (Non-DTS Models)

Remote Controls
Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls.
All controls may not have all features shown. Consult your dealer for a description and/or
demonstration of your remote control.
PANEL MOUNT FEATURES
a
e

c
d

17355

a - Neutral lock button d - Control handle tension adjustment

b - Throttle only button screw
c - Lanyard stop switch e - Control handle

Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock
button must be pushed in to move the control handle out of neutral.
Throttle Only Button - Allows engine throttle advancement without shifting the engine.
This is done by disengaging the shift mechanism from the control handle. The throttle only
button can be depressed only when the remote control handle is in the neutral position,
and should only be used to assist in starting the engine.
Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the
lanyard) moves far enough away from the operator's position to activate the switch. Refer
to Lanyard Stop Switch for information on the use of this switch.
Control Handle - Operation of the shift and throttle are controlled by the movement of the
control handle. Push the control handle forward from neutral with a quick firm motion to the
first detent for forward gear. Continue pushing forward to increase speed. Pull the control
handle back from neutral with a quick firm motion to the first detent for reverse gear and
continue pushing back to increase speed.
Control Handle Tension Adjustment Screw - (not visible) This screw is used to adjust
the effort required to move the remote control handle. Refer to instructions provided with
remote control for complete adjustment instructions.

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Getting to Know Your Power Package

CONSOLE MOUNT FEATURES

b
b
17356
a - Throttle Only Button b - Control Handle

Throttle Only Button - Allows engine throttle advancement without shifting the engine.
This is done by disengaging the shift mechanism from the control handle. The throttle only
button can be depressed only when the remote control handle is in the neutral position.
Control Handles - Operation of the the shift and throttle are controlled by the movement
of the control handle. Push the control handle forward from neutral with a quick firm motion
to the first detent for forward gear and continue pushing forward to increase speed. Pull
the control handle back from neutral with a quick firm motion to the first detent for reverse
gear and continue pushing back to increase speed.
Control Handle Tension Adjustment Screw - (not visible) This screw is used to adjust
the effort required to move the remote control handle. Refer to instructions provided with
remote control for complete adjustment instructions.
Zero Effort Features

a b

17357

a - Shift ever b - Throttle lever

Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into
reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift
lever to its center position. Shift into forward by moving the shift lever to its forward position.

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 Getting to Know Your Power Package

Throttle Lever - Throttle functions are controlled by the movement of the throttle lever.
Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT)
by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle
lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.

Remote Controls (DTS Models)

Remote Controls
IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote
control. Start in gear protection is provided by this control system and prevents the engine
from starting when the control is actuated in forward or reverse. Refer to the Mercury
Precision Parts/Quicksilver Accessories Guide.
The Digital Throttle and Shift System (DTS) required to operate this engine package
provides start and stop functions, throttle control, shift control, start in gear protection, and
emergency lanyard stop functions. The DTS system works with specialized helm
components such as a command module kit and electronic remote control. Consult your
dealer for a description and/or demonstration of your remote control.
Panel Mount Features

c
d - +
b e
f

a 17358

a- Lanyard stop switch

b- Control handle
c- Shift lock
d- Trim/tilt switch
e- Throttle only button
f- Start/stop button
g- Detent tension adjustment screw
h- Control handle friction adjustment screw

Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the
lanyard) moves far enough away from the operator's position to activate the switch. Refer
to Lanyard Stop Switch for information on the use of this switch.
Control Handle - Operation of the shift and throttle are controlled by the movement of the
control handle. Push the control handle forward from neutral with a quick, firm motion to
the first detent for forward gear. Continue pushing forward to increase speed. Pull the
control handle back from neutral with a quick, firm motion to the first detent for reverse gear
and continue pushing back to increase speed.
Shift Lock - Pressing the shift lock allows the engine to shift. The shift lock must always
be pressed when moving the control handle out of the neutral position.

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Getting to Know Your Power Package

Throttle Only Button - Allows engine throttle advancement without shifting the engine.
The throttle only button can be depressed only when the remote control is in the neutral
position, and should only be used to assist in starting or warming up the engine.
Start/Stop Button - Allows the boat operator to start or stop the engine without using the
ignition key.
Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease
the effort required to move the control handle out of the detent positions (cover must be
removed). Turning the screw clockwise will increase tension.
Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or
decrease the tension on the control handle (cover must be removed). This will help prevent
unwanted motion of the handle in rough water. Turn the screw clockwise to increase
tension and counterclockwise to decrease tension.
Console Mount Features - Single Engine

a c - +

d
g

h
e
b 17359
f
a- Control handle
b- Active light
c- Neutral light
d- Select key
e- Arrow trackpad
f- Throttle only/station select key
g- Detent tension adjustment
h- Control handle friction adjustment screw

Control Handle - Operation of the shift and throttle are controlled by the movement of the
control handle. Push the control handle forward from neutral with a quick, firm motion to
the first detent for forward gear. Continue pushing forward to increase speed. Pull the
control handle back from neutral with a quick, firm motion to the first detent for reverse gear
and continue pushing back to increase speed.
Active Light - The active light is illuminated to show the remote control is active and ready
for use.
Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.
Select Key - Selects System View on-screen options and confirms data entries.
Arrow Trackpad - Navigates through System View on-screen function messages.
Throttle Only/Station Select Key - Allows engine throttle advancement without shifting
the engine. The throttle only/station select button also allows the boat operator to select
which remote control is in control of the engine operation when operating with multiple
helms. Refer to Dual Helm Station Transfer.

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 Getting to Know Your Power Package

Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease
the effort required to move the control handle out of the detent positions (cover must be
removed). Turning the screw clockwise will increase tension.
Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or
decrease the tension on the control handle (cover must be removed). This will help prevent
unwanted motion of the handle in rough water. Turn the screw clockwise to increase
tension and counterclockwise to decrease tension.
Slim Binnacle Console Mount Features - Single Engine

a
c +
d
f

START
STOP

g
b e 17360
a- Control handle
b- Active light
c- Neutral light
d- Start/stop button
e- Throttle only/station select key
f- Detent tension adjustment
g- Control handle friction adjustment screw

Control Handle - Operation of the shift and throttle are controlled by the movement of the
control handle. Push the control handle forward from neutral with a quick, firm motion to
the first detent for forward gear. Continue pushing forward to increase speed. Pull the
control handle back from neutral with a quick, firm motion to the first detent for reverse gear
and continue pushing back to increase speed.
Active Light - The active light is illuminated to show the remote control is active and ready
for use.
Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.
Start/Stop Button - Allows the boat operator to start or stop the engine without using the
ignition key.
Throttle Only/Station Select Key - Allows engine throttle advancement without shifting
the engine. The throttle only/station select button also allows the boat operator to select
which remote control is in control of the engine operation when operating with multiple
helms. Refer to Dual Helm Station Transfer.
Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease
the effort required to move the control handle out of the detent positions (cover must be
removed). Turning the screw clockwise will increase tension.
Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or
decrease the tension on the control handle (cover must be removed). This will help prevent
unwanted motion of the handle in rough water. Turn the screw clockwise to increase
tension and counterclockwise to decrease tension.

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Getting to Know Your Power Package

Console Mount Features- Dual Engine

a

c - +

d h

i
ACTIVE
THROTTLE
ONLY
SYNC
e
STATION SELECT

b f
g 17365

a- Control handles f- Sync light

b- Active light g- Throttle only/station select key
c- Neutral light h- Detent tension adjustment
d- Select key i- Control handle friction adjustment
e- Arrow trackpad screw

Control Handle - Operation of the shift and throttle are controlled by the movement of the
control handle. Push the control handle forward from neutral with a quick, firm motion to
the first detent for forward gear. Continue pushing forward to increase speed. Pull the
control handle back from neutral with a quick, firm motion to the first detent for reverse gear
and continue pushing back to increase speed.
Active Light - The active light is illuminated to show the remote control is active and ready
for use.
Neutral Light - The neutral light is illuminated when the engine is in neutral gear position.
Select Key - Selects System View on-screen options and confirms data entries.
Arrow Trackpad - Navigates through System View on-screen function messages.
Sync Light - The sync light is illuminated when the RPM of the two engines are being
synchronized by the DTS system.
Throttle Only/Station Select Key - Allows engine throttle advancement without shifting
the engine. The throttle only/station select button also allows the boat operator to select
which remote control is in control of the engine operation when operating with multiple
helms. Refer to Dual Helm Station Transfer.
Detent Tension Adjustment Screw - This screw can be adjusted to increase or decrease
the effort required to move the control handle out of the detent positions (cover must be
removed). Turning the screw clockwise will increase tension.
Control Handle Friction Adjustment Screw - This screw can be adjusted to increase or
decrease the tension on the control handle (cover must be removed). This will help prevent
unwanted motion of the handle in rough water. Turn the screw clockwise to increase
tension and counterclockwise to decrease tension.
Synchronizing Dual Engines
The auto synchronizing feature, when engaged, will automatically adjust the port engine
speed to match the speed of the starboard engine.
Synchronizing of engines will automatically engage when the speed of both engines are
over 900 RPM for two seconds and remote control handles are positioned within 5° of each
other.

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 Getting to Know Your Power Package

Auto Synchronizing will stay engaged up to 95% throttle opening. The Sync light will turn
on when the engines are synchronized.

ACTIVE SYNC
THROTTLE
ONLY
STATION SELECT

3434

To disengage, move one or both control handles until they are more than 5° apart, reduce
engine speed below 900 RPM, or increase engine speed beyond 95%.
Dual Helm Station Transfer
The throttle only/station select button allows the boat operator to select which remote
control is in control of the engine operation.
The active light is illuminated at the remote control station that is in control of the engine.

! WARNING
Avoid serious injury or death from loss of boat control. The boat operator should never
leave the active station while engine is in gear. Helm transfer should only be attempted
while both stations are manned. One person helm transfer should only be performed
while engine is in neutral.

NOTE: Idle position is preferred when doing a station transfer. If conditions do not allow
the remote control to be placed at idle position, a station transfer can be done while in gear.
NOTE: Pressing and releasing station select button at new station allows the engine control
to be transferred to the new station. The control will automatically start adjusting engine
RPM and gear position to match the control handle setting at the new station. Adjust control
handles to the desired throttle and gear position.
1. Place active remote control lever to idle position.
2. Proceed to the inactive helm station and position remote control lever to the idle
position.
3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to
indicate the remote control station is in control of the engine.

b b
ACTIVE SYNC
ACTIVE THROTTLE
THROTTLE ONLY
ONLY STATION SELECT
STATION SELECT

a 3433
a
a - Active light b - Throttle only/station select button

4. The active light will switch off at the original remote control station.

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Getting to Know Your Power Package

SYNCHRONIZING DUAL HELMS PRIOR TO STATION TRANSFER

Pressing the station select button and holding it in allows the boat operator 10 seconds to
match up the control handle settings at the new station with the handle settings that are at
the old (to be inactive) station. If the handles are not matched, the neutral light will flash.
The light blinks faster as the handles are nearing match position. Once the light stays on
continuously, the handles are matched and the button can be released. Transfer process
is complete and the new station is now in control. If the button is held for over 10 seconds,
the station transfer is cancelled.
Zero Effort Features

a b

17357

a - Shift ever b - Throttle lever

Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into
reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift
lever to its center position. Shift into forward by moving the shift lever to its forward position.
Throttle Lever - Throttle functions are controlled by the movement of the throttle lever.
Increase the RPM by moving the throttle lever forward. Achieve Wide Open Throttle (WOT)
by placing the throttle lever in its full forward position. Decrease RPM by moving the throttle
lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.

Electrical System Overload Protection

If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. Find
and correct the cause before replacing the fuse or resetting the circuit breaker.
NOTE: In an emergency, when the engine must be operated and the cause for the
high-current draw cannot be located and corrected, turn off or disconnect all accessories
connected to the engine and instrumentation wiring. Reset the circuit breaker. If the breaker
remains open, the electrical overload has not been eliminated. Further checks must be
made on the electrical system. Contact your authorized dealer.

Page 22 90-864841060 MAY 2006

 Getting to Know Your Power Package

1. A circuit breaker protects the engine wiring harness and the instrumentation power
lead. Test the circuit breaker by pushing the red button. If the circuit breaker is
functioning properly, the yellow lever will appear. Reset after testing, or if tripped, by
pushing the yellow lever back into the housing.

