Mercury Mariner

Service Bulletin
Bulletin No. 2015-06
OEM No. 2015-05

Circulate to: Sales Manager Accounting Service Manager Technician Parts Manager

350, 400R Verado Product Launch Introduction

Models Affected
Models Covered Serial Number Or Year
1B968859–1B968883
350 and 400R
2B141124 and Above

Scope
Worldwide

Situation
The purpose of this bulletin is to highlight product information on the Verado 350 and 400R engine
• Specifications
• G3 diagnostic tool version compatibility
• Gearcase changes
• Steering head changes
• Midsection improvements
• Fuel system changes
• Air intake and supercharger
• Engine harness changes
• Decal accent color options (400R)
• Engine mounting screw recommendation
• Maintenance decals
• Maintenance reminder
• Low battery voltage RPM strategy
• Cowl improvements
• Models available

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2015-06 MARCH 2015 © 2015 Mercury Marine Page 1 / 9

350, 400R Verado Product Launch Introduction

Specifications
Models 350 400R
Horsepower 350 400
Kilowatts 261 298
Full throttle RPM range 5800–6400 6400–7000
Idle RPM in neutral gear* 600
Number of cylinders 6
Displacement 2,598 cc (158.5 cid)
Cylinder bore 82 mm (3.23 in.)
Stroke 82 mm (3.23 in.)
Spark plug NGK ILFR6G‑E
Spark plug gap 0.8 mm (0.0315 in.)
Spark plug hex size 16 mm
Gear ratio 1.75:1
US and Canada—91 (R+M)/2 Octane is required for best performance.
89 (R+M)/2 minimum is acceptable, however, performance losses may occur.
Recommended gasoline
Outside US and Canada—95 RON is required for best performance. 93 RON
minimum is acceptable, however, performance losses may occur.
SAE 25W‑40 Synthetic Blend Marine 4‑Stroke SAE 25W‑50 Synthetic Blend
Recommended oil
Engine Oil Racing 4‑Stroke Engine Oil
Heavy‑duty 137 mm
510 ml (17.2 fl oz)
Gearcase capacity (5.4 in.)
Sport Master — 620 ml (21 fl oz)
Engine oil capacity with oil filter
7.0 L (7.4 US qt)
replacement
Required battery type 12‑volt absorbed glass mat (AGM) battery
800 minimum marine cranking amps (MCA) with a minimum reserve capacity of
USA (SAE) battery type
135 minutes RC25 rating
International (EN) battery type 975 minimum cold cranking amps (CCA) with a minimum of 65 amp hours (Ah)

* Engine at normal operation temperature.

G3 Diagnostic Tool Version Compatibility

G3 release 1.6.1 is compatible and has similar functionality as experienced with previous Verado models using CDS.
NOTE:

Gearcase Changes
1. Heavy‑duty 137 mm (5.4 in.) 1.75:1 gearcase.
• Gearcase capacity is approximately 510 ml (17.2 fl oz). Do not overfill. Overfilling the gearcase will cause a
reduction in power.
• The gearcase fill/drain plug and the lubricant level plug are located on the propeller shaft bearing carrier.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 2 / 9 © 2015 Mercury Marine MARCH 2015 2015-06

 350, 400R Verado Product Launch Introduction

• The lubricant level plug is located at the 3 o'clock position.

a - Lubricant level plug

b - Fill/drain plug

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2. Sport Master 137 mm (5.4 in.) 1.75:1 gearcase.

• Gearcase capacity is approximately 620 ml (21 fl oz). Do not overfill. Overfilling the gearcase will cause a reduction
in power.
• The gearcase fill/drain plug and the lubricant level plug are located on the propeller shaft bearing carrier.
• The lubricant level plug is located at the 3 o'clock position.
• Low‑water pickups.
• Crescent leading edge.
• Straight, and camber right‑hand or left‑hand skeg is available.

