90-899883173 1207

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

*899883173*
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
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

5.7 MPI & 5.7 Horizon with Emissions Control

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.

Patrick C. Mackey
© 2007 Mercury Marine

President ‑ Mercury Marine, Fond du Lac, WI USA

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 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.
© 2007, 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.

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 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, dangers, warnings, cautions, and
notices, 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. These safety alerts follow ANSI
standard Z535.6‑2006 for product safety information in product manuals, instructions, and
other collateral materials. 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.

! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.

! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate
injury.

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 NOTICE
Indicates a situation which, if not avoided, could result in engine or major component
failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

! 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
The engine exhaust from this product contains chemicals known to the state of California
to cause cancer, birth defects or other reproductive harm.

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 TABLE OF CONTENTS

Section 1 - Warranty

Warranty Registration: United States and California Emissions Limited Warranty..................10

Canada....................................................................2 What Is Covered...............................................10
Warranty Registration: Outside the United States and Duration Of Coverage.......................................11
Canada....................................................................2 How To Obtain Warranty Coverage..................12
Transfer of Warranty................................................ 3 What Mercury Will Do.......................................12
Mercury Product Protection Plan: United States and What Is Not Covered........................................12
Canada....................................................................3 Components Of The Emission Control System 12
Mercury MerCruiser Limited Warranty Disclaimers And Limitations..............................14
(Gasoline‑Fueled Products Only) ...........................4 California Emission Control Warranty Statement. .14
3‑Year Limited Warranty Against Corrosion............6 Your Warranty Rights and Obligations.............14
Global Warranty Charts...........................................7 Manufacturer's Warranty Coverage..................14
Consumer Application Warranty Chart...............7 Owner's Warranty Responsibilities...................14
Commercial Application Warranty Chart.............8 Emission Control Information Label.......................15
Government Application Warranty Chart............9 Owner Responsibility........................................16
Mercury Installation Quality Certification Program. .9 Emission Certification Star Label...........................16

Section 2 - Getting to Know Your Power Package

Identification..........................................................20 Panel Mount Features....................................28

Engine Serial Number Decal..........................20 Console Mount Features ‑ Single Engine.......29
Transmissions................................................20 Slim Binnacle Console Mount Features ‑ Single
Velvet Drive Transmissions .........................20 Engine............................................................30
ZF Marine Transmissions.............................21 Console Mount Features‑ Dual Engine..........31
Walter V‑Drive Transmissions......................22 Synchronizing Dual Engines..........................31
Lanyard Stop Switch..............................................22 Dual Helm Station Transfer............................32
Instrumentation......................................................23 Synchronizing Dual Helms Prior To Station
VesselView.....................................................23 Transfer........................................................33
Digital Gauges................................................24 Zero Effort Features.......................................33
Analog Gauges...............................................25 Electrical System Overload Protection..................33
Remote Controls (Non‑DTS Models).....................25 Audio Warning System..........................................36
Remote Controls............................................25 Caution.............................................................36
Panel Mount Features..................................26 Severe..............................................................36
Console Mount Features..............................27 OBDM...............................................................37
Zero Effort Features.......................................27 Testing The Audio Warning System.................37
Remote Controls (DTS Models)............................28 Guardian Strategy.................................................37
Remote Controls............................................28

Section 3 - On the Water

Safe Boating Suggestions.....................................40 Operation Chart............................................42

Be Alert to Carbon Monoxide Poisoning................41 Starting and Stopping the Engine...................43
Good Ventilation...............................................41 Starting the Engine.......................................43
Poor Ventilation ...............................................42 Stopping the Engine.....................................44
Basic Boat Operation (Non‑DTS Models)..............42 Throttle‑Only Operation..................................44
Launching and Boat Operation.......................42 Freezing Temperature Operation...................44

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 Drain Plug and Bilge Pump...........................44 Boats Having An Open Front Deck..................48
Basic Boat Operation (DTS Models).................... 44 Boats With Front‑Mounted, Raised Pedestal
Launching and Boat Operation..................... 44 Fishing Seats...................................................48
Operation Chart.......................................... 44 Wave and Wake Jumping.................................... 49
Starting and Stopping the Engine................. 45 Impact with Underwater Hazards......................... 49
Starting the Engine..................................... 45 Conditions Affecting Operation............................. 50
Stopping the Engine.................................... 46 Weight Distribution (Passengers and Gear)
Throttle‑Only Operation.................................46 Inside the Boat.............................................. 50
Freezing Temperature Operation..................47 The Bottom of the Boat................................. 50
Drain Plug and Bilge Pump...........................47 Cavitation...................................................... 50
Protecting People in the Water............................. 47 Ventilation..................................................... 51
While You Are Cruising....................................47 Elevation and Climate................................... 51
While Boat Is Stationary.................................. 47 Getting Started..................................................... 51
High‑Speed and High‑Performance Operation.... 48 20‑Hour Break‑In Period............................... 51
Passenger Safety in Pontoon Boats and Deck After Break‑In Period.....................................51
Boats.................................................................... 48 End of First Season Checkup....................... 52

Section 4 - Specifications

Cruising RPM....................................................... 54 Engine Oil.............................................................55

Fuel Requirements...............................................54 Engine Specifications...........................................56
Fuel Ratings.....................................................54 Fluid Specifications.............................................. 57
Using Reformulated (Oxygenated) Gasoline Engine...........................................................57
(USA Only).......................................................54 Transmission.................................................57
Gasoline Containing Alcohol........................... 54

Section 5 - Maintenance

Owner/Operator Responsibilities.......................... 60 Changing ......................................................70

Dealer Responsibilities.........................................60 Battery..................................................................70
Maintenance.........................................................60 Multiple EFI Engine Battery Precautions....... 70
Do‑It‑Yourself Maintenance Suggestions.............61 Cleaning the Flame Arrestor................................ 71
Inspection.............................................................61 Positive Crankcase Ventilation Valve (PCV)... 72
Maintenance Schedule—Inboard Models............ 62 Changing..................................................... 72
Routine Maintenance.................................... 62 Cleaning The IAC Muffler.....................................72
Scheduled Maintenance................................ 62 Water‑Separating Fuel Filter................................ 73
Maintenance Log..................................................63 GEN III Models..............................................74
Engine Oil.............................................................64 Removal......................................................74
Checking....................................................... 64 Installation...................................................75
Filling.............................................................64 Lubrication............................................................75
Changing Oil and Filter................................. 65 Throttle Cable................................................75
Easy Engine Oil Drain System......................65 Transmission Linkage................................... 76
Engine Oil Drain Pump..................................66 Serpentine Drive Belt........................................... 77
Changing the Oil Filter.................................. 67 Checking..........................................................77
Transmission Fluid............................................... 67 Replacing Belt and/or Adjusting Tension.........77
Checking While the Engine is Warm............... 67 Flushing The Power Package.............................. 78
Checking While Engine is Cold........................68 Horizon Models................................................78
Changing......................................................... 68 The Boat Out of the Water...............................80
Engine Coolant.....................................................68 The Boat In the Water......................................81
Checking....................................................... 68
Filling.............................................................69

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 Section 6 - Storage

Cold Weather or Extended Storage....................... 86 Boat in the Water.........................................89

Preparing Power Package for Storage...........86 Boat out of the Water...................................91
Engine and Fuel System Preparation..........87 Three‑Point Manual Drain System.................93
Draining the Seawater System..............................88 Boat in the Water.........................................93
Drain System Identification............................. 88 Boat out of the Water...................................94
Air Actuated Single Point Drain System.......88 Battery Storage...................................................... 95
Three Point Manual Drain System...............89 Power Package Recommissioning........................95
Air Actuated Single Point Drain System.........89

Section 7 - Troubleshooting

Diagnosing EFI Problems......................................98 Poor Performance..........................................99

Diagnosing DTS Problems....................................98 Excessive Engine Temperature.....................99
Engine Guardian System....................................... 98 Insufficient Engine Temperature..................100
Troubleshooting Charts.........................................98 Low Engine Oil Pressure..............................100
Starter Motor Will Not Crank Engine, or Cranks Battery Will Not Recharge............................100
Slowly.............................................................98 Remote Control Is Difficult to Move, Has
Engine Will Not Start or Is Hard to Start.........99 Excessive Play, or Makes Unusual Sounds. 100
Engine Runs Rough, Misses, or Backfires.....99 Steering Wheel Jerks or Is Difficult to Turn. .101

Section 8 - Customer Assistance Information

Owner Service Assistance...................................104 Parts and Accessories Inquiries.................105

Local Repair Service.......................................104 Resolving a Problem.......................................105
Service Away From Home..............................104 Mercury Marine Service Offices......................105
Stolen Power Package...................................104 Ordering Literature..............................................106
Attention Required after Submersion..............104 United States and Canada..............................106
Replacement Service Parts............................104 Outside The United States and Canada.........106

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 Page iv 90-899883173 DECEMBER 2007
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 Section 1 - Warranty

Section 1 - Warranty 1
Table of Contents
Warranty Registration: United States and Canada What Is Covered .......................................... 10
.............................................................................. 2 Duration Of Coverage .................................. 11
Warranty Registration: Outside the United States How To Obtain Warranty Coverage ............. 12
and Canada.......................................................... 2 What Mercury Will Do .................................. 12
Transfer of Warranty............................................. 3 What Is Not Covered .................................... 12
Mercury Product Protection Plan: United States and Components Of The Emission Control
Canada................................................................. 3 System ......................................................... 12
Mercury MerCruiser Limited Warranty (Gasoline- Disclaimers And Limitations ......................... 14
Fueled Products Only) ......................................... 4 California Emission Control Warranty Statement
3-Year Limited Warranty Against Corrosion......... 6 ............................................................................ 14
Global Warranty Charts........................................ 7 Your Warranty Rights and Obligations ......... 14
Consumer Application Warranty Chart ........... 7 Manufacturer's Warranty Coverage ............. 14
Commercial Application Warranty Chart ........ 8 Owner's Warranty Responsibilities .............. 14
Government Application Warranty Chart ....... 9 Emission Control Information Label.................... 15
Mercury Installation Quality Certification Program Owner Responsibility ................................... 16
.............................................................................. 9 Emission Certification Star Label........................ 16
California Emissions Limited Warranty............... 10

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 Section 1 - Warranty

Warranty Registration: United States and Canada

To ensure that your warranty coverage begins promptly, your selling dealer should fill out
the Warranty Registration Card completely and mail it to the factory immediately upon sale
of the new product.
The Warranty Registration Card identifies the name and address of the original purchaser,
product model and serial number(s), date of sale, type of use and selling dealer’s code,
name, and address. The dealer also certifies that you are the original purchaser and user
of the product. A temporary Owner Warranty Registration Card will be presented to you
when you purchase the product.
Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send
you an owner resource guide that includes your warranty registration confirmation. If you
do not receive your owner resource guide within 60 days from date of new product sale,
please contact your selling dealer.
Because of your selling dealer’s ongoing interest in your satisfaction, the product should
be returned to him for warranty service.
The product warranty is not effective until the product is registered at the factory.
NOTE: Registration lists must be maintained by the factory and dealer on marine products
sold in the United States in the event that a safety recall notification under the Federal Boat
Safety Act is required.
You may change your address at any time, including at time of warranty claim, by calling
Mercury MerCruiser or sending a letter or fax to Mercury MerCruiser’s warranty registration
department with your name, old address, new address, and engine serial number. Your
dealer can also process this change of information.
United States customers or dealers may contact:
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
Canadian customers or dealers may contact:
Mercury Marine Canada Limited
2395 Meadowpine Blvd.
Mississauga, ON
Canada, L5N 7W6
Fax 1-800-663-8334

Warranty Registration: Outside the United States and Canada

To ensure that your warranty coverage begins promptly, your selling dealer should fill out
the warranty registration card completely and mail it to the distributor responsible for
administering the warranty registration and claim program for your area.