22529

Yellow lever style circuit breaker-typical

a - Yellow lever-shown tripped b - Red test button

2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse protects
the engine wiring harness if an electrical overload occurs.

mc74907-1

3. Four fuses are located on the port side of the engine. These fuses protect the main
power, fuel pump, ignition, and accessory circuits.

10715

90-864841060 MAY 2006 Page 23

Getting to Know Your Power Package

4. A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the
electrical system. Check for blown fuse if the ignition key is turned to the "START"
position and nothing happens (and circuit breaker is not tripped).

mc70525-1

Audio Warning System

Your Mercury MerCruiser power package may be equipped with an Audio Warning System.
The Audio Warning System will not protect the engine from damage. It is designed to warn
the operator that a problem has occurred.
The audio warning system will sound with a continuous horn if one of the following occurs:
• Engine oil pressure too low
• Engine temperature too hot
• Seawater pressure too low
The audio warning system will sound with an intermittent beeping if the following occurs:
• Transmission fluid temperature too hot
• Transmission pressure too low

! CAUTION
Operation of the engine after the audio warning system alarm has sounded could result
in damage to the power package. When the alarm has sounded, do not operate engine
except to avoid a hazardous situation.

If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if
possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser
dealer.
Testing The Audio Warning System
1. Turn the ignition switch to the "ON" position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.

Engine Guardian Strategy

IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle.
Engine Guardian Strategy is designed to help reduce the potential for engine damage by
reducing engine power when a potential problem is sensed by the ECM. Engine Guardian
monitors:
• Oil pressure
• Coolant temperature
• Seawater pressure

Page 24 90-864841060 MAY 2006

 Getting to Know Your Power Package

• Engine overspeed
• Exhaust Manifold Temperature [8.1 liter (496 cid) engines only]
Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if
any sensor on the power package fails.
For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will
reduce the available power level of the engine to help prevent damage from decreased
water flow to the engine. If the debris passes through and full water flow is restored, engine
power levels are restored to normal.
To avoid a possible recurrence of the problem you should contact an authorized dealer.
The ECM stores the fault and with this information the technician will be able to more rapidly
diagnose problems.

Transmission Guardian Strategy

IMPORTANT: Boat speed could be reduced to idle and may not respond to the throttle.
Transmission Guardian is a MerCruiser DTS feature that protects transmissions from
clutch damage. Transmission Guardian monitors the clutch pack pressure in forward and
reverse gears. If the transmission fluid pressure drops below a predetermined level,
Transmission Guardian lowers the engine torque and speed to prevent clutch slippage.
To avoid possible recurrence of the problem, you should contact an authorized dealer. The
ECM stores the fault and with this information the technician will be able to more rapidly
diagnose problems.

Warning Horn Signals

Most faults will cause the warning horn circuit to activate. How the warning horn activates
depends on how serious the problem is. There are four warning horn states:
• Caution - horn signal varies with product line and calibration. Minimal guardian.
• Warning - horn signal varies with product line and calibration.
• Severe - horn is beeping constantly.
• Critical - horn is beeping constantly and guardian will be at forced idle.
In addition, depending on the gauge package, there will be warning icons and fault
messages on the dash mounted gauges.

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Getting to Know Your Power Package

Emissions Information
Emission Control Information Label
A tamper-resistant Emission Control Information label is affixed in a visible location to the
engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions
statement, the label lists the engine serial number, family, FEL (emission level), date of
manufacture (month, year), and the engine displacement. Please note that the low
emissions certification will not affect the fit, function, or performance of the engines.
Boatbuilders and dealers may not remove the label or the part it is affixed to before sale.
If modifications are necessary, contact Mercury MerCruiser about the availability of
replacement decals 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. 2003
FAMILY XXXXX_XXXXXX
DISP X.XL
FEL. XX.X g/kW-hr
11018

Emission Control Label - Non CE Marked

"SERIAL#" - Engine Serial Number
"FAMILY" - Engine Family
"FEL." - Family Emission Limit
"D.O.M." - Date of Manufacture
"DISP" - Piston Displacement
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 0575
10652

Emission Control Label - CE Marked

"SERIAL#" - Engine Serial Number
"FAMILY" - Engine Family
"FEL." - Family Emission Limit
"D.O.M." - Date of Manufacture
"DISP" - Piston Displacement

Page 26 90-864841060 MAY 2006

 Getting to Know Your Power Package

CE - When this mark is present in the lower right corner of the Emission Control Information
Label, on the engine, the Declaration of Conformance applies. Refer to the front page of
this Manual for further information.
OWNER RESPONSIBILITY
The owner/operator is required to have routine engine maintenance performed to maintain
emission levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the
horsepower or allow emissions levels to exceed their predetermined factory specifications.
Star Label
Beginning January 1, 2003, one Three-Star label will be included with each factory-certified
Mercury MerCruiser engine.
All Mercury MerCruiser engines (500 hp and below) will have a Three-Star Ultra Low
Emission rating. The Three-Star label identifies that these engines meet the California Air
Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission
standards. Engines meeting these standards have 65% lower emissions than One-Star -
Low Emissions engines.
The Three-Star label will be affixed on the left side of the hull as shown.

XX 1234 XX
a b
mc79531

a - Recommended location b - Secondary location

90-864841060 MAY 2006 Page 27

Getting to Know Your Power Package

One Star - Low emission

The one-star label identifies personal watercraft, outboard,
sterndrive and inboard engines that meet the Air Resources
Board's Personal Watercraft and Outboard marine engine
2001 exhaust emission standards. Engines meeting these
standards have 75% lower emissions than conventional
carbureted two-stroke engines. These engines are
mc79569-1
equivalent to the U.S. EPA's 2006 standards for marine
engines.
Two Stars - Very Low emission

FO
IDA
The two-star label identifies personal watercraft, outboard,
sterndrive and inboard engines that meet the Air Resources
Board's Personal Watercraft and Outboard marine engine
2004 exhaust emission standards. Engines meeting these
standards have 20% lower emissions than One Star -
Low-Emission engines.
mc79570-1

Three Stars - Ultra Low emission

The three-star label identifies engines that meet the Air

A
SS
D
Resources Board's Personal Watercraft and Outboard
marine engine 2008 exhaust emission standards or the
Sterndrive and Inboard marine engine 2003 exhaust
emission standards. Engines meeting these standards
have 65% lower emissions than One Star - Low Emission
mc79571-1 engines.

Four Stars - Super Ultra Low emission

T
The Four Star label identifies engines that meet the Air
RN
F
Resources Board's Sterndrive and Inboard marine engine
2009 exhaust emission standards. Personal Watercraft and
Outboard marine engines may also comply with these
standards. Engines meeting these standards have 90%
lower emissions than One Star - Low Emission engines.
mc79572-1

Page 28 90-864841060 MAY 2006

 On The Water

Section 3 - On The Water

Table of Contents
Safe Boating Suggestions.................................. 30 While You Are Cruising ................................ 38
Be Alert To Carbon Monoxide Poisoning........... 31 While Boat Is Stationary ............................... 38
Good Ventilation ........................................... 32 High-Speed And High-Performance Boat Operation
Poor Ventilation ........................................... 32
Basic Boat Operation (Non-DTS Models)........... 32
............................................................................ 38
Passenger Safety In Pontoon Boats And Deck 3
Launching and Boat Operation.....................32 Boats................................................................... 39
Operation Chart ...................................... 33 Boats Having An Open Front Deck .............. 39
Starting and Stopping the Engine.................33 Boats With Front-Mounted, Raised Pedestal
Starting the Engine ................................. 33 Fishing Seats ............................................... 39
Stopping the Engine ............................... 34 Wave And Wake Jumping.................................. 40
Throttle Only Operation.................................34 Impact With Underwater Hazards....................... 40
Freezing Temperature Operation..................34 Conditions Affecting Operation........................... 41
Drain Plug and Bilge Pump...........................34 Weight Distribution (Passengers and Gear)
Basic Boat Operation (DTS Models)................... 34 Inside the Boat..............................................41
Launching and Boat Operation.....................34 Bottom Of Boat..............................................41
Operation Chart ...................................... 35 Cavitation......................................................41
Starting and Stopping the Engine.................35 Ventilation.....................................................42
Starting the Engine ................................. 35 Elevation And Climate...................................42
Stopping the Engine ............................... 36 Getting Started.................................................... 42
Throttle Only Operation.................................37 20-Hour Break-In Period...............................42
Freezing Temperature Operation..................37 After Break-In Period.....................................42
Drain Plug and Bilge Pump...........................38 End of First Season Checkup.......................43
Protecting People In The Water.......................... 38

90-864841060 MAY 2006 Page 29

On The Water

Safe Boating Suggestions

In order to safely enjoy the waterways, familiarize yourself with local and all other
governmental boating regulations and restrictions, and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
• Mercury MerCruiser strongly recommends that all powerboat operators complete a
boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard
Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating
law enforcement agency. Inquiries may be made to the Boating Hotline at
1-800-368-5647 or the Boat U.S. Foundation at 1-800-336-BOAT.
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment on board.
• Here are some suggestions of the types of safety equipment to carry when boating:
• Approved fire extinguishers
• Signal devices: flashlight, rockets or flares, flag and whistle or horn
• Tools necessary for minor repairs
• Anchor and extra anchor line
• Manual bilge pump and extra drain plugs
• Drinking water
• Transistor radio
• Paddle or oar
• Spare propeller, thrust hubs, and an appropriate wrench
• First aid kit and instructions
• Water-proof storage containers
• Spare operating equipment, batteries, bulbs and fuses
• Compass and map or chart of the area
• Personal flotation device (1 per person on board)
Watch for signs of weather change and avoid foul weather and rough-sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading or are near the back
(stern) of the boat. Shifting the drive unit into neutral is not sufficient.
Use personal flotation devices.
• Federal Law requires that there be a U. S. Coast Guard approved life jacket (personal
flotation device), correctly sized and readily accessible for every person on board, plus
a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all
times while in the boat.
Prepare other boat operators.
• Instruct at least 1 person on board in the basics of starting and operating the engine
and boat handling in case the driver becomes disabled or falls overboard.
Do not overload your boat.

Page 30 90-864841060 MAY 2006

 On The Water

• Most boats are rated and certified for maximum load (weight) capacities (refer to your
boat capacity plate). Know your boat's operating and loading limitations. Know if your
boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser
dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
• Do not allow anyone to sit or ride on any part of the boat that was not intended for such
use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing
seats and any rotating fishing seat; anywhere that sudden unexpected acceleration,
sudden stopping, unexpected loss of boat control or sudden boat movement could
cause a person to be thrown overboard or into the boat. Ensure that all passengers
have a proper seat and are in it before any boat movement.
Never be under the influence of alcohol or drugs while boating (it is the law).
• They impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
Be alert.
• The operator of the boat is responsible by law to maintain a proper lookout by sight and
hearing. The operator must have an unobstructed view particularly to the front. No
passengers, load or fishing seats should block the operators view when the boat is
above idle or planing transition speed. Watch out for others, the water and your wake.
Never drive your boat directly behind a water skier in case the skier falls.
• As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier who
was 61 m (200 ft.) in front of you in 5 seconds.
Watch fallen skiers.
• When using your boat for water skiing or similar activities, always keep a fallen or down
skier on the operator's side of the boat while returning to attend to the skier. The
operator should always have the down skier in sight and never back up to the skier or
anyone in the water.
Report accidents.
• Boat operators are required by law to file a Boating Accident Report with their state
boating law enforcement agency when their boat is involved in certain boating
accidents. A boating accident must be reported if 1) there is loss of life or probable loss
of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there
is damage to boats or other property where the damage value exceeds $500.00 or 4)
there is complete loss of the boat. Seek further assistance from local law enforcement.

Be Alert To Carbon Monoxide Poisoning

Carbon monoxide is present in the exhaust fumes of all internal combustion engines
including the outboards, sterndrives and inboard engines that propel boats, as well as the
generators that power various boat accessories. Carbon monoxide is a deadly gas that is
odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning, which should not be confused with
seasickness or intoxication, include headache, dizziness, drowsiness and nausea.

! WARNING
Avoid prolonged exposure to carbon monoxide. Carbon monoxide poisoning can lead to
unconsciousness, brain damage or death. Ensure that the boat, while at rest or
underway, is well ventilated.