57982

3. Gearcase mounting hardware and torque specification change.

• On L and XL models, the aft mounting screw has changed and the torque has increased to 100 Nm (73.7 lb‑ft).
• The gearcase mounting nut is taller. The new mounting nut exposes less threads on the mounting stud.
• The torque for the mounting hardware changed from 61 Nm (45 lb‑ft) to 75 Nm (55 lb‑ft).

a - Early design
a b b - Current design

57969

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2015-06 MARCH 2015 © 2015 Mercury Marine Page 3 / 9

350, 400R Verado Product Launch Introduction

Steering Head Change

1. The steering head has been changed to utilize a larger steering arm fastener. The larger fastener size is more robust and
has a 70% clamp load increase.

a - Early design
b - Current design

a b

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2. Heavy‑duty tie bar kits are available. These kits have larger pinned connections, larger bushings, a solid coupler, and
larger tie rod threaded ends, increasing the overall strength of the steering components.

58063

Dual engine tie bar

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 4 / 9 © 2015 Mercury Marine MARCH 2015 2015-06

 350, 400R Verado Product Launch Introduction

Recommended Distance
Dual Engine Tie Bar Length Kit Part Number
Center to Center
66.04 cm 66.04–67.95 cm
8M0096314
(26 in.) (26–26.75 in.)
71.12 cm 67.95–73.03 cm
8M0096315
(28 in.) (26.75–28.75 in.)
76.2 cm 73.03–78.11 cm
8M0096316
(30 in.) (28.75–30.75 in.)
81.28 cm 78.11–83.19 cm
8M0096317
(32 in.) (30.75–32.75 in.)
86.36 cm 83.19–88.27 cm
8M0096319
(34 in.) (32.75–34.75 in.)
91.44 cm 88.27–92.08 cm
8M0097267
(36 in.) (34.75–36.25 in.)

58065

Add a tie bar

Recommended Distance
Add a Tie Bar Length Kit Part Number
Center to Center
66.04 cm 66.04–67.95 cm
8M0096320
(26 in.) (26–26.75 in.)
71.12 cm 67.95–73.03 cm
8M0096321
(28 in.) (26.75–28.75 in.)
76.2 cm 73.03–78.11 cm
8M0096322
(30 in.) (28.75–30.75 in.)
81.28 cm 78.11–83.19 cm
8M0096323
(32 in.) (30.75–32.75 in.)
86.36 cm 83.19–88.27 cm
8M0096324
(34 in.) (32.75–34.75 in.)
91.44 cm 88.27–92.08 cm
8M0097268
(36 in.) (34.75–36.25 in.)
3. A tie bar bracket for single engine applications utilizing a kicker motor for steering is available (8M0097850).
4. A bracket for the joystick piloting is also available (8M0098927).

Midsection Improvements
• Tilt pin retainer rings have been anodized the color blue to make an inspection easier to visually identify the ring integrity.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2015-06 MARCH 2015 © 2015 Mercury Marine Page 5 / 9

350, 400R Verado Product Launch Introduction

• Driveshaft housing is a new design. The design change accepts a new side support assembly.

57984

Fuel System Changes

1. New fuel supply module (FSM).
• The FSM is based on the 150 FourStroke fuel system architecture.
2. Priming the FSM methods.
• Priming the FSM with a purge tool: Refer to the operation manual or installation manual for this priming procedure.
• Priming the FSM without a purge tool: Refer to the operation manual or installation manual for this priming
procedure.
3. Boat mounted water‑separating fuel filter.
• A boat mounted water‑separating fuel filter is included with the engine. This filter has a larger media area for
capturing contaminants, and an increased water separating capability with a removable water sensor. This filter has
replaced the engine mounted fuel filter.
4. In‑line fuel filter.
• An in‑line fuel filter is located inside the engine side fuel line connector and it is required when a boat mounted fuel
filter is installed. This filter captures debris that may be in the fuel line between the boat mounted filter and the fuel
line connection on the engine. This filter can be removed or replaced after one year or 100 hours of operation.

