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Mercruiser

These safety alerts follow ANSI standard Z535.6-2006 for product safety information in product manuals, instructions, and other collateral materials. IMPORTANT: Identifies information essential to the successful completion of a task. CAUTION: identifies a hazardous situation which, if not avoided, could result in minor or moderate injury.

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100% found this document useful (2 votes)

2K views268 pages

Mercruiser

Uploaded by

Joe Pudlak

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 268

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver,

#1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation.

4.3, 5.0 MPI & SEACORE 4.3, 5.0 MODELS INSTALLATION MANUAL
Models Covered
Alpha
Models covered 4.3 MPI 5.0 MPI Serial Number 1A300000 and above

Bravo
Models covered 4.3 MPI 5.0 MPI SeaCore 4.3 SeaCore 5.0 1A300000 and above Serial Nnumber

Notice
NOTICE After completing installation, these instructions should be placed with the product for the owner's future use. NOTICE Predelivery preparation instructions must be performed before delivering boat to the product owner.

Notice to Boat Manufacturer/Installer

Throughout this publication, dangers, warnings, cautions, and notices, (accompanied by the International Hazard Symbol) are used to alert the manufacturer or installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.62006 for product safety information in product manuals, instructions, and other collateral materials. Observe Them Carefully! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures.

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

Page i

2007 Mercury Marine

90-899883178 NOVEMBER 2007

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

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

NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action. NOTE: Refer to the appropriate Mercury MerCruiser Product Applications Manual for application recommendations. This installation manual has been written and published by Mercury MerCruiser to aid the boat manufacturer (OEM) in the installation of the products described herein. It is assumed that these personnel are familiar with marine product installation. Furthermore, it is assumed that they are familiar with, if not trained in, the recommended installation procedures of Mercury MerCruiser product. We could not possibly know of or advise the marine trade of all conceivable installations and of the possible hazards and/or results of each installation. Therefore, the OEM is responsible for any installation that does not fulfil the requirements of this manual. It is the responsibility of the boat manufacturer to select the appropriate engine/transom/ drive package (including the correct gear ratio and propeller) for a given boat. Mercury MerCruiser recommends that any new or unique hull/power package combination be thoroughly water tested prior to sale, to verify that the boat performs as desired, and that the engine operates in the appropriate RPM range. It is recommended that a Mercury MerCruiser Product Application Engineer (PAE) be contacted for assistance. For assistance outside the United States, contact the local Mercury Marine office or authorized distributor. All information, illustrations and specifications contained in this manual are based on the latest product information available at time of publication. Mercury Marine reserves the right to make changes at any time without obligation. As required, revisions to this manual will be sent to all OEM boat companies.

Page ii

Manual Outline
1 - Important Information 2 - Boat Construction 3 - Exhaust System 4 - Fuel System 5 - Cooling System 6 - Drive System and Engine Installation 7 - Electrical System 8 - Remote Controls 9 - Predelivery Preparation and Storage

Important Information

Boat Construction

Exhaust System

Fuel System

Cooling System

Drive System and Engine Installation

Electrical System

Remote Controls

Predelivery Preparation and Storage

1 2 3 4 5 6 7 8 9

Page iii

Page iv

SECTION - 1

IMPORTANT INFORMATION

SECTION 1 - IMPORTANT INFORMATION

Table of Contents
Torque Specifications.............................................................................................................................................. 2 Quicksilver Products................................................................................................................................................ 2 Accessories ...................................................................................................................................................... 2 Remote Controls and Instrumentation for the DTS System.................................................................................... 3 Identification............................................................................................................................................................ 3 Serial Number Decal Placement.......................................................................................................................3 Bravo Sterndrive Serial Number and Identification...........................................................................................3 Bravo Transom Serial Number..........................................................................................................................4 Bravo Three Notice: Trimin Limit Insert.................................................................................................................. 5 Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 5 Internal Power Steering With Internal Tie Bar Only ......................................................................................... 6 Internal Power Steering With Internal and External Tie Bar ............................................................................. 6 External Power Steering .................................................................................................................................. 6 External Power Steering With Low External Tie Bar ........................................................................................ 6 SeaCore Components and Castings....................................................................................................................... 6 Stainless Steel Fasteners........................................................................................................................................ 6 Corrosion Protection................................................................................................................................................ 7 Antifouling Paint..................................................................................................................................................... 7 Emission Control Information Label........................................................................................................................ 9 Owner Responsibility ...................................................................................................................................... 10 Star Label.............................................................................................................................................................. 10 Hang Tag............................................................................................................................................................... 11

90-899883178 NOVEMBER 2007

Page 1 / 12

IMPORTANT INFORMATION

SECTION - 1

Lubricants, Sealants, Adhesives

Tube Ref No.
34

Description Special Lubricant 101

Where Used Threads of stainless steel fasteners

Part No. 92-802865Q02

Torque Specifications
NOTE: Securely tighten all fasteners not listed below. NOTE: The propeller torque stated is a minimum torque value.
Description Exhaust tube clamp Exhaust pipe bolts Exhaust blockoff plate bolts Bravo One propeller nut Bravo Two propeller nut Bravo Three front propeller nut Bravo Three rear propeller nut Rear engine mounting bolts Steering cable coupler nut Steering system pivot bolts Sterndrive unit fasteners Transom assembly fasteners Mounting clip screw Hose clamps Water inlet fitting bolts Water inlet blockoff screw Fuel inlet fitting Gen III Cool Fuel Module captured nut Battery stud Propeller shaft anode screw Nm 3 34 34 75 81 136 81 47 47 34 68 34 12.2 2 5 5 lbin. 26 108 26 45 45 lbft 25 25 55 60 100 60 35 35 25 50 25

Then align tabs with grooves Then align tabs with grooves

Finger tight + 13/4 to 21/4 turns with a wrench. Do not overtighten. 19 811 19 168 7191 168

Quicksilver Products
Accessories
Quicksilver gauges, remote controls, steering systems, propellers, and other accessories are available for this product. Mercury MerCruiser recommends the use of Quicksilver parts on all applications. Refer to Mercury Precision Parts Accessories Guide for a complete listing. This Guide is available from: Attn: Parts Department Mercury Marine W6250 W. Pioneer Road P.O. Box 1939 Fond du Lac, WI 54935-1939 Outside of U.S.A., order through Distribution Center or Distributor.

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90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

Remote Controls and Instrumentation for the DTS System

The Digital Throttle and Shift system (DTS) requires the use of specialized helm components, including a command module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

Identification
Serial Number Decal Placement
There are 3 sets of engine, transom assembly, and sterndrive serial number decal strips provided with each power package. One should be used for each of the following: Engine Specification Decal Warranty Registration Card Operation, Maintenance and Warranty Manual identification page Affix engine serial number decal to specification / serial number decal.

8331

a
a - Specification/serial number decal

Bravo Sterndrive Serial Number and Identification

The sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive.

c d

25906

a - Bar code b - Serial Number

c - Gear ratio d - Model number

90-899883178 NOVEMBER 2007

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IMPORTANT INFORMATION

SECTION - 1

The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers.

25907

Bravo sterndrive serial number stamping a - Serial number stamping

Bravo Transom Serial Number

The Bravo transom serial number is stamped in the Ubolt plate of the Bravo transom assembly.

25904

Bravo transom assembly Ubolt plate a - Transom assembly serial Number

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90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers.

25905

Gimbal housing with serial number stamping a - Transom assembly serial Number

Bravo Three Notice: Trimin Limit Insert

NOTE: Bravo One, Two and Three Models are equipped with a trimin limit insert. It has been brought to our attention that some boats (predominantly deepVee heavy boats) will roll up on their side under certain, specific, operating conditions. The roll can be either to port or starboard and may be experienced while moving straight ahead, or while making a turn. The roll occurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near full trimin. While the boat will not roll completely over, the roll may be sufficient to unseat the operator or passengers, and thereby create an unsafe situation. The roll is caused by sternlift created from excessive sterndrive unit trimin. Under these extreme sternlift / bowdown conditions, instability can be created, which may cause the boat to roll. Weight distribution to the stern can reduce sternlift and, in some circumstances, help to control the condition. Weight distribution in the bow, port or starboard, may worsen the condition. The trimin limit insert reduces sternlift by preventing the sterndrive unit from reaching the last few degrees of full trim under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The need for this trimin limit insert, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.

! WARNING
On some boats, increased trimin range can cause handling problems at high speeds, resulting in personal injury or death. We recommend that only qualified personnel adjust the trimin limit inserts and test the boat for handling problems.

Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives you must select one of several possible steering systems.

NOTICE
Incorrect tie bar installation can damage the drive and steering system. Do not let the tie bar contact other components during severe turning conditions. Always calculate sufficient turning clearances, observe recommended tie bar arrangements, and check for proper installation before operating the boat.

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IMPORTANT INFORMATION

SECTION - 1

Internal Power Steering With Internal Tie Bar Only

At the lower end of the performance spectrum, boats not capable of speeds in excess of 97 km/ h. (60 MPH), the basic internal tie bar is recommended. It connects the slave sterndrive to the sterndrive that is directly connected to the factory power steering output. This internal tie bar is available in a variety of lengths from the sterndrive manufacturer.

Internal Power Steering With Internal and External Tie Bar

As a boat moves into the moderate performance range of 97113 km/h. (6070 MPH) or for a reduction in steering backlash, an external tie bar should be added. External tie bars are usually designed to attach at the aft power trim cylinder bosses. This location is an excellent choice because of its proximity to the propeller. HOWEVER, because of the potential overstress that can occur if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part Number 90362A3) should be installed to limit this potential tilt differential to about 20 degrees. IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with no internal tie bar when using the internal power steering system. This can cause excessive loads on the steering components on the sterndrive connected to the internal power steering system. These increased loads can damage the steering components, resulting in increased play in the steering of the boat.

External Power Steering

When boat speeds move past 113 km/h (70 MPH) or if additional steering backlash reduction is desired, external power steering is recommended. This normally will include an external tie bar mounted at the same general location as the power steering cylinders, which are generally attached at the top of the sterndrive's drive shaft housing. With this steering system, no internal tie bar should be used. These steering cylinders can be attached either inboard (between) or outboard of the sterndrives.

External Power Steering With Low External Tie Bar

For the fastest boats, over 129 km/h (80 MPH) , or for the ultimate in steering backlash reduction, use external power steering, BUT (where mechanically possible) with the external tie bar mounted at the trim cylinder boss location (as previously described in "Internal Power Steering with Internal and External Tie Bar" statements). Again, this system does not use an internal tie bar.

SeaCore Components and Castings

Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with special coatings. Do not replace SeaCore components with nonSeaCore. Use only the specified Mercury MerCruiser SeaCore components and castings on these power packages.

Stainless Steel Fasteners

SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in salt water environments. Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener destruction, improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have incorrect clamp loads. Apply a lubricant, such as Special Lubricant 101 or an equivalent, on the threads of stainless steel fasteners during installation to avoid galling. Lubricate at least the first 8 mm (1/4 in.) of the threads before installation.
Tube Ref No.
34

Description Special Lubricant 101

Where Used Threads of stainless steel fasteners

Part No. 92-802865Q02

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90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

Corrosion Protection
Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions or if using a stainless steel propeller, it is recommended that a Quicksilver AntiCorrosion Anode Kit and/or a MerCathode System with 2 additional transom mounted anode assemblies be installed (some models have a MerCathode System as standard equipment). A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. (Refer to Mercury Precision Parts Accessories Guide for part numbers.) Boats that are connected to AC shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while still providing a path to ground for dangerous fault (shock) currents. (Refer to Mercury Precision Parts Accessories Guide for part number.) IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.

Antifouling Paint
IMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty. Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

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IMPORTANT INFORMATION

SECTION - 1

IMPORTANT: If antifouling protection is required for boat hull or boat transom, copper base paint, if not prohibited by law, can be used. If using copper based antifouling paint, observe the following: Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (11/2 in.) UNPAINTED area on transom of the boat around these items.

b
8107

a - Painted boat transom

b - Minimum 40 mm (11/2 in.) unpainted area around transom assembly

NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint or an antifouling paint that DOES NOT contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, MerCathode system or items specified by boat manufacturer.

NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment such as brushes or highpressure washers to clean the MerCathode assembly.

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90-899883178 NOVEMBER 2007

SECTION - 1

IMPORTANT INFORMATION

Do not wash the sterndrive unit with a power washer as this can damage the coating on the reference wire of the MerCathode assembly, if equipped, and increase corrosion.

b
a - MerCathode reference electrode b - Do not paint c - Do not pressure wash
6211

Emission Control Information Label

A tamperresistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD (emission standard/level), date of manufacture (month, year), and the engine displacement. Please note that the low emissions certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.

NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the Declaration of Conformance applies. Refer to the front page of this manual for further information.

EMISSION CONTROL INFORMATION

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

X.XL

0575

Emission Control LabelCalifornia EmissionsCompliant "SERIAL#"Engine Serial Number "FAMILY"Engine Family "STD."Emissions Standard "D.O.M."Date of Manufacture

31656

90-899883178 NOVEMBER 2007

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IMPORTANT INFORMATION

SECTION - 1

"DISP"Piston Displacement

EMISSION CONTROL INFORMATION

NOT FOR SALE IN CALIFORNIA

REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD. XX.X g/kW-hr D.O.M. DISP
MMM YYYY

X.XL
31657

Emission Control LabelNot for Sale in California "SERIAL#"Engine Serial Number "FAMILY"Engine Family "STD."Emissions Standard "D.O.M."Date of Manufacture "DISP"Piston Displacement

Owner Responsibility
The operator must have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed their factory specifications.

Star Label
The 4.3 models meet the California Air Resources Board's ThreeStar Sterndrive and Inboard marine engine 2003 exhaust emission standards. The ThreeStar label will be affixed on the left side of the hull as shown.

XX 1234 XX

b
32973

a - Recommended location

b - Secondary location

Page 10 / 12

90-899883178 NOVEMBER 2007

SECTION - 1 One Star - Low emission

IMPORTANT INFORMATION

mc79569-1

The onestar label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted twostroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.

Two Stars - Very Low emission The twostar label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star LowEmission engines.

IDA

mc79570-1

Three Stars - Ultra Low emission The threestar label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star Low Emission engines.

mc79571-1

Four Stars - Super Ultra Low emission The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star Low Emission engines.

FN R

mc79572-1

Hang Tag
On 4.3 models, the Dealer must mark the appropriate box on one hang tag to match the Star label affixed to the boat. The dealer is responsible for displaying the hang tag in a visible location on the boat on display in California. Failure to properly display the hang tag could result in a citation and possible fine to the dealer from the California Air Resources Board. If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying the boat.

90-899883178 NOVEMBER 2007

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Page 1 / 12

EXHAUST SYSTEM

SECTION - 3

Exhaust System
Important Information

NOTICE
Improperly designing, installing, or modifying the engines exhaust system can introduce seawater or water from condensation into the combustion chambers, damaging the engine. The installing dealer or boat builder is responsible for proper installation of the exhaust system as explained in the installation instructions for the product. Engine damage resulting from water ingestion is not covered by the product warranty, unless the damage is the result of a defective part supplied by the engine manufacturer. The exhaust system must be installed in accordance with the information contained in this section to prevent water intrusion problems. Special care is required on the transom or hull exhaust applications, as these customdesigned exhaust systems can create a tuning effect that can cause water to be forced back into the engine. The instructions under Checking for Water Intrusion must be performed to ensure that water intrusion is not occurring. It is the boat manufacturer's responsibility for ensuring that water intrusion does not exist with their unique exhaust system. Engines with through propeller exhaust have been carefully designed and tested to avoid water intrusion problems and no additional testing is required. These applications require that only that exhaust elbow height be checked as outlined under Measuring Exhaust Elbow Height.

! WARNING
Installing the exhaust system incorrectly can lead to serious injury or death. When installing or designing exhaust systems, follow all federal, state, and local boating and safety standards for the market in which the boat will be sold. Exhaust system design and installation can affect: Noise level. Performance. Water Intrusion. Carbon monoxide levels. Component longevity.

Carbon Monoxide Poisoning

IMPORTANT: The following important information is covered in the owner's operation, maintenance and warranty manuals. You may also want to include this information in the boat owner's manual. Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives, and inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly gas that is odorless, colorless, and tasteless. Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache, dizziness, drowsiness, and nausea.

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

GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches to remove fumes.

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90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

1. Example of desired air flow through the boat.

mc79553-1

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

a
a - Operating the engine when the boat is moored in a confined space.

mc79554-1

b - Mooring close to another boat with its engine operating.

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

a
a - Operating the boat with the trim angle of the bow too high.

mc79556-1

b - Operating the boat with no forward hatches open (station wagon effect).

Measuring Exhaust Elbow Height

General Information
The height of the exhaust elbows must be within the dimensions specified to prevent water intrusion problems. Exhaust elbow risers must be installed, if needed, to obtain the proper exhaust elbow height and exhaust angle. Risers are limited to 152.4 mm (6 in.) on all 4.3 and 5.0 models. Measurement must be taken with the boat in the water. Load the boat as outlined to simulate the maximum loading conditions likely to be encountered in normal operation. IMPORTANT: Exhaust elbow height is measured to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. Refer to Water Lift Muffler. IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer. Any load distribution conditions that will affect the exhaust system must be clearly communicated to the operator in the owner's manual. For example, the number of people that can be located on the swim platform simultaneously should be included in the manual if this could pose a problem. Measurements under all loading conditions must be within the following specifications.
Minimum Exhaust Elbow Height Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models Specifications 330 mm (13 in.)

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EXHAUST SYSTEM Minimum Exhaust Hose Slope Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models

SECTION - 3

Specification within 45.7 cm (18 Specification for the remainder of in.) of the engine system (if applicable) 10 3

If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers. The maximum exhaust riser height is specified in the table below.
Riser Options Model 4.3, 5.0 MPI and SeaCore 4.3, 5.0 Models Low 76 mm (3 in.) and 43 mm (1.7 in.) Medium 76 mm (3 in.) and 43 mm (1.7 in.) High 152 mm (6 in.)

EXHAUST ANGLE MEASUREMENT

Measure the exhaust angle of each section of the exhaust system using an inclinometer as shown in the diagram below. Begin the measurement at the exhaust elbow outlet continuing along each section to the exhaust exit point of the boat. All exhaust angle measurements must be performed with the boat at rest in the water. Perform the first set of measurements without a load in the boat. Perform the second set of measurements with the boat fully loaded. See Loading Requirements.

c a

b
18582

Typical Exhaust a - Inclinometer b - Exhaust hose or tube

c - Minimum 305 mm (12 in.)

Boat Requirements
IMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height measurement. No prototype hulls or light layup hulls should be considered. Any measurement performed on nonproduction boats, prototype hulls, or light layup hulls could be inaccurate and could result in product damage. All boats that display a CE certification capacity plate must use the maximum capacity as stated on the CE certification capacity plate to perform the exhaust elbow waterline measurement. All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on the USCG capacity plate to perform the exhaust elbow waterline measurement.

Page 4 / 12

90-899883178 NOVEMBER 2007

EXHAUST SYSTEM

IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on designated seating excluding cabin space.

6 9 2 1 3 4 5 7 8
24863

Designated Seating Diagram This example uses 9 persons as the maximum passenger load.

NOTE: Use 0.50 lb. as the break point to round up or down to obtain a whole pound. 1. To determine the maximum cargo load multiply the maximum passenger load by the maximum cargo weight per passenger. 9 passengers 25 lb. = 225 lb. 2. To determine the preferred cargo distribution for aft, center, and bow storage: a. To determine the maximum aft storage cargo weight, multiply the maximum cargo weight by 25% 3. To determine the maximum center storage cargo weight, multiply the maximum cargo weight by 50% a. 225 lb. 50% = 112.50 lb. b. 112.50 lb. rounded up = 113 lb. 4. To determine the maximum bow storage cargo weight, multiply the maximum cargo weight by 25% 225 lb. 25% = 56.25 lb. 56.25 lb. rounded down = 56 lb. 5. To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb. (MerCruiser person weight) to get a 1485 lb. (total passenger load) 9 passengers 165 lb. = 1485 lb. 6. Subtract the swim platform load from the total passenger load to get the remaining weight to be placed in the boat. 1485 lb. 500 lb. = 985 lb. 7. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat. 985 lb. 165 lb. = 5.9 passengers 5.90 passengers rounded up = 6 passengers 8. Using the totals in this example load 56 lb. cargo in the aft storage, 113 lb. cargo in the center storage, and 56 lb. cargo in the bow storage onto the boat before adding passenger weight. Then, load six 165 lb. passengers, onto the boat with 500 lb. on the swim platform. 500 lb. + 225 lb. = 725 lb. 725 lb. + 165 lb. = 890 lb. 890 lb. + 165 lb. = 1055 lb. 1055 lb. + 165 lb. = 1220 lb. 1220 lb. + 165 lb. = 1385 lb. 1385 lb. + 165 lb. = 1550 lb.

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EXHAUST SYSTEM

SECTION - 3

1550 lb. + 165 lb. = 1715 lb.

g a c b d h e f
24864

Cargo, swim platform, and passenger weight loading diagram a - Swim platform load f - MerCruiser person weight (five) b - MerCruiser person weight (one) g - MerCruiser person weight (six) c - MerCruiser person weight (two) h - Aft storage d - MerCruiser person weight (three) i - Center storage e - MerCruiser person weight (four) j - Bow storage

Clear Hose Measurement Method

1. Obtain an 810 mm (5/163/8 in.) ID (inner diameter) clear hose approximately 4.5 m (15 ft.) long. Install a metal fitting or a weight on one end of the hose to keep that end of the hose below the waterline. The fitting or weight must not restrict water from filling the clear hose.

b b a c

24865

a - Clear hose b - Fitting

c - Unrestricted opening

IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water. 2. Put the weighted end of the clear hose over the side of the boat (port or starboard) that is sitting lower in the water. 3. Submerge the clear hose until completely filled with water. 4. Place a finger over the open end of the clear hose before removing it from the water. 5. Coil the excess clear hose into the bottom of the boat bilge. Keep the coil of clear hose below the waterline. 6. Keeping the clear hose in line with the engine's exhaust elbow, lift the end of the clear hose up to the highest point of the exhaust elbow.

Page 10 / 12

90-899883178 NOVEMBER 2007

SECTION - 3

EXHAUST SYSTEM

7. Slowly take the finger off of the end of the clear hose to let the water level stabilize. The water will seek the level of the water outside of the boat. Keep the clear hose close to the exhaust elbow and as vertical as possible.

c a d
8340

9142

a - Waterline b - Top of exhaust elbow c - Clear hose

d - Weight e - Measurement, waterline to top of exhaust elbow

Clear Hose Measurement Method from Seacock or Muffler Drain

IMPORTANT: Measure the exhaust elbow height to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. IMPORTANT: The engine must have been operated previously to fill the muffler with water. IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline height measurement on the side that sits lower in the water. 1. Attach a clear hose to the muffler drain point or seacock drain point. 2. Start the engine to fill the muffler and hose. 3. If attached to the seacock drain, open the seacock. 4. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that this open end section of the hose is as vertical as possible from the boat's bilge to the top of the exhaust elbow. 5. Coil excess hose in the bilge of the boat, keeping it below the water line. 6. Lower the open end of the hose and siphon water until it starts to come out of the hose. Put a finger over the hose and lift open end until it is at the top of the exhaust elbow. 7. Slowly take the finger off of the end of the hose to let the water level stabilize. The water will seek the level of the water outside the boat. Keep the hose close to the exhaust elbow and as vertical as possible.

90-899883178 NOVEMBER 2007

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EXHAUST SYSTEM

SECTION - 3

8. The measurement between the water in the hose and the top of the exhaust elbow is the exhaust elbow height. The maximum riser height is 15.2 cm (6 in.).

b
24866

Typical vertical water lift muffler a - Minimum exhaust elbow height with b - Clear hose for measuring waterline maximum load

24867

Typical horizontal water lift muffler a - Minimum exhaust elbow height with b - Clear hose for measuring waterline maximum load

Page 12 / 12

90-899883178 NOVEMBER 2007

! WARNING
Improper boat design and construction may result in serious injury or death. Adhere to all applicable marine regulations (United States Coast Guard [USCG], European Union Recreational Craft Directive [EURCD], etc.) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], etc.) when designing and constructing the boat and other components, such as the engine compartment, fuel delivery system, or exhaust system. The main concern of a boat's fuel system is safety; this must be achieved through a technically sound installation and constant inspection. The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats. The fuel tank is an integrated component of the boat. Refer to the special information on service and maintenance, which you have received from the tank manufacturer. Only a few points related to function and safety are listed here [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: All connections should be on the upper side of the tank.

90-899883178 NOVEMBER 2007

Page 3 / 4

FUEL SYSTEM

SECTION - 4

The drain plug at the lowest point on the tank serves to permit the removal of water and sediment. The tank breather pipe must have an inner diameter of at least 13 mm (1/2 in.) and must be fitted with a swan neck to prevent water from entering the tank. It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine. All fuel lines must be well secured. The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets. This prevents damage to the lines from abrasion. The following, but not limited to the following, additional fuel connection related points, applying to all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]: 1. Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities. 2. Using a digital vacuum gauge, measure the vacuum at the engine's fuel inlet. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg) through out engine operating range. IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels. It can also cause poor engine performance because of fuel starvation. 3. Use fuel lines that are Coast Guard approved (USCG Type A1).
Description Minimum fuel line diameter on singleengine gasoline installations Minimum fuel line diameter on multiengine gasoline installations with single pickup and line Specification 10 mm (3/8 in.) 13 mm ( in.) ID or larger

4. On multi-engine gasoline installations, use a fuel pickup and fuel tank supply line for each engine. If a single pickup and line is used, the line must be 13 mm ( in.) ID or larger. 5. On installations that require long lines or numerous fittings, use the fuel lines and fittings with an ID greater than 10 mm (3/8 in.). 6. Install the fuel lines so they are free of stress and firmly secured to prevent vibration and/or chafing. 7. Avoided sharp bends in the fuel lines. 8. Use a flexible fuel line to the fuel inlet fitting on the engine to absorb deflection when engine is running.

SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS

Page 4 / 4

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

SECTION 5 - COOLING SYSTEM

90-899883178 NOVEMBER 2007

Page 1 / 24

COOLING SYSTEM

SECTION - 5

Lubricant, Sealant, Adhesives

Tube Ref No.
9 116

Description Loctite 567 PST Pipe Sealant RTV 587 Ultra Blue Silicone Sealer

Where Used

Part No.

Hose fitting threads and plastic plug threads 92-809822 Sealing surfaces and screw shaft 92-809825

General Information
Mercury MerCruiser engines have either a seawater cooling system or a closed cooling system. Seawater cooling systems are sometimes called raw water cooling or standard cooling, while closed cooling systems are sometimes called fresh water cooling. On engines with seawater cooling, the engine is cooled entirely by the seawater in which the boat is being operated. Closed cooling systems use a combination of fresh water (antifreeze and water) and seawater for cooling. Both types of systems are designed to keep the engine operating temperature at approximately 71 degrees C (160 degrees F) for optimum performance, fuel economy and durability. (Refer to cooling system flow diagrams at end of section.) To monitor the cooling system, a temperature switch is incorporated into the audio warning system, which alerts the operator of an abnormal condition if the temperature exceeds approximately 93 degrees C (200 degrees F). A temperature sender is also employed to operate a temperature gauge at the dash. On dual helm applications, this sender must be replaced with a dual station sender to obtain the proper temperature reading at both stations. Refer to the Instrumentation and Controls section for more information. The cooling system must receive a sufficient amount of seawater under all operating conditions to operate properly. The design and installation of the seawater supply system is the boat manufacturer's responsibility. Cooling system components must be constructed, sized, and installed in accordance with the following guidelines.

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

Seawater Supply System

Seawater Supply Hose
Seawater Supply Hose Specifications Seawater inlet hose Seawater pickup Seacock (ABYC requirement) Sea strainer (optional) Low restriction with 32 mm (11/4 in.) connections 32 mm (11/4 in.) I.D. (wire reinforced)

Seawater Inlet Hose

A reinforced hose capable of supporting 10 in. Hg vacuum must be used to prevent the seawater inlet hose from collapsing from pump suction. The hose should be oil and seawater resistant. Use the shortest hose length possible with the least number of bends to minimize restriction. All connections must be secured with a hose clamp.

Page 2 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

Fasten hose as appropriate to maintain proper routing and to prevent chafing or contact with other moving parts.

7638

9361

Typical composite seawater pickup pump a - Seawater inlet hose connection

Typical brass seawater pickup pump

ThroughHull Seawater Pickup System

IMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction is created by seawater pump impeller.

c f b e b d a
7924

Typical installation shown with a through the hull seawater pickup a - Quicksilver seawater pickup and e - Seawater hose to engine seacock f - Seawater pump hose connector (if b - Hose clamp equipped) c - Seawater hose to seawater strainer g - Below seawater pump level d - Quicksilver seawater strainer IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as the pickup may create turbulence and allow air to flow into the propeller slipstream. This will cause propeller ventilation and will adversely affect boat performance. IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come in contact with steering system components, engine coupler, or drive shaft.

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COOLING SYSTEM

SECTION - 5

The seawater pickup must be large enough to permit sufficient seawater flow to engine seawater pickup pump for adequate engine cooling. The seawater pickup also must supply a positive head while underway. The seawater pickup should be located as close to the seawater pump inlet as possible and in an area where an uninterrupted, solid stream of seawater will flow past when the boat is underway.

Seawater Pickup
Either a throughtransom or throughhull seawater pickup can be used. Select pickup location to minimize seawater inlet hose length while providing an optimum location for seawater pickup. The location should be in an area that will provide a solid, airfree flow of seawater under all operating conditions. Avoid areas with a disturbed seawater flow, such as those behind or in close proximity to the propeller. Locations that are too far forward or outboard should also be avoided as these are prone to aeration problems at high boat trim angles and in turns. Check for aeration as outlined under Seawater Supply Test. IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as pickup may create turbulence and allow air to flow into the propeller slipstream. This will cause propeller ventilation and will adversely affect boat performance. Openings in seawater pickup should be approximately 3 mm (1/8 in.) maximum to prevent larger debris from entering and clogging the cooling system. IMPORTANT: Use a seawater strainer if the seawater pickup openings exceed 3 mm (1/8 in.). Provisions should be made to minimize galvanic corrosion, given the hull material being used and the composition of the surrounding components. Some industry standards and regulations also require that the pickup be connected into the boat's bonding system to minimize stray current corrosion. Refer to applicable standards and regulations for more details. IMPORTANT: External seawater pickup must have an integral seacock.

7532

Typical seacock

Page 4 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

b a g c

h i j
Typical transom pickup abcdeHose fitting Nut (4) Gasket Oring (4) Washer (4)
Description Loctite 567 PST Pipe Sealant Description RTV 587 Ultra Blue Silicone Sealer
7558

fghij-

Screw (4) Plastic plug Pickup Screen Screw (2)

Part No. 92-809822 Part No. 92-809825

Tube Ref No.

Where Used Hose fitting threads and plastic plug threads Where Used Sealing surfaces and screw shaft

Tube Ref No.

116

Seacock
The ABYC and other industry standards and regulations require the use of a seacock on certain types of applications to stop the entry of seawater in the event of a leak in the cooling system. Refer to applicable standards and regulations for specific requirements. The seacock also allows the seawater to be shut off when servicing the engine.

90-899883178 NOVEMBER 2007

Page 5 / 24

COOLING SYSTEM

SECTION - 5

The seacock must provide minimum restriction to seawater flow (see Specifications). A ball valve or gate valve is recommended. The ball valve is most common and is typically equipped with a lever type handle that operates in a 90 degree arc. This design gives a clear indication of whether the valve is open or shut. Industry standards and requirements typically require that the seacock be rigidly attached to the hull at the seawater pickup. Seacock location should be readily accessible for quick, easy operation.

7532

Typical seacock

Sea Strainer
A sea strainer is recommended if the boat is to be operated in an area with a high debris content. The strainer must be sized to minimize restriction (See Specifications) and to provide a reasonable service interval. Locate the strainer in an area that will be easily accessible for servicing. If the boat is not equipped with a seacock, the strainer should be located above the seawaterline to prevent seawater entry into boat when servicing. The strainer must have provision to allow draining in freezing temperature periods.

7533

Typical Sea Strainer

Page 6 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

Sterndrives With Closed Cooling Engines

Bravo Models with Closed Cooling
NOTE: Closed cooled Bravo models require a through the hull or through the transom pickup in addition to the sterndrive water inlets in order to meet the minimum flow specifications. When additional water inlets are used, a Yfitting is installed to the engine seawater pump.

c b d
8485

Dual seawater pickup for Bravo closed cooled engines a - Engine seawater pump c - Y fitting port to Bravo drive b - Hose from seawater pump inlet port d - Yfitting port to additional water inlet to Yfitting Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere do not require the dual seawater pickup with a bravo sterndrive on closed cooling models. Remove the Yfitting at the seawater pump inlet. Install a seawater suppy hose that meets MerCuiser specifications. Cut the hose to fit from the transom inlet fitting to the seawater pump inlet.

SeaCore Models
Some SeaCore models do not require a throughthehull or throughthetransom seawater pickup to meet the minimum flow specifications. See the chart, Seawater Pickups for SeaCore Sterndrive Engine Models.

SEACORE BRAVO ONE AND BRAVO THREE MODELS

The SeaCore Bravo One and Bravo Three engine packages do not require a throughthehull or throughthetransom seawater pickup in addition to the sterndrive water pickups if: The sterndrive gearcase has dual water pickups. The boat is capable of 64 km/h (40 MPH) with the boat fully loaded and operated within the specified operating range.

NOTE: When not installing the throughthehull or throughthetransom seawater pickup, see Installing the Seawater Supply Hose.

SEACORE BRAVO TWO MODELS

The SeaCore Bravo Two engine packages must have a throughthehull or throughthetransom seawater pickup in addition to the sterndrive side water pickups. Install the Yfitting at the engine's seawater pump inlet. See Installing the Y-Fitting.

90-899883178 NOVEMBER 2007

Page 7 / 24

COOLING SYSTEM

SECTION - 5

SEAWATER PICKUPS FOR SEACORE STERNDRIVE ENGINE MODELS

Seawater Pickups for SeaCore Sterndrive Engine Models Boat speed with the boat fully loaded and operated within the specified operating range SeaCore Bravo has side water pickup SeaCore Bravo has dual water pickup Throughthehull or throughthetransom seawater pickup

64 km/h (40 MPH) or greater

Not required See Installing the Seawater Supply Hose

30180

Less than 64 km/h (40 MPH)

30181
30180

Required See Installing the Y-Fitting

64 km/h (40 MPH) or greater

Required See Installing the Y-Fitting

30181

Greater or Less than 64 km/h (40 MPH) Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere.

Not required See Installing the Seawater Supply Hose

Coolant Recovery System

This system is equipped with a coolant recovery system that must be installed by the boat manufacturer. Coolant recovery bottle mounting location must meet these requirements: Within approximately 122 cm (4 ft.) of heat exchanger filler neck to allow connection with tubing provided. Even with or slightly above heat exchanger filler neck.

NOTE: This differs from the previous recommendation and has been changed to ensure that air does not enter the cooling system upon cool down. Accessible for observing level and servicing coolant.

a e b

f d

d
12838

12837

e
d - Plastic tubing e - Tubing clamp f - Heat exchanger fill neck

a - Recovery bottle b - Mounting bracket c - Screw and flat washer (2 each provided)

Hot Water Heater Hose Connections MPI Models

IMPORTANT: When connecting a cabin heater or hot water heater: Supply hose (from engine to heater) and return hose (from heater to engine) Must Not Exceed 16 mm (5/8 in.) inside diameter (ID). Make heater connections only at locations shown. Refer to manufacturers' instructions for complete installation information and procedures. Do not reposition engine temperature switch.

NOTICE
Blocking the coolant flow at the heater can cause reduced engine performance or overheating. Check for continuous coolant flow from the engine intake manifold to the water circulating pump.

90-899883178 NOVEMBER 2007

Page 11 / 24

COOLING SYSTEM

SECTION - 5

NOTICE
Prevent engine damage from overheating. In models equipped with closed cooling, low coolant levels may allow an air pocket to form when the hot water heater or cabin heater is mounted higher than the fill cap on the heat exchanger. Mount the heater lower than the fill cap of the heat exchanger and maintain the recommended coolant level.

Supply Hose Connection

NOTE: Some models may be equiped with additional fittings.

9255

Seawater cooled models with air or manual drain a - Location for hot water supply

a
9256

Closed cooled models a - Location for hot water supply

Page 12 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

a
9257

Seawater cooled models with multipoint drain a - Location for hot water supply

Return Hose Connection

9258

a - Return hose connection for hot water heater

b - Water circulating pump housing

IMPORTANT: A special fitting 22865526 may be used if the hex of the standard hose barb fitting contacts the water pump housing not allowing the fitting to turn before the fitting is tight.

a b

25133

a - Standard fitting

b - Special fitting

90-899883178 NOVEMBER 2007

Page 13 / 24

COOLING SYSTEM

SECTION - 5

Water Flow Diagrams

V6 and V8
V-8 BRAVO MODELS WITH CLOSED COOLING AND RISERS

h b a c p i d

e g f

c l

n o

m
abcdefghSeawater inlet Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump Thermostat housing i - Exhaust elbow j - Seawater pump k - Heat exchanger l - To power steering pump m - From seawater pump n - Seawater o - Ethylene glycol mix p - Check valve

8182

Page 14 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-6 ALPHA MODELS WITH CLOSED COOLING AND RISERS

a j e c

d f h m g
abcdefgSeawater inlet Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold Distribution housing
9393

n
h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - Heat exchanger m - Seawater n - Ethylene glycol mix

90-899883178 NOVEMBER 2007

Page 15 / 24

COOLING SYSTEM

SECTION - 5

V-8 BRAVO MODELS WITH CLOSED COOLING

i a h b

j k

e g c f n o

l m
abcdefghYfitting Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump Thermostat housing
9385

i - Exhaust elbow j - Seawater pump k - Heat exchanger l - To power steering cooler m - From seawater pump n - Seawater o - Ethylene glycol mix p - Check valve

Page 16 / 24

90-899883178 NOVEMBER 2007

SECTION - 5

COOLING SYSTEM

V-6 STERNDRIVE MODELS WITH CLOSED COOLING

a j i b

d f h m n
9386

g
abcdefgYfitting Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold Distribution housing

h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - Heat exchanger m - Seawater n - Ethylene glycol mix

90-899883178 NOVEMBER 2007

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COOLING SYSTEM

SECTION - 5

V-6 BRAVO MPD MODELS WITH SEAWATER COOLING

j b a

k i c d h g f e

9388

Page 23 / 24

COOLING SYSTEM

SECTION - 5

NOTES:

Page 24 / 24

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION 6 - DRIVE SYSTEM AND ENGINE INSTALLATION

Table of Contents
Transom Cutout....................................................................................................................................................... 5 Finding The Crankshaft Vertical Center Line....................................................................................................5 Single Engine ............................................................................................................................................. 5 Dual Engine ............................................................................................................................................... 6 Finding Crankshaft Horizontal Center Line (Xdimension)................................................................................6 90 Degree Tool Method ............................................................................................................................. 7 Tape Measure Method ............................................................................................................................... 7 Cutting Out the Transom...................................................................................................................................8 Checking The Transom Thickness..................................................................................................................10 General Information............................................................................................................................................... 11 Drive Shaft Extension Models.........................................................................................................................11 Rear Engine Mounts........................................................................................................................................11 All Bravo Models.............................................................................................................................................12 SeaCore and Closed Cooling Engine Models Seawater Inlets.......................................................................12 Alternative Mounting Of Gear Lube Monitor On Transom...............................................................................12 Air Pump..........................................................................................................................................................13 Transom Assembly Installation.............................................................................................................................. 13 Installing Gimbal Housing Assembly...............................................................................................................13 Installing the Alpha Inner Transom Plate........................................................................................................14 Installing Inner Transom Plate ........................................................................................................................ 14 Connecting Speedometer Pickup....................................................................................................................16 Water Inlet BlockOff Plate Installation.................................................................................................................. 17 Models With Alpha Sterndrive and Alternative Water Pickups........................................................................17 Alpha Models ........................................................................................................................................... 18 Water Inlet BlockOff Plate Installation............................................................................................................20 Alternative Water Pickups ........................................................................................................................ 20 Bravo Models ........................................................................................................................................... 20 Exhaust Preparation........................................................................................................................................22 Seawater Inlet Fitting and Gear Lube Monitor Fitting............................................................................................ 23 Alpha Gear Lube Monitor Connection At Gimbal Housing..............................................................................23 Seawater Inlet Fitting Installation....................................................................................................................24 Gear Lube Monitor Connection At Gimbal Housing........................................................................................25 Exhaust at Transom.............................................................................................................................................. 26 Transom Exhaust Connections.......................................................................................................................26 Power Trim Pump Installation................................................................................................................................ 27 Power Trim Pump............................................................................................................................................ 27 Power Trim Pump Connections and Filling.....................................................................................................27 Filling ....................................................................................................................................................... 28 Trim Limit Switch Connection..........................................................................................................................29 Steering System Installation.................................................................................................................................. 29 Hydraulic (Helm) Steering...............................................................................................................................29 Steering Helm and Cable................................................................................................................................29 Steering Cable Specifications.........................................................................................................................30 Installing Steering System...............................................................................................................................30 Sensor Steering Assembly.................................................................................................................................... 34 Installing the Pitot Sensor...................................................................................................................................... 35 Preliminary Transom Harness Connections.......................................................................................................... 36 Transom Harness............................................................................................................................................36

90-899883178 NOVEMBER 2007

Page 1 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Engine Installation................................................................................................................................................. 37 Transom Preparation.......................................................................................................................................37 Shift Cable Routing.........................................................................................................................................37 Engine Preparation .........................................................................................................................................38 Gen II Cool Fuel with Boost Pump Inlet Fitting................................................................................................ 39 Gen III Cool Fuel Module Inlet Fitting..............................................................................................................40 Engine Installation ..........................................................................................................................................41 Exhaust System Hose Connections................................................................................................................44 Engine Alignment Sterndrive Models..............................................................................................................45 Electrical Connections........................................................................................................................................... 47 Boat Harness and Instrumentation Connections.............................................................................................48 SmartCraft Product .................................................................................................................................. 49 Audio Warning System Connections...............................................................................................................49 MerCathode Connections................................................................................................................................50 Power Trim Electrical Connection...................................................................................................................50 Power Trim Pump Connections....................................................................................................................... 51 Battery Cables Connection..............................................................................................................................51 Fluid Connections.................................................................................................................................................. 51 Gear Lube Monitor Connection.......................................................................................................................51 PowerAssisted Steering Hoses......................................................................................................................52 Alpha Seawater Inlet Hose Connection...........................................................................................................53 Seawater Inlet Fitting Connection...................................................................................................................53 Coolant Recovery System...............................................................................................................................56 Alpha Shift Cable Installation................................................................................................................................ 57 Alpha Sterndrive Shift Cable Installation.........................................................................................................57 Shift Cable Travel .................................................................................................................................... 58 Separate Shift and Throttle Controls ....................................................................................................... 58 Installation ................................................................................................................................................ 59 Bravo Shift Cable Installation and Adjustment...................................................................................................... 62 Bravo Models Shift Cable Installation.............................................................................................................. 62 Bravo Models Shift Cable Adjustment.............................................................................................................63 DTS System Installation........................................................................................................................................ 66 Shift Cable Installation For DTS System............................................................................................................... 66 Throttle Cable Installation...................................................................................................................................... 67 Throttle Cable Installation And Adjustment.....................................................................................................67 Alpha Sterndrive Installation.................................................................................................................................. 68 Trim Cylinder Installation ......................................................................................................................... 73 Speedometer Connection Alpha Models.......................................................................................................74 Alpha Notice: Increased Trimin Range Capability.......................................................................................... 75 Alpha Trim Cylinder Spacer Removal.............................................................................................................75 Alpha Trim Cylinder Disassembly...................................................................................................................76 Alpha Trim Cylinder Reassembly....................................................................................................................77 Alpha Trim Cylinder Installation....................................................................................................................... 78 Bravo Sterndrive Installation................................................................................................................................. 80 Trim Cylinder Installation ......................................................................................................................... 87 Speedometer Connections Bravo Models..................................................................................................... 89 Trim Limit and Trim Position Settings.............................................................................................................. 90 Bravo Sterndrive Shift Check (Engine Running).............................................................................................90 Troubleshooting Shift Problems......................................................................................................................91 Paddle Wheel Speed Sensor Installation (If Equipped)..................................................................................94 Parts Provided ......................................................................................................................................... 94 Selecting Location ................................................................................................................................... 94 Transom Angle Requirements ................................................................................................................. 94 Installing Bracket ..................................................................................................................................... 95 Routing the Cable .................................................................................................................................... 95 Drilling Hole Through Transom (optional) ......................................................................................... 95 Without Drilling Hole Through Transom (optional) ............................................................................ 96

Page 2 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Installing and Removing the Paddle Wheel ............................................................................................. 96 Wiring Connections .................................................................................................................................. 96 Template Paddle Wheel Speed Sensor ................................................................................................ 97

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Lubricants, Sealants, Adhesives

Tube Ref No. Liquid soap
7 9 25 27

Description

Where Used Exhaust tubes Trim cylinder bolt threads Fuel inlet fitting Battery terminals All electrical connections Exhaust bellows mounting surface Gimbal housing studs Power steering bushings Upper and lower pivot bolts Clevis pin Steering cable end Rear engine mounting bolts Shift cable stud Trim cylinder end cap Shift cable pivot points Gear lube monitor Gear Lube Monitor Coupler splines Ujoint O-rings Drive shaft splines U-joint O-rings Driveshaft splines Bell housing studs Trim cylinder hardware Trim cylinder O-ring Water passage seals Shift cable end Power trim pump

Part No. Obtain Locally 92-809819 92-809822 92- 25711 3 92-86166Q1

Loctite 271 Threadlocker Loctite 567 PST Pipe Sealant Liquid Neoprene Bellows Adhesive

Special Lubricant 101

92-802865Q02

80 87

SAE Engine Oil 30W High Performance Gear Lubricant

Obtain Locally 92-858064K01

Engine Coupler Spline Grease

92-802869A1

2-4-C Marine Lubricant with Teflon

92-802859A1

114

Power Trim and Steering Fluid

92-858074K01

Special Tools
Tapered insert tool 9143579 Removes and installs the tapered insert retainer into the water inlet hose.
9197

Alignment Tool Assembly

91805475A 1 Aligns the engine and the sterndrive unit during installation.
9183

Shift Cable Adjustment Tool

9112427 Attaches over the shift cable, and aids in proper shift cable adjustment at the shift plate.

9186

Page 4 / 98

90-899883178 NOVEMBER 2007

SECTION - 6 Shift Slide Stabilizer

DRIVE SYSTEM AND ENGINE INSTALLATION 91865232

Holds the shift slide in the proper position as the sterndrive is installed onto the bell housing studs.
9184

Trim Cylinder End Cap Tool

91821709T

Allows easy removal of the trim cylinder end caps. Required if tilt limit spacers are to be installed or if the trim in limit spacer is to be removed (to allow additional trim in range).
9191

Dual Water Pickup Flush Gearcase Seal Kit

91881150K 1

Blocks off the front water inlet holes on the dual water inlet gearcases.
9194

Flushing Device

9144357Q 2

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

9192

Flushing Kit

91849996T 1

Use for flushing gearcases with low water inlets.

9195

Transom Cutout
Finding The Crankshaft Vertical Center Line
SINGLE ENGINE
1. Locate and mark the vertical center line on the transom, if known. This is also the crankshaft vertical center line. 2. If unknown, a compass can be used to locate the vertical center line: a. Mark identical locations on each side of the boat 304 mm (12 in.) from the bottom of the hull.

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

b. c.

Position the fixed end of a compass at the marks and draw arcs on the transom. Draw the crankshaft vertical center line through the intersection points of the 2 arcs.

b d

e c b e

7687

Single engine installation a - 304 mm (12 in.) b - Identical side marks c - Compass arc

d - Arc intersection points e - Crankshaft vertical center line

DUAL ENGINE
1. Locate and mark the vertical center line on the transom. Refer to Single Engine procedure. 2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical center lines on either side of the vertical center line.
Minimum Distance Between Crankshaft Vertical Center lines (Dual SideBySide) Model V6 and V8 Sterndrive Measurement 838 mm (33 in.)

IMPORTANT: Crankshaft vertical center lines must be an equal distance from boat vertical center line. 3. Draw the 2 crankshaft vertical center lines through the intersection of the marks.

b b

a
Dual installation a - Vertical center line b - 1/2 minimum distance between crankshaft center line marks

7688

c - Crankshaft vertical center lines

Finding Crankshaft Horizontal Center Line (Xdimension)

Xdimension can be measured by the 90 Degree Tool Method or by the Tape Measure Method.

Page 6 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

90 DEGREE TOOL METHOD

1. Construct the 90 degree tool.

b
a - 34.5 cm (139/16 in.)

7689

b - 1.2 m (4 ft)

IMPORTANT: The 34.5 cm (139/16 in.) dimension should only be raised or lowered after proper testing. To lower drive unit - Subtract from dimension "a". To raise drive unit - Add to dimension "a". 2. Place the 90 degree tool along the boat bottom at the vertical center line. 3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical center line. This is the crankshaft horizontal center line or Xdimension. 4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

c b c a
7690

7691

Single engine a - 90 degree tool along boat bottom at vertical center line b - Contact point

Dual engine c - Crankshaft horizontal center line

TAPE MEASURE METHOD

1. Determine the Xdimension from the following chart. IMPORTANT: This dimension should only be raised or lowered after proper testing.
Transom Angle (degrees) 16 15 14 13 12 11 10 Xdimension 36.4 cm (145/16 in.) 36.2 cm (141/4 in.) 36.0 cm (143/16 in.) 35.9 cm (141/8 in.) 35.7 cm (141/16 in.) 35.6 cm (14 in.) 35.4 cm (1315/16 in.)

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. On the vertical crankshaft center line, measure up from the bottom of the transom to the Xdimension selected previously. This is the crankshaft horizontal center line at the Xdimension. 3. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

a c c
7692

7693

Single engine a - Vertical center line b - Xdimension that corresponds to transom angle

Dual engine c - Crankshaft horizontal center line

Cutting Out the Transom

IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is suitable for most boats. Best mounting location for a particular boat, however, can be determined only by testing. 1. Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from XDimension. 2. Heavy duty applications: Subtract 25 mm (1 in.) from XDimension. 3. Above 40 km/h (25 mph): Use XDimension shown. 4. Above 80 km/h (50 mph): The XDimension can be increased to improve performance in some applications. However, pulling power for skiing will decrease. During testing, XDimension should be increased 13 mm (1/2 in.) at a time until desired performance is achieved but in no case should it ever be increased by more than:
Maximum Increase In XDimension Bravo One and Three Bravo Two 76 mm (3 in.) 25 mm (1 in.)

Extreme care should be taken when raising drive unit to ensure that water supply does not become aerated. Use clear water inlet hose to monitor incoming water and monitor engine temperature gauge to ensure engine does not overheat. In applications where cooling water to the engine is supplied by a through the hull or through the transom fitting, the sterndrive height will not cause cooling water aeration. IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed height will not be covered by Mercury MerCruiser warranty.

Page 8 / 98

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

1. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately).