90-864841060 MAY 2006 Page 31

On The Water

Good Ventilation
Ventilate the passenger area, open the side curtains or forward hatches to remove fumes.
1. Example of desired air flow through the boat.

mc79553-1

Poor Ventilation
Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with
insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide
detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open
area of a stationary boat that contains or is near an operating engine may be exposed to
a hazardous level of carbon monoxide.
1. Examples of poor ventilation while a boat is stationary:

a b mc79554-1

a - Operating the engine when the b - Mooring close to another boat with
boat is moored in a confined space its engine operating

2. Examples of poor ventilation while a boat is moving:

mc79556-1
a b
a - Operating the boat with the trim b - Operating the boat with no forward
angle of the bow too high hatches open (station wagon effect)

Basic Boat Operation (Non-DTS Models)

Launching and Boat Operation
IMPORTANT: Install bilge drain plug prior to launching boat.

! CAUTION
To avoid possible ingestion of water that can damage engine components, do not turn
the ignition key off when the engine is above idle speed. When launching your boat from
a steep ramp, enter the water slowly. Do not use the lanyard stop switch to shut off the
engine above idle speed. When coming off plane, if a large following wave may roll over
the boat's transom, apply a short, light burst of throttle to minimize the wave action against
the stern of the boat. Do not come off plane quickly and then shut off the engine. Also
avoid shifting into reverse while on plane.

Page 32 90-864841060 MAY 2006

 On The Water

OPERATION CHART
Operation Chart
BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING
Observe all gauges to
Observe all gauges to
check condition of Turn ignition key to the
Install bilge drain plug. check condition of engine. If
engine. If not normal, stop "OFF" position.
not normal, stop engine.
engine.
Check for fuel, oil, water, Turn battery switch to the
Open engine hatch. Listen for the audio alarm.
fluid and exhaust leaks. "OFF" position.
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Close seacock, if
Operate bilge blowers. Check steering operation.
equipped.
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if
Drain bilge.
equipped.
Close the drain system.
Check the engine oil.
Perform all other checks
specified by your dealer
and/or boat builder.
Listen for Audio Warning
Alarm to sound when the
ignition switch is in the
"ON" position.

Starting and Stopping the Engine

NOTE: Only perform those functions applicable to your power package.
STARTING THE ENGINE
1. Check all items listed in the Operation Chart.
2. Place the remote control handle in neutral.

! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage.
Ensure that there is sufficient water always available at water inlet holes during operation.

! WARNING
Explosive gasoline fumes collect in the engine compartment. Avoid injury or property
damage, operate the bilge blower for at least 5 minutes prior to starting the engine. If the
boat is not equipped with a bilge blower, open the engine hatch and leave it open while
starting the engine.
3. Turn ignition key to "START". Release key when engine starts and allow switch to return
to "ON" position. Allow engine to warm up (6-10 minutes on first start of the day).
4. If engine does not start after 3 attempts:
a. Push the throttle only button and position the remote control handle/throttle lever
to the 1/4 throttle position.
b. Turn ignition key to "START". Release key when engine starts and allow switch
to return to "ON" position.

90-864841060 MAY 2006 Page 33

On The Water

5. If engine does not start after step 4:

a. Move the remote control handle/throttle lever to full throttle position, then return
to 1/4 throttle.
b. Turn ignition key to "START". Release key when engine starts and allow switch
to return to "ON" position.
6. Inspect the power package for fuel, oil, water and exhaust leaks.
7. Move control handle with a firm, quick motion forward to shift to forward gear, or
backward to shift to reverse. After shifting, advance throttle to desired setting.

! CAUTION
Avoid damage to the drive system. Shifting the drive system at RPMs greater than engine
idle speed may cause internal damage to the drive system. Shift the drive system only
when the engine is at idle RPM.
STOPPING THE ENGINE
1. Move the remote control handle to neutral/idle and allow the engine to slow to idle
speed. If engine has been operated at high speed for a long period of time, allow the
engine to cool at idle speed for 3 to 5 minutes.
2. Turn ignition key to the "OFF" position.
Throttle Only Operation
1. Refer to Remote Controls section for remote control features.
2. Move the control lever to the idle/neutral position.
3. Depress and hold the throttle only button, and move the control lever to the idle/forward
or idle/reverse position.
4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause
engine speed to increase.
IMPORTANT: Moving the control lever back to the idle/neutral position will disengage the
throttle only button and allow the engine to shift into gear.
5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position.
Moving the control lever from the idle/neutral position to the idle/forward or idle/reverse
position without pressing the throttle only button will shift the unit into the chosen gear.
Freezing Temperature Operation
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions
must be taken to prevent freeze damage to the power package. Damage caused by
freezing is not covered by Mercury MerCruiser Limited Warranty.
Drain Plug and Bilge Pump
The engine compartment in your boat is a natural place for water to collect. For this reason,
boats are normally equipped with a drain plug and/or a bilge pump. It is very important to
check these items on a regular basis to ensure that the water level does not come into
contact with your power package. Components on your engine will be damaged if
submerged. Damage caused by submersion is not covered by the Mercury MerCruiser
Limited Warranty.

Basic Boat Operation (DTS Models)

Launching and Boat Operation
IMPORTANT: Install bilge drain plug prior to launching boat.

Page 34 90-864841060 MAY 2006

 On The Water

! CAUTION
To avoid possible ingestion of water that can damage engine components, do not turn
the ignition key off when the engine is above idle speed. When launching your boat from
a steep ramp, enter the water slowly. Do not use the lanyard stop switch to shut off the
engine above idle speed. When coming off plane, if a large following wave may roll over
the boat's transom, apply a short, light burst of throttle to minimize the wave action against
the stern of the boat. Do not come off plane quickly and then shut off the engine. Also
avoid shifting into reverse while on plane.

OPERATION CHART
Operation Chart
BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING
Observe all gauges to
Observe all gauges to
check condition of Turn ignition key to the
Install bilge drain plug. check condition of engine. If
engine. If not normal, stop "OFF" position.
not normal, stop engine.
engine.
Check for fuel, oil, water, Turn battery switch to the
Open engine hatch. Listen for the audio alarm.
fluid and exhaust leaks. "OFF" position.
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Close seacock, if
Operate bilge blowers. Check steering operation.
equipped.
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if
Drain bilge.
equipped.
Close the drain system.
Check the engine oil.
Perform all other checks
specified by your dealer
and/or boat builder.
Listen for Audio Warning
Alarm to sound when the
ignition switch is in the
"ON" position.

Starting and Stopping the Engine

NOTE: Perform only those functions applicable to your power package.
STARTING THE ENGINE
1. Check all items listed in the Operation Chart.
2. Place the remote control handle in neutral.

! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage.
Ensure that there is sufficient water always available at water inlet holes during operation.

90-864841060 MAY 2006 Page 35

On The Water

! WARNING
Explosive gasoline fumes collect in the engine compartment. Avoid injury or property
damage, operate the bilge blower for at least 5 minutes prior to starting the engine. If the
boat is not equipped with a bilge blower, open the engine hatch and leave it open while
starting the engine.

NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature
incorporates push button starting. Rather than holding the start button or key switch to start
the engine and then releasing it when the engine starts, SmartStart completely controls
the starting process. When the start button is pushed, the DTS system signals the engine
PCM to start the engine. If the engine does not start, the starting process times out after a
few seconds or when the engine reaches 400 RPM. Attempting to start the engine with the
engine already running will turn the engine off.
3. Turn ignition key to "RUN" position.
4. Turn the ignition key switch to the "START" position then release, or depress the start/
stop button and release. If the engine is cold, allow the engine to operate at idle for
6-10 minutes or until the engine temperature reaches 60 °C (140 °F).
5. If the engine does not start after three attempts:
a. Push the throttle-only button and position the remote control handle or throttle
lever to the 1/4 throttle position.
b. Turn the ignition key to "start." Release key when the engine starts and allow the
switch to return to the "on" position.
6. If the engine does not start after step 5:
a. Move the remote control handle.throttle lever to the full throttle position, then return
to 1/4 throttle.
b. Turn the ignition key to "start." Release key when the engine starts and allow the
switch to return to the "on" position.
7. Inspect the power package for fuel, oil, water, and exhaust leaks.
8. Move the control handle with a firm, quick motion forward to shift to forward gear, or
backward to shift to reverse. After shifting, advance throttle to desired setting.

! CAUTION
Avoid damage to the drive system. Shifting the drive system at RPMs greater than engine
idle speed may cause internal damage to the drive system. Shift the drive system only
when the engine is at idle RPM.
STOPPING THE ENGINE
1. Move the remote control handle to neutral/idle and allow the engine to slow to idle
speed. If engine has been operated at high speed for a long period of time, allow the
engine to cool at idle speed for 3 to 5 minutes.
2. The engine can be stopped by any one of the following 4 methods:
a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine
will stop and the control system will be deactivated.
b. Depress the start/stop button, if equipped. The engine will stop and the control
system will remain active.

Page 36 90-864841060 MAY 2006

 On The Water

c. Momentarily move the ignition key switch to the "START" position, then release
immediately. The control system will recognize that the engine is running and will
stop the engine. The control system will remain active. Moving the ignition key
switch to the "START" position again will issue a start request to the control system
and the control system will start the engine, if appropriate.
d. Activate the lanyard stop switch, if equipped. The engine will stop, but the control
system will remain active. The control system will not allow the engine to start if
the lanyard stop switch is activated.
Throttle Only Operation
NOTE: When operating in throttle only (neutral) mode, the DTS Control System will not
allow the engine speed to increase above 3500 RPM.
Zero effort remote controls: Zero effort remote controls have seperate throttle control
and shift control levers. Advancing the throttle control lever beyond the idle position while
the shift control lever is in the neutral position will cause engine speed to increase, but only
up to the maximum neutral engine speed of 3500 RPM.

! WARNING
When using a Digital Throttle and Shift (DTS) Zero Effort shift control lever, the DTS
Control System can shift the sterndrive unit or transmission at engine speeds greater
than idle. The resulting forward or reverse motion of the boat at engine speeds greater
than idle could be sudden and unexpected or create a hazardous situation, resulting in
injury or death and property damage, caused by a loss of boat control. Always place the
throttle control lever in the idle position before moving the DTS shift control lever into
forward or reverse gear position.

Panel Mount and Console Mount Remote Controls: Panel mount and console mount
remote controls are equipped with a throttle only button. To activate throttle only mode:
1. Refer to Remote Controls section for remote control features.
2. Move the control lever to the idle/neutral position.
3. Depress the throttle only button, and move the control lever to the idle/forward or idle/
reverse position. The DTS control system will sound two beeps on the audio warning
horn to indicate throttle only mode is active. On console mount remote controls, the
neutral light will begin to blink.
4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause
engine speed to increase.
IMPORTANT: Moving the control lever back to the idle/neutral position will deactivate the
throttle only mode and allow the engine to shift into gear.
5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position.
Moving the control lever from the idle/neutral position to the idle/forward or idle/reverse
position without pressing the throttle only button will shift the unit into the chosen gear.
Freezing Temperature Operation
IMPORTANT: If the boat is operated during periods of freezing temperature, precautions
must be taken to prevent freeze damage to the power package. Damage caused by
freezing is not covered by Mercury MerCruiser Limited Warranty.

90-864841060 MAY 2006 Page 37

On The Water

Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason,
boats are normally equipped with a drain plug and/or a bilge pump. It is very important to
check these items on a regular basis to ensure that the water level does not come into
contact with your power package. Components on your engine will be damaged if
submerged. Damage caused by submersion is not covered by the Mercury MerCruiser
Limited Warranty.

Protecting People In The Water

While You Are Cruising
It is very difficult for a person in the water to take quick action to avoid a boat heading in
their direction, even at slow speeds.

21604

Always slow down and exercise extreme caution any time you are boating in an area where
there might be people in the water.
Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient
force by the water on the propeller to cause the propeller to rotate. This neutral propeller
rotation can cause serious injury.
While Boat Is Stationary
! WARNING
Stop your engine immediately whenever anyone in the water is near your boat. Serious
injury to the person in the water is likely if contacted by a rotating propeller, a moving
boat, a moving gearcase, or any solid device rigidly attached to a moving boat or
gearcase.

Shift into neutral and shut off the engine before allowing people to swim or be in the water
near your boat.

High-Speed And High-Performance Boat Operation

If your boat is considered a high-speed or high-performance boat with which you are
unfamiliar, we recommend that you never operate it at its high speed capability without first
requesting an initial orientation and demonstration ride with your dealer or an operator
experienced with your boat. For additional information, refer to Hi-Performance Boat
Operation booklet (90-849250-R2) from your dealer, distributor or Mercury Marine.

