30 Tks

90-879288268 709
NOTE: The following applies to CE marked products only.
Declaration of Conformity – Mercury MerCruiser

This sterndrive or inboard engine when installed in accordance to Mercury MerCruiser's instructions complies with the
requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as amended by 2003/44/EC
Name of engine manufacturer: Mercury Marine MerCruiser

Address: 3003 N. Perkins Road
Town: Stillwater, OK Post Code: 74075 Country: USA
Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Address: Parc Industriel de Petit‑Rechain
Town: Verviers Post Code: 4800 Country: Belgium
Name of Notified Body for exhaust emission assessment: Det Norske Veritas AS
*879288268*
Address: Veritasveien 1
Town: Hovik Post Code: 1322 Country: Norway ID Number: 0575
Conformity assessment module used for exhaust

☐ B+C ☐ B+D ☐ B+E ☐ B+F ☐G ☒H
emissions:
or engine type approved according to: ☐ stage II of Directive 97/68/EC ☐ Directive 88/77/EC
Conformity assessment module used for noise emissions: A☐ Aa ☐ G☐ H☒
Other Community Directives applied: Electromagnetic Compatibility Directive 2004/108/EC
Description of Engines and Essential Requirements
Engine Type Fuel Type Combustion Cycle

☒ z or sterndrive with integral exhaust ☐ Diesel ☐ 2 stroke
☐ Inboard engine ☒ Petrol ☒ 4 stroke
Identification of Engines Covered by This Declaration of Conformity
3.0 TKS Models

Name of engine family Unique engine identification number: starting serial number EC Module H certificate number
3.0 TKS OW319169 RCD‑H‑1
4.3 TKS OW319169 RCD‑H‑1
5.0 TKS OW319169 RCD‑H‑1
5.7 TKS OW319169 RCD‑H‑1
other normative document/ Please specify in more detail

Essential requirements standards technical file
method (* = mandatory standard)
Annex 1.B—Exhaust Emissions
B.1 engine identification ☐ ☐ ☒
B.2 exhaust emission requirements ☒* ☐ ☐ * EN ISO 8178‑1:1996
B.3 durability ☐ ☐ ☒
B.4 owner's manual ☒ ☐ ☐ ISO 8665: 1995
Annex 1.C—Noise Emissions
C.1 Noise emission levels ☒* ☐ ☐ * EN ISO 14509
© 2012 Mercury Marine
C.2 Owner's manual ☐ ☒ ☐ Owner's manual
This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of the engine
manufacturer that the engine(s) mentioned above complies (comply) with all applicable essential requirements in the way
specified.
Name / function: Signature and title:
Mark Schwabero, President, Mercury
Marine
Date and place of issue: July 24, 2008

Stillwater, Oklahoma, USA
Regulatory contact:
Regulations and Product Safety Department
Mercury Marine
W6250 W. Pioneer Road
Fond du Lac, WI 54936
USA
Identification Record
Please record the following information:
Engine Model and Horsepower Engine Serial Number
Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
Transmission Model (Inboard) Gear Ratio Transmission Serial Number
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser®
power package. When contacting your Authorized Mercury MerCruiser Dealer about service, always specify model and serial
numbers.
The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury
Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change
specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, USA. Printed in USA.
© 2009, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Bravo Two, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode,
RideGuide, SmartCraft, Zero Effort, VesselView, Zeus, Axius, Total Command, M with Waves logo, Mercury with Waves logo,
and SmartCraft logo are all trademarks or registered trademarks of Brunswick Corporation. Mercury Product Protection logo is
a registered service mark of Brunswick Corporation.
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this manual.
The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready reference whenever you are on the water.
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Mercury MerCruiser
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth
in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not covered,
the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages and other
related information. Please review this important information.
Mercury Marine products are designed and manufactured to comply with our own high quality standards, applicable industry
standards and regulations, as well as certain emissions regulations. At Mercury Marine every engine is operated and tested
before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are
tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of
compliance with applicable standards and regulations. All Mercury Marine product, sold as new, receives the applicable limited
warranty coverage, whether the engine participated in one of the test programs described above or not.
Read This Manual Thoroughly

IMPORTANT: If you don’t understand any portion of this manual, contact your dealer for a demonstration of actual starting and
operating procedures.
Notice
Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the
International Hazard Symbol !

, may be used to alert the installer/user to special instructions concerning a particular service
or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while
performing the service, plus common sense operation, are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
! WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all
occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or
other reproductive harm.
TABLE OF CONTENTS
Section 1 - Warranty
Warranty Registration: United States and Canada.................... 2 Warranty for Government Applications............................... 8
Warranty Registration: Outside the United States and Mercury MerCruiser Warranty Charts........................................ 8
Canada...................................................................................... 2 Consumer Application Warranty Chart................................. 9
Transfer of Warranty.................................................................. 2 Commercial Application Warranty Chart............................ 10
Mercury Installation Quality Certification Program..................... 3 Government Application Warranty Chart............................ 11
Mercury Product Protection Plan: United States and Canada... 4 Emission Control Warranty Information................................... 11
Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Important Information........................................................ 11
Products Only) .......................................................................... 4 Emission Control Information Label.................................. 12
3‑Year Limited Warranty Against Corrosion.............................. 6 Owner Responsibility.................................................... 12
Global Application Warranty Charts........................................... 8 U.S. EPA Emissions Limited Warranty............................. 13
Warranty for Consumer Applications.................................. 8 Emission Control System Components............................ 13
Warranty for Commercial Applications............................... 8
Section 2 - Getting to Know Your Power Package

Identification............................................................................. 16 Console Mount Features.................................................... 20
Alpha Sterndrive Decal Identification................................ 16 Power Trim............................................................................... 20
Alpha Transom Serial Number......................................... 16 Single Engine Trim/Trailer.................................................. 21
Engine Serial Number Decal............................................ 17 Dual Engine Trim/Trailer.................................................... 21
Lanyard Stop Switch................................................................ 17 Electrical System Overload Protection‑Carbureted Engines... 21
Instrumentation........................................................................ 18 Audio Warning System............................................................ 24
Remote Controls...................................................................... 19 Testing The Audio Warning System................................... 24
Panel Mount Features........................................................ 19
Section 3 - On the Water

Safe Boating Suggestions........................................................ 26 Passenger Safety in Pontoon Boats and Deck Boats.............. 30
Be Alert to Carbon Monoxide Poisoning.................................. 27 Boats Having an Open Front Deck..................................... 30
Good Ventilation................................................................. 27 Boats With Front‑Mounted, Raised Pedestal Fishing Seats
Poor Ventilation ................................................................. 27 ........................................................................................... 31
Basic Boat Operation............................................................... 28 Wave and Wake Jumping........................................................ 31
Launching and Boat Operation......................................... 28 Impact with Underwater Hazards............................................. 31
Operation Chart............................................................ 28 Drive Unit Impact Protection............................................... 32
Starting and Stopping the Engine..................................... 28 Conditions Affecting Operation................................................ 32
Starting the Engine....................................................... 28 Weight Distribution (Passengers and Gear) Inside the
Stopping the Engine..................................................... 29 Boat.................................................................................. 32
Starting the Engine After It Has Been Stopped While In The Bottom of the Boat..................................................... 32
Gear.................................................................................. 29 Cavitation.......................................................................... 33
Throttle‑Only Operation.................................................... 29 Ventilation......................................................................... 33
Trailering the Boat............................................................ 29 Elevation and Climate....................................................... 33
Freezing Temperature Operation..................................... 29 Propeller Selection............................................................ 33
Drain Plug and Bilge Pump............................................... 30 Getting Started......................................................................... 33
Protecting People in the Water................................................ 30 20‑Hour Break‑In Period................................................... 33
While You Are Cruising...................................................... 30 After Break‑In Period........................................................ 34
While Boat Is Stationary..................................................... 30 End of First Season Checkup........................................... 34
High‑Speed and High‑Performance Operation........................ 30
Section 4 - Specifications
Fuel Requirements................................................................... 36 Using Reformulated (Oxygenated) Gasolines (USA Only) 36
Fuel Ratings....................................................................... 36 Gasolines Containing Alcohol............................................ 36
90-879288268 eng JULY 2009 Page i

Engine Oil............................................................................... 36 Fluid Specifications................................................................. 38
Engine Specifications............................................................. 37 Sterndrives........................................................................ 38
3.0 TKS........................................................................... 37 Engine............................................................................... 38
Section 5 - Maintenance
Owner/Operator Responsibilities............................................ 40 Cleaning the Flame Arrestor................................................... 50
Dealer Responsibilities........................................................... 40 Positive Crankcase Ventilation Valve (PCV).................... 51
Maintenance........................................................................... 40 Changing..................................................................... 51
Do‑It‑Yourself Maintenance Suggestions............................... 40 Changing the Water‑Separating Fuel Filter............................ 52
Inspection............................................................................... 41 Fuel Pump Sight Tube Inspection.......................................... 52
Maintenance Schedules......................................................... 41 Lubrication.............................................................................. 53
Routine Maintenance...................................................... 41 Steering System.............................................................. 53
Scheduled Maintenance.................................................. 41 Manual Steering System................................................. 54
Maintenance Log.................................................................... 42 Throttle Cable.................................................................. 55
Sealed Carburetor Mixture Screw.......................................... 43 Shift Cable ‑ Typical........................................................ 55
Engine Oil............................................................................... 43 Sterndrive Unit and Transom Assembly.......................... 56
Checking........................................................................... 43 Sterndrive U‑joint Shaft Splines and O‑rings (Sterndrive
Filling................................................................................ 44 Unit Removed)................................................................ 56
Changing Oil and Filter..................................................... 44 Engine Coupler................................................................ 56
Easy Engine Oil Drain System.................................... 44 Driveshaft Extension Models........................................... 57
Engine Oil Drain Pump................................................ 45 Propellers............................................................................... 57
Changing Filter............................................................ 45 Propeller Repair.............................................................. 57
Power Steering Fluid.............................................................. 46 Alpha Propeller Removal................................................. 58
Checking........................................................................... 46 Alpha Propeller Installation.............................................. 58
Filling................................................................................ 46 Drive Belts.............................................................................. 59
Changing.......................................................................... 46 Checking........................................................................... 59
Engine Coolant....................................................................... 46 Replacing ‑ Front Mount Models....................................... 59
Checking........................................................................... 46 Power Steering Pump Drive Belt, if equipped............. 59
Filling................................................................................ 47 Alternator Belt............................................................. 59
Changing ......................................................................... 48 Replacing ‑ Side Mount Models........................................ 60
Drive Unit Oil.......................................................................... 48 Power Steering Pump Drive Belt, if equipped............. 60
Checking........................................................................... 48 Alternator Belt............................................................. 60
Filling................................................................................ 48 Flushing the Power Package.................................................. 60
Changing.......................................................................... 48 Flushing Attachments....................................................... 61
Power Trim Fluid.................................................................... 50 Sterndrive Water Pickups................................................. 61
Checking........................................................................... 50 Battery.................................................................................... 62
Filling................................................................................ 50 Corrosion Protection............................................................... 62
Changing.......................................................................... 50 Painting Your Power Package.......................................... 66
Section 6 - Storage
Cold Weather or Extended Storage........................................ 68 Clearing Clogged Blue Drain Hoses................................ 73
Preparing Power Package for Storage............................ 68 Draining the Sterndrive.................................................... 74
Engine and Fuel System Preparation......................... 69 Battery Storage....................................................................... 75
Draining the Seawater System............................................... 69 Recommissioning the Power Package................................... 75
Single Point Drain System............................................... 70
Draining the Seawater Section of Models With Closed
Cooling............................................................................ 71
Section 7 - Troubleshooting
Starter Motor Will Not Crank Engine, Or Cranks Slow........... 78 Low Engine Oil Pressure........................................................ 79
Engine Will Not Start Or Is Hard To Start............................... 78 Battery Will Not Recharge...................................................... 79
Engine Runs Rough, Misses or Backfires.............................. 78 Remote Control Is Difficult to Move, Has Excessive Play, or
Poor Performance.................................................................. 78 Makes Unusual Sounds.......................................................... 80
Excessive Engine Temperature.............................................. 79 Steering Wheel Jerks or Is Difficult to Turn............................ 80
Insufficient Engine Temperature............................................. 79 Power Trim Does Not Operate (Motor Does Not Operate)..... 80
Page ii 90-879288268 eng JULY 2009

Power Trim Does Not Operate (Motor Operates but Sterndrive
Unit Does Not Move)................................................................ 80
Section 8 - Customer Assistance Information

Owner Service Assistance....................................................... 82 Parts and Accessories Inquiries................................... 82
Local Repair Service.......................................................... 82 Resolving a Problem.......................................................... 82
Service Away From Home.................................................. 82 Mercury Marine Service Offices......................................... 83
Stolen Power Package....................................................... 82 Ordering Literature................................................................... 83
Attention Required after Submersion................................. 82 United States and Canada................................................. 83
Replacement Service Parts................................................ 82 Outside the United States and Canada.............................. 84
90-879288268 eng JULY 2009 Page iii

Page iv 90-879288268 eng JULY 2009
Section 1 - Warranty 1
Table of Contents
Warranty Registration: United States and Canada................. 2 Warranty for Commercial Applications............................ 8
Warranty Registration: Outside the United States and Canada Warranty for Government Applications............................ 8
................................................................................................ 2 Mercury MerCruiser Warranty Charts..................................... 8
Transfer of Warranty............................................................... 2 Consumer Application Warranty Chart ........................... 9
Mercury Installation Quality Certification Program................. 3 Commercial Application Warranty Chart ...................... 10
Mercury Product Protection Plan: United States and Canada Government Application Warranty Chart ...................... 11
................................................................................................ 4 Emission Control Warranty Information................................ 11
Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Important Information..................................................... 11
Products Only) ....................................................................... 4 Emission Control Information Label............................... 12
3‑Year Limited Warranty Against Corrosion........................... 6 Owner Responsibility ............................................. 12
Global Application Warranty Charts....................................... 8 U.S. EPA Emissions Limited Warranty.......................... 13
Warranty for Consumer Applications............................... 8 Emission Control System Components......................... 13
90-879288268 eng JULY 2009 Page 1