Transom cutout template Transom drilling fixture kit 2. Follow instructions indicated on template or provided with drilling fixture. 3. Ensure that centerline on either the template or transom drilling fixture align with lines previously marked on transom. 4. Drill two 6 mm (1/4 in.) pilot holes at a 60 degree angle for hole saw guides. 5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole saw cutout is made incorrectly, drive unit steering lever may contact transom causing limited steering travel.

7893

7694

a b

7695

a - 51 mm (2 in.) hole saw holes (steering lever cutout)

b - 60 degrees versus transom angle

6. Cut the transom on the cut line at a 90 degree angle. If the transom cutout is made incorrectly the gimbal housing or exhaust system may improperly contact the boat transom causing transom mounting problems.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water absorption and deterioration of the transom.

a c
7696

d
a - Cut line b - 90 degrees to transom

c - Exhaust pipe area d - Mounting holes perpendicular to transom (8)

Checking The Transom Thickness

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts. 1. Ensure that transom thickness and surface conform to specifications.
Transom Specifications Thickness Between 51 57 mm (2 21/4 in.) for 203 mm (8 in.) to either side of the vertical center line Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.) Flatness Angle Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface Flat within 3 mm (1/8 in.) Outer Surface Flat within 2 mm (1/16 in.) 10 16 degrees

c
7697

a - Measuring thickness b - Measuring flatness

c - Suitable mandrel to check for uniform transom thickness

Page 10 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

General Information
Drive Shaft Extension Models
If the power package is equipped with a drive shaft extension, refer to the Drive Shaft Extension Installation Instructions (90866039) included with the engine package. Extensions for the gear lube monitor and MerCathode quick connects are used with drive shaft extention installations. Refer to your parts catalog for replacement part numbers.

Rear Engine Mounts

A fiber washer is cemented to the transom plate where the rear engine mount is attached to the transom plate. Verify the washer is in place before installing the engine. Normally the engine attaches to the transom plate with only the fiber washer in place. If the front engine mounts cannot be adjusted low enough to achieve proper engine alignment, spacer kit (12892619A01) can be ordered and installed as shown to raise the rear of the engine. Do not use the spacer unless alignment cannot be achieved with the front engine mount adjustment. IMPORTANT: The fiber washer must be used.

NOTE: Engine alignment is usually obtained using only the rear engine mount and the fiber washer. 1. Ensure that the fiber washer is in place.

a - Transom plate

16584

b - Fiber washer

2. Place the stainless steel washer on top of the transom plate mount only if needed to obtain proper alignment.

a c

b c

a - Transom plate b - Stainless steel washer

c - Stainless steel washer position to raise engine

16583

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

All Bravo Models

IMPORTANT: The trimin limit insert must be properly positioned before installing the trim cylinder anchor pin.

NOTE: When removing the sterndrive, note the position of the insert for reference when reinstalling the sterndrive. 1. Ensure that the trimin limit insert is positioned correctly for the appropriate Bravo model.

8548

Bravo One and Two (positioned forward) a - Trimin limit insert

8557

Bravo Three (positioned aft) a - Trimin limit insert IMPORTANT: The position of the trimin limit insert on the Bravo Three sterndrive should only be changed after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a particular boat application.

SeaCore and Closed Cooling Engine Models Seawater Inlets

Refer to Section 5, Sterndrives With Closed Cooling Engines for seawater pickup requirements and inlet connections.

Alternative Mounting Of Gear Lube Monitor On Transom

IMPORTANT: The mounting location specified must be above the steering lever on the transom assembly. Hose must be positioned to avoid moving parts (steering system, engine coupler). 1. Install the gear lube monitor bracket in the specified location and secure with lag screws and flat washers.

Page 12 / 98

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Install the gear lube monitor in the bracket. Secure the monitor with the retaining strap.

a c d b
a - Bracket b - Lag screw and flat washer

7706

c - Gear lube monitor and cap d - Retaining strap

Air Pump
NOTE: Some models have air pump mounted on the engine and other models have the air pump in a parts bag. 1. Select an easily accessible mounting location for the air pump. 2. Mount the air pump.

8992

Transom Assembly Installation

Installing Gimbal Housing Assembly
1. Carefully remove transom assembly from shipping carton. 2. Remove and read all tags attached to transom assembly.

7713

a - Shipping hardware 3. 4. 5. 6.

b - Trim cylinder suppport

Remove the shipping hardware. Remove the dust cover if boat will be shipped with drive installed. Do not remove the Shift Slide Installation Tool. Retain the serial number envelope.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Installing the Alpha Inner Transom Plate

1. 2. 3. 4. 5. Insert the wires, hoses, and shift cable through appropriate openings in inner transom plate. Position the gimbal housing on the transom and hold in place. Temporarily secure with hardware. Attach continuity wires. Place the transom harness ground ring terminal on top of the continuity circuit wire on transom bolt. 6. Secure the transom assembly with the hardware as shown. Torque the hardware.
Description Transom assembly hardware Nm 34 lb. in. lb. ft. 25

IMPORTANT: Tighten the transom assembly fasteners using an Xpattern torque sequence, starting from the middle fasteners. Tighten in small increments and go around the pattern several times until the proper torque is achieved. IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves.

h f

e i c
1

4 8 6

i g

1 8
24401

4 6

abcd-

Locknuts and flat washers (8) Hydraulic hoses Drive unit shift cable Trim limit and trim position sender wires e - Inner transom plate

fghij-

Transom harness ground wire Mercathode wires (if equipped) Jclip Torque sequence Steering lever continuity circuit wire

Installing Inner Transom Plate

1. Insert wires, hoses, and shift cable through appropriate openings in inner transom plate. 2. Position gimbal housing on transom and hold in place. 3. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the gimbal housing studs.

Page 14 / 98

90-899883178 NOVEMBER 2007

SECTION - 6 Tube Ref No.

DRIVE SYSTEM AND ENGINE INSTALLATION Description Special Lubricant 101 Where Used Gimbal housing studs Part No. 92-802865Q02

IMPORTANT: Tighten the transom assembly fasteners using an Xpattern torque sequence, starting from the middle fasteners. Tighten in small increments and go around the pattern several times until the proper torque is achieved. 4. Secure transom assembly with fasteners. Torque the fasteners.
Description Transom assembly hardware Nm 34 lb. in. lb. ft. 25

IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves.

90-899883178 NOVEMBER 2007

b
9283

b - Rubber Grommet

3. Remove and discard bell housing stastrap and clip that retains wires and speedometer hose.

f c a b e
a - StaStrap b - Clip c - Bell Housing Hose

9281

d - Bell Housing Assembly e - Speedometer Hose f - Trim Limit Switch Wire Harness

Page 18 / 98

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Cut the bell housing hose close to the bell housing as shown.

b
9285

a - Bell Housing Hose

b - Cut Line

5. Pull on hose to withdraw water tube through gimbal housing opening. Remove hose with remaining piece of water tube from gimbal housing.

9286

a - Bell Housing Hose

b - Water Tube (Cut Off Previously)

6. Stastrap (obtain locally) speedometer hose and trim limit switch wire harness together onto piece of hose remaining on bell housing. 7. Install the blockoff plate with new gasket. Secure with screws and lockwashers. Torque the screws.

7262

a - Blockoff plate b - Gasket

c - Screw d - Lockwasher

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DRIVE SYSTEM AND ENGINE INSTALLATION Description Water inlet block off screw Nm 5 lb. in. 45

SECTION - 6 lb. ft.

8. Install a through the hull or through the transom seawater pickup, seawater strainer, and seacock. 9. Connect the seawater inlet hose between seawater pump and seawater strainer. 10. Secure all hoses with hose clamps.

ALTERNATIVE WATER PICKUPS

A water inlet blockoff kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine. When installing the blockoff plate, it is necessary to cut the water hose that is located between the bell housing and the gimbal housing. This allows water to continue to circulate through the sterndrive unit for cooling.

BRAVO MODELS
1. Remove the tapered insert in the gimbal housing using the tapered insert tool. Discard the insert.

a
c

b
d

a - Tapered insert location in the gimbal housing b - Rachet and extension

Tapered insert tool

17857

c - Tapered insert d - Tapered insert tool

9143579

Page 20 / 98

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Install the blockoff plate with new gasket. Secure with screws and lockwashers. Torque the screws.

a d c

a - Blockoff plate b - Gasket

Description Water inlet block off screw

c - Screw d - Lockwasher
Nm 5

21683

lb. in. 45

lb. ft.

3. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2.

a d e c b
8489

a - Trim limit switch wires b - Speedometer hose c - Gimbal housing

d - Water hose e - Tapered insert

! WARNING
Improper reassembly of the Ujoint and pinion gear assembly can damage the sterndrive or sink the boat. The Ujoint bellows must provide a watertight seal to prevent water from entering the boat. Assemble and install the Ujoint and pinion gear as specified.

NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. The existing tie strap and clip can be reused if they are moved and repositioned after the hose is cut. 4. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where it is fitted into the bell housing in the area shown. Do not damage the Ujoint bellows. 5. Discard loose hose piece.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

6. Secure the trim limit switch wires and speedometer hose to the remaining section of water hose using existing tie strap and clip.

f b d
a - Tie strap b - Clip c - Water inlet hose

a
8490

d - Speedometer hose e - Trim limit wire harness f - Cutting area

7. Install a through the hull or through the transom seawater pickup, seawater strainer, and seacock. 8. Connect the seawater inlet hose between seawater pump and seawater strainer. 9. Secure all hoses with hose clamps.

Exhaust Preparation
IMPORTANT: When installing through the transom exhaust, it is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats. 1. If required, remove and discard clamps and bellows from gimbal housing. IMPORTANT: When installing through the propeller exhaust: With Bravo One and Bravo Two Sterndrives, an exhaust tube may be installed for a slight increase in performance. With most Bravo Three Sterndrive Models, an exhaust tube may be installed for a slight increase in performance. With a Silent Choice Exhaust System, the exhaust bellows must be removed and an exhaust tube must be installed. With any application, installation of an exhaust tube will increase exhaust noise. 2. If required, install exhaust tube on gimbal housing as follows: a. Remove and discard clamps and exhaust bellows. IMPORTANT: Failure to install the grounding clip can damage the exhaust tube due to corrosion. Always install the grounding clip. b. Install grounding clip on tube. c. Apply adhesive to exhaust bellows/tube mounting surface.
Tube Ref No.
27

Description Bellows Adhesive

Where Used Exhaust bellows mounting surface

Part No. 92-86166Q1

d. e.

Allow bellows adhesive to dry until no longer tacky (approximately 10 minutes). Position tube so that "SIDE" markings on tube are facing toward the right and left sides.

Page 22 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Install and torque the clamp.

c a
a - Exhaust tube b - Clamp c - "SIDE" marking
Description Exhaust tube clamp

b
8406

d - Exhaust tube e - Grounding clip

Nm 3

lbin. 26

lbft

Seawater Inlet Fitting and Gear Lube Monitor Fitting

Alpha Gear Lube Monitor Connection At Gimbal Housing
NOTE: The gear lube monitor hose is now in the parts bag on the engine. 1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal housing.

7704

a - Hose b - Quick release 90 degree fitting

c - Gimbal housing fitting d - Quick connect fitting

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Position quick release button on hose fitting away from water inlet fitting. Release button must not contact water fitting.

b f d c d
7705

Alpha transom a - Water inlet fitting b - Star washer and screw c - 90 degree hose fitting
Description Water inlet fitting bolts

d - Quick release button e - ACCEPTABLE positions f - NOT ACCEPTABLE position

Nm 5 lb. in. 45 lb. ft.

NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.

Seawater Inlet Fitting Installation

1. Install a new gasket, seawater inlet fitting, and screws. Torque screws.

a b

c d
Seawater inlet fitting shown with gear lube hose Jclip a - Seawater inlet fitting c - Gasket b - Screw (2) d - Star washers
Description Seawater inlet fitting screws Nm 5
21634

lb. in. 45

lb. ft.

Page 24 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Gear Lube Monitor Connection At Gimbal Housing

1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal housing.

d a c

b
Model with blockoff plate a - Hose b - Quick release 90 degree fitting
21623

c - Seawater inlet fitting d - Jclip

NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting, or blockoff plate if equipped. Release button must not contact water fitting or blockoff plate, if equipped. 2. Position quick release button on hose fitting away from water inlet fitting. Release button must not contact water fitting.

21624

Model with Quick connect seawater inlet fitting a - Gear lube monitor hose c - Quick release button b - Seawater inlet fitting

NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Exhaust at Transom
Transom Exhaust Connections
IMPORTANT: Exhaust pipe or blockoff plate and gimbal housing mating surface must be clean and free of nicks and scratches and Oring must be properly seated in groove or water may leak into boat.

a
21630

a - Seal 1. For through the transom exhaust installations, install a blockoff plate using four bolts and lockwashers. Tighten the bolts to the specified torque.

b c a a
a - Blockoff plate b - Bolts
Description Exhaust blockoff plate bolts

21625

c - Lockwashers

Nm 34

lb. in.

lb. ft. 25

2. For through the propeller exhaust installations, install the exhaust pipe. Tighten the bolts to the specified torque.

a
a - Engine exhaust pipe
Description Exhaust pipe to gimbal housing bolts
16231

Nm 34

lb. in.

lb. ft. 25

Page 26 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Power Trim Pump Installation

Power Trim Pump
1. Select an appropriate mounting location (floor or transom) for the trim pump that: Is within length limits of BLACK and GRAY hydraulic hoses coming from gimbal housing assembly. Is close to the battery so that trim pump battery leads can be connected. Allows easy access to trim pump oil fill and vent locations. Is in an area where pump will not be exposed to water. Prevents the power steering booster cylinder from coming in contact with the trim pump when the steering wheel is turned in either direction (right or left).

NOTE: Template 90863152 provides mounting hole location for floor or transom mounting. 2. Mount the pump in the desired location.

Power Trim Pump Connections and Filling

IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking from the system. 1. Connect hydraulic hoses to the trim pump. Ensure that the quick connect fittings completely seat when connecting the hoses.

a c g

h f b
abcd-

d
Positive battery lead Negative battery lead Harness connector BLACK hydraulic hose (UP hose)

7698

e
efghGRAY hydraulic hose (DOWN hose) Fill/vent cap Dual mount trim pump bracket Trim limit switch connected and secured

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Connect power trim pump control harness to trim pump.

a b

7699

a - Control harness

b - Trim pump connector

FILLING
1. If the oil level is below the "MIN" line specified fluid must be added. 2. Remove the fill cap from the reservoir.

NOTE: Fill cap is vented.

7701

Power tim pump reservoir showes the oil level is below "MIN" line a - Fill cap assembly b - Fill cap installed 3. Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir.

a
a - Reservoir
Tube Ref No.
114

b
7876

b - "MIN" and "MAX" lines

Description Where Used Power trim pump Part No. 92-858074K01

Power Trim and Steering Fluid

Page 28 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Install the fill cap.

Trim Limit Switch Connection

1. Connect the trim limit switch wires and secure with a wire retainer and tie strap.

b
a - Trim limit switch wires

7700

b - Wire retainer and cable tie

Steering System Installation

Hydraulic (Helm) Steering
If your power package is equipped with Compact Hydraulic Steering, refer to the Compact Hydraulic (Helm) Steering Installation Instructions .

Steering Helm and Cable

Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. The steering cable coupler nut must also have a means of locking it to the guide tube, as specified in ABYC requirements.

! WARNING
Failure to use a steering cable locking device can cause serious injury or death due to loss of boat control. Use a locking device, such as a selflocking coupler or external locking device when installing steering controls.

NOTE: All current production Quicksilver RideGuide steering cables have a selflocking coupler nut and do not require an external locking device. (Other cable manufacturers also make cables with selflocking coupler nut.)

7255

a - Quicksilver RideGuide steering cable selflocking coupler nut (identified by groove) IMPORTANT: If using a steering cable that does not have a selflocking coupler nut, an external locking device such as a locking sleeve must be used.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

1. Steering cable must be the correct length, particularly when installed in larger boats. 2. Avoid sharp bends, kinks, or loops in cable. 3. Fully extended steering cable end dimension must be as specified.

Steering Cable Specifications

IMPORTANT: Powerassisted steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.

a b e f

c d g
C L

k l

j i

7254

abcdef-

Coupler nut 7/8 14 UNF 28 thread 298 mm (113/4 in.) minimum Interface point 12.7 mm (1/2 in.) maximum 10.7 mm (27/64 in.) minimum flat 3.1 mm (7/64 in.) minimum radius

g - 15.9 mm (5/8 in.) maximum diameter end fitting h - 9.5 mm (3/8 in.) i - 9.8 mm (3/8 in.) diameter through hole (chamfered each side) j - 34.9 mm (13/8 in.) maximum k - 15.9 mm (5/8 in.) diameter tube l - Cable travel: midtravel position 429 mm (167/8 in.) total travel to be 203 mm (8 in.) minimum to 228 mm (9 in.) maximum travel each side of midtravel position 102 mm (4 in.) minimum to 114 mm (41/2 in.) maximum

Installing Steering System

NOTE: For dual installations, powerassisted steering unit can be mounted on port or starboard transom assembly. Measure exact distance between power package center lines. Select a tie bar from Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar installation instructions before proceeding. 1. Remove the protective shipping caps. 2. Inspect the bushings for debris. Lubricate the power steering bushings. 3. a

7709

a - Bushings

Page 30 / 98

90-899883178 NOVEMBER 2007

SECTION - 6 Tube Ref No.

DRIVE SYSTEM AND ENGINE INSTALLATION Description Special Lubricant 101 Where Used Power steering bushings Part No. 92-802865Q02

4. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.

b
a - Upper pivot bolt
Tube Ref No.
34

b - Lower pivot bolt

Where Used Upper and lower pivot bolts Part No. 92-802865Q02

21631

Description Special Lubricant 101

5. Position the steering assembly so that the pivot bolts will enter the bushings in the powerassisted steering control valve. 6. Install the upper and lower pivot bolts along with tab washers. Ensure that the tab washer tangs straddle the ridge on the inner transom plate.

a b

b
21632

Upper Pivot Bolt And Tab Washer Shown (Lower Similar) a - Tab washer tang b - Ridge 7. Turn the pivot bolts all the way in, by hand, to ensure proper steering assembly alignment. 8. Ensure that the steering assembly pivots freely. 9. Torque the pivot bolts. Bend the tab washer tabs against the corresponding flats on the bolt heads.

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTE: It may be necessary to tighten the pivot bolts further to align the flats on bolt head with the tabs on the washer.

a
21691

a - Pivot bolt
Description Upper and lower pivot bolt

b - Bent tab
Nm 34 lb. in. lb. ft. 25

! CAUTION
Contents under pressure. Moving the control valve cable guide tube with the hoses disconnected expels fluid from the ports. Wear eye protection while servicing the system. 10. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tube as shown, so that it will be less difficult to pull it out or push it in during connection.

b b

8496

a - Port 11. Connect the clevis to the steering lever. a. Lubricate the clevis pin.
Tube Ref No.
34

b - Control valve cable guide tube

Description Special Lubricant 101

Where Used Clevis pin

Part No. 92-802865Q02

Page 32 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Insert the clevis pin.

b a

a - Clevis c. d. Insert the cotter pin. Spread both ends of the cotter pin.

20396

b - Clevis pin

b c

a
a - Cotter pin b - Clevis pin

20399

c - Steering lever

IMPORTANT: Quicksilver RideGuide steering cable has a selflocking coupler nut and does not require an external locking sleeve or locking plate.

7255

a - Selflocking coupler nut

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTICE
Fastening any items to the steering cables or outer casings prevents normal operation. The steering cable and outer casing must be free to move back and forth. Do not fasten any items to the steering cable and outer casing.

7827

a - Steering cable and outer casing 12. Connect the steering cable as follows: a. Coat the steering cable end with a liberal amount of lubricant.
Tube Ref No.
34

Description Special Lubricant 101

Where Used Steering cable end

Part No. 92-802865Q02

b. Install the steering cable and secure with hardware as shown. IMPORTANT: Cable guide tube flat surfaces must be positioned vertically or slight feedback in the steering system could be encountered. c. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical position. Torque the coupler nut. Ensure that the flat surfaces are still aligned vertically after torque is applied to the coupler nut.

d g

h e f c

a b

d
7830

abcd-

Steering cable Grease fitting Cable coupler nut Cable guide tube

efgh-

Steering cable end Clevis Clevis pin Cotter pin

Sensor Steering Assembly

1. Remove nuts from upper 2 transom studs.

Page 34 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Remove cotter pin and clevis pin from steering lever. 3. Install new clevis pin and secure with existing cotter pin.

c a h d e a f

b
abcd4. 5. 6. 7. 8. 9. Transom stud holes Pitot tube connection Plug Guide

8403

efgh-

Cotter pin Clevis pin Tie strap Alignment mark

Slide guide onto the groove in the clevis pin. Bolt the steering assembly to the transom. Remove the brass plug from the transom. Install pitot barbed fitting. Attach pitot tube to barbed fitting and secure with a tie strap. Plug sensor into transom harness.

Installing the Pitot Sensor

IMPORTANT: The pitot hose must not come into contact with the steering system components or the engine coupler. 1. Remove the yellow cap from the quickconnect fitting at the transom.

mc79613-1

a - Male quickconnect fitting IMPORTANT: Ensure that the fittings snap into place.

b - Yellow plug

90-899883178 NOVEMBER 2007

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SECTION - 6

2. Connect the quickconnect pitot hose to the fitting on the transom.

b
mc79614-1

a - Female quickconnect fitting

b - Male quickconnect fitting

3. Connect the pitot hose quickconnect fitting on the transom.

12119

a - Pitot sensor

b - Quickconnect fitting on transom

Preliminary Transom Harness Connections

Transom Harness
The Transom harness connects to the engine harness and the following transom connections; engine to transom ground, analog trim, and the MerCathode. Wires are color coded and connections are tagged for easy installation. IMPORTANT: Secure ground ring terminal (black wire) to screw on port side of transom plate. 1. Ensure that the transom harness ground ring is secured with the continuity circuit wire on transom plate. 2. If equipped, connect the transom harness MerCathode connector to the MerCathode connector from transom. 3. Analog trim: Connect transom harness analog connector to the analog connector from transom. 4. Make all transom wiring connections and secure with clamps. Transom harness connector should be placed in a safe location and will be connected to the engine after the engine is installed.

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Engine Installation
Transom Preparation

NOTICE
Mismatched flywheel housing mounts and inner transom plate mounting hardware will result in improper engine alignment and possible engine damage. Ensure that the flywheel housing mounts and the inner transom plate mounting hardware, port and starboard, are the correct parts and match before installing the engine. 1. When installing mounts with knurled bottoms, use only the fiber washer. Do not install doublewound lockwashers to knurled mounts.

a
7960

Typical flywheel housing, all similar a - Latestyle mount: knurled surface b - Fiber washer 2. Position rear engine mount attaching hardware on the inner transom plate mounts as shown.

b
7839

a - Fiber Washer (2)

b - Locknut (2)

Shift Cable Routing

1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

b. c.

The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. The cable should then be routed under the starboard rear engine mount and turn toward the transom. The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine.

NOTE: Following this routing will prevent the engine coupler from damaging the cable.

8995

Refer to Section 8 - Remote Control.

Engine Preparation
1. Remove and read all tags attached to engine. 2. Remove all hardware that secures engine to shipping container. 3. Connect battery cables to engine. Observe the following: a. Ensure that the grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection. b. Install battery positive (+) wire directly to the large starter solenoid stud. c. Install negative () battery cable to the ground stud on the flywheel housing. d. After battery cables are connected, apply a thin coat of sealant to the terminals.
Description Battery stud Tube Ref No.
25

Nm 811 Description Liquid Neoprene Where Used Battery terminals

lb. in. 7197

lb. ft.

Part No. 92- 25711 3

e. Slide rubber boot over positive (+) terminal after making connection. 4. Drape battery cables over top of engine to prevent interference during installation.

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IMPORTANT: There is a fuse located at the starter solenoid. Do not remove this fuse.

8501

a - Positive (+) battery cable location b - Starter solenoid

c - 90 amp fuse Do not remove

5. If not already done, remove shipping plug from coupler and lubricate splines.

a
Typical a - Shipping plug
Tube Ref No.
91

7767

Description Engine Coupler Spline Grease

Where Used Coupler splines

Part No. 92-802869A1

Gen II Cool Fuel with Boost Pump Inlet Fitting

! WARNING
Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting, causing a fuel leak and possible fire or explosion. Always install fittings and plugs correctly, and do not tighten with power tools. 1. Remove the shipping plug from the brass inlet fitting. 2. Install an adapter or a fitting to the brass inlet fitting of the boost pump. To prevent cracking the casting or causing fuel leaks, turn the fuel inlet adapter or fitting in by hand until fingertight. Tighten the fitting an additional 13/4 to 21/4 turns with a wrench. DO NOT OVERTIGHTEN.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

IMPORTANT: Hold the brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet adapter fittings.

b c
Typical fuel boost pump a - Fuel inlet fitting b - Shipping plug
Tube Ref No.
9
25007

c - Boost pump

Description Loctite 567 PST Pipe Sealant

Where Used Fuel inlet fitting

Part No. 92-809822 Procedure

Description Fuel inlet adapter or fitting

Fingertight + 13/4 to 21/4 turns with a wrench. Do not overtighten.

Gen III Cool Fuel Module Inlet Fitting

! WARNING
Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting, causing a fuel leak and possible fire or explosion. Always install fittings and plugs correctly, and do not tighten with power tools. 1. Install an adaptor or a fitting to the brass inlet fitting of Gen III Cool Fuel Module. To prevent cracking the casting or causing fuel leaks, turn fuel inlet adaptor or fitting in by hand until fingertight. Tighten the fitting an additional 13/4 to 21/4 turns with wrench. DO NOT OVERTIGHTEN.