Page 38 90-864841060 MAY 2006

 On The Water

Passenger Safety In Pontoon Boats And Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any
passengers to stand or use seats other than those designated for traveling faster than idle
speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a
sudden throttle reduction, or a sharp change of boat direction, could throw them over the
front of boat. Falling over the front of the boat between the two pontoons will position them
to be run over.
Boats Having An Open Front Deck
No one should ever be on the deck in front of the fence while the boat is in motion. Keep
all passengers behind the front fence or enclosure.
Persons on the front deck could easily be thrown overboard or persons dangling their feet
over the front edge could get their legs caught by a wave and pulled into the water.

mc79555-1

! WARNING
Avoid serious injury or death from falling over the front end of a pontoon or deck boat
and being run over. Stay back from the front end of the deck and remain seated while
the boat is in motion.

Boats With Front-Mounted, Raised Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle
or trolling speed. Sit only in seats designated for traveling at faster speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated passenger
falling over the front of the boat.

mc79557-1

90-864841060 MAY 2006 Page 39

On The Water

Wave And Wake Jumping

! WARNING
Avoid serious injury or death from being thrown within or out of a boat when it lands after
jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all
occupants that if a wake or wave jump occurs, get low and hang on to a boat hand hold.

mc79680-1

Operating recreational boats over waves and wakes is a natural part of boating. However,
when this activity is done with enough speed to force the boat hull partially or completely
out of the water, certain hazards arise, particularly when the boat re-enters the water.
The primary concern is the boat changing direction while in the midst of the jump. In such
cases the landing may cause the boat to violently veer in a new direction. Such a sharp
change in direction or turn can cause occupants to be thrown out of their seats or out of
the boat.
There is another less common hazardous result from allowing your boat to launch off of a
wave or wake. If the bow of your boat pitches down far enough while airborne, upon water
contact it may penetrate under the water surface and submarine for an instant. This will
bring the boat nearly to a stop in an instant and can send the occupants flying forward. The
boat may also veer sharply to one side.

Impact With Underwater Hazards

Reduce speed and proceed with caution whenever you're driving a boat in shallow water
or in areas where the waters are suspected of having underwater obstacles that could be
struck by the underwater drive components, rudder or the boat bottom.

7576

IMPORTANT: The most important thing you can do to help reduce injury or impact damage
from striking a floating or underwater object is control the boat speed. Under these
conditions, boat speed should be kept to a maximum speed of
24 to 40 km/h (15 to 25 MPH).
Striking a floating/underwater object may result in an infinite number of situations. Some
of these situations could result in the following:
• The boat could move suddenly in a new direction. Such a sharp change in direction or
turn can cause occupants to be thrown out of their seats or out of the boat.
• A rapid reduction in speed. This will cause occupants to be thrown forward, even out
of the boat.
• Impact damage to the underwater drive components, rudder and/or boat.

Page 40 90-864841060 MAY 2006

 On The Water

Keep in mind, one of the most important things you can do to help reduce injury or impact
damage in these situations is control the boat speed. Boat speed should be kept to a
minimum planing speed when driving in waters known to have underwater obstacles.
After striking a submerged object, stop the engine as soon as possible and inspect the
drive system for any broken or loose parts. If damage is present or suspected, the power
package should be taken to an authorized Mercury MerCruiser dealer for a thorough
inspection and necessary repair.
The boat should be checked for hull fractures, transom fractures and water leaks.
Operating with damaged underwater drive components, rudder or boat bottom could cause
additional damage to other parts of the power package, or could affect control of the boat.
If continued operation is necessary, do so at greatly reduced speeds.

! WARNING
Avoid serious injury or death from loss of boat control. Continued boating with major
impact damage can result in sudden component failure with or without subsequent
impacts. Have the power package thoroughly inspected and any necessary repairs
made.

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to rear (stern):
• Generally increases speed and engine RPM
• Causes bow to bounce in choppy water
• Increases danger of following wave splashing into the boat when coming off plane
• At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
• Improves ease of planing
• Improves rough water ride
• At extremes, can cause the boat to veer back and forth (bow steer)
Bottom Of Boat
To maintain maximum speed, the boat bottom should be:
• Clean, free of barnacles and marine growth
• Free of distortion; nearly flat where it contacts the water
• Straight and smooth, fore and aft
Marine vegetation may accumulate when the boat is docked. This growth must be removed
before operation; it may clog the water inlets and cause the engine to overheat.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater
object, such as a gear housing or a propeller. Cavitation permits the propeller to speed up,
but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housing
or the propeller. Common causes of cavitation are:
• Weeds or other debris snagged on the propeller
• Bent propeller blade
• Raised burrs or sharp edges on the propeller

90-864841060 MAY 2006 Page 41

On The Water

Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the
propeller resulting in propeller speed-up and a reduction in boat speed. Air bubbles strike
the propeller blade and cause erosion of the blade surface. If allowed to continue, eventual
blade failure (breakage) will occur. Excessive ventilation is usually caused by:
• Drive unit trimmed out too far.
• A missing propeller diffuser ring.
• A damaged propeller or gear housing, which allows exhaust gases to escape between
propeller and gear housing.
• Drive unit installed too high on transom.
Elevation And Climate
Elevation and climate changes will affect the performance of your power package. Loss of
performance can be caused by:
• Higher elevations
• Higher temperatures
• Low barometric pressures
• High humidity
For you to have optimum engine performance under changing weather conditions, it is
essential that the engine be propped to allow the engine to operate at or near the top end
of the specified maximum RPM range with a normal boat load during your normal boating
weather conditions.
In most cases, recommended RPM can be achieved by changing to a lower pitch propeller.

Getting Started
20-Hour Break-In Period
IMPORTANT: The first 20 hours of operation is the engine break-in period. Correct break-in
is essential to obtain minimum oil consumption and maximum engine performance. During
this break-in period, the following rules must be observed:
• Do not operate below 1500 RPM for extended periods of time for the first 10 hours.
Shift into gear as soon as possible after starting and advance the throttle above 1500
rpm if conditions permit safe operation.
• Do not operate at one speed consistently for extended periods.
• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional
operation at full throttle is permissible (5 minutes at a time maximum).
• Avoid full throttle acceleration from idle speed.
• Do not operate at full throttle until the engine reaches normal operating temperature.
• Frequently check engine oil level. Add oil as needed. It is normal for oil consumption
to be high during the break-in period.
After Break-In Period
To help extend the life of your Mercury MerCruiser power package, the following
recommendations should be considered;
• Ensure that propeller allows the engine to operate at or near the top of the specified
WOT RPM range (Refer to Specifications and Maintenance) when at full throttle with
a normal boat load.

Page 42 90-864841060 MAY 2006

 On The Water

• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged

operation at WOT RPM.
• Change the engine oil and oil filter. Refer to Maintenance.
• Change the transmission oil and filter. Refer to Maintenance (ZF Transmission
models).1.
End of First Season Checkup
At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer
to discuss and/or perform scheduled maintenance items. If you are in an area where the
product is operated continuously, year-round, you should contact your dealer at the end of
the first 100 hours of operation or once yearly, whichever occurs first.

1. Require fluid and filter change after the first 25 hours and then every 100 hours.

90-864841060 MAY 2006 Page 43

On The Water

Notes:

Page 44 90-864841060 MAY 2006

 Specifications

Section 4 - Specifications
Table of Contents
Cruising RPM...................................................... 46 Engine Oil........................................................... 47
Fuel Requirements............................................. 46 Engine Specifications......................................... 48
Fuel Ratings ................................................. 46 Fluid Specifications............................................. 49
Using Reformulated (Oxygenated) Gasolines Transmission ................................................ 49
(USA Only) ................................................... 46 Engine .......................................................... 49
Gasolines Containing Alcohol ...................... 46

90-864841060 MAY 2006 Page 45

Specifications

Cruising RPM
Modern inboard engines operate at higher engine speeds than those produced just a few
years ago. This increased RPM along with better breathing is largely responsible for the
significant increase in horsepower of these new engines. Along with the higher WOT RPM
comes higher cruising RPM. This higher RPM is critical for optimum performance and
efficiency. The materials and design of the new engines allow these higher speeds without
durability penalty. In fact, over-propping the boat to reduce the cruising RPM to previous
levels will increase the susceptibility to engine damage from detonation and pre-ignition.
The recommended cruising RPM ranges are:
Cruising RPM for Peak Efficiency
Model RPM Range
8.1S Horizon 3200-3600
8.1S HO 3400-3800

Fuel Requirements
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage
resulting from the use of improper gasoline is considered misuse of the engine, and
damage caused thereby will not be covered under the limited warranty.
Fuel Ratings
Mercury MerCruiser engines will operate satisfactorily when using a major brand of
unleaded gasoline meeting the following specifications:
USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum.
Premium gasoline [92 (R+M)/2 Octane] is also acceptable. Do not use leaded gasoline.
Outside USA and Canada - having a posted pump Octane Rating of 90 RON minimum.
Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use
a major brand of leaded gasoline.
Using Reformulated (Oxygenated) Gasolines (USA Only)
This type of gasoline is required in certain areas of the USA. The 2 types of oxygenates
used in these fuels is Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the
oxygenate that is used in the gasoline in your area, refer to Gasolines Containing Alcohol.
These Reformulated Gasolines are acceptable for use in your Mercury MerCruiser engine.
Gasolines Containing Alcohol
If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl
alcohol), you should be aware of certain adverse effects that can occur. These adverse
effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can
also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb
moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the
fuel tank.
The fuel system components on your Mercury MerCruiser engine will withstand up to 10%
alcohol content in the gasoline. We do not know what percentage your boat's fuel system
will withstand. Contact your boat manufacturer for specific recommendations on the boat's
fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines
containing alcohol may cause increased:
• Corrosion of metal parts

Page 46 90-864841060 MAY 2006

 Specifications

• Deterioration of rubber or plastic parts

• Fuel permeation through rubber fuel lines
• Starting and operating difficulties

! WARNING
FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of the fuel system can be
a fire and explosion hazard which can cause serious bodily injury or death. Careful
periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel
components should be inspected for leakage, softening, hardening, swelling or corrosion.
Any sign of leakage or deterioration requires replacement before further engine
operation.

Because of possible adverse effects of alcohol in gasoline, it is recommended that only

alcohol-free gasoline be used where possible. If only fuel containing alcohol is available,
or if the presence of alcohol is unknown, increased inspection frequency for leaks and
abnormalities is required.
IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing
alcohol, storage of gasoline in the fuel tank for long periods should be avoided. Long
periods of storage, common to boats, create unique problems. In cars alcohol-blend fuels
normally are consumed before they can absorb enough moisture to cause trouble, but
boats often sit idle long enough for phase separation to take place. In addition, internal
corrosion may take place during storage if alcohol has washed protective oil films from
internal components.

Engine Oil
To help obtain optimum engine performance and to provide maximum protection, we
strongly recommend the use of the following oils listed in the order of recommendation:
1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC-W rated, 4 cycle oil.
2. MerCruiser / Quicksilver 25W40 NMMA FC-W rated oil.
3. A NMMA FC-W rated oil.
4. MerCruiser / Quicksilver 4-cycle 25W40, non FC-W rated oil.
5. A good grade straight weight detergent automotive oil per the operating chart below.

90-864841060 MAY 2006 Page 47

Specifications

NOTE: The use of non-detergent oils, multi-viscosity oils (other than as specified), non
FC-W rated synthetic oils, low quality oils or oils that contain solid additives are specifically
not recommended.

Page 48 90-864841060 MAY 2006

 Specifications

Engine Specifications
Models 8.1S Horizon 8.1S HO
Horsepower1. 370 420

Kilowatts1. 276 313

Displacement 8.1 L (496 cid)
Specified WOT RPM Range2. 4200-4600 4400-4800

Idle RPM in Neutral2. 6503.

Minimum Oil Pressure @ Idle4. 103 kPa (15 psi)

Minimum Oil Pressure @ 2000 RPM4. 207 kPa (30 psi)

Thermostat 71° C (160° F)
Timing @ Idle3. Not Adjustable
Firing Order 1-8-7-2-6-5-4-3
Electrical System 12-Volt Negative (-) Ground
Alternator Rating - Hot Operating Amps 65 amp
Alternator Rating - Cold Operating Amps 72 amp
Recommended Battery Rating (Non-DTS Models) (Minimum) 750 CCA, 950 MCA, or 180 Ah
Recommended Battery Rating (DTS Models) (Minimum) 800 CCA, 1000 MCA, or 190 Ah
Spark Plug Type AC Platinum (AC 41-983)
Spark Plug Gap 1.5 mm (0.060 in.)