Warranty Registration: United States and Canada

To ensure that your warranty coverage begins promptly, your selling dealer should fill out the Warranty Registration Card
completely and mail it to the factory immediately upon sale of the new product.
The Warranty Registration Card identifies the name and address of the original purchaser, product model and serial number(s),
date of sale, type of use and selling dealer’s code, name, and address. The dealer also certifies that you are the original
purchaser and user of the product. A temporary Owner Warranty Registration Card will be presented to you when you purchase
the product.
Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that
includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of
new product sale, please contact your selling dealer.
Because of your selling dealer’s ongoing interest in your satisfaction, the product should be returned to him for warranty
service.
The product warranty is not effective until the product is registered at the factory.
NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event
that a safety recall notification under the Federal Boat Safety Act is required.
You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a
letter or fax to Mercury MerCruiser’s warranty registration department with your name, old address, new address, and engine
serial number. Your dealer can also process this change of information.
United States customers or dealers may contact:
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax 920-929-5893
Canadian customers or dealers may contact:
Mercury Marine Canada Limited
2395 Meadowpine Blvd.
Mississauga,
Canada, L5N 7W6
Fax 1-800-663-8334
Warranty Registration: Outside the United States and Canada

To ensure that your warranty coverage begins promptly, your selling dealer should fill out the warranty registration card
completely and mail it to the distributor responsible for administering the warranty registration and claim program for your area.
The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use,
and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are
the original purchaser and user of the product. A copy of the warranty registration card, designated as the purchaser’s copy,
MUST be given to you immediately after the card has been completely filled out by the selling distributor or dealer. This card
represents your factory registration identification. Keep the card; if you ever need warranty service on this product, your dealer
may ask you for the warranty registration card to verify date of purchase and to use the information on the card to prepare the
warranty claim forms.
In some countries, the distributor will issue a permanent (plastic) warranty registration card to you within 30 days after receiving
the factory copy of the warranty registration card from your distributor or dealer. If you receive a plastic warranty registration
card, you may discard the purchaser’s copy that you received from the distributor or dealer when you purchased the product.
Ask your distributor or dealer if this plastic card program applies to you. For further information concerning the warranty
registration card and its relationship to warranty claim processing, refer to the International Warranty. See Table of Contents.
NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event
of a safety recall notification under the Federal Boat Safety Act.
Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s
name, address and engine serial number to Mercury Marine’s warranty registration department. In the United States mail to:
Page 2 90-879288268 eng JULY 2009

Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
920-929-5054
Fax 920-929-5893
In Canada mail to:
Mercury Marine Canada Limited
Mississauga,
Canada, L5N 7W6
Fax 1-800-663-8334
Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by
mail.
There is no charge for this service.
For products purchased outside the United States and Canada, contact the distributor in your country, or the distributor closest
to you.
Mercury Installation Quality Certification Program
15502
Mercury MerCruiser products installed by a Mercury Installation Quality Certified Manufacturer are Installation Quality certified
products and may receive an additional one (1) year of limited warranty coverage.
The Installation Quality Certification program was developed to recognize MerCruiser boatbuilder customers who have
achieved higher manufacturing standards. It is the first and only comprehensive manufacturer‑installation certification program
in the industry.
The program has three goals:
1. To enhance overall product quality.
2. To improve the boat ownership experience.
3. To enhance overall customer satisfaction.
The certification process is designed to review all facets of manufacturing and engine installation. The program is composed of
design, manufacturing and installation review stages with which builders must comply. Certification applies leading‑edge
methodologies to create:
• Efficiencies and best practices specific to engine installation.
• World‑class assembly and component specifications.
• Efficient installation processes.
• Industry standard end‑of‑line test procedures
Boat builders that successfully complete the program and meet all certification requirements earn Installation Quality System
Certified Manufacturer status and receive an additional one (1) year of Mercury limited factory warranty coverage on all
MerCruiser‑powered boats that are registered on and after the boat builder's certification date for all worldwide registrations.
90-879288268 eng JULY 2009 Page 3

Mercury has designated a section of our Website to promote the Installation Quality Certification Program and communicate its
benefits to consumers. For a current list of MerCruiser‑powered boat brands that have earned Installation Quality Certification,
visit www.mercurymarine.com/mercruiser_warranty.
Mercury Product Protection Plan: United States and Canada

IMPORTANT: Certain performance products, triple engine installations, and commercial applications are excluded from the
Mercury Product Protection Plan program.
The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical breakdowns that may
occur beyond the standard limited warranty. The plan may be purchased up to twelve months after the original engine
registration date and is available with terms ranging from one to five years.
The optional Mercury Product Protection Plan is the only factory authorized extended warranty plan available for your engine.
See your participating Mercury MerCruiser dealer for complete program details.
Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)

Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
What is Covered
Mercury Marine warrants its new products to be free of defects in material and workmanship during the period described
following.
Duration of Coverage
Warranty Period for Recreational Use
The warranty period begins on the date the product is first sold to a recreational‑use retail purchaser or the date on which
the product is first put into service, whichever occurs first. Products installed by an Installation Quality Certified Installer
receive one (1) year of additional warranty coverage. The repair or replacement of parts or the performance of service under
this warranty does not extend the life of this warranty beyond its original expiration date. The warranty period is specific to
the model covered; see your model for the base coverage period:
Coverage for Horizon Inboard Models, and Vazer 100 Sterndrive Models
The Limited Warranty for Horizon Inboard Models and Vazer 100 Models is four (4) years when installed by an
Installation Quality Certified Installer or three (3) years for non‑certified installations.
Coverage for SeaCore Sterndrive Models
The Limited Warranty for SeaCore Sterndrive Models is four (4) years when installed by an Installation Quality Certified
Installer or three (3) years for non‑certified installations.
Coverage for Tow Sports Inboard Models
The Limited Warranty for Tow Sports 5.7 TKS models is two (2) years when installed by an Installation Quality Certified
Installer or one (1) year for non‑certified installations.
The Limited Warranty for all other Tow Sports Inboard models is three (3) years when installed by an Installation
Quality Certified Installer or two (2) years for non‑certified installations.
Coverage for All Other Models
The Limited Warranty for all other Gasoline Sterndrive and Inboard models except those described above is two (2)
years when installed by an Installation Quality Certified Installer or one (1) year for non‑certified installations.
Warranty Period for Commercial Use
The warranty period begins on the date the product is first sold to a commercial‑use retail purchaser or the date on which
the product is first put into service, whichever occurs first. Commercial users of these products receive warranty coverage
for either one (1) year from the date of first retail sale or the accumulation of 500 hours of operation, whichever occurs first.
Commercial use is defined as any work‑related or employment‑related use of the product, or any use of the product that
generates income for any part of the warranty period, even if the product is only occasionally used for such purposes. The
repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty
beyond its original expiration date.
Transfer of Coverage
Unexpired warranty coverage can be transferred from one recreational‑use customer to a subsequent recreational‑use customer
upon proper reregistration of the product. Unexpired warranty coverage cannot be transferred either to or from a commercial‑use
customer.
Page 4 90-879288268 eng JULY 2009

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

Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute
the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by
Mercury Marine is completed and documented. Warranty coverage becomes available upon proper registration of the product by
the authorized dealer. Inaccurate warranty registration information regarding recreational use or subsequent change of use from
recreational to commercial (unless properly reregistered) may void the warranty at the sole discretion of Mercury Marine. Routine
maintenance must be performed according to the maintenance schedule in the Operation, Maintenance & Warranty manual in
order to obtain warranty coverage. Mercury Marine reserves the right to make any warranty coverage contingent upon proof of
proper maintenance.
What Mercury Marine Will Do

Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing
such part or parts with new or Mercury Marine certified remanufactured parts, or refunding the purchase price of the Mercury
Marine product. Mercury Marine reserves the right to improve or modify products from time to time without assuming an
obligation to modify products previously manufactured.
How to Obtain Warranty Coverage

The customer must provide Mercury Marine with a reasonable opportunity to repair and reasonable access to the product for
warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury Marine dealer authorized
to service the product. If the purchaser cannot deliver the product to such a dealer, written notice must be given to Mercury
Marine. Mercury Marine will then arrange for the inspection and any covered repair. The purchaser in that case shall pay for all
related transportation charges and travel time. If the service provided is not covered by this warranty, the purchaser shall pay for
all related labor and material and any other expenses associated with that service. The purchaser shall not, unless requested by
Mercury Marine, ship the product or parts of the product directly to Mercury Marine. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested in order to obtain coverage.
90-879288268 eng JULY 2009 Page 5

What Is Not Covered

This limited warranty does not cover the following:
• Routine maintenance items
• Adjustments
• Normal wear and tear
• Damage caused by abuse
• Abnormal use
• Use of a propeller or gear ratio that does not allow the engine to run in its recommended RPM range (see the Operation,
Maintenance & Warranty manual)
• Operation of the product in a manner inconsistent with the recommended operation and duty cycle section of the Operation,
Maintenance & Warranty manual
• Neglect
• Accident
• Submersion
• Improper installation (proper installation specifications and techniques are set forth in the installation instructions for the
product)
• Improper service
• Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product
• Jet pump impellers and liners
• Operation with fuels, oils, or lubricants that are not suitable for use with the product (see the Operation, Maintenance &
Warranty manual)
• Alteration or removal of parts
• Water entering the engine through the fuel intake, air intake, or exhaust system or damage to the product from insufficient
cooling water caused by blockage of the cooling system by a foreign body
• Running the engine out of water
• Mounting the engine too high on the transom
• Operating the boat with the engine over trimmed
Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any point, even by a
previous owner of the product, voids the warranty. Expenses related to haul‑out, launch, towing, storage, telephone, rental,
inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other type of incidental or
consequential damages are not covered by this warranty. Also, expenses associated with the removal or replacement of boat
partitions or other material in order to gain access to the product are not covered by this warranty. No individual or entity,
including Mercury Marine authorized dealers, has been given authority by Mercury Marine to make any affirmation,
representation, or warranty regarding the product, other than those contained in this limited warranty. If such affirmation,
representation, or warranty is made, it shall not be enforceable against Mercury Marine.
DISCLAIMERS AND LIMITATIONS

THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY
DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE
EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE
DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH
VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY.
3‑Year Limited Warranty Against Corrosion

3‑YEAR LIMITED WARRANTY AGAINST CORROSION
What Is Covered
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M2 Jet Drive,
Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be
rendered inoperative as a direct result of corrosion for the period of time described below.
Duration of Coverage
Page 6 90-879288268 eng JULY 2009

This limited corrosion warranty provides coverage for three (3) years from either the date the product is
first sold, or the date on which the product is first put into service, whichever occurs first. The repair and
replacement of parts, or the performance of service under this warranty does not extend the life of this
warranty beyond its original expiration date. Unexpired warranty coverage can be transferred to
subsequent (noncommercial use) purchaser upon proper re‑registration of the product. Warranty
coverage is terminated for used product repossessed from a retail customer, purchased at auction, from
a salvage yard, or from an insurance company that obtained the product as a result of an insurance
claim.
Condition That Must Be Met in Order to Obtain Warranty Coverage
Warranty coverage is available only to retail customers that purchase from a dealer authorized by
Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the
Mercury Marine specified pre‑delivery inspection process is completed and documented. Warranty
coverage becomes available upon proper registration of the product by the authorized dealer. Corrosion
prevention devices specified in the Operation, Maintenance & Warranty manual must be in use on the
boat, and routine maintenance outlined in the Operation, Maintenance & Warranty manual must be timely
performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants,
and touch‑up of nicks and scratches) in order to maintain warranty coverage. Mercury Marine reserves
the right to make warranty coverage contingent upon proof of proper maintenance.
What Mercury Will Do
Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a
corroded part, replacing such part or parts with new or Mercury Marine certified re‑manufactured parts, or
refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify
products from time to time without assuming an obligation to modify products previously manufactured.
How to Obtain Warranty Coverage
The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to
the product for warranty service. Warranty claims shall be made by delivering the product for inspection
to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a
dealer, written notice must be given to Mercury. We will then arrange for the inspection and any covered
repair. Purchaser in that case shall pay for all related transportation charges and/or travel time. If the
service provided is not covered by this warranty, purchaser shall pay for all related labor and material,
and any other expenses associated with that service. Purchaser shall not, unless requested by Mercury,
ship the product or parts of the product directly to Mercury. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested in order to obtain coverage.
What Is Not Covered
This limited warranty does not cover electrical system corrosion; corrosion resulting from damage,
corrosion which causes purely cosmetic damage, abuse or improper service; corrosion to accessories,
instruments, steering systems; corrosion to factory installed jet drive unit; damage due to marine growth;
product sold with less than a one year limited Product warranty; replacement parts (parts purchased by
the Customer); products used in a commercial application. Commercial use is defined as any work or
employment related use of the product, or any use of the product which generates income, for any part of
warranty period, even if the product is only occasionally used for such purposes.
90-879288268 eng JULY 2009 Page 7

Global Application Warranty Charts

Warranty for Consumer Applications
Standard Factory Limited Warranty by
Certification Status of Boat Manufacturer Consumer Limited
Engine Model Region
Installation Quality Corrosion Warranty
Not Certified
Certified
The Americas (excluding Brazil) 1 year 3 years
2 years
Brazil 2 years
Europe, Middle East, Africa 2 years 3 years
3 years
3.0 TKS Australia, New Zealand 2 years
Japan 1 year 1 year 1 year
South Pacific 2 years 2 years 2 years
Other Asia 1 year 1 year 1 year
Warranty for Commercial Applications

Certification Status of Boat Manufacturer Commercial Limited
Engine Model Region
Not Certified
Certified
The Americas (excluding
1 year 1 year 1 year
Brazil)
Brazil 2 years 2 years 2 years
Europe, Middle East, Africa
3.0 TKS
Australia, New Zealand
Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours
South Pacific
Other Asia
Warranty for Government Applications

Certification Status of Boat Manufacturer Government Limited
Engine Model Region
Not Certified
Certified
The Americas (excluding Brazil) 1 year 1 year 3 years
Brazil 2 years 2 years 2 years
Europe, Middle East, Africa 3 years
3.0 TKS Australia, New Zealand
Japan 1 year or 500 hours 1 year or 500 hours
1 year or 500 hours
South Pacific
Other Asia
Mercury MerCruiser Warranty Charts

IMPORTANT: Please refer to www.mercurymarine.com/global_warranty for the most currant Global Warranty Charts.
Page 8 90-879288268 eng JULY 2009

