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Operation - Brunswick Marine in EMEA Center

1. Warranty is limited to defects in material or workmanship but only when the consumer sale is made in the country to which distribution is authorized by us Should you have any questions concerning warranty coverage con tact your authorized dealer They will be pleased to answer any ques tions that you may have 120 Warranty Does Not Apply To The Following Minor adjustments and tune ups including checking cleaning or adjusting spark plugs ignition components carburetor settings filters belts controls and checking lubrication made in connec tion with normal services Damage caused by neglect lack of maintenance accident ab normal operation or improper installation or service or freezing temperatures Haul out launch towing charges removal and or replacement of boat partitions or material because of boat design for necessary access to the product all related transportation charges and or travel time etc Reasonable access must be provided to the prod uct for warranty service Customer must deliver product to an Au thorized Dealer Additional service work requested by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an Authorized Dealer may be cov ered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out etc and prior
2. 37 CA34 3 TO 5 DEGREES 38 CA284 i Power Trim Power Trim allows the operator to adjust the drive angle while under way to provide the ideal boat angle for varying load and water condi tions Also the Power Trim system Trailering feature allows the op erator to raise and lower the drive unit for trailering beaching launching and low speed below 1200 RPM engine speed shallow water operation CAUTION Never trim the drive unit UP OUT using TRAILER switch while boat is underway at engine speeds above 1200 RPM Use ex treme caution when operating with drive unit raised Severe damage to the drive unit may result if unit is raised beyond the gimbal ring support flanges at engine speeds above 1200 RPM 1 In most cases best overall performance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the wa ter Trimming Drive Unit UP OUT Can Lower the bow e Generally increase top speed e Increase clearance over submerged objects or a shallow bottom e Cause boat to accelerate and plane off slower e Inexcess cause boat porpoising bouncing or propeller ventila tion e Cause engine overheating if trimmed UP OUT to a point where any cooling water intake holes are above the water line Trimming Drive Unit DOWN IN Can e Help the boat accelerate and plane off quicker e Generally improve the ride in choppy water e n most cases reduce bo
3. Complete Engine Exhaust System Inspect externally for dam age and deterioration check all hose clamps for adequate tight ness Retorque gimbal ring clamping screws to 50 55 Ib ft 67 74 N m Check that both front engine mount locknuts are tightened se curely Then check to ensure that tab washers are bent down over adjusting nuts Check that rear engine mounts are torqued to 35 40 Ib ft 47 54 N m CA175 THIS PAGE IS INTENTIONALLY BLANK 25 CA26 eo 4 I CL Y 2 is ze 19 70 o oJojoTol CRUISELOG 6 26 CA197 Operation Instrumentation The following is a brief explanation of instrumentation typically found on some boats The owner operator should be familiar with all instru ments and their functions on the boat 1 Speedometer Indicates boat speed 2 Tachometer Indicates engine RPM 3 Oil Pressure Gauge Indicates engine oil pressure 4 Battery Meter Indicates battery voltage 5 Water Temperature Gauge Indicates engine operating tempera ture 6 Fuel Gauge Indicates fuel tank volume 7 Power Trim Gauge Indicates drive unit angle trim up out and down in 8 Hour Meter Records engine running time 9 Bilge Blower Switch Must be operated for five minutes before starting engine to ventilate bilge 10 Ignition Switch Allows operator to start and stop engine 27 CB218 1 70518 28 CA300 Audio Warning System Warning buzzer will sound if 1 Cooling sys
4. should be taken to inhibit corrosion IMPORTANT Corrosion damage that results from the improper application of anti fouling paint will not be covered by the lim ited warranty 1 Painting Boat Hull or Boat Transom Antifouling paint may be applied to boat hull and boat transom but you must observe the fol lowing precautions IMPORTANT DO NOT paint anodes or MerCathode System ref erence electrode and anode as this will render them ineffective as galvanic corrosion inhibitors IMPORTANT If anti fouling protection is required for boat hull or boat transom copper or tin base paints if not prohibited by law can be used If using copper or tin based anti fouling paints observe the following 2 Avoid any electrical interconnection between the MerCruiser Product Anodic Blocks or MerCathode System and the paint by al lowing a minimum of 1 1 2 in 40mm UNPAINTED area on transom of the boat around these items 3 Painting Drive Unit or Transom Assembly Drive unit and tran som assembly should be painted with a good quality marine paint or an anti fouling paint that DOES NOT contain copper tin or any other material that could conduct electrical current Do not paint drain holes anodes MerCathode system and items specified by boat manufacturer 4 Spray power package components on inside of boat every 2 3 weeks with Quicksilver Corrosion Guard to protect finish from dulling and corrosion External power package component
5. Counterclockwise to decrease tension Adjust to tension desired 4 Power Trim Switch See Power Trim section for detailed power trim operating procedures 5 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 6 Power Trim Adjustment Switch s Used on Three Button Trim Control Only See Power Trim section for detailed power trim operating procedures 35 CB185 CB186 Remote Controls Two Lever 1 Shift Lever shifts unit into gear with full lever movement Move lever forward to shift to FORWARD gear Move lever backward to shift to REVERSE gear Lever in full vertical position shifts to NEU TRAL A CAUTION Never shift unit into or out of gear unless throttle lever is a idle RPM 2 Throttle Lever allows engine RPM to be increased or decreased 3 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread screw all the way Out 4 DETENT Screw controls the effort needed to move control han dle out of NEUTRAL To increase tension turn screw clockwise to decrease turn screw counterclockwise Do not thread screw all the way Out IMPORTANT Boats equipped with dual power packages may have both shift levers on one control and both throttle levers on the other control
6. current draw cannot be located and corrected turn OFF or discon nect all accessories connected to engine and instrumentation wiring Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks must be made on electrical system 3 There are three fuses located in the fuel injection system electrical box These fuses control various EFI circuits A Fuel Pump Fuse 15 Amp B EOM Injector Fuse 10 Amp C EOM Battery Fuse 15 Amp 4 A20 amp fuse may be located in ignition switch I terminal lead to protect electrical system Check for blown fuse if key is turned to START and nothing happens and circuit breaker is not tripped 5 The Power Trim System is protected from overload by 110 amp fuse and a 20 amp in line fuse on Power Trim pump 6 Quicksilver Three Button Power Trim Control Panelis further pro tected by a 20 amp in line fuse 7 The Quicksilver MerCathode System has a 20 amp in line fuse is in the wire which connects to positive terminal on controller If fuse is blown system will not operate and a loss of corrosion protection will result 31 CB181 CB182 Remote Controls Panel Mounted Your boat may be equipped with one of many Quicksilvere remote controls available All controls feature an integral safety switch that allows starting engine in NEUTRAL only Also all controls may not have all features shown If boatis equipped with a remote control oth er t
7. gets thinner as eleva tion increases the engine begins to starve for air Humidity baromet ric pressure and temperature do have a noticeable effect on the density of air Heat and humidity thin the air This condition can be come particularly annoying when the propeller testing was done on a cool dry day Then later on a hot sultry day the boat doesn t seem to have the same performance Although some performance can be regained by dropping to a lower pitch propeller the basic problem still exists In some cases a gear ratio change to more reduction is possible and very beneficial Summer conditions of high temperature low barometric pressure and high humidity all combine to reduce the engine power This in turn is reflected in decreased boat speeds as much as 2 or 3 miles per hour in some cases Nothing will regain this speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an en gine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propel ler will in effect become too large Consequently the engine oper ates atless than its recommended RPM This will resultinfurtherloss of horsepower at the propeller with another decrease in boat speed This secondary loss however can be somewhat regained by switch ing to a lower pi
8. inspect INTERVAL At First 20 Hours of Operation Whenever Insufficient Seawater Flow is Suspected If Operating Tempera ture Exceeds Normal Range Every 100 Hours of Operation or Once Yearly Whichever Occurs First NOTE 1 See IMPORTANT INFORMATION for a list of 20 Hour Checkup maintenance 59 CA51 Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL Engine Alignment Check See Note 2 Engine Coupling Universal Joint Shaft Splines Lubricate See Note 2 Universal Joint Cross Bearings Inspect See Note 2 Steering System Lu bricate and inspect for loose damaged or missing parts Electrical System Check for loose or damaged wiring Cooling System Hoses and Clamps Inspect for damage and deteriora tion Check clamps for tightness Continuity Circuit Check components for loose connections bro ken or frayed wires Shift and Throttle Cable and Linkage Lubricate and inspect for loose damaged or missing parts Saltwater use Every 300 Hours of Operation or Once Yearly Whichever Occurs First Freshwater use Every 300 Hours of Operation or Once Every Two Years Whichever Occurs First Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichev er Occurs First NOTE 2 Refer to Lubrication
9. DRAIN hole or it oil appears milky brown drive unit is leaking and should be checked immediately by your Authorized MerCruiser Dealer Lower drive unit so anti ventilation plate is level Fill drive unitthrough OIL FILL DRAIN hole with Specified Gear Lube until an air free stream of lubricant flows from OIL VENT hole Remove tube from OIL FILL DRAIN hole Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 3 Fill gear lube monitor with Specified Gear Lube When oil starts to run outthe OIL VENT hole reinstall sealing washer and OIL VENT screw Tighten securely Continue to fill monitor to FILL mark on monitor Lubricate O ring on monitor neck with stern drive oil to ensure ease of installation and removal of cap Install monitor cap do not overtighten 69 CB221 CC270 Water Separating Fuel Filter Be careful when changing water separating fuel filter Gasoline is extremely flammable and highly explosive under certain con ditions Be sure ignition key is OFF Do not smoke or allow spark or open flame in area when changing fuel filter Wipe up any spilled fuel immediately 1 Remove water separating fuel filter by turning counterclockwise and sealing ring s from mounting bracket and discard Coat sealing rings on new filter with motor oil Thread filter clockwise onto bracket and tighten securely by hand Do not use a filter wrench Start and run engine Check filter connection for gasoline l
10. For additional information obtain acopy of our Hi Performance Boat Operation booklet Part Number 90 86168 3 from your dealer distributor or Mercury Marine 11 CA7 Conditions Affecting Operation Weight Distribution Positioning of weight passengers and gear inside the boat has the following effects Shifting weight to rear stern will e Generally increases speed and engine RPM e At extremes can cause boat to porpoise e Causes bow to bounce in choppy water e Increases danger of following wave splashing into boat when coming off plane Shifting weight to front bow will e Improve ease of planing e Improve rough water ride e At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum speed the following conditions of the boat bot tom should be observed A Clean free of barnacles and marine growth B Free of distortion nearly flat where it contacts the water C Straight and smooth fore and aft Marine vegetation may accumulate when boat is docked This growth must be removed before operation it may clog water inlets and cause engine to overheat CA9 Cavitation Cavitation occurs when water flow cannot follow the contour of a fast moving underwater object such as a gear housing or propeller Cavitation permits the propeller to speed up but the boat speed to reduce Cavitation can seriously erode the surface of the gear hous ing or
