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

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

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

Notice to Boat Manufacturer/Installer
Throughout this publication, dangers, warnings, cautions, and notices, (accompanied by the International Hazard Symbol) are used to alert the manufacturer or installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials. Observe Them Carefully! These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures.

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

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© 2007 Mercury Marine

90-899883178 NOVEMBER 2007

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

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

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

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

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

Important Information

Boat Construction

Exhaust System

Fuel System

Cooling System

Drive System and Engine Installation

Electrical System

Remote Controls

Predelivery Preparation and Storage

1 2 3 4 5 6 7 8 9

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SECTION - 1

IMPORTANT INFORMATION

SECTION 1 - IMPORTANT INFORMATION
Table of Contents
Torque Specifications.............................................................................................................................................. 2 Quicksilver Products................................................................................................................................................ 2 Accessories ...................................................................................................................................................... 2 Remote Controls and Instrumentation for the DTS System.................................................................................... 3 Identification............................................................................................................................................................ 3 Serial Number Decal Placement.......................................................................................................................3 Bravo Sterndrive Serial Number and Identification...........................................................................................3 Bravo Transom Serial Number..........................................................................................................................4 Bravo Three Notice: Trim‑in Limit Insert.................................................................................................................. 5 Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 5 Internal Power Steering With Internal Tie Bar Only ......................................................................................... 6 Internal Power Steering With Internal and External Tie Bar ............................................................................. 6 External Power Steering .................................................................................................................................. 6 External Power Steering With Low External Tie Bar ........................................................................................ 6 SeaCore Components and Castings....................................................................................................................... 6 Stainless Steel Fasteners........................................................................................................................................ 6 Corrosion Protection................................................................................................................................................ 7 Anti‑fouling Paint..................................................................................................................................................... 7 Emission Control Information Label........................................................................................................................ 9 Owner Responsibility ...................................................................................................................................... 10 Star Label.............................................................................................................................................................. 10 Hang Tag............................................................................................................................................................... 11

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1 Lubricants. remote controls. NOTE: The propeller torque stated is a minimum torque value. and other accessories are available for this product.S.IMPORTANT INFORMATION SECTION . Box 1939 Fond du Lac. Do not overtighten.2 2 5 5 lb‑in.A. order through Distribution Center or Distributor.O. 92-802865Q02 Torque Specifications NOTE: Securely tighten all fasteners not listed below. Refer to Mercury Precision Parts Accessories Guide for a complete listing. Pioneer Road P. Page 2 / 12 90-899883178 NOVEMBER 2007 . 34 Description Special Lubricant 101 Where Used Threads of stainless steel fasteners Part No. propellers. steering systems. Adhesives Tube Ref No. 19 8‑11 19 168 71‑91 168 – – – Quicksilver Products Accessories Quicksilver gauges. Sealants. WI 54935-1939 Outside of U. Description Exhaust tube clamp Exhaust pipe bolts Exhaust block‑off plate bolts Bravo One propeller nut Bravo Two propeller nut Bravo Three front propeller nut Bravo Three rear propeller nut Rear engine mounting bolts Steering cable coupler nut Steering system pivot bolts Sterndrive unit fasteners Transom assembly fasteners Mounting clip screw Hose clamps Water inlet fitting bolts Water inlet block‑off screw Fuel inlet fitting Gen III Cool Fuel Module captured nut Battery stud Propeller shaft anode screw Nm 3 34 34 75 81 136 81 47 47 34 68 34 12. 26 – – – – – – – – – – – 108 26 45 45 lb‑ft – 25 25 55 60 100 60 35 35 25 50 25 – – – – Then align tabs with grooves Then align tabs with grooves Finger tight + 1‑3/4 to 2‑1/4 turns with a wrench. Mercury MerCruiser recommends the use of Quicksilver parts on all applications.. This Guide is available from: Attn: Parts Department Mercury Marine W6250 W.

Maintenance and Warranty Manual identification page Affix engine serial number decal to specification / serial number decal. and sterndrive serial number decal strips provided with each power package.SECTION . a b c d 25906 a . 8331 a a . Identification Serial Number Decal Placement There are 3 sets of engine.Bar code b . transom assembly. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide. model number.1 IMPORTANT INFORMATION Remote Controls and Instrumentation for the DTS System The Digital Throttle and Shift system (DTS) requires the use of specialized helm components.Gear ratio d . gear ratio. and bar code is embedded in the ground plate located on the port side of the Bravo sterndrive.Serial Number c . One should be used for each of the following: • Engine Specification Decal • Warranty Registration Card • Operation.Specification/serial number decal Bravo Sterndrive Serial Number and Identification The sterndrive serial number. including a command module kit and electronic remote control.Model number 90-899883178 NOVEMBER 2007 Page 3 / 12 .

a 25904 Bravo transom assembly U‑bolt plate a .IMPORTANT INFORMATION SECTION .1 The serial number is also stamped on the sterndrive casting inside the back cover.Serial number stamping Bravo Transom Serial Number The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.Transom assembly serial Number Page 4 / 12 90-899883178 NOVEMBER 2007 . This is used as a permanent reference for authorized MerCruiser Dealers. a 25907 Bravo sterndrive serial number stamping a .

with the sterndrive unit trimmed at or near full trim‑in. It has been brought to our attention that some boats (predominantly deep‑Vee heavy boats) will roll up on their side under certain. and its effectiveness. instability can be created. We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for handling problems. The roll can be either to port or starboard and may be experienced while moving straight ahead. the roll may be sufficient to unseat the operator or passengers. help to control the condition. Do not let the tie bar contact other components during severe turning conditions. While the boat will not roll completely over. The need for this trim‑in limit insert. in some circumstances. or while making a turn.SECTION . may worsen the condition. Under these extreme stern‑lift / bow‑down conditions. which may cause the boat to roll. increased trim‑in range can cause handling problems at high speeds. The roll occurs most frequently at or near maximum speed. specific. NOTICE Incorrect tie bar installation can damage the drive and steering system. a 25905 Gimbal housing with serial number stamping a . Weight distribution in the bow. While this device should reduce the rolling tendency. Always calculate sufficient turning clearances. can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.1 IMPORTANT INFORMATION The serial number is also stamped on the gimbal housing. resulting in personal injury or death. Two and Three Models are equipped with a trim‑in limit insert. 90-899883178 NOVEMBER 2007 Page 5 / 12 . observe recommended tie bar arrangements. ! WARNING On some boats. The trim‑in limit insert reduces stern‑lift by preventing the sterndrive unit from reaching the last few degrees of full trim under. Multiple Sterndrive Steering Tie Bar Arrangements With multiple sterndrives you must select one of several possible steering systems. This is used as a permanent reference for authorized MerCruiser Dealers. and thereby create an unsafe situation. it may not eliminate the tendency entirely. port or starboard. The roll is caused by stern‑lift created from excessive sterndrive unit trim‑in. and check for proper installation before operating the boat. Weight distribution to the stern can reduce stern‑lift and.Transom assembly serial Number Bravo Three Notice: Trim‑in Limit Insert NOTE: Bravo One. operating conditions.

Stainless Steel Fasteners SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in salt water environments. Use only the specified Mercury MerCruiser SeaCore components and castings on these power packages. SeaCore Components and Castings Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and particular aluminum castings with special coatings. Again. resulting in increased play in the steering of the boat. 92-802865Q02 Page 6 / 12 90-899883178 NOVEMBER 2007 . improper clamp loads. or for the ultimate in steering backlash reduction. 34 Description Special Lubricant 101 Where Used Threads of stainless steel fasteners Part No. External Power Steering When boat speeds move past 113 km/h (70 MPH) or if additional steering backlash reduction is desired. HOWEVER. or both. Stainless steel fasteners are subject to galling when installed without lubrication. (60‑70 MPH) or for a reduction in steering backlash. a dual trim control kit (Part Number 90362A3) should be installed to limit this potential tilt differential to about 20 degrees. the basic internal tie bar is recommended. This normally will include an external tie bar mounted at the same general location as the power steering cylinders.) of the threads before installation. Apply a lubricant. Lubricate at least the first 8 mm (1/4 in. such as Special Lubricant 101 or an equivalent. external power steering is recommended. an external tie bar should be added. Galling can result in fastener destruction. IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with no internal tie bar when using the internal power steering system. (60 MPH). BUT (where mechanically possible) with the external tie bar mounted at the trim cylinder boss location (as previously described in "Internal Power Steering with Internal and External Tie Bar" statements). Internal Power Steering With Internal and External Tie Bar As a boat moves into the moderate performance range of 97‑113 km/h. which are generally attached at the top of the sterndrive's drive shaft housing. This location is an excellent choice because of its proximity to the propeller. Galled fasteners may appear to torque properly. These increased loads can damage the steering components. Tube Ref No. boats not capable of speeds in excess of 97 km/ h. but still have incorrect clamp loads. on the threads of stainless steel fasteners during installation to avoid galling. It connects the slave sterndrive to the sterndrive that is directly connected to the factory power steering output. this system does not use an internal tie bar. over 129 km/h (80 MPH) . Do not replace SeaCore components with non‑SeaCore.1 Internal Power Steering With Internal Tie Bar Only At the lower end of the performance spectrum. no internal tie bar should be used. With this steering system. External Power Steering With Low External Tie Bar For the fastest boats. External tie bars are usually designed to attach at the aft power trim cylinder bosses. These steering cylinders can be attached either inboard (between) or outboard of the sterndrives.IMPORTANT INFORMATION SECTION . This internal tie bar is available in a variety of lengths from the sterndrive manufacturer. because of the potential overstress that can occur if one sterndrive is trimmed much differently than the other. This can cause excessive loads on the steering components on the sterndrive connected to the internal power steering system. use external power steering.

A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while still providing a path to ground for dangerous fault (shock) currents. as this will render them ineffective as galvanic corrosion inhibitors. A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. (Refer to Mercury Precision Parts Accessories Guide for part numbers.SECTION . (Refer to Mercury Precision Parts Accessories Guide for part number. for severe conditions or if using a stainless steel propeller.1 IMPORTANT INFORMATION Corrosion Protection Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. Anti‑fouling Paint IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the limited warranty. However.) IMPORTANT: If AC shore power is not isolated from boat ground. Painting Boat Hull or Boat Transom: Anti‑fouling paint may be applied to boat hull and boat transom but you must observe the following precautions: IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System reference electrode and anode. 90-899883178 NOVEMBER 2007 Page 7 / 12 . the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.) Boats that are connected to AC shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode System with 2 additional transom mounted anode assemblies be installed (some models have a MerCathode System as standard equipment).

observe the following: • Avoid an electrical interconnection between the Mercury MerCruiser Product.) UNPAINTED area on transom of the boat around these items. Do not use any cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.IMPORTANT INFORMATION SECTION . if not prohibited by law. anodes.Painted boat transom b . MerCathode system or items specified by boat manufacturer. Do not paint drain holes. a b 8107 a . NOTICE Washing the MerCathode assembly can damage components and lead to rapid corrosion. or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in. copper base paint. If using copper based anti‑fouling paint. can be used.1 IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom. Anodic Blocks.Minimum 40 mm (1‑1/2 in. Page 8 / 12 90-899883178 NOVEMBER 2007 .) unpainted area around transom assembly NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint or an anti‑fouling paint that DOES NOT contain copper or any other material that could conduct electrical current.

O. DISP MMM YYYY X. EMISSION CONTROL INFORMATION THIS ENGINE CONFORMS TO XXXX CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD.O. if equipped.Do not paint c . function. and the engine displacement."—Date of Manufacture 31656 90-899883178 NOVEMBER 2007 Page 9 / 12 . NOTE: When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine."—Emissions Standard "D.M.Do not pressure wash 6211 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. the Declaration of Conformance applies. year).MerCathode reference electrode b .XL 0575 Emission Control Label—California Emissions–Compliant "SERIAL#"—Engine Serial Number "FAMILY"—Engine Family "STD. XX. Refer to the front page of this manual for further information. or performance of the engines. c a b a . date of manufacture (month.X g/kW-hr D.1 IMPORTANT INFORMATION Do not wash the sterndrive unit with a power washer as this can damage the coating on the reference wire of the MerCathode assembly.M. Please note that the low emissions certification will not affect the fit. If modifications are necessary. STD (emission standard/level). Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. contact Mercury MerCruiser about the availability of replacement decals before proceeding. the label lists the engine serial number.SECTION . family. In addition to the required emissions statement. and increase corrosion.

O. XX. The Three‑Star label will be affixed on the left side of the hull as shown. The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to exceed their factory specifications.O. DISP MMM YYYY X."—Emissions Standard "D.1 "DISP"—Piston Displacement EMISSION CONTROL INFORMATION NOT FOR SALE IN CALIFORNIA REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL # XXXXXXXX FAMILY XXXXXXXXXXXX STD. a XX 1234 XX b 32973 a .Recommended location b .Secondary location Page 10 / 12 90-899883178 NOVEMBER 2007 .IMPORTANT INFORMATION SECTION .M.X g/kW-hr D.3 models meet the California Air Resources Board's Three‑Star Sterndrive and Inboard marine engine 2003 exhaust emission standards.XL 31657 Emission Control Label—Not for Sale in California "SERIAL#"—Engine Serial Number "FAMILY"—Engine Family "STD. Star Label The 4.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.

Engines meeting these standards have 90% lower emissions than One Star ‑ Low Emission engines. Two Stars . outboard. Failure to properly display the hang tag could result in a citation and possible fine to the dealer from the California Air Resources Board. the Dealer must mark the appropriate box on one hang tag to match the Star label affixed to the boat. the dealer must place the hang tag in a visible location in the boat prior to displaying the boat. Engines meeting these standards have 75% lower emissions than conventional carbureted two‑stroke engines. 90-899883178 NOVEMBER 2007 Page 11 / 12 . FO IDA mc79570-1 Three Stars .Very Low emission The two‑star label identifies personal watercraft. Engines meeting these standards have 20% lower emissions than One Star ‑ Low‑Emission engines.SECTION .1 One Star .3 models.Ultra Low emission The three‑star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. FN R T mc79572-1 Hang Tag On 4. The dealer is responsible for displaying the hang tag in a visible location on the boat on display in California.Super Ultra Low emission The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards.Low emission IMPORTANT INFORMATION mc79569-1 The one‑star label identifies personal watercraft. Personal Watercraft and Outboard marine engines may also comply with these standards.S. If in California. sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. EPA's 2006 standards for marine engines. outboard. These engines are equivalent to the U. sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star ‑ Low Emission engines. SS A D mc79571-1 Four Stars .

1 NOTES: Page 12 / 12 90-899883178 NOVEMBER 2007 .IMPORTANT INFORMATION SECTION .

...................2 2 90-899883178 NOVEMBER 2007 Page 1 / 2 ................................................................2 Engine Bed....................................................................................................................................2 Checking Transom Thickness........................... 2 Transom Thickness and Surface Plane.................................................................................................................2 BOAT CONSTRUCTION SECTION 2 ...................2 Transom Cutout.........................SECTION ..........BOAT CONSTRUCTION Table of Contents Boat Construction..............................................................................................................................................................................................................................................................................

Transom Specifications Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.BOAT CONSTRUCTION SECTION .) 10 ‑16 degrees a e d b d c a . The strings should touch where they cross.) up or down adjustment exists after the mount is adjusted to contact the stringer.2 Boat Construction Transom Thickness and Surface Plane IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.Drive System And Engine Mounting.) dimension.) 6 mm (1/4 in.2 cm (22‑1/2 in.Transom plate coverage ‑ 203 mm (8 in.) NOTE: Although the engine mounts allow some adjustment. Make proper alterations to the boat stringer (structure) to obtain the 6 mm (1/4 in.) from center e .) to either side of the vertical center line Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.Inner surface c . Engine Bed IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.) Outer Surface ‑ Flat within 2 mm (1/16 in.Transom thickness b . This may be checked by tying a string from the left front mount location to the right rear mount location and another from right front to left rear.Drive System And Engine Mounting. Page 2 / 2 90-899883178 NOVEMBER 2007 .Outer surface 7508 d .) Flatness Angle Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in. Description Difference between starboard and port engine mount Mount adjustment up and down (minimum) Specification 57.Transom angle Transom Cutout Refer to Section 6 .) for 203 mm (8 in. This allows for future engine alignment or adjustments. Checking Transom Thickness Refer to Section 6 . it is a good practice to ensure that the front and rear mount locations in the vessel are parallel and in the same plane.