Fluid Specifications
Transmission
Model Capacity Fluid Type
500A 2.84 Liter (3.00 U.S. Quart)
5000V 3.30 Liter (3.5 U.S. Quart)
63A 4.00 Liter (4.5 U.S. Quart) Dexron III Automatic Transmission Fluid
63V 4.00 Liter (4.5 U.S. Quart)
80A 5.50 Liter (6 U.S. Quart)

Engine
IMPORTANT: All capacities are approximate fluid measures.
IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and
cooling systems (heat exchanger and fluid lines).

1. Performance obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power.
2. Measured using an accurate service tachometer with the engine at normal operating temperatures
3. Idle speed and timing on EFI models are not adjustable
4. Oil pressure must be checked with the engine at normal operating temperature.

90-864841060 MAY 2006 Page 49

Specifications

All Models Capacity Fluid Type

Mercury/Quicksilver Synthetic Blend MerCruiser Engine
Engine Oil (With Filter)1. 8.5 liters (9 U.S. qt.)
Oil 25W-40
Seawater Cooling System 2. 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water
Mercury Extended Life Coolant/Antifreeze or Extended
Closed Cooling System 18 liters (19 U.S. qt.) Life Ethylene Glycol 5/100 Coolant/Antifreeze mixed
50/50 with Purified Water

1. Always use the dipstick to determine the exact quantity of oil or fluid required.
2. Seawater cooling system capacity information is for winterization use only.

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 Maintenance

Section 5 - Maintenance
Table of Contents
Owner/Operator Responsibilities........................ 52 Engine Oil Drain Pump ........................... 57
Dealer Responsibilities....................................... 52 Changing Filter ....................................... 58
Maintenance....................................................... 52 Transmission Fluid.............................................. 58
Do It Yourself Maintenance Suggestions........... 53 Checking While the Engine is Warm ............ 58
Inspection........................................................... 53 Checking While Engine is Cold .................... 59
Maintenance Schedule - Inboard Models........... 54 Changing ...................................................... 59
Routine Maintenance ................................... 54 Engine Coolant................................................... 59
Each Day Start ....................................... 54 Checking ...................................................... 59
Each Day End ........................................ 54 Filling ............................................................ 60
Weekly ................................................... 54 Changing ..................................................... 60
Every Two Months or 50 Hours .............. 54 Cleaning The Flame Arrestor.............................. 60
Scheduled Maintenance ............................... 54
After the Initial 20 Hour Break-in ............ 54
Changing Water Separating Fuel Filter.............. 61
Serpentine Drive Belt.......................................... 63
5
Every 100 Hours or Annually (Whichever Checking ...................................................... 63
Occurs First) ........................................... 54 Replacing ..................................................... 64
Every 300 Hours or 3 Years ................... 54 Flushing the Seawater System—Inboard Models
Every 5 Years ......................................... 55 ............................................................................ 65
Maintenance Log................................................ 55 The Boat out of the Water—Inboard Models
Engine Oil........................................................... 55 ......................................................................65
Checking ...................................................... 56 The Boat in the Water—Inboard Models.......66
Filling ............................................................ 56 Battery................................................................ 68
Changing Oil and Filter ................................ 57 Multiple EFI Engine Battery Precautions.......68

90-864841060 MAY 2006 Page 51

Maintenance

Owner/Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication
and maintenance instructions are complied with for safe operation and to return the unit to
an authorized Mercury MerCruiser dealer for a periodic checkup.
Normal maintenance service and replacement parts are the responsibility of the owner/
operator and as such, are not considered defects in workmanship or material within the
terms of the warranty. Individual operating habits and usage contribute to the need for
maintenance service.
Proper maintenance and care of your power package will ensure optimum performance
and dependability and will keep your overall operating expenses at a minimum. See your
authorized Mercury MerCruiser dealer for service aids.

Dealer Responsibilities
In general, a dealer's responsibilities to the customer include predelivery inspection and
preparation such as:
• Ensure that the boat is properly equipped.
• Prior to delivery, make certain that the Mercury MerCruiser power package and other
equipment are in proper operating condition.
• Make all necessary adjustments for maximum efficiency.
• Familiarize the customer with the on-board equipment.
• Explain and demonstrate the operation of the power package and boat.
• Provide you with a copy of a Predelivery Inspection Checklist.
• Your selling dealer should fill out the Warranty Registration Card completely and mail
it to the factory immediately upon sale of the new product.

Maintenance
! WARNING
Avoid injury or death and product damage from an electrical shock, fire or explosion.
Always disconnect both battery cables from the battery before servicing the power
package.

! WARNING
Fuel vapors can be present in the engine compartment. Avoid injury or power package
damage caused by fuel vapors or explosion. Always ventilate the engine compartment
prior to servicing the power package.

IMPORTANT: Refer to the maintenance schedule for complete listing of all scheduled
maintenance to be performed. Some listings can be done by owner/operator, while others
should be performed by an authorized Mercury MerCruiser dealer. Before attempting
maintenance or repair procedures not covered in this manual, it is recommended that a
Mercury MerCruiser Service Manual be purchased and read thoroughly.
NOTE: Maintenance points are color coded for ease of identification. See the decal on
engine for identification.
Maintenance Point Color Codes
Blue Coolant

Page 52 90-864841060 MAY 2006

 Maintenance

Maintenance Point Color Codes

Yellow Engine Oil
Orange Fuel
Black Gear Lube Oil (Sterndrive models only)
Brown Transmission (Inboard models only)

Do It Yourself Maintenance Suggestions

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

Inspection
Inspect your power package often, and at regular intervals, to help maintain its top
operating performance and correct potential problems before they occur. The entire power
package should be checked carefully, including all accessible engine parts.
• Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as
necessary.
• Check plug leads and electrical leads for damage.
• Remove and inspect the propeller. If badly nicked, bent or cracked, contact your
authorized Mercury MerCruiser dealer.
• Repair nicks and corrosion damage on power package exterior finish. Contact your
authorized Mercury MerCruiser dealer.

90-864841060 MAY 2006 Page 53

Maintenance

Maintenance Schedule - Inboard Models

Routine Maintenance
NOTE: Only perform maintenance which applies to your particular power package.
EACH DAY START
• Check the crankcase oil (interval can be extended based on experience).
• Check the transmission fluid level.
EACH DAY END
• If operating in salt, brackish or polluted waters, flush the cooling system after each use.
WEEKLY
•Check the water inlets for debris or marine growth. Check the seawater strainer and
clean.
• Check the coolant level.
• Check the transmission fluid.
EVERY TWO MONTHS OR 50 HOURS
• Operating in saltwater or brackish or polluted water only: treat the power package with
Corrosion Guard.
• Check the battery connections and the fluid level.
• Ensure that the gauges and the wiring connections are secure. Clean the gauges.1.
Scheduled Maintenance
NOTE: Only perform maintenance which applies to your particular power package.
AFTER THE INITIAL 20 HOUR BREAK-IN
To help extend the life of your Mercury MerCruiser power package, the following is
recommended:
1. Change the engine oil and filter
2. Change the transmission fluid and filter on inboard models.
NOTE: ZF Marine requires the transmission fluid and filter be changed to preserve the
warranty.
EVERY 100 HOURS OR ANNUALLY (WHICHEVER OCCURS FIRST)
• Touch-up the paint on the power package.
• Change the crankcase oil and filter.
• Change the transmission fluid (ZF Transmission Models)2.
• Replace the water separating fuel filter element.
• Check the steering system and the remote control for loose, missing or damaged parts.
Lubricate the cables and the linkages.
•
Clean the flame arrestor, IAC muffler (MPI engines)3., and the crankcase ventilation
hoses. Inspect the PCV valve, if equipped.
EVERY 300 HOURS OR 3 YEARS
• Inspect the condition of the belts.
• Check the engine mount for tightness and retorque if necessary.
• Check the distributor cap, if equipped.

1. If operating in saltwater, interval is reduced to every 25 hours or 30 days whichever occurs first.
2. Require fluid and filter change after the first 25 hours and then every 100 hours.
3. Contact your authorized Mercury MerCruiser dealer to replace the IAC muffler.

Page 54 90-864841060 MAY 2006

 Maintenance

• Check the electrical system for loose, damaged, or corroded fasteners.

• Check the cooling system and the exhaust system hose clamps for tightness. Inspect
both systems for damage or leaks.
• Disassemble and inspect the seawater pump and replace worn components.
• Clean the seawater section of the closed cooling system. Clean, inspect, and test the
pressure cap. (Inboard and sterndrive models only)
• Inspect the exhaust system components and verify that the flapper valves are not
missing or worn, if equipped.
EVERY 5 YEARS
• Replace the coolant (every two years if extended life antifreeze coolant is not being
used). (Inboard and sterndrive models only)

Maintenance Log
Record all maintenance performed on your power package here. Be sure to save all work
orders and receipts.
Date Maintenance Performed Engine Hours

Engine Oil
! CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is
restricted by law. Do not spill oil or oil waste into the environment when using or servicing
your boat. Contain and dispose of oil or oil waste as directed by local authorities.

90-864841060 MAY 2006 Page 55

Maintenance

Checking
1. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The
boat must be at rest in the water.
2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60
seconds to allow trapped air to vent.
NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the
engine (flywheel end).

8480

a - Dipstick tube

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or
OK range mark on the dipstick.
3. Remove the dipstick and observe the oil level. Oil level must be between full or OK
range and add. Reinstall dipstick into dipstick tube.
Filling
IMPORTANT: Do not overfill the engine with oil.
IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid
required.

Page 56 90-864841060 MAY 2006

 Maintenance

1. Remove oil fill cap.

5581

a - Oil fill cap

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or
OK range mark on the dipstick.
2. Add the specified engine oil to bring the level up to, but not over, the full or OK range
mark on the dipstick. Recheck oil level.
3. Replace the fill cap.
All Models Capacity Fluid Type
8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil
Engine Oil (With Filter)
(9 U.S. Quart) 25W-40

Changing Oil and Filter

Refer to the Maintenance schedule for the change interval. Engine oil should be changed
before placing the boat in storage.
IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows
more freely, carrying away more impurities. Use only recommended engine oil (refer to
Specifications).
ENGINE OIL DRAIN PUMP
1. Loosen the oil filter to vent the system.
2. Remove the dipstick.
3. Install the oil pump onto the dipstick tube.

a
c
b
mc70571-1

a - Typical oil pump c - Oil drain hose

b - Dipstick tube

4. Insert the hose end of the crankcase oil pump onto an appropriate container and, using
the handle, pump until the crankcase is empty.
5. Remove the pump.
6. Install the dipstick.

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Maintenance

CHANGING FILTER
1. Remove and discard oil filter.

8479

a - Oil filter

2. Coat sealing ring on new filter with engine oil and install.
3. Tighten oil filter securely (following filter manufacturer's instructions). Do not
overtighten.
4. Remove oil fill cap.
IMPORTANT: Always use dipstick to determine exactly how much oil is required.
5. Add recommended engine oil to bring level up to the bottom of the OK range on the
dipstick.
6. With the boat at rest in the water, check the oil level and add specified fluid to bring the
oil level up to, but not over, the full or OK range.
NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the add mark to the
top of the OK range.
All Models Capacity Fluid Type
8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil
Engine Oil (With Filter)
(9 U.S. Quart) 25W-40

7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.
Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at
rest in the water.

Transmission Fluid
Checking While the Engine is Warm
1. Velvet Drive Transmissions - Stop engine and quickly check fluid level by turning
T-handle counterclockwise, to remove dipstick. Fluid level should be up to full mark. If
low, add specified fluid through dipstick tube on transmissions.

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 Maintenance

2. ZF Marine Transmissions - Stop engine and remove dipstick to check level. If fluid is
below top (Full) line, add specified fluid through dipstick hole. Do not overfill. Reinstall
dipstick with cap fully seated.
Checking While Engine is Cold
NOTE: Cold Fluid Level Check: To ease checking the fluid level, the dipstick can be marked
or scribed with a cold level mark.
1. Follow the procedure for the warm fluid level check, then allow the boat to sit overnight.
IMPORTANT: Be sure to push the dipstick all the way down into the dipstick tube when
checking the fluid level.
2. Remove the dipstick, wipe clean and reinsert.
3. Remove the dipstick, observe the fluid level and mark the cold fluid level.
4. Reinstall the dipstick, tighten the T-handle securely. Do not overtighten.
Changing
Contact your authorized Mercury MerCruiser dealer.