11. Propshaft Kilowatts 164 186 209 BSO SAV Rating 191 2 Displacement 350 C I D 5 7 L Engine Type Bore 4 00 in 101 6mm Stroke 3 48 in 88 39 mm Compression Ratio 9 4 1 Compression Pressure 180 psi 1241 kPa Maximum RPM 4200 4600 4400 4800 W O T RPM RPM Idle RPM in Forward 600 RPM Gear Fuel Pump Pressure 3 9 psi 21 48 kPa Oil Pressure x f 2000 RPM 30 55 psi 207 379 kPa Min Oil Pressure Idle 4 psi 28 kPa Thermostat 160 F 71 C Power Rated in Accordance with NMMA National Marine Manufacturers Association rating procedures Power Rated in Accordance with BSO SAV rating procedures This rating procedure is used to certify thatthe engine complies with Stage 1 Bodensee and Swiss Regulations Horsepow er differences shown result from differences in test RPM and allowable test tolerances 3 Measured using an accurate service tachometer 52 CA355 Tune Up Specification 350 Mag MODEL 5 7L EFI 5 7LX EFI EFI Gen AC MR43T AC MR43LTS Spark Plug Champion RV15YC4 Champion Type NGK BR6FS RS9YC NGK BPR6ESS Spark Plug 040 in 045 in Gap 1mm 1 1mm Timing Idle Firing Order 1 8 4 3 6 5 7 2 12 Volt Negative El Syst ectrical System Ground Alternator Rating 65 Amps Minimum Recommended Battery Rating 550 cca 700 mca or 120Ah 1 Timing must be set using a special procedure as outlined in the appropriate Service Manual Timing cannot be properly set
12. a posted pump Octane Rating of 90 RON minimum Premium gasoline 98 RON is also accept able If unleaded gasoline is not available use a major brand of leaded gasoline CA291 USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol also These Reformulated Gasolines are acceptable for use in your Mer Cruiser engine CA277 GASOLINES CONTAINING ALCOHOL If the gasoline in your area contains either methanol methyl alco hol or ethanol ethyl alcohol you should be aware of certain ad verse effects that can occur These adverse effects are more severe with methanol Increasing the percentage of alcohol in the fuel can also worsen these adverse effects Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air resulting in a separation of the water alcohol from the gasoline in the fuel tank 49 The fuel system components on your MerCruiser engine will with stand up to 1096 alcohol content in the gasoline We do not know what percentage your boat s fuel system will withstand Contact your boat manufacturer for specific recommendations on the boats fuel system components fuel tanks fuel
13. limited Product warranty except for Bravo and TRS Drive Units nor 6 Product used in commercial appli cation IV ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES VI ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIM ITED TO THE LIFE OF THIS WARRANTY SOME STATES OR COUNTRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLU SION OR LIMITATION OF INCIDENTAL OR CONSEQUEN TIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLU SION 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 or country to country Other details of this warranty are contained in paragraphs IV V and VI of the United States and Canada Product Warranty and paragraphs Ill IV V and VI of the International Product Warranty contained in this manual which paragraphs are in corporated herein by reference Mercury Marine products are built using the most advanced corro sion protection process available This manufacturing system com plemented by dealer and customer participation in an anti corrosion preventive maintenance program provides protection against repair costs incurred by the effects of marine corrosion 119 OWNER S RESPONSIBILITY Protection against certain types of corrosion damage must be pro vided by using such systems as the Quicksilver MerCatho
14. or 4 there is complete loss of the boat Seek further assistance from local law enforcement CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his her direction even at slow speed 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 coasting and the drive unit is in neutral position 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 Shift the drive unit into neutral and shut off the engine before allowing people to swim or be in the water near your boat Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CA283 High speed And High performance Boat Operation If your boat is considered a high speed or high performance boat with which you are unfamiliar we recommend that you never operate itatits high speed capability without first requesting an initial orienta tion and familiarization demonstration ride with your dealer or an op erator experienced with your boat
15. or open valve Check sight tube for fuel Have Authorized Mer Cruiser Dealer replace pump if fuel is present Do not attempt to start en gine for at least 5 minutes Refer to STARTING PRO CEDURES Service ignition system Replace filter If contaminated drain tank Fill with fresh fuel Replace kinked lines or blow out lines with com pressed air to remove ob struction Have EFI system checked by an Authorized Mer Cruiser Dealer Possible Cause Idle speed too low Faulty ignition system com ponent Clogged fuel filters Stale or contaminated fuel Kinked or clogged fuel line or fuel tank vent line Flame arrestor with foreign material EFI system fault plugged Engine Runs Rough Misses And Or Backfires Remedy Have EFI system checked by an Authorized Mer Cruiser Dealer Service ignition system Replace filters If contaminated drain tank Fill with fresh fuel Replace kinked line or blow out line with compressed air to remove obstruction Clean flame arrestor Have EFI system checked by an Authorized Mer Cruiser Dealer Poor Performance Possible Cause Throttle not fully open Damaged or improper pro peller Excessive bilge water Boat overloaded or load improperly distributed Boat bottom fouled or dam aged Flame arrestor dirty EFI system fault Remedy Inspect throttle cable and linkages for proper opera tion Replace Drain and check
16. propeller Common causes of cavitation are A Weeds or other debris snagged on propeller or gear housing B Bent propeller blade or damaged gear housing skeg C Raised burrs or sharp edges on propeller or gear housing CA10 Ventilation Ventilation is caused by surface air or exhaust gases which are intro duced around the propeller resulting in propeller speedup and a re duction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ring C A damaged propeller or gear housing which allows exhaust gases to escape between propeller and gear housing D Drive unit installed too high on transom CA294 Propeller Selection IMPORTANT Installed propeller must allow engine to run at its specified maximum wide open throttle revolutions per minute RPM Use an accurate service tachometer to verify engine operating RPM It is the responsibility of the boat manufacturer and or the selling dealer to equip the power package with the correct propeller s Spe cified engine wide open throttle WOT and operating RPM range are listed in SPECIFICATIONS IMPORTANT Theengines covered in this manual are equipped with an RPM rev limiter that is set to an upper or limited RPM amount This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from ex cessive engine RPM Once the RPM drop into th
17. pump drive belt closed cooling If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage 2 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 3 Power Steering Pump Drive Belt Inspect drive belt for excessive wear or damage 4 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 5 Seawater Pickup Pump Drive Belt Models with Closed Cooling System Only Inspect drive belt for excessive wear or damage 6 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 83 CA204 84 CA241 Corrosion And Corrosion Protection Whenever two or more dissimilar metals like those found on the stern drive are submerged in a conductive solution such as saltwa ter polluted water or water with a high mineral content a chemical reaction takes place causing electrical current to flow between met als The electrical current flow causes the metal that is most chemi cally active or anodic to erode This is known as galvanic corrosion and if not controlled it will in time cause the need for replacement of power package components exposed to water IMPORTANT Replace sacrificial anodes if eroded 50 or more 1 Universal Anodic Plate serves as a sacrificia
18. Center closest to you for the transferable warranty proce dure that would apply to you 123 Q Guard Product Protection Plan United States And Canada Only Certain performance products triple engine installations and com mercial applications are excluded The Mercury Marine Q Guard Product Protection Plan provides cov erage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q Guard Product Protection Plan is the only Factory Plan available for your engine Two three or four year term plans can be purchased up to 180 days after the original engine purchase date See your participating MerCruiser dealer for complete program de tails 124 Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local Autho rized Dealer should the need for service arise Only he has the facto ry trained mechanics knowledge special tools and equipment and the genuine Quicksilver parts and accessories to properly service your engine should the need occur He knows your engine best Quicksilver parts and accessories are engineered and built by Mer cury Marine specifically for MerCruiser stern drives 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 r
19. LITIES In general a dealer s responsibilities to the customer include prede livery inspection and preparation such as e Make sure that the boat is properly equipped e Priorto delivery make certain that the MerCruiser power package and other equipment are in proper operating condition e Make all necessary adjustments for maximum efficiency e Familiarize the customer with the on board equipment e Explain and demonstrate the operation of the power package and boat e Atthe time of delivery the dealer should provide you with a copy of a Predelivery Inspection Checklist e Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product CA318 Freezing Temperature Operation IMPORTANT If boat is operated during periods of freezing tem perature precautions must be taken to prevent freezing dam age to power package Refer to COLD WEATHER or EX TENDED STORAGE for draining instructions Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty CA17 Drive Unit Impact Protection The Power Trim hydraulic system is designed to provide impact pro tection for drive unit If a submerged object is struck while boat is moving forward the hydraulic system will cushion the kickup of drive unit as it clears the object reducing damage to unit After drive unit has cleared object the hydraulic system allows drive unit to return t
20. OFF 47 CA41 Open engine hatch Turn equipped Operate bilge blowers if so equipped Open fuel shutoff valve Open seacock if so equipped Place drive unit in full down in position Perform all other checks specified by your dealer and or boat builder 48 battery switch ON if so Operation Chart BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Observe all condition of engine If not normal stop engine Check for fuel oil wa ter fluid and exhaust leaks etc Check shift and throttle control op eration Check steering operation Observe all gauges to monitor engine condition Turn ignition key OFF Turn bat tery switch OFF if so equipped Close fuel valve Close sea cock if so equipped Flush cool ing system if in saltwa ter area CA261 Specifications Fuel Recommendations IMPORTANT Use of improper gasoline can damage your en gine seriously Engine damage resulting from use of improper gasoline is considered misuse of engine and damage caused thereby will not be covered under the limited warranty FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows USA and Canada having a posted pump Octane Rating of 87 R M 2 minimum Premium gasoline 92 R M 2 Octane is also acceptable DO NOT use leaded gasoline Outside USA and Canada having
21. OPERATION amp MAINTENANCE MANUAL 5 7L EFI 5 7LX EFI 350 Magnum EFI Gen Alpha One 91995 Brunswick Corporation 90 806582963 196 OPERATION 8 MAINTENANCE MANUAL 5 7L EFI 5 7LX EFI 350 Magnum EFI Gen Alpha One 1995 Brunswick Corporation 90 806582963 196 CA1 Identification Record Please Record the Following Information Engine Model and Horsepower 2 Engine Serial Number 3 Transom Assembly Serial Number 4 Stern Drive Unit Serial Number and Gear Ratio 5 Propeller Number 6 Propeller Pitch 7 Hull Identification Number HIN Purchase Date 8 SS Boat Manufacturer Boat Model Length SERIAL NUMBERS The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting your Authorized 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 1995 Brunswick Corporation The following are registered trademarks of Brunswick Corporation Auto blend Jet Prop Mariner Merc MerCathode MerCruiser Mercury Mercury Marine Quicksilv
22. Operate Motor Runs But Drive Unit Does Not Move Possible Cause Remedy e Trim pump oil level low e Fil pump with oil e Drive unit binding in e Check for obstruction gimbal ring 111 CA320 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Regis tration Card completely and mails it to the factory immediately upon sale of the new product It identifies 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 Upon receipt of the Warranty Registration Card at the factory you will be issued a plastic Owner Warranty Registration Card which is your only valid registration identification It must be presented to the servicing dealer should warranty service be required War ranty claims will not be accepted without presentation of this card Atemporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service dur ing this period present the temporary registration card to the deal er He will attach it to your warranty claim form Because of your selling dealer s continuing pe