........................... 4 Boat Requirements..............................................SECTION ...................................................................................................................................................................................................................................................2 Good Ventilation ........................................................................................................EXHAUST SYSTEM Table of Contents Exhaust System...........................................................................................................................................10 Clear Hose Measurement Method from Seacock or Muffler Drain.............................................................. 2 Important Information................ 3 General Information....................................3 EXHAUST SYSTEM SECTION 3 ............... 6 Loading the Boat—Without a Capacity Plate................................................................................................................................................................................................................................................2 Carbon Monoxide Poisoning......................................................................................................................................................................................................................................................................................................................7 Example .................................................................................... 2 Poor Ventilation ...................................................................................................................... 8 Clear Hose Measurement Method....... 3 Measuring Exhaust Elbow Height.......................................................................................................................................................................5 Loading the Boat with a Capacity Plate..................... 11 3 90-899883178 NOVEMBER 2007 Page 1 / 12 ..............................5 Example ......................................................................................................................................................................................................................................................................................................3 Exhaust Angle Measurement ...............4 Loading Requirements......................................................

and nausea. Special care is required on the transom or hull exhaust applications. as these custom‑designed exhaust systems can create a tuning effect that can cause water to be forced back into the engine. The instructions under Checking for Water Intrusion must be performed to ensure that water intrusion is not occurring. installing.EXHAUST SYSTEM SECTION . or forward hatches to remove fumes. Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards. or death. The installing dealer or boat builder is responsible for proper installation of the exhaust system as explained in the installation instructions for the product.3 Exhaust System Important Information NOTICE Improperly designing. • Performance. unless the damage is the result of a defective part supplied by the engine manufacturer. which should not be confused with seasickness or intoxication. and inboard engines that propel boats. Page 2 / 12 90-899883178 NOVEMBER 2007 . It is the boat manufacturer's responsibility for ensuring that water intrusion does not exist with their unique exhaust system. Early symptoms of carbon monoxide poisoning. Engine damage resulting from water ingestion is not covered by the product warranty. The exhaust system must be installed in accordance with the information contained in this section to prevent water intrusion problems. as well as the generators that power various boat accessories. dizziness. sterndrives. and tasteless. or modifying the engine’s exhaust system can introduce seawater or water from condensation into the combustion chambers. Exhaust system design and installation can affect: • Noise level. • Carbon monoxide levels. You may also want to include this information in the boat owner's manual. • Component longevity. maintenance and warranty manuals. open side curtains. damaging the engine. Keep the boat well ventilated while at rest or underway and avoid prolonged exposure to carbon monoxide. ! WARNING Carbon monoxide poisoning can lead to unconsciousness. These applications require that only that exhaust elbow height be checked as outlined under Measuring Exhaust Elbow Height. Engines with through propeller exhaust have been carefully designed and tested to avoid water intrusion problems and no additional testing is required. ! WARNING Installing the exhaust system incorrectly can lead to serious injury or death. include headache. and local boating and safety standards for the market in which the boat will be sold. brain damage. follow all federal. colorless. • Water Intrusion. When installing or designing exhaust systems. Carbon monoxide is a deadly gas that is odorless. Carbon Monoxide Poisoning IMPORTANT: The following important information is covered in the owner's operation. state. GOOD VENTILATION Ventilate passenger area. drowsiness.

) 90-899883178 NOVEMBER 2007 Page 3 / 12 .0 MPI and SeaCore 4. on a very calm day.3.3. to obtain the proper exhaust elbow height and exhaust angle. 5. Risers are limited to 152.0 models. Load the boat as outlined to simulate the maximum loading conditions likely to be encountered in normal operation. Examples of poor ventilation while a boat is moving: a a . 2. b mc79556-1 b .Operating the boat with no forward hatches open (station wagon effect). 5. 1. Example of desired air flow through the boat. 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. permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.Mooring close to another boat with its engine operating. IMPORTANT: Exhaust elbow height is measured to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. Refer to Water Lift Muffler.4 mm (6 in. Measurements under all loading conditions must be within the following specifications. Measurement must be taken with the boat in the water. if needed. Install 1 or more carbon monoxide detectors in your boat.0 Models Specifications 330 mm (13 in. IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer. mc79553-1 POOR VENTILATION Under certain conditions.3 EXHAUST SYSTEM 1.Operating the engine when the boat is moored in a confined space. For example. Any load distribution conditions that will affect the exhaust system must be clearly communicated to the operator in the owner's manual. the number of people that can be located on the swim platform simultaneously should be included in the manual if this could pose a problem. Minimum Exhaust Elbow Height Model 4. Measuring Exhaust Elbow Height General Information The height of the exhaust elbows must be within the dimensions specified to prevent water intrusion problems. Examples of poor ventilation while a boat is stationary: a a . Although the occurrence is rare.Operating the boat with the trim angle of the bow too high. Exhaust elbow risers must be installed.SECTION . b mc79554-1 b .3 and 5.) on all 4.

• All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as stated on the USCG capacity plate to perform the exhaust elbow waterline measurement.) of the engine system (if applicable) 10° 3° If the exhaust elbow height or exhaust angle is insufficient.3 Specification within 45. Riser Options Model 4.) and 43 mm (1. No prototype hulls or light layup hulls should be considered.) High 152 mm (6 in.) EXHAUST ANGLE MEASUREMENT Measure the exhaust angle of each section of the exhaust system using an inclinometer as shown in the diagram below.0 MPI and SeaCore 4. 5. See Loading Requirements.) and 43 mm (1.0 Models Low 76 mm (3 in. All exhaust angle measurements must be performed with the boat at rest in the water.Inclinometer b . or light layup hulls could be inaccurate and could result in product damage. 5. The maximum exhaust riser height is specified in the table below.3.Exhaust hose or tube c .3. Perform the second set of measurements with the boat fully loaded.) Medium 76 mm (3 in. Any measurement performed on non‑production boats. prototype hulls. Page 4 / 12 90-899883178 NOVEMBER 2007 .) Boat Requirements IMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height measurement. • All boats that display a CE certification capacity plate must use the maximum capacity as stated on the CE certification capacity plate to perform the exhaust elbow waterline measurement. Begin the measurement at the exhaust elbow outlet continuing along each section to the exhaust exit point of the boat. c a b 18582 Typical Exhaust a . 5. 5.0 Models SECTION .3.Minimum 305 mm (12 in.0 MPI and SeaCore 4.7 in.7 in. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers.3.EXHAUST SYSTEM Minimum Exhaust Hose Slope Model 4. modify the exhaust system or install the appropriate exhaust riser.7 cm (18 Specification for the remainder of in. Perform the first set of measurements without a load in the boat.

) 4. Measurements used for official Mercury MerCruiser audit at the OEM boat builder must be performed on current production boats.84 m (29 ft.84 m (29 ft. must add the maximum rated swim platform weight capacity to the swim platform. safe. gallon of gasoline = 6 lb. etc. b. ballast tanks. gallon of water = 8.5 to obtain a whole person. • 1 U.4 persons rounded down = 2 persons. Weights can be used to simulate these load conditions if desired.SECTION . 2. No prototype hulls or light layup hulls will be considered for official audit purposes.) long. • 1 liter of water = 1 kg • 1 U. 1.84 m (29 ft. the swim platform must be installed for the waterline height measurement. • 1 liter of gasoline = 0. arch.) to the swim platform . not including boats that are 8.84 kg (165 lb.84 m (29 ft.84 kg (165 lb. Boats 8.) per person. television. ballast tanks. (bench seat length) ÷ 20 in. if applicable. Refer to the following conversions.) long.4 persons. battery charger. • 55 in. (seat width) = 2. Take the maximum capacity weight as listed on the capacity plate (XXXX lb. the maximum capacity load is the number of persons that can sit on designated seating plus cargo excluding cabin space. 2.) long and greater than 8. For the purpose of MerCruiser waterline height measurements: • One person is equivalent to 74.75 persons. 5.) long.75 persons rounded up = 3 persons.84 m (29 ft. This gives the whole number and remainder of 74. fresh water tanks or holding tanks. ballast sacks. generator. Loading the Boat with a Capacity Plate For boats with a capacity plate. Boats 8. that do not have a maximum rated swim platform weight capacity must add 226. Fill the fuel tanks.) long.S.3 EXHAUST SYSTEM • • • For boats that do not have a capacity plate.72 kg 3.) persons to load onto the boat. stereo/entertainment equipment. Loading Requirements 1.3 lb.) • Cargo per person is equivalent to 11. 2. Round up or down at 0. must add181. (seat width) = 2. IMPORTANT: Use 20 inches for average passenger seat width when measuring bench seating. Persons.S. See the examples listed below.84 kg (165 lb. Use the following guide to determine the correct swim platform load: a. (bench seat length) ÷ 20 in.) long and greater than 8. Place weights in the corresponding area for which the load is being replaced. anchor. If a swim platform is an option. not including boats that are 8.80 kg (500 lb. 2.84 m (29 ft.84 m (29 ft.34 kg (25 lb. Next divide the weight by 74.) to the swim platform.45 Kg (400 lb.) long that do not have a maximum rated swim platform weight capacity.) long. Boats less than 8. Measurements used for official Mercury MerCruiser audit at OEM boat builders must use the CE certification maximum load for any boat model that will be sold outside of the United States. • 48 in. carpet. use the maximum load for persons and gear as listed on the capacity plate to determine the number of persons to place onto the boat for exhaust elbow waterline height measurements.84 m (29 ft. and heater tanks to simulate fully loaded condition. tower. washer/dryer. Add weight for any additional boat options: extra battery. Boats less than 8. Gear) and subtract the swim platform load. must add the maximum rated swim platform weight capacity to the swim platform. 90-899883178 NOVEMBER 2007 Page 5 / 12 . d. c.

) long that does not have a maximum rated swim platform weight capacity. Measure the exhaust elbow waterline height. Load cargo weight onto the boat before loading passenger weight. load cargo (leftover persons weight) onto the boat. Perform the first measurement with the swim platform loaded and the person taking the waterline measurement on the boat. Page 6 / 12 90-899883178 NOVEMBER 2007 .45 Kg (400 lb. 9. as the break point to round up or down to obtain a whole pound. 24860 24861 CE Capacity Plate USCG Capacity Plate IMPORTANT: If there is not enough seating for the number of people.EXHAUST SYSTEM SECTION .3 3.50 lb. Repeat until a person weight is is loaded into each seat in that row.84 m (29 ft. Put the remainder of a person in the next available seat. EXAMPLE NOTE: This example uses a boat that is less than 8. If applicable. NOTE: The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity plate. 4. Distribute cargo as described below. 8. NOTE: The following example is provided as a reference. and must add 181. and measure the exhaust elbow waterline height after each person weight is loaded onto the boat. Load a person weight into a seat. Preferred Cargo Distribution Aft storage 25% Center storage 50% Optional Cargo Distribution Aft storage 25% None 50% None 100% None Center storage 75% 75% None 100% None None Bow storage None 25% 50% None None 100% Bow storage 25% 5. See Boat loading diagram. choose the storage application from the Optional Cargo Distribution table that best applies to your boat configuration.84 m (29 ft.) to the swim platform NOTE: Use 0. IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat. 6. and bow storage. not including a boat that is 8. IMPORTANT: If the boat configuration does not allow for aft. 7. treat the leftover weight as cargo. center.) long. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded into each seat. Load the swim platform if equipped.

• 565 lb.24 persons – 4 persons = 0. + 165 lb. Remainder persons ÷ MerCruiser person weight = remainder MerCruiser person weight • 0. • 1100 lb. Maximum load (persons and gear) from capacity plate – swim platform load = remaining weight to be placed in the boat. (bench seat length) ÷ 20 in. load four 165‑lb.4 persons. • 1060 lb. IMPORTANT: Use 20 inches for average passenger seat width when measuring bench seating. • 400 lb. (seat width) = 2. + 165 lb. + 40 lb. Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the boat • 700 lb. = 1060 lb.4 persons rounded down = 2 persons. 90-899883178 NOVEMBER 2007 Page 7 / 12 . Total number of persons – number of whole persons = remaining persons • 4. (seat width) = 2. = 40 lb. = 1100 lb.75 persons rounded up = 3 persons. person onto boat seating with 400 lb. • 48 in.24 × 165 lb. ÷ 165 lb. = 565 lb. • 895 lb. + 165 lb.SECTION .5 to obtain a whole person. 2. IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.3 EXHAUST SYSTEM 1. 5. per person is to be added to the boat before loading passenger weight onto the boat. Using the totals in this example. d a b c e f 24862 Boat loading diagram a . – 400 lb. + 165 lb.MerCruiser person weight (two) d . on the swim platform. persons and one 40‑lb.MerCruiser person weight (four) f . = 700 lb.Swim platform load b . 2.MerCruiser person weight (one) c .24 remaining persons 4. An additional weight of 25 lb. (bench seat length) ÷ 20 in. Round up or down at 0. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person weight = maximum passenger load for measurement. = 4.24 persons 3. • 55 in.75 persons. See the examples below. 1. • 730 lb. = 730 lb. 2.MerCruiser person weight (three) e .Remainder MerCruiser person weight (five) Loading the Boat—Without a Capacity Plate For boats that do not display a capacity plate. = 895 lb. the number of persons to be loaded onto the boat for measuring purposes is the number of persons that can sit on designated seating excluding cabin space.

4. and bow storage. Perform the first measurement with the swim platform loaded and the person measuring the waterline on the boat. IMPORTANT: If the boat configuration does not allow for aft.) long. (MerCruiser person weight) = XXXX lb. This example uses a boat that is 8. add a weight of 25 lb.3 Number of persons × 165 lb. Continue the process moving forward toward the bow of the boat to the next row of seats until a person weight is loaded into each seat. and must add 226.) to the swim platform . Maximum passenger load from the calculation above – swim platform load if applicable. 10. Load the cargo onto the boat. Load a person weight into a seat. choose the storage application from the Optional Cargo Distribution table that best applies to your boat configuration.) long and greater than 8. See Example. 8.84 m (29 ft. 3.EXHAUST SYSTEM SECTION . Repeat until a person weight is is loaded into each seat in that row. EXAMPLE NOTE: The following example is provided as a reference. IMPORTANT: To account for cargo. 9. maximum passenger load.84 m (29 ft. This gives the number of 165‑lb. Measure the exhaust elbow waterline height. 5. per person to the boat before loading passenger weight onto the boat. Calculate the cargo by multiplying 25 lb. Divide the weight by 165 lb. persons to load onto the boat. center. per person. Distribute cargo as described below.80 Kg (500 lb. that does not have a maximum rated swim platform weight capacity. 2. Preferred Cargo Distribution Aft storage 25% Center storage 50% Optional Cargo Distribution Aft storage 25% None 50% None 100% None Center storage 75% 75% None 100% None None Bow storage None 25% 50% None None 100% Bow storage 25% • 6. Round up to next whole number. IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat. 7. Load the swim platform if equipped. and measure the exhaust elbow waterline height after each person weight is loaded onto the boat. Page 8 / 12 90-899883178 NOVEMBER 2007 . See Example 3. by the number of persons that can sit on designated seating excluding cabin space.

× 50% = 112. + 165 lb.SECTION . (MerCruiser person weight) to get a 1485 lb. + 165 lb. 6. cargo in the bow storage onto the boat before adding passenger weight. = 985 lb. • 985 lb. multiply the maximum cargo weight by 50% a. + 165 lb. • 9 passengers × 25 lb.50 lb. and bow storage: a. – 500 lb. + 225 lb. 90-899883178 NOVEMBER 2007 Page 9 / 12 . • 1485 lb. = 725 lb. To determine the maximum bow storage cargo weight.25 lb. To determine the maximum cargo load multiply the maximum passenger load by the maximum cargo weight per passenger. = 225 lb. multiply the maximum cargo weight by 25% 3. To determine the maximum center storage cargo weight.3 EXHAUST SYSTEM IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on designated seating excluding cabin space.50 lb. + 165 lb.25 lb. center. on the swim platform. To determine the maximum aft storage cargo weight. onto the boat with 500 lb. • 890 lb. = 5. NOTE: Use 0. 2. ÷ 165 lb. as the break point to round up or down to obtain a whole pound. Then. multiply the maximum cargo weight by 25% • 225 lb.9 passengers • 5. • 500 lb. + 165 lb. × 25% = 56. = 1485 lb. • 1385 lb. • 1055 lb. and 56 lb. 1. 5. rounded up = 113 lb. = 1220 lb. cargo in the center storage. cargo in the aft storage. = 890 lb. Using the totals in this example load 56 lb. 7. • 1220 lb. 112. passengers. rounded down = 56 lb. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum number of passengers to load onto the boat. 113 lb. To determine the maximum number of passengers to load onto the boat. load six 165 lb. = 1550 lb. b. 6 9 2 1 3 4 5 7 8 24863 Designated Seating Diagram This example uses 9 persons as the maximum passenger load. • 725 lb. Subtract the swim platform load from the total passenger load to get the remaining weight to be placed in the boat. 4.90 passengers rounded up = 6 passengers 8. multiply 9 passengers by 165 lb. = 1385 lb. = 1055 lb. (total passenger load) • 9 passengers × 165 lb. • 56. 225 lb. To determine the preferred cargo distribution for aft.50 lb.

Place a finger over the open end of the clear hose before removing it from the water.Swim platform load f . and passenger weight loading diagram a .MerCruiser person weight (two) h .Aft storage d . 6. Install a metal fitting or a weight on one end of the hose to keep that end of the hose below the waterline.MerCruiser person weight (three) i .EXHAUST SYSTEM SECTION . Page 10 / 12 90-899883178 NOVEMBER 2007 . Coil the excess clear hose into the bottom of the boat bilge. 4. 2.5 m (15 ft. 5.MerCruiser person weight (four) j .MerCruiser person weight (five) b . Keeping the clear hose in line with the engine's exhaust elbow. lift the end of the clear hose up to the highest point of the exhaust elbow. Put the weighted end of the clear hose over the side of the boat (port or starboard) that is sitting lower in the water. Keep the coil of clear hose below the waterline.MerCruiser person weight (one) g .) long.Center storage e .3 • 1550 lb. The fitting or weight must not restrict water from filling the clear hose. perform the exhaust elbow waterline height measurement on the side that sits lower in the water.Bow storage Clear Hose Measurement Method 1. Submerge the clear hose until completely filled with water.) ID (inner diameter) clear hose approximately 4. 3. b b a c 24865 a .Unrestricted opening IMPORTANT: On engines equipped with more than one exhaust elbow.MerCruiser person weight (six) c . Obtain an 8–10 mm (5/16–3/8 in. + 165 lb.Clear hose b .Fitting c . swim platform. = 1715 lb. g a c b d h e f 24864 i j Cargo.