Consumer Application Warranty Chart

Limited Corrosion
Consumer Application: Standard Factory Limited Warranty by Region & Boat Brand
Warranty
Non‑Certified Boat Brand Certified Boat Brand All Boat Brands
Vazer,
Vazer Vazer Standard
and and Models,
Standar Models Scorpio Standar Models Scorpio and and
Region SeaCore SeaCore SeaCore
d with n 377 d with n 377 Models
Closed Closed with
Cooling Cooling Closed
Cooling
USA and
1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years
Canada
Latin
1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years
America
Mexico 1 year 3 years 1 year 1 year 1 year 4 years 1 year 1 year 1 year 4 years
Europe 2 years 3 years 2 years 2 years 3 years 4 years 3 years 3 years 3 years 4 years
Japan 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year
Australia 3 years 3 years
and New 2 years 3 years 3 years all Tow 2 years 3 years 3 years all Tow 3 years 4 years
Zealand Sports Sports
South
1 year 3 years 1 year 1 year 1 year 3 years 1 year 1 year 3 years 4 years
Pacific
Asia
(excludin
g Japan,
3 years 3 years
South
2 years 2 years 2 years all Tow 2 years 2 years 2 years all Tow 2 years 2 years
Pacific,
Sports Sports
Australia,
New
Zealand)
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies.
NOTE: In regions where TBD (To Be Determined) is listed, check with your local dealer for warranty length and conditions.
90-879288268 eng JULY 2009 Page 9

Commercial Application Warranty Chart

Limited Corrosion
Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand
Warranty
Vazer,
and and Models,
Closed Closed with
Cooling
1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
USA and 1 year or 1 year or
500 500 500 500 500 500 none none
Canada 500 hours 500 hours
hours hours hours hours hours hours
Latin 1 year or 1 year or
500 500 500 500 500 500 none none
America 500 hours 500 hours
Mexico 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year 1 year
1 year or 1 year or
Europe 500 500 500 500 500 500 none none
500 hours 500 hours
1 year or 1 year or
Japan 500 500 500 500 500 500 none none
500 hours 500 hours
Australia 1 year or 1 year or 1 year or 1 year or 1 year or 1 year or
1 year or 1 year or
and New 500 500 500 500 500 500 none none
500 hours 500 hours
Zealand hours hours hours hours hours hours
South 1 year or 1 year or
500 500 500 500 500 500 none none
Pacific 500 hours 500 hours
Asia
(excludin
g Japan,
500 500 500 500 500 500 none none
Pacific, 500 hours 500 hours
Australia,
New
Zealand)
NOTE: In regions where the Certified Boat Builder program is not applicable, the regular warranty always applies
Page 10 90-879288268 eng JULY 2009

Government Application Warranty Chart

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

Important Information
To identify the applicable emission control warranty coverage for a particular product, refer to the Emission Control
Information label affixed to the engine.
Engines designated as exempt from either Federal EPA or California emission control regulations are not covered by a
separate emission control component warranty. The product's Mercury MerCruiser manufacturer's warranty is not affected by
the engine's designation under Federal EPA or California emission control regulations.
For a list of typical emission control related engine components, refer to Emission Control System Components in the
warranty section of your owners manual.
90-879288268 eng JULY 2009 Page 11

Emission Control Information Label

A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by
Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, STD
(emission standard/level), date of manufacture (month, year), and the engine displacement. Please note that the low emissions
certification will not affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or
the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of
replacement decals before proceeding.
NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine, the
Declaration of Conformance applies. Refer to the front page of this manual for further information.
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
SERIAL # XXXXXXXX MMM YYYY
D.O.M.
FAMILY XXXXXXXXXXXX
DISP X.XL
STD. XX.X g/kW-hr 0575
31656
Emission Control Label—California Emissions–Compliant
"SERIAL#"—Engine Serial Number

"FAMILY"—Engine Family
"STD."—Emissions Standard
"D.O.M."—Date of Manufacture
"DISP"—Piston Displacement
EMISSION CONTROL
INFORMATION
NOT FOR SALE IN CALIFORNIA

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

"FAMILY"—Engine Family
"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.
Page 12 90-879288268 eng JULY 2009

U.S. EPA Emissions Limited Warranty

Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of
three years or 480 hours of engine use whichever occurs first to the retail purchaser, that the engine is designed, built, and
equipped so as to conform at the time of sale with applicable regulations under section 213 of the Clean Air Act, and that the
engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations.
Emission Control System Components

The emission‑related warranty covers all components whose failure would increase an engine's emission of any regulated
component including the following list of components:
1. Fuel metering system
a. Carburetor and internal parts (or fuel pressure regulator or fuel injection system)
b. Air/fuel ratio feedback and control system
c. Cold start enrichment system
d. Intake valves
2. Air induction system
a. Controlled hot air intake system
b. Intake manifold
c. Air filter
d. Turbo charger systems
e. Heat riser valve and assembly
3. Ignition system
a. Spark plugs
b. Magneto or electronic ignition system
c. Spark control system
d. Ignition coil or control module
e. Ignition wires
4. Lubrication system
a. Oil pump and internal parts
b. Oil injectors
c. Oil meter
5. Positive crankcase ventilation (PCV) system
a. PCV valve
b. Oil filler cap
6. Exhaust system
a. Exhaust manifold
b. Exhaust elbow
c. Intermediate exhaust elbow
d. Lower exhaust pipe
e. Tailpipe
7. Catalysts or thermal reactor system
a. Catalytic converter
b. Thermal reactor
c. Exhaust manifold
d. Exhaust valves
8. Miscellaneous items used in above systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware
b. Pulleys, belts, and idlers
c. Vacuum, temperature, check and time sensitive valves and switches
d. Electronic controls
NOTE: The emission‑related warranty does not cover components whose failure would not increase an engine's emissions on
any regulated pollutant.
90-879288268 eng JULY 2009 Page 13

Notes:
Page 14 90-879288268 eng JULY 2009


Table of Contents
Identification......................................................................... 16
Alpha Sterndrive Decal Identification............................. 16
Console Mount Features .............................................. 20
Power Trim........................................................................... 20
2
Alpha Transom Serial Number...................................... 16 Single Engine Trim/Trailer ............................................ 21
Engine Serial Number Decal......................................... 17 Dual Engine Trim/Trailer ............................................... 21
Lanyard Stop Switch............................................................. 17 Electrical System Overload Protection‑Carbureted Engines
Instrumentation..................................................................... 18 .............................................................................................. 21
Remote Controls................................................................... 19 Audio Warning System......................................................... 24
Panel Mount Features .................................................. 19 Testing The Audio Warning System ............................. 24
90-879288268 eng JULY 2009 Page 15

Identification
The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power
package. When contacting MerCruiser about service, always specify model and serial numbers.
Alpha Sterndrive Decal Identification

The drive serial number is located on the port side of the Alpha sterndrive.
The drive ratio is located on the starboard side of the Alpha sterndrive.
Alpha sterndrive
a - Drive gear ratio decal (starboard)
b - Serial number decal (port)
a b
25681
Alpha Transom Serial Number

The transom serial number is located on the top of the transom assembly.
25619
Alpha transom assembly serial number
Page 16 90-879288268 eng JULY 2009

Engine Serial Number Decal

The serial number decal is located on the aft portion of the starboard side of the block, near the starter motor.
32121
The engine, transom, and drive serial numbers are also located on the engine identification plate.
a - Engine serial number

b - Transom serial number
c - Drive serial number
32636
Lanyard Stop Switch

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

b b - Lanyard
c - Clips to the operator
c
74608
Accidental ejections, such as falling overboard, are more likely to occur in:
• low‑sided sport boats
• bass boats
• high performance boats
Accidental ejections can also occur from:
• poor operating practices
• sitting on the seat or gunwale at planing speeds
90-879288268 eng JULY 2009 Page 17

• standing at planing speeds
• operating at planing speeds in shallow or obstacle infested waters
• releasing your grip on the steering wheel that is pulling in one direction
• consuming alcohol or drugs
• high speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) in length when stretched out, with an element on one end
made to be inserted into the switch and a snap on the other end for attaching to the operator. The lanyard is coiled to make its
at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out
length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close
to the normal operator's position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or
tie a knot in the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance
depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the
boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be
required to operate the engine in an emergency (e.g. if the operator is accidentally ejected).
! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the stop switch using a lanyard.
Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of
the following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the
front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.
• Loss of power and directional control in heavy seas, strong current or high winds.
• Loss of control when docking.
! WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Instrumentation
The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar
with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have
your boat dealer explain the particular gauges and normal readings for your boat.
50
90
60
3
4
5 a- Speedometer
b- Tachometer
80 100
40 70 110 70 2 6
60
50 120 C H
30 40
L H 10 16
30 1
c- Oil pressure gauge

KPH 7
20
80 X 1000
10 0 8 BATT TEMP
MPH RPM OIL
d- Voltmeter
e- Water temperature
a b c d e gauge
f - Fuel gauge
g - Hour meter
0 4 0 0 0 0 0
h - Bilge blower switch
4
i - Ignition switch
4
CRUISELOG
FUEL
TRIM
j - Power trim gauge
f g h i j 14671
Speedometer: Indicates boat speed.

Tachometer: Indicates engine RPM.
Oil Pressure Gauge: Indicates engine oil pressure.
Voltmeter: Indicates battery voltage.
Water Temperature Gauge: Indicates engine operating temperature.
Page 18 90-879288268 eng JULY 2009

Fuel Gauge: Indicates quantity of fuel in tank.
Hour meter: Records engine operating time.
Bilge Blower Switch: Operates bilge blower.
Ignition Switch: Allows operator to start and stop engine.
Power Trim Gauge: Indicates sterndrive unit angle (trim up/out and down/in).
Remote Controls
Your boat may be equipped with a Mercury Precision Parts or Quicksilver remote controls. All controls may not have all
features shown. Consult your dealer for a description and/or demonstration of your remote control.
Panel Mount Features

a e a- Neutral lock button
b- Throttle only button
f c- Lanyard stop switch
d- Control handle tension adjustment screw
e- Control handle
b f- Trim/tilt button
c
d
mc77019-1
Neutral Lock Button ‑ Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the
control handle out of neutral.
Throttle Only Button ‑ Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the
neutral position, and should only be used to assist in starting the engine.
Lanyard Stop Switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away
from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.
Control Handle ‑ Operation of the shift and throttle are controlled by the movement of the control handle. Push the control
handle forward from neutral with a quick firm motion to the first detent for forward gear. Continue pushing forward to increase
speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and continue
pushing back to increase speed.
Control Handle Tension Adjustment Screw ‑ (not visible) This screw is used to adjust the effort required to move the
remote control handle. Refer to instructions provided with remote control for complete adjustment instructions.
Trim/Tilt Button ‑ Refer to Power Trim.
90-879288268 eng JULY 2009 Page 19

Console Mount Features

b a- Throttle Only Button
b b- Control Handle
d c c- Power Trim Switch
d- Trailer Switch
a d
a c mc79503-1
Throttle Only Button ‑ Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the
neutral position.
Control Handles ‑ Operation of the the shift and throttle are controlled by the movement of the control handle. Push the control
handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to
increase speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and
continue pushing back to increase speed.
Control Handle Tension Adjustment Screw ‑ (not visible) This screw is used to adjust the effort required to move the
remote control handle. Refer to instructions provided with remote control for complete adjustment instructions.
Power Trim Switch ‑ See Power Trim section for detailed power trim operating procedures.
Trailer Switch ‑ Used to raise drive unit for trailering, launching, beaching or shallow water operation. See Power Trim for
detailed trailer switch operation.
Power Trim
Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load
and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering,
beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
! WARNING
Excessive trim can cause serious injury or death at high speeds. Use caution when trimming the sterndrive, and never trim
out beyond the gimbal ring support flanges while the boat is underway or at engine speeds above 1200 RPM.
For best performance trim the sterndrive unit so that the boat bottom is at a 3‑5° angle to the water.
3-5
mc79528
Trimming sterndrive unit up/out can:

• Generally increase top speed
• Increase clearance over submerged objects or a shallow bottom
• Cause boat to accelerate and plane off slower
Page 20 90-879288268 eng JULY 2009

• In excess, cause boat porpoising (bouncing) or propeller ventilation
• Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the water line
mc78529
Trimming sterndrive unit down/in can:

• Help the boat accelerate and plane off quicker
• Generally improve the ride in choppy water
• In most cases, reduce boat speed
• If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane.
This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a
significant wave is encountered.
mc79530
Single Engine Trim/Trailer

Single engine applications will have a button that can be pressed to trim the sterndrive unit up or down.
To raise the sterndrive unit for trailering, beaching, launching, low speed (below 1200 rpm), and shallow water operation push
the trim button to raise the sterndrive unit to the full up/out position.
Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.
Dual Engine Trim/Trailer

NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering
systems. If using an external tie bar, raise and lower all drives together as a unit.
Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have
separate buttons for each sterndrive unit.
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.
Electrical System Overload Protection‑Carbureted Engines

If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected
before replacing the fuse or resetting the circuit breaker.
NOTE: In an emergency, when the engine must be operated and the cause for the high current draw cannot be located and
corrected, turn off or disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker. If
the breaker remains open, the electrical overload has not been eliminated. Further checks must be made on the electrical
system. Contact your authorized dealer.
90-879288268 eng JULY 2009 Page 21

1. A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker
can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the
yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
Yellow lever style circuit breaker-typical

a - Yellow lever‑shown tripped
b - Red test button
22529
2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring
harness if an electrical overload occurs.
mc74907-1
3. A 15 amp accessory fuse is located on the rear of the engine. This fuse protects the accessory circuits. A 20 amp fuse is
located on the top of the engne to protect the TKS circuit.
7524
Page 22 90-879288268 eng JULY 2009

4. A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse
if the ignition key is turned to the "START" position and nothing happens (and circuit breaker is not tripped).
mc70525-1
5. The power trim system is protected from overload by a 110 amp fuse and a 20 amp spade fuse on the power trim pump.
The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or
battery connection.
a - 20 amp spade fuse

b - 110 amp fuse
b 9208
6. The Quicksilver Three‑Button Power Trim Control Panel is further protected by a 20 amp in‑line fuse.
mc70527-1
90-879288268 eng JULY 2009 Page 23

7. The Quicksilver MerCathode System has a 20 amp in‑line fuse in the wire which connects to the positive (+) terminal on
controller. If the fuse is blown, the system will not operate resulting in a loss of corrosion protection.
mc79977
Audio Warning System

Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not
protect the engine from damage. It is designed to warn the operator that a problem has occurred.
The audio warning system will sound with a continuous horn if one of the following occurs:
• Engine oil pressure too low
• Engine temperature too hot
• Sterndrive oil level too low
NOTICE
A continuous horn indicates a critical fault. Operating the engine during a critical fault can damage components. If the
warning horn emits a continuous beep, do not operate the engine unless avoiding a hazardous situation.
If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be
determined, contact your authorized Mercury MerCruiser dealer.
Testing The Audio Warning System

1. Turn the ignition switch to the "ON" position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
Page 24 90-879288268 eng JULY 2009