23. Package Inboard Engine and accessories attached thereto hereafter referred to as Product to be free from defects in material and workmanship but only when the consumer sale is made in the country to which distribution is authorized by us This warranty shall become effective only upon our receipt of a completed Warranty Registration Card which shall identify the Product so registered by serial number This warranty shall remain in effect for a period of one 1 year from date of pur chase Since this warranty applies to defects in material and workman ship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of mainte nance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit 5 Alteration or removal of parts or 6 Water en tering engine cylinder s through the exhaust system or carbure tor s Reasonable access must be provided to the product for warran ty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other conse quential damages or 2 Removal and or replacement of b
24. Paint 92 78373 12 132 Vent Screw O ring 12 19183 CC172 Literature Order Form Model Horsepower Serial Number Year Service Manual shows the complete assembly and disassembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Part Number Qty Total Official Use Only Price Service Manual 30 00 Engine Service Manual Drive Service Manual 90 30 00 Remote Control Parts Manual 4 95 Engine Only Parts Manual 4 95 Drive Only Operation and Main 5 00 tenance Manual AK AZ DE HI ID IA ME MI MT NV NH NY OR VT Sales WV WY Tax Orders Totaling up to 20 00 add 3 00 Ship 20 01 50 00 add 4 00 Hand 50 01 up Free an Grand Total 133 Sub Total must be collected from customers in all states except Please Return with Payment to Mercury Marine Attn Publications Dept 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 METHOD OF PAYMENT NO CASH OR C O D Personal Check Cashiers Check Money Order Visa MasterCard Month Year Spa ESESPAEEEEEIESIEESE E27 Card Number Expiration Date SR CUM CR Signature Date 7 Telephone Number 134
25. R button is held depressed after drive unit reaches end of upward travel an internal circuit breaker will open and pump will stop Should this happen release button and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed A CAUTION When lowering or raising stern drives equipped with a dual engine tie bar kit in the trailering position stern drives must be lowered evenly to prevent tie bar from becoming twisted Fail ure to lower stern drives evenly may result in tie bar or stern drive s damage 1 Trailer Button Both Versions Press button until drive unit reach es desired height for trailering drive units 2 Two Button Trim Control Dual Buttons in Handle used to control both drive units from the handle Press UP on button s to trim drive unit UP OUT Press down on button s to trim drive unit DOWN IN A Forward Trim Button Used to trim the port drive unit B Rear Trim Button Used to trim the starboard drive unit 3 Three Button Trim Control Trim Adjustment Switches With a single integral trim button in the handle to control two drive units simultaneously these two switches control the Fine Tune adjust ment of each drive unit Using these Fine Tune Switches set each drive unit to the desired trim angle Then use the single trim switch in the handle to control the trim of both drive units simultaneously 4 Three Button Trim Control Single T
26. RE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN CONTACT YOUR NEAREST MERCRUISER SERVICE CENTER Provide the following important information e Your name address and telephone number e The model and serial number s e Your dealer s name and location e Date of purchase e Present hours of operation e Details of problem or complaint e Boat make and size e Propeller pitch and or part number e Normal use and approximate gross load 126 Please bear in mind that Service Centers resolve all problems through the dealership using the dealer s facilities equipment and personnel This is the reason we request you use the preceding steps in sequence when you have a problem or complaint Our expe rience has shown that this is the most expedient and successful pro cedure to follow to ensure satisfaction to our customers FOLLOW STEP THREE ONLY AFTER COMPLETING STEPS ONE AND TWO AND YOUR COMPLAINT HAS NOT BEEN RE SOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT United States MERCRUISER 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 Canada Contact Nearest Regional Service Center Other Countries Contact the Nearest Marine Power International Service Center The customer service representatives will review all the facts in volved If they feel some further action can be taken they will advise the Service Center They will contact your dealer to bring the problem to a satisfactory co
27. at speed e f in excess lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane This can result in an unexpected turn in either direction called bow steer ing or over steering if any turn is attempted or if a significant wave is encountered 39 CB187 73976 73977 40 CB188 POWER TRIM OPERATION PANEL MOUNT REMOTE CONTROL IMPORTANT If TRAILER button is held depressed after drive unit reaches end of upward travel an internal circuit breaker will open and pump will stop Should this happen release button and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Press button until drive unit reaches desired height 2 Trim Up Out Press UP on Trim switch until drive unit reaches de sired trim position 3 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position CB189 POWER TRIM OPERATION CONSOLE MOUNT REMOTE CONTROL SINGLE ENGINE VERSION 4 Trailer Position Press button until drive unit reaches desired height 5 Trim Up Out Press UP on Trim switch until drive unit reaches de sired trim position 6 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position 41 CB190 CA285 POWER TRIM OPERATION DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL TWO BUTTON AND THREE BUTTON VERSIONS IMPORTANT If TRAILE
28. ate Check all items listed in OPERATION CHART Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual Place drive unit in full down in position Place control handle in NEUTRAL FLOODED ENGINE Turn ignition switch to ON position Place the throttle lever at 5096 position Attempt to start engine As soon as en gine starts return throttle to the idle position 46 Turn ignition key to START Release key when engine starts and allow switch to return to RUN position Check oil pressure gauge immediately after engine starts If oil pressure is not within specified range see SPECIFICATIONS stop engine immediately and determine cause After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnormally high If itis stop engine immediately and determine cause Be sure charging system is functioning correctly Observe power package for fuel oil water and exhaust leaks To shift drive unit into gear move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shiftto REVERSE After shifting drive unit advance throttle to de sired setting To shift drive unit out of gear move control shift lever to NEUTRAL and allow engine to drop to IDLE speed If engine has been run at high speed for a long period of time allow engine to cool by run ning at IDLE speed for 3 to 5 minutes Turn ignition key to
29. bles Clean and tighten faulty connections Repair or replace damaged wiring Replace and or adjust Test battery 109 Remote Control Operates Hard Binds Has Ex cessive Free play Or Makes Unusual Sounds 110 Possible Cause Insufficient lubrication on shift and throttle linkage fasteners Loose or missing shift and throttle linkage fasteners Obstruction in shift or throttle linkages Shift or kinked throttle cable Possible Cause Low power steering pump fluid level Drive belt loose or in poor condition Insufficient lubrication on steering system compo nents Loose or missing steering fasteners or parts Contaminated steering fluid power Remedy Lubricate Check all linkages If any are loose or missing see Authorized MerCruiser Dealer immediately Remove obstruction Straighten cable or have dealer replace cable if damaged beyond repair Remedy Refill system with fluid Replace and or adjust Lubricate Check all parts and fasten ers If any are loose or missing see Authorized MerCruiser Dealer immedi ately Drain and replace Power Trim Does Not Operate Motor Doesn t Run Possible Cause Remedy Blown fuse e Replace fuse Loose or dirty electrical Check all associated elec connections or damaged trical connections and wiring wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not
30. corrosion agent 4 Perform all checks in OPERATION CHART in the BEFORE STARTING column 44 CAUTION Refer to FLUSHING COOLING SYSTEM before starting engine 5 Start engine and closely observe instrumentation to make sure that all systems are functioning correctly 6 Carefully inspect engine for fuel oil fluid water and exhaust leaks 7 Check steering system shift and throttle control for proper opera tion 8 Check fuel pump sight tube for evidence of fuel indicating a rup tured fuel pump diaphragm 104 CA194 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks Slow Possible Cause Battery switch turned off Remote control not in neu tral position Open circuit breaker or blown fuse Loose or dirty electrical connections or damaged wiring Bad battery Remedy Turn switch on Position control lever in neutral Check and reset circuit breaker or replace fuse Check all electrical con nections and wires espe cially battery cables Clean and tighten faulty connection Test and replace if bad Engine Will Not Start Or Is Hard To Start Possible Cause Improper starting proce dure Empty fuel tank or fuel shutoff valve closed Faulty fuel pump Engine flooded Faulty ignition system com ponent Clogged fuel filter Stale or contaminated fuel Fuel line or tank vent line kinked or clogged EFI System fault Remedy Read starting procedure Fill tank
31. cylinder block as follows A Port Side from cylinder block B Starboard Side from Y fitting Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sen sor in the upper hole of the fitting This sensor must not be loos ened or removed It is tightened to a critical specification at the factory 3 Remove drain plugs from bottom of exhaust manifolds port and stbd 4 Repeatedly clean out drain holes using a stiff piece of wire Do this until entire system is drained 101 CA193 E Z9 102 CA208 NOTE lt may be necessary to lift or bend hoses to allow water to drain completely Crank engine over slightly to purge any water trapped in seawater pickup pump Do not allow engine to start 5 Remove hose from power steering cooler 6 Loosen hose clamp and disconnect the hose from engine circulat ing pump After cooling system has drained completely coat drain plug threads with Quicksilver Perfect Seal and reinstall drain plugs Reconnect hoses and tighten all hose clamps securely IMPORTANT MerCruiser recommends that propylene glycol antifreeze nontoxic and biodegradable which makes it friendly to lakes and rivers be used in seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is rec ommended for use in marine engines Be certain to follow the propylene glycol manufacturer
32. d portion of Steering Cable and Propeller Shaft Quicksil ver Special Lubricant 101 5 Stern Drive Unit Quicksilver High Performance Gear Lube 6 Gimbal Bearing Quicksilver U Joint and Gimbal Bearing Grease 7 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard 8 Power Trim System Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor oil Continued on next page 55 9 Crankcase Oil Quicksilver 4 Cycle Marine Engine Oil Refer to SPECIFICATIONS for alternatives and oil recommendations for varying ambient temperatures 10 Closed Cooling System Coolant 50 50 mixture of ethylene glycol antifreeze must meet GM specification 1825 M and tap water Areas where temperatures generally do not go below 32 F 0 C rust inhibitor and tap water is acceptable 11 Gasoline Stabilizer Quicksilver Gasoline Stabilizer for Marine Engines 12Grease Fittings on Drive Shaft Extension Models Quicksilver U Joint and Gimbal Bearing Grease 56 CA200 Maintenance Chart Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER OPERATOR TASK INTERVAL Engine Crankcase Oil Check level Power Steering Fluid Check level Stern Drive Unit Oil Check level Battery Check level and inspect for damage Fuel Pump Sight Tube Check that no fuel is present Power Trim Pump Oil Check level Anodes Insp