Lower the open end of the hose and siphon water until it starts to come out of the hose.Clear hose d . If attached to the seacock drain.Measurement. 5.3 EXHAUST SYSTEM 7. perform the exhaust elbow waterline height measurement on the side that sits lower in the water. b c a d 8340 e 9142 a . Slowly take the finger off of the end of the clear hose to let the water level stabilize. keeping it below the water line. Route the remainder of the hose toward the engine's exhaust manifold and elbow. 90-899883178 NOVEMBER 2007 Page 11 / 12 .Top of exhaust elbow c . 6. Attach a clear hose to the muffler drain point or seacock drain point. The water will seek the level of the water outside the boat. 7. Keep the clear hose close to the exhaust elbow and as vertical as possible. 2. 4. Put a finger over the hose and lift open end until it is at the top of the exhaust elbow. The water will seek the level of the water outside of the boat.SECTION . open the seacock. waterline to top of exhaust elbow Clear Hose Measurement Method from Seacock or Muffler Drain IMPORTANT: Measure the exhaust elbow height to the waterline inside of the water lift muffler (instead of the water line outside of the boat) on applications so equipped. Keep the hose close to the exhaust elbow and as vertical as possible. IMPORTANT: On engines equipped with more than one exhaust elbow. 3.Waterline b . Start the engine to fill the muffler and hose. Ensure that this open end section of the hose is as vertical as possible from the boat's bilge to the top of the exhaust elbow.Weight e . 1. IMPORTANT: The engine must have been operated previously to fill the muffler with water. Coil excess hose in the bilge of the boat. Slowly take the finger off of the end of the hose to let the water level stabilize.

The measurement between the water in the hose and the top of the exhaust elbow is the exhaust elbow height.Clear hose for measuring waterline maximum load a b 24867 Typical horizontal water lift muffler a .3 8.Minimum exhaust elbow height with b .2 cm (6 in. a b 24866 Typical vertical water lift muffler a .Clear hose for measuring waterline maximum load Page 12 / 12 90-899883178 NOVEMBER 2007 .Minimum exhaust elbow height with b .EXHAUST SYSTEM SECTION . The maximum riser height is 15.).

................................................................................................................................................................................................................................FUEL SYSTEM Table of Contents Fuel Delivery System ........................................................................ 4 4 90-899883178 NOVEMBER 2007 Page 1 / 4 ............................... 2 California Regulations for 2007—Low‑Permeation Fuel Hose.....................................3 Special Information About Electric Fuel Pumps .........................................................................................................................SECTION .............4 FUEL SYSTEM SECTION 4 ..............................................2 Fuel Lines and Fittings....2 Fuel Delivery System .............................

Refer to the Engine Compartment/Fuel System Pressure and Temperature Test in the Mercury MerCruiser Product Applications Manual.) and Coast Guard regulations for complete guidelines. use a fuel pickup and fuel tank supply line for each engine. or offered for sale in California that uses an engine from a manufacturer that chooses Option 2. sold. On installations that require long lines or numerous fittings. Fuel Lines and Fittings We recommended that you measure the exact route and length of the fuel lines before the first installation of the engine to prevent problems later in connecting them to the engine. It can also cause poor engine performance because of fuel starvation.FUEL SYSTEM SECTION .4 Fuel Delivery System California Regulations for 2007—Low‑Permeation Fuel Hose California Regulations for New 2007 and Later Spark-Ignition Inboard/Sterndrive Pleasurecraft (3) Requirements of engine manufacturers and boat manufacturers under Option 2 and using Low Permeation Fuel Line Hose: (A) Each manufacturer that chooses Option 2 must provide written instructions.) from the bottom of fuel tank to prevent picking up impurities. The maximum measured vacuum at the engine's fuel inlet must not exceed 6. • Ensure that the fuel pickup is at least 25 mm (1 in. sold. Low Permeation Fuel Line Hose is USCG Type A1‑15. as part of the installation materials provided to purchasers of the engine.) 13 mm (½ in. If a single pickup and line is used. • Use fuel lines that are Coast Guard approved USCG Type A1. Hg) throughout engine operating range. or offered for sale in California.9 kPa (2 in. the line must be 13 mm (½ in. boating standards and regulations specify the sole use of USCG Type A1 fuel lines in the engine compartment or in any location in the boat where a break in the line could result in a discharge of 150 cc (5 oz.) of fuel in 2½ minutes. • Using a digital vacuum gauge. measure the vacuum at the engine's fuel inlet. use the fuel lines and fittings with an ID greater than 10 mm (3/8 in. to use Low Permeation fuel Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale. Use the Engine Compartment/Fuel System Pressure and Temperature Test to determine if the fuel pressure and temperature are within an acceptable range. • Follow the minimum fuel line diameter specification listed below. reduce the number of fittings or insulate the components. If the temperature is excessive.). Only a few points related to function and safety are listed here. The U.S. Refer to boating standards (NMMA. delivered or imported into California for introduction into commerce. defined as not exceeding 15 g/m²/24 h with CE10 fuel at 23° C as specified in SAE J 1527—Marine Fuel Hoses.) ID or larger. reduce the fuel line length. etc. Temperature increases significantly with increased engine compartment height. IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels.) ID or larger • • • On multi-engine gasoline installations. (B) Each boat manufactured must install Low Permeation Fuel Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale. • Page 2 / 4 90-899883178 NOVEMBER 2007 . Route the fuel lines as low as possible in the engine compartment to keep them in the coolest region. Description Minimum fuel line diameter on single‑engine gasoline installations Minimum fuel line diameter on multi‑engine gasoline installations with single pickup and line Specification 10 mm (3/8 in. ABYC. or that is introduced.

European Union– Recreational Craft Directive [EU‑RCD]. • Keep the fuel line free of stress and firmly secured to prevent vibration and chafing. The main concern of a boat's fuel system is safety. This is particularly true if winter blend fuels with a high RVP (Reid Vapor Pressure) are encountered in warmer temperature areas. causing the temperature of the fuel system to increase. IMPORTANT: If the engine is equipped with a boost pump. due to a broad range of possible configurations and the numerous regulations and standards that cover this area. from the filler pipe to the fuel pump. is the same in principle for all boats. The fuel delivery system must be designed to deliver the fuel to the engine with minimal restriction and at the lowest temperature. Society of Automotive Engineers [SAE]. The flexable line will absorb deflection between the engine and the hull structure when the engine is running. fuel starvation results when the boater attempts to resume operation. • Keep all the fuel lines well secured. Hg) or less and fuel inlet temperature to 44° C (110° F) or less. Secure the fuel line with clamps that will not pinch or kink the line. Mercury MerCruiser makes no attempt in this manual to cover all aspects of design and integration of the fuel delivery system. etc. ABYC. During this time the engine heat soaks.9 kPa (2 in. The fuel delivery system is an integral part of the boat.4 FUEL SYSTEM • Route the slope of the fuel line as consistent as possible to avoid high spots that can trap vapor and contribute to vapor locking problems. International Standards Organization [ISO]. the combination of heat and vacuum in the fuel system causes the fuel to vaporize. The applicable standards and regulations for the markets where your product will be sold should be observed. Only a few points related to function and safety are listed here [Refer to boating standards (NMMA. • Do not route the fuel line with sharp bends. • Ensure that the holes where the fuel lines run through the bulkheads are carefully rounded off or protected with grommets to prevent damage from vibration and chafing. Upon restart. The fuel system cannot handle this vapor and therefore. Excessive restriction in the fuel delivery system may cause a condition known as vapor locking. This filter is provided with the engine package. • Use a flexible fuel line to connect the fuel supply line to the fuel inlet fitting on the engine. or exhaust system. fuel delivery system. 90-899883178 NOVEMBER 2007 Page 3 / 4 .) and the standards they reference (American Boat and Yacht Council [ABYC]. Gasoline is extremely sensitive to vaporizing if placed under a vacuum (low pressure) and exposed to moderate or high temperatures. such as the engine compartment. To minimize the potential for this problem. Depending upon the degree of vapor locking. The fuel system. an in‑line filter must be installed between the fuel tank and the boost pump. Do not install a in‑line fuel filter on Vazer models. etc.SECTION . The following general guidelines are provided: ! WARNING Improper boat design and construction may result in serious injury or death. Refer to the special information on service and maintenance. The 100 Vazer model is equipped with a fuel pre‑filter already installed on the engine. along with any information from the fuel system component manufacturers. This typically occurs after the engine has been operated at high RPM and then shut off and allowed to sit for 15 minutes to 2 hours. Adhere to all applicable marine regulations (United States Coast Guard [USCG]. which you have received from the tank manufacturer.) and Coast Guard regulations for complete guidelines]: • All connections should be on the upper side of the tank. The fuel tank is an integrated component of the boat. this must be achieved through a technically sound installation and constant inspection.) when designing and constructing the boat and other components. the guidelines should be observed to limit fuel delivery restriction to 6. this can range from a hesitation or bog when accelerating to a complete stalling of the engine. etc.

5.) and the standards they reference (American Boat and Yacht Council [ABYC]. 3. Hg) through out engine operating range. but not limited to the following. • Poor driveability. The following. • Difficult warm‑starting. use the fuel lines and fittings with an ID greater than 10 mm (3/8 in.) from the bottom of fuel tank to prevent picking up impurities. SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS ! WARNING Improper boat design and construction may result in serious injury or death. applying to all engines unless otherwise stated. Society of Automotive Engineers [SAE]. measure the vacuum at the engine's fuel inlet. Use a flexible fuel line to the fuel inlet fitting on the engine to absorb deflection when engine is running. fuel delivery system. Use fuel lines that are Coast Guard approved (USCG Type A1).) ID or larger. etc. Fuel pickup should be at least 25 mm (1 in. If a single pickup and line is used. additional fuel connection related points.FUEL SYSTEM SECTION . Avoided sharp bends in the fuel lines. the line must be 13 mm (½ in. use a fuel pickup and fuel tank supply line for each engine. This prevents damage to the lines from abrasion. It can also cause poor engine performance because of fuel starvation. • Piston detonation due to lean fuel mixture.9 kPa (2 in. must be considered [Refer to boating standards (NMMA. Page 4 / 4 90-899883178 NOVEMBER 2007 . IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's fuels.) when designing and constructing the boat and other components. Description Minimum fuel line diameter on single‑engine gasoline installations Minimum fuel line diameter on multi‑engine gasoline installations with single pickup and line Specification 10 mm (3/8 in. On multi-engine gasoline installations. International Standards Organization [ISO]. 6.). • The tank breather pipe must have an inner diameter of at least 13 mm (1/2 in.) and Coast Guard regulations for complete guidelines]: 1. Adhere to all applicable marine regulations (United States Coast Guard [USCG]. It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine.) and must be fitted with a swan neck to prevent water from entering the tank. The installation of additional filters may cause: • Fuel vapor locking. ABYC. European Union– Recreational Craft Directive [EU‑RCD]. 7. 8. Using a digital vacuum gauge. or exhaust system. such as the engine compartment. All fuel lines must be well secured.4 • The drain plug at the lowest point on the tank serves to permit the removal of water and sediment. etc. 2. The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets. On installations that require long lines or numerous fittings. etc.) ID or larger 4. The maximum measured vacuum at the engine's fuel inlet must not exceed 6. Install the fuel lines so they are free of stress and firmly secured to prevent vibration and/or chafing.) 13 mm (½ in.

........................................................................... 12 Return Hose Connection ................................................................................ 7 Seawater Pickups for SeaCore Sterndrive Engine Models ................................ 11 Supply Hose Connection ...................................................................................COOLING SYSTEM Table of Contents General Information........ 3 Seawater Pickup........................... 16 V‑6 Sterndrive Models With Closed Cooling .................................................................................... 10 Description..................................... 2 Seawater Supply System...................................................................................................................................................................... 2 Seawater Supply Hose.......................................................................................................................2 Seawater Inlet Hose............ 19 V‑8 Bravo Models With Seawater Cooling (Except MPD Models) ...............................................................................................................................................5 Sea Strainer........................................................................................................... 18 V‑8 Bravo MPD Models With Seawater Cooling .................................................................................................................................. 23 5 90-899883178 NOVEMBER 2007 Page 1 / 24 ......................................................................................................................... 20 V‑6 Bravo Models With Seawater Cooling (Except MPD Models) ...................................................................................................................................................................................................9 Installing the Seawater Supply Hose................................................ 15 V‑8 Bravo Models With Closed Cooling .....................................................................................................................................14 V‑8 Bravo Models With Closed Cooling and Risers .............................................................................................................................................................................. 22 V‑6 and V‑8 Alpha Models With Seawater Cooling (Except MPD Models) .....................................6 Sterndrives With Closed Cooling Engines..................................................................................................................................... 7 Bravo Models with Closed Cooling.................. 13 Water Flow Diagrams......................................................................................................... 14 V‑6 Alpha Models With Closed Cooling and Risers ........................................................................10 Coolant Recovery System..............................................................................................................2 Through‑Hull Seawater Pickup System................................................................ 7 SeaCore Models..........................................................................................................7 SeaCore Bravo One and Bravo Three Models ..................................................................................4 Seacock...5 COOLING SYSTEM SECTION 5 ......................... 7 SeaCore Bravo Two Models .................................................................................................. 14 V‑6 and V‑8.........................................................................................................................................................................................................................................................................................................................................11 Hot Water Heater Hose Connections ‑ MPI Models .............................................................................. 17 V‑6 Bravo MPD Models With Seawater Cooling ...........................................................................................................................................................................SECTION ...................................................................................................................................................................................................................................................................................................10 Antifreeze Recommendations............................................................................................................................................... 8 Installing the Y‑Fitting......................9 Closed Cooling..................................................................................................................................................................................................................................................................... 21 V‑6 and V‑8 Alpha MPD Models With Seawater Cooling .....................................

Seawater Supply System Seawater Supply Hose Seawater Supply Hose Specifications Seawater inlet hose Seawater pickup Seacock (ABYC requirement) Sea strainer (optional) Low restriction with 32 mm (1‑1/4 in. a temperature switch is incorporated into the audio warning system. the water pump. Use the shortest hose length possible with the least number of bends to minimize restriction. Hg vacuum must be used to prevent the seawater inlet hose from collapsing from pump suction.) connections 32 mm (1‑1/4 in. The design and installation of the seawater supply system is the boat manufacturer's responsibility. (Refer to cooling system flow diagrams at end of section. and other components will overheat and suffer damage. On engines with seawater cooling. A temperature sender is also employed to operate a temperature gauge at the dash.COOLING SYSTEM SECTION . Closed cooling systems use a combination of fresh water (antifreeze and water) and seawater for cooling. Both types of systems are designed to keep the engine operating temperature at approximately 71 degrees C (160 degrees F) for optimum performance. Sealant. Provide a sufficient supply of water to the water inlets during operation. Hose fitting threads and plastic plug threads 92-809822 Sealing surfaces and screw shaft 92-809825 General Information Mercury MerCruiser engines have either a seawater cooling system or a closed cooling system. sized. On dual helm applications.) I.5 Lubricant. All connections must be secured with a hose clamp. The cooling system must receive a sufficient amount of seawater under all operating conditions to operate properly. The hose should be oil and seawater resistant. NOTICE Without sufficient cooling water. Adhesives Tube Ref No. Cooling system components must be constructed. the engine is cooled entirely by the seawater in which the boat is being operated. which alerts the operator of an abnormal condition if the temperature exceeds approximately 93 degrees C (200 degrees F). Refer to the Instrumentation and Controls section for more information. Page 2 / 24 90-899883178 NOVEMBER 2007 . and installed in accordance with the following guidelines.) To monitor the cooling system. (wire reinforced) Seawater Inlet Hose • • • • A reinforced hose capable of supporting 10 in. 9 116 Description Loctite 567 PST Pipe Sealant RTV 587 Ultra Blue Silicone Sealer Where Used Part No. the engine.D. Seawater cooling systems are sometimes called raw water cooling or standard cooling. fuel economy and durability. this sender must be replaced with a dual station sender to obtain the proper temperature reading at both stations. while closed cooling systems are sometimes called fresh water cooling.

Seawater pump hose connector (if b .Below seawater pump level d . engine coupler. IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks.5 COOLING SYSTEM • Fasten hose as appropriate to maintain proper routing and to prevent chafing or contact with other moving parts. a a 7638 9361 Typical composite seawater pickup pump a . This will cause propeller ventilation and will adversely affect boat performance.Quicksilver seawater pickup and e .Seawater hose to engine seacock f .Seawater inlet hose connection Typical brass seawater pickup pump Through‑Hull Seawater Pickup System IMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction is created by seawater pump impeller. Hoses must not come in contact with steering system components. 90-899883178 NOVEMBER 2007 Page 3 / 24 . or drive shaft.Quicksilver seawater strainer IMPORTANT: Do not install the seawater pickup directly in line with the propeller. g c f b e b d a 7924 b Typical installation shown with a through the hull seawater pickup a .Seawater hose to seawater strainer g . as the pickup may create turbulence and allow air to flow into the propeller slipstream.Hose clamp equipped) c .SECTION .

as pickup may create turbulence and allow air to flow into the propeller slip‑stream. such as those behind or in close proximity to the propeller. Locations that are too far forward or outboard should also be avoided as these are prone to aeration problems at high boat trim angles and in turns. IMPORTANT: External seawater pickup must have an integral seacock. This will cause propeller ventilation and will adversely affect boat performance. The location should be in an area that will provide a solid. given the hull material being used and the composition of the surrounding components. Openings in seawater pickup should be approximately 3 mm (1/8 in. Provisions should be made to minimize galvanic corrosion. 7532 Typical seacock Page 4 / 24 90-899883178 NOVEMBER 2007 . Seawater Pickup Either a through‑transom or through‑hull seawater pickup can be used. The seawater pickup also must supply a positive head while underway. Some industry standards and regulations also require that the pickup be connected into the boat's bonding system to minimize stray current corrosion.). IMPORTANT: Use a seawater strainer if the seawater pickup openings exceed 3 mm (1/8 in. The seawater pickup should be located as close to the seawater pump inlet as possible and in an area where an uninterrupted. solid stream of seawater will flow past when the boat is underway. Check for aeration as outlined under Seawater Supply Test. IMPORTANT: Do not install the seawater pickup directly in line with the propeller.) maximum to prevent larger debris from entering and clogging the cooling system. Select pickup location to minimize seawater inlet hose length while providing an optimum location for seawater pickup.5 • • • The seawater pickup must be large enough to permit sufficient seawater flow to engine seawater pickup pump for adequate engine cooling. Avoid areas with a disturbed seawater flow. Refer to applicable standards and regulations for more details.COOLING SYSTEM SECTION . air‑free flow of seawater under all operating conditions.