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 Section 1 - Warranty

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 and dealer’s code number,
name, and address. The distributor or dealer also certifies that you are the original
purchaser and user of the product. 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 or dealer. This card represents your factory
registration identification. Keep the card; if you ever need 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.
In some countries, the distributor will issue a permanent (plastic) warranty registration card
to you within 30 days after receiving the factory copy of the warranty registration card from
your distributor or dealer. If you receive a plastic warranty registration card, you may
discard the purchaser’s copy that you received from the distributor or dealer when you
purchased the product. Ask your distributor or dealer if this plastic card program applies to
you. For further information concerning the warranty registration card and its relationship
to warranty claim processing, refer to the International Warranty. See Table of Contents.
NOTE: Registration lists must be maintained by the factory and dealer on marine products
sold in the United States in the event of a safety recall notification under the Federal Boat
Safety Act.

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 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
In Canada mail to:
Mercury Marine Canada Limited
2395 Meadowpine Blvd.
Mississauga, ON
Canada, L5N 7W6
Fax 1-800-663-8334
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 distributor closest to you.

Mercury Product Protection Plan: United States and Canada

(Certain performance products, triple engine installations, and commercial applications are
excluded.)

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 Section 1 - Warranty

The Mercury Product Protection Plan provides coverage against unexpected mechanical
and electrical breakdowns that may occur beyond the standard limited warranty.
The optional Mercury Product Protection Plan is the only Factory Plan available for your
engine.
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after
the original engine registration date.
See your participating Mercury MerCruiser dealer for complete program details.

Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products

Only)
Mercury MerCruiser Limited Warranty (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 following.

Duration of Coverage
Warranty Period for Recreational Use
The warranty period begins on 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. Products installed by an Installation Quality Certified Installer receive one
(1) year of additional warranty coverage. 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. The warranty period is specific to the model covered;
see your model for the base coverage period:
Coverage for Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, and Vazer 100
Models The Limited Warranty for Sterndrive Models with Closed Cooling, Inboard Models, Scorpion 377 Models, and
Vazer 100 Models is four (4) years when installed by an Installation Quality Certified Installer or three (3) years for
noncertified installations.
Coverage for SeaCore Sterndrive Models
The Limited Warranty for SeaCore Sterndrive Models is four (4) years when installed by an Installation Quality Certified
Installer or three (3) years for noncertified installations.
Coverage for Standard Models
The Limited Warranty for Standard Models, which do not include Sterndrive Models with Closed Cooling, Inboard Models,
Scorpion 377 Models, Vazer 100 Models, or SeaCore Sterndrive Models, is two (2) years when installed by an Installation
Quality Certified Installer or one (1) year for noncertified installations.
Warranty Period for Commercial Use
The warranty period begins on the date the product is first sold to a commercial‑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‑related or employment‑related use of the product, or any use of the product that 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.

Transfer of Coverage
Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer
upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use
customer.

Termination of Coverage
Warranty coverage is terminated for used product obtained in any of the following ways:
• Repossession from a retail customer
• Purchase at auction
• Purchase from a salvage yard
• Purchase from an insurance company that obtained the product as a result of an insurance claim

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 Section 1 - 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 pre‑delivery inspection process specified by Mercury Marine
is completed and documented. Warranty coverage becomes available upon proper registration of the product by the authorized
dealer. Inaccurate warranty registration information regarding recreational use or subsequent change of use from recreational to
commercial (unless properly reregistered) may void the warranty at the sole discretion of Mercury Marine. Routine maintenance
must be performed according to the maintenance schedule in the Operation, Maintenance & Warranty manual in order to obtain
warranty coverage. Mercury Marine reserves the right to make any warranty coverage contingent upon proof of proper maintenance.

What Mercury Marine Will Do

Mercury Marine'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 Marine
product. Mercury Marine 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 Marine 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 Marine dealer authorized to service the
product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury Marine. Mercury Marine
will then arrange for the inspection and any covered repair. The purchaser in that case shall pay for all related transportation charges
and travel time. If the service provided is not covered by this warranty, the purchaser shall pay for all related labor and material and
any other expenses associated with that service. The purchaser shall not, unless requested by Mercury Marine, ship the product or
parts of the product directly to Mercury Marine. 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 the following:
• Routine maintenance items
• Adjustments
• Normal wear and tear
• Damage caused by abuse
• Abnormal use
• Use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation,
Maintenance & Warranty manual)
• Operation of the product in a manner inconsistent with the recommended operation and duty cycle section of the Operation,
Maintenance & Warranty manual
• Neglect
• Accident
• Submersion
• Improper installation (proper installation specifications and techniques are set forth in the installation instructions for the product)
• Improper service
• Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product
• Jet pump impellers and liners
• Operation with fuels, oils, or lubricants that are not suitable for use with the product (see the Operation, Maintenance & Warranty
manual)
• Alteration or removal of parts
• Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient
cooling water caused by blockage of the cooling system by a foreign body
• Running the engine out of water
• Mounting the engine too high on the transom
• Operating the boat with the engine over trimmed

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 Section 1 - Warranty

Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any point, even by a previous
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 or replacement of boat partitions or other material in
order to gain 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. If such affirmation, representation, or warranty is made, it 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

3-YEAR LIMITED WARRANTY AGAINST CORROSION
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.
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 and
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
(noncommercial use) purchaser upon proper re‑registration of the product. Warranty coverage is terminated
for used product repossessed from a retail customer, purchased at auction, from a salvage yard, or from an
insurance company that obtained the product as a result of an insurance claim.
Condition 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, Maintenance & Warranty manual must be in use on the boat, and routine
maintenance outlined in the Operation, Maintenance & Warranty 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

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 Section 1 - Warranty

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 the 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 warranty period, even
if the product is only occasionally used for such purposes.

Global Warranty Charts

IMPORTANT: Please refer to www.mercurymarine.com/global_warranty for the most
currant Global Warranty Charts.
Consumer Application Warranty Chart
Limited Corrosion
Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand
Warranty
Non-Certified Boat Brand Certified Boat Brand All Boat Brands
Vazer,
Standard
Vazer and Vazer and
Models,
Models Models
Scorpion Scorpion and and
Region Standard SeaCore with Standard SeaCore with SeaCore
377 377 Models
Closed Closed
with
Cooling Cooling
Closed
Cooling
USA and
1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years
Canada
Latin
1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years
America
Mexico 1 year 3 years 1 year 1 year 1 year 4 years 1 year 1 year 1 year 4 years
Europe 2 years 3 years 2 years 2 years 3 years 4 years 3 years 3 years 3 years 4 years
Japan 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year
Australia 3 years all 3 years all
and New 2 years 3 years 3 years Tow 2 years 3 years 3 years Tow 3 years 4 years
Zealand Sports Sports
South
1 year 3 years 1 year 1 year 1 year 3 years 1 year 1 year 3 years 4 years
Pacific
Asia
(excluding
Japan,
3 years all 3 years all
South
2 years 2 years 2 years Tow 2 years 2 years 2 years Tow 2 years 2 years
Pacific,
Sports Sports
Australia,
New
Zealand)
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies.
NOTE: In regions where TBD (To Be Determined) is listed, check with your local dealer for warranty length and conditions.

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 Section 1 - Warranty

Commercial Application Warranty Chart

Limited Corrosion
Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand
Warranty
Non-Certified Boat Brand Certified Boat Brand All Boat Brands
Vazer,
Standard
Vazer and Vazer and
Models,
Models Models
Scorpion Scorpion and and
Region Standard SeaCore with Standard SeaCore with SeaCore
377 377 Models
Closed Closed
with
Cooling Cooling
Closed
Cooling
USA and 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
Canada 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Latin 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
America 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Mexico 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
Europe none none
500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
Japan none none
500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Australia
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
and New none none
500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Zealand
South 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
Pacific 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Asia
(excluding
Japan,
South 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
Pacific, 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Australia,
New
Zealand)
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies

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 Section 1 - Warranty

Government Application Warranty Chart

Limited Corrosion
Government Application: Standard Factory Limited Warranty by Region & Boat Brand
Warranty
Non-Certified Boat Brand Certified Boat Brand All Boat Brands
Vazer,
Standard
Vazer and Vazer and
Models,
Models Models
Scorpion Scorpion and and
Region Standard SeaCore with Standard SeaCore with SeaCore
377 377 Models
Closed Closed
with
Cooling Cooling
Closed
Cooling
USA and
1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years
Canada
Latin 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
America 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Mexico 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1year
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
Europe none none
500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
Japan none none
500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Australia
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
and New none none
500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Zealand
South 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
Pacific 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Asia
(excluding
Japan,
South 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
none none
Pacific, 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours 500 hours
Australia,
New
Zealand)
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies

Mercury Installation Quality Certification Program

15502

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 Section 1 - Warranty

Mercury MerCruiser products installed by a Mercury Installation Quality Certified

Manufacturer are Installation Quality certified products and may receive an additional one
(1) year of limited warranty coverage.
The Installation Quality Certification program was developed to recognize MerCruiser
boatbuilder customers who have achieved higher manufacturing standards. It is the first
and only comprehensive manufacturer‑installation certification program in the industry.
The program has three goals:
1. To enhance overall product quality.
2. To improve the boat ownership experience.
3. To enhance overall customer satisfaction.
The certification process is designed to review all facets of manufacturing and engine
installation. The program is composed of design, manufacturing and installation review
stages with which builders must comply. Certification applies leading‑edge methodologies
to create:
• Efficiencies and best practices specific to engine installation.
• World‑class assembly and component specifications.
• Efficient installation processes.
• Industry standard end‑of‑line test procedures
Boat builders that successfully complete the program and meet all certification
requirements earn Installation Quality System Certified Manufacturer status and receive
an additional one (1) year of Mercury limited factory warranty coverage on all
MerCruiser‑powered boats that are registered on and after the boat builder's certification
date for all worldwide registrations.
Mercury has designated a section of our Website to promote the Installation Quality
Certification Program and communicate its benefits to consumers. For a current list of
MerCruiser‑powered boat brands that have earned Installation Quality Certification, visit
www.mercurymarine.com/mercruiser_warranty.