33. de System and or Galvanic Isolator These certain types of corrosion damage are damage due to stray electrical currents on shore power con nections nearby boats submerged metal or improper application of copper base anti fouling paint If anti fouling protection is required Tri Butyl Tin Adipate TBTA base antifouling paints are recommended on MerCruiser boating applications In areas where Tri Butyl Tin Adipate base paints are prohibited by law copper base paints can be used on the boat hull and transom Do not apply paint to the MerCruiser drive unit or tran som assembly In addition care must be taken to avoid an electrical interconnection between the MerCruiser Product and the paint Cor rosion damage that results from the improper application of copper base paint will not be covered by this limited warranty TRANSFER OF WARRANTY This Limited Warranty is transferable to subsequent purchasers for the remainder of the unused portion of the 3 year limited warranty Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty coverage The table explains some of the types of services that are not covered by warranty Keep in mind that warranty covers repairs that are needed within the warranty period because of defects in material and workmanship In stallation errors accidents normal wear and a variety of other causes that affect the product are not covered
34. e Crankcase Ventilation Valve PCV Emissions Testing 0ooooooooo Miscellaneous Maintenance Euri MEM Bottom Of Boat s veis e RICE caus edes Inspection And Maintenance Cold Weather or Extended Storage Power Package Lay Up Draining Instructions ooooocoooooo Battery Winter Storage o Power Package Recommissioning Troubleshooting cr 242 eee Warranty Information ssssessesese Owner Warranty Registration International Owner Registration Warranty Policies u eek ios lp ure en Mercruiser Limited Warranty Gasoline Engines Mercruiser International Warranty Gasoline Engines 3 Year Limited Warranty Against Corrosion Failure Warranty Coverage 222224 Transferable Warranty lssssluuus Q Guard Product Protection Plan Owner Service Assistance ooooo o Service Centers 2 2 namen Customer Service Literature General Maintenance PartS Literature Order Form 0 0 00 c cece eee ee CA165 Welcome You have selected one of the finest marine power packages available It in corporates numerous design features to assure operating ease and durabil ity With proper care and maintenance you will thoroughly enjoy using this product for many boating seasons To ensure ma
35. e are controlled by the movement of the control handle Push the control handle for ward from Neutral with a quick firm motion to the first detent for For ward 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 Continue pushing backto increase speed 33 CB184 Remote Controls Console Mounted 1 Control Handle s 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 det ent 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 Continue pushing back to increase speed 2 Throttle Only Button Allows engine throttle advancement with out shifting the engine This is done by disengaging the shift mecha nism 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 3 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control han dle cover must be removed to adjust This will help prevent Creep of the remote control handle Turn screw Clockwise to increase ten sion and
36. e recommended operating RPM range normal engine operation resumes Selecta propeller that will allow the engine power package to operate at or near the top end of the recommended wide open throttle oper ating RPM range with a normal load High RPM caused by an exces sive trim angle should not be used in determining correct propeller selection If full throttle operation is below the recommended range the propel ler must be changed to prevent loss of performance and possible en gine damage On the other hand operating an engine above the rec ommended operating RPM range will cause higher than normal wear and or damage Generally there is a 200 300 RPM change between propeller pitches After initial propeller selection the following common problems may require that the propeller be changed to a lower pitch e Warmer weather and greater humidity cause an RPM loss e Operating in a higher elevation causes an RPM loss e Operating with a damaged propeller or dirty boat bottom causes an RPM loss e Operating with increased load additional passengers pulling ski ers etc For better acceleration such as is needed for water skiing use the next lower pitch propeller However do not operate at full throttle when using the lower pitch propeller but not pulling skiers How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide open throttle pow er of an engine Since air containing oxygen
37. e to swamp the transom In this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the preceding paragraph In any of these situations water entering the engine could cause se vere damage to internal parts Refer to Attention Required After Submersion CA21 Stolen Power Package If your power package is stolen immediately advise the local authori ties and Mercury Marine of the model and serial number s and to whom the recovery is to be reported This Stolen Motor information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors CA22 Replacement Service Parts Electrical ignition and fuel system components on MerCruiser gasoline power packages are designed and manufactured to comply with U S Coast Guard rules and regulations to minimize risks of fire or explosion Use of replacement electrical ignition or fuel system compo nents which do not comply to these rules and regulations could result in a fire or explosion hazard and should be avoided When servicing the electrical ignition and fuel systems it is ex tremely important that all components are properly installed and tightened If not any electrical or ignition component would permit sparks to ignite fuel vapors from fuel system leaks if they existed Marine engines are expected to operate at or near full throttle for
38. eaks If leaks exist recheck filter installation If leaks continue stop engine im mediately and contact your Authorized MerCruiser Dealer Make sure no leaks exist before closing engine hatch CB220 Fuel Pump Sight Tube Inspection 2 The engine fuel pump and Vapor Separator Tank VST is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphragm IMPORTANT If fuel is visible in tube fuel pump or Vapor Sepa rator Tank VST should be replaced by your Authorized Mer Cruiser Dealer immediately 71 CA70 CA286 E Lubrication STEERING SYSTEM 1 IfSteering Cable Has Grease Fittings With cable fully retracted into cable housing lubricate fitting with 2 4 C Marine Lubricant with Teflon Do not grease steering cable while extended Hydraulic lock could occur and cause loss of steering control NOTE If steering cable does not have grease fitting inner wire of cable cannot be greased 2 With steering cable fully extended lubricate exposed part of cable with Special Lubricant 101 3 Lubricate steering system pivot points with SAE 30W motor oil On dual engine boats lubricate all pivot points including tie bar pivot points with SAE 30W motor oil CA72 SHIFT CABLE 4 Lubricate pivot points with SAE 30W motor oil CA73 THROTTLE CABLE 5 Lubricate pivot points with SAE 30W motor oil 73 CA74 CA287 DRIVE UNIT AND TRANSOM ASSEMBLY 6 Lubricate gimbal bearing with Quick
39. eason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Parts And Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accesso ries should be directed to your local Authorized Dealer The dealer has the necessary information to order parts and accessories for you should he not have them in stock Only Authorized Dealers can pur chase genuine Quicksilver parts and accessories from the factory Mercury Marine does not sell to unauthorized dealers or retail cus tomers When inquiring on parts and accessories the dealer re quires the motor model and serial number s to order the correct parts 125 Resolving A Problem Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser Any problems with service sales warranty or operation of your MerCruiser power package will be resolved by your dealer He also is your primary source of information on your boat power package and trailer Should there be a misunderstand ing or if your problem has not been resolved to your satisfaction please follow these steps STEP ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Misunderstandings or complaints can be quickly resolved by the dealer If you are unable to obtain satisfaction contact the dealer ship s owner STEP TWO IF YOU REQUI
40. ect for erosion Gear Housing Water Pickups Check for ma rine growth or debris 57 CA49 Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER OPERATOR TASK INTERVAL Drive Belts All Inspect condition and check tension Propeller Shaft Saltwater use Every 50 Hours of Lubricate Operation or 60 Days Whichever Power Package Occurs First Exterior Freshwater use Every 100 Hours Every 100 Hours of Operation or 120 Days Whichever Occurs First Surfaces Spray with of Operation or 120 Days Whichever rust preventative Occurs First Power Package Exterior Surfaces Once a Year Clean and paint Cooling System Flush seawater section Saltwater use After Each Use 58 CA357 Only perform maintenance which applies to your particular power package Scheduled Maintenance to be Performed by Dealer TASK 20 Hour Checkup See NOTE 1 Seawater Pickup Pump Disassemble and Inspect Crankcase Oil and Filter Change Ignition System Clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose Clean and inspect Positive Crankcase Venti lation PCV Valve Change 350 Mag Model Stern Drive unit Oil Gimbal Ring Clamping Screws Retorque to 50 55 Ib ft 67 74 N m Rear Engine Mounts Check torque to 35 40 Ib ft 47 54 N m Gimbal Bearing Lubricate Cooling System Clean
41. er Ride Guide and Thruster CA365 ABC12345Z123 19 48 12345 CA353 Table Of Contents Welcome aes e Pee es GC c tr te HP s Read This Manual Thoroughly ooooooocccoooo Lanyard SIOD3SWIUCIT cures Stet een vee ens Safe Boating Suggestions ooooocoooccooccnncco o Protecting People In The Water 000 5 High speed And High performance Boat Operation Conditions Affecting Operation ooocooocccccccco o Weight Distribulioni ac x EO trm xe Bon Bottom of Boat eere nahen Gavitatio EE oos set tao ined dc ca A dte Pon SUM ae ken VentllatiOn ux es ER ae Dr POP inue Propeller Selection oooooooocoococcrn en How Elevation And Climate Affect Performance Important Information 00 e eee eee eee Operation And Maintenance sse Freezing Temperature Operation Drive Unit Impact Protection ooo ooo oooo Emissions Information ui ia EUR ricca Bl Attention Required After Submersion Trailering Boat vrai eo aa Launching And Boat Operation Care Stolen Power Package sseeusssesss Replacement Service Parts o oooccoccooco Do It Yourself Maintenance Suggestions Diagnosing EFI Problems 00 00 eee eee 20 Hour Break In Period 0000 cece ee eee After Break In Period 0 cece cece e
42. ervice 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 form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registra tion Card from your distributor dealer If you receive a plastic War ranty Registration Card you may discard the Purchaser s Copy that you received from the distributor dealer when you purchased the product Ask your distributor dealer if this plastic card program applies to you For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing refer to the International Warranty Refer to Table of Contents IMPORTANT Registration lists must be maintained by the fac tory and dealer in some countries by law It is our desire to have ALL products registered at the factory should it ever be neces sary to contact you Make sure your dealer distributor fills out the warranty registration card immediately and sends the facto ry copy to the Marine Power International Service Center for your area 113 Warranty Policies Mercruiser Limited Warranty Gasoline Engines UNITED STATES AND CANADA ONLY 114 We warrant each new production not those made for high per formance purposes MerCruiser Stern Drive Power
43. ess you are aware of the precautions Cautions and Warn ings and procedures required Your safety is of our concern If you attempt to service the product yourself we suggest you or der the service manual for that model The service manual out lines 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 per form 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 21 e Also if you partially disassemble an engine or drive assembly and are unable to repairit 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 prob lem It may be a very simple adjustment to correct the problem e Do not telephone the dealer service office or the factory to at tempt for them to diagnose a problem or request the repair proce dure It is difficult for them to diagnose a problem over the tele phone e Your Authorized Dealer is there to service your power package He has qualified factory trained mechanics It is recommended you have the dealer do periodic maintenance checks on your power package Have him winterize it