The seacock also allows the seawater to be shut off when servicing the engine. Refer to applicable standards and regulations for specific requirements. 92-809822 Part No. 116 Seacock The ABYC and other industry standards and regulations require the use of a seacock on certain types of applications to stop the entry of seawater in the event of a leak in the cooling system. 92-809825 Tube Ref No.SECTION . 9 Where Used Hose fitting threads and plastic plug threads Where Used Sealing surfaces and screw shaft Tube Ref No.5 COOLING SYSTEM b a g c d e f h i j Typical transom pickup abcdeHose fitting Nut (4) Gasket O‑ring (4) Washer (4) Description Loctite 567 PST Pipe Sealant Description RTV 587 Ultra Blue Silicone Sealer 7558 fghij- Screw (4) Plastic plug Pickup Screen Screw (2) Part No. 90-899883178 NOVEMBER 2007 Page 5 / 24 .

7532 Typical seacock Sea Strainer A sea strainer is recommended if the boat is to be operated in an area with a high debris content.COOLING SYSTEM SECTION . The strainer must have provision to allow draining in freezing temperature periods. easy operation. the strainer should be located above the seawater‑line to prevent seawater entry into boat when servicing.5 The seacock must provide minimum restriction to seawater flow (see Specifications). This design gives a clear indication of whether the valve is open or shut. The ball valve is most common and is typically equipped with a lever type handle that operates in a 90 degree arc. The strainer must be sized to minimize restriction (See Specifications) and to provide a reasonable service interval. Industry standards and requirements typically require that the seacock be rigidly attached to the hull at the seawater pickup. Locate the strainer in an area that will be easily accessible for servicing. Seacock location should be readily accessible for quick. A ball valve or gate valve is recommended. If the boat is not equipped with a seacock. 7533 Typical Sea Strainer Page 6 / 24 90-899883178 NOVEMBER 2007 .

See Installing the Y-Fitting.Engine seawater pump c . SeaCore Models Some SeaCore models do not require a through‑the‑hull or through‑the‑transom seawater pickup to meet the minimum flow specifications. SEACORE BRAVO TWO MODELS The SeaCore Bravo Two engine packages must have a through‑the‑hull or through‑the‑transom seawater pickup in addition to the sterndrive side water pickups.Y‑fitting port to additional water inlet to Y‑fitting Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere do not require the dual seawater pickup with a bravo sterndrive on closed cooling models. When additional water inlets are used. Install a seawater suppy hose that meets MerCuiser specifications. see Installing the Seawater Supply Hose. See the chart. Seawater Pickups for SeaCore Sterndrive Engine Models. Remove the Y‑fitting at the seawater pump inlet.5 COOLING SYSTEM Sterndrives With Closed Cooling Engines Bravo Models with Closed Cooling NOTE: Closed cooled Bravo models require a through the hull or through the transom pickup in addition to the sterndrive water inlets in order to meet the minimum flow specifications. Install the Y‑fitting at the engine's seawater pump inlet.Y‑ fitting port to Bravo drive b . • The boat is capable of 64 km/h (40 MPH) with the boat fully loaded and operated within the specified operating range. NOTE: When not installing the through‑the‑hull or through‑the‑transom seawater pickup.Hose from seawater pump inlet port d . 90-899883178 NOVEMBER 2007 Page 7 / 24 . Cut the hose to fit from the transom inlet fitting to the seawater pump inlet. a Y‑fitting is installed to the engine seawater pump.SECTION . SEACORE BRAVO ONE AND BRAVO THREE MODELS The SeaCore Bravo One and Bravo Three engine packages do not require a through‑the‑hull or through‑the‑transom seawater pickup in addition to the sterndrive water pickups if: • The sterndrive gearcase has dual water pickups. a c b d 8485 Dual seawater pickup for Bravo closed cooled engines a .

COOLING SYSTEM SECTION . Not required See Installing the Seawater Supply Hose 30181 30180 Page 8 / 24 90-899883178 NOVEMBER 2007 .5 SEAWATER PICKUPS FOR SEACORE STERNDRIVE ENGINE MODELS Seawater Pickups for SeaCore Sterndrive Engine Models Boat speed with the boat fully loaded and operated within the specified operating range SeaCore Bravo has side water pickup SeaCore Bravo has dual water pickup Through‑the‑hull or through‑the‑transom seawater pickup 64 km/h (40 MPH) or greater Not required See Installing the Seawater Supply Hose 30180 Less than 64 km/h (40 MPH) 30181 30180 Required See Installing the Y-Fitting 64 km/h (40 MPH) or greater Required See Installing the Y-Fitting 30181 Greater or Less than 64 km/h (40 MPH) Models operated above the fiftieth parallel of the northern hemisphere or below the fiftieth parallel of the southern hemisphere.

Cut a 101. refer to Mercury Parts Catalog. 2. Standard Cooling Systems (Bravo) to order the specified bulk hose. remove the Y‑fitting at the seawater pump inlet. Properly secure all hoses to all fittings to prevent water leaking into the boat. 4. NOTE: For models with quick connection fittings and pull test information.6 mm (4 in. Installing the Seawater Supply Hose For engine models not using through‑the‑hull or through‑the‑transom seawater pickup: 1. require a Y‑fitting at the engine seawater pump inlet port. Cut off any excess hose as needed. and quick connect fittings that meet MerCruiser specifications. Install a seawater supply hose to the Y‑fitting port and the through‑the‑hull or through‑the‑transom seawater pickup. a c b d abcd8485 Typical Y‑fitting installation Engine seawater pump Hose 101. NOTE: For models not factory‑equipped with a seawater supply hose. Install a seawater supply hose to the Y‑fitting port and the sterndrive's water inlet at the transom.6 mm (4 in. and hose clamps that meets MerCruiser specifications.) leneth piece of the supply hose and install it to the seawater pump inlet and the Y‑fitting port. 3. Closed Cooling Systems (Bravo) to order the specified Y‑fitting. Cut off any excess hose as needed. hose clamps. refer to the Mercury Parts Catalog. refer to Section 6. 3. 4. seawater supply bulk hose. Seawater Inlet Fitting Connection .) from seawater pump inlet to Y‑fitting port Y‑fitting port to water inlet at transom Y‑fitting port to through‑the‑hull or through‑the‑transom seawater pickup NOTE: For models not factory equipped with a Y‑fitting. 1. Cut off any excess hose as needed. Install a seawater supply hose that meets MerCruiser specifications to the engine's seawater pump inlet. If applicable. 90-899883178 NOVEMBER 2007 Page 9 / 24 . The Y‑fitting directs the seawater from the sterndrive and through‑the‑hull or through‑the‑transom seawater pickup to the engine's seawater pump to meet the minimum flow specifications.SECTION . Route the seawater supply hose directly to the seawater inlet fitting on the transom. Properly secure the hose at both ends to prevent water leaking into the boat.5 COOLING SYSTEM Installing the Y‑Fitting Engine models that require a through‑the‑hull or through‑the‑transom seawater pickup. 2.

which can be corrosive in salty. When closed cooling is used. The term full closed cooling. Antifreeze Recommendations NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. we recommend that only an extended‑life antifreeze be used. which provides increased coolant velocity through the engine and heat exchanger to prevent hot spots and improve performance. The ethylene glycol coolant mixture is circulated through the exhaust cooling passages as well as the engine cooling passages. a mixture of antifreeze and water is circulated through the water jackets in the engine block. Extended‑life coolant is available from Texaco under the name Havoline Extended Life Dex Cool. In this manner. The heat is then carried away by the seawater and discharged overboard via the exhaust elbows. Factory installed closed cooling systems come filled with an extended life antifreeze. If you are installing closed cooling kits at your facility. Here the coolant rejects heat to seawater (water in which the boat is being operated). when filling coolant recovery bottle. polluted. This additional cooling capacity translates into longer cooling system life with fewer problems regardless of where the boat is operated. where most after‑market systems fall short of this mark. while ensuring that the two coolants are separated. The design of the heat exchanger allows for the transfer of heat. Contact your sales representative to order your closed cooling systems factory installed or refer to the Mercury Precision Parts and Accessories Guide to obtain the part numbers for the accessory kits. All antifreeze should be mixed 50/50 with pure water (Quicksilver coolant is already pre‑mixed). Only coolants that state that they are compatible with Dex Cool should be used. Mercury MerCruiser's closed cooling systems are developed by the same people who design our engines to ensure compatibility and the same high quality standards. cylinder heads. Mixing this coolant with even a small amount of regular antifreeze will require that the service interval be reduced 2 years. This coolant allows for a service interval of 5 years or 1000 hours (whichever occurs first).COOLING SYSTEM SECTION . Prestone also offers a version of this antifreeze called Extended Life 5/100. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed. An exclusive double‑acting thermostat is used on V6 and V8 models. we would also encourage you to use the extended Life coolant to allow your customer to take advantage of the reduced maintenance costs.e. Our systems employ several exclusive features to provide unsurpassed cooling efficiency and durability. and—on some applications—the exhaust manifolds to dissipate the heat. Mercury MerCruiser's heat exchangers also incorporate several state‑of‑the‑art designs to enhance the heat transfer between the coolants for an additional margin of cooling capacity. the expensive engine components are never exposed to seawater. which is simultaneously being passed through the exchanger. Refer to Water Flow Diagrams.5 Closed Cooling Description Closed cooling is a standard feature on some models and is available as an accessory or a factory installed option on others. Pre‑mixed extended life coolant is available from Quicksilver or can be purchased at most automotive stores and other locations where antifreeze is sold. be sure to observe the special filling procedure in the installation instructions. or mineral laden water areas. When adding coolant to these systems (i. If installing closed cooling kits at your facility. installing hot water heater). Closed Cooling System Capacity Page 10 / 24 90-899883178 NOVEMBER 2007 . versus 2 years or 400 hours for standard antifreeze. Extended‑life coolants can be identified by their orange color (vs. green for standard coolant) and their corresponding orange cap on the container. also known as full fresh water cooled or full FWC refers to the use of an ethylene glycol mixture in the engine and the exhaust water jackets. Features like these allow our systems to continually operate at WOT in water temperatures up to 38 °C (100 °F). This coolant is then passed though a heat exchanger.

NOTE: This differs from the previous recommendation and has been changed to ensure that air does not enter the cooling system upon cool down. 90-899883178 NOVEMBER 2007 Page 11 / 24 .Screw and flat washer (2 each provided) Hot Water Heater Hose Connections ‑ MPI Models IMPORTANT: When connecting a cabin heater or hot water heater: • Supply hose (from engine to heater) and return hose (from heater to engine) Must Not Exceed 16 mm (5/8 in. NOTICE Blocking the coolant flow at the heater can cause reduced engine performance or overheating.Plastic tubing e .Tubing clamp f .Heat exchanger fill neck a . Coolant recovery bottle mounting location must meet these requirements: • Within approximately 122 cm (4 ft.) inside diameter (ID).Mounting bracket c .) of heat exchanger filler neck to allow connection with tubing provided.5 8. • Accessible for observing level and servicing coolant. • Make heater connections only at locations shown. • Do not reposition engine temperature switch.Recovery bottle b .SECTION .1S Models All Other Models 18 liters (19 quarts) 19 liters (20 quarts) COOLING SYSTEM Coolant Recovery System This system is equipped with a coolant recovery system that must be installed by the boat manufacturer. • Even with or slightly above heat exchanger filler neck. • Refer to manufacturers' instructions for complete installation information and procedures. c c a e b f d d 12838 12837 e d . Check for continuous coolant flow from the engine intake manifold to the water circulating pump.

Supply Hose Connection NOTE: Some models may be equiped with additional fittings. In models equipped with closed cooling.Location for hot water supply Page 12 / 24 90-899883178 NOVEMBER 2007 . a 9255 Seawater cooled models with air or manual drain a .Location for hot water supply a 9256 Closed cooled models a . low coolant levels may allow an air pocket to form when the hot water heater or cabin heater is mounted higher than the fill cap on the heat exchanger.5 NOTICE Prevent engine damage from overheating. Mount the heater lower than the fill cap of the heat exchanger and maintain the recommended coolant level.COOLING SYSTEM SECTION .

Special fitting 90-899883178 NOVEMBER 2007 Page 13 / 24 .Location for hot water supply Return Hose Connection a b 9258 a . a b 25133 a .Water circulating pump housing IMPORTANT: A special fitting 22‑865526 may be used if the hex of the standard hose barb fitting contacts the water pump housing not allowing the fitting to turn before the fitting is tight.SECTION .5 COOLING SYSTEM a 9257 Seawater cooled models with multi‑point drain a .Return hose connection for hot water heater b .Standard fitting b .

Ethylene glycol mix p .Seawater o .5 Water Flow Diagrams V‑6 and V‑8 V-8 BRAVO MODELS WITH CLOSED COOLING AND RISERS h b a c p i d j k e g f c l n o m abcdefghSeawater inlet Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump Thermostat housing i .Seawater pump k .COOLING SYSTEM SECTION .Check valve 8182 Page 14 / 24 90-899883178 NOVEMBER 2007 .Exhaust elbow j .Heat exchanger l .From seawater pump n .To power steering pump m .

Thermostat housing j .Ethylene glycol mix 90-899883178 NOVEMBER 2007 Page 15 / 24 .SECTION .Seawater n .Seawater pump l .Exhaust elbow k .Heat exchanger m .Water circulating pump i .5 COOLING SYSTEM V-6 ALPHA MODELS WITH CLOSED COOLING AND RISERS i b k a j e c l d f h m g abcdefgSeawater inlet Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold Distribution housing 9393 n h .

Seawater o .COOLING SYSTEM SECTION .5 V-8 BRAVO MODELS WITH CLOSED COOLING i a h b j k c p d e g c f n o l m abcdefghY‑fitting Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump Thermostat housing 9385 i .Check valve Page 16 / 24 90-899883178 NOVEMBER 2007 .Heat exchanger l .Exhaust elbow j .Seawater pump k .Ethylene glycol mix p .To power steering cooler m .From seawater pump n .

Ethylene glycol mix 90-899883178 NOVEMBER 2007 Page 17 / 24 .5 COOLING SYSTEM V-6 STERNDRIVE MODELS WITH CLOSED COOLING a j i b k l c e d f h m n 9386 g abcdefgY‑fitting Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold Distribution housing h .Seawater pump l .Water circulating pump i .Seawater n .Exhaust elbow k .SECTION .Thermostat housing j .Heat exchanger m .

COOLING SYSTEM SECTION .5 V-6 BRAVO MPD MODELS WITH SEAWATER COOLING j b a k i c d h g f e 9388 abcdef- Seawater inlet Power steering cooler Drain plug Fuel cooler Exhaust and seawater outlet Exhaust manifold ghijk- Check valve Water circulating pump Thermostat housing Exhaust elbow Seawater pump Page 18 / 24 90-899883178 NOVEMBER 2007 .

From seawater pump 90-899883178 NOVEMBER 2007 Page 19 / 24 .5 COOLING SYSTEM V-8 BRAVO MPD MODELS WITH SEAWATER COOLING j b a k d i c e h d g f l m abcdefgSeawater inlet Power steering cooler Drain plug Gen III Cool Fuel Module Exhaust and seawater outlet Exhaust manifold Check valve 9387 h .To power steering cooler m .Water circulating pump i .Seawater pump l .Exhaust elbow k .Thermostat housing j .SECTION .

5 V-8 BRAVO MODELS WITH SEAWATER COOLING (EXCEPT MPD MODELS) i b c a h j c k l m abcdefgSeawater inlet Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump n d g e f 9389 h .Drain from starboard exhaust manifold l .Exhaust elbow j .Thermostat housing i .To power steering cooler m .Check valve Page 20 / 24 90-899883178 NOVEMBER 2007 .From seawater pump n .COOLING SYSTEM SECTION .Seawater pump k .

SECTION .5 COOLING SYSTEM V-6 BRAVO MODELS WITH SEAWATER COOLING (EXCEPT MPD MODELS) j b a i k h d f c e g abcdefSeawater inlet Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold ghijk- 9390 Distribution housing Water circulating pump Thermostat housing Exhaust elbow Seawater pump 90-899883178 NOVEMBER 2007 Page 21 / 24 .

5 V-6 AND V-8 ALPHA MPD MODELS WITH SEAWATER COOLING j a b i c e d h g f 9391 abcde- Seawater inlet (from transom) Power steering cooler Drain plug Fuel cooler Exhaust and seawater outlet fghij- Exhaust manifold Check valve Water circulating pump Thermostat housing Exhaust elbow Page 22 / 24 90-899883178 NOVEMBER 2007 .COOLING SYSTEM SECTION .

5 COOLING SYSTEM V-6 AND V-8 ALPHA MODELS WITH SEAWATER COOLING (EXCEPT MPD MODELS) a j b i c e h d f 9392 g abcdeSeawater inlet (from transom) Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet fghijExhaust manifold Distribution housing Water circulating pump Thermostat housing Exhaust elbow 90-899883178 NOVEMBER 2007 Page 23 / 24 .SECTION .