Table of Contents
Safe Boating Suggestions.................................................... 26 Passenger Safety in Pontoon Boats and Deck Boats.......... 30
Be Alert to Carbon Monoxide Poisoning............................... 27 Boats Having an Open Front Deck ............................... 30
Good Ventilation ........................................................... 27 Boats With Front‑Mounted, Raised Pedestal Fishing
Poor Ventilation ........................................................... 27 Seats ............................................................................ 31
Basic Boat Operation............................................................ 28
Launching and Boat Operation...................................... 28
Wave and Wake Jumping..................................................... 31
Impact with Underwater Hazards......................................... 31 3
Operation Chart ..................................................... 28 Drive Unit Impact Protection ......................................... 32
Starting and Stopping the Engine.................................. 28 Conditions Affecting Operation............................................. 32
Starting the Engine ................................................ 28 Weight Distribution (Passengers and Gear) Inside the
Stopping the Engine .............................................. 29 Boat............................................................................... 32
Starting the Engine After It Has Been Stopped While In The Bottom of the Boat.................................................. 32
Gear............................................................................... 29 Cavitation....................................................................... 33
Throttle‑Only Operation................................................. 29 Ventilation...................................................................... 33
Trailering the Boat......................................................... 29 Elevation and Climate.................................................... 33
Freezing Temperature Operation.................................. 29 Propeller Selection......................................................... 33
Drain Plug and Bilge Pump............................................ 30 Getting Started..................................................................... 33
Protecting People in the Water............................................. 30 20‑Hour Break‑In Period................................................ 33
While You Are Cruising ................................................ 30 After Break‑In Period..................................................... 34
While Boat Is Stationary ............................................... 30 End of First Season Checkup........................................ 34
High‑Speed and High‑Performance Operation..................... 30
90-879288268 eng JULY 2009 Page 25

Safe Boating Suggestions

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions
and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
• We recommend that all powerboat operators complete a boating safety course. In the US, the U.S. Coast Guard Auxiliary,
the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For
more information in the US, call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment on board.
• Here are some suggestions of the types of safety equipment to carry when boating:
• Approved fire extinguishers
• Signal devices: flashlight, rockets or flares, flag and whistle or horn
• Tools necessary for minor repairs
• Anchor and extra anchor line
• Manual bilge pump and extra drain plugs
• Drinking water
• Transistor radio
• Paddle or oar
• Spare propeller, thrust hubs, and an appropriate wrench
• First aid kit and instructions
• Water‑proof storage containers
• Spare operating equipment, batteries, bulbs and fuses
• Compass and map or chart of the area
• Personal flotation device (1 per person on board)
Watch for signs of weather change and avoid foul weather and rough‑sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Shifting the drive
unit into neutral is not sufficient.
Use personal flotation devices.
• Federal Law requires that there be a U. S. Coast Guard approved life jacket (personal flotation device), correctly sized and
readily accessible for every person on board, plus a throwable cushion or ring. We strongly advise that everyone wear a
life jacket at all times while in the boat.
Prepare other boat operators.
• Instruct at least 1 person on board in the basics of starting and operating the engine and boat handling in case the driver
becomes disabled or falls overboard.
Do not overload your boat.
• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your
boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized
Mercury MerCruiser dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of
seats, gunwales, transom, bow, decks, raised fishing seats and any rotating fishing seat; anywhere that sudden
unexpected acceleration, sudden stopping, unexpected loss of boat control or sudden boat movement could cause a
person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat
movement.
Never be under the influence of alcohol or drugs while boating (it is the law).
• They impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
Be alert.
Page 26 90-879288268 eng JULY 2009

• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have
an unobstructed view particularly to the front. No passengers, load or fishing seats should block the operators view when
the boat is above idle or planing transition speed. Watch out for others, the water and your wake.
Never drive your boat directly behind a water skier in case the skier falls.
• As an example, your boat traveling at 40 km/h (25 MPH) will overtake a fallen skier who was 61 m (200 ft.) in
front of you in 5 seconds.
Watch fallen skiers.
• When using your boat for water skiing or similar activities, always keep a fallen or down skier on the operator's side of the
boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to
the skier or anyone in the water.
Report accidents.
• Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when
their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable
loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other
property where the damage value exceeds $500.00 or 4) there is complete loss of the boat. Seek further assistance from
local law enforcement.
Be Alert to Carbon Monoxide Poisoning

Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and
inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly
gas that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include
headache, dizziness, drowsiness and nausea.
! WARNING
Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest
or underway and avoid prolonged exposure to carbon monoxide.
Good Ventilation
Ventilate the passenger area, open the side curtains or forward hatches to remove fumes.
1. Example of desired air flow through the boat.
mc79553-1
Poor Ventilation
Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in
carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that
contains or is near an operating engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while a boat is stationary:
a - Operating the engine when

the boat is moored in a
confined space
a b mc79554-1 b - Mooring close to another
boat with its engine operating
90-879288268 eng JULY 2009 Page 27

2. Examples of poor ventilation while a boat is moving:
a - Operating the boat with the

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

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

NOTE: Only perform those functions applicable to your power package.
Starting the Engine
1. Check all items listed in the Operation Chart.
2. Place the remote control handle in neutral.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
Page 28 90-879288268 eng JULY 2009

! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before
starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes.
3. Turn ignition key to "START". Release key when engine starts and allow switch to return to "ON" position. Allow the engine
to warm up (6–10 minutes on the first start of the day).
NOTE: If the engine has not run for a long period of time it may require a couple of attempts.
4. If engine does not start after 3 attempts:
a. Push the throttle only button and position the remote control handle/throttle lever to the 1/4 throttle position.
b. Turn ignition key to "START". Release key when engine starts and allow switch to return to "ON" position.
5. If engine does not start after step 4:
a. Move the remote control handle/throttle lever to full throttle position, then return to 1/4 throttle.
b. Turn ignition key to "START". Release key when engine starts and allow switch to return to "ON" position.
6. Inspect the power package for fuel, oil, water and exhaust leaks.
7. Move control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting,
advance throttle to desired setting.
NOTICE
Shifting into gear at engine speeds above idle will damage the gearcase. Shifting into gear when the engine is not running
can cause misalign the clutch, preventing proper shifting. Always shift the gearcase into gear when the engine is operating at
idle. If you must shift while the engine is not operating, rotate the propeller shaft in the appropriate direction during shifting.
Stopping the Engine

1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at
high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes.
2. Turn ignition key to the "OFF" position.
Starting the Engine After It Has Been Stopped While In Gear

IMPORTANT: Avoid stopping the engine if the sterndrive unit is in gear. If the engine does stop, refer to the following
procedure:
1. Push and pull repeatedly on the remote control handle until handle returns to the neutral/idle position. This may take
several tries if the power package was operating above idle RPM when the engine stopped.
2. After the handle returns to the neutral/idle position, resume normal starting procedures.
Throttle‑Only Operation
1. Refer to Remote Controls section for remote control features.
2. Move the control lever to the idle/neutral position.
3. Depress and hold the throttle only button, and move the control lever to the idle/forward or idle/reverse position.
4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase.
IMPORTANT: Moving the control lever back to the idle/neutral position will disengage the throttle only button and allow the
engine to shift into gear.
5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position. Moving the control lever from the
idle/neutral position to the idle/forward or idle/reverse position without pressing the throttle only button will shift the unit into
the chosen gear.
Trailering the Boat

Your boat can be trailered with the sterndrive unit in the up or down position. Adequate clearance is required between the road
and sterndrive when transporting.
If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit
which is available from your authorized Mercury MerCruiser dealer.
Freezing Temperature Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze
damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty.
90-879288268 eng JULY 2009 Page 29

Drain Plug and Bilge Pump

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

While You Are Cruising
It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.
21604
Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller
to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.
While Boat Is Stationary

! WARNING
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the water is near your boat.
Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat.
High‑Speed and High‑Performance Operation

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

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats
other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a
large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat.
Falling over the front of the boat between the two pontoons will position them to be run over.
Boats Having an Open Front Deck

No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence
or enclosure.
Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their
legs caught by a wave and pulled into the water.
mc79555-1
Page 30 90-879288268 eng JULY 2009

! WARNING
Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
Boats With Front‑Mounted, Raised Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats
designated for traveling at faster speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.
mc79557-1
Wave and Wake Jumping

! WARNING
Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave
or wake jumping whenever possible.
mc79680-1
Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with
enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat
re‑enters the water.
The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the
boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their
seats or out of the boat.
There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat
pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an
instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer
sharply to one side.
Impact with Underwater Hazards

Reduce speed and proceed with caution whenever you're driving a boat in shallow water or in areas where the waters are
suspected of having underwater obstacles that could be struck by the underwater drive components, rudder or the boat bottom.
mc79679-1
90-879288268 eng JULY 2009 Page 31

IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or
underwater object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of
24 to 40 km/h (15 to 25 mph).
Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could result in the
following:
• The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occupants to be
thrown out of their seats or out of the boat.
• A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.
• Impact damage to the underwater drive components, rudder and/or boat.
Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situations is control
the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater
obstacles.
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose
parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a
thorough inspection and necessary repair.
The boat should be checked for hull fractures, transom fractures and water leaks.
Operating with damaged underwater drive components, rudder or boat bottom could cause additional damage to other parts of
the power package, or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.
! WARNING
Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel
experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
Drive Unit Impact Protection

The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck
while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object,
reducing damage to the unit. After the sterndrive unit has cleared the object, the hydraulic system allows the sterndrive unit to
return to its original operating position, preventing loss of steering control and engine overspeed.
Use extreme caution when operating in shallow water or where underwater objects are known to be present. No impact
protection is provided in reverse; use extreme care to prevent striking submerged objects while operating in reverse.
IMPORTANT: Impact protection system cannot be designed to ensure total protection from impact damage under all
conditions.
Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to rear (stern):
• Generally increases speed and engine RPM
• Causes bow to bounce in choppy water
• Increases danger of following wave splashing into the boat when coming off plane
• At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
• Improves ease of planing
• Improves rough water ride
• At extremes, can cause the boat to veer back and forth (bow steer)
The Bottom of the Boat

To maintain maximum speed, the boat bottom should be:
• Clean, free of barnacles and marine growth
• Free of distortion; nearly flat where it contacts the water
• Straight and smooth, fore and aft
Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the
water inlets and cause the engine to overheat.
Page 32 90-879288268 eng JULY 2009

Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the
gear housing or the propeller. Common causes of cavitation are:
• Weeds or other debris snagged on the propeller
• Bent propeller blade
• Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up
and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to
continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
• Drive unit trimmed out too far
• A missing propeller diffuser ring
• A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing
• Drive unit installed too high on transom
Elevation and Climate

Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by:
• Higher elevations
• Higher temperatures
• Low barometric pressures
• High humidity
For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to
allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your
normal boating weather conditions.
In most cases, recommended RPM can be achieved by changing to a lower pitch propeller.
Propeller Selection
IMPORTANT: The engines covered in this manual are equipped with an RPM rev‑limiter that is set to an upper RPM limit. This
limit, which is slightly above the normal operating range of the engine, helps prevent damage from excessive engine RPM.
Once the RPM returns to the recommended operating RPM range, normal engine operation resumes.
The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer
to Mercury Marine's web page http://www.mercurymarine.com/everything_you_need_to_know_about_propellers6.
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 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 a dirty boat bottom 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 waterskiing, use the next lower pitch propeller. When not pulling skiers, do not
operate at full throttle when using the lower pitch propeller.
Getting Started
20‑Hour Break‑In Period
IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil
consumption and maximum engine performance. During this break‑in period, the following rules must be observed:
• Do not operate below 1500 RPM for extended periods of time for the first 10 hours. Shift into gear as soon as possible after
starting and advance the throttle above 1500 rpm if conditions permit safe operation.
• Do not operate at one speed consistently for extended periods.
90-879288268 eng JULY 2009 Page 33

• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is
permissible (5 minutes at a time maximum).
• Avoid full throttle acceleration from idle speed.
• Do not operate at full throttle until the engine reaches normal operating temperature.
• Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period.
After Break‑In Period

To help extend the life of your Mercury MerCruiser power package, the following recommendations should be considered;
• Ensure that propeller allows the engine to operate at or near the top of the specified WOT RPM range (Refer to
Specifications and Maintenance) when at full throttle with a normal boat load.
• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at WOT RPM.
• Change the engine oil and oil filter. Refer to Maintenance.
• Change the sterndrive lube or transmission oil and filter. Refer to Maintenance (ZF Transmission models).1.
End of First Season Checkup

At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform
scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact
your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
1. Require fluid and filter change after the first 25 hours and then every 100 hours.
Page 34 90-879288268 eng JULY 2009

Table of Contents
Fuel Requirements............................................................... 36 Engine Specifications........................................................... 37
Fuel Ratings ................................................................. 36 3.0 TKS.......................................................................... 37
Using Reformulated (Oxygenated) Gasolines (USA Only) Fluid Specifications............................................................... 38
...................................................................................... 36 Sterndrives ................................................................... 38
Gasolines Containing Alcohol ....................................... 36 Engine .......................................................................... 38
Engine Oil............................................................................. 36
90-879288268 eng JULY 2009 Page 35

Fuel Requirements
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper
gasoline is considered misuse of the engine and any resulting damage will not be covered under the limited warranty.
Fuel Ratings
Mercury MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline meeting the following
specifications:
USA and Canada—having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium gasoline 92 (R+M)/2 Octane is
also acceptable. Do not use leaded gasoline.
Outside USA and Canada—having a posted pump Octane Rating of 91 RON minimum. Premium gasoline (98 RON) is also
acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline.
Using Reformulated (Oxygenated) Gasolines (USA Only)

This type of gasoline is required in certain areas of the USA. The 2 types of oxygenates used in these fuels is alcohol (ethanol)
or ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to Gasolines Containing
Alcohol.
These reformulated gasolines are acceptable for use in your Mercury MerCruiser engine.
Gasolines Containing Alcohol

If the gasoline in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain
adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in
the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a
separation of the water‑alcohol mixture from the gasoline in the fuel tank.
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We
do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific
recommendations on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing
alcohol may increase:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through the rubber fuel lines
• Difficulty starting and operating the engine
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
Because of the possible adverse effects of alcohol in gasoline, we recommend only alcohol‑free gasoline when possible. If the
only fuel available contains alcohol or if you do not know whether the fuel contains alcohol, inspect for leaks and abnormalities
more frequently.
IMPORTANT: When operating a Mercury MerCruiser engine on gasoline containing alcohol, do not store the gasoline in the
fuel tank for long periods. Cars normally consume alcohol‑blend fuels before they can absorb enough moisture to cause
trouble, boats often sit idle long enough for phase separation to take place. Internal corrosion may take place during storage if
alcohol has washed protective oil films from internal components.
Engine Oil
To help obtain optimum engine performance and to provide maximum protection, we recommend using the following oil:
Application Recommended Oil