44. esting dealer or agency will be equipped with the appropriate test equipment and adapters for this en gine The only item that must be supplied by the boat owner op erator is the exhaust elbow test probes These test probes should have been provided with your power package They should be carried aboard your boat at all times Refer to Emis sions Testing procedure found later in this manual CA18 Attention Required After Submersion e Before recovery contact a MerCruiser Dealer e After recovery immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to power package CA19 Trailering Boat Boat can be trailered with drive unit in up or down position Ade quate road clearance is required between road and gear housing skeg when trailering with drive unit in down position If adequate road clearance is a problem place drive unit in full trailer position and support with an optional trailer kit which is available from your Authorized MerCruiser Dealer C Launching And Boat Operation Care 44 CAUTION During launching from a trailer if the unloading ramp is steep or the trailer bed must be tilted the boat may enter the water rap idly and at a steep angle This may force water through the ex haust system into the cylinders The more weight on the tran som the more likely this is to occur Slowing down rapidly or stopping suddenly may cause a follow ing wav
45. factory approval has been given to have the work performed at this facility All incidental and or consequential damages storage charges telephone or rental charges of any type inconvenience or loss of time or income are the owner s responsibility Use of other than Quicksilver replacement parts when making warranty repairs Oils lubricants or fluids changed as a matter of normal mainte nance is customer s responsibility unless loss or contamination of same is caused by product failure that would be eligible for war ranty consideration Participating in or preparing for racing or other competitive activ ity 121 Engine noise does not necessarily indicate a serious engine prob lem If diagnosis indicates a serious internal engine condition which could result in a failure condition responsible for noise should be corrected under the warranty Lower unit and or propeller damage caused by striking a sub merged object is considered a marine hazard Water entering the engine via the carburetor or exhaust system or submersion Also water in the starter motor Starter motors and or armatures or field coil assembly which are burned or where lead is thrown out of commutator because of ex cess cranking Valve or valve seat grinding required because of wear Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material block ing inlets or power package being
46. for cause of entry Reduce load or redistribute load more evenly Clean or repair as neces sary Clean flame arrestor Have EFI system checked Excessive Engine Tempera ture Possible Cause Seacock closed Drive belt loose or in poor condition Seawater structed pickups ob Faulty thermostat Faulty seawater pickup pump Seawater discharge re stricted or plugged Remedy Open Replace and or adjust belt Remove obstruction Replace Repair Clean exhaust elbows Insufficient Engine Temperature Possible Cause Faulty Thermostat Remedy Replace Low Engine Oil Pressure Possible Cause Insufficient oil in crankcase Excessive oil in crankcase causing it to become aerated Diluted or improper viscosity oil Remedy Check and add oil Check and remove re quired amount of oil Check for cause of excessive oil improper filling bad fuel pump etc Change oil and oil filter us ing correct grade and vis cosity oil Determine cause for dilution excessive id ling faulty fuel pump etc Battery Will Not Come Up On Charge Possible Cause Excessive current draw from battery Loose or dirty electrical connections or damaged wiring Alternator drive belt loose or in poor condition Unacceptable battery con dition Remedy Turn off non essential ac cessories Check all associated elec trical connections and wires especially battery ca
47. for engine coupler lubrication and or related information 60 CA240 Only perform maintenance which applies to your particular power package SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL Engine Exhaust System Saltwater use Every 50 Hours of Inspect externally for Operation or 60 Days Whichever damage deterioration Occurs First and restrictions Check Freshwater use Every 100 Hours clamps for tightness of Operation or 120 Days Whichev er Occurs First Ignition System Check timing and adjust if needed Fuel filters Replace Steering Head and Remote Control Inspect and lubricate Once a Year Quicksilver MerCathode System Test output Throttle Body Inspect Drive Unit Bellows and Clamps Inspect 61 CA187 62 CA186 Checking Fluid Levels CHECKING CRANKCASE OIL Stop engine Allow approximately five minutes for oil to drain into oil pan Boat must be at rest in water 1 Remove dipstick Wipe clean and reinstall fully into dipstick tube 2 Remove dipstick and observe oil level Oil level must be between FULL and ADD If oil level is below ADD 3 Remove oil filler cap Add specified oil to bring level up to but not over FULL mark on dipstick IMPORTANT Do not overfill crankcase oil CA55 CHECKING POWER STEERING PUMP FLUID Stop engine and position drive unit Straight back 4 Remove FILLCAP DIPSTICK and observe level Add specified fluid if required Rei
48. fy any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIM ITED TO THELIFE OF THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS 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 115 Mercruiser International Warranty Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA 116 We warrant each new production not those made for high per formance purposes MerCruiser Stern Drive Power Package Inboard Engine and accessories attached thereto hereafter referred to as Product to be free from defects in material and workmanship but only when the consumer sale is made in the country to which distribution is authorized by us This warranty shall remain in effect for a period of one 1 year from date of purchase Since this warranty applies to defects in material and workman ship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of mainte nance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Opera
49. han shown consult your dealer for a description and or demon stration of the control 1 Neutral Lock Bar Prevents accidental shift and throttle engage ment Neutral lock bar must be pulled Up to move the control handle out of neutral 2 Throttle Only Button Allows engine throttle advancement with out shifting the engine This is done by disengaging the shift mecha nism 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 3 Power Trim Switch See Power Trim for detailed power trim operating procedures 4 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 5 Lanyard Stop Switch Turns ignition Off whenever the opera tor when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch atthe front of this manual for safety warning on the use of this switch 6 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control han dle This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterclockwise to decrease tension Adjust to tension desired 7 Control Handle Operation of the shift and throttl
50. ications are available from Mercury Marine Attn Publications Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Ma rine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s 130 CA363 General Maintenance Parts Engine Parts 5 7L EFI 350 Magnum EFI 5 7LX EFI Gen Alpha One Alpha One Oil Filter 14957 Spark Plug Distributor Cap Spark Plug Wire Set Thermostat 807252 2 807252 2 160 F Thermostat Gaskets 27 47510 27 47510 27 53045 1 27 53045 1 Alternator Belt 57 48120A1 57 48120A1 Power Steering Belt 57 37619T 57 37619T Water Pump Belt 57 74271T 57 74271T Water Separating 35 807172 35 807172 Filter Quicksilver Motor 92 816096A12 92 816096A12 Oil Storage Seal 92 86145A12 92 86145A12 Valvtane Plus 92 17955A12 92 17955A12 Gasoline Stabilizer 92 817529A12 92 817529A12 for Marine Engines Fuel System 92 17885A12 92 17885A12 Cleaner Corrosion Guard 92 815869A12 92 815869A12 Spray 131 Drive Parts Par Apo eflon 2 4 C Marine Lubricant 92 825407A3 with U Joint and Gimbal 92 828052A2 Bearing Grease Engine Coupler Spline Grease 92 816391A4 High Performance Gear Lube 92 816026A1 Touch Up Spray
51. 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 CB129 Diagnosing EFI Problems Your Authorized MerCruiser Dealer has the proper service tools for diagnosing problems on the Electronic Fuel Injection EFI System The Electronic Control Module ECM on this engine 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 22 CA24 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 mini mum oil consumption and maximum engine performance Dur ing this break in period the following rules must be observed Do not operate below 1500 RPM for extended periods of time for first 10 hours Shift into gear as soon as possible after starting and advance throttle above 1500 RPM if conditions permit safe op eration Do not operate at one speed consistently for extended periods Do not exceed 3 4 throttle during first 10 hours During next 10 hours occasional operation at full throttle is permissible 5 min utes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operat ing temperature F
52. it 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 Quicksilver Gasoline Stabilizer for Marine Engines 92 817529A12 is highly recommended for addition during storage periods See Cold Weather or Extended Storage later in this manual 50 CA43 Crankcase Oil To help obtain optimum engine performance and to provide maxi mum protection we strongly recommend the use of Quicksilver 4 Cycle Marine Engine Oil If not available a good grade straight weight detergent automotive oil of correct viscosity with an API clas sification of CD or SG may be used The chart below is a guide to crankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not avail able a multiviscosity 20W 40 SG or CD or as a second but less preferable choice 20W 50 SG or CD may be used IMPORTANT The use of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oils or oils which contain solid additives are specifically not recommended Quicksilver 4 Cycle Marine Engine Oil UN am SAE 30W SG or CD SAE 20W SG or CD 32 F 50 F 0 C 10 C 70534 AIR TEMPERATURE 51 CA370 Engine Specifications 350 Mag MODEL 5 7L EFI 5 7LX EFI EFI Gens Propshaft Horsepower 220 250 280 BSO SAV Rating 256
53. l anode Remove plug from drive shaft housing to access attaching screw and insert 1 2 inch socket Unthread attaching screw and remove univer sal anodic plate Do not remove screw Install new anodic plate and tighten screw securely Install plug 2 Anodic Plate serves as a sacrificial anode Unscrew both at taching screws and remove Install a new anodic plate and tighten securely 3 MerCathode System if so equipped Electrode assembly re places Anodic block System should be tested to ensure adequate output Test should be made where boat is moored using Quicksilver Refer ence Electrode and Test Meter Contact your Authorized MerCruiser Dealer to arrange for this test 4 Anode Kit if so equipped Mounted to boat transom Acts as a sacrificial anode Replace as required 85 CA162 86 CA163 1 Trim Cylinder Anodes are mounted on each trim cylinder To replace the trim cylinder anodes A Remove two screws from each anode B Install new anodes and tighten securely CA164 2 Propeller Anode is located in front of the propeller between the front side of the propeller and the gear housing Refer to Propeller section in this manual for propeller removal and installation To re place the propeller anode A Remove propeller B Remove two screws from anode C Install new anode and tighten securely D Reinstall propeller 87 CA168 In addition to the corrosion protection devices the following steps
54. lines and fittings Be aware that gasolines containing alcohol may cause increased e Corrosion of metal parts e Deterioration of rubber or plastic parts e Fuel permeation through rubber fuel lines e Starting and operating difficulties FIRE AND EXPLOSION HAZARD Fuel leakage from any part of fuel system can be a fire and explosion hazard which can cause serious bodily injury or death Careful periodic inspection of en tire fuel system is mandatory particularly after storage All fuel components including fuel tanks whether plastic metal or fi berglass fuel lines fittings fuel filters and carburetors fuel in jection components should be inspected for leakage soften ing hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine oper ation Because of possible adverse effects of alcohol in gasoline it is rec ommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alco hol is unknown increased inspection frequency for leaks and abnor malities is required IMPORTANT When operating a 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 mois ture to cause trouble but boats often s
55. most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard auto motive engine For example one of the most important and probably the least sus pected special replacement part is the cylinder head gasket Since saltwater is highly corrosive the steel type automotive head gasket cannot be used A marine engine head gasket uses special materials to resist corrosive action Since marine engines must be capable of running at or near maxi mum RPM much of the time special valve springs valve lifters pis tons bearings camshafts and other heavy duty moving parts are re quired for long life and peak performance These are but a few of the many special modifications that are re quired in MerCruiser marine engines to provide long life and depend able performance 20 CA199 Do It Yourself Maintenance Suggestions If you are one of those persons who likes to do it yourself here are some suggestions for you Present day marine equipment such as your MerCruiser power package are highly technical pieces of machinery Electronic ig nition and special fuel injection systems provide greater fuel econ omies but also are more complex for the untrained mechanic Do not attempt any repairs which are not covered in this manual unl