5 NOTES: Page 24 / 24 90-899883178 NOVEMBER 2007 .COOLING SYSTEM SECTION .

..........................................................................................................12 Alternative Mounting Of Gear Lube Monitor On Transom................29 Steering System Installation.....................................................................................................................................................................................DRIVE SYSTEM AND ENGINE INSTALLATION Table of Contents Transom Cutout...................................................................................................................................17 Alpha Models ............................................................................................................................................................................................................... 14 Connecting Speedometer Pickup.................................................................................................... 35 Preliminary Transom Harness Connections........................................................13 Installing the Alpha Inner Transom Plate......29 Steering Helm and Cable................. 34 Installing the Pitot Sensor...................................................................................................................26 Power Trim Pump Installation.....................................................11 Rear Engine Mounts...........................................................................................8 Checking The Transom Thickness........................12 SeaCore and Closed Cooling Engine Models Seawater Inlets......................................... 18 Water Inlet Block‑Off Plate Installation.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5 Finding The Crankshaft Vertical Center Line.............................................................................................. 27 Power Trim Pump Connections and Filling............................................................. 27 Power Trim Pump...............6 DRIVE SYSTEM AND ENGINE INSTALLATION SECTION 6 ......................................................................................20 Alternative Water Pickups .............................................................................................................. 20 Bravo Models ...................................................6 90 Degree Tool Method ............................................................................................. 5 Dual Engine .................................................................................................... 17 Models With Alpha Sterndrive and Alternative Water Pickups..................................................................................22 Seawater Inlet Fitting and Gear Lube Monitor Fitting........................................................................... 7 Cutting Out the Transom.......................................................................................................................... 7 Tape Measure Method .................................... 11 Drive Shaft Extension Models................................ 36 Transom Harness..................................................................................14 Installing Inner Transom Plate ....................................27 Filling ..................5 Single Engine ............................................23 Seawater Inlet Fitting Installation..............................10 General Information....................................................................................................................................................................................13 Transom Assembly Installation..............................12 Air Pump............................................................................................................................................30 Installing Steering System................................................................................................................ 29 Hydraulic (Helm) Steering.......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 28 Trim Limit Switch Connection...............................................................................................................................................................................................................................................30 Sensor Steering Assembly........................................................24 Gear Lube Monitor Connection At Gimbal Housing.................................................................................................................................................................. 13 Installing Gimbal Housing Assembly................................................................................................................................................................................................................................................................................................................ 6 Finding Crankshaft Horizontal Center Line (X‑dimension)................SECTION .........................................................................................................................................25 Exhaust at Transom..................................................................................36 6 90-899883178 NOVEMBER 2007 Page 1 / 98 .........................................................................................................................................................................................................................................................................11 All Bravo Models............................................................................................ 20 Exhaust Preparation............................................................................................................................................. 26 Transom Exhaust Connections.................................................................................................................................................................29 Steering Cable Specifications....................................................................................................................................................................................................................................................................................................................................................... 23 Alpha Gear Lube Monitor Connection At Gimbal Housing...16 Water Inlet Block‑Off Plate Installation.................................

.............................................57 Shift Cable Travel .................................. 78 Bravo Sterndrive Installation.........................................................94 Parts Provided ..................67 Alpha Sterndrive Installation................................................................................................................................................................................................. 90 Bravo Sterndrive Shift Check (Engine Running).................................. 39 Gen III Cool Fuel Module Inlet Fitting........................................................................... 58 Separate Shift and Throttle Controls ..............................................56 Alpha Shift Cable Installation.................................................................................................................................................................................................................................................................................................................................... 75 Alpha Trim Cylinder Spacer Removal........ 94 Transom Angle Requirements ................................................................................................48 SmartCraft Product ..................................................................................................... 89 Trim Limit and Trim Position Settings.................................................... 87 Speedometer Connections ‑ Bravo Models...................................................................................63 DTS System Installation............................................................................... 59 Bravo Shift Cable Installation and Adjustment..................49 MerCathode Connections...................................................................................................................... 57 Alpha Sterndrive Shift Cable Installation........................................................................................................50 Power Trim Pump Connections..................................................................75 Alpha Trim Cylinder Disassembly.........................................................................................................................50 Power Trim Electrical Connection.............................................................................................................................................................................77 Alpha Trim Cylinder Installation...........37 Engine Preparation .. 66 Throttle Cable Installation...................................................................DRIVE SYSTEM AND ENGINE INSTALLATION SECTION ...............................................................................................................................................................................................................................................................38 Gen II Cool Fuel with Boost Pump Inlet Fitting.................................................................................................44 Engine Alignment Sterndrive Models....6 Engine Installation.................................................................................................. 94 Selecting Location ....................................... 49 Audio Warning System Connections........................................................................................................................................................................ 37 Transom Preparation...............................................................................................................................................................................91 Paddle Wheel Speed Sensor Installation (If Equipped)................... 47 Boat Harness and Instrumentation Connections....................................................................................................................................................................................................................................................................... 94 Installing Bracket ...................................90 Troubleshooting Shift Problems............................................................................................................................................................................................................................................................. 51 Battery Cables Connection............................................. 62 Bravo Models Shift Cable Installation............................................................................................................................................................................. 58 Installation ............................................................................................................................ 95 Drilling Hole Through Transom (optional) ..................37 Shift Cable Routing......................................................................................................................................................................................................................................................................................................41 Exhaust System Hose Connections.................................................................................. 95 Without Drilling Hole Through Transom (optional) ............................................................................. 80 Trim Cylinder Installation ..................................................................................... 67 Throttle Cable Installation And Adjustment...51 Fluid Connections........................ 95 Routing the Cable ......................................................................................................................................................................................................................................................................................................................................................... 73 Speedometer Connection ‑ Alpha Models............................................................51 Power‑Assisted Steering Hoses...........52 Alpha Seawater Inlet Hose Connection............................................................................................................................................................................................................................................................................................................................................................ 51 Gear Lube Monitor Connection....................................................................................... 68 Trim Cylinder Installation .............................................................................................................................................................................................................................................................................................53 Coolant Recovery System..... 96 Page 2 / 98 90-899883178 NOVEMBER 2007 .....................53 Seawater Inlet Fitting Connection..................................................................................................................................... 62 Bravo Models Shift Cable Adjustment.....................................................................................................................................................................................................................45 Electrical Connections.....................................................................................................................................................................................................................40 Engine Installation ................................................................................ 66 Shift Cable Installation For DTS System.76 Alpha Trim Cylinder Reassembly.............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................74 Alpha Notice: Increased Trim‑in Range Capability...................................................................................................................................

.......................................................................................................................................... 96 Wiring Connections ...........6 DRIVE SYSTEM AND ENGINE INSTALLATION Installing and Removing the Paddle Wheel ............... 97 90-899883178 NOVEMBER 2007 Page 3 / 98 ............................................. 96 Template ‑ Paddle Wheel Speed Sensor ...........................SECTION .....................................................................................

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

Lubricants, Sealants, Adhesives
Tube Ref No. Liquid soap
7 9 25 27

Description

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

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

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

34

Special Lubricant 101

92-802865Q02

80 87

SAE Engine Oil 30W High Performance Gear Lubricant

Obtain Locally 92-858064K01

91

Engine Coupler Spline Grease

92-802869A1

95

2-4-C Marine Lubricant with Teflon

92-802859A1

114

Power Trim and Steering Fluid

92-858074K01

Special Tools
Tapered insert tool 91‑43579 Removes and installs the tapered insert retainer into the water inlet hose.
9197

Alignment Tool Assembly

91‑805475A 1 Aligns the engine and the sterndrive unit during installation.
9183

Shift Cable Adjustment Tool

91‑12427 Attaches over the shift cable, and aids in proper shift cable adjustment at the shift plate.

9186

Page 4 / 98

90-899883178 NOVEMBER 2007

SECTION - 6 Shift Slide Stabilizer

DRIVE SYSTEM AND ENGINE INSTALLATION 91‑865232

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

Trim Cylinder End Cap Tool

91‑821709T

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

Dual Water Pick‑up Flush Gearcase Seal Kit

91‑881150K 1

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

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

Flushing Kit

91‑849996T 1

Use for flushing gearcases with low water inlets.
9195

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

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

b. c.

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

a

b d

e c b e

7687

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

d - Arc intersection points e - Crankshaft vertical center line

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

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

b b

c

c

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

7688

c - Crankshaft vertical center lines

Finding Crankshaft Horizontal Center Line (X‑dimension)
X‑dimension can be measured by the 90 Degree Tool Method or by the Tape Measure Method.

Page 6 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

90 DEGREE TOOL METHOD
1. Construct the 90 degree tool.

a

90

b
a - 34.5 cm (13‑9/16 in.)

7689

b - 1.2 m (4 ft)

IMPORTANT: The 34.5 cm (13‑9/16 in.) dimension should only be raised or lowered after proper testing. • ‑To lower drive unit - Subtract from dimension "a". • To raise drive unit - Add to dimension "a". 2. Place the 90 degree tool along the boat bottom at the vertical center line. 3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical center line. This is the crankshaft horizontal center line or X‑dimension. 4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

c b c a
7690

b

a

7691

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

Dual engine c - Crankshaft horizontal center line

TAPE MEASURE METHOD
1. Determine the X‑dimension from the following chart. IMPORTANT: This dimension should only be raised or lowered after proper testing.
Transom Angle (degrees) 16 15 14 13 12 11 10 X‑dimension 36.4 cm (14‑5/16 in.) 36.2 cm (14‑1/4 in.) 36.0 cm (14‑3/16 in.) 35.9 cm (14‑1/8 in.) 35.7 cm (14‑1/16 in.) 35.6 cm (14 in.) 35.4 cm (13‑15/16 in.)

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

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

a c c
7692

a

b

b

7693

Single engine a - Vertical center line b - X‑dimension that corresponds to transom angle

Dual engine c - Crankshaft horizontal center line

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

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

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90-899883178 NOVEMBER 2007

SECTION . Transom cutout template Transom drilling fixture kit 2.60 degrees versus transom angle 6. 3. Using a hole saw cut the two 51 mm (2 in. If the transom cutout is made incorrectly the gimbal housing or exhaust system may improperly contact the boat transom causing transom mounting problems.6 DRIVE SYSTEM AND ENGINE INSTALLATION 1. 90-899883178 NOVEMBER 2007 Page 9 / 98 . Drill two 6 mm (1/4 in.51 mm (2 in. 7893 7694 a b 7695 a . drive unit steering lever may contact transom causing limited steering travel. 4.) hole saw holes (steering lever cutout) b . Cut the transom on the cut line at a 90 degree angle. 5. Follow instructions indicated on template or provided with drilling fixture. Ensure that centerline on either the template or transom drilling fixture align with lines previously marked on transom.) pilot holes at a 60 degree angle for hole saw guides. If the hole saw cutout is made incorrectly. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately).) holes for the steering lever cutout.

Transom Specifications Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.Cut line b .Suitable mandrel to check for uniform transom thickness Page 10 / 98 90-899883178 NOVEMBER 2007 .Mounting holes perpendicular to transom (8) Checking The Transom Thickness IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.) Outer Surface ‑ Flat within 2 mm (1/16 in.Measuring flatness c . Ensure that transom thickness and surface conform to specifications.6 7.Measuring thickness b . 1. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water absorption and deterioration of the transom.Exhaust pipe area d . b a c 7696 d a .) Flatness Angle Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .90 degrees to transom c .) to either side of the vertical center line Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.) 10 ‑16 degrees a b c 7697 a .

Rear Engine Mounts A fiber washer is cemented to the transom plate where the rear engine mount is attached to the transom plate.Transom plate 16584 b .SECTION . Do not use the spacer unless alignment cannot be achieved with the front engine mount adjustment. a c b a b c a .Stainless steel washer c . Normally the engine attaches to the transom plate with only the fiber washer in place. refer to the Drive Shaft Extension Installation Instructions (90‑866039) included with the engine package.Transom plate b . spacer kit (12‑892619A01) can be ordered and installed as shown to raise the rear of the engine. Refer to your parts catalog for replacement part numbers. 1. Ensure that the fiber washer is in place. Place the stainless steel washer on top of the transom plate mount only if needed to obtain proper alignment. Verify the washer is in place before installing the engine.Fiber washer 2.6 DRIVE SYSTEM AND ENGINE INSTALLATION General Information Drive Shaft Extension Models If the power package is equipped with a drive shaft extension. Extensions for the gear lube monitor and MerCathode quick connects are used with drive shaft extention installations. If the front engine mounts cannot be adjusted low enough to achieve proper engine alignment. a b a . IMPORTANT: The fiber washer must be used.Stainless steel washer position to raise engine 16583 90-899883178 NOVEMBER 2007 Page 11 / 98 . NOTE: Engine alignment is usually obtained using only the rear engine mount and the fiber washer.

Install the gear lube monitor bracket in the specified location and secure with lag screws and flat washers. 1. Hose must be positioned to avoid moving parts (steering system. a 8548 Bravo One and Two (positioned forward) a . Ensure that the trim‑in limit insert is positioned correctly for the appropriate Bravo model.Trim‑in limit insert a 8557 Bravo Three (positioned aft) a . NOTE: When removing the sterndrive. Contact the boat manufacturer if you are not sure of the original position for a particular boat application. SeaCore and Closed Cooling Engine Models Seawater Inlets Refer to Section 5. Page 12 / 98 90-899883178 NOVEMBER 2007 .6 All Bravo Models IMPORTANT: The trim‑in limit insert must be properly positioned before installing the trim cylinder anchor pin.Trim‑in limit insert IMPORTANT: The position of the trim‑in limit insert on the Bravo Three sterndrive should only be changed after the boat has been properly tested.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Alternative Mounting Of Gear Lube Monitor On Transom IMPORTANT: The mounting location specified must be above the steering lever on the transom assembly. 1. engine coupler). Sterndrives With Closed Cooling Engines for seawater pickup requirements and inlet connections. note the position of the insert for reference when reinstalling the sterndrive.

6 DRIVE SYSTEM AND ENGINE INSTALLATION 2. Install the gear lube monitor in the bracket. Carefully remove transom assembly from shipping carton. Remove and read all tags attached to transom assembly. Mount the air pump. 6. 1.Bracket b . Select an easily accessible mounting location for the air pump. 2. Secure the monitor with the retaining strap. a b 7713 a . 5. Do not remove the Shift Slide Installation Tool. 4.Shipping hardware 3.Retaining strap Air Pump NOTE: Some models have air pump mounted on the engine and other models have the air pump in a parts bag.Gear lube monitor and cap d . b .SECTION . 8992 Transom Assembly Installation Installing Gimbal Housing Assembly 1. a c d b a .Lag screw and flat washer 7706 c . Remove the dust cover if boat will be shipped with drive installed. Retain the serial number envelope. 90-899883178 NOVEMBER 2007 Page 13 / 98 .Trim cylinder suppport Remove the shipping hardware. 2.

and shift cable through appropriate openings in inner transom plate. Position the gimbal housing on the transom and hold in place. and shift cable through appropriate openings in inner transom plate. in. ft. 2. Temporarily secure with hardware. Page 14 / 98 90-899883178 NOVEMBER 2007 . Attach continuity wires. 3. Insert the wires. 6.) of the threads of the gimbal housing studs. hoses. lb. Tighten in small increments and go around the pattern several times until the proper torque is achieved. 2. Position gimbal housing on transom and hold in place. Insert wires. Description Transom assembly hardware Nm 34 lb. 25 IMPORTANT: Tighten the transom assembly fasteners using an X‑pattern torque sequence. d 5 7 j h f 3 e i c 1 a 2 5 7 4 8 6 i g 3 2 b 1 8 24401 4 6 abcd- Locknuts and flat washers (8) Hydraulic hoses Drive unit shift cable Trim limit and trim position sender wires e . Apply lubricant to the first 8 mm (1/4 in. Secure the transom assembly with the hardware as shown. IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves. starting from the middle fasteners. Place the transom harness ground ring terminal on top of the continuity circuit wire on transom bolt.6 Installing the Alpha Inner Transom Plate 1. 5. hoses.Inner transom plate fghij- Transom harness ground wire Mercathode wires (if equipped) J‑clip Torque sequence Steering lever continuity circuit wire Installing Inner Transom Plate 1. 3. Torque the hardware. 4.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .

90-899883178 NOVEMBER 2007 Page 15 / 98 . 25 IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves. Description Transom assembly hardware Nm 34 lb. 4. Torque the fasteners. lb. starting from the middle fasteners.6 Tube Ref No.SECTION . 92-802865Q02 IMPORTANT: Tighten the transom assembly fasteners using an X‑pattern torque sequence. in. 34 DRIVE SYSTEM AND ENGINE INSTALLATION Description Special Lubricant 101 Where Used Gimbal housing studs Part No. Tighten in small increments and go around the pattern several times until the proper torque is achieved. Secure transom assembly with fasteners. ft.

Torque sequence f .Locknuts and flat washers (8) b . Page 16 / 98 90-899883178 NOVEMBER 2007 . g d c a f a 5 7 a a 3 2 4 8 6 23138 b 1 e a .Hydraulic hoses and MerCathode wire c .Ground from transom harness Connecting Speedometer Pickup NOTICE Removing the plug from the speedometer pickup fitting can introduce water into the bilge.6 IMPORTANT: Transom harness ground must be attached as shown. 1. Do not remove the the plug unless you intend to make a connection to a speedometer pickup.Steering lever continuity wires d .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Remove the protective cap from the male quick connect.Transom plate continuity wires e .Trim sender and trim limit wires g .