Engine Coolant
Checking
! WARNING
Allow the engine to cool down before removing the coolant pressure cap. A sudden loss
of pressure could cause hot coolant to boil and discharge violently. After the engine has
cooled, turn the cap 1/4 turn to allow any pressure to escape slowly, then push down and
turn the cap all the way off.

1. With the engine at normal operating temperature, check the coolant level in the coolant
recovery bottle.

5649

a - Coolant recovery bottle

2. Add the specified fluid as necessary.

Tube Ref No. Description Where Used Part No.

Extended Life Antifreeze/
122 Closed Cooling System 92-877770K1
Coolant

90-864841060 MAY 2006 Page 59

Maintenance

Filling
! CAUTION
Alcohol or Methanol based antifreeze or plain water, are not recommended for use in the
coolant section of the Closed Cooling System at any time.

! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage.
Ensure that there is sufficient water always available at water inlet holes during operation.

! CAUTION
Air trapped in the closed cooling section of an engine cooling system can cause the
engine to overheat resulting in engine damage. To minimize the possibility of trapping
air when initially filling the closed cooling system, position the boat so that the front of the
engine is higher than the rear of the engine.

NOTE: Add coolant only when engine is at normal operating temperature.

1. Remove the fill cap from the coolant recovery bottle and inspect the gasket. Replace
the gasket if necessary.
IMPORTANT: This closed cooling system flows coolant at a high rate. Higher idle speeds
increase dispersion of trapped air into the system making it more difficult to purge trapped
air. Operate at idle during filling and air purging when specified.
2. Fill to the full mark with the specified coolant.

Tube Ref No. Description Where Used Part No.

Extended Life Antifreeze/
122 Closed Cooling System 92-877770K1
Coolant

3. Install the fill cap onto the coolant recovery bottle.

Changing
Contact your authorized Mercury MerCruiser dealer.

Cleaning The Flame Arrestor

! WARNING
Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive
under certain conditions. Be careful when cleaning flame arrestor; ensure that ignition is
off. Do not smoke or allow sources of spark or open flame in area when cleaning flame
arrestor.

1. Remove the engine cover.

2. Loosen the flame arrestor clamp and remove the flame arrestor.

! WARNING
Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive
under certain conditions. Never use gasoline as a cleaning solvent.

Page 60 90-864841060 MAY 2006

 Maintenance

3. Clean the flame arrestor with solvent. Dry with compressed air or allow to air dry
completely.

8478

a - Flame arrestor

4. Install flame arrestor. Tighten the flame arrestor clamp.

5. Install the engine cover.

Changing Water Separating Fuel Filter

! WARNING
Avoid serious injury or death from a gasoline fire or explosion; gasoline is extremely
flammable and highly explosive under certain conditions. When servicing the fuel system
components ensure that the engine is cool, the ignition switch is in the off position, and
that the lanyard stop switch, if equipped, is in the off position. Do not smoke or allow
spark or open flame in the area. Wipe up any spilled fuel immediately. Ensure that no
fuel leaks exist before closing the engine hatch.

1. Allow the engine to cool down.

NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to
filter removal.
2. Close fuel supply valve, if equipped.
3. Disconnect the Cool Fuel Module harness from the engine wiring harness.
4. Turn the key switch to the start position and allow the starter to operate for 5 seconds.
5. Turn key switch to off position.

90-864841060 MAY 2006 Page 61

Maintenance

6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool
Fuel Module. Do not remove the filter assembly retaining screws from the filter cap.
d

b h

f
g

8837

a- Cool Fuel Module e- Fuel filter element

b- Cool Fuel Module harness f- Filter cup
c- Filter cap g- Cool Fuel Module filter reservoir
d- Filter assembly retaining screw h- O-ring

7. Unseat the filter assembly by grasping the filter assembly handle and pulling upward.
Do not remove the filter assembly from the Cool Fuel Module at this time.
8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the
filter assembly and into the Cool Fuel Module filter reservoir.
9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a
clockwise direction while holding the filter cup stationary.
10. Remove the used water separating fuel filter element from the filter cup, place it in a
clean, approved container.
11. Dispose of any water or debris that may be in the filter cup.
12. Install a new water separating fuel filter element into the filter cup. Push the element
into the cup until completely seated.
13. Install new O-ring on the filter cup.
14. Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counter
clockwise direction while holding the filter cup stationary, until the filter cap locks
securely into place.
15. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel,
and align the screws retained in the filter cap with the screw holes in the Cool Fuel
Module. Tighten the filter assembly retaining screws until hand tight.
16. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each
filter assembly retaining screw.

Page 62 90-864841060 MAY 2006

 Maintenance

Description Nm lb. in. lb. ft.

Filter assembly retaining screw 6 53

17. Open fuel supply valve, if equipped.

18. Reconnect the Cool Fuel Module harness to the engine wiring harness.
19. Supply cooling water to the engine.
20. Properly ventilate the engine compartment.
21. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist,
stop the engine immediately. Recheck the filter installation, clean spilled fuel and
properly ventilate the engine compartment. If leaks continue, stop engine immediately
and contact your authorized Mercury MerCruiser dealer.

Serpentine Drive Belt

! WARNING
Avoid possible serious injury. Make sure engine is shut off and ignition key is removed
before inspecting belt.

f d

e
c 8119

a - Idler pulley d - Alternator pulley

b - Water circulating pump pulley e - Seawater pump pulley
c - Crankshaft pulley f - Tensioner pulley

Checking
1. Inspect the drive belt for proper tension and for the following:
• Excessive wear
• Cracks
NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal
cracks (in the direction of belt length) that join transverse cracks are NOT acceptable.
• Fraying
• Glazed surfaces

90-864841060 MAY 2006 Page 63

Maintenance

• Proper tension - 13 mm (1/2 in.) deflection, with moderate thumb pressure, on the
belt at the location that has the longest distance between two pulleys.

mc75130-1

Replacing
IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation
as before.
The belt tensioner is designed to operate within the limits of arm movement provided by
the cast stops when the belt length and geometry are correct.
If the tensioner is contacting either of the limits during operation, check the mounting
brackets and the belt length. Loose brackets, bracket failure, accessory drive component
movement, incorrect belt length, or belt failure can cause the tensioner to contact the limits.
See your authorized MerCruiser dealer for service if these conditions exist.

! CAUTION
The belt tensioner assembly contains a high tension spring. Rapid release of the
tensioner, or allowing the tensioner to snap back quickly, could injure the operator or
cause product damage. Relieve the spring tension slowly to avoid injury or product
damage.

1. Use a breaker bar and appropriate socket to hold back the tensioner and relieve the
belt tension. Rotate the tensioner away from belt until it stops. Remove the belt from
the idler pulley and slowly relieve the tension on the breaker bar.

a
8117

Breaker bar with arrow in direction of movement to relieve tension.

a - Breaker bar

Page 64 90-864841060 MAY 2006

 Maintenance

2. Remove the belt and reroute the replacement belt according to the belt routing diagram.
3. Use a breaker bar and appropriate socket to position the tensioner back to the engine
running location and slide the belt over the tensioner pulley. Slowly relieve the tensioner
to the belt.

a
8117

Breaker bar with arrow in direction of movement to reposition in tension.

a - Breaker bar

Flushing the Seawater System—Inboard Models

The Boat out of the Water—Inboard Models
IMPORTANT: Flushing the power package is most effective when performed with the boat
out of the water.
IMPORTANT: We recommend flushing after each outing in salty, brackish, mineral-laden,
or polluted water and before cold weather and extended storage.

! WARNING
Contact with moving drive components and the propeller can cause personal injury or
death. To avoid possible injury, remove the propeller and ensure that no people or
animals are in the area of the drive unit while flushing.

1. Close the seacock, if equipped, then disconnect the seawater inlet hose from the
seawater pump.
2. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater
pump and immediately plug the hose.
3. Using a suitable adapter, connect the flushing hose from the water source to the water
inlet of the seawater pump.

90-864841060 MAY 2006 Page 65

Maintenance

! CAUTION
Flush water will collect in the exhaust system when the engine is not operating, resulting
in engine damage. Do not supply flush water for more than 15 seconds without the engine
operating.
4. Completely open the water source to provide maximum water supply.
5. Place the remote control in the neutral idle speed position.
6. Start the engine.

! CAUTION
Avoid engine damage from overheating. If the engine is operated above 1400 RPM
during flushing, suction created by the seawater pickup pump may collapse the flushing
water hose, causing the engine to overheat.
7. Depress the throttle-only button and slowly advance the throttle until the engine
reaches 1300 RPM (± 100 RPM).

! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature
gauge and ensure that the engine is operating in the normal range.
8. Observe the water temperature gauge to ensure that the engine is operating in the
normal range.
9. Operate the engine with the transmission in neutral for a minimum of 10 minutes.
10. For power packages operated in salty, brackish, mineral-laden, or polluted water:
Continue to operate the engine until the discharge water is clear.
11. Slowly return the throttle to idle speed position.

! CAUTION
Flush water will collect in the exhaust system when the engine is not operating, resulting
in engine damage. Do not supply flush water for more than 15 seconds without the engine
operating.
12. Stop the engine.
13. Immediately shut off the supply water and remove the flushing attachment.
14. Install the water inlet hose to the seawater inlet of the seawater pump. Tighten the hose
clamp securely.
The Boat in the Water—Inboard Models
IMPORTANT: Flushing the power package is most effective when performed with the boat
out of the water.
IMPORTANT: We recommend flushing the engine after each outing in salty, brackish,
mineral-laden, or polluted water and before cold weather and extended storage.

! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. Disconnecting
the seawater inlet hose will cause water to enter the bilge. Close the seacock before
removing the seawater inlet hose.

1. Close the seacock, if equipped, then disconnect the seawater inlet hose to prevent
water from siphoning into the engine or boat.

Page 66 90-864841060 MAY 2006

 Maintenance

! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. Disconnecting
the seawater inlet hose will cause water to enter the bilge. Disconnect and immediately
plug the seawater inlet hose to prevent water from siphoning into the engine or boat.
2. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater
pump, and immediately plug the hose to prevent water from siphoning into the engine
or boat.
3. Using a suitable adapter, connect the flushing hose from the water source to the water
inlet of the seawater pump.

! CAUTION
Flush water will collect in the exhaust system when the engine is not operating, resulting
in engine damage. Do not supply flush water for more than 15 seconds without the engine
operating.
4. Completely open the water source to provide maximum water supply.
5. Place the remote control in the neutral idle speed position.
6. Immediately start the engine.

! CAUTION
Avoid engine damage from overheating. If the engine is operated above 1400 RPM
during flushing, suction created by the seawater pickup pump may collapse the flushing
water hose, causing the engine to overheat.
7. Depress the throttle-only button and slowly advance the throttle until the engine
reaches 1300 RPM (± 100 RPM).

! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature
gauge and ensure that the engine is operating in the normal range.
8. Observe the water temperature gauge to ensure that the engine is operating in the
normal range.
9. Operate the engine with the transmission in neutral for a minimum of 10 minutes.
10. For power packages operated in salty, brackish, mineral-laden, or polluted water:
Continue to operate the engine until the discharge water is clear.
11. Slowly return the throttle to idle speed position.

! CAUTION
Flush water will collect in the exhaust system when the engine is not operating, resulting
in engine damage. Do not supply flush water for more than 15 seconds without the engine
operating.
12. Stop the engine.
13. Immediately shut off the supply water and remove the flushing attachment.
14. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or
the seawater inlet hose to be reconnected prior to operating the engine.

90-864841060 MAY 2006 Page 67

Maintenance

Battery
Refer to specific instructions and warnings accompanying your battery. If this information
is not available, observe the following precautions when handling a battery.

! WARNING
Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery
to start engine. Do not recharge a weak battery in the boat. Remove battery and recharge
in a ventilated area away from fuel vapors, sparks or flames.