All MerCruiser engines Mercury MerCruiser Full‑Synthetic Engine Oil, 20W‑40, NMMA FC‑W rated
If the Mercury MerCruiser Full‑Synthetic, 20W‑40 oil is unavailable, you can use the following lubricants, listed in order of
recommendation:
1. Mercury/Quicksilver 25W‑40 Synthetic Blend, NMMA FC‑W–rated 4‑cycle MerCruiser oil
2. Mercury/Quicksilver 25W‑40, NMMA FC‑W–rated 4‑cycle MerCruiser oil
3. Other recognized brands of NMMA FC‑W–rated 4‑cycle oils
Page 36 90-879288268 eng JULY 2009

4. A good‑grade, straight‑weight detergent automotive oil per the operating chart below.
NOTE: We do not recommend non‑detergent oils, multi‑viscosity oils (other than as specified), non FC‑W–rated synthetic oils,
low‑quality oils, or oils that contain solid additives.
Mercury Full-Synthetic MerCruiser Engine Oil, 20W-40, NMMA FC-W rated
ORDER OF PREFERENCE
MerCruiser/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W rated 4-cycle MerCruiser oil
Mercury/Quicksilver 25W-40, NMMA FC-W rated 4-cycle MerCruiser oil
Other recognized brands of NMMA FC-W rated oils
SAE40W
SAE30W
SAE 20W
0° C 10° C
(32° F) (50° F)
AIR TEMPERATURE 32878
Engine Specifications
3.0 TKS
NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power.
All measurements are taken with the engine at normal operating temperature.
RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures.
Oil pressure must be checked with the engine at normal operating temperature.
NOTE: Oil pressure specifications are for reference and may vary.
Propshaft power 101 kW (135 hp)

Displacement 3.0 L (181 cid)
Hot 72 A
Alternator amperage
Cold 65 A
WOT 4400–4800
RPM Rev limiter 4950
Idle in neutral 700
At 2000 RPM 207 kPa (30 psi)
Minimum oil pressure
At idle 28 kPa (4 psi)
Seawater‑cooled models
Thermostat 71° C (160° F)
Models with closed cooling
Timing at idle 2° ATDC
Firing order 1‑3‑4‑2
Minimum battery rating 375 CCA, 475 MCA, 90 Ah
AC MR43LTS
Spark plug type Champion RS12YC
NGK BPR6EFS
Spark plug gap 0.9 mm (0.045 in.)
90-879288268 eng JULY 2009 Page 37

Fluid Specifications
Sterndrives
NOTE: Oil capacity includes the drive lube monitor.
Model Capacity Fluid Type

Alpha One 1892 mL (64 oz) High Performance Gear Lubricant
Engine
IMPORTANT: All capacities are approximate fluid measures.
3.0 TKS Capacity Fluid Type

Engine oil (with filter) 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser 20W‑40, NMMA FC‑W rated oil.
Seawater cooling system 9 L (8.5 US qt) Propylene glycol and purified water
Mercury Extended Life Coolant Antifreeze or extended life ethylene glycol 5/100
Closed cooling system 9 L (8.5 US qt)
antifreeze mixed 50/50 with purified water
Page 38 90-879288268 eng JULY 2009

Table of Contents
Owner/Operator Responsibilities.......................................... 40 Cleaning the Flame Arrestor................................................. 50
Dealer Responsibilities......................................................... 40 Positive Crankcase Ventilation Valve (PCV) ................ 51
Maintenance......................................................................... 40 Changing ............................................................... 51
Do‑It‑Yourself Maintenance Suggestions............................. 40 Changing the Water‑Separating Fuel Filter.......................... 52
Inspection............................................................................. 41 Fuel Pump Sight Tube Inspection........................................ 52
Maintenance Schedules....................................................... 41 Lubrication............................................................................ 53
Routine Maintenance..................................................... 41 Steering System............................................................ 53
Scheduled Maintenance................................................ 41 Manual Steering System................................................ 54
Maintenance Log.................................................................. 42 Throttle Cable................................................................ 55
Sealed Carburetor Mixture Screw........................................ 43 Shift Cable ‑ Typical....................................................... 55
Engine Oil............................................................................. 43 Sterndrive Unit and Transom Assembly........................ 56
Checking ....................................................................... 43 Sterndrive U‑joint Shaft Splines and O‑rings (Sterndrive
Filling ............................................................................ 44 Unit Removed)............................................................... 56
Changing Oil and Filter ................................................. 44
Easy Engine Oil Drain System .............................. 44
Engine Coupler.............................................................. 56
Driveshaft Extension Models......................................... 57 5
Engine Oil Drain Pump .......................................... 45 Propellers............................................................................. 57
Changing Filter ...................................................... 45 Propeller Repair............................................................. 57
Power Steering Fluid............................................................ 46 Alpha Propeller Removal............................................... 58
Checking ....................................................................... 46 Alpha Propeller Installation............................................ 58
Filling ............................................................................ 46 Drive Belts............................................................................ 59
Changing ...................................................................... 46 Checking ....................................................................... 59
Engine Coolant..................................................................... 46 Replacing ‑ Front Mount Models .................................. 59
Checking ....................................................................... 46 Power Steering Pump Drive Belt, if equipped ....... 59
Filling ............................................................................ 47 Alternator Belt ........................................................ 59
Changing ..................................................................... 48 Replacing ‑ Side Mount Models .................................... 60
Drive Unit Oil........................................................................ 48 Power Steering Pump Drive Belt, if equipped ....... 60
Checking ....................................................................... 48 Alternator Belt ........................................................ 60
Filling ............................................................................ 48 Flushing the Power Package................................................ 60
Changing ...................................................................... 48 Flushing Attachments ................................................... 61
Power Trim Fluid.................................................................. 50 Sterndrive Water Pickups ............................................. 61
Checking ....................................................................... 50 Battery.................................................................................. 62
Filling ............................................................................ 50 Corrosion Protection............................................................. 62
Changing ...................................................................... 50 Painting Your Power Package ...................................... 66
90-879288268 eng JULY 2009 Page 39

Owner/Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are
complied with for safe operation and to return the unit to an authorized Mercury MerCruiser dealer for a periodic checkup.
Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not
considered defects in workmanship or material within the terms of the warranty. Individual operating habits and usage
contribute to the need for maintenance service.
Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your
overall operating expenses at a minimum. See your authorized Mercury MerCruiser dealer for service aids.
Dealer Responsibilities
In general, a dealer's responsibilities to the customer include predelivery inspection and preparation such as:
• Ensure that the boat is properly equipped.
• Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating
condition.
• Make all necessary adjustments for maximum efficiency.
• Familiarize the customer with the on‑board equipment.
• Explain and demonstrate the operation of the power package and boat.
• Provide you with a copy of a Predelivery Inspection Checklist.
• Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon
sale of the new product.
Maintenance
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire
or explosion. Always ventilate the engine compartment before servicing the power package.
IMPORTANT: Refer to the maintenance schedule for the complete listing of all scheduled maintenance to be performed. Some
items should be performed only by an authorized Mercury MerCruiser dealer only. Before attempting maintenance or repair
procedures not covered in this manual, we recommend that you purchase a Mercury MerCruiser service manual and read it
thoroughly.
NOTE: Maintenance points are color‑coded for ease of identification.
Maintenance Point Color Codes

Yellow Engine oil
Black Drive lube
Brown Power steering fluid
Blue Raw water flush
Do‑It‑Yourself Maintenance Suggestions

Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery.
Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the
untrained mechanic.
If you are one of those persons who likes to do it yourself, here are some suggestions for you.
• Do not attempt any repairs unless you are aware of the Cautions, Warnings and procedures required. Your safety is our
concern.
• If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual
outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't
understand. Do not attempt repairs if you do not understand the procedures.
Page 40 90-879288268 eng JULY 2009

• There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs unless you
have these special tools and/or equipment. You can cause damage to the product in excess of the cost a dealer would
charge you.
• Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must
reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer
immediately upon having a problem. It may be a very simple adjustment to correct the problem.
• Do not telephone the dealer, service office or the factory to attempt for them to diagnose a problem or to request the repair
procedure. It is difficult for them to diagnose a problem over the telephone.
Your authorized dealer is there to service your power package. They have qualified factory trained mechanics.
It is recommended you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the
fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating
season when you want trouble free boating pleasure.
Inspection
Inspect your power package often, and at regular intervals, to help maintain its top operating performance and correct potential
problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.
• Check for loose, damaged or missing parts, hoses and clamps; tighten or replace as necessary.
• Check plug leads and electrical leads for damage.
• Remove and inspect the propeller. If badly nicked, bent or cracked, contact your authorized Mercury MerCruiser dealer.
• Repair nicks and corrosion damage on power package exterior finish. Contact your authorized Mercury MerCruiser dealer.
Maintenance Schedules
Routine Maintenance
NOTE: Only perform maintenance that applies to your particular power package.
Task Interval Maintenance to Be Performed

• Check the engine oil level. (You can extend this interval based on experience with the
product.)
• Check the sterndrive gear lube level.
Each day start • Check the trim pump oil level.
• Check the power‑assisted steering pump or the compact hydraulic steering fluid level,
depending on the steering system of your model.
• If operating in saltwater, brackish water, or polluted water, flush the seawater section of the
Each day end cooling system after each use.
• Check the water inlets for debris or marine growth.

• Check and clean the seawater strainer, if equipped.
Weekly • Check the coolant level.
• Inspect the sterndrive anodes and replace if 50% eroded.
• Lubricate the propeller shaft and retighten the nut. (If operating only in freshwater, you can
extend the interval to every four months.)
• If operating in saltwater, brackish water, or polluted water, apply Corrosion Guard to the
Every two months or 50 power package.
hours • Check the battery connections and the fluid level.
• Ensure that the gauges and the wiring connections are secure. Clean the gauges. (If
operating in saltwater, reduce this interval to every 25 hours or 30 days, whichever occurs
first.)
Scheduled Maintenance
NOTE: Only perform maintenance which applies to your particular power package.
90-879288268 eng JULY 2009 Page 41

Task Interval Maintenance to Be Performed

After the initial 20‑hour
Change the engine oil and filter.
break‑in period
Every 50 hours or 2
All Bravo models except 496 : Lubricate the engine coupler (lubricate the engine coupler every 50
months
hours if operated at idle for prolonged periods of time).
(whichever occurs first)
• Touch‑up the paint on the power package.
• Change the engine oil and filter.
• Change the sterndrive gear lube.
• On models with closed cooling, check the coolant level and antifreeze concentration for
adequate freeze protection. Correct if necessary. Refer to the Specifications section.
• Tighten the connection of the gimbal ring to the steering shaft to specifications.
• Replace the water‑separating fuel filter.
Every 100 hours or
• Check the steering system and the remote control for loose, missing, or damaged parts.
annually
Lubricate the cables and the linkages.
• Check the continuity circuit for loose or damaged connections. Test the MerCathode unit
output if equipped.
• Clean the flame arrestor, IAC muffler, and the crankcase ventilation hoses. Inspect the PCV
valve, if equipped.
• Inspect the condition and the tension of the belts.
• Driveshaft extension models: Lubricate the driveshaft U‑joints, and tailstock input and output
bearings.
Every 150 hours or

annually All Bravo models except 496: Lubricate the engine coupler.
• Check the engine mounts for tightness and torque if necessary.
• Check the electrical system for loose, damaged, or corroded fasteners.
• Inspect the condition of the spark plugs, spark plug wires, and the distributor cap and rotor, if
equipped. Replace as necessary.
• Check the cooling system and the exhaust system hose clamps for tightness. Inspect both
systems for damage or leaks.
• Disassemble and inspect the seawater pump and replace worn components.
• On models with closed cooling, clean the seawater section of the closed cooling system.
Every 300 hours or 3 Clean, inspect, and test the pressure cap.
years • Inspect the exhaust system components. If the package was equipped with water shutters
(flapper valves), verify that they are not missing or worn.
• Check the engine alignment.
• Inspect the U‑joints, the splines, the bellows, and check the clamps.
• Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting.
• Inspect the gimbel bearing for roughness. Replace if necessary. See your certified Mercury
MerCruiser dealer.
• Vazer models, Alpha models, and 496 MAG Bravo models only: Lubricate the engine coupler.
• Replace the coolant/anitifreeze. Replace every two years if not using extended‑life coolant/
Every 5 years antifreeze.
Maintenance Log
Record all maintenance performed on your power package here. Be sure to save all work orders and receipts.
Date Maintenance Performed Engine Hours
Page 42 90-879288268 eng JULY 2009

Date Maintenance Performed Engine Hours
Sealed Carburetor Mixture Screw

IMPORTANT: Changing the mixture setting on this engine can affect the exhaust emissions level and void the emissions
certification. Do not adjust or remove the mixture settings or remove the mixture screw seals. See your authorized Mercury
dealer or emissions testing agency.
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).
a - Dipstick tube
7150
90-879288268 eng JULY 2009 Page 43

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.
3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and add. Reinstall dipstick into
dipstick tube.
Filling
IMPORTANT: Do not overfill the engine with oil.
IMPORTANT: Always use the dipstick to determine the exact quantity of oil or fluid required.
1. Remove oil fill cap.
a - Oil fill cap
7519
IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick.
2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on the dipstick. Recheck oil
level.
3. Replace the fill cap.
Engine Model Capacity Fluid Type

3.0 TKS 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser Oil 20W‑40
Changing Oil and Filter

Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.
IMPORTANT: Change engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more
impurities. Use only recommended engine oil (refer to Specifications).
Easy Engine Oil Drain System

NOTE: Boat must be out of water to perform this procedure.
1. Loosen the oil filter to vent the system.
2. Remove the bilge drain plug.
Page 44 90-879288268 eng JULY 2009

3. Pull tether through the bilge drain.
a f
c
b
d e 7284
a- Bilge drain plug

b- Tether
c- Clip
d- Oil drain hose plug
e- Oil drain hose
f- Bilge drain flange
4. Place the oil drain hose in a suitable container.