56. mounted too high Use of fuels and lubricants which are not suitable for use with or on the product Our limited warranty does not apply to any damage to our prod ucts caused by the installation or use of parts and accessories which are not manufactured or sold by us Failures which are not related to the use of those parts or accessories are covered un der warranty if they otherwise meet the terms of the limited war ranty for that product 122 Transferable Warranty The product 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 Direct Sale By Owner e Thesecond owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner s plastic Owner Warranty Registration Card and a copy of the bill of sale to Show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 e Anew Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file e There is no charge for this service Outside the United States and Canada please contact the dis tributor in your country or the Marine Power International Ser vice
57. nce Inspect power package often and at regular intervals to help main tain 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 tight en or replace as required Check plug leads and electrical leads for damage Remove and inspect propeller If badly nicked bent or cracked see your dealer Repair nicks and corrosion damage on power package exterior fin ish Use Quicksilver spray paints see your Authorized MerCruiser Dealer 95 CA175 THIS PAGE IS INTENTIONALLY BLANK 96 CA336 Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT MerCruiser strongly recommends that this ser vice should be performed by an Authorized MerCruiser Dealer Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty CAUTION Avoid Engine or Stern Drive Damage DO NOT operate engine without water flowing thru seawater pickup pump as pump im peller may be damaged and subsequent overheating damage to engine or stern drive unit may result IMPORTANT Before starting engine a water source must be at tached to the seawater intake openings in gear housing Follow all warnings and flushing attachment procedures stated in FLUSHING COOLING SYSTEM 1 Runengine sufficiently to bring it up to normal operating tem
58. nclusion ALL SERVICE WORK IS DONE BY THE AUTHORIZED DEALER USING THE DEALER S FACILITIES OUR SERVICE CENTERS AND FACTORY DO NOT HAVE FACILITIES TO SERVICE OR RE PAIR YOUR PRODUCT 127 Service Centers UNITED STATES MerCruiser 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6566 Fax 405 743 6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga Ontario L4Y 2C2 Canada Telephone 905 270 4481 Fax 905 270 4510 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 e 11 Fax 32 87 31 19 65 128 AUSTRALIA PACIFIC Marine Power International Pty Ltd P B 1420 132 140 Frankston Road Dandenong Victoria 3164 Australia Telephone 61 3 791 5822 Fax 61 3 791 5880 ASIA Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 129 Customer Service Literature English language publ
59. nd or drive unit to overheat A CAUTION Watch temperature gauge on dash to ensure that engine does not overheat To prevent silt and or salt buildup in cooling system flush with fresh water at specified intervals CA191 If flushing cooling system with boat in water raise drive unit to TRAIL ER position install flushing attachment and lower drive unit to full down in position 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 With drive unit in normal operating position partially open water tap about 1 2 maximum Place remote control in NEUTRAL idle speed positron and start engine Operate engine at idle speed in NEUTRAL for about 10 minutes or until discharge water is clear Stop engine shut off water and remove flushing attachment CB66 Seawater Pump Impeller This maintenance should be performed by an Authorized MerCruiser Dealer 4 Seawater pump impeller should be inspected whenever insuffi cient seawater flow is suspected if operating temperature exceeds normal range 81 CA358 Drive Belts Make sure engine is shut off and ignition key is removed before inspecting belts All drive belts must be periodically inspected for condition and ten sion Perform the following inspections of alternator drive belt power steering pump drive belt if so equipped and seawater pickup
60. ne eee 20 Hour Checkup ee hed eet RR Rhe ERA OBEFAllON nosci rein a ei DR eer ate SA Seen ak Instrumentation 0 002 cece cee eee Audio Warning System 0 0 c eee eee eee Electrical System Overload Protection Remote Controls Panel Mounted Remote Controls Console Mounted Remote Controls Two Lever ssuuuusss Power Trim oooocoococcocc eee Starting Shifting And Stopping 00 Operation Chart usc aes tat uc esce ine caste Aon Specifications 2 a nea epit wi O pane Ewes Fuel Recommendations useeuuss Grankease Olla oe 2 5 noi pita en wie alata inn a a aiu qs hie Engine Specifications ooooooooooommom Tune up Specification ooooooocmoommmoo GaDaCIllBS 3 5 carder iden ee dius Maintenance oocccccccc esee Maintenance Aids suus Maintenance Chart oococcccccccco coo Checking Fluid Levels GharngingFlulds sce ei cr eres caida Water Separating Fuel Filter Fuel Pump Sight Tube Inspection Lubrication se sereni ndra ona cece cee eee Propeller cc wari cede eed aden did Sane ER Gates Flushing Cooling System Seawater Pump Impeller DriveBelts s eile e ee ex pee Corrosion And Corrosion Protection EMISSIONS i oou a C even Changing Positiv
61. nstall FILLCAP DIPSTICK IMPORTANT If fluid is not visible in pump contact your Autho rized MerCruiser Dealer 63 CA189 64 CB40 CHECKING DRIVE UNIT OIL 1 Check gear lube monitor oil level keep oil level at or near Fill line Check for water at bottom of monitor and or if oil appears a milk tan contact your Authorized MerCruiser Dealer immediately both conditions indicate a water leak somewhere in the drive unit See Filling Reservoir IMPORTANT If more than 2 fl oz 59ml of Quicksilver High Performance Gear Lube is required to fill monitor a seal may be leaking Damage to drive unit may occur due to lack of lubrica tion Contact your Authorized MerCruiser Dealer for service CB41 CHECKING POWER TRIM PUMP FLUID Place drive unit in full down in position 2 Remove fill cap from reservoir and observe oil level Level must be up to but not over bottom of filler neck Add Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor oil if required to bring level to bottom of filler neck Replace cap A Check that Cap plug has been removed and discarded from filler neck B Fill cap is vented frequently check that vent is open and unre stricted 65 CA201 CA63 i Changing Fluids See MAINTENANCE CHART for lubricant change frequency Lubri cant should be changed before placing boat in storage Power Trim or Power Steering fluids do not require changing Coolant in closed cooling sys
62. o original operating position preventing loss of steering control and engine overspeed Use extreme caution when operating in shallow water or where un derwater objects are known to be present Use extreme care to pre vent striking submerged object while operating in REVERSE No im pact protection is provided in REVERSE If drive unit should strike a submerged object stop engine as soon as possible and inspect drive unit for damage If damage is present or suspected boat should be taken to an Authorized MerCruiser Dealer for thorough inspection and necessary repair Operating a damaged drive unit could cause additional damage to other parts of drive unit or could affect control of boat If continued running is nec essary do so at greatly reduced speeds IMPORTANT Impact protection system cannot be designed to ensure total protection from impact damage under all condi tions CA331 0 Emissions Information Your engine may be equipped with special design features and spe cial tuning to minimize the emission output from the engine If so it is very important that you strictly adhere to the following e Recommended maintenance schedules particularly the ignition system e Proper engine tuning procedures to ensure these features remain in good operating order e Proper steps to maintain the engine within specifications Use only MerCruiser replacement parts to ensure compliance with emission regulations IMPORTANT The t
63. oat partitions or material because of boat design for necessary ac cess to the Product V VI VII VIII Claim shall be made under this warranty by delivering the Prod uct for inspection to a MerCruiser dealer authorized to service the Purchaser s product If purchaser cannot deliver Product to such authorized dealer he may give notice in writing to the Company We shall then arrange for the inspection and repair provided such service is covered under this warranty Purchas er shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other ex penses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped with transportation charges prepaid The Warranty Registration Card is the only valid registration identification and must be presented at the time warranty service is required Warranty claims will not be accepted without presentation of the Warranty Registration Card Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workman ship as covered by this Warranty We reserve the right to im prove the design of any Product without assuming any obliga tion to modi
64. opriate test equipment and adapters for this en gine The only item that must be supplied by the boat owner op erator is the exhaust elbow test probes These test probes should have been provided with your power package They should be carried aboard your boat at all times 2 Remove plugs from both exhaust elbows 3 Install exhaust elbow adapter fittings into elbows Apply Loctite Pipe Sealant with Teflon to threads that go into elbow Tighten it se curely 4 Insert exhaust probes into fittings and tighten securely The testing agency will connect their adapters and test equipment to the probes to conduct the test Once the test is complete remove the test probes and fittings Apply Quicksilver Perfect Seal to the threads of both plugs and reinstall them into elbows Be sure to save the test probes and fittings and keep them onboard for future use 93 CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use Recharge every 30 to 45 days or when specific gravity drops below battery manufactur er s specifications Refer to specific instructions and warnings accompanying your bat tery If this information is not available observe the following precau tions when handling a battery Do not use jumper cables and a booster battery to start engine Do not recharge a weak battery in the boat Remove battery and recharge in a ventilated area away from fuel vapors sparks or flames Batteries con
65. p the engine whenever passengers are boarding unloading or are near the back stern of the boat Just 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 wearable type life jacket per sonal 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 one 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 When in doubt contact your dealer or the boats manufac turer Know your boat s operating and loading limitations Make sure everyone in the boat is properly seated Don t allow anyone to sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat any where 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 Never be under the influence of alcohol or drugs while boat ing it is the law The
66. pera ture Shut off engine and change oil and oil filter 2 Flush cooling system Refer to Flushing Cooling System proce dure shown earlier in this manual 97 CA192 98 CA304 Avoid Fire or Explosion Be sure engine compartment is well venti lated and no gasoline vapors are present during the following opera tion Avoid Fire or Explosion Fuel injection system is pressurized during operation Do not attempt to remove plug from vapor separator tank until pressure is relieved fuel could spray on hot engine causing fire or explosion The pressure will be relieved automatically after engine has been turned OFF for 2 minutes 3 Prepare fuel system for extended storage as follows A Make sure engine has been turned OFF for at least 2 minutes to ensure fuel pressure has been relieved from vapor serarator tank VST Remove plug from top of vapor separator tank Add approximately 1 fluid ounce 30 ml of Quicksilver 2 Cycle Outboard Oil to fuel in the vapor separator tank Reinstall the plug in top of vapor separator tank Shut off the fuel supply to the engine s fuel pump Start and run engine at idle speed until the vapor separator tank and fuel injection system are empty and engine stops 4 Fill fuel tank s with fresh gasoline that does not contain alcohol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat gasoline Follow instructions on container 5 If boat is to be placed in sto