! WARNING
Batteries contain acid which can cause severe burns. Avoid contact with skin, eyes and
clothing. If electrolyte is spilled or splashed on any part of the body, immediately flush
the exposed area with liberal amounts of water and obtain medical aid as soon as
possible. Safety glasses and rubber gloves are recommended when handling batteries
or filling with electrolyte.

Multiple EFI Engine Battery Precautions

Alternators: Alternators are designed to charge the battery that supplies electrical power
to the engine that the alternator is mounted on. When batteries for 2 different engines are
connected, one alternator will supply all of the charging current for both batteries. Normally,
the other engine's alternator will not be required to supply any charging current.
EFI Electronic Control Module (ECM): The ECM requires a stable voltage source. During
multiple engine operation, an onboard electrical device may cause a sudden drain of
voltage at the engine's battery. The voltage may go below the ECM's minimum required
voltage. Also, the alternator on the other engine may now start charging. This could cause
a voltage spike in the engine's electrical system.
In either case, the ECM could shut off. When the voltage returns to the range that the ECM
requires, the ECM will reset itself, and the engine will operate normally. The ECM shuts off
and resets itself so quickly that the engine may only seem to have an ignition miss.
Batteries: Boats with multi-engine EFI power packages require each engine be connected
to its own battery. This ensures that the engine's ECM has a stable voltage source.
Battery Switches: Battery switches should always be positioned so each engine is
operating off of its own battery. Do not operate engines with switches in both or all position.
In an emergency, another engine's battery can be used to start an engine with a dead
battery.
Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering
accessories in the boat. They should not be used to charge the battery of another engine
in the boat unless the type of isolator is specifically designed for this purpose.
Generators: The generators battery should be considered another engine's battery.

Page 68 90-864841060 MAY 2006

 Storage

Section 6 - Storage
Table of Contents
Cold Weather or Extended Storage.................... 70 Air Actuated Single Point Drain System........73
Preparing Power Package for Storage..........70 Boat in the Water ................................... 73
Engine and Fuel System Preparation .... 71 Boat out of the Water ............................. 75
Draining the Seawater System........................... 71 Manual Drain System....................................77
Drain System Identification...........................72 Boat in the Water ................................... 77
Air Actuated Single Point Drain System Boat out of the Water ............................. 78
............................................................... 72 Battery Storage................................................... 78
Manual Drain System ............................. 73 Power Package Recommissioning..................... 78

90-864841060 MAY 2006 Page 69

Storage

Cold Weather or Extended Storage

IMPORTANT: Mercury MerCruiser strongly recommends that this service should be
performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing
temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty.

! CAUTION
Seawater that is trapped in or remains in the cooling system seawater section during cold
weather or winter storage can freeze resulting in cooling system or engine damage.
Completely drain the seawater from the cooling system seawater section for winter
storage or immediately after cold weather operation when the possibility of freezing
temperatures exist.

IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the
manufacturers instructions, be used in the seawater section of the cooling system for
freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze
contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow
the propylene glycol manufacturer's recommendations.
Preparing Power Package for Storage
1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient
amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline.
Follow instructions on the container.
2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel
without alcohol is not available): Fuel tanks should be drained as low as possible and
Mercury/Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel
remaining in the tank. Refer to Fuel Requirements for additional information.
3. Flush the cooling system. Refer to the Maintenance section.
4. Supply cooling water to engine. Refer to the Maintenace section
5. Operate the engine sufficiently to bring it up to normal operating temperature and allow
fuel with Mercury/Quicksilver Gasoline Stabilizer to circulate through the fuel system.
Shut off the engine.
6. Change the oil and oil filter.
7. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System
Preparation.
8. Drain the engine seawater cooling system. Refer to Draining the Seawater System.

! CAUTION
If the boat is in the water, the seacock must remain closed until the engine is to be
restarted to prevent water from flowing back into the cooling system or the boat. If the
boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged to
prevent water from flowing back into the cooling system or the boat. As a precautionary
measure, attach a tag to the ignition switch or steering wheel of the boat with the warning:
Open the seacock or reconnect the water inlet hose before starting the engine.
9. For additional assurance against freezing and rust, after draining, fill the seawater
cooling system with propylene glycol mixed to the manufacturer's recommendation to
protect engine to the lowest temperature to which it will be exposed during freezing
temperatures or extended storage.
10. Store the battery according to the manufacturer's instructions.

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 Storage

ENGINE AND FUEL SYSTEM PREPARATION

! WARNING
Avoid serious injury or death from a gasoline fire or explosion; gasoline is extremely
flammable and highly explosive under certain conditions. When servicing the fuel system
components ensure that the engine is cool, the ignition switch is in the off position, and
that the lanyard stop switch, if equipped, is in the off position. Do not smoke or allow
spark or open flame in the area. Wipe up any spilled fuel immediately. Ensure that no
fuel leaks exist before closing the engine hatch.

! WARNING
Fuel vapors can be present in the engine compartment. Avoid injury or power package
damage caused by fuel vapors or explosion. Always ventilate the engine compartment
prior to servicing the power package.

1. In a 23 liter (6 U.S.gal.) remote fuel tank mix:

a. 19 liter (5 U.S. gal) regular unleaded 87 octain (90 RON) gasoline
b. 1.89 liter (2 U.S. qts.) Premium Plus 2-Cycle TC-W3 Outboard Oil
c. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel
System Treatment and Stabilizer Concentrate

Tube Ref No. Description Where Used Part No.

Premium Plus 2-cycle TC-W3
115 Fuel system 92-802824A1
Outboard Oil
Fuel System Treatment &
124 Fuel system 802875A1
Stabilizer

2. Allow the engine to cool down.

IMPORTANT: Immediately wipe up any fuel spills or sprays.
3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not
equipped with a fuel shut off valve.
4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting.
IMPORTANT: Supply cooling water to the engine.
5. Start and operate the engine at 1300 rpm for 5 minutes.
6. After specified operating time is complete, slowly return throttle to idle rpm and shut
engine off.
IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the
engines fuel system to become completely dry.
7. Replace the water separating fuel filter element. Refer to Section 5 for proper
procedure.

Draining the Seawater System

! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. Ensure that
the boat is out of the water, the seacock is closed (if equipped) or the seawater inlet hose
is disconnected and plugged on both ends, and the bilge pump is operating before
beginning the draining procedure.

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Storage

! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. When the
drain system is open excess water can enter the bilge. Do not operate the engine with
the drain system open.

IMPORTANT: Only drain the seawater section of the closed cooling system.
IMPORTANT: The boat must be as level as possible to ensure complete draining of the
cooling system.
Your power package is equipped with a drain system. Refer to Drain System
Identification to determine which instructions apply to your power package.
IMPORTANT: The engine must not be operating at any point during the draining procedure.
Drain System Identification
AIR ACTUATED SINGLE POINT DRAIN SYSTEM
c

b
8294

a - Actuator fitting c - Manual release valve

b - Green indicators

b
a 17254

a - Port side drain location b - Starboard side drain location

Page 72 90-864841060 MAY 2006

 Storage

MANUAL DRAIN SYSTEM

a
a
17255

a - Blue drain plug locations

Air Actuated Single Point Drain System

BOAT IN THE WATER
NOTE: This procedure is written for the air pump that is attached to the engine. However,
any air source can be used.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Remove the air pump from the engine.
3. Ensure that the lever on top of the pump is flush with the handle (horizontal).
4. Install the air pump on the actuator fitting.
5. Pull lever on air pump (vertical) to lock pump on the fitting.
c e

a
d

8293
b
a - Actuator fitting d - Air pump
b - Green indicators e - Lever (locking)
c - Manual release valve

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Storage

6. Pump air into the system until both green indicators extend and water drains from both
sides of the engine. The port side will begin draining before the starboard side.
c

b
8294

a - Actuator fitting c - Manual release valve

b - Green indicators

7. Verify that water is draining from each opening. If not, use the Manual Drain System
instructions.

b
a 17254

a - Port side drain location b - Starboard side drain location

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep
the green indicators extended.
9. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit
by pulling the fuse marked "CD".
10. Crank the engine over slightly with the starter motor to purge any water trapped in the
seawater pump. Do not allow engine to start.
11. Remove the air pump from the air manifold and return it to the mounting bracket.
12. Mercury MerCruiser recommends leaving the drain system open while transporting the
boat or while performing other maintenance. This helps ensure that all water is drained.

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 Storage

13. Before launching the boat, pull up on the manual release valve. Verify that the green
indicators are no longer extended.

a
6135

a - Green indicators

14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to
operating the engine.
BOAT OUT OF THE WATER
NOTE: This procedure is written for the air pump that is attached to the engine. However,
any air source can be used.
1. Place the boat on a lever surface to ensure complete draining of system.
2. Remove the air pump from the engine.
3. Ensure that the lever on top of the pump is flush with the handle (horizontal).
4. Install the air pump on the actuator fitting.
5. Pull lever on air pump (vertical) to lock pump on the fitting.
c e

a
d

8293
b
a - Actuator fitting d - Air pump
b - Green indicators e - Lever (locking)
c - Manual release valve

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Storage

6. Pump air into the system until both green indicators extend and water drains from both
sides of the engine. The port side will begin draining before the starboard side.
c

b
8294

a - Actuator fitting c - Manual release valve

b - Green indicators

7. Verify that water is draining from each opening. If not, use the Manual Drain System
instructions.

b
a 17254

a - Port side drain location b - Starboard side drain location

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep
the green indicators extended.
9. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit
by pulling the fuse marked "CD".
10. Crank the engine over slightly with starter motor to purge any water trapped in the
seawater pump. Do not allow engine to start.
11. Remove the air pump from the air manifold and return it to the mounting bracket.
12. Mercury MerCruiser recommends leaving the drain system open while transporting the
boat or while performing other maintenance. This helps ensure that all water is drained.

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 Storage

13. Before launching the boat, pull up on the manual release valve. Verify that the green
indicators are no longer extended.

a
6135

a - Green indicators

Manual Drain System

BOAT IN THE WATER
NOTE: Use this procedure if the air actuated single point drain system fails.
NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain
when hoses are disconnected.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

a
a
17255

a - Blue drain plug locations

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser
recommends leaving the drain system open while transporting the boat or while
performing other maintenance to ensure that all water is drained.
5. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit
by pulling the fuse marked "CD".
6. Crank the engine over slightly with starter motor to purge any water trapped in the
seawater pickup pump. Do not allow the engine to start.
7. Prior to launching the boat or starting the engine, close the drain system by installing
the four blue drain plugs.
8. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to
operating the engine.

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BOAT OUT OF THE WATER

NOTE: Use this procedure if the air actuated single point drain system fails.
NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain
when hoses are disconnected.
1. Place the boat on a lever surface to ensure complete draining of the system.
2. Remove two blue drain plugs from the seawater pickup pump (front, starboard side).

a
a
17255

a - Blue drain plug locations

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser
recommends leaving the drain system open while transporting the boat or while
performing other maintenance to ensure that all water is drained.
5. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit
by pulling the fuse marked "CD".
6. Crank the engine over slightly with starter motor to purge any water trapped in the
seawater pickup pump. Do not allow the engine to start.
7. Prior to launching the boat or starting the engine, close the drain system by installing
the two blue drain plugs.

Battery Storage
Whenever the battery will be stored for an extended period of time, be sure the cells are
full of water and the battery is fully charged and in good operating condition. It should be
clean and free of leaks. Follow the battery manufacturer's instructions for storage.

Power Package Recommissioning

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.

! CAUTION
Avoid electrical system damage. When installing the battery, be sure to connect the
negative (-) battery cable to the negative (-) battery terminal and the positive (+) battery
cable to the positive (+) battery terminal.
2. Install a fully charged battery. Clean the battery cable clamps and terminals and
reconnect cables. Tighten each cable clamp securely when connecting.
3. Coat the terminal connections with a battery terminal anti-corrosion agent.
4. Perform all the checks in the before starting column of the Operation Chart.

Page 78 90-864841060 MAY 2006

 Storage

! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage.
Ensure that there is sufficient water always available at water inlet holes during operation.
5. Start the engine and closely observe instrumentation to ensure that all systems are
functioning correctly.
6. Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks.
7. Inspect the steering system, shift and throttle control for proper operation.