5. Remove the drain plug from the oil drain hose.
6. After oil has drained completely, install the drain plug in the oil drain hose.
7. Push the hose through bilge drain and install the plug.
Engine Oil Drain Pump

1. Loosen the oil filter to vent the system.
2. Remove the dipstick.
3. Install the oil pump onto the dipstick tube.
a - Typical oil pump

b - Dipstick tube
c - Oil drain hose
a
c
b
mc70571-1
4. Insert the hose end of the crankcase oil pump onto an appropriate container and, using the handle, pump until the
crankcase is empty.
5. Remove the pump.
6. Install the dipstick.
Changing Filter
1. Remove and discard oil filter.
2. Coat sealing ring on new filter with engine oil and install.
3. Tighten oil filter securely (following filter manufacturer's instructions). Do not overtighten.
4. Remove oil fill cap.
IMPORTANT: Always use dipstick to determine exactly how much oil is required.
5. Add recommended engine oil to bring level up to the bottom of the OK range on the dipstick.
6. With the boat at rest in the water, check the oil level and add specified fluid to bring the oil level up to, but not over, the full
or OK range.
NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the add mark to the top of the OK range.
90-879288268 eng JULY 2009 Page 45

Engine Model Capacity Fluid Type

3.0 TKS 3.8 L (4 US qt) Mercury Full‑Synthetic MerCruiser Oil 20W‑40
7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine. Allow approximately 5 minutes for
the oil to drain into the oil pan. The boat must be at rest in the water.
Power Steering Fluid

Checking
1. Stop the engine and center the sterndrive unit.
2. Remove the fill cap/dipstick and observe the level.
a. Proper fluid level with engine at normal operating temperature should be within the warm range.
b. Proper fluid level with engine cold should be within the cold range.
a - Power steering pump fill cap/

dipstick
b - Cold range
a c - Warm range
b
7158
3. Fill to full line with specified fluid.

IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer.
Filling
1. Remove the fill cap/dipstick and observe the level.
2. Add Quicksilver Power Trim and Steering Fluid or Dexron III Automatic Transmission Fluid (ATF) to bring the fluid level up
to the proper level.
Tube Ref No. Description Where Used Part No.

Power Trim and Steering
114 Power steering system 92-858074K01
Fluid
3. Reinstall the fill cap/dipstick.
Changing
Power steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized
Mercury MerCruiser dealer.
Engine Coolant
Checking
! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow
the engine to cool down before removing the coolant pressure cap.
Page 46 90-879288268 eng JULY 2009

1. Remove the cap from the thermostat housing and observe the fluid level.
a - Thermostat housing cap
17291
2. The coolant level in the thermostat housing should be at the bottom of the filler neck. If the coolant level is low, contact
your authorized Mercury MerCruiser dealer.
3. Install the cap onto the thermostat housing.
IMPORTANT: When reinstalling the pressure cap, be sure to tighten it until it seats on the filler neck.
4. With the engine at normal operating temperature, check the coolant level in the coolant recovery bottle.
5. The coolant level should be between the "ADD" and "FULL" marks.
6102
6. Add the specified fluid as necessary.

Extended Life Antifreeze/
122 Closed Cooling System 92-877770K1
Coolant
Filling
NOTICE
Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed
cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be
exposed.
NOTICE
NOTICE
Air trapped in the closed cooling system can cause the engine to overheat, resulting in engine damage. Minimize the
possibility of trapping air when initially filling the closed cooling system by positioning the boat so that the front of the engine
is higher than the rear of the engine.
NOTE: Add coolant only when engine is at normal operating temperature.
90-879288268 eng JULY 2009 Page 47

1. Remove the fill cap from the coolant recovery bottle.

2. Fill to the "FULL" line with the specified coolant.

Extended Life Antifreeze/
122 Closed Cooling System 92-877770K1
Coolant
3. Install the fill cap onto the coolant recovery bottle.
Changing
Contact your authorized Mercury MerCruiser dealer.
Drive Unit 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
NOTE: Oil level will fluctuate during operation. Oil level should be checked with the engine cold, before starting.
1. Check the gear lube oil level. Keep the oil level within the recommended operating range. If any water is visible at the
bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury
MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Filling
IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lubricant is required to fill the monitor, a seal may be
leaking. Damage to the sterndrive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser
dealer.
1. Remove the gear lube monitor cap.
2. Fill the monitor with the specified fluid so that the oil level is in the operating range. Do not overfill.

High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
3. Replace the cap.
NOTE: When filling the entire sterndrive unit refer to Changing instructions, following.
Changing
1. Remove the gear lube monitor from the bracket.
a - Gear lube monitor

a
7159
2. Empty the contents into a suitable container.

3. Install the gear lube monitor in the bracket.
Page 48 90-879288268 eng JULY 2009

4. Place the sterndrive unit in full trim limit out position, remove the oil fill/drain screw and sealing washer and drain the oil.
a - Oil fill\drain screw

b - Sealing washer
b
7160
a
5. Remove the oil vent screw and sealing washer. Allow the oil to drain completely.
a - Oil vent screw

b - Sealing washer
7161
IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and
should be checked immediately by your authorized Mercury MerCruiser dealer.
6. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with
specified gear lubricant until an air‑free stream of lubricant flows from oil vent hole.

High Performance Gear
87 Sterndrive unit 92-858064K01
Lubricant
IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in sterndrive unit.
7. Install the oil vent screw and sealing washer.
8. Continue to pump gear lubricant into the drive through the oil fill/drain hose until the gear lubricant appears in the gear lube
monitor.
9. Fill the monitor so that the oil level is in the operating range. Do not overfill. Ensure that the rubber gasket is inside the cap
and install. Do not overtighten.
NOTE: Oil capacity includes gear lube monitor.
Model Capacity Fluid Type

Alpha One 1892 ml (64 oz) High Performance Gear Lubricant
10. Remove the pump from the oil fill/drain hole. Quickly install the sealing washer and oil fill/drain screw. Tighten securely.
11. Recheck the oil level after the first use.
IMPORTANT: Oil level in the gear lube monitor will rise and fall during sterndrive operation; always check the oil level when the
sterndrive is cool and the engine is shut down.
90-879288268 eng JULY 2009 Page 49

Power Trim Fluid

Checking
IMPORTANT: Check the oil level with the sterndrive unit in the full down/in position only.
1. Place the sterndrive unit in full down/in position.
2. Remove the fill cap from the reservoir.
a - Fill cap
b - Reservoir fill neck
a
c - "MIN" and "MAX" lines
5573
c
3. Observe the oil level. Level must be between the "MIN" and "MAX" lines on the reservoir.
NOTE: Fill cap is vented.
4. Fill as necessary with the specified fluid.

114 Power trim pump 92-858074K01
Fluid
Filling
1. Remove the fill cap from the reservoir.
2. Add lubricant to bring level to the bottom of the filler neck.

114 Power trim pump 92-858074K01
Fluid
3. Install the cap.
Changing
Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized
Mercury MerCruiser dealer.
Cleaning the Flame Arrestor

! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
1. Disconnect and remove the crankcase ventilation hose from the fitting on the flame arrestor and valve cover.
Page 50 90-879288268 eng JULY 2009

2. Remove the flame arrestor.
a - Flame arrestor
b b - Flame arrestor nut and
washer
c - Crankcase ventilation hose
a
7164
3. Clean the flame arrestor with warm water and a mild detergent.
4. Inspect the flame arrestor for holes, cracks, or deterioration. Replace if necessary.
5. Allow the flame arrestor to air dry completely before use.
6. Clean the crankcase ventilation hose with warm water and a mild detergent. Dry with compressed air or allow to air dry
completely.
7. Inspect the crankcase ventilation hose for cracks or deterioration. Replace if necessary.
8. Install the flame arrestor, sealing washer, and locknut. Torque the flame arrestor locknut to specification.
Description Nm lb‑in. lb‑ft

Flame arrestor nut 12 106
9. Connect the crankcase ventilation hose to the fitting on the flame arrestor and valve cover.
Positive Crankcase Ventilation Valve (PCV)

Changing
NOTE: We recommend the use of Mercury MerCruiser replacement parts to ensure compliance with emission regulations.
NOTE: On V6 models the PCV valve is non‑serviceable and is an internal component of the valve cover.
1. Remove the PCV valve.
2. Disconnect the PCV valve from the hose and discard the valve.
a - PCV valve
b - Hose
b
a
17290
3. Install a new PCV valve in the valve cover and reconnect the hose.
4. Ensure the PCV valve is tightly seated in the valve cover.
90-879288268 eng JULY 2009 Page 51

Changing the Water‑Separating Fuel Filter

! WARNING
1. Allow the engine to cool down.

NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal.
2. Close fuel supply valve, if equipped.
3. Wrap the water separating fuel filter with a cloth to help catch any fuel spills or spray.
4. Remove and discard the water separating fuel filter and sealing ring from the mounting bracket.
5. Coat the sealing ring on the new filter with engine oil.
Tube Ref. No. Description Where Used Part No.

Synthetic Blend MerCruiser Engine Oil
Filter sealing ring 92‑883725K01
SAE25W‑40
6. Thread filter onto bracket and tighten securely by hand. Do NOT use a filter wrench.
a a - Fuel filter base

b - Sealing ring
c - Fuel filter
b
6527
7. Open fuel supply valve, if equipped.

8. Ensure that engine compartment is properly ventilated.
9. Supply cooling water to the engine.
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately.
Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop the
engine immediately and contact your authorized Mercury MerCruiser dealer.
Fuel Pump Sight Tube Inspection

1. The engine fuel pump is equipped with a sight tube which gives visible evidence of a ruptured fuel pump diaphram.
IMPORTANT: If fuel is visible in tube, the fuel pump should be replaced by your Authorized Mercury MerCruiser Dealer
immediately.
a - Sight tube
7162
Page 52 90-879288268 eng JULY 2009

Lubrication
Steering System
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
NOTE: If the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased.
1. If the steering cable has grease fittings: Turn the steering wheel until the steering cable is fully retracted into the cable
housing. Apply approximately three pumps of grease from a typical hand‑operated grease gun.
a - Steering cable grease fitting
6221

34 Special Lubricant 101 Steering cable grease fitting 92-802865Q02
2. Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable.
a - Extended steering cable
6222

34 Special Lubricant 101 Steering cable 92-802865Q02
90-879288268 eng JULY 2009 Page 53

3. Lubricate the steering pin.
a - Steering pin
mc71904-1

Steering pin 92‑883725K01
SAE25W‑40
4. On dual engine boats: Lubricate the tie bar pivot points.

Tie bar pivot points 92‑883725K01
SAE25W‑40
5. Upon first starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering
system operates properly before getting underway.
Manual Steering System

1. Inspect the bushings for debris and lubricate the bushings.
a
a - Bushings
7167

34 Special Lubricant 101 Steering cable end bushings 92-802865Q02
Page 54 90-879288268 eng JULY 2009

Throttle Cable
1. Lubricate the pivot points and the guide contact surfaces.
a - Pivot points
7169

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

1. Lubricate the pivot points and the guide contact surfaces.
b a - Pivot points
b - Guide contact surfaces
mc79736

Synthetic Blend MerCruiser Engine Oil Shift cable pivot points &
92‑883725K01
SAE25W‑40 guide contact surfaces
90-879288268 eng JULY 2009 Page 55

Sterndrive Unit and Transom Assembly

1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
a - Gimbal bearing grease fitting
mc77068-1

U-joint and Gimbal
42 Gimbal bearing 92-802870A1
Bearing Grease
2. For propeller shaft lubrication, refer to Propellers.
Sterndrive U‑joint Shaft Splines and O‑rings (Sterndrive Unit Removed)

1. Coat sterndrive U‑joint O‑rings and driveshaft splines with grease.
a - U‑joint O‑rings (3)

b - Driveshaft splines
b
17293

Engine Coupler Spline
91 Driveshaft splines and U-joint O-rings 92-802869A 1
Grease
2. For propeller shaft lubrication, refer to Propellers.
Engine Coupler
1. Lubricate engine coupler splines through grease fittings on coupler by applying approximately 8‑10 pumps of grease from a
typical hand‑operated grease gun.
Page 56 90-879288268 eng JULY 2009

NOTE: If the boat is operated at idle for prolonged periods of time, coupler should be lubricated in the Alpha Models ‑
every 150 hours.
Alpha drive coupler

a - Engine coupler grease fitting
a 6213

Engine Coupler Spline
91 Coupler 92-802869A 1
Grease
NOTE: Alpha Models ‑ Your power package is equipped with a sealed engine coupler and Perm‑a‑Lube U‑joints. The sealed
coupler and shaft splines can be lubricated without removing the sterndrive unit. The Perm‑a‑Lube U‑joints do not require
lubrication.
Driveshaft Extension Models

1. Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10–12 pumps of grease
from a typical hand‑operated grease gun.
2. Lubricate the driveshaft grease fittings by applying approximately 3–4 pumps of grease from a typical hand‑operated
grease gun.
a a 17014
a - Driveshaft grease fittings

b - Transom end grease fitting
c - Engine end grease fitting

U-Joint and Gimbal Transom end grease fitting, engine end grease fitting,
42 92-802870A1
Bearing Grease driveshaft grease fittings
Propellers
Propeller Repair
Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.
90-879288268 eng JULY 2009 Page 57

Alpha Propeller Removal

! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed.
Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the
engine from starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
1. Place wood block between propeller blade and anti‑ventilation plate to prevent rotation. Straighten bent tabs on tab
washer.
2. Turn propeller shaft nut counterclockwise to remove nut.
3. Slide tab washer, drive sleeve, propeller and thrust hub off propeller shaft.
Alpha Propeller Installation

NOTICE
Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the
propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval.
IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is
questionable.
a- Propeller shaft
b- Thrust hub
d
c- Flo‑Torq II drive hub
d- Propeller
e- Drive sleeve
f- Locking tab washer
e f g- Propeller nut
a
b c
6215
g
1. Apply a liberal coat of one of the following lubricants to the propeller shaft.