58159

5. A fuel demand valve (FDV) is no longer required on the fuel supply hose. The vent and purge valves are not used with this
fuel delivery system; therefore, a primer bulb can be utilized, if desired.

Air Intake and Supercharger

• The cold air intake system has been designed to deliver cool fresh air from outside the cowl to the supercharger, lowering
the intake air temperature.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 6 / 9 © 2015 Mercury Marine MARCH 2015 2015-06

 350, 400R Verado Product Launch Introduction

• Inlet flow path to the electronic throttle control has changed.

58068

• Water‑cooled supercharger end cap.

• Water‑cooled supercharger housing.
• Supercharger rotor changed.

Engine Harness Changes

The engine harness has been changed to allow easy access to the clean power connector, power steering signal harness
connector, and boat sensor harness connector. The water‑in‑fuel harness connector is inside the electrical box and is long
enough that it can be connected outside of the electrical box.

a a- 14‑pin
b- Clean power
c- 6‑pin boat sensor
d- Power steering signal
b
c
d

57980

Decal Accent Color Options (400R)

Seven decal color options are available for the 400R Race engine. These colors are: yellow, orange, red, purple, green, blue,
and carbon fiber. A factory template version will be available to install the custom color decal on the engine. The template
version will be gray in the areas where the decals should be applied.

57981

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2015-06 MARCH 2015 © 2015 Mercury Marine Page 7 / 9

350, 400R Verado Product Launch Introduction

Decal Kit Part Numbers

Yellow—8M0096291 Orange—8M0096290 Red—8M0096288 Purple—8M0096287
Green—8M0096289 Blue—8M0096286 Carbon Fiber—8M0097812

Engine Mounting Screw Recommendation

Mercury Marine recommends these engines utilize six mounting screws secured with two nuts on each screw. The top screws
must have one vacant transom mounting bracket hole between the screws. Only one locknut per screw is allowed.

a - Locknut
a b b - Nut
c - Vacant hole

57973

Maintenance Decals
1. Maintenance schedule—The maintenance decal on the electrical cover now incorporates the maintenance schedule
inspection and replacement items.
2. Accessory drive belt—A decal placed on the accessory drive belt tensioner base allows for a quick evaluation of the
overall belt length. When the arrow on the tensioner is pointing to the red target window on the decal, the belt should be
replaced.

a - Tensioner arrow
a b - Red target window (replace the belt)

57255

Maintenance Reminder
Verado 350 and 400R have the maintenance reminder enabled. There are a number of SmartCraft gauges capable of
displaying this reminder.

Low Battery Voltage RPM Strategy

The engine operation low RPM strategy has changed. During low speed engine operation, the PCM will gradually increase the
RPM in incremental steps when the battery is below a specific voltage. During this charging strategy when the battery voltage is
above the threshold, the PCM will gradually decrease the RPM.

Cowl Improvements
• Latch cables have been improved and are more resistant to corrosion.

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

Page 8 / 9 © 2015 Mercury Marine MARCH 2015 2015-06

 350, 400R Verado Product Launch Introduction

• Improved cowl seals.

• Improved cowl and panel alignment.

Models Available
350
• Colors—black, cool white, warm white
• Length—L, XL, XXL, CL, CXL, CXXL
• Joystick piloting
• Heavy‑duty 137 mm (5.4 in.) 1.75:1 gearcase only
400R
• Colors—black, cool white
• Length—L, XL, XXL, CL, CXL, CXXL
• Joystick piloting
• Heavy‑duty 1.75:1 gearcase
• Sport Master 137 mm (5.4 in.) 1.75:1 gearcase models

THE INFORMATION IN THIS DOCUMENT IS CONFIDENTIAL AND PROTECTED BY COPYRIGHT AND IS THE PROPERTY OF MERCURY MARINE.

This document is provided for the sole and exclusive use of the original recipient as prescribed by Mercury Marine and may not be distributed or copied, digitally or
otherwise, without the prior written consent of Mercury Marine.

2015-06 MARCH 2015 © 2015 Mercury Marine Page 9 / 9