Secure hose with tie strap. resulting in damage to the sterndrive.Male quick connect b . Secure the hose to the transom with the hose clip and screw that are provided in the parts bag. When using a block‑off plate ensure that the water hose between the bell housing and gimble housing is cut and removed. engine coupler. 3. When installing the block‑off plate. Water Inlet Block‑Off Plate Installation Models With Alpha Sterndrive and Alternative Water Pickups A water inlet block‑off kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine.SECTION . it is necessary to cut the water hose that is located between the bell housing and the gimbal housing.Hose e . a b c c e d b 7703 Typical a . causing boat damage or possible sinking. Position or install the speedometer hose away from moving parts or pinch points. or driveshaft.6 DRIVE SYSTEM AND ENGINE INSTALLATION 2. such as steering system components. Ensure that the hose does not contact the steering system components or the engine coupler and drive shaft.Barbed fitting d . 90-899883178 NOVEMBER 2007 Page 17 / 98 . This allows water to continue to circulate through the sterndrive unit for cooling. NOTICE Obstructions in the water passages will keep cooling water from circulating through the engine. which could damage the hose.) speedometer hose (not provided) from speedometer to barb fitting.Female quick connect c .Tie strap ! CAUTION A ruptured speedometer hose can introduce water into the bilge. Connect a 4 mm (5/32 in.

DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .Bell Housing Hose d 9281 d . a a . Remove rubber grommet from cavity around tube.Rubber Grommet 3.Sta‑Strap b .Trim Limit Switch Wire Harness Page 18 / 98 90-899883178 NOVEMBER 2007 . a b c a b 9260 a .Clip c .Screws c .Bell Housing Assembly e . Cut water tube off close to cover.Water Tube (Cut Off In Previous Step) b 9283 b .Water Tube 2.Water Tube Cover b .Speedometer Hose f .6 ALPHA MODELS 1. Remove and discard the screws and cover. f c a b e a . Remove and discard bell housing sta‑strap and clip that retains wires and speedometer hose.

6 DRIVE SYSTEM AND ENGINE INSTALLATION 4.Lockwasher 90-899883178 NOVEMBER 2007 Page 19 / 98 .Bell Housing Hose b . Remove hose with remaining piece of water tube from gimbal housing.Bell Housing Hose b . Torque the screws. Sta‑strap (obtain locally) speedometer hose and trim limit switch wire harness together onto piece of hose remaining on bell housing. a b 9285 a . Secure with screws and lockwashers.SECTION . b a a 9286 a .Cut Line 5. c d a b 7262 a .Water Tube (Cut Off Previously) 6. Install the block‑off plate with new gasket.Block‑off plate b . Cut the bell housing hose close to the bell housing as shown. Pull on hose to withdraw water tube through gimbal housing opening. 7.Screw d .Gasket c .

in. When using a block‑off plate ensure that the water hose between the bell housing and gimble housing is cut and removed. a c b d a . This allows water to continue to circulate through the sterndrive unit for cooling. Connect the seawater inlet hose between seawater pump and seawater strainer. BRAVO MODELS 1. 45 SECTION . 8.Tapered insert d . resulting in damage to the sterndrive. it is necessary to cut the water hose that is located between the bell housing and the gimbal housing. ALTERNATIVE WATER PICKUPS A water inlet block‑off kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine. Install a through the hull or through the transom seawater pickup. Discard the insert.Rachet and extension Tapered insert tool 17857 c . When installing the block‑off plate. 10.6 lb. and seacock. Secure all hoses with hose clamps.Tapered insert tool 91‑43579 Page 20 / 98 90-899883178 NOVEMBER 2007 . 9.DRIVE SYSTEM AND ENGINE INSTALLATION Description Water inlet block off screw Nm 5 lb. Remove the tapered insert in the gimbal housing using the tapered insert tool. NOTICE Obstructions in the water passages will keep cooling water from circulating through the engine.Tapered insert location in the gimbal housing b . seawater strainer. ft.

4. The existing tie strap and clip can be reused if they are moved and repositioned after the hose is cut. a d e c b 8489 a . Cut completely through the water hose 127 mm (5 in. Install the block‑off plate with new gasket.Gasket Description Water inlet block off screw c . 5. Torque the screws. NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2. 90-899883178 NOVEMBER 2007 Page 21 / 98 .Gimbal housing d . Move the trim limit switch wires and speedometer hose aside.Lockwasher Nm 5 21683 lb. 45 lb. a d c a b a . 3.Block‑off plate b .SECTION .) in front of the aft end of the hose where it is fitted into the bell housing in the area shown.Tapered insert ! WARNING Improper reassembly of the U‑joint and pinion gear assembly can damage the sterndrive or sink the boat. Do not damage the U‑joint bellows. Secure with screws and lockwashers. in. ft. Assemble and install the U‑joint and pinion gear as specified. Discard loose hose piece.Trim limit switch wires b .Screw d .Water hose e .6 DRIVE SYSTEM AND ENGINE INSTALLATION 2.Speedometer hose c . The U‑joint bellows must provide a watertight seal to prevent water from entering the boat.

DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

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

c

e

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

a
8490

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

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

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

Description Bellows Adhesive

Where Used Exhaust bellows mounting surface

Part No. 92-86166Q1

d. e.

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

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90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

f.

Install and torque the clamp.

e

d

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

b
8406

d - Exhaust tube e - Grounding clip

Nm 3

lb‑in. 26

lb‑ft –

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

d

a

b

c

7704

a - Hose b - Quick release 90 degree fitting

c - Gimbal housing fitting d - Quick connect fitting

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

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

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

e

a

b f d c d
7705

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

d - Quick release button e - ACCEPTABLE positions f - NOT ACCEPTABLE position
Nm 5 lb. in. 45 lb. ft.

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

Seawater Inlet Fitting Installation
1. Install a new gasket, seawater inlet fitting, and screws. Torque screws.

a b

a

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

lb. in. 45

lb. ft.

Page 24 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

Gear Lube Monitor Connection At Gimbal Housing
1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal housing.

d a c

a

b
Model with block‑off plate a - Hose b - Quick release 90 degree fitting
21623

c - Seawater inlet fitting d - J‑clip

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

b

a

c

21624

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

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

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

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

a
21630

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

b c a a
a - Block‑off plate b - Bolts
Description Exhaust block‑off plate bolts

21625

c - Lockwashers

Nm 34

lb. in.

lb. ft. 25

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

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

Nm 34

lb. in.

lb. ft. 25

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90-899883178 NOVEMBER 2007

• Is close to the battery so that trim pump battery leads can be connected. • Prevents the power steering booster cylinder from coming in contact with the trim pump when the steering wheel is turned in either direction (right or left). Power Trim Pump Connections and Filling IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking from the system. 2. Mount the pump in the desired location. • Is in an area where pump will not be exposed to water. Connect hydraulic hoses to the trim pump. a c g h f b abcd- d Positive battery lead Negative battery lead Harness connector BLACK hydraulic hose (UP hose) 7698 e efghGRAY hydraulic hose (DOWN hose) Fill/vent cap Dual mount trim pump bracket Trim limit switch connected and secured 90-899883178 NOVEMBER 2007 Page 27 / 98 . Select an appropriate mounting location (floor or transom) for the trim pump that: • Is within length limits of BLACK and GRAY hydraulic hoses coming from gimbal housing assembly. NOTE: Template 90‑863152 provides mounting hole location for floor or transom mounting.6 DRIVE SYSTEM AND ENGINE INSTALLATION Power Trim Pump Installation Power Trim Pump 1. • Allows easy access to trim pump oil fill and vent locations. 1. Ensure that the quick‑ connect fittings completely seat when connecting the hoses.SECTION .

a b 7701 Power tim pump reservoir showes the oil level is below "MIN" line a .Fill cap installed 3. NOTE: Fill cap is vented.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . If the oil level is below the "MIN" line specified fluid must be added.Reservoir Tube Ref No.Fill cap assembly b . 92-858074K01 Power Trim and Steering Fluid Page 28 / 98 90-899883178 NOVEMBER 2007 . Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir. Remove the fill cap from the reservoir.Control harness b . 2.6 2. 114 b 7876 b . a a .Trim pump connector FILLING 1. Connect power trim pump control harness to trim pump."MIN" and "MAX" lines Description Where Used Power trim pump Part No. a b 7699 a .

Install the fill cap. such as a self‑locking coupler or external locking device when installing steering controls. NOTE: All current production Quicksilver RideGuide steering cables have a self‑locking coupler nut and do not require an external locking device. as specified in ABYC requirements. Connect the trim limit switch wires and secure with a wire retainer and tie strap. Trim Limit Switch Connection 1. The steering cable coupler nut must also have a means of locking it to the guide tube. ! WARNING Failure to use the correct cables or other steering system components can cause serious injury or death due to loss of boat control. 90-899883178 NOVEMBER 2007 Page 29 / 98 . Use a locking device.6 DRIVE SYSTEM AND ENGINE INSTALLATION 4. Use only approved or required components when installing steering systems. (Other cable manufacturers also make cables with self‑locking coupler nut. a b a .) a 7255 a .Wire retainer and cable tie Steering System Installation Hydraulic (Helm) Steering If your power package is equipped with Compact Hydraulic Steering.Trim limit switch wires 7700 b . ! WARNING Failure to use a steering cable locking device can cause serious injury or death due to loss of boat control.SECTION . Steering Helm and Cable Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook.Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove) IMPORTANT: If using a steering cable that does not have a self‑locking coupler nut. refer to the Compact Hydraulic (Helm) Steering Installation Instructions . an external locking device such as a locking sleeve must be used.

) maximum Installing Steering System NOTE: For dual installations.15.) maximum diameter end fitting h . Select a tie bar from Mercury Precision Parts / Quicksilver Accessory Guide. power‑assisted steering unit can be mounted on port or starboard transom assembly. kinks.) minimum to 228 mm (9 in.6 1. Avoid sharp bends.7 mm (1/2 in.) diameter through hole (chamfered each side) j .) minimum to 114 mm (4‑1/2 in. Steering cable must be the correct length. Lubricate the power steering bushings.7 mm (27/64 in.9.) i . Steering Cable Specifications IMPORTANT: Power‑assisted steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.9 mm (1‑3/8 in. 3.) minimum radius g .) minimum flat 3.) minimum Interface point 12.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .9. a b e f c d g C L k l j i h 7254 abcdef- Coupler nut ‑ 7/8 ‑ 14 UNF ‑ 28 thread 298 mm (11‑3/4 in. 2. or loops in cable. Remove the protective shipping caps.8 mm (3/8 in.Cable travel: mid‑travel position ‑ 429 mm (16‑7/8 in.34.) total travel to be 203 mm (8 in.) diameter tube l . 1.Bushings Page 30 / 98 90-899883178 NOVEMBER 2007 . 2. Measure exact distance between power package center lines. Inspect the bushings for debris. 3.9 mm (5/8 in.) maximum travel each side of mid‑travel position ‑ 102 mm (4 in.9 mm (5/8 in. a 7709 a .15.1 mm (7/64 in. particularly when installed in larger boats. Refer to tie bar installation instructions before proceeding.) maximum k .5 mm (3/8 in. Fully extended steering cable end dimension must be as specified.) maximum 10.

9. Torque the pivot bolts. 92-802865Q02 4. 34 b .SECTION . 8. by hand. Ensure that the tab washer tangs straddle the ridge on the inner transom plate.Tab washer tang b . Position the steering assembly so that the pivot bolts will enter the bushings in the power‑assisted steering control valve. Install the upper and lower pivot bolts along with tab washers. 34 DRIVE SYSTEM AND ENGINE INSTALLATION Description Special Lubricant 101 Where Used Power steering bushings Part No. Ensure that the steering assembly pivots freely. 6.6 Tube Ref No. a b a a b 21632 Upper Pivot Bolt And Tab Washer Shown (Lower Similar) a . to ensure proper steering assembly alignment. a b a . Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.Lower pivot bolt Where Used Upper and lower pivot bolts Part No. 92-802865Q02 21631 Description Special Lubricant 101 5. 90-899883178 NOVEMBER 2007 Page 31 / 98 .Ridge 7.Upper pivot bolt Tube Ref No. Turn the pivot bolts all the way in. Bend the tab washer tabs against the corresponding flats on the bolt heads.

Tube Ref No.Port 11. lb. Connect the clevis to the steering lever. While wearing eye protection to avoid expelled fluid. in. 10. a. 25 ! CAUTION Contents under pressure.Control valve cable guide tube Description Special Lubricant 101 Where Used Clevis pin Part No. Moving the control valve cable guide tube with the hoses disconnected expels fluid from the ports. move the control valve cable guide tube as shown.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . a b b a 8496 a . Lubricate the clevis pin. so that it will be less difficult to pull it out or push it in during connection.Bent tab Nm 34 lb.6 NOTE: It may be necessary to tighten the pivot bolts further to align the flats on bolt head with the tabs on the washer.Pivot bolt Description Upper and lower pivot bolt b . ft. 34 b . a b b a 21691 a . Wear eye protection while servicing the system. 92-802865Q02 Page 32 / 98 90-899883178 NOVEMBER 2007 .

20396 b . Insert the clevis pin. Insert the cotter pin.Clevis pin a 20399 c .Cotter pin b . b a a . Spread both ends of the cotter pin. a 7255 a . d.Clevis pin c b c a a .SECTION .6 DRIVE SYSTEM AND ENGINE INSTALLATION b.Self‑locking coupler nut 90-899883178 NOVEMBER 2007 Page 33 / 98 .Clevis c.Steering lever IMPORTANT: Quicksilver RideGuide steering cable has a self‑locking coupler nut and does not require an external locking sleeve or locking plate.

34 Description Special Lubricant 101 Where Used Steering cable end Part No. d g h e f c a b d 7830 abcd- Steering cable Grease fitting Cable coupler nut Cable guide tube efgh- Steering cable end Clevis Clevis pin Cotter pin Sensor Steering Assembly 1. Ensure that the flat surfaces are still aligned vertically after torque is applied to the coupler nut. IMPORTANT: Cable guide tube flat surfaces must be positioned vertically or slight feedback in the steering system could be encountered. 92-802865Q02 b. Connect the steering cable as follows: a. Torque the coupler nut.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . The steering cable and outer casing must be free to move back and forth.6 NOTICE Fastening any items to the steering cables or outer casings prevents normal operation. Page 34 / 98 90-899883178 NOVEMBER 2007 . Tube Ref No. Remove nuts from upper 2 transom studs. Install the steering cable and secure with hardware as shown. a 7827 a . c. Do not fasten any items to the steering cable and outer casing.Steering cable and outer casing 12. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical position. Coat the steering cable end with a liberal amount of lubricant.

Remove cotter pin and clevis pin from steering lever. 6. b . 9. 7. Attach pitot tube to barbed fitting and secure with a tie strap. 1.6 DRIVE SYSTEM AND ENGINE INSTALLATION 2. Install pitot barbed fitting. Remove the brass plug from the transom. Installing the Pitot Sensor IMPORTANT: The pitot hose must not come into contact with the steering system components or the engine coupler.SECTION . Plug sensor into transom harness. 8. 3. b a mc79613-1 a . c a h d e a f b abcd4. Transom stud holes Pitot tube connection Plug Guide g 8403 efgh- Cotter pin Clevis pin Tie strap Alignment mark Slide guide onto the groove in the clevis pin.Male quick‑connect fitting IMPORTANT: Ensure that the fittings snap into place. Bolt the steering assembly to the transom. Install new clevis pin and secure with existing cotter pin. 5. Remove the yellow cap from the quick‑connect fitting at the transom.Yellow plug 90-899883178 NOVEMBER 2007 Page 35 / 98 .

analog trim.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .Quick‑connect fitting on transom Preliminary Transom Harness Connections Transom Harness The Transom harness connects to the engine harness and the following transom connections. 2. Connect the quick‑connect pitot hose to the fitting on the transom. Wires are color coded and connections are tagged for easy installation. connect the transom harness MerCathode connector to the MerCathode connector from transom. a b mc79614-1 a . 3. Make all transom wiring connections and secure with clamps.Male quick‑connect fitting 3. b a 12119 a . Page 36 / 98 90-899883178 NOVEMBER 2007 . Connect the pitot hose quick‑connect fitting on the transom. Ensure that the transom harness ground ring is secured with the continuity circuit wire on transom plate. engine to transom ground.Female quick‑connect fitting b . 4. Transom harness connector should be placed in a safe location and will be connected to the engine after the engine is installed. 1. If equipped. IMPORTANT: Secure ground ring terminal (black wire) to screw on port side of transom plate.Pitot sensor b .6 2. Analog trim: Connect transom harness analog connector to the analog connector from transom. and the MerCathode.

all similar a .Fiber washer 2. When installing mounts with knurled bottoms. 1. port and starboard.Fiber Washer (2) b .SECTION .6 DRIVE SYSTEM AND ENGINE INSTALLATION Engine Installation Transom Preparation NOTICE Mismatched flywheel housing mounts and inner transom plate mounting hardware will result in improper engine alignment and possible engine damage. b a 7960 Typical flywheel housing. a b 7839 a . are the correct parts and match before installing the engine. use only the fiber washer.Late‑style mount: knurled surface b . Position rear engine mount attaching hardware on the inner transom plate mounts as shown. Ensure that the flywheel housing mounts and the inner transom plate mounting hardware. Route the intermediate shift cable from the transom assembly to the shift actuator as follows: 90-899883178 NOVEMBER 2007 Page 37 / 98 .Locknut (2) Shift Cable Routing 1. Do not install double‑wound lockwashers to knurled mounts.