34 Special Lubricant 101 Propeller shaft 92-802865Q02
94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1

2-4-C Marine Lubricant
95 Propeller shaft 92-802859A 1
with PTFE
2. Slide thrust hub onto propeller shaft, with stepped side toward propeller hub.
3. Install Flo‑Torq II Drive Hub into propeller.
NOTE: The drive sleeve is tapered and will slide fully into the propeller as the nut is tightened and properly torqued.
4. Align splines and place propeller on propeller shaft.
5. Install drive sleeve and locking tab washer.
6. Install and torque the propeller nut.
Description Nm lb‑in. lb‑ft

Propeller nut (minimum) 75 – 55
7. Bend three tabs on the tab washer down into the grooves in spline washer. After the first use, bend the three tabs straight
and retorque the propeller nut. Bend tabs back down into spline washer. Check propeller at least after 20 hours of
operation. Do not operate with loose propeller.
Page 58 90-879288268 eng JULY 2009

Drive Belts
! WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition
key before adjusting tension or inspecting belts.
b
a a- Power steering pump pulley
b- Water circulating pump pulley
c- Crankshaft pulley
d d- Alternator pulley
7170
Checking
1. Inspect the drive belt for proper tension and for the following:
• Excessive wear
• Cracks
NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of
belt length) that join transverse cracks are NOT acceptable.
• Fraying
• Glazed surfaces
• Proper tension ‑ 6 mm (1/4 in.) deflection, with moderate thumb pressure, on the belt at the location that has the
longest distance between two pulleys.
Replacing ‑ Front Mount Models

Power Steering Pump Drive Belt, if equipped
1. Loosen power steering pump attaching bolts and mounting bolts.
2. Pivot power steering pump toward engine, as required, until belt can be removed.
3. Install new drive belt on pulleys. Adjust tension.
a- Power steering belt

d b- Spacer block
c- Alternator
d- Alternator belt
a
c
b
7172
Description
Deflection 6 mm ( 1/4 inches)
Alternator Belt
1. Remove the power steering belt, if equipped.
90-879288268 eng JULY 2009 Page 59

2. Remove the two port side, front engine mount bracket assembly screws and washers.
3. Remove the spacer block between the bracket assembly and the engine block. It may be necessary to tape gently on the
spacer to allow removal.
4. Loosen the alternator. Remove and replace the alternator belt.
5. Replace the spacer block between the bracket assembly and the engine block. Install the two screws using the flat and
lockwashers removed previously. Torque the two spacer block screws.
Description Nm lb. in. lb. ft.

Spacer block screws 28 21
6. Install power steering belt, if equipped. Adjust tension of both drive belts.
Description
Replacing ‑ Side Mount Models

Power Steering Pump Drive Belt, if equipped
1. Loosen power steering pump attaching bolts and mounting bolts.
2. Pivot power steering pump toward engine, as required, until belt can be removed.
3. Install new drive belt on pulleys. Adjust the tension to the specification following.
b a - Power steering belt

b - Alternator belt
c - Alternator
c
17296
Description
Alternator Belt
1. Remove power steering pump drive belt, if equipped.
2. Loosen the alternator. Remove and replace the alternator belt.
3. Install power steering belt, if equipped. Move the power steering brace to its original position and adjust tension of both
drive belts.
Description
Flushing the Power Package

Your boat comes equipped with through the sterndrive water pickups. See Sterndrive Water Pickups (following) for the
flushing procedure. Consult your authorized Mercury MerCruiser dealer for further explanation.
IMPORTANT: Alpha 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
Page 60 90-879288268 eng JULY 2009

Flushing Attachments
Flushing Device 91‑44357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing
the cooling system or operating the engine.
9192
Sterndrive Water Pickups

This Mercury MerCruiser sterndrive is equipped with side water pickups. Side pickups require the flushing attachment (44357Q
2).
5773
Side 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 5. or Step 6.

NOTE: Closed cooled models are equipped with a heat exchanger on the side of the engine.
2. If flushing the cooling system with the boat in the water:
a. Raise the 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.
3. 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 anti‑ventilation plate.
b. Remove propeller.
c. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
90-879288268 eng JULY 2009 Page 61

4. Connect hose between flushing attachment and water source.

5. With sterndrive in normal operating position, open the water source completely.
6. 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.
7. Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
8. Observe the water temperature gauge to ensure that the engine is operating in the normal range.
9. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear.
10. Slowly return throttle to idle speed position.
11. Stop engine.
12. Shut off water and remove flushing attachment.
13. This step is only required if the boat is to be stored in the water. After the flush procedure is completed, remove the
seawater inlet hose from the thermostat housing and plug the hose to prevent water from siphoning into the boat. This
prevents seawater from contaminating the engine flush.
14. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating
engine.
Battery
Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following
precautions when handling a battery.
! WARNING
Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious
injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away
from sparks or flames.
! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
Corrosion Protection
NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning
equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.
c a a - MerCathode reference electrode

b - Do not paint
c - Do not pressure wash
b
6211
Page 62 90-879288268 eng JULY 2009

Whenever two or more dissimilar metals (like those found on the sterndrive) are submerged in a conductive solution, such as
saltwater, polluted water or water with a high mineral content, a chemical reaction takes place causing electrical current to flow
between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known
as galvanic corrosion and, if not controlled, it will in time cause the need for replacement of power package components
exposed to water. Refer to the Marine Corrosion Protection Guide (90‑88181301).
Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate
conditions. However, for severe conditions (i.e. when using a stainless steel propeller, docking/mooring in areas with rapid
water flow, etc.), it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System be installed
(some models have a MerCathode System as standard equipment).
6
1
7
5 4
3 2 8
1 2 3 4
5 6 7 8 17276
1- Gearcase anodic plate

2- Ventilation plate anode
3- Gimbal mounted anodic block
4- MerCathode System
5- Anode kit
6- Trim cylinder anodes
7- Bearing carrier anodes (Alpha only)
8- Propshaft Anode (Bravo III standard)
IMPORTANT: Replace sacrificial anodes if eroded 50 percent or more.
90-879288268 eng JULY 2009 Page 63

The following sacrificial anodes are installed at different locations on your power package. These anodes help protect against
galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package.
Gearcase Anodic Plate ‑ Mounted on the underside of the lower gearcase.
a - Anode
10952
Ventilation Plate Anode ‑ Mounted on the front of the gearcase.
a - Anode
6122
Drive Mounted Anodic Block (if equipped) ‑ Mounted to underside of gimbal housing.
5640
MerCathode System ‑ Electrode assembly replaces Anodic block. System should be tested to ensure adequate output. The
test should be performed where boat is moored, using Quicksilver Reference Electrode and Test Meter. Contact your
authorized Mercury MerCruiser dealer.
Page 64 90-879288268 eng JULY 2009

IMPORTANT: To ensure that the MerCathode reference electrode is not damaged, do not paint or pressure wash.
a a - MerCathode controller
b - MerCathode assembly
6206
Anode Kit (if equipped) ‑ Mounted to the boat transom.
5642
Trim Cylinder Anodes ‑ Mounted on each trim cylinder.
a - Trim cylinder anodes
7460
Bearing Carrier Anode (Alpha) ‑ Located in front of the propeller, between the front side of the propeller and the gear
housing.
a - Bearing carrier anode

b - Screws
a
7461
90-879288268 eng JULY 2009 Page 65

In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion:
1. Paint your power package, refer to Painting Your Power Package.
2. Spray power package components on inside of boat annually with Corrosion Guard to protect finish from dulling and
corrosion. External power package components may also be sprayed.
3. All lubrication points, especially steering system, shift and throttle linkages, should be kept well lubricated.
4. Flush cooling system periodically, preferably after each use.
Painting Your Power Package

IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the
limited warranty.
1. Painting Boat Hull or Boat Transom: Anti‑fouling paint may be applied to boat hull and boat transom but you must
observe the following:
IMPORTANT: Do NOT paint anodes or MerCathode System reference electrode and anode, as this will render them
ineffective as galvanic corrosion inhibitors.
IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper or tin base paints, if not prohibited
by law, can be used. If using copper or tin based anti‑fouling paints, observe the following:
• Avoid any electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System
and the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.
a - Painted boat transom

b - Unpainted Area on Transom
b
5578
2. Painting Sterndrive Unit or Transom Assembly: Sterndrive unit and transom assembly should be painted with a good
quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct
electrical current. Do not paint drain holes, anodes, MerCathode system, and items specified by boat manufacturer.
Page 66 90-879288268 eng JULY 2009

Section 6 - Storage
Section 6 - Storage
Table of Contents
Cold Weather or Extended Storage...................................... 68 Clearing Clogged Blue Drain Hoses.............................. 73
Preparing Power Package for Storage.......................... 68 Draining the Sterndrive.................................................. 74
Engine and Fuel System Preparation .................... 69 Battery Storage..................................................................... 75
Draining the Seawater System............................................. 69 Recommissioning the Power Package................................. 75
Single Point Drain System............................................. 70
Draining the Seawater Section of Models With Closed
Cooling........................................................................... 71
90-879288268 eng JULY 2009 Page 67

Section 6 - Storage
Cold Weather or Extended Storage

IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury
MerCruiser dealer. Damage caused by freezing temperatures is not covered by the Mercury MerCruiser Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
the seacock or unplug and reconnect the water inlet hose before starting the engine.
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used
in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol
antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol
manufacturer's recommendations.
Preparing Power Package for Storage

1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount of Quicksilver Gasoline
Stabilizer for Marine Engines to treat the gasoline. Follow instructions on the container.
2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel
tanks should be drained as low as possible and Mercury/Quicksilver Gasoline Stabilizer for Marine Engines added to any
fuel remaining in the tank. Refer to Fuel Requirements for additional information.
3. Flush the cooling system. Refer to the Maintenance section.
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. Change the oil and oil filter.
7. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System Preparation.
8. Drain the engine seawater cooling system. Refer to Draining the Seawater System.
NOTICE
9. Ensure that the sterndrive vent holes and water drain holes and passages are unobstructed and open (refer to Draining
Instructions).
10. 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.
11. Store boat with drive unit in full down/in position.
12. Store the battery according to the manufacturer's instructions.
Page 68 90-879288268 eng JULY 2009

Section 6 - Storage
Engine and Fuel System Preparation
! WARNING
! 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. Prepare carbureted fuel system for extended storage as follows:

a. Start engine.
b. Provide cooling water to the engine as done in the previous step.
c. Remove flame arrestor assembly.
d. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off
valve.
e. While operating engine at fast idle (1300 RPM), fog internal surfaces of induction system and combustion changers
by spraying approximately 227 g (8 oz.) of Mercury/Quicksilver Storage Seal or SAE 20W engine oil into carburetor
bores.
f. Spray the remaining 57 g (2 oz.) of Storage Seal (or oil) rapidly into carburetor, just as the engine begins to stall, due
to lack of fuel. Allow engine to stop.

Storage Seal Rust
119 Carburetor 92-858081K03
Inhibitor
g. Turn ignition key to "OFF" position.
2. Refer to Flushing the Power Package and appropriately remove the water supply the the seawater pickup pump.
3. Clean the flame arrestor and crankcase ventilation hoses and reinstall.
4. Lubricate all items listed in the Lubrication section.
5. On models with closed cooling systems: Test coolant to ensure that it will withstand the lowest temperature expected
during storage.
6. Service batteries according to the manufacturer's instructions.
7. Clean the outside of the engine and repaint any areas required with Mercury/Quicksilver Light Gray Primer and Phantom
Black Paint. After paint has dried, wipe down the outside of the engine with Corrosion Guard.

120 Corrosion Guard Outside of engine 92-802878 55
8. For sterndrive unit lay‑up, refer to appropriate Mercury MerCruiser sterndrive service manual.
9. Replace the fuel filter. Refer to the Maintenance section for proper procedure.
10. Change the oil and oil filter.
Draining the Seawater System

! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat
from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational
before draining. Do not operate the engine with the drain system open.
IMPORTANT: Only drain the seawater section of the closed cooling system.
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system.
IMPORTANT: The engine must not be operating at any point during the draining procedure.
90-879288268 eng JULY 2009 Page 69

Section 6 - Storage
Single Point Drain System

! CAUTION
Disconnecting the blue drain hoses can cause serious burns due to hot water. Check all hose connections before operating
the engine and never disconnect the hoses until the engine has had suffient time to cool.
NOTICE
If the boat is at rest in the water with the engine off, an open seacock or water inlet hose could introduce water into the
engine's cooling system or the boat. Keep the seacock or water inlet hose plugged until ready to start the engine. Attach a
tag to the ignition switch or steering wheel to inform others of the water inlet connection.
IMPORTANT: Do not start or operate engine at any point in this procedure.

1. If draining with the boat in the water, close the seacock (if equipped) or remove and plug the water inlet hose. If draining
with the boat out of the water, place the boat on a level surface to ensure complete draining of the system.
2. Turn on the bilge pump.
3. Push the quick connect fitting release buttons and remove the blue drain hoses from the bracket.
a - Release button
b - Blue drain hoses
a
17217
4. Pull the T‑handle until the hose guide is in contact with the quick connect fittings.
a - T‑handle
a b - Hose guide
b 7183
5. Push down on the T‑handle to force the blue drain hoses below their connection points on the block.
6. Ensure water is draining from blue drain hoses. If water is not draining from all blue drain hoses, refer to Clearing Clogged
Drain Hoses.
7. Leave the blue drain hoses disconnected until all water has drained from the engine.
8. Pull the T‑handle until the quick connect fittings on the blue drain hoses are within reach.
9. Install the quick connect fittings on the bracket. Pull on the blue drain hoses to ensure they are firmly connected.
10. Push down on the T‑handle until seated.
11. Turn off the bilge pump.
12. If the boat was drained in the water, prior to operating the engine open the seacock (if equipped) or unplug and reconnect
the water inlet hose.
IMPORTANT: The next time the engine is started, visually inspect that the blue drain hoses are connected and not leaking.
Page 70 90-879288268 eng JULY 2009

Section 6 - Storage
Draining the Seawater Section of Models With Closed Cooling

NOTICE
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.
1. If draining with the boat in the water, close the seacock (if equipped) or remove and plug the water inlet hose. If draining
with the boat out of the water, place the boat on a level surface to ensure complete draining of the system.
2. Remove the drain plug from the following locations:
a. Aft (rear) drain plug from the heat exchanger.
a - Heat exchanger drain plug
a 7184
b. Bottom of exhaust manifold.
a - Exhaust manifold drain plug
7186
3. Clean out the drain holes with a stiff piece of wire until the entire system is drained.
NOTE: It may be necessary to lift or bend hoses to allow water to drain completely.
90-879288268 eng JULY 2009 Page 71

Section 6 - Storage
4. Remove and lower the hose from the water inlet to the power steering cooler (if equipped), or the water inlet to the heat
exchanger.
48856
a - Power steering cooler, if equipped

b - Water inlet to heat exchanger hose
5. Ensure the gear housing water vent and drain holes, speedometer pitot hole, and trim tab cavity vent and drain holes are
open and unobstructed.
a a- Gear housing vent holes

b- Trim tab cavity drain holes
c- Gear housing drain hole
d- Speedometer pitot hole
c
b
d
7329
6. Crank the engine over slightly with the starter motor to purge any water trapped in seawater pickup pump. Do not allow the
engine to start.
7. After the cooling system has been drained completely, apply sealant to the aft heat exchanger plug.
a - Heat exchanger drain plug
a 7184
Page 72 90-879288268 eng JULY 2009