California Emissions Limited Warranty

NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product
line. In order to comply with CARB warranty regulations, and for that limited purpose only,
model year shall have the same meaning as calendar year. As an example, 2003 model
year products refers to products manufactured during calendar year 2003.
The California Air Resources Board has promulgated air emissions regulations for inboard
and sterndrive engines. The regulations apply to all inboard and sterndrive engines that
were manufactured for the 2003 model year and later. Mercury Marine, in compliance with
those regulations, provides this limited warranty for the emission control systems (see the
components of the emission control system listed following), and further warrants that the
inboard or sterndrive engine was designed, built, and equipped to conform with all
applicable regulations adopted by the California Air Resources Board pursuant to its
authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. For
information regarding the limited warranty for the non‑emissions related components of the
inboard or sterndrive engine, please see the limited warranty statement for your engine.
What Is Covered
NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product
line. In order to comply with CARB warranty regulations, and for that limited purpose only,
model year shall have the same meaning as calendar year. As an example, 2003 model
year products refers to products manufactured during calendar year 2003.

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 Section 1 - Warranty

NOTE: Your dealer will register your engine for warranty coverage for you. The warranty
registration process is not related in any way to the process of obtaining a license, title or
registration from state boating authorities. You should ask your dealer to update your
warranty registration information to reflect a change of address or a transfer of ownership.
(This change may be made at any time.) See the Warranty Registration section of your
manual or your dealer for more information.
Mercury Marine warrants the components of the emissions control systems (see the
components of the emission control system listed following) of its new, 2003 model year
and later California certified inboard and sterndrive engines, registered to a California
resident, to be free from defects in material or workmanship that cause the failure of a
warranted part to be identical in all material respects to that part as described in the
application of Mercury Marine for certification from the California Air Resources Board, for
the period of time, and under the conditions identified below. The cost to diagnose a
warranty failure is covered under the warranty (if the warranty claim is approved). Damage
to other engine components caused by the failure of a warranted part will also be repaired
under warranty.
Duration Of Coverage
NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product
line. In order to comply with CARB warranty regulations, and for that limited purpose only,
model year shall have the same meaning as calendar year. As an example, 2003 model
year products refers to products manufactured during calendar year 2003
This limited warranty provides coverage for the components of the emissions control
systems. Select emission control parts from model year 2003‑2005 (inboard or sterndrive)
engines are warranted for 2 years from either the date the product is first sold, or first put
into service, whichever occurs first. Select emission control parts from 2006‑2007 (inboard
or sterndrive) engines are warranted for 2 years from either the date the product is first
sold, or first put into service, whichever occurs first. Select emission control parts from 2008
(inboard or sterndrive) engines are warranted for 3 years or 480 hours, whichever first
occurs, from either the date the product is first sold, or first put into service, whichever
occurs first. Select emission control parts from 2009 and later (inboard or sterndrive)
engines are warranted for 3 years or 480 hours, whichever first occurs, from either the date
the product is first sold, or first put into service, whichever occurs first. Emission related
normal maintenance items such as spark plugs and filters, that are on the warranted parts
list (see following) are warranted up to their first required replacement interval only. (See
Maintenance Schedule). The repair or replacement of parts, or the performance of service
under this warranty, does not extend the life of this warranty beyond its original expiration
date. Unexpired warranty coverage can be transferred to a subsequent purchaser. (See
instructions on transfer of warranty). Warranty coverage is terminated for used product
repossessed from a retail customer, purchased at auction, from a salvage yard, or from an
insurance company that obtained the product as a result of an insurance claim.

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 Section 1 - 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, please notify Mercury Marine and
Mercury 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 Mercury Will Do
Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our
expense and at our option, repairing or replacing defective 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.
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 wide‑open‑throttle RPM
range (see Specifications), operation of the product in a manner inconsistent with the
recommended operation procedures, 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 Specifications), alteration or removal of parts, or water
entering the engine through the fuel intake, air intake or exhaust system. 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.
Non‑warranty maintenance, replacement, or repair of emission control devices and
systems may be performed by any marine engine repair establishment or individual. The
use of non‑Mercury parts for non‑warranty maintenance or repairs will not be grounds for
disallowing other warranty work. The use of add‑on (as defined at section 1900 (b)(1) and
(b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted
by the California Air Resources Board may be grounds for disallowing a warranty claim, at
the discretion of Mercury Marine. Failures of warranted parts caused by the use of a
non‑exempted add‑on or modified part will not be covered.
Components Of The Emission Control System
1. Fuel Metering System
a. Carburetor and internal parts (and/or pressure regulator or fuel injection system)
b. Air/fuel ratio feedback and control system

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 Section 1 - Warranty

c. Cold start enrichment system

d. Intake valve(s)
2. Air Induction System
a. Controlled hot air intake system
b. Intake manifold
c. Air filter
d. Turbocharger systems
e. Heat riser valve and assembly
3. Ignition System
a. Spark plugs
b. Magneto or electronic ignition system
c. Spark advance/retard system
d. Ignition coil and/or control module
e. Ignition wires
4. Lubrication System
a. Oil pump and internal parts
b. Oil injector(s)
c. Oil meter
5. Positive Crankcase Ventilation (PCV) System
a. PCV Valve
b. Oil filler cap
6. Exhaust System.
a. Exhaust manifold
b. Exhaust elbow
c. Intermediate exhaust elbow
d. Lower exhaust pipe
e. Tailpipe
7. Catalysts or Thermal Reactor System
a. Catalytic converter
b. Thermal reactor
c. Exhaust manifold
d. Exhaust valve(s)
8. Miscellaneous Items Used in Above Systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting
hardware
b. Pulleys, belts, and idlers
c. Vacuum, temperature, check and time sensitive valves and switches
d. Electronic controls

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 Section 1 - Warranty

Disclaimers And Limitations

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.

If you have any questions regarding your warranty rights and responsibilities, refer to
Owner Service Assistance for contact information.

California Emission Control Warranty Statement

Your Warranty Rights and Obligations
The California Air Resources Board is pleased to explain the emission control system
warranty on your 2003 model year1. and later inboard or sterndrive engine. In California,
new inboard and sterndrive engines must be designed, built and equipped to meet the
State's stringent anti‑smog standards. Mercury Marine must warrant the emission control
system on your inboard or sterndrive engine for the periods of time listed below provided
there has been no abuse, neglect or improper maintenance of your inboard or sterndrive
engine.
Your emission control system may include parts such as the carburetor or fuel injection
system, the ignition system, and catalytic converter. Also included may be hoses, belts,
connectors and other emission‑related assemblies.
Where a warrantable condition exists, Mercury Marine will repair your inboard or sterndrive
engine at no cost to you; including diagnosis, parts and labor.
Manufacturer's Warranty Coverage
For 2003‑2008 spark‑ignition inboard and sterndrive marine engines: Select emission
control parts from model year1. 2003‑2008 inboard and sterndrive engines are warranted
for 2 years. If any emission‑related part on your engine is defective under warranty, the
part will be repaired or replaced by Mercury Marine.
Owner's Warranty Responsibilities
As the inboard or sterndrive engine owner, you are responsible for the performance of the
required maintenance listed in your owner's manual. Mercury Marine recommends that you
retain all receipts covering maintenance on your inboard or sterndrive engine, but Mercury
Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the
performance of all scheduled maintenance.
As the inboard or sterndrive engine owner, you should however be aware that Mercury
Marine may deny you warranty coverage if your inboard or sterndrive engine or a part has
failed due to abuse, neglect, improper maintenance or unapproved modifications. Warranty
coverage is terminated for used product repossessed from a retail customer, purchased
at auction, from a salvage yard, or from an insurance company that obtained the product
as a result of an insurance claim.

1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty
regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003
model year products refers to products manufactured during calendar year 2003.

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 Section 1 - Warranty

You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine
dealer authorized to service the product as soon as a problem exists. The warranty repairs
will be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, refer to
Owner Service Assistance for contact 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, STD (emission standard/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.
NOTE: When the CE 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.

EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
SERIAL # XXXXXXXX MMM YYYY
D.O.M.
FAMILY XXXXXXXXXXXX
DISP X.XL
STD. XX.X g/kW-hr 0575

31656
Emission Control Label—California Emissions–Compliant
"SERIAL#"—Engine Serial Number
"FAMILY"—Engine Family
"STD."—Emissions Standard
"D.O.M."—Date of Manufacture
"DISP"—Piston Displacement

EMISSION CONTROL
INFORMATION

NOT FOR SALE IN CALIFORNIA

REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
SERIAL # XXXXXXXX D.O.M. MMM YYYY
FAMILY XXXXXXXXXXXX
STD. XX.X g/kW-hr DISP X.XL
31657
Emission Control Label—Not for Sale in California
"SERIAL#"—Engine Serial Number
"FAMILY"—Engine Family

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 Section 1 - Warranty

"STD."—Emissions Standard
"D.O.M."—Date of Manufacture
"DISP"—Piston Displacement
Owner Responsibility
The operator must have routine engine maintenance performed to maintain emission levels
within prescribed certification standards.
The operator may not modify the engine in any manner that alters the horsepower or allows
emissions levels to exceed their factory specifications.

Emission Certification Star Label

Your boat is labeled on the hull with one of the following star labels. The Symbol for Cleaner
Marine Engines Means:
1. Cleaner Air and Water ‑ for a healthier lifestyle and environment.
2. Better Fuel Economy ‑ burns up to 30‑40 percent less gas and oil than conventional
carbureted two‑stroke engines, saving money and resources.
3. Longer Emission Warranty ‑ Protects consumer for worry free operation.
Beginning January 1, 2003, one Three‑Star or Four‑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 or Four‑Star Super Ultra Low Emission rating. The Star label identifies that
these engines meet the California Air Resources Board's Sterndrive and Inboard marine
engine 2007 and later exhaust emission standards. Engines meeting these standards have
65‑90% lower emissions than One‑Star – Low Emissions engines.
The Star label will be affixed on the left side of the hull as shown.

XX 1234 XX
a b

32770
a - Recommended location b - Secondary location

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 Section 1 - Warranty

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

SS
The three‑star label identifies engines that meet the Air
A 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 engines.
mc79571-1

Four Stars - Super Ultra Low emission

T
The Four Star label identifies engines that meet the Air
RN
Resources Board's Sterndrive and Inboard marine engine
F

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

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 Section 1 - Warranty

Notes:

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 Section 2 - Getting to Know Your Power Package

Section 2 - Getting to Know Your Power Package

Table of Contents
Identification........................................................ 20 Panel Mount Features...................................28 2
Engine Serial Number Decal.........................20 Console Mount Features - Single Engine.....29
Transmissions...............................................20 Slim Binnacle Console Mount Features - Single
Velvet Drive Transmissions ................... 20 Engine...........................................................30
ZF Marine Transmissions ....................... 21 Console Mount Features- Dual Engine.........31
Walter V-Drive Transmissions ................ 22 Synchronizing Dual Engines.........................31
Lanyard Stop Switch........................................... 22 Dual Helm Station Transfer...........................32
Instrumentation................................................... 23 Synchronizing Dual Helms Prior To Station
VesselView....................................................23 Transfer .................................................. 33
Digital Gauges...............................................24 Zero Effort Features......................................33
Analog Gauges.............................................25 Electrical System Overload Protection............... 33
Remote Controls (Non-DTS Models).................. 25 Audio Warning System....................................... 36
Remote Controls...........................................25 Caution ......................................................... 36
Panel Mount Features ............................ 26 Severe .......................................................... 36
Console Mount Features ........................ 27 OBDM .......................................................... 37
Zero Effort Features......................................27 Testing The Audio Warning System ............. 37
Remote Controls (DTS Models).......................... 28 Guardian Strategy............................................... 37
Remote Controls...........................................28

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 Section 2 - Getting to Know Your Power Package

Identification
The serial numbers are the manufacture's keys to numerous engineering details which
apply to your MerCruiser power package. When contacting MerCruiser about service,
always specify model and serial numbers.
Engine Serial Number Decal
The serial number decal is located on top of the engine.