67. r spline washer continuity washer propeller and thrust hub off propeller shaft CA79 REPAIR Some damaged propellers can be repaired See your dealer CA288 INSTALLATION IMPORTANT If reusing tab washer carefully inspect tabs for cracks or other damage Replace tab washer if condition is questionable 4 Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft Anti Corrosion Grease Special Lubricant 101 or 2 4 C Marine Lubricant with Teflon 5 Slide thrust hub into propeller hub with stepped side toward pro peller hub 6 Align splines and place propeller and thrust hub on propeller shaft 7 Placecontinuity washer spline washer and tab washer onto shaft 8 Install propeller nut Tighten nut securely A minimum of 55 Ibs ft 75 N m torque is required Bend three tabs on tab washer down into grooves in spline washer After first use bend the three tabs straight retighten propeller nut to minimum 55 lbs ft torque 75 N m Bend tabs back down into spline washer Check propeller at least after 20 hours of operation Do not operate with loose propeller 79 80 CA83 Flushing Cooling System When flushing be certain the area around propeller is clear and no one is standing nearby To avoid possible injury remove pro peller 44 CAUTION Do not run engine above 1500 RPM when flushing Suction created by seawater pickup pump may collapse flushing hose causing engine a
68. rage with fuel containing alcohol in fuel tanks if fuel without alcohol is not available Vapor sepa rator tank on engine must be run dry at idle RPM Fuel tanks should be drained completely and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Refer to FUEL RE QUIREMENTS for additional information 6 Close fuel shut off valve if so equipped A CAUTION Avoid Damage To Stern Drive Unit Stern drive unit should be stored in full down position Universal Joint bellows may de velop a set if unit is stored in raised position and may fail when unit is returned to service 7 Place drive unit in the full down position OU m oO CB232 CA234 A 4 Draining Instructions DRAINING SEAWATER RAW WATER COOLED MODELS CAUTION If boat is to remain in water after draining seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses A CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use if the possibility of freezing temperatures exist Failure to comply may result in trapped water causing freeze and or corro sion damage to engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from
69. rd of unstable boat passen gers a particular concern in bow rider type boats 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking While activation of the lanyard stop switch will result in immedi ate power shut down a boat can continue to coast for some dis tance 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 As we cannot possibly know of and advise the boating public of all conceivable boat motor types and or poor operating prac tices the final decision of whether to use a lanyard stop switch rests with you the owner driver We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be re quired to operate the engine and boat in an emergency CA281 Safe Boating Suggestions In order to safely enjoy the waterways familiarize yourself with local and other governmental boating regulations and restrictions and consider the following suggestions e Know and obey all nautical rules and laws of the waterways Boat operators should complete a boating safety course Courses are offered in the U S A by 1 The U S Coast Guard Auxiliary 2 The Power Squadron 3 The Red Cross and 4 your state or provincial boating la
70. requently check crankcase oil level Add oil if needed It is nor mal for oil consumption to be high during break in period After 20 hour break in period drain crankcase oil and replace oil filter see MAINTENANCE Fill crankcase with correct oil see SPECIFICATIONS CA211 After Break In Period To help extend the life of your MerCruiser power package the follow ing recommendations should be considered Use a propeller that allows the engine to operate at or near the top of the maximum RPM range See Specifications section when at full throttle with a normal boat load Operation at 3 4 throttle setting or lower is recommended Refrain from prolonged operation at maximum full throttle RPM 23 CA239 20 Hour Checkup After first 20 hours of operation an Authorized MerCruiser Dealer should be contacted for the following maintenance The boat owner is responsible for any charges 24 Change crankcase oil and filter Check all fluid levels Cooling System Inspect all hoses for damage and deterioration check all hose clamps for adequate tightness Inspect ignition system and timing Check for loose missing or damaged parts Check shift and throttle cable adjustments lubricate and inspect for loose damaged or missing parts Steering System Lubricate and inspect for loose damaged or missing parts Inspect all drive belts Check engine alignment Include proper lubrication of U joint and splined shaft
71. rim Switch in Handle used to trim both drives simultaneously after drives have been fine tuned as described above 43 EZ CB193 POWER TRIM OPERATION THREE BUTTON TRIM PANEL USED ON MODELS WITH TWO LEVER CONTROL IMPORTANT If TRAILER button is held depressed after drive unit reaches end of upward travel an internal circuit breaker will open and pump will stop Should this happen release button s and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Simultaneously press the UP button top along with the UP OUT button center until drive unit reaches desired trail er position 2 Trim Drive Unit UP OUT Press center UP OUT button until drive unit reaches desired trim position 3 Trim Drive Unit IN DOWN Press IN button until drive unit reaches desired trim position 45 C Starting Shifting And Stopping Before starting engine operate bilge blower for at least five min utes to remove any explosive fumes from engine compartment If boat is not equipped with a bilge blower open engine hatch and leave open while starting engine IMPORTANT Observe the following C D Do not start engine without water being supplied to seawater pickup pump to prevent pump or engine damage Do not operate starter motor continuously for more than 30 seconds Never shift drive unit unless engine is at Idle RPM Perform the following as appropri
72. rsonal interest in your satisfaction the product should be returned to him for war ranty service If your plastic card is not received within 30 days from date of new product sale please contact your selling dealer The product warranty is not effective until the productis registered at the factory NOTICE Registration lists must be maintained by factory and dealer on marine products sold in the United States should notifi cation under the Federal Boat Safety Act be required 112 International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Regis tration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration claim program for your area The Warranty Registration Card identifies your name and ad dress product model and serial number s date of sale type of use and the selling distributor s dealer s code number name and address The distributor dealer also certifies that you are the origi nal purchaser and user of the product A copy of the Warranty Registration Card designated as the Pur chaser s Copy MUST be given to you immediately after the card has been completely filled out by the selling distributor dealer This card represents your factory registration identification and should be retained by you for future use when required Should you ever require warranty s
73. s may also be sprayed 5 Alllubrication points especially steering system shift and throttle linkages should be kept well lubricated 6 Flush cooling system periodically preferably after each use 89 CA359 74807 74820 90 CB454 Emissions CA360 Changing Positive Crankcase Ventilation Valve PCV The 350 Magnum EFI Gen engine is equipped with a positive crank case ventilation valve PCV This valve should be changed every 100 hours of operation or at least once a year whichever occurs first 1 Remove POV valve from starboard valve cover Disconnect it from the hose and discard valve Install new PCV valve in valve cover and reconnect hose Ensure valve is tightly seated in valve cover CA361 Emissions Testing The 350 Magnum EFI Gen engine can be equipped with special de sign features and special tuning to minimize the emission output from the engine If the kit has been installed your engine complies with Stage 1 Bodensee and Swiss Regulations You should follow e Recommended maintenance schedules particularly as to the igni tion system e Proper engine tuning procedures to ensure these features remain in good operating order e Proper steps to maintain the engine within specifications Use only MerCruiser replacement parts to ensure compliance with emission regulations 91 CA102 INSTALLING TEST PROBES IMPORTANT The testing dealer or agency will be equipped with the appr
74. s recommendations 7 Make sure gear housing water drain holes are open 8 For additional assurance against freezing and rust remove ther mostat cover and thermostat Fill engine seawater cooling system with a mixture of antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage Us ing a new gasket reinstall thermostat and cover Tighten cover bolts securely Perform all checks inspections lubrication and fluid changes out lined in MAINTENANCE CHART under AT LEAST ONCE A YEAR 103 CA115 Battery Winter Storage Follow battery manufacturer s instructions for storage CA116 Power Package Recommissioning To prevent possible injury or damage to equipment do not in stall battery until all maintenance has been performed on en gine 1 Check that all cooling system hoses are connected properly and hose clamps are tight A CAUTION When Installing battery be sure to connect NEGATIVE bat tery cable to NEGATIVE battery terminal and POSITIVE battery cable to POSITIVE battery terminal If battery cables are reversed electrical system damage will result 2 Install fully charged battery Clean battery cable clamps and ter minals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat terminal connections with a battery terminal anti
75. s warranty gives you specific legal rights and you may also have other legal rights which vary from country to country MARINE POWER INTERNATIONAL Division of Brunswick Corporation Fond du Lac Wisconsin 54935 U S A 117 3 Year Limited Warranty Against Corrosion Failure APPLICABLE IN THE UNITED STATES CANADA AND AUSTRALIA 118 We warrant parts and assemblies of each 1988 and newer pro duction MerCruiser Product sold with a one year limited Prod uct warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inopera tive as a direct result of corrosion provided the following simple precautionary steps which are specified in Owner s Manuals have been taken 1 Specified maintenance procedures such as replacement of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below This warranty shall become effective upon receipt of a com pleted standard Product warranty registration card and shall re main effective for a period of three years from the date of pur chase This warranty does not cover 1 electrical system corrosion 2 corrosion resulting from damage abuse or improper ser vice 3 corrosion to accessories instruments steering sys tems 4 damage due to marine growth 5 Product sold with less than a one year
76. silver U Joint and Gimbal Bearing Grease 7 For propeller shaft lubrication see PROPELLER 8 Lubricate engine coupler splines thru grease fitting on coupler us ing Quicksilver Engine Coupler Spline Grease NOTE Your engine is equipped with a sealed engine coupler and Perm a Lube U joints The sealed coupler and shaft splines can be lubricated without removing the drive unit The Perm a Lube U joints do not require lubrication The engine coupler is lubricated with Quicksilver Engine Coupler Spline Grease Contact your Authorized MerCruiser Dealer for this service A CAUTION Speedometer water hose must be disconnected from drive unit BEFORE removing drive unit Failure to do this will result in a broken fitting if drive unit is removed 75 CA77 Propeller Remote Control must be in NEUTRAL and ignition key removed from switch before removing and or installing propeller Place a block of wood between anti ventilation plate and propel ler to protect hands from propeller blades and to prevent pro peller from rotating when removing propeller nut A CAUTION Periodically check propeller nut for tightness during boating season A minimum of 55 lbs ft 75 N m torque is required CA78 REMOVAL 1 Place wood block between propeller blade and anti ventilation plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washe
77. tain acid which can cause severe burns Avoid contact with skin eyes and clothing Batteries also produce hy drogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmo sphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an ex plosion which may shatter the battery and could cause blind ness or other serious injury Safety glasses and rubber gloves are recommended when han dling batteries or filling with electrolyte Hydrogen gases that escape from the battery during charging are explosive When charging batteries be sure battery compartment or area where batteries are located is well vented Battery electrolyte is a cor rosive acid and should be handled with care If electrolyte is spilled or splashed on any part of the body immediately flush the exposed area with liberal amounts of water and obtain medi cal aid as soon as possible CA104 Bottom Of Boat To maintain maximum speed the following conditions of the boat bot tom should be observed e Clean free of barnacles and marine growth e Free of distortion nearly flat where it contacts water e Straight and smooth fore and aft ANTI FOULING PAINTS See Anti Fouling Paint recommendations and related information on previous pages IMPORTANT Refer to CORROSION AND CORROSION PRO TECTION for additional information CA105 Inspection And Maintena