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IMPORTANT: Hold brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet adaptor fittings.

b
9360

a - Fuel inlet fitting

Tube Ref No.
9

b - Gen III Cool Fuel Module

Where Used Fuel inlet fitting Part No. 92-809822 Procedure Fingertight + 13/4 to 21/4 turns with a wrench. Do not overtighten.

Description Loctite 567 PST Pipe Sealant

Description Fuel inlet adaptor or fitting

NOTE: An installation jig (91806794A02) can be used to align and adjust engine mounts. Refer to instructions with fixture for proper use. 1. Remove the engine cover, if equipped.

a b

9289

Closed cool model shown, seawater cooled similar a - Engine cover knob b - Engine cover

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Attach a suitable sling to the front and rear lifting eyes on engine and adjust so that engine is level when suspended.

! CAUTION
9375

a - Center lifting eye (engine alignment only)

b - Lifting eye

3. Lift engine into position (in boat) using an overhead hoist. 4. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tube with exhaust pipe bellows.
Tube Ref No. Description Liquid soap Where Used Exhaust tubes Part No. Obtain Locally

5. To help with installation, apply lubricant into the exhaust tubes. IMPORTANT: The quick drain oil fitting clearance must be greater than 13 mm (1/2 in.) from the engine compartment and boat bottom. 6. If equipped with quick drain oil: Ensure that the quick drain oil fitting has a clearance of more than 13 mm (1/2 in.) from the engine compartment and boat bottom. 7. If clearance is 13 mm (1/2 in.) or less:Remove the quick drain oil fitting and install the oil drain plug from parts bag directly into the engine oil pan. 8. If clearance is greater than 13 mm (1/2 in.):

d e

7771

a - Bilge drain plug b - Tether c - Quick oil drain hose plug a. b. c.

d - Flange e - Toward interior of boat f - Clip

Push end of oil drain hose out of boat hull through flange. Pull oil drain hose out until it is 304 cm (12 in.) from the flange. Move alignment clip on the oil drain hose and squeeze to position it on the hose just inside of the boat hull against the flange.

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Connect bilge drain plug to oil drain hose plug using clip.

b c d

7618

a - Oil drain hose b - Alignment clip

c - Clip d - Bilge drain plug

e. Push oil drain hose through flange into boat hull. f. Install bilge drain plug in hull. 9. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the rear engine mounting bolts.
Tube Ref No.
34

Description Special Lubricant 101

Where Used Rear engine mounting bolts

Part No. 92-802865Q02

10. Install both rear engine mounting bolts and hardware and torque. Do not relieve hoist tension.

c c e d e a f
7961

g b f
7772

b
abcdDescription Rear engine mounting bolts

Rear engine mount Inner transom plate mount Bolt Washer

e - Spacer f - Fiber washer g - Stainless steel washer (optional spacer kit)

Nm 47 lb. in. lb. ft. 35

11. Loosen both adjusting nuts on front engine mounts to allow for adjustment during alignment. 12. Attach the front mounts to the stringers. 13. Remove the engine hoist.

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SECTION - 6

Exhaust System Hose Connections

NOTICE
Hot spots in exhaust hoses can damage hoses and cause leaks. Ensure that discharge water from the exhaust elbow flows without restriction through all hoses and fittings. Exhaust hoses must be properly installed on exhaust elbow outlets. Discharge water from the exhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots that could burn through the hose.

7628

7629

Correct

Incorrect

a c d e
Exhaust connection a - Maximum misalignment +/ 5 degrees b - Exhaust outlet centerline (14 degrees vs. crankshaft centerline) c - Exhaust hose centerline

b
9290

d - Angle vs. horizontal e - Horizontal (level surface)

IMPORTANT: Exhaust hoses/tubes should be secured at each connection with at least 2 hose clamps. All exhaust connections, including those at the exhaust elbow, should be secured with 2 hose clamps. ABYC standards also specify the use of stainless steel clamps with a minimum 13 mm (1/2 in.) band width. Do not use spring tension clamps.

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1. Torque all exhaust hose or exhaust tube clamps.

a
7631

a - Hose clamps
Description Hose clamps Nm 3 lbin. 26 lbft

Engine Alignment Sterndrive Models

1. If applicable, open perforated area in bell housing dust cover.

8378

a - Dust cover

NOTICE
Improper use of the alignment tool may result in personal injury or damage to the gimbal bearing or engine coupler. Do not operate the engine with the alignment tool installed. Do not attempt to force the alignment tool, raise or lower the engine with the tool inserted in the gimbal bearing or engine coupler, or raise the engine mount bracket above the top of the engine mount stud. IMPORTANT: Alignment tools from other manufacturers may cause improper alignment and damage to the gimbal bearing or engine coupler. Use only the Quicksilver Alignment Tool. 2. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines.
Alignment Tool Assembly 91805475A 1

3. If the alignmet tool does not fit, remove it and carefully raise or lower the front end of the engine as necessary. 4. If applicable, attach the engine hoist to the engine aligment hook to raise or lower the front end of engine.

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SECTION - 6

NOTE: Models not equipped with engine alingment hooks; require adjusting the front engine mounts equally to raise and lower the front end of the engine. 5. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines. NOTE: It may be necessary to hit the Alignment Tool with a synthane hammer to set the gimbal bearing to the coupler. 6. If necessary, firmly strike the sides of the Alignment Tool at 90 degree increments to help align the gimbal bearing.

d a b

e
a - Alignment Tool b - Gimbal bearing c - Engine coupler d - Hammer e - 90 degree increments

7784

7. Repeat step 4. until the Alignment Tool installs easily (SLIDES FREELY WITH MINIMAL EFFORT) all the way into and out of engine coupler splines. Do not check by turning the alignment tool. IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer. This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer (structure) to obtain the 6 mm (1/4 in.) dimension. IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required to align engine. 8. Adjust front engine mounts until they rest on boat stringers. 9. Relieve hoist tension entirely and fasten both front mounts to boat stringer using 9 mm (3/8 in.) lag bolts.

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10. Recheck alignment with Alignment Tool. Tool must enter coupling splines freely. If not, readjust front mounts.

b a

8503

a - Alignment Tool (use only recommended Alignment Tool)

b - End to be inserted through gimbal housing assembly

11. When alignment is correct, tighten locknut securely. Recheck alignment. 12. Bend tab down on adjusting nut.

a b c d

8504

a - Nut and lockwasher b - Adjustment nut

c - Direction (counterclockwise) to raise front of engine d - Tab washer

13. Remove Alignment Tool. If not installing drive, fold bell housing dust cover flap back into place and tape shut for boat shipment. Dust cover flap will have to be removed before operating engine. 14. Remove the engine alignment hook from the engine.

Electrical Connections
IMPORTANT: Refer to the following precautions when working on or around the electrical harness, or when adding other electrical accessories, to avoid damage to the electrical system. Do not tap accessories into the engine harness. Do not puncture wires for testing (probing). Do not reverse the battery leads. Do not splice wires into the harness. Do not attempt diagnostics without the proper, approved service tools.

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SECTION - 6

IMPORTANT: When routing all wire harnesses and hoses, ensure that they are routed and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts.
Tube Ref No.
25

Description Liquid Neoprene

Where Used All electrical connections

Part No. 92- 25711 3

Boat Harness and Instrumentation Connections

We recommend the use of Quicksilver Instrumentation and Wiring Harnesses. On dual station applications, oil pressure and water temperature senders (on engine) must be changed. See Section 7-Boat Harness and Installation Connections. The four basic gauges that must be used with the engine are: Tachometer Oil pressure Water temperature Voltmeter IMPORTANT: Maximum accessory load on the engine harness is 15 amps. If additional accessory load is needed, an accessory kit is available. 1. If an extension harness is required, connect the boat harness to the extension harness and connect the extension harness to the engine harness. Ensure that the harness does not rub or get pinched. 2. Fasten harnesses to boat at least every 46 cm (18 in.) using appropriate fasteners.

23135

Typical a - Engine harness plug 3. Connect 14pin harness to engine. Turn locking ring until firm snap is felt.

23136

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SMARTCRAFT PRODUCT
A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine rpm, coolant temperature, water pressure, battery voltage, fuel consumption, and engine operating hours. The Smartcraft instrument package will also aid in engine diagnostics. The SmartCraft instrument package will display critical engine alarm data and potential problems. Refer to the Mercury SmartCraft Operator's Supplement (9010229023) for the warning functions monitored and basic operation of the SmartCraft Instrument package. Refer to the instructions included with the instruments for installation instructions.

Audio Warning System Connections

! WARNING
Installing nonpotted electrical components in explosive environments can result in serious injury or death from fire or explosion. Install all nonpotted electrical components such as warning alarms away from environments where fuel or fuel vapor is present such as engine or fuel tank compartments. 1. Select a location for audio warning alarm that meets all of the following: Alarm can be easily heard, yet is out of sight Alarm can be easily accessed for installation and maintenance Alarm will remain dry Alarm is within length limits of the 46 cm (18 in.) purple alarm wire that connects to the "I" terminal or 12 volt source on switched side of ignition switch.

NOTE: The terminal to which wire is attached must have no voltage when ignition switch is in the OFF position. 2. Place alarm in desired location and secure to wire bundle with tie strap provided. 3. Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge or ignition switch. Tighten connection securely. 4. Connect TAN/BLUE wire from alarm to TAN/ BLUE wire from instrument harness. 5. Place the small (transparent) decals on the bottom of the water temperature and the oil pressure gauges. 6. Place the large decal on the instrument panel or other appropriate location easily viewed by the operator.

ALARM INDICATES LOW OIL OR OVERHEATING

a
APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION:

b
AUDIO WARNING HORN WILL SOUND WHEN: 1. ENGINE OIL PRESSURE IS TOO LOW 2. ENGINE TEMP. IS TOO HIGH, OR 3. DRIVE OIL LEVEL IS TOO LOW TO TEST AUDIO WARNING HORN: TURN KEY TO "ON" POSITION (ENGINE OFF)

7799

a - Small decal (transparent)

b - Larger decal

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SECTION - 6

7. Test audio warning system during Predelivery Preparation section.

MerCathode Connections
The MerCathode controller assembly is located on the engine. The engine harness supports the MerCathode system. The engine harness has a MerCathode connector which connects to a MerCathode connector on the transom harness. 1. Connect the battery wire the battery positive (+) terminal. 2. Spray the battery terminals with a battery connection sealant to help retard corrosion. IMPORTANT: Opposite end of RED/PURPLE wire must be connected directly to battery positive (+) terminal. Do not connect it to a switched positive (+) circuit. MerCathode system must function continuously for proper corrosion protection.

a b f

d e

c
25180

a - MerCathode controller b - RED/PURPLE wire to positive (+) battery terminal c - Electrode on transom assembly

d - Ground wire (in the engine harness, no hookup needed) e - Connector on the transom harness f - Engine harness to the MerCathode controller

Power Trim Electrical Connection

ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information) ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also specified. MerCruiser has developed three methods to facilitate compliance with ABYC recommendations. These come in the form of one standard production and two accessory kits. Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: a. The red current conductor (for the trim pump) must be connected to the switched side of the battery switch and either:

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Accessory Part Numbers

Part Number 8M2000587 8M2000588

provided with circuit protection within 7 inches of the power source or Provided with circuit protection within 40 inches of the point of connection with the power source and sheathed the entire length of wire from the point of connection to the source and the circuit protection device. This will require the use of an Accessory cable kit.
Description Cable Assembly Trim Pump Cable Assembly Trim Pump Color Red Red Length 72 inches 40 inches Type Fused Sheathed

Power Trim Pump Connections

1. Connect power trim pump BLACK () battery cable to negative () battery terminal and pump's RED (+) battery cable to positive (+) battery terminal or to the switched side of the battery switch.

b
6842

a - Positive battery lead

b - Negative battery lead

Battery Cables Connection

IMPORTANT: Engine electrical system is negative () ground. 1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal. 2. Connect engine negative () battery cable (usually BLACK) to negative () battery terminal. 3. Tighten connections securely with a wrench. 4. Spray battery terminals with a battery connection sealant to help retard corrosion.

Fluid Connections
Gear Lube Monitor Connection
IMPORTANT: Route hoses to determine the minimum length of hose needed and trim off the excess to avoid low spots in the system. Avoid kinks and route in a straight path to avoid low spots (traps) in the system. 1. Locate the gear lube monitor quick connect at the rear of the engine. 2. Locate the gear lube monitor quick connect at transom. IMPORTANT: Hose must not come in contact with steering system components, engine coupler, Ujoint shaft, or drive shaft.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

3. Fasten the quick connect.

7800

a - Gear lube monitor hose assembly from transom b - Gear lube monitor hose assembly from gear lube monitor

c - Quick connect fitting

PowerAssisted Steering Hoses

IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks. 1. Disconnect the quick connect fittings on the powerassisted steering hoses. 2. Connect the powerassisted steering hoses to the control valve. Ensure that the quick connects snap into place. 3. Route hoses as appropriate to avoid contact with the steering system components. 4. Use extra hose clips to secure hose to transom.

a a a b
a - Hydraulic lines

b
16225

b - Powerassisted steering control valve

NOTE: Steering Fluid can be added at this time if desired.

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Alpha Seawater Inlet Hose Connection

1. 1. Connect water inlet hose to water inlet fitting on transom.

a
a - Water inlet tube b - Hose clamp 2. Secure with hose clamp.

b
7802

c - Seawater inlet hose

Seawater Inlet Fitting Connection

IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly.

NOTE: The retainer clip must be in the closed position prior to installation. 1. Install the seawater inlet hose assembly to the water inlet fitting. a. Position the retainer clip in the closed position.

a b
8512

Seawater inlet hose assembly a - Retainer clip closed c - Hose decal b - Quick connect fitting Position the seawater inlet hose assembly with the center of the retainer clip and the hose decal toward the engine. IMPORTANT: Tabs and slots are sized to only mate at the correct orientation. Mate the small tab with the small slot. b.

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SECTION - 6

Align the slots of the quick connect fitting to the tabs of the water inlet fitting.

g h

b c

e f
8513

abcdd.

Quick connect fitting Small slot Large slot Seawater inlet fitting

efgh-

Small tab Large tab Center of retainer clip (toward engine) Centerline of water inlet fitting (toward engine)

Ensure that the center line of the water inlet fitting and the center of the retainer clip are positioned toward the engine. 2. Push the seawater inlet hose assembly onto the water inlet fitting until connected.

NOTE: The retainer clip snaps into place and resumes the closed position when properly connected.

b
8514

Shown with engine removed for visual clarity a - Centerline of water inlet fitting c - Hose decal b - Retainer clip in closed position IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly. 3. Perform a pull test on the water hose quick connection.

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Pull on the seawater inlet hose near the connection point with an approximate force of 111 N (25 lbf). If the seawater inlet hose does not become separated from the seawater inlet fitting when force is applied, the seawater inlet hose is connected and sealed properly.

a b

8515

Shown with engine removed for visual clarity a - Seawater inlet hose c - Seawater inlet fitting b - Quick connect fitting If the seawater inlet hose does become separated from the seawater inlet fitting, reinstall as specified. c. When all steps have been completed, check for any leaks at this connection. 4. Connect the seawater inlet hose to the engine seawater pump. b.

NOTE: The seawater inlet hose connects to the engine and the transom.

b e a c d
8516

Seawater inlet hose assembly a - Seawater inlet hose d - Seawater inlet fitting b - To engine e - Hose clamps c - Quick connect fitting 5. Models Using The Seawater Extension Hose Assembly:

NOTE: The seawater inlet hose connects to the engine and the transom, the seawater extension hose assembly connects to the transom and the seawater inlet hose.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

When connecting the seawater extension hose assembly to the seawater inlet hose assembly, position the center of the retainer clip away from the engine.

e a c

8517

Shown with engine removed for visual clarity a - Retainer clip position (away from d - Quick connect fitting (to seawater inlet engine) fitting) b - Seawater extension hose e - Seawater inlet fitting (to transom) c - Seawater inlet hose (to engine seawater pump) IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly. b. Perform a pull test and ensure that the requirements for checking the integrity of the connection are met.

NOTE: The seawater extension hose assembly connects to the transom and the seawater inlet hose.

g g g d b a
a - Seawater inlet hose b - Quick connect fitting to extension hose c - Quick connect male fitting d - Extension hose

g e c
8518

e - Quick connect fitting to seawater inlet fitting f - Seawater inlet fitting g - Hose clamp

Coolant Recovery System

NOTE: This section applies to Closed Cooled models only. 1. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: Within limits of clear plastic tubing. Level with or above the heat exchanger fill neck.

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Accessible for observing coolant level and filling. 2. Mount coolant recovery bottle and mounting bracket in desired location using two 19 mm (3/4 in.) long screws and flat washers. 3. Route plastic tubing to recovery bottle. Ensure that tubing is positioned away from any moving parts. Cut plastic tubing as required and connect to bottom connection on recovery bottle and secure with tubing clamp provided. IMPORTANT: Seal the plastic tubing connections completely to ensure the coolant recovery system operates properly. 4. Fasten plastic tubing to boat, as necessary, with 2 hose clips and13 mm (1/2 in.) long screws (provided).

b a

c d
7804

a - Recovery bottle and mounting bracket b - Screws and flat washers

c - Plastic tubing d - Tubing clamp

5. Connect plastic tubing to bayonet fitting on heat exchanger. Secure with tubing clamp provided.

NOTE: Use side cutter pliers or similar to compress ring type clamps. Use standard pliers to install springtension type.

Alpha Shift Cable Installation

Alpha Sterndrive Shift Cable Installation
IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control. If shift cable end guide moves in direction "A" when control lever is placed in FORWARD, remote control is set up for RIGHTHAND (RH) propeller rotation. If shift cable end guide moves in direction "B" when control lever is placed in FORWARD, remote control is set up for LEFTHAND (LH) propeller rotation.

A B
Arrow indicates direction of motion IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.
6614

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

SHIFT CABLE TRAVEL

We recommend the use of a Quicksilver remote control and cable. Refer to Mercury Precision Parts Accessories Guide for selection. However, if a control other than Quicksilver is to be used, control must provide specified shift cable travel (at the shift plate end).
Description Shift cable travel1 Specification 73 mm (27/8 in.)80 mm (31/8 in.)2

1 At the shift plate end 2 With a 6.89 kg (1520 lb) load applied to the cable end guide

NOTE: On engines with Alpha drives, the measurement indicated above can be taken by installing the remote control shift cable and using the shift assist assembly (provided) to place the proper load on the shift cable. 1. Place a mark on the tube against the edge of the cable end guide.

d e

a b c

7809

a
a - Shift assist assembly b - Remote control shift cable in FORWARD gear position c - Edge of cable end guide d - Remote control shift cable in REVERSE gear position e - Measurement taken from mark to edge of cable end guide

SEPARATE SHIFT AND THROTTLE CONTROLS

IMPORTANT: If boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS, the shift assist assembly that is shipped with the engine should not be used. The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly.

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The Spacer Kit (2311284A1) will have to be ordered to connect remote control shift cable when shift assist assembly is not used.

c b a d
7810

a - Clevis pin b - Washer

c - Spacer d - Cotter pin

NOTE: Do not discard shift assist assembly until after it is used below. IMPORTANT: Shift cable must be connected at the remote control for the appropriate rotation (LH or RH) drive unit, as explained following: RIGHTHAND ROTATION Control cable will have to be installed in remote control so that cable end will move in direction "A" when shift handle is placed in the FORWARD position. LEFTHAND ROTATION Control cable will have to be installed in remote control so that cable end will move in direction "B" when shift handle is placed in the FORWARD position.

A B
INSTALLATION
1. Remove shift assist assembly.
6614

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Remove shift cable attaching hardware.

b
7812

a - Shift assist 3. Install intermediate cable.

b - Shift plate

7813

4. Secure the brass barrel retainer with the cotter pin. 5. Secure the cable end guide with washers (one on each end of the end guide) and cotter pin. 6. Locate center of remote control and control cable play (backlash). IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making the following adjustment. a. a. Shift remote control to NEUTRAL. b. Push in on control cable end with enough pressure to remove play and mark position "a" on tube. c. Pull out on control cable end with enough pressure to remove play and mark position "b" on tube.

Page 60 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Measure distance between marks "a" and "b" and mark position "c" halfway between marks "a" and "b."

7815

7. Temporarily install control cable end guide into shift lever and insert anchor pin. 8. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of control cable end guide. 9. Place remote control and and sterndrive unit in FORWARD gear. 10. Install the remote control shift cable. 11. Place remote control handle in NEUTRAL. 12. Install the shift assist assembly. Ensure that it fits over the clevis pin and barrel stud with no resistance. 13. Install the fastening hardware. If shift assist assembly attaching points will not align, verify controller is in NEUTRAL. Remove the shift cable and reposition the adjustment barrel as required to allow the shift assembly to be installed with no effort.

d a

e b
With shift assist assembly a - Remote control shift cable b - Shift assist assembly c - Clevis pin (and cotter pin not shown)
7818

d - Large ID washer e - Small ID washer and cotter pin

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

d a c e

f g

i h b
7841

abcde-

Without shift assist assembly Remote control shift cable Clevis pin Cotter pin (existing) (not shown) Spring (existing) (not shown) Washer (existing)

fghi-

Washer Spacer Washer (existing) Cotter pin (existing)

Bravo Shift Cable Installation and Adjustment

Bravo Models Shift Cable Installation
NOTE: Bravo Models Only: Using shift cable adjustment tool (9112427), shift cables can be adjusted with or without the sterndrive installed, using the following procedure.
Shift Cable Adjustment Tool 9112427

IMPORTANT: Sterndrive propeller rotation is determined by the shift cable installation in the remote control. Bravo One/Two If shift cable end guide moves in direction A when control lever is placed in FORWARD, remote control is set up for RIGHTHAND (RH) propeller rotation. Bravo One/Two If shift cable end guide moves in direction B when control lever is placed in FORWARD, remote control is set up for LEFTHAND (LH) propeller rotation.

A
Arrow indicates direction of motion

21620

Page 62 / 98

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Bravo Three Front propeller on sterndrive is always LH Rotation and rear propeller is always RH Rotation. Shift cable end guide must move in direction A, when control lever is placed in FORWARD gear position.

A
21621

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.

Bravo Models Shift Cable Adjustment

1. Remove the adjustment tool.

21611

a - Adjustment tool 2. Loosen the adjustable stud and move it to dimension, as shown. Retighten stud.

b
21612

a - Adjustable stud 3. Install sterndrive shift cable. 4. Install cotter pin.

b - 76 mm (3 in.) (center of pivot bolt to center of stud)

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

5. Insert cotter pin from top and spread ends fully.

21616

a - Sterndrive shift cable b - Long cotter pin

c - Short cotter pin

6. Place adjustment tool over sterndrive shift cable, as shown. Hold tool in place using a piece of tape over the barrel retainer.

21615

a - Adjustment tool

b - Sterndrive shift cable

7. Locate center of remote control and control cable play (backlash). IMPORTANT: Keep center mark "C" aligned with control cable end guide edge when making the following adjustment. a. Shift remote control to NEUTRAL. b. Push in on control cable end with enough pressure to remove play and mark position "a" on tube. c. d. Pull out on control cable end with enough pressure to remove play and mark position "b" on tube. Measure distance between marks "a" and "b" and mark position "c" halfway between marks "a" and "b."

7815

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

8. Temporarily install control cable end guide into shift lever and insert anchor pin. 9. Adjust control cable barrel so that hole in barrel centers with vertical center line of stud. Ensure that backlash center mark is aligned with edge of control cable end guide. 10. Remove control cable end guide from shift lever by removing clevis pin.

a b

21613

a - Control cable end guide b - Clevis pin c - Backlash center 11. 12. 13. 14. 15. 16.

d - Control cable barrel e - Stud, washer and cotter pin

Install the control cable. Install the washer and cotter pin to secure the barrel. Install the clevis pin. Install the cotter pin into the clevis pin from the top and spread the ends. Remove the adjustment tool. Shift remote control lever into FORWARD position. Place end of adjustment tool in barrel retainer. If slot does not fit over stud, loosen shift lever stud and slide stud up or down until slot in tool fits over stud. When adjustment is correct, retighten stud. 17. Lift the adjustment tool so that the slot is above the stud. 18. Shift the remote control into REVERSE and repeat the adjustment process.

21614

a - RH rotation Bravo One, Two, Three FORWARD, LH rotation Bravo One and Two REVERSE slot

b - LH rotation Bravo One and Two FORWARD, RH rotation Bravo One, Two and Three REVERSE slot

19. Remove adjustment tool. 20. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180 degrees. 21. Lubricate shift cable pivot points.
Tube Ref No.
80

Description SAE Engine Oil 30W

Where Used Shift cable pivot points

Part No. Obtain Locally

90-899883178 NOVEMBER 2007

Page 65 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

DTS System Installation

Refer to DTS System Installation section 7 - Electrical System

Shift Cable Installation For DTS System

IMPORTANT: Do not move the shift cable stud on the shift arm. IMPORTANT: The shift cable barrel is preset and CANNOT be adjusted. 1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows: a. The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. The cable should then be routed under the starboard rear engine mount and turn toward the transom. The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine.

b. c.

NOTE: Following this routing will prevent the engine coupler from damaging the cable.

8995

NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the predelivery inspection. 2. Apply lubricant to the threads of the shift cable stud.
Tube Ref No.
34

Description Special Lubricant 101

Where Used Shift cable stud

Part No. 92-802865Q02

3. Install the intermediate shift cable to the shift actuator on the engine.

Page 66 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Tighten locknut until it contacts and then loosen 1/2 turn.

b e a f d c

8996

a - Shift actuator b - Shift cable c - Locknut 5. Insert cotter pin from top and spread ends.

d - Shift cable stud e - Shift cable barrel f - Washers

8997

a - Cotter pin

Throttle Cable Installation

Throttle Cable Installation And Adjustment
IMPORTANT: When installing throttle cables, ensure that cables are routed to avoid sharp bends and / or avoid contact with moving parts. Do not fasten any items to throttle cables. 1. Place remote throttle lever in idle position and attach cable to throttle body, following cable manufacturers instructions.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever.) Adjust barrel on throttle cable to align with hole in anchor plate. Ensure hole in barrel positions cable as shown. Tighten locknut until it contacts washer, and then loosen 1/2 turn.

c
8217

a - Locknut and flatwasher b - Cable barrel

c - Cable end

Alpha Sterndrive Installation

1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)

7713

Typical a - Dust cover b - Trim cylinder support

Page 68 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Remove gear lube monitor cap. Fill with lubricant.