Remove all hardware that secures engine to shipping container. 4. above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. Observe the following: a. ft. Drape battery cables over top of engine to prevent interference during installation. Install battery positive (+) wire directly to the large starter solenoid stud. Part No.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . d. 2. Page 38 / 98 90-899883178 NOVEMBER 2007 . Ensure that the grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection. Connect battery cables to engine. 71‑97 lb. Remove and read all tags attached to engine. Engine Preparation 1. c. Description Battery stud Tube Ref No. 92. b. 25 Nm 8‑11 Description Liquid Neoprene Where Used Battery terminals lb. The cable should then be routed under the starboard rear engine mount and turn toward the transom. in. c. Install negative (‑) battery cable to the ground stud on the flywheel housing.Remote Control. apply a thin coat of sealant to the terminals. After battery cables are connected. NOTE: Following this routing will prevent the engine coupler from damaging the cable. The cable should come through the transom. b.25711 3 e.6 a. 8995 Refer to Section 8 . Slide rubber boot over positive (+) terminal after making connection. The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine. 3.

90 amp fuse ‑ Do not remove 5. 90-899883178 NOVEMBER 2007 Page 39 / 98 .6 DRIVE SYSTEM AND ENGINE INSTALLATION IMPORTANT: There is a fuse located at the starter solenoid. 2. c a b 8501 a . a Typical a .SECTION . and do not tighten with power tools. 1.Starter solenoid c . 92-802869A1 Gen II Cool Fuel with Boost Pump Inlet Fitting ! WARNING Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting. Always install fittings and plugs correctly. If not already done. DO NOT OVERTIGHTEN. causing a fuel leak and possible fire or explosion. To prevent cracking the casting or causing fuel leaks. 91 7767 Description Engine Coupler Spline Grease Where Used Coupler splines Part No.Shipping plug Tube Ref No. Remove the shipping plug from the brass inlet fitting. remove shipping plug from coupler and lubricate splines. Install an adapter or a fitting to the brass inlet fitting of the boost pump.Positive (+) battery cable location b . Do not remove this fuse. Tighten the fitting an additional 1‑3/4 to 2‑1/4 turns with a wrench. turn the fuel inlet adapter or fitting in by hand until finger‑tight.

Fuel inlet fitting b . Gen III Cool Fuel Module Inlet Fitting ! WARNING Improper installation of brass fittings or plugs into the fuel pump or fuel filter base can crack the casting.Shipping plug Tube Ref No. To prevent cracking the casting or causing fuel leaks.Boost pump Description Loctite 567 PST Pipe Sealant Where Used Fuel inlet fitting Part No. Do not overtighten. and do not tighten with power tools.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .6 IMPORTANT: Hold the brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet adapter fittings. turn fuel inlet adaptor or fitting in by hand until finger‑tight. Page 40 / 98 90-899883178 NOVEMBER 2007 . causing a fuel leak and possible fire or explosion. Install an adaptor or a fitting to the brass inlet fitting of Gen III Cool Fuel Module. a b c Typical fuel boost pump a . Always install fittings and plugs correctly. 9 25007 c . 92-809822 Procedure Description Fuel inlet adapter or fitting Finger‑tight + 1‑3/4 to 2‑1/4 turns with a wrench. Tighten the fitting an additional 1‑3/4 to 2‑1/4 turns with wrench. 1. DO NOT OVERTIGHTEN.

Refer to instructions with fixture for proper use. 92-809822 Procedure Finger‑tight + 1‑3/4 to 2‑1/4 turns with a wrench. 1. a a b 9360 a . if equipped.Engine cover knob b .Engine cover 90-899883178 NOVEMBER 2007 Page 41 / 98 . Remove the engine cover. 9 b .6 DRIVE SYSTEM AND ENGINE INSTALLATION IMPORTANT: Hold brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet adaptor fittings.Gen III Cool Fuel Module Where Used Fuel inlet fitting Part No. Description Loctite 567 PST Pipe Sealant Description Fuel inlet adaptor or fitting NOTE: An installation jig (91‑806794A02) can be used to align and adjust engine mounts.Fuel inlet fitting Tube Ref No. a b 9289 Closed cool model shown.SECTION . Do not overtighten. seawater cooled similar a .

DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .6 2.Lifting eye 3.Bilge drain plug b . 7. IMPORTANT: The quick drain oil fitting clearance must be greater than 13 mm (1/2 in. d .Clip Push end of oil drain hose out of boat hull through flange.Toward interior of boat f . b.) from the engine compartment and boat bottom. Pull oil drain hose out until it is 304 cm (12 in. apply lubricant into the exhaust tubes. Move alignment clip on the oil drain hose and squeeze to position it on the hose just inside of the boat hull against the flange. b a b ! CAUTION 9375 a . c. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tube with exhaust pipe bellows.Flange e .): d e a b f c 7771 a . 6. To help with installation. Attach a suitable sling to the front and rear lifting eyes on engine and adjust so that engine is level when suspended. Page 42 / 98 90-899883178 NOVEMBER 2007 . If equipped with quick drain oil: Ensure that the quick drain oil fitting has a clearance of more than 13 mm (1/2 in. Lift engine into position (in boat) using an overhead hoist.) from the flange.Quick oil drain hose plug a. 4. 8.) from the engine compartment and boat bottom.Center lifting eye (engine alignment only) b . Tube Ref No.Tether c .) or less:Remove the quick drain oil fitting and install the oil drain plug from parts bag directly into the engine oil pan. If clearance is greater than 13 mm (1/2 in. Obtain Locally 5. If clearance is 13 mm (1/2 in. Description Liquid soap Where Used Exhaust tubes Part No.

Push oil drain hose through flange into boat hull. 9. c c e d e a f 7961 g b f 7772 a b abcdDescription Rear engine mounting bolts Rear engine mount Inner transom plate mount Bolt Washer e .) of the threads of the rear engine mounting bolts. 35 11. Loosen both adjusting nuts on front engine mounts to allow for adjustment during alignment. Install bilge drain plug in hull. Do not relieve hoist tension. Attach the front mounts to the stringers.6 DRIVE SYSTEM AND ENGINE INSTALLATION d. Remove the engine hoist. lb. 13. in.Spacer f .SECTION .Fiber washer g . 92-802865Q02 10. ft. 90-899883178 NOVEMBER 2007 Page 43 / 98 . Apply lubricant to the first 8 mm (1/4 in.Alignment clip c . Tube Ref No.Bilge drain plug e. 34 Description Special Lubricant 101 Where Used Rear engine mounting bolts Part No.Clip d . b c d a 7618 a . Connect bilge drain plug to oil drain hose plug using clip.Stainless steel washer (optional spacer kit) Nm 47 lb. Install both rear engine mounting bolts and hardware and torque. 12.Oil drain hose b . f.

including those at the exhaust elbow.Horizontal (level surface) IMPORTANT: Exhaust hoses/tubes should be secured at each connection with at least 2 hose clamps.6 Exhaust System Hose Connections NOTICE Hot spots in exhaust hoses can damage hoses and cause leaks.) band width. All exhaust connections. Page 44 / 98 90-899883178 NOVEMBER 2007 .Maximum misalignment +/‑ 5 degrees b .Exhaust outlet centerline (14 degrees vs. ABYC standards also specify the use of stainless steel clamps with a minimum 13 mm (1/2 in. should be secured with 2 hose clamps. Ensure that discharge water from the exhaust elbow flows without restriction through all hoses and fittings. Discharge water from the exhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots that could burn through the hose. Do not use spring tension clamps.Exhaust hose centerline b 9290 d .Angle vs.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . 7628 7629 Correct Incorrect a c d e Exhaust connection a . horizontal e . Exhaust hoses must be properly installed on exhaust elbow outlets. crankshaft centerline) c .

4. Torque all exhaust hose or exhaust tube clamps. Do not operate the engine with the alignment tool installed. If the alignmet tool does not fit. If applicable. IMPORTANT: Alignment tools from other manufacturers may cause improper alignment and damage to the gimbal bearing or engine coupler. or raise the engine mount bracket above the top of the engine mount stud. a 8378 a . a 7631 a .Dust cover NOTICE Improper use of the alignment tool may result in personal injury or damage to the gimbal bearing or engine coupler. 2. 26 lb‑ft – Engine Alignment Sterndrive Models 1. Do not attempt to force the alignment tool.Hose clamps Description Hose clamps Nm 3 lb‑in. Use only the Quicksilver Alignment Tool. raise or lower the engine with the tool inserted in the gimbal bearing or engine coupler. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines. open perforated area in bell housing dust cover.6 DRIVE SYSTEM AND ENGINE INSTALLATION 1. attach the engine hoist to the engine aligment hook to raise or lower the front end of engine.SECTION . 90-899883178 NOVEMBER 2007 Page 45 / 98 . If applicable. Alignment Tool Assembly 91‑805475A 1 3. remove it and carefully raise or lower the front end of the engine as necessary.

Repeat step 4. firmly strike the sides of the Alignment Tool at 90 degree increments to help align the gimbal bearing. This allows for future engine alignment or adjustments. require adjusting the front engine mounts equally to raise and lower the front end of the engine. Adjust front engine mounts until they rest on boat stringers.) up or down adjustment exists after the mount is adjusted to contact the stringer.Hammer e . 5. IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 6 mm (1/4 in.Gimbal bearing c .Engine coupler d .90 degree increments 7784 7.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . 8.6 NOTE: Models not equipped with engine alingment hooks.) lag bolts. NOTE: It may be necessary to hit the Alignment Tool with a synthane hammer to set the gimbal bearing to the coupler.) dimension. Do not check by turning the alignment tool. Make proper alterations to the boat stringer (structure) to obtain the 6 mm (1/4 in. Relieve hoist tension entirely and fasten both front mounts to boat stringer using 9 mm (3/8 in. until the Alignment Tool installs easily (SLIDES FREELY WITH MINIMAL EFFORT) all the way into and out of engine coupler splines. 9. IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required to align engine. If necessary.Alignment Tool b . 6. d a b c a e a . Page 46 / 98 90-899883178 NOVEMBER 2007 . Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines.

• Do not tap accessories into the engine harness.Adjustment nut c . Electrical Connections IMPORTANT: Refer to the following precautions when working on or around the electrical harness. tighten locknut securely. Remove the engine alignment hook from the engine. a b c d 8504 a . • Do not reverse the battery leads. Dust cover flap will have to be removed before operating engine. • Do not puncture wires for testing (probing). • Do not splice wires into the harness. 14. fold bell housing dust cover flap back into place and tape shut for boat shipment. Recheck alignment with Alignment Tool. b a 8503 a . approved service tools. Recheck alignment.Alignment Tool (use only recommended Alignment Tool) b . Remove Alignment Tool.Nut and lockwasher b .End to be inserted through gimbal housing assembly 11.SECTION . If not. When alignment is correct. to avoid damage to the electrical system. readjust front mounts. If not installing drive.6 DRIVE SYSTEM AND ENGINE INSTALLATION 10. or when adding other electrical accessories.Tab washer 13. Bend tab down on adjusting nut. 12.Direction (counterclockwise) to raise front of engine d . Tool must enter coupling splines freely. • Do not attempt diagnostics without the proper. 90-899883178 NOVEMBER 2007 Page 47 / 98 .

ensure that they are routed and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . 1. connect the boat harness to the extension harness and connect the extension harness to the engine harness. 92. a 23135 Typical a . oil pressure and water temperature senders (on engine) must be changed.6 IMPORTANT: When routing all wire harnesses and hoses. 25 Description Liquid Neoprene Where Used All electrical connections Part No. Turn locking ring until firm snap is felt. an accessory kit is available. Connect 14‑pin harness to engine. If an extension harness is required.) using appropriate fasteners.Engine harness plug 3. Ensure that the harness does not rub or get pinched.25711 3 Boat Harness and Instrumentation Connections We recommend the use of Quicksilver Instrumentation and Wiring Harnesses. If additional accessory load is needed. The four basic gauges that must be used with the engine are: • Tachometer • Oil pressure • Water temperature • Voltmeter IMPORTANT: Maximum accessory load on the engine harness is 15 amps. Fasten harnesses to boat at least every 46 cm (18 in. 2 1 23136 Page 48 / 98 90-899883178 NOVEMBER 2007 . 2. See Section 7-Boat Harness and Installation Connections. On dual station applications. Tube Ref No.

Connect TAN/BLUE wire from alarm to TAN/ BLUE wire from instrument harness. 2. 6. battery voltage. Place the large decal on the instrument panel or other appropriate location easily viewed by the operator. and engine operating hours. yet is out of sight • Alarm can be easily accessed for installation and maintenance • Alarm will remain dry • Alarm is within length limits of the 46 cm (18 in. Tighten connection securely. fuel consumption.Small decal (transparent) b . Place the small (transparent) decals on the bottom of the water temperature and the oil pressure gauges. The SmartCraft instrument package will display critical engine alarm data and potential problems. 4. IS TOO HIGH. OR 3. ENGINE TEMP. 1. Refer to the Mercury SmartCraft Operator's Supplement (90‑10229023) for the warning functions monitored and basic operation of the SmartCraft Instrument package. Audio Warning System Connections ! WARNING Installing non‑potted electrical components in explosive environments can result in serious injury or death from fire or explosion. water pressure.SECTION . A few of the functions the instrument package will display are engine rpm. ENGINE OIL PRESSURE IS TOO LOW 2. Select a location for audio warning alarm that meets all of the following: • Alarm can be easily heard.) purple alarm wire that connects to the "I" terminal or 12 volt source on switched side of ignition switch. coolant temperature.Larger decal 90-899883178 NOVEMBER 2007 Page 49 / 98 .6 DRIVE SYSTEM AND ENGINE INSTALLATION SMARTCRAFT PRODUCT A Mercury SmartCraft System instrument package can be purchased for this product. ALARM INDICATES LOW OIL OR OVERHEATING a APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION: b AUDIO WARNING HORN WILL SOUND WHEN: 1. 5. Install all non‑potted electrical components such as warning alarms away from environments where fuel or fuel vapor is present such as engine or fuel tank compartments. DRIVE OIL LEVEL IS TOO LOW TO TEST AUDIO WARNING HORN: TURN KEY TO "ON" POSITION (ENGINE OFF) 7799 a . 3. NOTE: The terminal to which wire is attached must have no voltage when ignition switch is in the OFF position. Refer to the instructions included with the instruments for installation instructions. The Smartcraft instrument package will also aid in engine diagnostics. Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge or ignition switch. Place alarm in desired location and secure to wire bundle with tie strap provided.

MerCathode Connections The MerCathode controller assembly is located on the engine. • Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: a. (See ABYC for additional information) ABYC further recommends. IMPORTANT: Opposite end of RED/PURPLE wire must be connected directly to battery positive (+) terminal. Wire length requirements and location of circuit protection are also specified. MerCathode system must function continuously for proper corrosion protection. These come in the form of one standard production and two accessory kits. the power trim pump may not be connected to the continuously energized circuit (battery).DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . MerCruiser has developed three methods to facilitate compliance with ABYC recommendations.RED/PURPLE wire ‑ to positive (+) battery terminal c .MerCathode controller b . if a boat is equipped with a battery switch.6 7. a b f d e c 25180 a . • Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery.Ground wire (in the engine harness. The engine harness has a MerCathode connector which connects to a MerCathode connector on the transom harness. no hookup needed) e .Electrode on transom assembly d . 2. The engine harness supports the MerCathode system. Spray the battery terminals with a battery connection sealant to help retard corrosion. Do not connect it to a switched positive (+) circuit. Test audio warning system during Predelivery Preparation section.Connector on the transom harness f . The red current conductor (for the trim pump) must be connected to the switched side of the battery switch and either: Page 50 / 98 90-899883178 NOVEMBER 2007 . It must be connected to the switched side of the battery switch.Engine harness to the MerCathode controller Power Trim Electrical Connection ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. Connect the battery wire the battery positive (+) terminal. 1.

Locate the gear lube monitor quick connect at transom. or drive shaft. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal. Connect power trim pump BLACK (–) battery cable to negative (–) battery terminal and pump's RED (+) battery cable to positive (+) battery terminal or to the switched side of the battery switch. 4. a b 6842 a .SECTION . Connect engine negative (–) battery cable (usually BLACK) to negative (–) battery terminal. Description Cable Assembly – Trim Pump Cable Assembly – Trim Pump Color Red Red Length 72 inches 40 inches Type Fused Sheathed Power Trim Pump Connections 1. Avoid kinks and route in a straight path to avoid low spots (traps) in the system. 1. 2. IMPORTANT: Hose must not come in contact with steering system components. engine coupler. This will require the use of an Accessory cable kit. 2.Negative battery lead Battery Cables Connection IMPORTANT: Engine electrical system is negative (‑) ground. Fluid Connections Gear Lube Monitor Connection IMPORTANT: Route hoses to determine the minimum length of hose needed and trim off the excess to avoid low spots in the system. Locate the gear lube monitor quick connect at the rear of the engine.Positive battery lead b . 3. Tighten connections securely with a wrench.6 DRIVE SYSTEM AND ENGINE INSTALLATION • • Accessory Part Numbers Part Number 8M2000587 8M2000588 provided with circuit protection within 7 inches of the power source or Provided with circuit protection within 40 inches of the point of connection with the power source and sheathed the entire length of wire from the point of connection to the source and the circuit protection device. U‑joint shaft. Spray battery terminals with a battery connection sealant to help retard corrosion. 1. 90-899883178 NOVEMBER 2007 Page 51 / 98 .