25902

Serial numbers and maintenance color codes decal

The engine serial number is also stamped in the engine block.
Transmissions
VELVET DRIVE TRANSMISSIONS
On Velvet Drive In‑Line and V‑Drive Transmissions (71C, 72C, 72C V‑Drive, with or without
Walter transmissions) the gear ratio (in forward gear) is marked on transmission
identification plate. Transmission output shaft rotation and propeller rotation required (in
forward gear) is indicated on a decal on transmission case. Transmission rotation is
described when viewed from the rear of transmission.

7424

In‑Line transmission shown (others similarly located)

a - Transmission identification plate c - Output flange rotation decal (in
b - Gear ratio (in Forward gear) Forward gear)

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 Section 2 - Getting to Know Your Power Package

On the Velvet Drive 5000A and 5000V Transmissions the transmission identification plate
indicates gear ratio, serial number and model.

7370

Velvet Drive 5000A ‑ 8 degree down‑angle transmission shown (5000V ‑ V‑drive similar)
a - Transmission identification plate

ZF MARINE TRANSMISSIONS
On the ZF Marine 8 Degree Down‑Angle and V‑Drive Transmissions, the transmission
identification plate indicates gear ratio, serial number, and model.

7449

Typical ZF Marine down‑angle transmission shown (V‑drive similar)

a - Transmission identification plate

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 Section 2 - Getting to Know Your Power Package

WALTER V-DRIVE TRANSMISSIONS

On the Walter V‑Drive Transmissions, the transmission identification plate indicates gear
ratio, serial number, and model.

7452

Walter RV‑36 V‑drive

a - Transmission identification plate

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

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 Section 2 - Getting to Know Your Power Package

• consuming alcohol or drugs

• high speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) 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
If the operator falls out of the boat, stop the engine immediately to reduce the possibility
of serious injury or death from being struck by the boat. Always properly connect the
operator to the stop switch using a lanyard.

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 serious injury or death from deceleration forces resulting from accidental or
unintended stop switch activation. The boat operator should never leave the operator's
station without first disconnecting the stop switch lanyard from the operator.

Instrumentation
VesselView
Your power package may come equipped with the following system viewer.

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 Section 2 - Getting to Know Your Power Package

Your power package may be connected to a SmartCraft VesselView display. This display
provides a single, easy‑to‑use source for real‑time information about a variety of vessel
systems. The interactive VesselView display continuously monitors and reports information
about speed and performance, trim angle, water temperature and depth, and other
operating data. When VesselView detects a problem with any connected system, it displays
an alarm message to signal the problem to the boat operator.

24797
Typical VesselView application
VesselView may also be connected to other vessel systems, such as GPS, generators,
and cabin environmental controls. This comprehensive vessel integration allows the
operator to monitor and control a wide range of vessel systems from a single, convenient
display.
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 (requires a SmartCraft oil pressure sender kit), battery voltage,
fuel consumption, and engine operating hours.
SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a
constant speed with an engine speed between 500 and 1200 RPM.

a b

c
26238

SmartCraft gauges
a - Tachometer c - LCD system view display
b - Speedometer

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 Section 2 - Getting to Know Your Power Package

The SmartCraft instrument package also aids in Engine Guardian diagnostics. The
SmartCraft Instrument package displays critical engine alarm data and potential problems.
Refer to the manual with your gauge package for the warning functions monitored by 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

Reference Gauge Function

a Speedometer Indicates boat speed.
b Tachometer Indicates engine RPM.
c Oil pressure gauge Indicates engine oil pressure.
d Voltmeter Indicates battery voltage.
e Coolant temperature gauge Indicates engine operating temperature.
f Fuel gauge Indicates quantity of fuel in tank.
g Hour meter Records engine operating time.
h Bilge blower switch Operates the bilge blower.
i Ignition switch Allows the operator to start and stop engine.

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.

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 Section 2 - Getting to Know Your Power Package

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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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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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- Detent tension adjustment screw
g- 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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 Section 2 - 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.
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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 Section 2 - 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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 Section 2 - 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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 Section 2 - 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
STAT ION 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 STAT ION 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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 Section 2 - 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. The
cause must be found and corrected before replacing the fuse or resetting the circuit
breaker.
IMPORTANT: Always store spare fuses in the boat for replacement.
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.

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 Section 2 - Getting to Know Your Power Package

A circuit breaker provides protection for 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 appears. Push the yellow lever into the housing to
reset the circuit breaker.

22529

a - Yellow lever (shown tripped)

b - Red test button

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

mc74907-1

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

33214
Engine fuses

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 Section 2 - Getting to Know Your Power Package

Two 10 amp fuses protect the O2 (oxygen) sensors. These are located at the rear of the
engine, near the 14‑pin connector.

33177
Oxygen sensor fuses
A 15 amp accessory fuse protects the accessory circuits.
c
a b

32206

a - Fuse cover
b - 15 amp fuse
c - Power harness

A power harness, connected to the engine starting battery, minimizes voltage drop to the
electrical system. This harness is protected by a 5 amp fuse. This connection is located at
the rear of the engine, near the 14‑pin connector.

33179

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 Section 2 - Getting to Know Your Power Package

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

mc70525-1

Audio Warning System

IMPORTANT: The audio warning system alerts the operator that a problem has occurred.
It does not protect the engine from damage.
Your Mercury MerCruiser power package may be equipped with an audio warning system.
Most faults cause the warning horn circuit to activate. How the warning horn activates
depends on the severity of the problem.
There are three warning horn states:
• Caution
• Severe
• Onboard Diagnostic Marine (OBDM) fault
Caution
If a caution is detected, the audio warning system will sound for six one‑second intervals.
ON ON ON ON ON ON
1 1 1 1 1 1
a 1 1 1 1 1
OFF OFF OFF OFF OFF OFF

b
33402
a - Horn (on or off)
b - Time (in seconds)

Below are some examples of a caution fault:

• Transmission fluid temperature is too hot
• Drive oil is low
• Sensor failure
Severe
IMPORTANT: If you experience a severe fault, contact your authorized Mercury
MerCruiser dealer.

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 Section 2 - Getting to Know Your Power Package

If a severe fault is detected, the audio warning system will sound for six seconds, turn off
for six seconds, then sound for six more seconds.
ON ON

a 6 6 6

OFF

b
33403
a - Horn (on or off)
b - Time (in seconds)

Below are some examples of a severe fault:

• Engine oil pressure is too low
• Engine temperature is too hot
• Seawater pressure is too low
• Transmission pressure is low (select models)
OBDM
If an OBDM fault is detected, the audio warning system sound with one five‑second horn,
then one short, 1/2‑second horn every 60 seconds for certain faults related to the emissions
or fuel system. See your authorized Mercury MerCruiser dealer for assistance.
ON ON ON ON

a 5 60 ½ 60 ½ 60 ½

OFF OFF OFF

b
33404
a - Horn (on or off)
b - Time (in seconds)

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.

Guardian Strategy
Engine Guardian reduces the potential for engine damage by restricting engine power
when the PCM detects a potential problem. Below are some examples of what Engine
Guardian monitors:
• Oil pressure
• Engine overspeed
• Exhaust manifold temperature
IMPORTANT: Guardian can reduce power anywhere from 100% to idle, depending on the
severity of the problem. If forced to idle, boat speed might not respond to throttle operation.
The PCM stores the fault for diagnostics. For example, if the water inlet becomes partially
blocked, Guardian reduces 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, Guardian restores engine power to normal. To avoid recurrence of the problem,
contact an authorized Mercury MerCruiser dealer.

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 Section 2 - Getting to Know Your Power Package

As another example, 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.

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 Section 3 - On the Water

Section 3 - On the Water

Table of Contents
Safe Boating Suggestions.................................. 40 While You Are Cruising ................................ 47
Be Alert to Carbon Monoxide Poisoning............. 41 While Boat Is Stationary ............................... 47
Good Ventilation ........................................... 41 High-Speed and High-Performance Operation
Poor Ventilation ........................................... 42
Basic Boat Operation (Non-DTS Models)........... 42
............................................................................ 48
Passenger Safety in Pontoon Boats and Deck Boats 3
Launching and Boat Operation.....................42 ............................................................................ 48
Operation Chart ...................................... 42 Boats Having An Open Front Deck .............. 48
Starting and Stopping the Engine.................43 Boats With Front-Mounted, Raised Pedestal
Starting the Engine ................................. 43 Fishing Seats ............................................... 48
Stopping the Engine ............................... 44 Wave and Wake Jumping................................... 49
Throttle-Only Operation.................................44 Impact with Underwater Hazards........................ 49
Freezing Temperature Operation..................44 Conditions Affecting Operation........................... 50
Drain Plug and Bilge Pump...........................44 Weight Distribution (Passengers and Gear)
Basic Boat Operation (DTS Models)................... 44 Inside the Boat..............................................50
Launching and Boat Operation.....................44 The Bottom of the Boat.................................50
Operation Chart ...................................... 44 Cavitation......................................................50
Starting and Stopping the Engine.................45 Ventilation.....................................................51
Starting the Engine ................................. 45 Elevation and Climate...................................51
Stopping the Engine ............................... 46 Getting Started.................................................... 51
Throttle-Only Operation.................................46 20-Hour Break-In Period...............................51
Freezing Temperature Operation..................47 After Break-In Period.....................................51
Drain Plug and Bilge Pump...........................47 End of First Season Checkup.......................52
Protecting People in the Water........................... 47

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 Section 3 - On the Water

Safe Boating Suggestions

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.
• We recommend that all powerboat operators complete a boating safety course. In the
US, the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your
state or provincial boating law enforcement agency provide courses. For more
information in the US, call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
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.
• 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.

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 Section 3 - On the Water

• 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
Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep
the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon
monoxide.

Good Ventilation
Ventilate the passenger area, open the side curtains or forward hatches to remove fumes.

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 Section 3 - On the Water

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.
OPERATION CHART
Operation Chart
WHILE
BEFORE STARTING AFTER STARTING AFTER STOPPING
UNDERWAY
Observe all gauges to Observe all gauges
check condition of to check condition of Turn ignition key to the
Install bilge drain plug.
engine. If not normal, engine. If not normal, "OFF" position.
stop engine. stop engine.
Check for fuel, oil,
Listen for the audio Turn battery switch to the
Open engine hatch. water, fluid and
alarm. "OFF" position.
exhaust leaks.
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Check steering Close seacock, if
Operate bilge blowers.
operation. equipped.

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 Section 3 - On the Water

Operation Chart
WHILE
BEFORE STARTING AFTER STARTING AFTER STOPPING
UNDERWAY
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if equipped. Drain bilge.
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.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will
overheat and suffer damage. Provide a sufficient supply of water to the water inlets during
operation.

! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death
from fire or explosion. Before starting the engine, operate the bilge blower or vent the
engine compartment for at least five minutes.
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.
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.

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 Section 3 - On the Water

NOTICE
Shifting into gear at engine speeds above idle will damage the drive system. Shift the
drive into gear only when the engine is operating at idle.
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.
OPERATION CHART
Operation Chart
WHILE
BEFORE STARTING AFTER STARTING AFTER STOPPING
UNDERWAY
Observe all gauges to Observe all gauges
check condition of to check condition of Turn ignition key to the
Install bilge drain plug.
engine. If not normal, engine. If not normal, "OFF" position.
stop engine. stop engine.
Check for fuel, oil,
Listen for the audio Turn battery switch to the
Open engine hatch. water, fluid and
alarm. "OFF" position.
exhaust leaks.

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 Section 3 - On the Water

Operation Chart
WHILE
BEFORE STARTING AFTER STARTING AFTER STOPPING
UNDERWAY
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Check steering Close seacock, if
Operate bilge blowers.
operation. equipped.
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if equipped. Drain bilge.
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.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will
overheat and suffer damage. Provide a sufficient supply of water to the water inlets during
operation.

! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death
from fire or explosion. Before starting the engine, operate the bilge blower or vent the
engine compartment for at least five minutes.

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.

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 Section 3 - On the Water

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.

NOTICE
Shifting into gear at engine speeds above idle will damage the drive system. Shift the
drive into gear only when the engine is operating at idle.
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.
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
The Digital Throttle and Shift (DTS) Zero Effort control can shift the engine or transmission
at speeds greater than idle, causing unexpected boat movement, which may result in
injury, death, or property damage due to loss of boat control. Always place the throttle
control lever in the idle position before moving the 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:

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 Section 3 - On the Water

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.
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
A spinning propeller, a moving boat, or any solid device attached to the boat can cause
serious injury or death to swimmers. Stop the engine immediately whenever anyone in
the water is near your boat.

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 Section 3 - On the Water

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 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.

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
Sitting or standing in an area of the boat not designed for passengers at speeds above
idle can cause serious injury or death. Stay back from the front end of deck boats or raised
platforms 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

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 Section 3 - On the Water

Wave and Wake Jumping

! WARNING
Wave or wake jumping can cause serious injury or death from occupants being thrown
within or out of the boat. Avoid wave or wake jumping whenever possible.

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.

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 Section 3 - 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
Operating a boat or engine with impact damage can result in product damage, serious
injury, or death. If the vessel experiences any form of impact, have an authorized Mercury
Marine dealer inspect and repair the vessel or power package.

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)
The Bottom of the 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 increases propeller speed while
reducing boat speed. 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

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 Section 3 - 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, follow these
recommendations:
• Ensure that propeller allows the engine to operate at or near the top of the specified
WOT RPM range. Refer to Specifications and Maintenance.
• Operate the engine at 3/4 throttle or lower. Refrain from prolonged operation at
wide‑open‑throttle RPM.

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 Section 3 - On the Water

• 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.

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 Section 4 - Specifications

Section 4 - Specifications
Table of Contents
Cruising RPM...................................................... 54 Engine Oil........................................................... 55
Fuel Requirements............................................. 54 Engine Specifications......................................... 56
Fuel Ratings ................................................. 54 Fluid Specifications............................................. 57
Using Reformulated (Oxygenated) Gasoline Engine...........................................................57
(USA Only) ................................................... 54 Transmission.................................................57
Gasoline Containing Alcohol ........................ 54

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 Section 4 - Specifications

Cruising RPM
Material and design advancements allow modern inboard engines operate at higher engine
speeds than their predecessors. Increased RPM significantly increases the horsepower of
these new engines and is a critical part performance and efficiency. The materials and
design of the new engines allow these higher speeds without durability penalty.
Over‑propping the boat to reduce its cruising RPM to previous levels increases the engine's
susceptibility to engine damage from detonation and pre‑ignition. The recommended
cruising RPM ranges are:
Cruising RPM for peak efficiency
Model RPM range
5.7 MPI and Horizon 5.7 3400–3800

Fuel Requirements
NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to
become empty during operation.

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
will not be covered under the limited warranty.

Fuel Ratings
Mercury MerCruiser engines will operate satisfactorily with any major brand of unleaded
gasoline that meets the following specifications:
USA and Canada ‑ 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 ‑ 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) Gasoline (USA Only)
Reformulated gasoline is required in certain areas of the USA and are acceptable for use
in your Mercury MerCruiser engine. The two types of oxygenates used in these fuels are
alcohol (ethanol) and ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the
gasoline in your area, refer to Gasoline Containing Alcohol.

Gasoline Containing Alcohol

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl
alcohol), be aware of possible adverse effects. These adverse effects are more severe with
methanol and worsen according to the percentage of alcohol in the fuel.
Alcohol in gasoline can absorb moisture from the air, causing the water and the alcohol to
separate from the gasoline in the fuel tank.
IMPORTANT: 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 your boat's fuel system components (fuel tanks, fuel lines, and
fittings).
Be aware that gasoline containing alcohol may cause increased:

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 Section 4 - Specifications

• Corrosion of metal parts

• Deterioration of rubber or plastic parts
• Fuel permeation through rubber fuel lines
• Starting and operating difficulties

! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death.
Periodically inspect all fuel system components for leaks, softening, hardening, swelling,
or corrosion, particularly after storage. Any sign of leakage or deterioration requires
replacement before further engine operation.

IMPORTANT: If you use gasoline that contains or might contain alcohol, you must increase
the frequency of inspection for leaks and abnormalities.
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 maintain optimum engine performance and to provide maximum protection, we
recommend the following oil:
Application Recommended Oil
Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40,
All MerCruiser engines with Emissions Control
NMMA FC‑W rated

IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements
for non‑catalyzed engines. Some marine‑grade lubricants contain high levels of
phosphorus, which can damage the catalyst system on MerCruiser engines. Although
these high‑phosphorus lubricants may allow for acceptable engine performance, exposure
over time will damage the catalyst. Catalysts damaged by lubricants containing high levels
of phosphorus may not be covered by the MerCruiser Limited Warranty.
If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the
following lubricants, listed in order of recommendation, for short periods of time:
1. Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W rated 4‑cycle oil
2. Other recognized brands of NMMA FC‑W–rated oils

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 Section 4 - Specifications

NOTE: We do not recommend 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.

Mercury MerCruiser Full-Synthetic Engine Oil, 20W-40, NMMA FC-W rated

ORDER OF PREFERENCE MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle oil

Other recognized brands of NMMA FC-W rated oils

SAE40W

SAE30W

SAE 20W

0° C 10° C
(32° F) (50° F)
AIR TEMPERATURE 31655

Engine Specifications
NOTE: Performance specifications are obtained and corrected in accordance with SAE
J1228/ISO 8665 Crankshaft Power.
All measurements are taken with the engine at normal operating temperature.
RPM range is measured using an accurate service tachometer with the engine at normal
operating temperatures.
Oil pressure must be checked with the engine at normal operating temperature.
Model 5.7 MPI and Horizon 5.7
Power 224 kW (300 hp)
Displacement 5.7 L (350 cid)
Specified WOT RPM range 4600–5000
Idle RPM in neutral 600
Minimum oil pressure at idle 41 kPa (6 psi)
Thermostat (seawater cooled models) 71° C (160° F)
Thermostat (closed cooled models) 77° C (170° F)
Timing at idle Not Adjustable
Firing order 1‑8‑4‑3‑6‑5‑7‑2
Electrical system 12 V negative (–) ground
Alternator rating 65 A
Minimum battery rating (non‑DTS models) 750 CCA, 950 MCA, or 180 Ah
Minimum battery rating (DTS models) 800 CCA, 1000 MCA, or 190 Ah
Spark plug type AC Platinum (AC 41‑993)
Spark plug gap 1.5 mm (0.060 in.)

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 Section 4 - Specifications

Fluid Specifications
Engine
IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required.
All Models Capacity Fluid Type
Mercury Full‑Synthetic MerCruiser Engine
Engine oil (with filter) 4.25 L (4.50 US qt)
Oil 20W‑40
Seawater cooling system (winterization use
20 L (21 US qt) Propylene glycol and purified water
only)
Mercury Extended Life Coolant Antifreeze
Closed cooling system 18 L (19 US qt) or extended life ethylene glycol 5/100
antifreeze mixed 50/50 with purified water

Transmission
Model Capaci Fluid Type
5000A 2.84 L (3.00 US qt)
Dexron III Automatic Transmission Fluid
5000V 3.30 L (3.50 US qt)
71C In‑Line 1.66 L (1.75 US qt)
71C Gear Reduction 2.84 L (3.00 US qt) Dexron III Automatic Transmission Fluid
71C Remote V‑Drive 1.66 L (1.75 US qt)
72C In‑Line 1.66 L (1.75 US qt)
72C Gear Reduction 1.66 L (1.75 US qt)
Dexron III Automatic Transmission Fluid
72C Remote V‑Drive 1.66 L (1.75 US qt)
72C V‑Drive 3.79 L (4.00 US qt)
63A 4.00 L (4.5 US qt)
Dexron III Automatic Transmission Fluid
63V 4.00 L (4.5 US qt)

NOTE: Walters V‑Drive applications have two fluid service points: the transmission and
the v‑drive gear box. Refer to the Walters owner's manual for capacity and intervals.

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 Section 4 - Specifications

Notes:

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 Section 5 - Maintenance

Section 5 - Maintenance
Table of Contents
Owner/Operator Responsibilities........................ 60 Changing ......................................................70
Dealer Responsibilities....................................... 60 Battery................................................................ 70
Maintenance....................................................... 60 Multiple EFI Engine Battery Precautions....... 70
Do-It-Yourself Maintenance Suggestions........... 61 Cleaning the Flame Arrestor............................... 71
Inspection........................................................... 61 Positive Crankcase Ventilation Valve
Maintenance Schedule—Inboard Models........... 62 (PCV) ........................................................... 72
Routine Maintenance....................................62 Changing ................................................ 72
Scheduled Maintenance................................62 Cleaning The IAC Muffler................................... 72
Maintenance Log................................................ 63 Water-Separating Fuel Filter............................... 73
Engine Oil........................................................... 64 GEN III Models..............................................74
Checking.......................................................64 Removal ................................................. 74
Filling.............................................................64
Changing Oil and Filter.................................65
Installation .............................................. 75
Lubrication.......................................................... 75
5
Easy Engine Oil Drain System......................65 Throttle Cable................................................75
Engine Oil Drain Pump..................................66 Transmission Linkage...................................76
Changing the Oil Filter..................................67 Serpentine Drive Belt.......................................... 77
Transmission Fluid.............................................. 67 Checking ...................................................... 77
Checking While the Engine is Warm ............ 67 Replacing Belt and/or Adjusting Tension ..... 77
Checking While Engine is Cold .................... 68 Flushing The Power Package............................. 78
Changing ...................................................... 68 Horizon Models ............................................ 78
Engine Coolant................................................... 68 The Boat Out of the Water ........................... 80
Checking.......................................................68 The Boat In the Water .................................. 81
Filling.............................................................69

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 Section 5 - 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
Performing service or maintenance without first disconnecting the battery can cause
product damage, personal injury, or death due to fire, explosion, electrical shock, or
unexpected engine starting. Always disconnect the battery cables from the battery before
maintaining, servicing, installing, or removing engine or drive components.

! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty
breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine
compartment before servicing the power package.

IMPORTANT: Refer to the maintenance schedule for complete listing of all scheduled
maintenance to be performed. Whereas you can perform some items, others should be
performed only by an authorized Mercury MerCruiser dealer. Before attempting
maintenance or repair procedures not covered in this manual, we recommend that you
purchase a Mercury MerCruiser service manual and read it thoroughly.
NOTE: Maintenance points are color coded for ease of identification. See the decal on
engine for identification.

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 Section 5 - Maintenance

Maintenance Point Color Codes

Blue Coolant
Yellow Engine oil
Orange Fuel
Brown Transmission

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.

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 Section 5 - Maintenance

Maintenance Schedule—Inboard Models

Routine Maintenance
NOTE: Only perform maintenance that applies to your particular power package.
Task Interval Maintenance to Be Performed
• Check the engine oil level. You can extend this interval based on experience
Each day start with the product.
• Check the transmission fluid level.
• If operating in saltwater, brackish water, or polluted water, flush the seawater
Each day end
section of the cooling system after each use.
• Check the water inlets for debris or marine growth.
• Check and clean the seawater strainer, if equipped.
Weekly
• Check the coolant level.
• Check the transmission fluid.
• If operating in saltwater, brackish water, or polluted water, apply Corrosion
Guard to the power package.
Every two months or 50 • Check the battery connections and the fluid level.
hours • Ensure that the gauges and the wiring connections are secure. Clean the
gauges. If operating in saltwater, reduce this interval to every 25 hours or 30
days, whichever occurs first.

Scheduled Maintenance
NOTE: Only perform maintenance that applies to your particular power package.
Task Interval Maintenance to Be Performed
Change the engine oil and filter.
After the initial 20‑hour • Change the engine oil and filter.
break‑in period • Change the transmission fluid and filter. ZF Marine requires changing the
transmission fluid and filter maintain warranty.
• Touch up the paint on the power package.
• Change the engine oil and filter.
• Change the transmission fluid (ZF Transmission Models).
• If the condition of the spark plugs, spark plug wires, and the distributor cap
and rotor was satisfactory at the initial inspection (as listed in Every 300
hours or 3 years), inspect the condition of these components. Replace as
Every 100 hours or necessary.
annually • Replace the water‑separating fuel filter element.
(whichever occurs first) • Clean the flame arrestor, IAC muffler (MPI engines), and the crankcase
ventilation hoses. Inspect the PCV valve, if equipped.
NOTE: On MerCruiser V6 models, the PCV valve is a non‑serviceable, internal
component of the valve cover assembly.
• Inspect the condition and the tension of the belts.
• Check the coolant level and antifreeze concentration for adequate freeze
protection. Correct if necessary. Refer to the Specifications section.

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 Section 5 - Maintenance

Task Interval Maintenance to Be Performed

• Check the engine mounts for tightness and tighten to specifications if
necessary.
• Inspect the condition of the spark plugs, spark plug wires, and the distributor
cap and rotor, if equipped. Replace as necessary. If the condition of these
components is satisfactory at inspection, repeat inspection every 100 hours
or once a year, whichever occurs first.
Every 300 hours or 3 • Check the electrical system for loose, damaged, or corroded fasteners.
years
• Check the cooling system and the exhaust system hose clamps for tightness.
(whichever occurs first)
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.
• Inspect the exhaust system components. If the package was equipped with
water shutters (flapper valves), verify that they are not missing or worn.
• Replace the coolant/anitifreeze. Replace every two years if not using
Every 5 years
extended‑life coolant/antifreeze.

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

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 Section 5 - Maintenance

Engine Oil
Checking
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by
law. Use caution not to spill oil, coolant, or other fluids into the environment when using
or servicing your boat. Be aware of the local restrictions governing the disposal or
recycling of waste, and contain and dispose of fluids as required.

1. Stop the engine. Allow the oil to drain into the oil pan for approximately five minutes
with the boat 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: Install the dipstick with oil level indication marks facing the rear of the engine
(flywheel end).

33139
Possible dipstick locations
3. Inspect the dipstick reading, which should indicate a level between the full or "OK" mark
and the "ADD" mark. Reinstall the dipstick into the dipstick tube. If the oil level is low,
refer to Filling.
Filling
IMPORTANT: Do not overfill the engine with oil. Always use the dipstick to determine the
exact quantity of oil or fluid required.

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 Section 5 - Maintenance

1. Remove oil fill cap.

33140
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
4.25 L
Engine oil (with filter) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40
(4.5 US qt)

Changing Oil and Filter

See 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 the
Specifications section).
Easy Engine Oil Drain System
NOTE: The boat must be out of water to perform this procedure.
1. Loosen the oil filter to vent the system.
2. Allow sufficient time for the oil to drain from the filter down into the engine block.
3. Remove the bilge drain plug.

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 Section 5 - Maintenance

4. Pull tether through the bilge drain.

a f
c
b

d e 7284

a - Bilge drain plug d - Oil drain hose plug

b - Tether e - Oil drain hose
c - Clip f - Bilge drain flange

5. Place the oil drain hose in a suitable container.

6. Remove the drain plug from the oil drain hose.
7. After oil has drained completely, install the drain plug in the oil drain hose.
8. Push the hose through bilge drain and install the plug.
9. Replace the engine oil filter. See Changing the Oil Filter.
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 - Oil pump
b - Dipstick tube
c - Oil drain hose

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

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 Section 5 - Maintenance

Changing the Oil Filter

1. Remove and discard oil filter.
a
b

33141

a - Oil filter (in‑line exhaust) b - Oil filter (V‑drive exhaust)

2. Coat the sealing ring on the new filter with engine oil.
3. Install and tighten the oil filter securely following the filter manufacturer's instructions.
Do not overtighten.
4. Remove oil fill cap.
5. Use the dipstick to determine the amount of engine oil required. Replace the dipstick.
6. Add the required amount of the recommended oil to bring the level up to the bottom of
the OK range on the dipstick.
7. With the boat at rest in the water, repeat steps 5 and 6 if necessary.
NOTE: Adding 0.95 L (1 US qt) of engine oil raises the level from the add mark to the top
of the OK range.
All Models Capacity Fluid Type
4.25 L
Engine oil (with filter) Mercury Full‑Synthetic MerCruiser Engine Oil 20W‑40
(4.50 US qt)

8. Start the engine and operate for three minutes, checking for leaks.
9. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes
with the boat at rest in the water.

Transmission Fluid
Checking While the Engine is Warm
1. Velvet Drive Transmissions ‑ Stop the engine and immediately 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.
2. ZF Marine Transmissions ‑ Stop the engine and remove the 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.
3. Walter V‑Drive Transmissions ‑ Stop the engine and remove the dipstick to check the
level. If the fluid is below the top (full) line, add the specified fluid through the breather
elbow. Do not overfill. Reinstall the dipstick with the cap fully seated.

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 Section 5 - Maintenance

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
! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting
in serious injury from burns. Allow the engine to cool down before removing the coolant
pressure cap.

1. Remove the cap from the heat exchanger and observe the fluid level.

33172
Heat exchanger cap
2. The coolant level in the heat exchanger should be at the bottom of the filler neck. If the
coolant level is low, contact your authorized Mercury MerCruiser dealer.
3. Install the cap onto the heat exchanger.
IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the
filler neck.
4. With the engine at normal operating temperature, check the coolant level in the coolant
recovery bottle.

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 Section 5 - Maintenance

5. The coolant level should be between the "ADD" and "FULL" marks.

6102

6. Add the specified fluid as necessary.

Tube Ref No. Description Where Used Part No.

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

Filling
NOTICE
Using propylene glycol antifreeze in the closed cooling system can damage the cooling
system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze
solution suitable to the lowest temperature to which the engine will be exposed.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will
overheat and suffer damage. Provide a sufficient supply of water to the water inlets during
operation.

NOTICE
Air trapped in the closed cooling system can cause the engine to overheat, resulting in
engine damage. Minimize the possibility of trapping air when initially filling the closed
cooling system by positioning the boat so that the front of the engine is higher than the
rear of the engine.

NOTE: Add coolant only when the engine is at normal operating temperature.
1. Remove the fill cap from the coolant recovery bottle. Inspect the gasket and replace if
necessary.
IMPORTANT: Coolant flows at a high rate of speed in this closed cooling system. Higher
idle speeds can trap air in the system and make purge procedures more difficult. Operate
at idle when filling the system or purging air.
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. Check the antifreeze concentration for adequate freeze protection and correct if
necessary. Refer to the Specifications section.
4. Install the fill cap to the coolant recovery bottle.

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 Section 5 - Maintenance

Changing
Contact your authorized Mercury MerCruiser dealer.

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
Recharging a weak battery in the boat, or using jumper cables and a booster battery to
start the engine, can cause serious injury or product damage from fire or explosion.
Remove the battery from the boat and recharge in a ventilated area away from sparks or
flames.

! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out
sulfuric acid, which can cause severe burns. Ventilate the area around the battery and
wear protective equipment when handling or servicing batteries.

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.

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 Section 5 - Maintenance

Cleaning the Flame Arrestor

! WARNING
Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned
so that the engine cannot start. Do not smoke or allow sources of spark or open flame in
the area while servicing. Keep the work area well ventilated and avoid prolonged
exposure to vapors. Always check for leaks before attempting to start the engine and
wipe up any spilled fuel immediately.

1. Remove the engine cover.

2. Disconnect and remove the crankcase ventilation hose from the fitting on the flame
arrestor and valve cover.
3. Remove the flame arrestor.

f
33180

a - Engine cover knob d - Cover mount bracket

b - Engine cover e - Flame arrestor
c - Nuts, flame arrestor f - Crankcase ventilation hose

4. Clean the flame arrestor with warm water and a mild detergent.
5. Inspect the flame arrestor for holes, cracks or deterioration. Replace if necessary.
6. Allow the flame arrestor to air dry completely before use.
7. Clean the crankcase ventilation hose with warm water and a mild detergent. Dry with
compressed air or allow to air dry completely.
8. Inspect the crankcase ventilation hose for cracks or deterioration. Replace if necessary.
9. Install the flame arrestor and flame arrestor bracket. Torque the flame arrestor bracket
nuts.
Description Nm lb‑in. lb‑ft
Flame arrestor bracket nut 12 106 –

10. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve
cover.

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 Section 5 - Maintenance

11. Install the engine cover.

Positive Crankcase Ventilation Valve (PCV)
CHANGING
IMPORTANT: Use only Mercury MerCruiser replacement parts to ensure compliance with
emission regulations.
1. Remove the PCV valve from the port valve cover.

33143
a - PCV valve (hose not shown)

2. Disconnect the PCV valve from the hose and discard the valve.
3. Install a new PCV valve in the valve cover and reconnect the hose.
4. Ensure that the PCV valve is tightly seated in the valve cover.