5497

a - Gear lube monitor cap

Tube Ref No.
87

b - "OPERATING RANGE" line

Where Used Gear lube monitor Part No. 92-858064K01

Description High Performance Gear Lubricant

3. Push dribble valve stem in until gear lube appears.

7851

a - Dribble valve stem 4. Once gear lube appears, release dribble valve stem. 5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING RANGE" (full) line with specified fluid. Do not overfill.
Tube Ref No.
87

Description High Performance Gear Lubricant

Where Used Gear lube monitor

Part No. 92-858064K01

6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap. IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing drive unit or water may leak into boat. 7. Ensure that rubber gasket and water passage Oring are properly positioned in bell housing.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

8. Coat bell housing studs with lubricant.

a c b

7852

a - Rubber gasket b - Water passage Oring

Tube Ref No.
95

c - Studs (6)

Description 2-4-C Marine Lubricant with Teflon

Where Used Bell housing studs

Part No. 92-802859A1

9. Grease sterndrive Ujoint Orings, and drive shaft splines. A grease packet for this procedure is provided with the sterndrive packaging.

a a b
7853

a - Ujoint Orings
Tube Ref No.
91

b - Drive shaft splines

Where Used Ujoint O-rings Where Used Drive shaft splines Part No. 92-802869A1 Part No. 92-802869A1

Description Engine Coupler Spline Grease Description Engine Coupler Spline Grease

Tube Ref No.

Page 70 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

10. Ensure Ujoint bellows are clean and free of debris.

7854

a - Ujoint bellows 11. Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft. Do this by placing remote control shift lever in: FORWARD gear position for RH drive or REVERSE gear position for LH drive unit.

c a

d b
7855

a - Shift shaft b - Shift shaft coupler

c - Shift slide d - Slot

IMPORTANT: Shift slide assembly is free to rotate on core wire. Ensure that shift slide remains in upright position and is properly engaged with shift shaft lever roller while installing drive unit. 12. Engage shift shaft roller into shift shaft lever. 13. Place gasket on bell housing.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

14. Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide.

b c c
a - Shift shaft lever b - Roller
Shift Slide Stabilizer
7859

c - Shift Shaft Slide Stabilizer Tool d - Gasket

91865232

15. Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE while simultaneously turning propeller shaft COUNTERCLOCKWISE.

7856

a - Drive unit shift shaft IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dual engine installations. The LH rotation drive unit can be identified by the decal on the back side of the upper drive shaft housing, which states: "Alpha One Counter Rotation" 16. Install sterndrive unit as follows: a. Position trim cylinder straight back (over top of acceleration plate). Be careful not to scratch acceleration plate or trim cylinders. b. Guide Ujoint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into drive shaft housing. Ensure that shift slide remains upright and engaged with bell housing shift shaft lever. c. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align Ujoint shaft splines with engine coupler splines while sliding sterndrive into bell housing.

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90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

IMPORTANT: If drive unit will not slide into bell housing, ensure that the shift shaft and couplers are positioned properly. Do not force drive unit into position.

b
7857

a - Gasket d. e. f.

b - Shift slide

Remove Shift Slide Stabilizer Tool and discard. Slide sterndrive all the way into bell housing. Secure sterndrive to bell housings using fasteners as shown. Torque the fasteners.

a b

7858

a - Locknut and flat washers

b - Locknut and continuity circuit washer (no flat washer at this location)
Nm 68 lb. in. lb. ft. 50

Description Sterndrive unit fasteners

17. Return remote control shift lever to the NEUTRAL position.

TRIM CYLINDER INSTALLATION

1. Install trim cylinders on aft end of sterndrive unit with hardware as shown.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

2. Install the plastic caps by snapping in place.NOTE: Upon installation of hardware apply lubricant to all components except plastic caps.

a b c d e

b
a - Aft anchor pin b - Bushings c - Flat washers
Tube Ref No.
95

a
d - Ering clips e - Plastic caps

7849

Description 2-4-C Marine Lubricant with Teflon

Where Used Trim cylinder hardware

Part No. 92-802859A1

3. Position the sterndrive unit serial number decal.

Speedometer Connection Alpha Models

1. Raise drive to gain access to area between gimbal housing and sterndrive, immediately above the transom end of the antiventilation plate. 2. Align plastic slots on male and female portions and insert. 3. Push down to secure.

4803

a - Male end of speedometer tube fitting

b - Female end of speedometer tube fitting

Page 74 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Ensure that the speedometer tube is secured and out of the way of moving parts.

b a

8029

a - Male end of speedometer tube fitting

b - Female end of speedometer tube fitting

Alpha Notice: Increased Trimin Range Capability

The Alpha trim cylinders provide the capability for an increased trimin range. A spacer can be removed from the trim cylinders to increase the trimin range by approximately 11/2 degrees. This will improve the acceleration on some boats by forcing the bow down more quickly. If the spacers are to be removed, the boat must be water tested to ensure that the increased trimin range does not cause any undesired boat handling characteristics (bowsteer, chinewalk, etc.) if the sterndrive is trimmed in while the boat is operated at higher speeds. The boat should be tested under all conceivable load conditions and maneuvers to ensure that the additional trimin does not pose a problem. The final decision and responsibility for use of the additional trimin range is left up to the boat manufacturer.

Alpha Trim Cylinder Spacer Removal

1. Disconnect "UP" trim hose from "UP" port on trim cylinder. 2. Disconnect "DOWN" trim hose from hydraulic connector on gimbal housing. Plug holes with 2238609 plug.

d b a
a - "UP" hose b - "UP" port on trim cylinder
7843

c - "DOWN" hose d - Hydraulic connector

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

3. Remove front power trim cylinder mounting hardware.

b d
a - Front anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
4827

d - Ering (port and starboard) (2) e - Plastic caps (port and starboard) (2)

4. Remove rear power trim cylinder mounting hardware.

e b
7844

a - Rear anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)

d - Ering (port and starboard) (2) e - Plastic caps (port and starboard) (2)

Alpha Trim Cylinder Disassembly

! CAUTION
Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and lint free during reassembly. IMPORTANT: During service procedures, clamp the trim cylinder on the front mounting flange. Clamping the center section of the trim cylinder can cause damage. 1. Remove plug previously installed, if applicable.

Page 76 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

2. Remove end cap with spanner wrench and remove piston rod assembly from cylinder.

7845

a - Piston rod assembly

Trim Cylinder End Cap Tool

b - Cylinder
91821709T

3. Remove bolt, washer, and spacer. Be careful not to lose check balls. Discard spacer.

h d e f g c
7846

a
abcd-

Trim cylinder shock piston bolt Spacer Washer Springs (3)

efgh-

Spring pins (3) Check balls (3) Shock piston assembly Oring

Alpha Trim Cylinder Reassembly

! CAUTION
Contamination can damage the hydraulic system or cause the system to malfunction. Failure of power trim or steering components can result in injury or product damage. Ensure that the work area, shop tools and all components are clean and lint free during reassembly. 1. Apply sealant to threads of shock piston bolt.
Tube Ref No.
7

Description Loctite 271 Threadlocker

Where Used Trim cylinder bolt threads

Part No. 92-809819

2. Install washer and bolt and torque.

Description Trim cylinder shock piston bolt Nm 23 lb. in. lb. ft. 17

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

IMPORTANT: During service procedures, clamp the trim cylinder on the front mounting flange. Clamping the center section of the trim cylinder can cause damage. IMPORTANT: Use only 24C with Teflon on the end cap threads. Other substances may act as an insulator and cause poor electrical continuity between the cap and cylinder, which could promote corrosion. 3. Apply lubricant to end cap threads and install piston rod assembly into cylinder. 4. Torque end cap using the spanner wrench.

a b

c
a - End cap b - Piston rod assembly
Tube Ref No.
34

7847

c - Cylinder

Description Special Lubricant 101

Where Used Trim cylinder end cap Nm 61

Part No. 92-802865Q02 lb. in. lb. ft. 45

Description Trim cylinder end cap

5. Position trim cylinder rear connecting ends.

7848

a - Port trim cylinder b - Starboard trim cylinder

c - Connecting ends (offset as shown)

Alpha Trim Cylinder Installation

1. Install trim cylinders forward mounting hardware. 2. Coat area in trim cylinder between bushings with lubricant. 3. Replace anchor pin and install bushings and washers.

Page 78 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

4. Attach Erings and plastic caps to end of anchor pin.

b d
a - Front anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
Tube Ref No.
95
4827

d - Ering (port and starboard) (2) e - Plastic caps (port and starboard) (2)

Description 2-4-C Marine Lubricant with Teflon

Where Used Trim cylinder hardware

Part No. 92-802859A1

5. 6. 7. 8.

Install trim cylinders rear mounting hardware. Coat area in trim cylinder between bushings with lubricant. Replace anchor pin and install bushings and washers. Attach Erings and plastic caps to end of anchor pin.

e b
7844

a - Rear anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
Tube Ref No.
95

d - Ering (port and starboard) (2) e - Plastic caps (port and starboard) (2)

Description 2-4-C Marine Lubricant with Teflon

Where Used Trim cylinder

Part No. 92-802859A1

9. Reconnect trim hoses after air bleeding power trim cylinders and hoses following procedures outlined in Mercury MerCruiser Service Manual 14.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Bravo Sterndrive Installation

1. If applicable, remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)

b
8993

Typical a - Dust cover b - Trim cylinder support

2. Remove gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE".

5497

Gear lube monitor a - Gear lube monitor cap

Tube Ref No.
87

b - "OPERATING RANGE" line

Where Used Gear Lube Monitor Part No. 92-858064K01

Description High Performance Gear Lubricant

Page 80 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

3. To purge air from the system, push in on the dribble valve stem until the new gear lube appears.

a - Dribble Valve

21440

4. Release the dribble valve. 5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING RANGE" (full) line with specified fluid. Do not overfill.

c b a

19947

Gear lube monitor a - Gear lube level at the "ADD" mark b - Gear lube level at the "OPERATING RANGE"
Tube Ref No.
87

c - Cap

Description High Performance Gear Lubricant

Where Used Gear Lube Monitor

Part No. 92-858064K01

6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap.

19962

a - Gear lube monitor cap

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7. Coat the Orings on the sterndrive Ujoint with lubricant

a
a - Orings 8. Coat the splines on the sterndrive Ujoint with lubricant.

a
21441

a
a - Splines
Tube Ref No.
91 91

21442

Description Engine Coupler Spline Grease Engine Coupler Spline Grease

Where Used U-joint O-rings Driveshaft splines

Part No. 92-802869A1 92-802869A1

9. Ensure that the Ujoint bellows are clean and free of debris.

Bell housing of the transom assembly a - Ujoint bellows edge b - Ujoint bellows

21456

Page 82 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

10. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the bell housing studs.

a a

a - Bell housing studs (6)

Tube Ref No.
95

21457

b - Tube of lubricant
Where Used Part No. 92-802859A1

Description 2-4-C Marine Lubricant with Teflon

Bell housing studs

11. Lubricate the shift linkage Oring.

a
21678

a - Shift linkage Oring

Tube Ref No.
95

Description 2-4-C with Teflon

Where Used O-ring

Part No. 92-802859A1

12. Lubricate the water passage seal.

a
21679

a - Water passage seal

90-899883178 NOVEMBER 2007

Page 83 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION Tube Ref No.

SECTION - 6 Description Where Used Water passage seals Part No. 92-802859A1

2-4-C Marine Lubricant with Teflon

13. Pull out the shift linkage as far as it moves. The jaws will open.

b
a

c c
5311

a - Shift linkage assembly b - Jaws open

c - Underside of lower lip

21471

IMPORTANT: As the sterndrive is inserted into the entry of the bell housing, the shift cable must be closely checked to ensure that it enters the jaws of the shift linkage assembly of the sterndrive. 14. Place remote control in NEUTRAL position.

NOTE: As the bell housing shift cable enters the shift linkage assembly, it pushes the assembly back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps "A", "B" and "C."

5312

IMPORTANT: If the bell housing shift cable does not line up to properly enter the jaws of the shift linkage assembly, use your hand to guide the cable into place while installing the sterndrive. 15. Place the driveshaft housing in position on bell housing and install the sterndrive, as follows:

Page 84 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Remove the nuts from the trim cylinders.

d e
a - Socket b - Wrench c - Anchor pin b. d - Ground wires e - Trim cylinders
21521

Position the sterndrive so that the universal joint shaft aligns with the bell housing bore.

c
a - Universal joint b - Bell housing c.

21518

c - Shift linkage d - Shift cable

Guide the Ujoint shaft through the bearing in the gimbal housing and into the engine coupler. Ensure that the shift linkage jaws engage the bell housing shift cable assembly.

c
21519

a - Shift cable b - Shift linkage jaws open

c - Shift linkage jaws engage the shift cable

90-899883178 NOVEMBER 2007

Page 85 / 98

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

If necessary, rotate the propeller shaft COUNTERCLOCKWISE slightly (using a propeller) to align the Ujoint shaft splines with the splines in the engine coupling, then slide the sterndrive all the way into bell housing.

b a c

a - Bell housing studs b - Dribble valve

c - Shift cable

21520

16. Secure the sterndrive to the bell housing with 4 flat washers and 6 locknuts. Do not use flat washers on the ground plate.

Ground plate with serial number and gear ratio a - Washers not used here

25908

Page 86 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

17. Start from the center and torque the nuts.

a b
25909

a - Locknut (6) flat washers (4)

Description Sterndrive fasteners

b - Torque wrench
Nm 68 lb. in. lb. ft. 50

TRIM CYLINDER INSTALLATION

1. Install the mounting hardware of the trim cylinder forward as shown 2. Lubricate the anchor pin threads to prevent the threads from galling. 3. Hand thread the locknuts onto the pin. Do not tighten at this time.

NOTE: Upon installation of hardware apply lubricant to all stainless steel components.

d e

14326

Front abcdAnchor pin Retainer clip groove Flat washer (large I.D.) Retainer clip
Description 2-4-C Marine Lubricant with Teflon

efgh-

Bushing Flat washer (small I.D.) Locknut Plastic cap

Part No. 92-802859A1

Tube Ref No.

Where Used Trim cylinder hardware

IMPORTANT: On Bravo One, Two, and Three Models the trimin limit insert must be properly positioned before installing the trim cylinder anchor pin in the following steps.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTE: Ensure that the trimin limit insert is reinstalled in the same position as before removal of the sterndrive. If you are not sure of the original position, contact the boat manufacturer for their recommendation. Refer to Special Information at the front of this section before reinstalling the trimin limit insert.

14571

a - Trimin limit insert Bravo One and Two (positioned forward)

b - Trimin limit insert Bravo Three (positioned aft)

IMPORTANT: The position of the trimin limit insert on the Bravo Three sterndrive should only be changed after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a particular boat application. 4. Install the mounting hardware of the trim cylinder aft as shown. 5. Lubricate the anchor pin threads to prevent the threads from galling. 6. Handthread locknuts onto the anchor pin.

NOTE: Upon installation of hardware apply lubricant to all Stainless steel components.

d e

c
a - Aft anchor pin b - Larger flat washers (2) c - Bushings (4)
Tube Ref No.
95

f
9295

d - Small ID flat washers (2) e - Locknuts (2) f - Plastic caps (2)

Where Used Trim cylinder hardware Part No. 92-802859A1

Description 2-4-C Marine Lubricant with Teflon

7. Tighten the locknuts until the washer and locknut contact the shoulder on the anchor pin.

Page 88 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

8. Install plastic caps and tighten handtight only.

a b b a c

21677

a - Socket and tool b - Wrench tool

c - Plastic cap (4)

Speedometer Connections Bravo Models

1. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately atop the transom end of the antiventilation plate. 2. Insert speedometer tube fitting into opening on topside of antiventilation plate, in position shown.

b
5319

a - Tube fitting

b - Opening

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.

5320

a - Fitting installed (handle pointing forward)

Trim Limit and Trim Position Settings

To adjust the trim limit switch and the trim position sender see Section 9Predelivery Preparation for the appropriate procedure.

Bravo Sterndrive Shift Check (Engine Running)

! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the antiventilation plate. This test requires sufficient water supply to your engine and sterndrive. 1. Check sterndrive for proper gear shift with boat out of water. 2. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/ IN position. Do not allow the sterndrive skeg to contact the ground.

a b

4805

Typical single handle remote control shown a - Drive trim switch b - Drive trailer button 3. Connect a garden water hose between flushing attachment and water source.
Dual Water Pickup Flush Gearcase Seal Kit Flushing Device 91881150K 1 9144357Q 2

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SECTION - 6 Flushing Kit

DRIVE SYSTEM AND ENGINE INSTALLATION 91849996T 1

4. Partially open water source until water continuously leaks out around the flushing device.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation. 5. Place remote control handle in NEUTRAL, idle speed position and start engine.

NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of each gear FORWARD, NEUTRAL, and REVERSE, at idle speed position. NOTE: The operator at the remote control handle should feel a slight detent before and after each gear. FORWARDdetentNEUTRALdetentREVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment. 6. Move the remote control handle to FORWARD, idle speed position. 7. Check that the sterndrive propeller shaft is turning in the FORWARD direction. 8. Shift the remote control handle to NEUTRAL, idle speed position. 9. Check that the sterndrive propeller shaft is not turning. 10. Shift the remote control handle to REVERSE, idle speed position. 11. Check that the sterndrive propeller shaft is turning in the REVERSE direction. 12. If the sterndrive will not shift: a. Remove the sterndrive and check for proper shift hook ups. b. Check that the shift cables are connected IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/ or contact with moving parts. DO NOT fasten any items to shift cables.

Troubleshooting Shift Problems

NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear. 1. When installing the control box in the side panel of the boat, ensure that the cables have enough clearance to operate. This is necessary because the cables move up and down when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, the cables will be interfered with; this will cause very hard shifting. NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.

7873

Proper cable bend

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

7872

Improper cable bend 2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull, it does not have any extremely sharp bends in it as this will cause stiff shifting. IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends on tooshort cables result in kinks and toolong cables require unnecessary bends or loops. Both conditions place extra stress on the cables. IMPORTANT: Shift cable/throttle cable lubrication points use 24C with Teflon. 3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.

b c

d
a - Remote control end b - Engine end
Tube Ref No.
95

7874

c - Adjusting barrel d - Lubricating point

Where Used Shift cable end Part No. 92-802859A1

Description 2-4-C Marine Lubricant with Teflon

NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GEN II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.) thickness. Cable radius at any one point must not be less than 305 mm (12 in.).
4000 GEN II Series Panel Mount Remote Control Description Mounting surface maximum thickness Minimum cable bend radius at any point Specification 25 mm (1 in.) 305 mm (12 in.)

4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 cm (3 ft) of the control box.

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DRIVE SYSTEM AND ENGINE INSTALLATION

5. Ensure that the cable is not permanently kinked. 6. Ensure that there is proper clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE. 7. Ensure that the engine was not set down on the intermediate shift cable during installation, as this will crush the inner cable tubing and cause improper and / or stiff shifting. 8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of the shift plate. 9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1.5 m (5 ft) of the shift plate. 10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud.

NOTE: Lubricate attaching points with engine oil.

Description SAE 30W Engine Oil Where Used Shift cable pivot points Part Number Obtain Locally

11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows:

NOTE: Cable route is the same for through transom and through prop exhaust. a. The cable should come through the transom, above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power steering valve and loop over to the shift plate on the engine, where it is connected to the anchor points on the shift plate. Following this routing will prevent the engine coupler from damaging the cable.

8995

Through prop exhaust shown

NOTE: NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the predelivery inspection 12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls. Refer to 90865523 Instruction Sheet for more information.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Paddle Wheel Speed Sensor Installation (If Equipped)

PARTS PROVIDED

e a b
ABCD

d c h f g
abcdeSpare pin yoke Wire retainer Connector Bracket Paddle wheel fghij-

i i j
29269

Flat washer (2) #10 19 mm (3/4 in.) screw (4) Cable cap #6 12 mm (1/2 in.) screw (4) Clamp (2)

SELECTING LOCATION
Single engine installation Mount paddle wheel on the transom where the propeller blade is rotating downward. Usually the right (starboard) side to minimize cavitation. If feasible, mount at least 50 mm (2 in.) beyond the swing radius of the propeller. Dual engine installation Mount the paddle wheel between the engines as close to the center line (keel) of the boat as possible. On slower, heavier displacement boats, however, positioning it farther from the keel is acceptable.

NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes or outlets for live wells or any protrusion that may cause turbulence or cavitation.

TRANSOM ANGLE REQUIREMENTS

Standard 13 to 20 transoms No special adjustment required.

29272

a - 13 transom angle

b - 20 transom angle

Stepped or undercut transom with 3 angles A small shim of tapered plastic, metal or wood must be fabricated and installed as shown. Mount the paddle wheel on the step for best performance.

a
29276

a - Shim

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

INSTALLING BRACKET
1. Cut out the template. At the location selected, tape the template to the transom. Make sure the black dotted line on the template is aligned with the transom bottom edge, as shown.

NOTE: The mounting template provided is located on the last page of this instruction sheet. 2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on the template. To prevent drilling too deeply, wrap masking tape around the drill bit 22 mm (7/8 in.) from the point end of drill bit. NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drilling about 1.5 mm (1/16 in.) deep to prevent surface cracks. 3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to the two #10 screws provided. Using the washer provided, attach and tighten the bracket to the hull making sure the bracket is flush with the underside of the hull. 4. Fill any gap between the housing and the transom with a caulking material, as shown. Using a putty knife, smooth the surface to ensure proper water flow.

a b

c
a - Template b - 50 mm (2 in.) c - #10 screw

29282

d - Flat washer (2) e - Caulking

ROUTING THE CABLE

DRILLING HOLE THROUGH TRANSOM (OPTIONAL) 1. Select a transom location for the hole above the water line that does not interfere with other cables and controls. 2. Drill a 15 mm (5/8 in.) diameter hole. 3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or a comparable marine sealer after the cable has been routed through.

NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. The hole for the second clamp should be positioned halfway between the first clamp and the cap covering the transom hole drilled for the cable. 4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm (1/2 in.) deep. 5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads, install the cable clamps and feed the cable through cable cap.

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL) Route the cable over the transom or through a drain hole that is above the water line.

a b

c e d
29285

abcde-

Splash well drain hole Cable cap Cable clamp Paddle wheel assembly Distance between first cable clamp and top of paddle wheel 25.4 mm (1.0 in.)

INSTALLING AND REMOVING THE PADDLE WHEEL

Installation Slide the pins into the slots in the bracket and snap the tabs into place. Removal squeeze open (unlock) the tabs and pull on the paddle wheel.

b
a - Tabs b - Pins

29288

WIRING CONNECTIONS
IMPORTANT: Before making wire connections, make sure wires are routed through the transom.

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SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs inside the connector. Have the wiring routed through the transom. Push each wire terminal into its respective location in the connector. Push wire in until they snap into place. Secure wires into connector with the wire retainer.

DC BA

WHT YEL BL U BL K

D C BA
29289

b
a - Connector

b
b - Wire retainer

TEMPLATE - PADDLE WHEEL SPEED SENSOR

29291

a - Drill holes here b - Align dotted line with the transom bottom edge and fold under

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

NOTES:

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Power Trim Electrical Connection

NOTE: ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information) ABYC further recommends: if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also specified. MerCruiser has developed three methods to facilitate compliance with ABYC recommendations. These come in the form of one standard production and two accessory kits.

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ELECTRICAL SYSTEM

SECTION - 7

1. Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery. 2. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: The red current conductor (for the trim pump) must be: a. Connected to the switched side of the battery switch and either: i. provided with circuit protection within 7 inches of the power source or ii. Provided with circuit protection within 40 inches of the point of connection with the power source, sheathed the entire length of wire from the point of connection to the source and the circuit protection device. This will require the use of an accessory kit.
Part Number 8M2000587 8M2000588 Description Cable Assembly Trim Pump Cable Assembly Trim Pump Color Red Red Length 72 inches 40 inches Type Fused Sheathed

Batteries
Battery
IMPORTANT: Boating industry standards (NMMA, BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: It is recommended (required in some states) that battery be installed in an enclosed case. Refer to regulations for your area. IMPORTANT: Engine electrical system is negative () ground. 1. Select a battery that meets all of the following specifications: 12volt marine type cranking battery Deep cycle batteries are not recommended for cranking applications Tapered post connectors or side terminal connectors. IMPORTANT: Do not use a battery with wing nut connectors. Battery cables should always be tightened with a wrench. Spray terminals with a battery connection sealant to retard corrosion. The battery should have a capacity rating of at least:
Engine (Cyl./Type) V6 and V8 MPI models V8 DTS models Minimum Required Cranking Battery Size 750cca, 950 mca or 180 AH 800 cca, 1000 mca or 180 AH

Battery Cables
Select proper size positive (+) and negative () battery cables. Using the following chart, battery should be located as close to engine as possible. Add the positive (+) and negative () battery cable lengths together. Divide by 2 to obtain the average cable length. IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and a subsequent failure.

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90-899883178 NOVEMBER 2007

SECTION - 7 Cable Length Less than or equal to 1.1m (3.5 ft.) 1.1 1.8m (3.5 6 ft.) 1.8 2.3m (6 7.5 ft.) 2.3 2.9m (7.5 9.5 ft.) 2.9 3.7m (9.5 12 ft.) 3.7 4.6m (12 15 ft.) 4.6 5.8m (15 19 ft.)