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Storage

Notes:

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 Troubleshooting

Section 7 - Troubleshooting
Table of Contents
Diagnosing EFI Problems................................... 82 Excessive Engine Temperature.......................... 83
Diagnosing DTS Problems................................. 82 Insufficient Engine Temperature......................... 84
Engine Guardian System.................................... 82 Low Engine Oil Pressure.................................... 84
Starter Motor Will Not Crank Engine, Or Cranks Battery Will Not Come Up On Charge................ 84
Slow.................................................................... 82 Remote Control Operates Hard, Binds, Has
Engine Will Not Start Or Is Hard To Start........... 82 Excessive Free-play Or Makes Unusual Sounds
Engine Runs Rough, Misses And/Or Backfires ............................................................................ 84
............................................................................ 83 Steering Wheel Turns Hard Or Jerky.................. 84
Poor Performance............................................... 83

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Troubleshooting

Diagnosing EFI Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing
problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM)
on these engines has the ability to detect some problems with the system when they occur,
and store a Trouble Code in the ECM's memory. This code can then be read later by a
service technician using a special diagnostic tool.

Diagnosing DTS Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing
problems on Digital Throttle and Shift (DTS) Systems. The Electronic Control Module
(ECM)/Propulsion Control Module (PCM) on these engines has the ability to detect some
problems with the system when they occur, and store a Trouble Code in the ECM/PCM's
memory. This code can then be read later by a service technician using a special diagnostic
tool.

Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early
indications of problems. The system will respond to a problem by emitting a continuous
beep and/or reducing engine power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The horn will turn off when
throttle speed is within the allowable limit. Consult an authorized Mercury MerCruiser
dealer for assistance.

Starter Motor Will Not Crank Engine, Or Cranks Slow

Possible Cause Remedy
Battery switch turned off. Turn the switch on.
Remote control not in neutral position. Position the control lever in neutral.
Open circuit breaker or blown fuse. Check and reset the circuit breaker or replace fuse.
Check all electrical connections and wires (especially
Loose or dirty electrical connections or damaged
battery cables). Clean and tighten all faulty
wiring.
connections.
Test the battery and charge if necessary; replace if
Bad battery or low battery voltage.
bad.
Lanyard stop switch activated. Check the lanyard stop switch.

Engine Will Not Start Or Is Hard To Start

Possible Cause Remedy
Lanyard stop switch activated. Check the lanyard stop switch.
Improper starting procedure. Read the starting procedure.
Insufficient fuel supply. Fill fuel tank or open valve.
Faulty ignition system component. Service the ignition system.
Clogged fuel filter. Replace fuel filter.
Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to
Fuel line or tank vent line kinked or clogged.
remove obstruction.
Faulty wire connections. Check wire connections.

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 Troubleshooting

Possible Cause Remedy

Have EFI System checked by an authorized Mercury
EFI system fault.
MerCruiser dealer.

Engine Runs Rough, Misses And/Or Backfires

Possible Cause Remedy
Clogged fuel filter. Replace filter.
Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air
Kinked or clogged fuel line or fuel tank vent line.
to remove obstruction.
Flame Arrestor dirty. Clean Flame Arrestor.
Faulty ignition system component. Service ignition system.
Have EFI system checked by an authorized Mercury
Idle speed too low.
MerCruiser dealer.
Have EFI System checked by an authorized Mercury
EFI System fault.
MerCruiser dealer.

Poor Performance
Possible Cause Remedy
Throttle not fully open. Inspect the throttle cable and linkages for proper operation.
Damaged or improper propeller. Replace the propeller.
Excessive bilge water. Drain and check for cause of entry.
Boat overloaded or load improperly distributed. Reduce load or redistribute load more evenly.
Flame arrestor dirty. Clean the flame arrestor.
Boat bottom fouled or damaged. Clean or repair as necessary.
Ignition problem. See Engine Runs Rough, Misses or Backfires.
Engine overheating. See Excessive Engine Temperature.
Have EFI System checked by an authorized Mercury
EFI System fault
MerCruiser dealer.

Excessive Engine Temperature

Possible Cause Remedy
Water inlet or seacock closed. Open.
Drive belt loose or in poor condition. Replace or adjust belt.
Seawater pickups or sea strainer obstructed. Remove obstruction.
Faulty thermostat. Replace.
Coolant level (if equipped) low in closed cooling Check for cause of low coolant level and repair. Fill
section. system with proper coolant solution.
Heat Exchanger or Fluid Cooler plugged with foreign Clean Heat Exchanger, Engine Oil Cooler, and
material Transmission Oil Cooler (if equipped).
Loss of pressure in closed cooling section. Check for leaks. Clean, inspect and test pressure cap.
Faulty seawater pickup pump. Repair.
Seawater discharge restricted or plugged. Clean exhaust elbows.

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Troubleshooting

Insufficient Engine Temperature

Possible Cause Remedy
Faulty thermostat. Replace.

Low Engine Oil Pressure

Possible Cause Remedy
Insufficient oil in crankcase. Check and add oil.
Excessive oil in crankcase (causing it to become Check and remove required amount of oil. Check for
aerated). cause of excessive oil (improper filling).
Change oil and oil filter, using correct grade and
Diluted or improper viscosity oil. viscosity oil. Determine cause for dilution (excessive
idling).

Battery Will Not Come Up On Charge

Possible Cause Remedy
Excessive current draw from battery. Turn off non-essential accessories.
Alternator drive belt loose or in poor condition. Replace and/or adjust.
Unacceptable battery condition. Test battery, replace if necessary.
Check all associated electrical connections and wires
Loose or dirty electrical connections or damaged
(especially battery cables). Clean and tighten faulty
wiring.
connections. Repair or replace damaged wiring.
Faulty alternator Test alternator output, replace if necessary.

Remote Control Operates Hard, Binds, Has Excessive Free-play Or

Makes Unusual Sounds
Possible Cause Remedy
Insufficient lubrication on shift and throttle linkage
Lubricate.
fasteners.
Obstruction in shift or throttle linkages. Remove obstruction.
Check all throttle linkages. If any are loose or missing,
Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer
immediately.
Straighten cable or have authorized Mercury
Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond
repair.

Steering Wheel Turns Hard Or Jerky

Possible Cause Remedy
Low power steering pump fluid level. Check for leak. Refill system with fluid.
Drive belt loose or in poor condition. Replace and/or adjust.
Insufficient lubrication on steering components. Lubricate.
Check all parts and fasteners if any are loose or missing,
Loose or missing steering fasteners or parts.
see authorized Mercury MerCruiser dealer immediately.
Contaminated power steering fluid. See authorized Mercury MerCruiser dealer.

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 Customer Assistance Information

Section 8 - Customer Assistance Information

Table of Contents
Owner Service Assistance.................................. 86 Parts And Accessories Inquiries ............ 87
Local Repair Service .................................... 86 Resolving A Problem .................................... 87
Service Away From Home ........................... 86 Mercury Marine Service Offices ................... 87
Stolen Power Package ................................. 86 Ordering Literature.............................................. 88
Attention Required After Submersion ........... 86 United States and Canada ........................... 88
Replacement Service Parts .......................... 86 Outside The United States and Canada ...... 88

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Customer Assistance Information

Owner Service Assistance

Local Repair Service
Always return your Mercury MerCruiser powered boat to your authorized dealer should the
need for service arise. Only he has the factory trained mechanics, knowledge, special tools
and equipment and the genuine Quicksilver parts and accessories1. to properly service
your engine should the need occur. He knows your engine best.
Service Away From Home
If you are away from your local dealer and the need arises for service, contact the nearest
authorized dealer. Refer to the Yellow Pages of the telephone directory. If, for any reason,
you cannot obtain service, contact the nearest Regional Service Center. Outside the United
States and Canada, contact the nearest Marine Power International Service Center.
Stolen Power Package
If your power package is stolen, immediately advise the local authorities and Mercury
Marine of the model and serial numbers and to whom the recovery is to be reported. This
information is maintained in a database at Mercury Marine to aid authorities and dealers
in recovery of stolen power packages.
Attention Required After Submersion
1. Before recovery, contact an authorized Mercury MerCruiser dealer.
2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is
required to reduce the possibility of serious engine damage.
Replacement Service Parts
! WARNING
Serious injury or death may occur to the boating public if boat systems are incorrectly
designed, manufactured, or installed. To minimize risks of fire or explosion, electrical,
ignition and fuel system components on Mercury Marine power products are designed
and manufactured to comply with numerous international directives, federal regulations,
voluntary standards, and product installation instructions.
Use or installation of replacement electrical, ignition or fuel system components, which
do not comply with these directives, regulations, standards and instructions could result
in a fire or explosion hazard and should be avoided.

Marine engines are expected to operate at or near full throttle for most of their life. They
are also expected to operate in both fresh and saltwater environments. These conditions
require numerous special parts. Care should be exercised when replacing marine engine
parts as specifications are quite different from those of the standard automotive engine.
For example, one of the most important, and probably the least suspected special
replacement part, is the cylinder head gasket. Since saltwater is highly corrosive, the
steel-type automotive head gasket cannot be used. A marine engine head gasket uses
special materials to resist corrosive action.
Since marine engines must be capable of running at or near maximum RPM much of the
time, special valve springs, valve lifters, pistons, bearings, camshafts and other heavy duty
moving parts are required for long life and peak performance.
These are but a few of the many special modifications that are required in Mercury
MerCruiser marine engines to provide long life and dependable performance.
1. Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser sterndrives
and inboards.

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 Customer Assistance Information

PARTS AND ACCESSORIES INQUIRIES

All inquiries concerning Quicksilver replacement parts and accessories should be directed
to your local authorized dealer. The dealer has the necessary information to order parts
and accessories for you should he not have them in stock. Only authorized dealers can
purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does
not sell to unauthorized dealers or retail customers. When inquiring on parts and
accessories, the dealer requires the engine model and serial numbers to order the
correct parts.
Resolving A Problem
Satisfaction with your Mercury MerCruiser product is very important to your dealer and to
us. If you ever have a problem, question or concern about your power package, contact
your dealer or any authorized Mercury MerCruiser dealership. If additional assistance is
required, take these steps:
1. Talk with the dealership's sales manager or service manager. If this has already been
done, then contact the owner of the dealership.
2. Should you have a question, concern or problem that cannot be resolved by your
dealership, please contact Mercury Marine Service Office for assistance. Mercury
Marine will work with you and your dealership to resolve all problems.
The following information will be needed by the service office:
• Your name and address
• Daytime telephone number
• Model and serial numbers for your power package
• The name and address of your dealership
• Nature of problem
Mercury Marine Service Offices are listed on the next page.
Mercury Marine Service Offices
For assistance, call, fax or write. Please include your daytime telephone number with mail
and fax correspondence.
Telephone Fax Mail

Mercury MerCruiser
(405) 743 6566 (405) 743 6570 3003 N. Perkins Rd.
Stillwater, OK 74075

Mercury Marine Ltd.

2395 Meadowpine Blvd.
(905) 567 MERC (6372) (905) 567 8515
Mississauga, Ontario L5N 7W6
Canada

Mercury Marine Australia

132-140 Frankston Road
(61) (3) 9791 5822 (61) (3) 9793 5880
Dandenong, Victoria 3164
Australia

Marine Power - Europe, Inc.

Parc Industriel de Petit-Rechain
(32) (87) 32 32 11 (32) (87) 31 19 65
B-4800 Verviers,
Belgium

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Customer Assistance Information

Telephone Fax Mail

Mercury Marine - Latin America & Caribbean
11650 Interchange Circle North,
(954) 744 3500 (954) 744 3535
Miramar, FL 33025
U.S.A.

Mercury Marine - Japan

283-1 Anshin-cho
(81) 53 423 2500 (81) 53 423 2510
Hamamatsu, Shizuoka 435-0005
Japan

Mercury Marine Singapore

72 Loyang Way
(65) 6546 6160 (65) 6546 7789
, 508762
Singapore

Ordering Literature
Before ordering literature, please have the following information about your power package
available:
• Model
• Serial Number
• Horsepower
• Year built
United States and Canada
For information on additional literature that is available for your particular Mercury
MerCruiser power package and how to order that literature contact your nearest dealer or
contact
Mercury Marine Publications
P.O. Box 1939
Fond du Lac, WI 54936-1939
(920) 929-5110
Fax (920) 929-4894
Outside The United States and Canada
Contact your nearest dealer or Marine Power Service Center for information on additional
literature that is available for your particular Mercury MerCruiser power package and how
to order that literature.
Please return with payment to:
Mercury Marine
Attn: Publications Department
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Ship To: (Please Print Or Type - This Is Your Shipping Label)
Name
Address
City State ZIP

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