Cleaning The IAC Muffler

! WARNING
Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned
so that the engine cannot start. Do not smoke or allow sources of spark or open flame in
the area while servicing. Keep the work area well ventilated and avoid prolonged
exposure to vapors. Always check for leaks before attempting to start the engine and
wipe up any spilled fuel immediately.

NOTE: The IAC muffler may be installed in the throttle body or in the IAC adapter. Locate
your IAC muffler by removing the engine cover.
1. Remove the engine cover.

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 Section 5 - Maintenance

2. Remove the IAC muffler.

33269

IAC muffler installed in the IAC adapter

3. Inspect the IAC muffler for holes, cracks, or deterioration. Replace the IAC muffler if
damaged.
IMPORTANT: Do not get cleaner on electrical connections and do not use cleaner
containing methyl ethyl ketone.
4. Clean the IAC muffler with warm water and a mild detergent. Replace if necessary.
5. Allow the IAC muffler to completely, then install.

Water‑Separating Fuel Filter

! WARNING
Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned
so that the engine cannot start. Do not smoke or allow sources of spark or open flame in
the area while servicing. Keep the work area well ventilated and avoid prolonged
exposure to vapors. Always check for leaks before attempting to start the engine and
wipe up any spilled fuel immediately.

! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can
cause a fire or explosion. Allow the engine to cool completely and release all fuel pressure
before servicing any part of the fuel system. Always protect eyes and skin from
pressurized fuel and vapors.

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 Section 5 - Maintenance

GEN III Models

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

REMOVAL
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.
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.
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.

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 Section 5 - Maintenance

INSTALLATION
1. Install a new water‑separating fuel filter element into the filter cup. Push the element
into the cup until completely seated.
2. Install new O‑ring on the filter cup.
3. 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.
4. 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.
5. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each
filter assembly retaining screw.
Description Nm lb. in. lb. ft.
Filter assembly retaining screw 6 53

6. Open fuel supply valve, if equipped.

7. Reconnect the Cool Fuel Module harness to the engine wiring harness.
8. Properly ventilate the engine compartment.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will
overheat and suffer damage. Provide a sufficient supply of water to the water inlets during
operation.
9. Supply cooling water to the engine.
10. 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.

Lubrication
Throttle Cable
1. Lubricate the pivot points and the guide contact surfaces.
b

5577

a - Pivot points b - Guide contact surfaces

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 Section 5 - Maintenance

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Throttle cable pivot points &
92‑883725K01
Oil SAE25W‑40 guide contact surfaces

Transmission Linkage
IMPORTANT: The poppet ball must be centered in the detent hole for each F‑N‑R position.
1. Lubricate the detent ball and the holes in the shift lever.

5934
a
In‑Line Transmission
Tube Ref. No. Description Where Used Part No.
Synthetic Blend MerCruiser Engine Detent ball and shift lever
92‑883725K01
Oil SAE25W‑40 holes

2. Lubricate the shift cable pivot points.

a
5935

a - Pivot points

Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine
Shift cable pivot points 92‑883725K01
Oil SAE25W‑40

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 Section 5 - Maintenance

Serpentine Drive Belt

! WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off
the engine and remove the ignition key before adjusting tension or inspecting belts.

e b
d
c 6089

a - Idler pulley d - Alternator pulley

b - Circulating pump pulley e - Seawater pump pulley
c - Crankshaft 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
• 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 Belt and/or Adjusting Tension

IMPORTANT: If a belt is to be reused, it should be installed in the same direction of rotation
as before.
NOTE: Belt deflection is to be measured on the belt at the location that has the longest
distance between two pulleys.
1. Loosen the 16 mm (5/8 in.) locking nut on the adjustment stud.
2. Turn the adjustment stud and loosen the belt.
3. If a new serpentine drive belt is required, remove the old belt and install a new belt onto
the pulleys.
4. Put a wrench on the adjustment stud 16 mm (5/8 in.) locking nut.

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 Section 5 - Maintenance

5. Use a 8 mm (5/16 in.) socket and tighten adjusting the stud to adjust the belt deflection.
6. Using one of the 2 methods following, check for correct deflection.
a. Push down with moderate thumb pressure on the longest stretch of belt. Proper
deflection is 13 mm (1/2 in.).
b. Attach the Kent Moore© Belt Tension Gauge to the belt. The gauge has different
ranges for new and used belts.

E
N
TO
W
2.83

E
COLO for

N
R GU PATE918

b
IDE NT

NEWTONE

14980
a - Kent Moore© Tension Gauge b - Serpentine belt

7. While holding the adjustment stud at the correct belt tension, tighten the 16 mm
(5/8 in.) locking nut.

a b

6119

a - 8 mm (1/16 in.) adjusting stud b - 16 mm (5/8 in.) locking nut

8. Operate the engine for a short period of time and recheck the belt adjustment.

Flushing The Power Package

Horizon Models
NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water
applications. Flushing is recommended after each outing for best results.
1. Close the seacock, if equipped, or remove the water inlet hose and plug the inlet.
2. Attach the quick connect fitting to a water hose.
3. Remove the blue cap from the flush socket on the engine

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will
overheat and suffer damage. Provide a sufficient supply of water to the water inlets during
operation.

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 Section 5 - Maintenance

NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust
system, damaging the engine. Do not supply flush water for more than 15 seconds without
the engine operating.
4. Snap the quick connect fitting and the water hose into the flush socket on the engine.

33389
V‑drive shown (inline similar)
5. Open the water source completely.
6. Start the engine within 15 seconds.
7. Operate the engine at 1300 RPM, +/‑ 100 RPM.
8. Allow engine to reach normal operating temperature. Watch the temperature gauge on
the dash to ensure that the engine does not overheat.
9. Flush the engine for a minimum of 10 minutes or until the discharge water is clear.
10. Shut off the engine.

NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust
system, damaging the engine. Do not supply flush water for more than 15 seconds without
the engine operating.
11. Turn off water source within 15 seconds of shutting off engine.
12. Disconnect the quick connect fitting and water hose from the flush socket on the engine
by pressing the release button on the flush socket
13. Attach to the next engine, if equipped, and repeat procedure.
14. Turn off the water source.
15. Remove the quick connect fitting from the water hose.
16. Replace the blue cap into the flush socket on the engine.
17. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to
operating the engine.
NOTE: If the unit is to be stored in the water, the seacock should remain closed until time
of usage. If unit is to be stored out of the water, open the seacock.

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 Section 5 - Maintenance

The Boat Out of the Water

IMPORTANT: Flushing the power package is most effective when performed with the boat
out of the water.
IMPORTANT: Flushing is needed If the engine package has been operated in salty,
brackish, mineral‑laden or polluted water. For best results flushing is recommended after
each outing and before cold weather and extended storage.

! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the
water with a propeller installed. Before installing or removing a propeller, place the drive
unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
Place a block of wood between the propeller blade and the anti‑ventilation plate.

1. Models with Walter V-Drive Transmissions:

a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from
the transmission seawater inlet fitting.
b. If not equipped with a seacock, disconnect the seawater inlet hose from the
transmission seawater inlet fitting and plug the seawater inlet hose.

6091

c. Using appropriate connector, connect the flushing water hose to the transmission
seawater inlet fitting.
d. Proceed to step 3
2. All other models:
a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from
the seawater pump inlet fitting..
b. If not equipped with a seacock, disconnect the seawater inlet hose from the
seawater pump and plug the hose.

10839

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 Section 5 - Maintenance

c. Using a suitable adapter, connect the flushing hose from the water source to the
water inlet of the seawater pump.
d. Proceed to step 3.

NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust
system, damaging the engine. Do not supply flush water for more than 15 seconds without
the engine operating.
3. Completely open the water source to provide maximum water supply.
4. Place the remote control in the neutral idle speed position.
5. Immediately start the engine.

NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse
the water supply hose and overheat the engine. Do not operate the engine above 1400
RPM out of the water and without sufficient cooling water supply.
6. Depress the throttle only button and slowly advance the throttle until the engine reaches
1300 RPM (± 100 RPM).
7. Observe the water temperature gauge to ensure that the engine is operating in the
normal range.
8. Operate the engine with the transmission in neutral for a minimum of 10 minutes.
9. For power packages operated in salty, brackish, mineral‑laden or polluted water:
Continue to operate the engine until the discharge water is clear.
10. Slowly return the throttle to idle speed position.

NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust
system, damaging the engine. Do not supply flush water for more than 15 seconds without
the engine operating.
11. Stop the engine.
12. Immediately shut off the supply water and remove the flushing attachment.
13. Install the water inlet hose to the seawater inlet of the seawater pump or V‑Drive water
inlet.
14. Tighten hose clamp securely.
15. Attach to the next engine, if equipped, and repeat procedure.
The Boat In the Water
IMPORTANT: Flushing the power package is most effective when performed with the boat
out of the water.

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 Section 5 - Maintenance

IMPORTANT: Flushing is needed If the engine package has been operated in salty,
brackish, mineral‑laden or polluted water. For best results flushing is recommended after
each outing and before cold weather and extended storage.

NOTICE
Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in
engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug
the seawater inlet hose immediately after disconnecting it.

1. Models with Walter V-Drive Transmissions:

a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from
the transmission seawater inlet fitting.

NOTICE
Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in
engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug
the seawater inlet hose immediately after disconnecting it.
b. If not equipped with a seacock, disconnect the seawater inlet hose from the
transmission seawater inlet fitting and immediately plug the seawater inlet hose
to prevent water from siphoning into the engine or boat.

6091

c. Using suitable adapter, connect the flushing water hose to the transmission
seawater inlet fitting.
d. Proceed to step 3
2. All other models:
a. Close the seacock, if equipped, and then disconnect the seawater inlet hose from
the seawater pump inlet fitting.

NOTICE
Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in
engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug
the seawater inlet hose immediately after disconnecting it.

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 Section 5 - Maintenance

b. If not equipped with a seacock, disconnect the seawater inlet hose from the
seawater pump inlet fitting and immediately plug the seawater inlet hose to prevent
water from siphoning into the engine or boat.

10839

c. Using a suitable adapter, connect the flushing hose from the water source to the
water inlet of the seawater pump.
d. Proceed to step 3.

NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust
system, damaging the engine. Do not supply flush water for more than 15 seconds without
the engine operating.
3. Completely open the water source to provide maximum water supply.
4. Place the remote control in the neutral idle speed position.
5. Immediately start the engine.

NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse
the water supply hose and overheat the engine. Do not operate the engine above 1400
RPM out of the water and without sufficient cooling water supply.
6. Depress the throttle only button and slowly advance the throttle until the engine reaches
1300 RPM (± 100 RPM).
7. Observe the water temperature gauge to ensure that the engine is operating in the
normal range.
8. Operate the engine with the transmission in neutral for a minimum of 10 minutes.
9. For power packages operated in salty, brackish, mineral‑laden or polluted water:
Continue to operate the engine until the discharge water is clear.
10. Slowly return the throttle to idle speed position.

NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust
system, damaging the engine. Do not supply flush water for more than 15 seconds without
the engine operating.
11. Stop the engine.
12. Immediately shut off the water supply and remove the flushing attachment.
13. Remove the flushing connector from the water inlet.