ELECTRICAL SYSTEM Cable Gauge 25 mm2 (4) 35 mm2 (2) 50mm2 (1) 50mm2 (0) 70mm2 (00) 95mm2 (000) 120mm2 (0000)

Both positive (+) and negative (-) cables

Multiple MPI Engine Battery Information

Batteries: Boats with multiengine MPI power packages require each engine be connected to its own battery. This ensures that the engine's Electronic Control Module (ECM) has a stable voltage source. Battery switches: Battery switches should always be positioned so each engine is operating off its own battery. Do not operate engines with switches in BOTH or ALL position. In an emergency, another engine's battery can be used to start an engine with a dead battery. Battery isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.

NOTE: Sure Power Industries Inc., Model 32023A meets this design specification. 1. The boat may have 2 engines connected to a single Model 32023A battery isolator. 2. The Model 32023A battery isolator is connected to 2 banks of batteries. 3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank. 4. The second battery in each bank is connected in parallel to the cranking battery. 5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2 charging sources, 120 amps (maximum alternator output). 6. When the engines are operating, either engine's alternator could be charging either bank of batteries through the Model 32023A battery isolator. Any other manufacturer's battery isolator that is the same type as the Sure Power Inc., Model 32023A could also be used. Generators: The generator's battery should be considered another engine's battery.

Boat Harness and Installation Connections

Engine Harness and Accessory Power Supply
If the engine harness is used to supply power for boat accessories (lights, blower, pumps, stereo, or any other electrical device using the engine wiring harness for power), the maximum accessory power available on the 14pin wiring harness is 15 amps. Relay kits are available to provide additional accessory power at the helm. This maximum is fuseprotected and must be observed. If the fuse opens, the engine will stop and will not restart until the fuse is corrected.

Boat Wiring
NOTE: Twin engines are treated as two single engines in the same boat. No twin engine disconnect is required.

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ELECTRICAL SYSTEM

SECTION - 7

SINGLE STATION

25043

DUAL STATION

25041

On dual helm installations, use the extension harness from the engine to the lower station. Use the Yadapter to connect the upper and lower stations. Use the proper length harness from the Y to the lower station. Use the proper length harness from the Y to the upper station.

25132

Yadapter for dual helm installations

Boat Harness Installation GuidelinesMPI Sterndrive

BOAT HARNESS DEUTSCH CONNECTOR TO ENGINE
Select the boat harness by length.

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90-899883178 NOVEMBER 2007

SECTION - 7 Boat Harness Length of the Boat Harness 61 cm (02 ft.) 4.6 m (15 ft.) 6.0 m (20 ft.) 7.3 m (24 ft.) 8.8 m (29 ft.) 12.2 m (40 ft.) Boat Harness and Key Switch Three Position (off/run/start) 84896537 K02 84896537 K15 84896537 K20 84896537 K24 84896537 K29 84896537 K40

ELECTRICAL SYSTEM

Boat Harness (key switch is not included) 84896537 A02 84896537 A15 A84896537 20 84896537 A24 84896537 A29 84896537 A40

NOTE: Extension harnesses are available if longer length is needed.

KEY SWITCH CONNECTOR

1. A mounting bezel is not available for the three position key switch.

NOTE: 899203A01 Decal and washer kit is available for the three position key switch if needed.

25046

Typical three position key switch (off/run/start) 2. The four position key switch is available with mounting hardware.

25045

25044

Typical four position key switch (off/accessory/run/start)

NOTE: When installing the ignition verify that the drain hole in the barrel of the switch is positioned downward for proper drainage. 3. For dual helm installation, a key switch is used at the upper and lower station. The key switches must operate independently. IMPORTANT: For dual helm installation, both key switches used must be modified to operate independently. IMPORTANT: Cutting the black / yellow stripe wire disconnects the E stop circuit incorporated in the the key switch.

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ELECTRICAL SYSTEM

SECTION - 7

4. To modify the key switches, cut the black / yellow stripe wire at each key switch and cover both open wire ends with heat shrink tubing.

25136

Typical key switch a - Black/yellow stripe wire IMPORTANT: The key switch at the station being used should be the only key switch in the "run" position. If both station key switches are in the "run" position the engine cannot be turned off with the key switch and the lanyard stop switches will not function. 5. If a momentary stop switch is added, the "stop" switch will override the key switch and the engine will shut off when the stop switch is activated. 6. If a stop button is desired on a dual helm installation. the black wire and black/yellow stripe wire can be clipped at the key switch and connected to a normally open momentary button switch. Any marine momentary push button, rocker style or toggle switch could be utilized to create the "stop" switch. Label the switch on the dash after installation. 7. To Install a momentary "stop" switch: a. Cut the black wire at the key switch and cover the cut wire at the key switch with heat shrink tubing. b. Install an eye terminal on the black wire from the connector side. Cover cut wire ends with heat shrink tubing. c. Install an eye terminal on the black/yellow stripe wire from the connector side. Cover cut wire ends with heat shrink tubing. d. Connect the black wire and the black/yellow stripe wire eye terminals to a momentary switch.

d b

c
25137

Typical key switch with momentary "stop" switch for MPI models a - Black wire with eye terminals c - Eye terminals connected to momentary switch b - Black/yellow stripe wire with eye terminals. d - Momentary switch

TRIM SWITCH
The trim switch connection is only used on Mercury outboards. MerCruiser models require a separate trim harness from the trim control to the power the trim pump connection. A Yharness is available with adapters to connect the dual helm power trim harnesses together to connect to the power trim pump. DTS models do not need the separate trim harness.

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90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Use the power trim adapter harness for the single helm harness connection the remote control to the power trim pump.

25166

Power trim adapter harness For dual helm installation, use a power trim extention harness from the upper and lower helm to a Yharness.

25168

Power trim extention harness An adapter connects the Yharness to the power trim pump, (The original hog nose Yharness).

25171

25172

Power trim Yharness

Power trim adapter harness

NEUTRAL SWITCH
The neutral switch connects to the remote control. On dualhelm installations, the lower and the upper station controls need a neutral safety switch.

LANYARD STOP SWITCH

PPL and PPL/WHT wires are connected together through a normally closed stop switch. When the lanyard is pulled and the switch is tripped, the circuit is opened and the power to the engine, ECM, or ignition system is interrupted and the engine is shut off. If a lanyard stop switch is not used, or an E stop switch is used, these two wires must be plugged together for the engine to run.

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ELECTRICAL SYSTEM

SECTION - 7

OPTIONAL E STOP
The E stop lanyard switch connection is used on Mercury outboards and can be used on MerCruiser MPI engines. The black and black/yellow wires are connected together through a lanyard switch that is normally open. When the lanyard is pulled and the switch is is tripped, the circuit will close and ground the ECM to shut the engine off. When this connection is not used, the wires should be kept separate and capped.

WARNING HORN
The audio warning horn and connections are included with the Mercury harness assemblies. (Another horn is also supplied with the engine for those using custom wiring systems.)

ACCESSORY RELAY CONNECTION

Accessory relay kit connection. The 14-pin wiring system is able to provide up to 15 amps of accessory power to the helm through the purple wire (key controlled) or the red wire (constant on) circuit. This harness is fuse protected on the engine with a 15amp fuse on the engine. If the fuse is blown, the engine will not start or continue to run. An accessory relay kit connected to this location can provide up to 40 amps of accessory power. The key switch will powerup the relay in the "accessory" position and "run" position.

25048

Relay With Power Harness

ADDITIONAL RELAY KIT

An additional 40amp relay kit can be installed and connected to a junction box at the dash gauge connection location. This location will power up with the key in the "run" position only. The use of both relay kits will result in a maximum of 80 amps of key controlled power at the helm. This multiplies out on dual engine and dual helm applications as long as the power wires to the helm are adequate to carry the total current demand.

25144

Accessory relay harness

GAUGE CONNECTION
The gauge connection of the boat harness connects to the analog gauge harness. If SmartCraft instrumentation is used, connect to a a SmartCraft junction box.

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90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

If a combination of SmartCraft and analog is used, an AGI (analog gauge interface) kit is used to provide analog instrumentation. The AGI harness connects to the junction box along with the SmartCraft connection. IMPORTANT: The AGI requires setting the tachometer signal to digital with CDS or DDT.

AGI (Analog Gauge Interface)

Length of the Harness 1.5 m (5 ft.) 3.0 m (10 ft.) 4.6 m (15 ft.) Analog Gauge Harness (14 pin) 84892990T01 84892990T10 84892990T15

IMPORTANT: On dualhelm installations, the oil pressure sender and the cooling temperature sender must be changed to special dualhelm senders, unless the SmartCraft and an AGI kit are used.

i j f e d c b

25052

abcde-

Analog gauge harness Connector to boat harness Trim Tach Key on (+) Temp

fghij-

Oil Ground () Can (+) or spare Can () or spare 12V (+)

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ELECTRICAL SYSTEM

SECTION - 7

A system link adapter can be used to connect SmartCraft link gauges without a System Gauge (requires resetting tach signal to digital with CDS or DDT) fuel tank and trim gauge setting will be defaulted. There is no provision with link gauge to calibrate these gauges.

25147

System Link SC 100 adapter

CAN P (CAN 1) CONNECTIONS

CAN P (CAN 1) connection with a terminator resistor in place: If a this is a dual engine and the SmartCraft instrumentation is used, the terminator resistor is removed and a jumper harness connects the CAN P (CAN 1) lines together so that the engines will share SmartCraft data. The resistors on the engines are the required terminator resistors for the SmartCraftequipped dual engine applications. If the boat is dual engine and dual helm, the terminator resistor at the lower helm is removed from the connector. The jumper harness is installed at the upper station.

25149

Two pin link harnessCAN

CAN V (CAN 3) CONNECTION

CAN V (CAN 3) connection is not currently used by MerCruiser. Leave the protective cap in place.

GENERAL REPOWER INFORMATION

Harness adapters are used for installing 14pin engines into boats with 10pin wiring harnesses and 10pin engines into boats with 14pin wiring harnesses.

25054

14pin engine to 10pin boat wiring harness 25054 a - 10pin boat harness connection b - 14pin engine connection

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ELECTRICAL SYSTEM

NOTE: The adapter used with 10pin engine to 14pin boat wiring harness includes a 15amp fuse.

25055

10pin engine to 14pin boat wiring harness a - 10pin engine connection c - 14pin boat harness connection b - 15amp fuse For repower of the original 10pin engines with the 14pin engines: If adapters are used, a separate CAN (blue data cable) harness is required for SmartCraft instrumentation. Remove the terminator resistor on the engine and connect the CAN harness If a 14pin engine (limited to 15 amps of current draw) is installed into a 10pin wired boat, boat accessories may need to be rewired to meet the new amperage load limitation. Accessory kits are available to provide additional amperage to the helm. The fuel tank, auxiliary tank, and paddle wheel harness has been changed on MerCruiser to match the harness used by Mercury Outboard. The new harness is needed to replace the original harness for any 10pin engine installation using SmartCraft fuel level or paddle wheel.

a f

d
25150

Typical MPI engine a - 14pin connector b - 16pin transom harness connector c - DLC and depth transducer connector

d - Fuel paddle wheel connector e - Standard terminator resistor (remove and connect CAN harness if necessory for repower) f - 50amp circuit breaker
Part Number 84859743T03

Qty. 1

Description Fuel tank, auxiliary tank, and paddle wheel harness

TRANSOM HARNESSMPI
This transom harness is designed so that connections can be made after the transom is installed in the boat but before the engine is installed. Connections made before the engine is installed are: Mercathode connection Trim connections Ground connection

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ELECTRICAL SYSTEM

SECTION - 7

SmartCraft sensor connections Secure the wiring and position the engine connector out of the way until the engine is installed. After the engine is in place, make the single connection between the transom and the engine.

b a h
25155

g f
abcd-

d e

Transom harnessMPI 16pin connector to engine harness SmartCraft steering sensor SmartCraft petot sensor MerCathode

e - Trim gauge sender (orange with white stripe is for analog gauges) f - Trim gauge sender ground (black is common) g - Trim gauge sender (orange with pink stripe is for digital gauges) h - Transom ground (to the transom bonding screw)

TRANSOM HARNESSDTS
DTS engines are shipped with an adapter to connect the transom harness to the power trim pump.

c d e f

j g a i
abcdeTransom HarnessDTS 16pin connector to engine harness Power trim connects to power trim harness (color coded) SmartCraft steering sensor SmartCraft pitot sensor Trim gauge sender for analog gauges

h
25154

f - MerCathode g - Transom ground (to the transom bonding strap screw) h - Trim gauge sender for digital gauges i - DTS power trim harness connects to power trim pump j - DTS power trim harness connects to transom DTS harness

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90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

TRANSOM GROUND CONNECTION

The ground wire for the transom is incorporated into the transom harness included with the engine. Connect the ground wire in the transom harness under the bonding strap screw on the transom. Do not connect any other ground wires here. Use the ground studs on the flywheel housing for other grounding needs.

NOTE: In some cases, a ground wire to connect to the flywheel housing may be attached to the bonding screw on the transom. This ground wire is not needed with the transom harness,but can be connected to the flywheel housing or removed. In any case the grounding wire in the transom harness must be connected to the bonding strap screw.

25173

Ground wire from the transom harness to the transom bonding strap screw a - Bonding strap screw b - Ground wire from transom harness

90-899883178 NOVEMBER 2007

Page 15 / 38

ELECTRICAL SYSTEM

SECTION - 7

Wiring Diagrams
Transom HarnessMPI
a
C B A

BLK-PNK PNK-DK BLU

L R

GRA-BLK

BLK-PNK GRA-BLK
R

A C B

WHT-LT BLU

c
1

ORN-PNK

A B C D E F G H J K L M N P R S

GRA-BLK BLK-PNK WHT-LT BLU PNK-DK BLU ORN-PNK ORN-WHT ORN BRN BLK BLK
L R

ORN-WHT

ORN BRN

B A

d e

BLK

g
abcdSteering Pitot Analog trim Mercathode efgh-

23812

Analog trim Ground Digital Trim 16 pin connector

Page 16 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Transom HarnessDTS
b
BLK-PNK ORN-PNK GRA-BLK
A C B

C B A

BLK-PNK PNK-DK BLU

L R

GRA-BLK

BLK-PNK GRA-BLK
R

A C B

WHT-LT BLU

d
1

A B C D E F G H J K L M N P R S

GRA-BLK BLK-PNK WHT-LT BLU PNK-DK BLU ORN-PNK ORN-WHT ORN BRN BLK BLK
L R

ORN-WHT

e
ORN BRN
B A

BLK

GRN DK BLU BLK

PPL

k
1 1

g j
abcdef-

23810

h
ghijkGround Trim down Relay power Trim up 16 pin connector

Steering Digital trim Pitot Analog trim Mercathode Analog trim

90-899883178 NOVEMBER 2007

Page 17 / 38

ELECTRICAL SYSTEM

SECTION - 7

Boat Harness
DRAWING

2 7 1 11 10 4 3 8 5 9
1234514pin Deutsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 - Lanyard (outboard) or E Stop connection
12340

7 - Warning horn 8 - Accessory relay connection (15amp) 9 - Gauge connector/CAN connector for SmartCraft 10 - CAN P (CAN 1) with resistor cap 11 - CAN V (CAN 3) with weather cap

Page 18 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

DIAGRAM
A B A B

ORG GRN

WHT DKBLU

A B

RED BLK ORG GRN PPL GRY YEL WHT DKBLU PPL_WHT BLK RED

A B C D E F G H J K A B C

8 7
1 1

PPL

1
BRN

PPL_WHT

PPL

A B C D E F G H J K L M N P

GRN YEL_RED GRY BRN YEL GRN_WHT BLU_WHT DKBLU WHT ORG BLK_YEL PPL BLK RED

BLK

BLK_YEL

BLK

6
1
PPL

YEL_RED

4
1

RED
RED BLU_WHT GRN_WHT RED BLK PPL_WHT PPL BLK_YEL YEL_RED

3 2
12339

A B C A B C D E F

12345-

14pin Deutsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 - Lanyard (outboard) or E Stop connection

78910 11 -

Warning horn Accessory relay connection (15amp) Gauge connector CAN P (CAN 1) with resistor cap CAN V (CAN 3) with weather cap

NOTE: Dual engines are treated as two singles in the same boat and are not connected together. NOTE: The lanyard stop switch (PPL and PPL/WHT wires) breaks power to the ECM or ignition to stop the engine. The switch is normally closed until activated. Therefore the PPL and PPL/WHT wires must be connected together if Lanyard Stop Switch is not used, or if the E Stop Switch is used. NOTE: E Stop Switch (BLK and BLK/YEL wires) connects ground to ECM to stop engine. The switch is normally open; the circuit closes when switch is activated. Wires must be separate unless connected through E Stop Switch. Up to 15 amps total accessory power can be provided; on purple wire (switched) and the red wire (continuous power). An accessory relay kit can be used for loads up to 40amps. Refer to the MerCruiser Parts and Accessory Guide or MerCruiser Rigging Guide

90-899883178 NOVEMBER 2007

Page 19 / 38

ELECTRICAL SYSTEM

SECTION - 7

Analog Gauge Harness

DRAWING

8 9 10

2 3 4 5 6 7
12312

12345-

Connector to boat harness Trim Tach Key on (+) Temp

678910 -

Oil Ground () CAN (+) or spare CAN () or spare 12V (+)

DIAGRAM
BRN_WHT

2 3 4 5 6 7

GRY

PPL

A B C D E F G H J K

DK_BLU WHT BRN_WHT GRY PPL TAN LTBLU BLK RED

TAN

LTBLU

BLK

WHT

8 9 10
12318

DK_BLU

RED

12345-

Connector to boat harness Trim Tach Key on (+) Temp

678910 -

Oil Ground () CAN (+) or spare CAN () or spare 12V (+)

Page 20 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly)
a b

c
a - Connection to control box b - Connection to trim pump

12323

c - Connections to trim limit switch

90-899883178 NOVEMBER 2007

Page 21 / 38

ELECTRICAL SYSTEM

SECTION - 7

b
A
C1

B
DK BLU-WHT

RED

GRN-WHT RED

3 1
C2

4 2

PPL-WHT DK BLU-WHT

a
1
T2 T1

c
a - Connection to control box b - Connection to trim pump

1
12322

c - Connections to trim limit switch

Page 22 / 38

90-899883178 NOVEMBER 2007

GRN-WHT

SECTION - 7

ELECTRICAL SYSTEM

Power Trim System

BLU/WHT

BLK GRN/WHT

RED

BLK

a
RED/PPL

c
BLU/WHT

RED

BLK

e
YEL/RED YEL/RED RED/PPL GRN/WHT PPL/WHT
BLU/WHT

GRN/WHT

d g f
BLU/WHT

BLK

7866

abcd-

20 A fuse Ground bolt (floor mount) UP solenoid DOWN solenoid

e - 110 A fuse f - Yharness (optional) g - Neutral switch to instrument wiring harness h - Trim limit switch

90-899883178 NOVEMBER 2007

Page 23 / 38

BLK

ELECTRICAL SYSTEM

SECTION - 7

Adaptor Harness for Power Trim PumpDTS

A B C

PPL DK BLU GRN

a - To power trim pump b - To transom DTS harness

1 1
d
23809

b c

c - To transom DTS harness d - Not used on DTS

14Pin Engine Harness Connector

Mechanical 14Pin Connector PinOut Pin A B C D E F G H J K L M N P PINK BLACK PURPLE DK GREEN/YELLOW DK BLUE WHITE LT BLUE Open Open ORANGE/WHITE BROWN/DK BLUE GRAY/WHITE YELLOW/BLACK TAN Wire Color + 12 Volt Ground () Wake EStop Analog oil pressure CAN 1+ CAN 1 Spare Spare Analog trim position Audio warning horn Tachometer/Link gauge Crank Analog coolant temperature Function

DTS Information and Installation

Special Tools DTS Installation
Data Cable Puller 91888462A1

Installation Guidelines for DTS System Components

! WARNING
Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control. To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system.

Page 24 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

DATA HARNESS

! WARNING
Prevent serious injury or death from a loss of boat control. Pulling on or flexing connectors can loosen terminals and cause open or intermittent electrical connections, which will interrupt control of throttle and shifting. Do not pull on cable connectors when pulling cables through the boat. Do not allow cables to flex at connection points. Fasten all electrical harnesses within 25.4 cm (10 in.) of any connection.

CONNECTORS
IMPORTANT: Connectors should never have to be forced into the receptacle. Ensure that connectors are free of any lubricant or dielectric grease before installation. When the connector is properly aligned, it will only take a small amount of pressure to insert it into the receptacle. Rotate the locking collar to secure the electrical connection.

NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than 12.2 m (40 ft.), contact Mercury Marine for more information.

Weather Caps
Weather caps are to be used whenever there are any unused connectors on a harness. Verify all connections are tight to prevent moisture or corrosion occurring inside the connections. Typical weather caps are as follows:

4958

a
a - 10 pin cap b - 5 pin cap

d
c - 3 pin cap d - 2 pin cap

DTS Battery Specifications

IMPORTANT: Do not use deep cycle batteries for the main engine starting battery. IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: It is recommended (required in some states) that the battery be installed in an enclosed case. Refer to regulations for your area.
Minimum SAE Starting Battery Requirements BCI GRP 24 MCA CCA Ah 1000 800 180 (International Rating)

NOTE: Due to the wide variety of battery manufacturers throughout the world, ratings and physical battery sizes will vary. Check with the manufacturer for a starting battery with a MCA, CCA, or Ah specification that will be equal to or greater than the SAE Standard J537 specified previously.

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ELECTRICAL SYSTEM

SECTION - 7

IMPORTANT: For DTS products, each engine must be equipped with its own starting battery. If your boat application requires additional battery loads for boat accessories or marine electronics, it is recommended that an auxiliary battery or batteries be installed.

! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery posts with hex nuts to avoid loose connections. When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to specifications.
Description Hex nuts Nm 13.5 lb. in. 120 lb. ft.

IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine installation manual for size requirements. Spray terminals with a battery connection sealant to help retard corrosion. Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied.
NOTICE - DTS & Optimax Engines
DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating. 13.5Nm (120 lbs. in.)

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
37-895387 Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.

DO NOT USE WING NUTS.

3486

Junction Box (if Equipped)

Although the junction box connections are watertight, it is recommended that the junction box be mounted in an area that stays relatively dry. Mount in an area where the wiring connection will not get stepped on or disturbed. Mount in an area that is accessible for troubleshooting and servicing the system. Ensure the DTS command module harness will reach all the connection points. Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.

Page 26 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Seal all unused connections with weather caps.

b a d

e
29220

a - Clamp b - Weather cap (859318T 2) c - Junction box

d - 25.4 cm (10 in.) e - DTS command module harness

Data Harness Installation

Data Harness Pulling Procedure
IMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads, and spark plugs), high power VHF coax, or radios. An electrical field generated from these components could cause interference with data transmission. IMPORTANT: Do not route data harness near sharp edges, hot surfaces, or moving parts. Fasten cables away from any sharp edges, fasteners, or objects that could wear into the harness. IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be 7.6 cm (3 in.) for the final wiring installation. 1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs that could cut the harness. 2. Install cable pulling tool to data harness. 3. Secure pulling tool with two cable ties. IMPORTANT: The cable ties must be tight to prevent any slipping during installation.

3836

Data Cable Puller

91888462A1

IMPORTANT: Carefully inspect data harness pins to ensure all pins are securely fastened to data harness connector end following installation.

NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.

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ELECTRICAL SYSTEM

SECTION - 7

Connecting 14 Pin Data Harness Single Engine

SINGLE HELM
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).

b a

3619

a - 14 pin data harness

b - Clamp or cable tie

DUAL HELM

c d

e
a - 14 pin data harness b - Helm 2 (upper helm) auxilary c - Helm 1 (lower helm) primary

3682

d - Dual helm adapter (Y harness) e - Clamp or cable tie

Page 28 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Connecting 14 Pin Data Harness Dual Engine

SINGLE HELM
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).

b
a - 14 pin data harness

3977

b - Clamp or cable tie

DUAL HELM
a

c b c

e
a - Helm 2 (upper helm) b - Helm 1 (lower helm) c - 14 pin data harness

3978

d - Dual helm adapter (Y harness) e - Clamp or cable tie

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Page 29 / 38

ELECTRICAL SYSTEM

SECTION - 7

DTS Command Module and Harness Installation

Installing DTS Command Module and Harness Single Engine
HARNESS INSTALLATION
Locate a routing path for the harness connections so they reach their installation points. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness. Fasten and support the harness with clamps or cable ties along the routing path. Make sure all connections are tight and seal all unused connectors with weather caps.

b
3622

Single Helm Application a - DTS command module harness

b - Clamp or cable tie

Page 30 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

NOTE: For dual helm application Remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm closest to the engine), and seal connectors with weather caps.

Terminator CAN 1

Terminator CAN 2

f d h g b c

d
3677

abcd-

Dual Helm Application Helm 2 (upper helm) Helm 1 (lower helm) DTS command module harness Clamp or cable tie

efgh-

CAN P (CAN 1) connector CAN X (CAN 2) connector Weather caps Terminator resistors, blue (CAN P and CAN X)

MODULE INSTALLATION
Although the Command Module connection is watertight, it is recommended that it be mounted in an area that stays relatively dry. Mount in an area where the wiring connection will not get stepped on or disturbed. Mount in an area that is accessible for troubleshooting and servicing the system. Ensure the wiring harness connected to the command module will reach all the connection points.

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Page 31 / 38

ELECTRICAL SYSTEM

SECTION - 7

Mounting the Command Module with the supplied rubber grommets/bushings to minimize vibration.

3939

a - DTS Command Module

Installing DTS Command Module and Harness Dual Engine

HARNESS INSTALLATION
Locate a routing path for the harness connections so they reach their installation points. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness. Fasten and support the harness with clamps or cable ties along the routing path.