Section 6 - Storage

19 Perfect Seal Aft heat exchanger plug 92-34227Q02
8. Prior to launching the boat or starting the engine, install the drain plugs, reconnect the hoses, and tighten all hose clamps
securely.
9. If the boat was drained in the water, open the seacock (if equipped) or unplug and reconnect the water inlet hose prior to
operating the engine.
Clearing Clogged Blue Drain Hoses

! CAUTION
Disconnecting the blue drain hoses can cause serious burns due to hot water. Check all hose connections before operating
the engine and never disconnect the hoses until the engine has had suffient time to cool.
1. If the engine can be started proceed to Step 2. If the engine cannot be started, proceed to Step 8.
2. If one hose is flowing freely, reconnect it to the bracket.
3. Ensure the clogged blue drain hose is in the correct position below its connection point on the block.
4. Turn on the bilge pump and supply water to the water inlets. If the boat is out of the water, install the flushing attachment
and open the water source fully to provide maximum water flow.
a - Flushing attachment
7358
Flushing Device 91‑44357Q 2
Attaches to the water intakes; provides a fresh water connection when

flushing the cooling system or operating the engine.
9192
5. Start the engine and allow it to operate at idle until the obstruction is cleared from the hose or for approximately 1 minute,
whichever occurs first.
6. Check for water draining from the blue drain hose. If after 1 minute of idling, the blue drain hose is still clogged, proceed to
Step 7. If water is draining, shut off the engine and continue with Step 3 of Single Point Drain System.
7. Shut off the engine. Disconnect the water source if connected to a flush device.
90-879288268 eng JULY 2009 Page 73

Section 6 - Storage
8. Attach the female end of the water hose adapter fitting to a water supply.
7252
Hose Adapter Fitting (22-863840)
9. Attach the clogged blue drain hose to the male end of the water hose adapter fitting.
10. Fully open the water supply and allow it to run for 1 minute.
11. Turn off the water supply. Disconnect the water hose adapter from the blue drain hose and the water hose.
12. Push down on the T‑handle to force the blue drain hoses down below their connection points on the block.
13. Check for water draining from the blue drain hose. If the blue drain hose is still clogged, shut off the bilge pump and
reattach the blue drain hoses following the steps below. The unit will need to be serviced by an authorized Mercury
MerCruiser dealer.
a. Pull the T‑handle until the quick connect fittings on the blue drain hoses are within reach.
b. Install the quick connect fittings on the bracket. Pull on the blue drain hoses to ensure they are firmly connected.
c. Push down on the T‑handle until seated.
14. If water is draining from the blue drain hose, continue with Step 4 of Single Point Drain System.
Draining the Sterndrive

NOTE: This procedure is needed only for salty, brackish, mineral laden, or polluted water applications; and for freezing
temperatures or extended storage.
1. Insert a small wire repeatedly to make sure that vent holes, water drain holes, and passages are unobstructed and open.
e
b
a f
c
6146
Sterndrive Water Drain Holes

a - Speedometer pitot tube
b - Trim tab cavity vent hole
c - Trim tab cavity drain passage
d - Gear housing water drain hole (one each at port and starboard)
e - Gear housing cavity vent hole
f - Gear housing cavity drain hole
Page 74 90-879288268 eng JULY 2009

Section 6 - 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.
2. Lower the sterndrive to the full down/in position.
3. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol mixed to the
manufacturer's recommendation to protect the engine to the lowest temperature to which it will be exposed during freezing
temperatures or extended storage
Battery Storage
Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully
charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for
storage.
Recommissioning the Power Package

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
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.
90-879288268 eng JULY 2009 Page 75

Section 6 - Storage
Notes:
Page 76 90-879288268 eng JULY 2009

Table of Contents
Starter Motor Will Not Crank Engine, Or Cranks Slow......... 78 Battery Will Not Recharge.................................................... 79
Engine Will Not Start Or Is Hard To Start............................. 78 Remote Control Is Difficult to Move, Has Excessive Play, or
Engine Runs Rough, Misses or Backfires............................ 78 Makes Unusual Sounds........................................................ 80
Poor Performance................................................................ 78 Steering Wheel Jerks or Is Difficult to Turn.......................... 80
Excessive Engine Temperature............................................ 79 Power Trim Does Not Operate (Motor Does Not Operate)... 80
Insufficient Engine Temperature........................................... 79 Power Trim Does Not Operate (Motor Operates but
Low Engine Oil Pressure...................................................... 79 Sterndrive Unit Does Not Move)........................................... 80
90-879288268 eng JULY 2009 Page 77

Starter Motor Will Not Crank Engine, Or Cranks Slow

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

Lanyard stop switch activated. Check the lanyard stop switch.
Improper starting procedure. Read the starting procedure.
Insufficient fuel supply. Fill fuel tank or open valve.
Turn the key switch off and wait 5 minutes. Push the throttle only button, push
Engine flooded. the remote control handle/throttle lever to the 1/4 throttle position, and attempt
to restart.
Faulty ignition system component. Service the ignition system.
Clogged fuel filter. Replace fuel filter.
Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to remove
Fuel line or tank vent line kinked or clogged.
obstruction.
Faulty wire connections. Check wire connections.
TKS fuse blown. Check TKS fuse. Replace the fuse if blown.
Engine Runs Rough, Misses or Backfires

Clogged fuel filter. Replace filter.
Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to remove
Kinked or clogged fuel line or fuel tank vent line.
obstruction.
Flame Arrestor dirty. Clean Flame Arrestor.
Faulty ignition system component. Service ignition system.
Poor Performance
Throttle not fully open. Inspect the throttle cable and linkages for proper operation.
Damaged or improper propeller. Replace the propeller.
Excessive bilge water. Drain and check for cause of entry.
Boat overloaded or load improperly distributed. Reduce load or redistribute load more evenly.
Flame arrestor dirty. Clean the flame arrestor.
Boat bottom fouled or damaged. Clean or repair as necessary.
Ignition problem. See Engine Runs Rough, Misses or Backfires.
Page 78 90-879288268 eng JULY 2009


Engine overheating. See Excessive Engine Temperature.
Running rich. Have authorized Mercury MerCruiser dealer check and repair.
Excessive Engine Temperature

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

Faulty thermostat. Replace.
Low Engine Oil Pressure

Insufficient oil in crankcase. Check and add oil.
Excessive oil in crankcase (causing it to Check and remove required amount of oil. Check for cause of excessive oil
become aerated). (improper filling).
Change oil and oil filter, using correct grade and viscosity oil. Determine
Diluted or improper viscosity oil.
cause for dilution (excessive idling).
Battery Will Not Recharge

Excessive current draw from battery. Turn off non‑essential accessories.
Alternator drive belt loose or in poor condition. Replace and/or adjust.
Unacceptable battery condition. Test battery, replace if necessary.
Check all associated electrical connections and wires (especially
Loose or dirty electrical connections or damaged
battery cables). Clean and tighten faulty connections. Repair or
wiring.
replace damaged wiring.
Faulty alternator Test alternator output, replace if necessary.
90-879288268 eng JULY 2009 Page 79

Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual

Sounds
Insufficient lubrication on shift and throttle linkage
Lubricate.
fasteners.
Obstruction in shift or throttle linkages. Remove obstruction.
Check all throttle linkages. If any are loose or missing, see
Loose or missing shift and throttle linkages.
authorized Mercury MerCruiser dealer immediately.
Straighten cable or have authorized Mercury MerCruiser dealer
Shift or throttle cable kinked.
replace cable if damaged beyond repair.
Steering Wheel Jerks or Is Difficult to Turn

Low power steering pump fluid level. Check for leak. Refill system with fluid.
Drive belt loose or in poor condition. Replace and/or adjust.
Insufficient lubrication on steering components. Lubricate.
Check all parts and fasteners if any are loose or missing, see authorized
Loose or missing steering fasteners or parts.
Mercury MerCruiser dealer immediately.
Contaminated power steering fluid. See authorized Mercury MerCruiser dealer.
Power Trim Does Not Operate (Motor Does Not Operate)

Replace fuse. Fuses may be located near the dash trim switch, at the trim pump, in the
Blown fuse.
positive (red) power trim battery lead near the battery switch, or a combination of these.
Loose or dirty electrical
Check all associated electrical connections and wires (especially battery cables). Clean and
connections or damaged
tighten faulty connection. Repair or replace wiring.
wiring.
Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not
Move)
Trim pump oil level low. Fill pump with oil.
Drive unit binding in gimbal ring. Check for obstruction.
Page 80 90-879288268 eng JULY 2009


Table of Contents
Owner Service Assistance.................................................... 82 Parts and Accessories Inquiries ............................ 82
Local Repair Service .................................................... 82 Resolving a Problem .................................................... 82
Service Away From Home ............................................ 82 Mercury Marine Service Offices ................................... 83
Stolen Power Package ................................................. 82 Ordering Literature............................................................... 83
Attention Required after Submersion ........................... 82 United States and Canada ........................................... 83
Replacement Service Parts .......................................... 82 Outside the United States and Canada ........................ 84
90-879288268 eng JULY 2009 Page 81

Owner Service Assistance

Local Repair Service
If you need service for your Mercury MerCruiser–powered boat, take it to your authorized dealer. Only authorized dealers
specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine
Quicksilver parts and accessories to properly service your engine.
NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser
sterndrives and inboards.
Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. Refer to the
Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Regional Service
Center. Outside the United States and Canada, contact the nearest Marine Power International Service Center.
Stolen Power Package

If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers
and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities
and dealers in recovery of stolen power packages.
Attention Required after Submersion

1. Before recovery, contact an authorized Mercury MerCruiser dealer.
2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of
serious engine damage.
Replacement Service Parts

! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both
fresh and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine
engine parts, because specifications are different from those of the standard automotive engine. For example, one of the most
important special replacement parts, is the cylinder head gasket. Marine engines cannot use steel‑type automotive head
gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.
Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve
springs, valve lifters, pistons, bearings, camshafts and other heavy‑duty moving parts.
Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.
Parts and Accessories Inquiries

Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has
the necessary information to order parts and accessories for you if they are not in stock. Only authorized dealers can purchase
genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail
customers. When inquiring on parts and accessories, the dealer requires the engine model and serial numbers to order the
correct parts.
Resolving a Problem
Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem,
question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you
need additional assistance:
1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and
service manager have been unable to resolve the problem.
2. If your question, concern, or problem cannot be resolved by your dealership, please contact Mercury Marine Service Office
for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
The following information will be needed by the Service Office:
• Your name and address
Page 82 90-879288268 eng JULY 2009

• Daytime telephone number

• Model and serial numbers for your power package
• The name and address of your dealership
• Nature of problem
Mercury Marine Service Offices are listed on the next page.
Mercury Marine Service Offices

For assistance, call, fax or write. Please include your daytime telephone number with mail and fax correspondence.
Telephone Fax Mail
Mercury MerCruiser
(405) 743 6566 (405) 743 6570 3003 N. Perkins Rd.
Stillwater, OK 74075
Mercury Marine Ltd.

(905) 567 MERC (6372) (905) 567 8515
Mississauga, Ontario L5N 7W6
Canada
Mercury Marine Australia

132-140 Frankston Road
(61) (3) 9791 5822 (61) (3) 9793 5880
Dandenong, Victoria 3164
Australia
Marine Power - Europe, Inc.

Parc Industriel de Petit-Rechain
(32) (87) 32 32 11 (32) (87) 31 19 65
B-4800 Verviers,
Belgium
Mercury Marine - Latin America & Caribbean

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

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

72 Loyang Way
(65) 6546 6160 (65) 6546 7789
, 508762
Singapore
Ordering Literature
Before ordering literature, please have the following information about your power package available:
• Model
• Serial number
• Horsepower
• Year built
United States and Canada

For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order
that literature contact your nearest dealer or contact us at:
Mercury Marine Publications
P.O. Box 1939
(920) 929 5110
Fax (920) 929 4894
90-879288268 eng JULY 2009 Page 83

Outside the United States and Canada

Contact your nearest dealer or Marine Power Service Center for information on additional literature that is available for your
particular Mercury MerCruiser power package and how to order that literature.
Print or type your mailing address, which be used as your shipping label, and include your order and payment. Mail to:
Mercury Marine
Attn: Publications Department
W6250 West Pioneer Road
P.O. Box 1939
USA
Page 84 90-879288268 eng JULY 2009

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90-879288268 709

NOTE: The following applies to CE marked products only.

Declaration of Conformity – Mercury MerCruiser

Name of engine manufacturer: Mercury Marine MerCruiser

Name of Authorized Representative: Brunswick Marine in EMEA Inc.

Conformity assessment module used for exhaust

Description of Engines and Essential Requirements

Engine Type Fuel Type Combustion Cycle

Identification of Engines Covered by This Declaration of Conformity

3.0 TKS Models

other normative document/ Please specify in more detail

C.2 Owner's manual ☐ ☒ ☐ Owner's manual

Date and place of issue: July 24, 2008

Engine Model and Horsepower Engine Serial Number

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Read This Manual Thoroughly

International Hazard Symbol !

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

Section 2 - Getting to Know Your Power Package

Section 3 - On the Water

90-879288268 eng JULY 2009 Page i

Page ii 90-879288268 eng JULY 2009

Section 8 - Customer Assistance Information

90-879288268 eng JULY 2009 Page iii

90-879288268 eng JULY 2009 Page 1

Warranty Registration: United States and Canada

Warranty Registration: Outside the United States and Canada

Page 2 90-879288268 eng JULY 2009

Mercury Installation Quality Certification Program

90-879288268 eng JULY 2009 Page 3

Mercury Product Protection Plan: United States and Canada

Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)

Page 4 90-879288268 eng JULY 2009

Conditions That Must Be Met in Order to Obtain Warranty Coverage

What Mercury Marine Will Do

How to Obtain Warranty Coverage

90-879288268 eng JULY 2009 Page 5

What Is Not Covered

DISCLAIMERS AND LIMITATIONS

3‑Year Limited Warranty Against Corrosion

Page 6 90-879288268 eng JULY 2009

90-879288268 eng JULY 2009 Page 7

Global Application Warranty Charts

Warranty for Commercial Applications

Warranty for Government Applications

Mercury MerCruiser Warranty Charts

Page 8 90-879288268 eng JULY 2009

Consumer Application Warranty Chart

90-879288268 eng JULY 2009 Page 9

Commercial Application Warranty Chart

Page 10 90-879288268 eng JULY 2009

Government Application Warranty Chart

Emission Control Warranty Information

90-879288268 eng JULY 2009 Page 11

Emission Control Information Label

Emission Control Label—California Emissions–Compliant