78. tch propeller that allows the engine to again run at recommended RPM For boaters to realize optimum engine performance under changing weather conditions it is essential that the engine be propped to allow it to operate at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load Not only does this allow the engine to develop full power but equally important is the fact that the engine also will be operating in an RPM range that discourages damaging detonation This of course en hances overall reliability and durability of the engine CA13 Important Information Operation And Maintenance OWNER OPERATOR RESPONSIBILITIES It is the operator s responsibility to perform all safety checks to en sure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized Mer Cruiser Dealer for a periodic checkup Normal maintenance service and replacement parts are the respon sibility of the owner operator and as such are not considered defects in workmanship or material within the terms of the warranty Individu al operating habits and usage contribute to the need for maintenance service Proper maintenance and care of your power package will assure op timum performance and dependability and will keep your overall op erating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 DEALER RESPONSIBI
79. tem should be changed at specified in tervals by your Authorized MerCruiser Dealer CHANGING CRANKCASE OIL AND FILTER IMPORTANT Change oil when engine is warm from operation Warm oil flows more freely carrying away more impurities Use only recommended motor oil see SPECIFICATIONS 1 With engine at normal operating temperature remove dipstick In stall Quicksilver Crankcase Oil Pump onto dipstick tube Insert hose end of crankcase oil pump into an appropriate container and using pump handle pump until crankcase is empty Remove crankcase oil pump 2 Turn oil filter counterclockwise to left remove and discard old oil filler and old sealing ring Coat sealing ring on new filter with motor oil Install new sealing ring and filter by turning clockwise to right Tighten filter securely Do not overtighten 3 Removeoilfiller cap Add correcttype oil see SPECIFICATIONS to bring level up to but not over FULL mark on dipstick IMPORTANT Always use dipstick to determine exactly how much oil is required 67 68 CA67 CHANGING DRIVE UNIT OIL MODELS WITH GEAR LUBE MONITOR IF SO EQUIPPED IMPORTANT Use only specified gear lubricant in drive unit See SPECIFICATIONS Place drive unit in trim out position Do Not Raise to TRAILER Posi tion 1 Remove OIL FILL DRAIN screw and sealing washer 2 Remove OIL VENT screw and sealing washer Allow oil to drain completely IMPORTANT Itany water drained from OIL FILL
80. tem water temperature rises too high 2 Engine oil pressure gets too low 3 Drive unit oil level gets too low A CAUTION Avoid engine damage Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred When the buzzer sounds with the engine running stop engine im mediately Investigate cause and correct it if possible If cause can not be determined consult your Authorized MerCruiser Dealer IMPORTANT Warning buzzer will sound for 2 seconds when ig nition key is turned to RUN position and engine is not started This allows the operator to test the warning buzzer prior to start ing the engine 29 LK N AY S SS MERCATHODE A A A R DIE E 30 CB293 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 replac ing fuse or resetting circuit breaker 1 A circuit breaker provides protection for engine wiring harness and instrumentation power lead Reset by pushing RESET button IN 2 A90 Amp fuse is located on the large post of the starter solenoid This fuse is designed to protect the engine wiring harness if an elec trical overload occurs In an emergency when engine must be operated and cause for high
81. this may be accomplished by using up length in the way the lanyard and clip are attached to the operator such as wrapping the lanyard around the operator s wrist or leg or by tying a simple knot in the lanyard Read the Safety Warning on this page and the following page before electing to install use or not to use such a switch The following advantages and disadvantages of a lanyard stop switch should be considered before electing to use or not to use such a switch ADVANTAGES The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch This would occur if the operator falls or moves within the boat a sufficient distance from the operator s position This type of accident is most likely in certain types of boats such as low sided boats and high performance boats It is also likely as a result of poor operating practices such as sit ting on the back of the seat at planing speeds standing at plan ing speeds operating at high speeds in shallow or obstacle in fested waters releasing your grip on a steering wheel that is pulling in one direction drinking and driving or daring high speed boat maneuvers DISADVANTAGES Inadvertent activation of the switch is also a possibility This could cause any or all of the following poten tially hazardous situations 1 Loss of balance and falling forwa
82. tion with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other competitive activity or operating with a racing type lower unit or 5 Alteration or removal of parts or 6 Water entering engine cylinder s through exhaust system or carbure tor s Reasonable access must be provided to the Product for war ranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replace ment of boat partitions or material because of boat design for necessary access to the Product Claim shall be made under this warranty by delivering the Prod uct for inspection to a MerCruiser dealer authorized to service the Product If purchaser cannot deliver Product to such autho rized dealer he may give notice in writing to the Marine Power Service Center or distributor The Marine Power Service Center or distributor shall then arrange for the inspection and repair provided such service is covered under this warranty Purchas er shall pay for all related transportation charges and or travel time If the service is not covered by this warranty purchaser shall pay for all related labor and material and any other ex penses associated with that service Any Product or parts shipped by purchaser for inspection or repair must be shipped
83. using the conventional method 53 CA356 Capacities 350 Mag MODEL 7L EFI 7LX EFI a Approx 5 5 U S Quarts w New Filter 1 5 2 L Drive Unit Oil Approximately 39 2 fl oz Capacity 1160ml Drive Unit Oil Capacity w Reservoir Seawater Cooling 15 U S Quarts System 14 1 L Always use dipstick to determine exact quantity of oil required Seawater Cooling System capacity information is for winterization use only Approximately 64 fl oz 1892ml 54 CA290 Maintenance Always disconnect battery cables from battery before working around electrical system components to prevent injury to your self or damage to electrical system IMPORTANT Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed Some list ings can be done by owner operator while others should be performed by an Authorized MerCruiser Dealer Before attempt ing maintenance or repair procedures not covered in this manu al it is recommended that a MerCruiser Service Manual s be purchased and read thoroughly NOTE Maintenance points are color coded for ease of identifica lion See the decal on engine for identification Maintenance Aids 1 Power Steering System Quicksilver Power Trim and Steering Fluid or Dexron Ill automatic transmission fluid ATF 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Expose
84. w enforcement agency Inquiries may be made to the Boating Hotline 1 800 368 5647 or the Boat U S Foundation information number 1 800 336 BOAT We strongly recommend that all powerboat operators attend one of these courses You should also review the NMMA Sources of Waterway Information booklet It lists regional sources of safety cruising and local naviga tion and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made e Check safety equipment on board Here are suggestions of the types of safety equipment to carry when boating 1 Approved fire extinguisher s paddle or oar 2 Signal devices flashlight rockets or flares flag and whistle or horn 3 Spare propeller thrust hubs and an appropriate wrench 4 Tools for necessary minor repairs first aid kit and book 5 Anchor and extra anchor line water proof storage containers 6 6 Manual bilge pump and extra drain plugs compass and map or chart of area 7 Spare operating equipment batteries bulbs fuses etc 8 Transistor radio 9 Drinking water 8 Know 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 Sto
85. with transportation charges prepaid V VI VII VIII Purchaser must provide proof of purchase and substantiate date of purchase by presenting the Purchaser s Copy of the Warranty Registration Card or the plastic Warranty Registra tion Card to the dealer authorized to service the Product If ei ther of these items is not available purchaser must provide a copy ofthe original Bill of Sale Sales Contract for the Product to be serviced Warranty claims will not be accepted until ade quate proof of purchase is presented by purchaser and date of purchase has been substantiated Our obligation under this Warranty shall be limited to repairing a defective part or AT OUR OPTION refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obli gation to modify any Product previously manufactured ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY IMPLIED WARRANTIES ARE LIM ITED TO THE LIFE OF THIS WARRANTY SOME COUN TRIES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS OR THE EXCLUSION ORLIMI TATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSIONS MAY NOT APPLY TO YOU Thi
86. ximum performance and carefree use we ask that you thoroughly read this manual The Operation and Maintenance 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 MerCruiser products We sincerely hope your boating will be pleasant CONSUMER AFFAIRS DEPARTMENT CA166 Read This Manual Thoroughly IF YOU DON T UNDERSTAND ANY PORTION CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES NOTICE Throughout this publication and on your power package WARN INGS and CAUTIONS accompanied by the International Hazard Symbol may be used to alert the installer user to special instruc tions concerning a particular service or operation that may be haz ardous if performed incorrectly or carelessly Observe them care fully These Safety Alerts alone cannot eliminate the hazards that they signal Strict compliance with these special instructions while per forming the service plus common sense operation are major acci dent prevention measures WARNING Hazards or unsafe practices which could result in severe personal injury or death A CAUTION CAUTION Hazards or unsafe practices which could result in mi nor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessar
87. y for proper operation and or maintenance The operator driver is responsible for the correct and safe op eration of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used al CA280 Lanyard Stop Switch ANNIE NAS 74608 1 Some boats come equipped with a lanyard stop switch A lanyard stop switch can also be installed as an accessory The purpose of this switch is to turn off the engine ignition whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch 2 Thelanyardis acord usually between 4 and 5 feet 1220 and 1524 mm in length when stretched out with an element on one end made to be inserted into the switch and a metal snap on the other end for attaching to the operator It is coiled to make its at rest condition as short as possible so as to minimize the likelihood of lanyard entangle ment with nearby objects It is made as long as it is in its stretched condition to minimize the likelinood of accidental activation should the operator choose to move around in an area close to the normal operator s position If for any reason it is desired to have a shorter functional lanyard
88. y 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 main tain a proper lookout by sight and hearing The operator must have an unobstructed view particularly to the front No passen gers load or fishing seats should block the operators view when operating the boat above idle or planing transition speed Watch the other guy 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 25 miles per hour 40 km hr in 5 seconds will overtake a fallen skier who was 200 feet in front of you Watch fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the opera tor s side of the boat while returning to attend the skier The opera tor 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

Operation - Brunswick Marine in EMEA Center

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