Page 32 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Make sure all connections are tight and seal all unused connectors with weather caps.

c a
Terminator CAN 2
Terminator CAN 1

b
Terminator CAN 2

Terminator CAN 1

d
Single Helm Application a - CAN link harness b - CAN X (CAN 2) Terminator resistors do not remove c - CAN P (CAN 1) connectors

e
3689

d - Clamp or cable tie e - DTS command module harness

90-899883178 NOVEMBER 2007

Page 33 / 38

ELECTRICAL SYSTEM

SECTION - 7

NOTE: For dual helm application Remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm closest to the engine), and seal connectors with weather caps.

b c

e a d

1
4079

Dual helm application a - Weather caps b - CAN link harness c - Helm 2

d - DTS Command Module harness e - Termination resistors do not remove from helm 2 f - Helm 1

Page 34 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

Ensure the wiring harness connected to the command module will reach all the connection points.

4080

a - DTS Command Module

Analog Gauge Interface (AGI)

Analog Gauge Interface (AGI) Installation
NOTE: This Analog Gauge Interface (AGI) can only be used with the 14 pin Digital Throttle and Shift (DTS) system to drive analog and/or SmartCraft System Link gauges. For analog gauges, use ring terminals on AGI harness to connect to analog sender inputs on gauge backs, and tape back any unused terminals. For SmartCraft System Link gauges, use 3 pin System Link connection on AGI harness. The AGI system can support 10 System Link gauges per helm, 2 helms maximum. IMPORTANT: Mount AGI module with wires coming out of potting facing downward to prevent moisture from collecting at base of wires and wicking into module. Route and secure all wires and harnesses away from hot or moving parts. 1. With screws and washers supplied in kit, mount the AGI module securely under dash or helm in close proximity to gauges being used. 2. Refer to the following table for AGI harness wire color/analog gauge sender input connections. Tape back any unused terminals. Secure connections per gauge manufacturers specifications.
Analog Gauge Type Tachometer Oil Pressure/Oil Level Water Temperature Trim Positions AGI Harness Wire Color Gray Blue Tan Brown/White

90-899883178 NOVEMBER 2007

SECTION - 8

Lubricant, Sealant, Adhesives

Tube Ref No.
95

Description 2-4-C Marine Lubricant with Teflon

Where Used Shift cable end

Part No. 92-802859A1

Special Tools
Dual Water Pickup Flush Gearcase Seal Kit 91881150K 1

Blocks off the front water inlet holes on the dual water inlet gearcases.
9194

Flushing Device

9144357Q 2

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

9192

Flushing Kit

91849996T 1

Use for flushing gearcases with low water inlets.

9195

Male to Male 10 Pin Adapter

84892452A01 Allows connection between CAN 1 communications cable and Computer Diagnostic System in applications where a junction box is not used. 84892663

4621

Can 1 Diagnostic Cable

Connects into a junction box or male to male adapter cable for Command Module configuration. Not for use with DDT.
4680

Adapter Harness

84822560A13 Data link harness between engine and Computer Diagnostic System (CDS) or Digital Diagnostic Terminal (DDT).
5826

Page 2 / 28

90-899883178 NOVEMBER 2007

SECTION - 8 Computer Diagnostic System (CDS)

REMOTE CONTROLS Order through SPX Monitors all electrical systems for proper function, diagnostics. and calibration purposes. For additional information, pricing, or to order the Computer Diagnostic System contact: SPX Corporation 28635 Mound Rd. Warren, MI 48092 or call: USA 18003452233 Canada 8003452233 Europe 49 6182 959 149 Australia (03) 95446222 SPX P/N MM46225

4520

Breakout Box

Connects to Propulsion Control Module (PCM) to test engine circuits and components without probing wires. May be used with Computer Diagnostic System (CDS).
5974

Terminal Test Probe Kit

SPX P/N MM46523

Test probes adapt test meter leads to harness connections without damaging harness terminals. May be used with Computer Diagnostic System (CDS).
7915

12 Volt Shunt Connector

889675A01 Connects to data harness allowing operation of the DTS system with the Digital Diagnostic Terminal.
8036

Adapter Harness

84822560A5 Data link harness between engine and Digital Diagnostic Terminal (DDT).
4009

2 to 4 Pin Harness Adapter

84822560A12 Adapts the 2 pin Digital Diagnostic Terminal harness to the 4 pin connector on the engine.
4679

90-899883178 NOVEMBER 2007

Page 3 / 28

REMOTE CONTROLS DMT 2004 Digital Multimeter 91892647A01

SECTION - 8

H z TEMP mA V Hz mV
OFF

A
IG IP
TEMP

Measures RPM, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately reads in high RFI environments.
Hz

COM

4516

Remote Control Installation

Locating and Drilling Mounting Area
1. Locate area of boat where the remote control is to be mounted. Allow sufficient clearance for handle movement and clearance for the wiring. 2. Select the correct template for mounting application. 3. Place template over mounting area; cut and drill as instructed on template. IMPORTANT: After cutting mounting area, make sure opening is free of sharp edges.

3600

a - Template

Installing DTS Panel Mount Control

1. Ensure opening is free of sharp edges. 2. Route wiring for the remote control into opening.

26744

3. Connect trim harness and lever harness.

Page 4 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

4. Insert the bayonet end into bracket hole. This will prevent connector from pulling out. IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle movement.

a
5086

a - Trim harness 5. Place the remote control into the opening.

b - Lever harness

3250

6. Fasten the remote control with three #12 x 1.25 in. long screws.

a a
3251

a - Mounting screw (3) 7. Control Handle Tension Adjustment This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "" to decrease tension.

90-899883178 NOVEMBER 2007

Page 5 / 28

REMOTE CONTROLS

SECTION - 8

8. Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "" to decrease tension.

3252

a - Control handle tension adjustment screw b - Detent tension adjustment screw 9. Install front and back bezel covers with attaching screws.

b c

3254

a - Front cover b - Back cover

c - Screw (2) M4 x 12

Installing DTS Single Handle Console Control

1. Ensure opening is free of sharp edges. 2. Route wiring for the remote control into opening.

3509

3. Connect trim, lever and trackpad harnesses. 4. Insert the bayonet end of the lever harness into bracket hole. This will prevent connector from pulling out.

Page 6 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle movement.

b c a
5098

a - Trim harness b - Lever harness 5. Place the remote control into the opening.

c - Trackpad harness

3296

90-899883178 NOVEMBER 2007

Page 7 / 28

REMOTE CONTROLS

SECTION - 8

6. Fasten the remote control with four M6 x 40 long screws.

b c
a - Mounting screw (4) M6 x 40 b - Washer
3297

c - Nut nylon insert

! CAUTION
Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket. 7. Control Handle Tension Adjustment Screw This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "" to decrease tension. 8. Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "" to decrease tension.

b
5102

a - Detent tension adjustment

b - Control handle tension adjustment

Page 8 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

9. Install the side cover with attaching screws.

b a
3298

a - Attaching screws (4) M4 x 20

b - Side cover (2)

Installing DTS Dual Handle Console Control

1. Make sure opening is free of sharp edges. 2. Route wiring for the remote control into opening.

3606

3. Insert the bayonet ends into bracket holes. This will prevent connectors from pulling out.

90-899883178 NOVEMBER 2007

Page 9 / 28

REMOTE CONTROLS

SECTION - 8

IMPORTANT: Allow slack in the trim button harness going to the control handle. This harness will flex and move during control handle movement.

b c d

a
a - Bayonet ends b - Trim button harness c - Blue paint dot 4. Place the remote control into the opening.

d - Yellow paint dot e - Starboard engine f - Port engine

3305

3306

Page 10 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

5. Fasten the remote control with four M6 x 40 screws.

b c
a - Mounting Screw (4) M6 x 40 b - Washer
3307

c - Nut nylon insert

! CAUTION
Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket.

! CAUTION
Overtightening the detent tension adjustment screw can damage the control module. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket. 6. Control Handle Tension Adjustment Screw This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "" to decrease tension. 7. Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "" to decrease tension.

b
5102

a - Detent tension adjustment

b - Control handle tension adjustment

90-899883178 NOVEMBER 2007

Page 11 / 28

REMOTE CONTROLS

SECTION - 8

8. Install the side cover with attaching screws.

a b

3308

a - Side cover (2)

b - Attaching screws (4) M4 x 20

Installing DTS Zero Effort Control

1. Ensure opening is free of sharp edges. 2. Route wiring for the remote control into opening. 3. Connect trim, lever and adaptor harnesses.
G RN/W HT G RN/WHT B LU/W HT B LU/W HT

b
R ED

LEVER 1

f
5181

a - Throttle adaptor harness b - Remote control c - Trim harness

R ED

d - Trackpad not used e - Lever 1 harness (blue) f - Trim adaptor harness

Page 12 / 28

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

4. Ensure the control is positioned so the forwardneutralreverse (FNR) decal is in the correct orientation.

b c d

5184

b c d a

5182

Forward Cant Models a - Reverse b - Neutral

Aft Cant Models c - Forward d - FNR decal location

5. Ensure the control is position so the forwardneutralreverse ("FNR") decal is in the correct orientation.

a b

c
a - Throttle lever b - Trim switch

c b
c - Shift lever d - "FNR" label

a
4749

NOTICE
Chipped paint can lead to rapid corrosion. Always install a nylon washer between each screw and the control plate.

90-899883178 NOVEMBER 2007

Page 13 / 28

REMOTE CONTROLS

SECTION - 8

6. Secure control to the console using the 8 X 11/4 in. self tapping screws and nylon washers.

a b c d
5192

a - 8 X 11/4 in. self tapping screw (4) b - Nylon washer (4)

c - Control quadrant assembly d - Console

Sterndrive Shift Cable Information

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SECTION - 8

REMOTE CONTROLS

Left-hand (LH) propeller rotation drive unit - While turning propeller shaft CLOCKWISE, move remote control shift handle into full FORWARD position. Clutch should engage before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear. Retighten stud. Shift remote control several times and stop in FORWARD to recheck shift cutout switch position. Pin must be centered.

a b
7871

a - Adjustable stud

b - Shift interrupt switch plunger

Bravo Sterndrive Shift Check (Engine Running)

a b

4805

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REMOTE CONTROLS Flushing Device Flushing Kit 9144357Q 2 91849996T 1

SECTION - 8

4. Partially open water source until water continuously leaks out around the flushing device.

Troubleshooting Shift Problems

7873

Proper cable bend

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SECTION - 8

REMOTE CONTROLS

7872

b c

d
a - Remote control end b - Engine end
Tube Ref No.
95

7874

c - Adjusting barrel d - Lubricating point

Where Used Shift cable end Part No. 92-802859A1

Description 2-4-C Marine Lubricant with Teflon

4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 cm (3 ft) of the control box.

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REMOTE CONTROLS

SECTION - 8

NOTE: Lubricate attaching points with engine oil.

Description SAE 30W Engine Oil Where Used Shift cable pivot points Part Number Obtain Locally

11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows:

8995

Through prop exhaust shown

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SECTION - 8

REMOTE CONTROLS

DTS Remote Control Sterndrive

IMPORTANT: Boat must be equipped with Mercury electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in FORWARD or REVERSE.

T R I M
SO CL R L SE ET L C
F R

RN U
8994

The Digital Throttle and Shift System (DTS) required to operate this engine package provides start, stop, throttle, shift control, start in gear protection and emergency lanyard stop function. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide. The Digital Throttle and Shift system (DTS) works with specialized helm component, command module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.

DTS Calibration
Special Tools DTS Calibration
Male to Male 10 Pin Adapter Can 1 Diagnostic Cable Adapter Harness Computer Diagnostic System (CDS) 84892452A01 84892663 84822560A13 Order through SPX

Methods of Calibration
NOTE: DTS system calibration must be performed following complete system installation. It must also be completed after an accessory or replacement part is added to the system that requires new configuration codes. A DTS system reset must be performed prior to calibration, or if an error is made during the calibration setup. Mercury Marine Computer Diagnostic System (CDS) Connect the CDS to the CAN bus circuit and follow the helm configuration setup on the computer diagnostic screen.

Setting Trailer and Trim Limit

Setting Trailer Limit with CDS
IMPORTANT: Incorrectly configuring the trim limit using a DDT or CDS can create a programming error in the engine's PCM. Always set the trailer limit before setting the trim limit. If you configure the limit incorrectly, contact the Mercury Marine Technical Service Department for further instructions.

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REMOTE CONTROLS

SECTION - 8

The function of the trailer limit: Outboard - To limit the maximum tilt up position, preventing damage to the cowl. 1. 2. 3. 4. 5. 6. 7. MerCruiser - To limit the maximum trailer up position, preventing damage to swim platforms etc. Connect the CDS to the engine data link harness. Turn the ignition key to the "RUN" position. Select the correct engine location. Open the Tool Box icon in the CDS. Open the Active Diagnostics Icon. Scroll down the Active Diagnostics window and highlight "Trailer Limit". Run the trim system completely in (down) and hold the trim button in for 34 seconds. This will configure the PCM to recognize the maximum trim in position according to the trim position sensor. Run the test. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to store the current position in the ECU." Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.

8. 9. 10.

Setting Trim Limit with CDS

IMPORTANT: Incorrectly configuring the trim limit using a DDT or CDS can create a programming error in the engine's PCM. Always set the trailer limit before setting the trim limit. If you configure the limit incorrectly, contact the Mercury Marine Technical Service Department for further instructions. IMPORTANT: The engine must be running above 2000 RPM in gear to initiate the trim limit. The trim limit configures the PCM to control the maximum up trim limit. The trim limit function is only supported if the PCM has input for the three wire trim sensor. 1. Connect the CDS to the engine data link harness. 2. Turn the ignition key to the "RUN" position. 3. Open the Tool Box icon in the CDS. 4. Open the Active Diagnostics Icon. 5. Scroll down the Active Diagnostics window and highlight "Trim Limit". 6. Run the test. 7. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to store the current position in the ECU." 8. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.

Troubleshooting Procedure
Troubleshooting Information
NOTE: All of the following are determined by the calibration of the PCM. Upgrading the calibration can result in changes to these settings.

DEFAULT SENSOR VALUES

Default sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignition values, when the sensor in question has exceeded its preprogrammed diagnostic limits. Default sensor values typically are used when the sensor has a circuit high or circuit low fault. Most temperature sensors default to 0 C (32 F). This can be verified by unplugging the sensor in question and watching the data stream value with the CDS. Most pressure sensors default to a preprogrammed number also. MAP sensors usually default to 100 kPa (29.5 in. Hg). This can be verified by unplugging the sensor in question and watching the data stream value. Other pressure sensors will have their own default values which may be determined as described previously.

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SECTION - 8

REMOTE CONTROLS

FAULT CONDITIONS
Most faults can be detected with the engine running, or keyon, engine off. However, some faults require the presence of engine RPM, and cannot be detected keyon, engine off. Examples of this type of fault are EST (cylinders 1 through 8) shorted circuit and all injector faults (fuel and direct). Some faults are only detected in the keyon, engine off mode. Examples of the type of fault would be EST (cylinders 1 through 8) open circuit. In addition, some faults are programmed to ignore certain engine speeds. For example, the low block pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled until enough RPM has been achieved to develop a reasonable amount of water pressure. Therefore, this fault will not be set at idle. Faults also take a certain time to set. The time it takes to set a fault varies greatly and can also vary with engine RPM. Faults generally set faster at higher engine speed.

STICKY/NON-STICKY FAULTS
All faults are classified as either sticky or nonsticky. Sticky means that the fault, once set, will continue to show up as active, even if the circuit or problem has corrected itself. A key switch cycle is required to reset a sticky fault. A nonsticky fault is a fault that will change it's status from active to inactive without requiring a key switch cycle. TheCDS will continue to display a sticky fault as active, even though the cause of the fault has been corrected. Cycle the key to reset all faults if there is difficulty correcting a fault.

ENGINE GUARDIAN
Almost every fault will cause the guardian program (within the PCM) to become active. The amount of guardian protection is expressed as a percentage. The higher the percentage, the more power the engine is allowed to produce. If available power is showing 100%, then guardian is not currently active and the engine is capable of producing full power. On a DTS engine, guardian closes the ETC to reduce engine power. NonDTS engine reduce engine power by changing injector and ignition operation. Guardian is always accompanied by another fault or faults that actually caused the guardian to become active. The more severe the fault, the more the guardian reduces available power. A small problem, such as a noncritical sensor going circuit high or circuit low, will result in available power of 90% depending on product line. A severe problem such as low oil pressure, or a DTS shift or throttle actuator failing, will result in forced idle which is usually displayed as 56% available power. Several minor faults occurring at the same time will cause the PCM to treat the faults as a more severe situation.

WARNING HORN SIGNALS

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Boat out of the Water ............................................................................................................................... 36 Manual SinglePoint Drain System.................................................................................................................. 38 Boat in the Water ..................................................................................................................................... 38 Boat out of the Water ............................................................................................................................... 39 Three Point Manual Drain System..................................................................................................................40 Boat in the Water ..................................................................................................................................... 40 Boat out of the Water ............................................................................................................................... 41 MultiPoint Drain (MPD) System.....................................................................................................................42 Boat out of the Water ............................................................................................................................... 42 Boat in the Water ..................................................................................................................................... 44 Battery Storage...................................................................................................................................................... 46 Power Package Recommissioning........................................................................................................................ 46

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PREDELIVERY PREPARATION AND STORAGE

Lubricant, Sealant, Adhesives

Tube Ref No.
34 80 87 94 95 114 115 124

Description Special Lubricant 101 SAE Engine Oil 30W High Performance Gear Lubricant Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon Power Trim and Steering Fluid Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer

Where Used Propeller shaft splines Power trim pump Gear Lube Monitor Propeller shaft splines Propeller shaft splines Power steering pump Power trim pump Fuel system Fuel system

Part No. 92-802865Q02 Obtain Locally 92-858064K01 92-802867Q 1 92-802859A1 92-858074K01 92-858026K01 858071K01

Special Tools
Propeller Nut Tool 91805457T 1

Aids in the removal and installation of the front propeller nut.

10677

Flushing Device

9144357Q 2

Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.

9192

Flushing Kit

91849996T 1

Use for flushing gearcases with low water inlets.

9195

Dual Water Pickup Flush Gearcase Seal Kit

91881150K 1

Blocks off the front water inlet holes on the dual water inlet gearcases.
9194

90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Predelivery Preparation
Once the power package installation is complete, the following final steps should be taken to prepare power package for delivery to the customer. It is the boat manufacturer's responsibility to perform these procedures or to make arrangement with the dealer to have these procedures completed.

Engine Oil

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

CHECKING
1. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat must be at rest in the water. 2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.

NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end). IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. 3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and add. Fill as necessary with specified fluid. NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the ADD mark to the top of the OK range.

ADDING ENGINE OIL

IMPORTANT: Do not overfill the engine with oil. 1. Remove oil fill cap.

6077

a - Oil fill cap IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. 2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.

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90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

3. Replace the fill cap.

Power Steering Fluid

IMPORTANT: Use only specified lubricant. IMPORTANT: Running the pump dry will damage the pump. Always check steering fluid levels before operating the boat. 1. Position sterndrive unit so that it is straight back. 2. Remove fill cap from power steering pump and check fluid level using dipstick. Add fluid as required.

NOTE: Be prepared to add fluid to pump when first starting engine.

b
9356

a - Fill cap
Tube Ref No.
114

b - Dipstick
Description Where Used Power steering pump Where used Power steering pump Part No. 92-858074K01 Part Number Obtain locally

Power Trim and Steering Fluid

Description Dexron III Automatic Transmission Fluid

Power Trim Pump

1. Check oil level with sterndrive unit in the full DOWN/IN position. IMPORTANT: Use only specified lubricant.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

2. Raise and lower sterndrive unit (to the full UP/OUT position) 6 to 10 times to purge air from system. Check oil level visually, (with drive unit in the full DOWN/IN position). Oil level should be maintained within the "MIN" and "MAX" lines on the reservoir.

c
8539

a - Fill cap (top and underneath side views) b - Reservoir fill neck
Tube Ref No.
114

c - "MIN" and "MAX" lines

Description Power Trim and Steering Fluid Description SAE Engine Oil 30W

Where Used Power trim pump Where Used Power trim pump

Part No. 92-858074K01 Part No. Obtain Locally

Tube Ref No.

3. Check the power trim pump hose fittings for leaks. If fluid is visible at the fittings, check connections.

Drive unit gear lube monitor

IMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always check oil level when drive is cool and engine is shut down. 1. Remove the gear lube monitor cap. 2. Fill the gear lube monitor to the Operating Range (full) line.

7884

Typical a - Gear lube monitor cap

Tube Ref No.
87

b - Operating Range (full) line

Where Used Gear Lube Monitor Part No. 92-858064K01

Description High Performance Gear Lubricant

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90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

3. Ensure that the rubber gasket is inside the gear lube monitor cap. 4. Install the gear lube monitor cap. Do not overtighten. 5. Recheck gear lube level after first use.

Filling Coolant Recovery Bottle

NOTE: This section applies to Closed Cooled models only. 1. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution. Reinstall cap. 2. Recheck coolant level after first WOT boat test and add coolant, if necessary. 3. Maintain coolant level in coolant recovery reservoir between ADD and FULL marks with engine at normal operating temperature.

Alpha Trim Limit Switch Adjustment

ANALOG GUAGES

! CAUTION
Trimming the sterndrive creates pinch points, which can cause personal injury. Stay clear from the sterndrive when trimming or tilting. IMPORTANT: Follow these procedures exactly as outlined below. Incorrect switch adjustment can cause the drive unit to move beyond the gimbal ring support flanges, causing product damage. 1. Alpha sterndrive, adjust trim limit switch as follows:

NOTE: Trim limit switch is located on the port side of gimbal ring. a. Loosen screws and turn trim limit switch clockwise to end of slots.

b
7879

Trim limit switch a - Screws b. c. b - Slots

Ensure drive unit is in the full DOWN/IN position. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.

7880

Trim limit switch a - Rotate Counterclockwise To Adjust

a
7881

Alpha trim cylinder extended a - Maximum520 mm (203/4 in.) e. Retighten screws when adjustment is correct.

Bravo Trim Limit Switch Adjustment Analog Gauges

! CAUTION
Trimming the sterndrive creates pinch points, which can cause personal injury. Stay clear from the sterndrive when trimming or tilting. IMPORTANT: Follow these procedures exactly as outlined below. Incorrect switch adjustment can cause the drive unit to move beyond the gimbal ring support flanges, causing product damage. IMPORTANT: All Bravo models must have the triminlimit insert positioned properly before performing the trim position sender adjustment.

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90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

1. Ensure that the triminlimit insert is positioned as shown for the appropriate Bravo model.

8548

8557

Bravo One and Two (positioned forward) a - Triminlimit insert

Bravo Three (positioned aft)

2. Bravo sterndrive, adjust trim limit switch as follows: a. Loosen screws and turn trim limit switch clockwise to end of slots.

Trim limit switch a - Screws b. c.

16524

Ensure drive unit is in the full DOWN/IN position. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.

Trim limit switch a - Rotate Counterclockwise To Adjust

21675

a
8558

Bravo trim cylinder extended a - Trim Limit Dimension 213/4 in. (552 mm) e. Retighten screws when adjustment is correct.

Trim Position Sender Adjustment Analog Gauges

1. Loosen both trim position sender retaining screws.

a - Retaining screws

21676

b - Trim position sender

IMPORTANT: Do not start the engine during this procedure. 2. Turn ignition key to RUN position. 3. Trim sterndrive unit to the full DOWN/IN position.

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90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

4. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown.

a
7883

a - Trim gauge needle 5. Tighten retaining screws and turn ignition key to the OFF position.

a - Retaining screws

21674

b - Trim position sender

Trim Position Sender Adjustment SmartCraft Gauges Scan Tool Method

a - Trim position sender

21076

b - Retaining screws

1. Trim the sterndrive unit to the full DOWN/IN position. 2. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. 4. 5. 6.

Turn ignition key switch to the RUN position. Set the scan tool to display TRIM POS counts and note the value displayed. TRIM POS counts must be between 20 and 24 counts. If TRIM POS counts are within specified range, proceed to step 6. Otherwise: a. Loosen both trim position sender retaining screws. b. Rotate the trim position sender until TRIM POS counts are within the specified range, preferably near the middle of the range. c. Tighten the trim position sender retaining screws. d. Verify TRIM POS counts are still within the specified range. Repeat steps "a" through "c" if necessary. 7. Turn the ignition key switch to the OFF position, disconnect the scan tool from the Diagnostic Link connector, and install the weather cap in the Diagnostic Link connector.

Trim Position Sender Adjustment SmartCraft Gauges Multimeter Method

a - Trim position sender

21076

b - Retaining screws

1. Trim the sterndrive unit to the full DOWN/IN position. 2. Disconnect trim position sender wires from engine wiring harness connections. 3. Connect Multimeter leads to trim position sender wires and set Multimeter to display resistance (Ohms). 4. Note resistance reading. Resistance must be between 16 and 20 Ohms. 5. If resistance reading is within specified range, proceed to step 6. Otherwise: a. Loosen both trim position sender retaining screws. Rotate the trim position sender until resistance reading is within the specified range, preferably near the middle of the range. c. Tighten the trim position sender retaining screws. d. Verify resistance reading is still within the specified range. Repeat steps "a" through "c" if necessary. 6. Disconnect the trim position sender wires from the multimeter leads and reconnect trim position sender wires to engine wiring harness connections. 7. Refer to Mercury SmartCraft Operator's Manual for final Trim Calibration procedure. b.

Propeller Selection
IMPORTANT: Installed propeller must allow engine to run at its specified maximum WOT rpm. Use an accurate service tachometer to verify engine operating rpm.