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 Section 5 - Maintenance

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.
15. Repeat the flushing procedure on the next engine, if equipped.

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 Section 6 - Storage

Section 6 - Storage
Table of Contents
Cold Weather or Extended Storage.................... 86 Air Actuated Single Point Drain System........89
Preparing Power Package for Storage..........86 Boat in the Water ................................... 89
Engine and Fuel System Preparation .... 87 Boat out of the Water ............................. 91
Draining the Seawater System........................... 88 Three-Point Manual Drain System................93
Drain System Identification...........................88 Boat in the Water ................................... 93
Air Actuated Single Point Drain System Boat out of the Water ............................. 94
............................................................... 88 Battery Storage................................................... 95
Three Point Manual Drain System ......... 89 Power Package Recommissioning..................... 95

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 Section 6 - 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.

NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or
freeze damage. Drain the seawater section of the cooling system immediately after
operation or before any length of storage in cold weather. If the boat is in the water, keep
the seacock closed until restarting the engine to prevent water from flowing back into the
cooling system. If the boat is not fitted with a seacock, leave the water inlet hose
disconnected and plugged.

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the
boat reminding the operator to open the seacock or unplug and reconnect the water inlet
hose before starting the engine.
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. Check the antifreeze concentration. Refer to the Specifications section.
3. 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.
4. Flush the cooling system. Refer to the Maintenance section.
5. Supply cooling water to engine. Refer to the Maintenance section
6. 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.
7. Change the oil and oil filter.
8. Prepare the engine and fuel system for storage. See Engine and Fuel System
Preparation.
9. Drain the engine seawater cooling system. See Draining the Seawater System.

NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or
freeze damage. Drain the seawater section of the cooling system immediately after
operation or before any length of storage in cold weather. If the boat is in the water, keep
the seacock closed until restarting the engine to prevent water from flowing back into the
cooling system. If the boat is not fitted with a seacock, leave the water inlet hose
disconnected and plugged.

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 Section 6 - Storage

10. 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.
11. Store the battery according to the manufacturer's instructions.
ENGINE AND FUEL SYSTEM PREPARATION

! WARNING
Fuel is flammable and explosive. Ensure the key switch is off and the lanyard is positioned
so that the engine cannot start. Do not smoke or allow sources of spark or open flame in
the area while servicing. Keep the work area well ventilated and avoid prolonged
exposure to vapors. Always check for leaks before attempting to start the engine and
wipe up any spilled fuel immediately.

! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty
breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine
compartment before servicing the power package.

NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to
become empty during operation.

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

a. 19 liter (5 US gal.) regular unleaded 87 octane (90 RON) gasoline
b. 1.89 liter (2 US qt.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil
c. 150 ml (5 oz) Fuel System Treatment and Stabilizer or 30 ml (1 oz) Fuel System
Treatment and Stabilizer Concentrate

Tube Ref No. Description Where Used Part No.

Premium Plus 2-cycle TC-W3
115 Fuel system 92-858026K01
Outboard Oil
Fuel System Treatment &
124 Fuel system 858071K01
Stabilizer

2. Allow the engine to cool.

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 five minutes.
6. After the specified operating time is complete, slowly return the throttle to idle and shut
the engine off.
IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the
engine's fuel system to become completely dry.
7. Replace the water separating fuel filter element. Refer to Section 5.

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 Section 6 - Storage

Draining the Seawater System

! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing
the boat to sink. Remove the boat from the water or close the seacock, disconnect and
plug the seawater inlet hose, and ensure the bilge pump is operational before draining.
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.
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the
manufacturer's 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.
Drain System Identification
NOTE: All drain plugs are fitted with blue wing nuts.
AIR ACTUATED SINGLE POINT DRAIN SYSTEM

b c

c
a
d

33144 33150
Closed‑cooled models Seawater-cooled models
a - Blue drain plug location c - Air manifold
b - Blue air pump d - Green indicators

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 Section 6 - Storage

THREE POINT MANUAL DRAIN SYSTEM

a
a 6126

a - Blue drain plug

Air Actuated Single Point Drain System

BOAT IN THE WATER
NOTE: This procedure is written for the blue 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 blue 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 - Blue air pump
b - Green indicators e - Lever (locking)
c - Manual release valve

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.

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 Section 6 - Storage

7. Immediately remove the blue drain plug from the side of the thermostat housing or the
heat exchanger. This must be removed within 30 seconds to properly vent the cooling
system.

b c

c
a
d

33144 33150
Closed Cooled Models Seawater Cooled Models
a - Blue drain plug location c - Air manifold
b - Blue air pump d - Green indicators

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

b 6133

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

9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep
the green indicators extended.
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. Reinstall the blue drain plug in the thermostat housing or heat exchanger.
12. Remove the blue air pump from the air manifold and return it to the mounting bracket.
13. 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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 Section 6 - Storage

14. 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

15. 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 blue 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 blue 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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 Section 6 - 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.

b c

c
a
d

33144 33150
Closed Cooled Models Seawater Cooled Models
a - Blue drain plug location c - Air manifold
b - Blue air pump d - Green indicators

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

b 6133

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. Crank the engine over slightly with starter motor to purge any water trapped in the
seawater pump. Do not allow engine to start.
10. Remove the air pump from the air manifold and return it to the mounting bracket.
11. 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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 Section 6 - Storage

12. 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

Three‑Point Manual Drain System

BOAT IN THE WATER
NOTE: Use this procedure if your engine is not equipped with an air‑actuated single‑point
drain system or if the air‑actuated single point drain system fails.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Remove the blue drain plug from the distribution housing (lower front, port side).

6138

a - Blue drain plug

3. To properly vent the cooling system, remove the blue drain plug from the side of the
thermostat housing within 30 seconds.
a

6139

a - Blue drain plug location

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 Section 6 - Storage

4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

a 6140

a - Blue drain plugs

5. Verify that water is draining from each opening.

6. Allow the system to drain for a minimum of five minutes. We recommend leaving the
drain system open while transporting the boat or performing other maintenance to
ensure that all water is drained.
7. 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.
8. Before launching the boat or starting the engine, close the drain system by installing
the four blue drain plugs.
9. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to
operating the engine.
BOAT OUT OF THE WATER
NOTE: Use this procedure if your engine is not equipped with an air‑actuated single‑point
drain system or if the single‑point drain system fails.
1. Place the boat on a level surface to ensure complete draining of the system.
2. Remove three blue drain plugs: one from the distribution housing (lower front, port side)
and two from the seawater pickup pump (front, starboard side).

a a
6142

a - Blue drain plug

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. We recommend leaving the
drain system open while transporting the boat or performing other maintenance to
ensure that all water is drained.
5. 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.
6. Before launching the boat or starting the engine, close the drain system by installing
the three blue drain plugs.

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 Section 6 - Storage

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
Disconnecting or connecting the battery cables in the incorrect order can cause injury
from electrical shock or can damage the electrical system. Always disconnect the
negative (‑) battery cable first and connect it last.
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.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will
overheat and suffer damage. Provide a sufficient supply of water to the water inlets 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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 Section 6 - Storage

Notes:

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 Section 7 - Troubleshooting

Section 7 - Troubleshooting
Table of Contents
Diagnosing EFI Problems................................... 98 Excessive Engine Temperature....................99
Diagnosing DTS Problems................................. 98 Insufficient Engine Temperature.................100
Engine Guardian System.................................... 98 Low Engine Oil Pressure.............................100
Troubleshooting Charts...................................... 98 Battery Will Not Recharge...........................100
Starter Motor Will Not Crank Engine, or Cranks Remote Control Is Difficult to Move, Has
Slowly............................................................98 Excessive Play, or Makes Unusual Sounds
Engine Will Not Start or Is Hard to Start........ 99 ....................................................................100
Engine Runs Rough, Misses, or Backfires....99 Steering Wheel Jerks or Is Difficult to Turn
Poor Performance.........................................99 ....................................................................101

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 Section 7 - 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.

Troubleshooting Charts
Starter Motor Will Not Crank Engine, or Cranks Slowly
Possible Cause Remedy
Battery switch turned off. Turn the switch on.
Remote control not in neutral position. Position the control lever in neutral.
Check and reset the main power circuit breaker or
replace the fuse. Check the 5 amp fuse on the power
Open circuit breaker or fuse.
harness connected to the battery, and replace if
necessary.
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.

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 Section 7 - Troubleshooting

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

Engine Runs Rough, Misses, 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
Reduce load or redistribute load more evenly.
distributed.
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 MerCruiser
EFI System fault
dealer.

Excessive Engine Temperature

Possible Cause Remedy
Water inlet or seacock closed. Open.
Drive belt loose or in poor condition. Replace or adjust belt.

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 Section 7 - Troubleshooting

Possible Cause Remedy

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.

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 Recharge

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 Is Difficult to Move, Has Excessive 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.

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 Section 7 - Troubleshooting

Steering Wheel Jerks or Is Difficult to Turn

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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 Section 7 - Troubleshooting

Notes:

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 Section 8 - Customer Assistance Information

Section 8 - Customer Assistance Information

Table of Contents
Owner Service Assistance................................ 104 Parts and Accessories Inquiries ........... 105
Local Repair Service .................................. 104 Resolving a Problem .................................. 105
Service Away From Home ......................... 104 Mercury Marine Service Offices ................. 105
Stolen Power Package ............................... 104 Ordering Literature............................................ 106
Attention Required after Submersion ......... 104 United States and Canada ......................... 106
Replacement Service Parts ........................ 104 Outside The United States and Canada .... 106

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 Section 8 - Customer Assistance Information

Owner Service Assistance

Local Repair Service
If you need service for your Mercury MerCruiser–powered boat, take it to your authorized
dealer. Only authorized dealers specialize in Mercury MerCruiser products and have
factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and
accessories to properly service your engine.
NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine
specifically for Mercury MerCruiser sterndrives and inboards.
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
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on
Mercury Marine products comply with federal and international standards to minimize risk
of fire or explosion. Do not use replacement electrical or fuel system components that do
not comply with these standards. When servicing the electrical and fuel systems, properly
install and tighten all components.

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. Exercise care when replacing marine engine parts,
because specifications are different from those of the standard automotive engine. For
example, one of the most important special replacement parts, is the cylinder head gasket.
Marine engines cannot use steel‑type automotive head gaskets because saltwater is highly
corrosive. A marine engine head gasket uses special materials to resist corrosion.
Because marine engines must be capable of running at or near maximum RPM much of
the time, they also have special valve springs, valve lifters, pistons, bearings, camshafts
and other heavy‑duty moving parts.
Mercury MerCruiser marine engines have other special modifications to provide long life
and dependable performance.

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 Section 8 - Customer Assistance Information

PARTS AND ACCESSORIES INQUIRIES

Direct any inquiries concerning Quicksilver replacement parts and accessories to your local
authorized dealer. The dealer has the necessary information to order parts and accessories
for you if they are not 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 you need additional
assistance:
1. Talk with the dealership's sales manager or service manager. Contact the owner of the
dealership if the sales manager and service manager have been unable to resolve the
problem.
2. If your question, concern, or problem 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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 Section 8 - 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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