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PREDELIVERY PREPARATION AND STORAGE

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. Specified engine WOT and operating rpm range are listed in the Mercury MerCruiser Operation, Maintenance and Warranty Manual attached to the engine. Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT operating rpm range with a normal load. If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage. After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch. Warmer weather and greater humidity cause a loss of rpm. Operating in a higher elevation causes a loss of rpm. Operating with increased load (additional passengers, pulling skiers) causes a loss of rpm. For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle when using the lower pitch propeller but not pulling skiers. Because of the many variables of boat design, only testing will determine the best propeller for a particular application. Available propellers are listed in the Mercury Precision Parts Accessories Guide. See BOAT IN THE WATER TESTS, Maximum RPM Test at the back of this manual.

Alpha Sterndrive Propeller Installation

7885

1. To aid in future removal of the propeller, liberally coat propeller shaft splines with lubricant.
Tube Ref No.
34

Description Special Lubricant 101

Where Used Propeller shaft splines

Part No. 92-802865Q02

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed through propeller nut after torquing it.

ALPHA MODELS
1. Install propeller with attaching hardware as shown. 2. Torque the nut, then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer. 3. Bend the 3 tabs down into grooves.

d e a b c g
abcdDescription Alpha propeller nutAlpha propeller nut1.
5301

Propeller shaft splines Forward thrust hub Flotorque II drive hub Propeller

e - Drive sleeve adapter f - Locking tab washer g - Propeller nut

Nm 75

lb. in.

lb. ft. 55

Then align tabs with grooves.

Bravo Sterndrive Propeller Installation

a b c
4826

a - Wood block b - Propeller

c - Propeller nut under socket

1. The propeller torque stated is the minimum torque value.

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90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

BRAVO ONE MODELS

IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the propeller shaft. 1. Coat the propeller shaft spline with one of the following Quicksilver lubricants.
Tube Ref No.
34 95 94

Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon Anti-Corrosion Grease

Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines

Part No. 92-802865Q02 92-802859A1 92-802867Q 1

NOTE: Anticorrosion grease is for salt water applications only. 2. Install the propeller with the attaching hardware as shown. 3. Torque the propeller nut.

d e a b c g
abcd5301

Typical Bravo One models Propeller shaft splines e - Drive sleeve adapter Forward thrust hub f - Tab washer FloTorque II drive hub g - Propeller nut Propeller

a b

c
d e f g

19816

abcd-

Bravo One XR models Propeller shaft Propeller hub insert with snubbers Propeller Thick washer

e - Washer f - Washer g - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.

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PREDELIVERY PREPARATION AND STORAGE Description Bravo One propeller nut Nm 75 lb. in.

SECTION - 9 lb. ft. 55

NOTE: Bravo One XR models do not use the tab washer. 4. Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer. 5. Bend the three tabs down into the grooves.

c d e

4750

a - Prop b - Tab washer c - Drive sleeve adapter

d - Tab bent down e - Propeller nut

BRAVO TWO MODELS

Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon Anti-Corrosion Grease

Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines

Part No. 92-802865Q02 92-802859A1 92-802867Q 1

NOTE: Anticorrosion grease is for salt water applications only. 2. Install the propeller with the attaching hardware as shown.

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90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

3. Torque the propeller nut.

c d f a b e
Bravo Two a - Propeller shaft splines b - Forward thrust hub c - Propeller
8566

d - Spline washer e - Tab washer f - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.

Description Bravo Two propeller nut Nm 81 lb. in. lb. ft. 60

4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer. 5. Bend the three tabs down into the grooves.

c d e

4750

a - Prop b - Tab washer c - Drive sleeve adapter

d - Tab bent down e - Propeller nut

BRAVO THREE
1. Coat the propeller shaft spline with one of the following Quicksilver lubricants.
Tube Ref No.
34 95 95

Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon 2-4-C Marine Lubricant with Teflon

Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines

Part No. 92-802865Q02 92-802859A1 92-802859A1

NOTE: Anticorrosion grease is for salt water applications only.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

2. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub. 3. Align splines and place front propeller on propeller shaft. 4. Install front propeller locknut and torque using the Propeller Nut tool.
Propeller Nut Tool Description Bravo Three front propeller nut 91805457T 1 Nm 136 lb. in. lb. ft. 100

5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 6. Align splines and install aft propeller. 7. Install propeller nut and torque.
Description Bravo Three rear propeller nut Nm 81 lb. in. lb. ft. 60

8. Install propeller shaft anode and screw and torque.

e f b a j
5304

i g h

abcdeDescription

Bravo Three Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller

fghij-

Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode
Nm 19 lb. in. 168 lb. ft.

Propeller shaft anode screw

Battery Connection
IMPORTANT: Engine electrical system is negative () ground. 1. Ensure that all battery terminal connections are tight.

Priming the Fuel System

IMPORTANT: Use a portable fuel tank with a primer bulb fuel line.

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

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PREDELIVERY PREPARATION AND STORAGE

1. Disconnect the fuel line from the fuel tank to the fuel inlet fitting and plug the line, if attached to the engine. 2. Attach portable fuel tank to the fitting and secure tightly. 3. Squeeze the primer bulb until the bulb becomes firm. 4. Turn the ignition switch to the "RUN" position for 3 seconds and then turn OFF.

NOTE: Do not turn the key switch to the "START" position during the priming. 5. Repeat Step 3. and Step 4. three more times. IMPORTANT: Before disconnecting the fuel line primer bulb, ensure that the bulb is soft and does not still have fuel in it to prevent spilling fuel. 6. Disconnect the primer bulb fuel line from the fuel inlet fitting. 7. Remove the plug from the fuel tank fuel line. 8. Attach the fuel line from the fuel tank to the fuel inlet and tighten securely.

Test Running Engine

! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury.

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

BOAT OUT OF THE WATER

For engine operation tests with the boat out of the water: IMPORTANT: If using a flushing attachment over the water inlet holes with a water hose, do not use full water source pressure. 1. Install a flushing attachment over the sterndrive water inlet holes. 2. Connect a hose between the flushing attachment and a water source. 3. Open the water source about 1/2 maximum. Do not use full water pressure. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet, need a supply of cooling water available to both the sterndrive unit and to the engine during operation. 4. On Engines With Through The Hull Water Inlet, supply sufficient cooling water to the engine. 5. Proceed to Testing Preparation.

BOAT IN THE WATER

For engine operation tests with the boat in the water: IMPORTANT: If using a test tank the water level must be above the water inlet holes on the sterndrive unit or the through the hull pickup. 1. Ensure that the water level is above the water inlet holes on the sterndrive or the through the hull pickup. 2. Proceed to Testing Preparation.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

TESTING PREPARATION

! WARNING
Leaving the helm unattended while performing tests with the boat in the water may result in loss of boat control causing serious injury or death. Ensure someone is at the helm at all times, unless the boat is secured to a dock. 1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight.

NOTE: Refer to appropriate Mercury MerCruiser Operation, Maintenance and Warranty Manual for operating specifications. Refer to appropriate Mercury MerCruiser Service Manual for fluid capacity information. 2. Check crankcase oil level. IMPORTANT: Oil level in monitor will rise and lower during sterndrive operation. Always check oil level when sterndrive is cool and engine is shut down. 3. Check sterndrive unit oil level in the monitor. 4. Check drive belt tension. 5. Test Audio Warning system in accordance with instructions on instrumentation panel decal. 6. Supply water to the engine either by putting boat in the water or by using the correct flush device. IMPORTANT: If using a test tank, ensure water level is above water intake holes. IMPORTANT: If using a flush test device, do not use full water tap pressure. During operation, do not operate the engine above 1500 RPM to ensure the engine seawater pump suction does not collapse the hose to the water source causing the engine water supply to stop.

5752

5773

Low water pickup

Side pickup

IMPORTANT: Engines may also use a through the hull or through the transom inlet. If so, water must be provided to these inlets or air flow must be blocked. If a blockoff plate is used, the through the transom or through the hull fitting is the only water inlet to the engine.
Flushing Device Flushing Kit 9144357Q 2 91849996T 1

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PREDELIVERY PREPARATION AND STORAGE

TESTING
1. 2. 3. 4. Place sterndrive in neutral , idle speed and start engine. Slowly advance throttle until engine reaches 1300 rpm (+/100 rpm). Watch all gauges for normal readings. Turn steering wheel RIGHT/STARBOARD, then LEFT/PORT, and ensure drive unit turns the correct way. 5. Inspect engine compartment for water, oil, fuel, and exhaust leaks. 6. Turn steering wheel PORT until it stops and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes): a. Check for an obstruction between gimbal ring and gimbal housing and all moving steering components b. Ensure that steering lever is not contacting cutout in transom. If contact is being made, modify cutout c. Check steering cable end dimension with cable FULLY EXTENDED. 7. Turn steering wheel STARBOARD until it stops and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes): a. Turn off engine. b. Remove cap/dipstick from power steering pump. Check fluid level and add if necessary.

7890

a
a - Dipstick (full when hot line)

Boat In The Water Tests

ENGINE IDLE SPEED
Engine should idle at RPM as specified in appropriate Mercury MerCruiser Operation, Maintenance, and Warranty Manual with boat in the water, drive unit in FORWARD gear and engine at normal operating temperature. If idle speed is incorrect, proceed as follows: 1. Ensure that throttle cable has been adjusted properly.

WIDE OPEN THROTTLE TEST

IMPORTANT: To operate engine at full throttle before the breakin period is complete, follow this procedure. 1. Place remote control in neutral , idle speed and start engine. 2. Slowly advance throttle until engine reaches 1300 rpm (+/100 rpm). 3. Watch all gauges for normal readings. 4. When engines reaches mornal operating temperature, run the boat up on plane. 5. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM. 6. To test if the correct propeller has been installed, operate boat (with normal load on board) at WOT and check RPM with an accurate tachometer. Engine RPM should be near top of the specified range so that, under a heavy load, engine speed will not fall below specifications. If engine speed is too high, replace propeller with a higher pitch propeller. Normally a 25 mm (1 in.) propeller pitch change causes an RPM change of 150 RPM.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

7. Return to idle speed. 8. Shut off engine. 9. Check coolant level and add coolant if necessary.

CHECKING SHIFT OPERATION

With sterndrive unit installed and engine operating, ensure that drive unit shifts properly, as explained following: 1. Shift into FORWARD and REVERSE gear, ensuring that clutch engages before engine begins to accelerate. 2. Accelerate engine while in FORWARD and REVERSE gear to ensure that engine does not stop. 3. If the proper results are not achieved in the previous steps, shift cables must be readjusted. 4. Shifting from FORWARD and REVERSE to NEUTRAL: ensure drive unit is in NEUTRAL before remote control shift lever comes to the NEUTRAL detent position. Perform this check using various shifting rates to ensure that the drive unit shifts the same whether shifting fast or slow.

Flushing the Power Package

The boat can be equipped with a combination of any of three different types of water pickups: through the hull, through the transom, and through the sterndrive. The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. IMPORTANT: Engines that require dual water pickups require a throughthehull or throughthetransom pickup in addition to the sterndrive water inlets. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a throughthehull or throughthetransom pickup need a supply of cooling water available to both the sterndrive and to the engine during operation.

FLUSHING ATTACHMENTS

c
Flushing attachments for dual water pickup a - Flushing device b - Hose attachment
Flushing Device Dual Water Pickup Flush Gearcase Seal Kit
21514

Flushing attachments for side water pickup c - Dual water pickup flush gearcase seal kit
9144357Q 2 91881150K 1

21515

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SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

STERNDRIVE WATER PICKUPS

There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require the flushing attachment (44357Q 2).

5752

5773

Dual water pickup

Side water pickup

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results.

NOTICE
Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine. Keep the seacock closed until starting the engine. 1. On seawater cooled models: Proceed to Step 4. or Step 5. 2. On models with the sterndrive seawater inlet blocked, supply water to the sterndrive and to the engine. See Alternative Water Pickups. 3. On models using the sterndrive seawater inlet and a throughhull or throughtransom alternative water pickup, supply water to only the sterndrive by taking the following steps to block, or disconnect and block, the hose from the alternative seawater pickup pump inlet Yfitting. a. If equipped with a seacock, close the seacock in the hose from the alternative water pickup. b. If not equipped with a seacock, disconnect the hose from the alternative water pickup and plug both ends. c. If there is not a hose running to the transom, refer to Alternative Water Pickups. 4. If flushing the cooling system with the boat in the water: a. Raise sterndrive to trailer position. b. Install the appropriate flushing attachment over the water inlet holes in the gear housing. c. Lower sterndrive to full down (in) position. 5. If flushing the cooling system with the boat out of the water: a. Lower sterndrive to full down (in) position.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

b. Remove propeller. c. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 6. Connect hose between flushing attachment and water source. 7. With sterndrive in normal operating position, open the water source fully. 8. Place the remote control in the neutral idle speed position and start engine.

NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. 9. Depress the throttleonly button and slowly advance the throttle until the engine reaches 1300 RPM ( 100 RPM). 10. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. 12. Slowly return throttle to idle speed position. 13. Stop engine. 14. Shut off water and remove flushing attachment. 15. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine. 16. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.

ALTERNATIVE WATER PICKUPS

IMPORTANT: Two water sources are needed for this procedure.

NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. IMPORTANT: Models with the sterndrive water inlet blocked off at the gimbal housing and using a throughhull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation. 1. If flushing the cooling system with the boat in the water: a. Raise sterndrive to trailer position. b. Install the appropriate flushing attachment over the water inlet holes in the gear housing. c. Lower sterndrive unit to full down (in) position. 2. If flushing the cooling system with the boat out of the water: a. Lower sterndrive to full down (in) position.

! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the antiventilation plate. b. Remove propeller. c. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 3. Connect hose between flushing attachment and water source. 4. Close the seacock, if equipped, to prevent water from siphoning into the engine or boat.

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PREDELIVERY PREPARATION AND STORAGE

5. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine or boat.

6147

6. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater pump.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 7. With sterndrive in normal operating position, open the water source fully. 8. Place the remote control in neutral idle speed position and start engine.

NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. 9. Slowly advance throttle until engine reaches 1300 RPM (+/100 RPM). 10. Observe the water temperature gauge to ensure that the engine is operating in the normal range. 11. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. 12. Slowly return throttle to idle speed position. 13. Stop engine. 14. Shut off the water and remove flushing attachments. 15. If the boat is out of the water: Install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp securely. 16. If the boat is in the water: Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine.

SeaCore Power Package Flushing Procedure

NOTE: Flushing is needed only for salt, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. IMPORTANT: Flushing the SeaCore power package with the boat and sterndrive in the water is less effective. Flushing the SeaCore power package is most effective when performed with the boat and sterndrive out of the water, such as on a boat lift or trailer.

MODELS USING THE STERNDRIVE WATER PICKUP

IMPORTANT: The system is designed to flush the Bravo sterndrive and the engine with one water source. Do not block or remove the inlet water hose from the sterndrive to the engine.

NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: Refer to Alternative Water Pickups.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Place a block of wood between the propeller blade and the antiventilation plate. IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends. 1. Remove the boat from the water. 2. Close the seacock, if equipped.

c a b

For visual clarity, the secock shown is not installed a - Hose fitting to engine c - Handle (closed position) b - Seacock d - To water source pickup attachment 3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive. 4. Ensure that the inlet water hose from the sterndrive to the engine is connected. 5. Remove the quickconnect fitting from the parts bag supplied with the engine. 6. Attach the quickconnect fitting to a water hose.

18510

18487

a - Quick connect fitting (water hose end)

b - Water hose

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PREDELIVERY PREPARATION AND STORAGE

7. Snap the quickconnect fitting with the water hose into the flush socket on the engine.

a b

a - Water hose b - Quickconnect fitting (water hose end)

18489

c - Flush socket

8. Open the water source of the water hose to a full flow. 9. Allow the water to flush the sterndrive for 30 seconds. 10. Place the remote control in neutral idle speed position and start engine.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 11. 12. 13. 14. 15. 16. Operate the engine at idle speed in neutral gear. Do not exceed 1200 RPM. Monitor the engine temperature while operating the engine. Flush the engine for 5 to 10 minutes or until discharge water is clear. Shut off the engine. Allow the water to flush the sterndrive for 10 seconds. Turn off the water source.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

17. Disconnect the quickconnect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket.

a b

a - Quickconnect fitting (water hose end)

18488

b - Flush socket release button

18. Remove the quickconnect fitting from the water hose.

18487

a - Quickconnect fitting (water hose end)

b - Water hose

19. Retain the quickconnect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access. IMPORTANT: Do not store the quickconnect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty.

25900

Quickconnect fitting stored in the boat a - Quickconnect fitting (water hose end)

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PREDELIVERY PREPARATION AND STORAGE

20. Insert the dust cover in the flush socket on the engine.

a b

Dust cover installed in the flush socket a - Dust cover b - Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If unit is to be stored out of the water, open the seacock. 21. Open the seacock, if equipped, or reconnect the alternative water inlet source prior to operating the engine.

18490

Cold Weather or Extended Storage

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

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

Preparing Power Package for Storage

1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline. Follow instructions on the container. 2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Mercury/ Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank. Refer to Fuel Requirements for additional information.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. Flush the cooling system. Refer to the Maintenance section. IMPORTANT: In order to run the engine as required in the remainder of the storage preparation procedure, water must be supplied to the engine as described in the flushing procedure. 4. Provide cooling water to the engine as done in the previous step. 5. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel with Mercury/Quicksilver Gasoline Stabilizer to circulate through the fuel system. Shut off the engine. 6. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System Preparation. Perform this operation. 7. Drain the engine seawater cooling system. Refer to Draining the Seawater System.

NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged. 8. Ensure that the sterndrive vent holes and water drain holes and passages are unobstructed and open (refer to Draining Instructions). 9. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be exposed during freezing temperatures or extended storage.

NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position. 10. Store boat with drive unit in full down/in position. 11. Store the battery according to the manufacturer's instructions.

ENGINE AND FUEL SYSTEM PREPARATION

! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package. 1. In a 23 liter (6 U.S.gal.) remote fuel tank mix: a. 19 liter (5 U.S. gal) regular unleaded 87 octane (90 RON) gasoline b. 1.89 liter (2 U.S. qts.) Premium Plus 2Cycle TCW3 Outboard Oil c. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System Treatment and Stabilizer Concentrate

Page 30 / 46

90-899883178 NOVEMBER 2007

SECTION - 9 Tube Ref No.

115 124

PREDELIVERY PREPARATION AND STORAGE Description Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer Where Used Fuel system Fuel system Part No. 92-858026K01 858071K01

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

Draining the Seawater System

! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining. Do not operate the engine with the drain system open. IMPORTANT: Only drain the seawater section of the closedcooling system. IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system. Your power package is equipped with a drain system. Refer to Drain System Identification to determine which instructions apply to your power package. IMPORTANT: The engine must not be operating at any point during the draining procedure. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

Drain System Identification

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

c a b c a b d d
6124 6125

Closed Cooled Models a - Blue drain plug location b - Blue air pump

Seawater Cooled Models c - Air manifold d - Green indicators

a b c

d d
Scorpion Models a - Blue air pump b - Air manifold c - Green indicators d - Blue drain plug locations
21125

MANUAL SINGLE POINT DRAIN SYSTEM

a b
6128

a - Blue handle

b - Blue drain plug location

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PREDELIVERY PREPARATION AND STORAGE

THREE POINT MANUAL DRAIN SYSTEM

a
a - Blue drain plug

a
6126

MULTI-POINT DRAIN (MPD) SYSTEM

b a
93235672

b a

10226

M110050

6129

a - Side of cylinder block

b - Bottom of exhaust manifolds

b a
6130

a - Water circulating pump hose

b - Fuel cooler to thermostat housing

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

6131

a - Check valve (if equipped)

AirActuated SinglePoint Drain System

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

b
a - Actuator fitting b - Green indicators c - Manual release valve

8293

d - Air pump e - Lever (locking)

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

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PREDELIVERY PREPARATION AND STORAGE

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

c a b c a b d d
6124 6125

Closed Cooled Models a - Blue drain plug location b - Blue air pump

Seawater Cooled Models c - Air manifold d - Green indicators

a b c

d d
Scorpion Models a - Blue air pump b - Air manifold c - Green indicators d - Blue drain plug locations
21125

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

a
a - Port side drain location

6133

b - Starboard side drain location

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended. 10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow engine to start. 11. Reinstall the blue drain plug in the thermostat housing or heat exchanger. 12. Remove the air pump from the air manifold and return it to the mounting bracket. 13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. 14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a
6135

a - Green indicators 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.

BOAT OUT OF THE WATER

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Place the boat on a lever surface to ensure complete draining of system. 2. Remove the air pump from the engine. 3. Ensure that the lever on top of the pump is flush with the handle (horizontal). 4. Install the air pump on the actuator fitting. 5. Pull lever on air pump (vertical) to lock pump on the fitting.

b
a - Actuator fitting b - Green indicators c - Manual release valve

8293

d - Air pump e - Lever (locking)

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PREDELIVERY PREPARATION AND STORAGE

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

c a b c a b d d
6124 6125

Closed Cooled Models a - Blue drain plug location b - Blue air pump

Seawater Cooled Models c - Air manifold d - Green indicators

a b c

d d
Scorpion Models a - Blue air pump b - Air manifold c - Green indicators d - Blue drain plug locations
21125

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

a
a - Port side drain location

6133

b - Starboard side drain location

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended. 9. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump. Do not allow engine to start. 10. Remove the air pump from the air manifold and return it to the mounting bracket. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained. 12. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

a
6135

a - Green indicators

Manual SinglePoint Drain System

BOAT IN THE WATER
1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not force the handle as this will create new threads. 3. Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system.

b a

6136

a - Blue handle

b - Blue drain plug location

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PREDELIVERY PREPARATION AND STORAGE

4. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.

b a
a - Drain location orange or red
6137

b - Blue drain plug

5. Allow the system to drain for a minimum of five minutes. We recommend leaving the drain system open while transporting the boat or performing other maintenance. 6. Reinstall the blue drain plug in the thermostat housing. 7. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten the handle, as this action will create new threads. 8. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine.

BOAT OUT OF THE WATER

1. Place the boat on a level surface to ensure complete draining of system. 2. Rotate the blue handle counterclockwise until it stops (approximately two turns). The red on the handle shaft indicates that the drain system is open. Do not overtighten the handle, as this action will create new threads.

6141

a - Blue handle

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. Visually verify that water is draining. If water does not drain, remove the blue drain plug from the distribution housing and drain manually.

b a
a - Drain location orange or red
6137

b - Blue drain plug

4. Allow the system to drain for a minimum of five minutes. We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained. 5. Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug. The handle is fully seated when no red is visible. Do not overtighten handle, as this action will create new threads.

Three Point Manual Drain System

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

6138

a - Blue drain plug

Page 40 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

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

6139

a - Blue drain plug location 4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

a
a - Blue drain plugs

6140

5. Verify that water is draining from each opening. 6. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained. 7. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 8. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain plugs. 9. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.

BOAT OUT OF THE WATER

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 1. Place the boat on a level surface to ensure complete draining of the system.

90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

2. Remove three blue drain plugs: one from the distribution housing (lower front, port side) and two from the seawater pickup pump (front, starboard side).

a
6142

a - Blue drain plug 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained. 5. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 6. Prior to launching the boat or starting the engine, close the drain system by installing the three blue drain plugs.

MultiPoint Drain (MPD) System

BOAT OUT OF THE WATER
1. Place the boat on a level surface to ensure complete draining of the system. 2. Remove the blue drain plugs from the following locations. If necessary, clean out the drain holes using a stiff piece of wire. Do so until the entire system is drained. a. Port and starboard side of cylinder block b. Bottom of exhaust manifolds

b a
93235672

b a

10226

M110050

6129

a - Cylinder block drain plug

b - Exhaust manifold drain plug

Page 42 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

Watercirculating pump hose

a
6143

a - Drain plug d. Fuelcoolertothermostathousing hose

6144

a - Drain plug e. Check valve

6131

a - Drain plug (if equipped)

90-899883178 NOVEMBER 2007

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PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

3. On models with a seawater pickup pump, remove the two blue drain plugs. If the seawater pickup pump does not have blue drain plugs, or you are unable to access them, loosen the clamps and remove both hoses.

a
6145

b
a - Hose clamps b - Blue drain plugs 4. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 5. After the cooling system has been drained completely, install the drain plugs, reconnect the hoses, and tighten all hose clamps securely.

BOAT IN THE WATER

1. Close the seacock (if equipped) or remove and plug the water inlet hose. 2. Remove the blue drain plugs from the following locations. If necessary, clean out the drain holes using a stiff piece of wire. Do so until the entire system is drained. a. Port and starboard side of cylinder block b. Bottom of exhaust manifolds

b a
93235672

b a

10226

M110050

6129

a - Cylinder block drain plug

b - Exhaust manifold drain plug

Page 44 / 46

90-899883178 NOVEMBER 2007

SECTION - 9

PREDELIVERY PREPARATION AND STORAGE

Watercirculating pump hose

a
6143

a - Drain plug d. Fuelcoolertothermostathousing hose

6144

a - Drain plug e. Check valve

6131

a - Drain plug (if equipped)

90-899883178 NOVEMBER 2007

Page 45 / 46

PREDELIVERY PREPARATION AND STORAGE

SECTION - 9

a
6145

b
a - Hose clamps b - Blue drain plugs 4. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow the engine to start. 5. Before launching the boat or starting the engine, close the drain system by installing the blue drain plugs. 6. Open the seacock, if equipped, or unplug and reconnect the water inlet hose before operating the engine.

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

Power Package Recommissioning

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

! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative () battery cable first and connect it last. 2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect cables. Tighten each cable clamp securely when connecting. 3. Coat the terminal connections with a battery terminal anticorrosion agent. 4. Perform all the checks in the before starting column of the Operation Chart.

NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation. 5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly. 6. Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks. 7. Inspect the steering system, shift and throttle control for proper operation.

Page 46 / 46

90-899883178 NOVEMBER 2007

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