Connect the power‑assisted steering hoses to the control valve. 1. Route hoses as appropriate to avoid contact with the steering system components.Gear lube monitor hose assembly from gear lube monitor c . Page 52 / 98 90-899883178 NOVEMBER 2007 . Use extra hose clips to secure hose to transom.Hydraulic lines a b 16225 b .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . a a a b a . Ensure that the quick connects snap into place. b c a 7800 a .Gear lube monitor hose assembly from transom b .Power‑assisted steering control valve NOTE: Steering Fluid can be added at this time if desired. Fasten the quick connect. 4. 3. 2. Disconnect the quick connect fittings on the power‑assisted steering hoses.Quick connect fitting Power‑Assisted Steering Hoses IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks.6 3.

Position the retainer clip in the closed position.Hose decal b . a.Quick connect fitting Position the seawater inlet hose assembly with the center of the retainer clip and the hose decal toward the engine. 1. Install the seawater inlet hose assembly to the water inlet fitting. 1. c a a .Retainer clip closed c .Hose clamp 2.6 DRIVE SYSTEM AND ENGINE INSTALLATION Alpha Seawater Inlet Hose Connection 1. Mate the small tab with the small slot.Seawater inlet hose Seawater Inlet Fitting Connection IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly. Connect water inlet hose to water inlet fitting on transom. b 7802 c . b.Water inlet tube b . NOTE: The retainer clip must be in the closed position prior to installation. IMPORTANT: Tabs and slots are sized to only mate at the correct orientation. c a b 8512 Seawater inlet hose assembly a . Secure with hose clamp. 90-899883178 NOVEMBER 2007 Page 53 / 98 .SECTION .

Centerline of water inlet fitting c .6 c. c a b 8514 Shown with engine removed for visual clarity a . Push the seawater inlet hose assembly onto the water inlet fitting until connected.Hose decal b . g h a b c e f 8513 d abcdd. Align the slots of the quick connect fitting to the tabs of the water inlet fitting. Perform a pull test on the water hose quick connection.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . 3. Page 54 / 98 90-899883178 NOVEMBER 2007 . NOTE: The retainer clip snaps into place and resumes the closed position when properly connected. Quick connect fitting Small slot Large slot Seawater inlet fitting efgh- Small tab Large tab Center of retainer clip (toward engine) Centerline of water inlet fitting (toward engine) Ensure that the center line of the water inlet fitting and the center of the retainer clip are positioned toward the engine.Retainer clip in closed position IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly. 2.

the seawater inlet hose is connected and sealed properly.Hose clamps c .Seawater inlet fitting b . NOTE: The seawater inlet hose connects to the engine and the transom. If the seawater inlet hose does not become separated from the seawater inlet fitting when force is applied. c.Seawater inlet fitting b . Models Using The Seawater Extension Hose Assembly: NOTE: The seawater inlet hose connects to the engine and the transom. the seawater extension hose assembly connects to the transom and the seawater inlet hose. reinstall as specified. e b e a c d 8516 Seawater inlet hose assembly a . 4.Quick connect fitting If the seawater inlet hose does become separated from the seawater inlet fitting.Seawater inlet hose d .SECTION . a b c 8515 Shown with engine removed for visual clarity a .To engine e .6 DRIVE SYSTEM AND ENGINE INSTALLATION a. Pull on the seawater inlet hose near the connection point with an approximate force of 111 N (25 lbf).Seawater inlet hose c . Connect the seawater inlet hose to the engine seawater pump.Quick connect fitting 5. When all steps have been completed. check for any leaks at this connection. b. 90-899883178 NOVEMBER 2007 Page 55 / 98 .

Seawater extension hose e .Quick connect male fitting d . b.Retainer clip position (away from d .Seawater inlet fitting (to transom) c . • Level with or above the heat exchanger fill neck.Quick connect fitting to seawater inlet fitting f .Seawater inlet fitting g . NOTE: The seawater extension hose assembly connects to the transom and the seawater inlet hose. When connecting the seawater extension hose assembly to the seawater inlet hose assembly. Perform a pull test and ensure that the requirements for checking the integrity of the connection are met. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: • Within limits of clear plastic tubing.Extension hose g e c 8518 f e .Hose clamp Coolant Recovery System NOTE: This section applies to Closed Cooled models only. Page 56 / 98 90-899883178 NOVEMBER 2007 . 1.Seawater inlet hose b .6 a.Quick connect fitting (to seawater inlet engine) fitting) b . d b e a c 8517 Shown with engine removed for visual clarity a .Quick connect fitting to extension hose c . g g g d b a a .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . position the center of the retainer clip away from the engine.Seawater inlet hose (to engine seawater pump) IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected properly.

Screws and flat washers c . remote control is set up for RIGHT‑HAND (RH) propeller rotation. Mount coolant recovery bottle and mounting bracket in desired location using two 19 mm (3/4 in. NOTE: Use side cutter pliers or similar to compress ring type clamps. Fasten plastic tubing to boat. 3. Connect plastic tubing to bayonet fitting on heat exchanger. Cut plastic tubing as required and connect to bottom connection on recovery bottle and secure with tubing clamp provided. Route plastic tubing to recovery bottle. Secure with tubing clamp provided. • If shift cable end guide moves in direction "A" when control lever is placed in FORWARD. IMPORTANT: Seal the plastic tubing connections completely to ensure the coolant recovery system operates properly. A B Arrow indicates direction of motion IMPORTANT: When installing shift cables. • If shift cable end guide moves in direction "B" when control lever is placed in FORWARD.Plastic tubing d .6 DRIVE SYSTEM AND ENGINE INSTALLATION • Accessible for observing coolant level and filling.) long screws (provided). 6614 90-899883178 NOVEMBER 2007 Page 57 / 98 .Tubing clamp 5. Ensure that tubing is positioned away from any moving parts.Recovery bottle and mounting bracket b . Do not fasten any items to shift cables. with 2 hose clips and13 mm (1/2 in.SECTION .) long screws and flat washers. ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. remote control is set up for LEFT‑HAND (LH) propeller rotation. 2. 4. Use standard pliers to install spring‑tension type. Alpha Shift Cable Installation Alpha Sterndrive Shift Cable Installation IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control. b a b c d 7804 a . as necessary.

Measurement taken from mark to edge of cable end guide SEPARATE SHIFT AND THROTTLE CONTROLS IMPORTANT: If boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS.6 SHIFT CABLE TRAVEL We recommend the use of a Quicksilver remote control and cable. the shift assist assembly that is shipped with the engine should not be used. control must provide specified shift cable travel (at the shift plate end). 1. The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly.8‑9 kg (15‑20 lb) load applied to the cable end guide NOTE: On engines with Alpha drives. Place a mark on the tube against the edge of the cable end guide.Remote control shift cable ‑ in REVERSE gear position e . Refer to Mercury Precision Parts Accessories Guide for selection. However.)‑80 mm (3‑1/8 in.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Description Shift cable travel1 Specification 73 mm (2‑7/8 in.Edge of cable end guide d . the measurement indicated above can be taken by installing the remote control shift cable and using the shift assist assembly (provided) to place the proper load on the shift cable. if a control other than Quicksilver is to be used.Shift assist assembly b .)2 1 At the shift plate end 2 With a 6.Remote control shift cable ‑ in FORWARD gear position c . d e a b c 7809 a a . Page 58 / 98 90-899883178 NOVEMBER 2007 .

6614 90-899883178 NOVEMBER 2007 Page 59 / 98 .Cotter pin NOTE: Do not discard shift assist assembly until after it is used below.Washer c . IMPORTANT: Shift cable must be connected at the remote control for the appropriate rotation (LH or RH) drive unit. c b a d 7810 a .6 DRIVE SYSTEM AND ENGINE INSTALLATION The Spacer Kit (23‑11284A1) will have to be ordered to connect remote control shift cable when shift assist assembly is not used.Spacer d . Remove shift assist assembly. as explained following: RIGHT‑HAND ROTATION ‑ Control cable will have to be installed in remote control so that cable end will move in direction "A" when shift handle is placed in the FORWARD position. LEFT‑HAND ROTATION ‑ Control cable will have to be installed in remote control so that cable end will move in direction "B" when shift handle is placed in the FORWARD position.Clevis pin b .SECTION . A B INSTALLATION 1.

Pull out on control cable end with enough pressure to remove play and mark position "b" on tube. 6. Shift remote control to NEUTRAL.Shift assist 3. a.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Locate center of remote control and control cable play (backlash). Secure the cable end guide with washers (one on each end of the end guide) and cotter pin. 5. Push in on control cable end with enough pressure to remove play and mark position "a" on tube. Secure the brass barrel retainer with the cotter pin. Page 60 / 98 90-899883178 NOVEMBER 2007 . IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making the following adjustment. a b 7812 a . a.6 2. b . b. Remove shift cable attaching hardware. c. Install intermediate cable.Shift plate 7813 4.

Install the remote control shift cable. Place remote control and and sterndrive unit in FORWARD gear. 10. If shift assist assembly attaching points will not align. Install the shift assist assembly. Temporarily install control cable end guide into shift lever and insert anchor pin.Large ID washer e . Place remote control handle in NEUTRAL. verify controller is in NEUTRAL. Remove the shift cable and reposition the adjustment barrel as required to allow the shift assembly to be installed with no effort.Clevis pin (and cotter pin not shown) 7818 d .Remote control shift cable b .Small ID washer and cotter pin 90-899883178 NOVEMBER 2007 Page 61 / 98 . 13.6 DRIVE SYSTEM AND ENGINE INSTALLATION d. 9. Install the fastening hardware. 11.SECTION . Ensure that backlash center mark is aligned with edge of control cable end guide. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud. d a c e b With shift assist assembly a .Shift assist assembly c . 8." c b a 7815 7. 12. Ensure that it fits over the clevis pin and barrel stud with no resistance. Measure distance between marks "a" and "b" and mark position "c" half‑way between marks "a" and "b.

Shift Cable Adjustment Tool 91‑12427 IMPORTANT: Sterndrive propeller rotation is determined by the shift cable installation in the remote control. A Arrow indicates direction of motion B 21620 Page 62 / 98 90-899883178 NOVEMBER 2007 . • Bravo One/Two ‑ If shift cable end guide moves in direction B when control lever is placed in FORWARD.6 d a c e f g i h b 7841 abcde- Without shift assist assembly Remote control shift cable Clevis pin Cotter pin (existing) (not shown) Spring (existing) (not shown) Washer (existing) fghi- Washer Spacer Washer (existing) Cotter pin (existing) Bravo Shift Cable Installation and Adjustment Bravo Models Shift Cable Installation NOTE: Bravo Models Only: Using shift cable adjustment tool (91‑12427). using the following procedure. shift cables can be adjusted with or without the sterndrive installed.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . remote control is set up for LEFT‑HAND (LH) propeller rotation. • Bravo One/Two ‑ If shift cable end guide moves in direction A when control lever is placed in FORWARD. remote control is set up for RIGHT‑HAND (RH) propeller rotation.

Retighten stud. ensure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts.SECTION .76 mm (3 in. A 21621 IMPORTANT: When installing shift cables. Loosen the adjustable stud and move it to dimension.) (center of pivot bolt to center of stud) 90-899883178 NOVEMBER 2007 Page 63 / 98 .6 DRIVE SYSTEM AND ENGINE INSTALLATION • Bravo Three ‑ Front propeller on sterndrive is always LH Rotation and rear propeller is always RH Rotation. 4. Shift cable end guide must move in direction A.Adjustment tool 2. Do not fasten any items to shift cables.Adjustable stud 3. as shown. a b 21612 a . when control lever is placed in FORWARD gear position. Bravo Models Shift Cable Adjustment 1. a 21611 a . Install cotter pin. Install sterndrive shift cable. Remove the adjustment tool. b .

Place adjustment tool over sterndrive shift cable. c." c b a 7815 Page 64 / 98 90-899883178 NOVEMBER 2007 . Shift remote control to NEUTRAL.Short cotter pin 6.6 5. a b c 21616 a .Sterndrive shift cable b . a. d.Long cotter pin c . IMPORTANT: Keep center mark "C" aligned with control cable end guide edge when making the following adjustment. b.Adjustment tool b . Locate center of remote control and control cable play (backlash). Hold tool in place using a piece of tape over the barrel retainer. Measure distance between marks "a" and "b" and mark position "c" half‑way between marks "a" and "b. Push in on control cable end with enough pressure to remove play and mark position "a" on tube. Insert cotter pin from top and spread ends fully.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . as shown.Sterndrive shift cable 7. a b 21615 a . Pull out on control cable end with enough pressure to remove play and mark position "b" on tube.

loosen shift lever stud and slide stud up or down until slot in tool fits over stud. 14. Ensure that backlash center mark is aligned with edge of control cable end guide. Two and Three REVERSE slot 19.LH rotation Bravo One and Two FORWARD. Adjust control cable barrel so that hole in barrel centers with vertical center line of stud. Place end of adjustment tool in barrel retainer. 17. Shift remote control lever into FORWARD position. 13. d . Remove the adjustment tool. Remove control cable end guide from shift lever by removing clevis pin. b a 21614 a .Stud. 21.SECTION . LH rotation Bravo One and Two REVERSE slot b . retighten stud. 18.6 DRIVE SYSTEM AND ENGINE INSTALLATION 8. Shift the remote control into REVERSE and repeat the adjustment process.Control cable barrel e . When adjustment is correct. 9.Control cable end guide b . RH rotation Bravo One. Tube Ref No. 12. Lift the adjustment tool so that the slot is above the stud. 10. If slot does not fit over stud. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180 degrees. 15. Obtain Locally 90-899883178 NOVEMBER 2007 Page 65 / 98 . washer and cotter pin Install the control cable. 80 Description SAE Engine Oil 30W Where Used Shift cable pivot points Part No. Install the washer and cotter pin to secure the barrel. 16. Install the cotter pin into the clevis pin from the top and spread the ends. Remove adjustment tool. Two.Clevis pin c . 20. Install the clevis pin. Lubricate shift cable pivot points.RH rotation Bravo One.Backlash center 11. Three FORWARD. Temporarily install control cable end guide into shift lever and insert anchor pin. c d a b c d e 21613 a .

92-802865Q02 3. If this cannot be done or is not done at your manufacturing facility. Route the intermediate shift cable from the transom assembly to the shift actuator as follows: a.Electrical System Shift Cable Installation For DTS System IMPORTANT: Do not move the shift cable stud on the shift arm.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Install the intermediate shift cable to the shift actuator on the engine. c. Tube Ref No. 34 Description Special Lubricant 101 Where Used Shift cable stud Part No. The cable should then be routed under the starboard rear engine mount and turn toward the transom. Page 66 / 98 90-899883178 NOVEMBER 2007 . Apply lubricant to the threads of the shift cable stud. IMPORTANT: The shift cable barrel is preset and CANNOT be adjusted. above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine.6 DTS System Installation Refer to DTS System Installation section 7 . 8995 NOTE: A final check of the adjustments should be made with the boat in the water and engine running. The cable should come through the transom. 2. arrangement should be made with the dealer to do this as part of the pre‑delivery inspection. NOTE: Following this routing will prevent the engine coupler from damaging the cable. b. 1.

Cotter pin Throttle Cable Installation Throttle Cable Installation And Adjustment IMPORTANT: When installing throttle cables. 1. b e a f d c 8996 a .Shift cable stud e . Place remote throttle lever in idle position and attach cable to throttle body.Shift actuator b .6 DRIVE SYSTEM AND ENGINE INSTALLATION 4.Locknut 5. Do not fasten any items to throttle cables. ensure that cables are routed to avoid sharp bends and / or avoid contact with moving parts.Shift cable c . d . Insert cotter pin from top and spread ends. Tighten locknut until it contacts and then loosen 1/2 turn. 90-899883178 NOVEMBER 2007 Page 67 / 98 .Washers a 8997 a .Shift cable barrel f . following cable manufacturer’s instructions.SECTION .

and then loosen 1/2 turn. Remove trim cylinder support and dust cover from bell housing studs. Ensure hole in barrel positions cable as shown. Install cable end guide on throttle lever.Cable barrel c .Cable end Alpha Sterndrive Installation 1.) a b 7713 Typical a . (Retain elastic stop nuts and flat washers.6 2.Trim cylinder support Page 68 / 98 90-899883178 NOVEMBER 2007 . Tighten locknut until it contacts washer.Locknut and flatwasher b .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever. b a c 8217 a . then push cable barrel end lightly toward throttle lever end.) Adjust barrel on throttle cable to align with hole in anchor plate.Dust cover b .

87 b . Ensure that the rubber gasket is inside the monitor cap. Push dribble valve stem in until gear lube appears. IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing drive unit or water may leak into boat. Install the gear lube monitor cap. Do not overtighten the cap. 92-858064K01 Description High Performance Gear Lubricant 3. Once gear lube appears.‑ Gear lube monitor cap Tube Ref No. 5. release dribble valve stem.SECTION . a 7851 a . 7. 92-858064K01 6. 90-899883178 NOVEMBER 2007 Page 69 / 98 . 87 Description High Performance Gear Lubricant Where Used Gear lube monitor Part No. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING RANGE" (full) line with specified fluid. Do not overfill.6 DRIVE SYSTEM AND ENGINE INSTALLATION 2. Remove gear lube monitor cap. Fill with lubricant.Dribble valve stem 4."OPERATING RANGE" line Where Used Gear lube monitor Part No. a b 5497 a . Ensure that rubber gasket and water passage O‑ring are properly positioned in bell housing. Tube Ref No.

and drive shaft splines. 95 c . a c b c 7852 a .6 8. Coat bell housing studs with lubricant. 92-802869A1 Part No.Drive shaft splines Where Used Ujoint O-rings Where Used Drive shaft splines Part No. 92-802859A1 9.Water passage O‑ring Tube Ref No.Studs (6) Description 2-4-C Marine Lubricant with Teflon Where Used Bell housing studs Part No. 92-802869A1 Description Engine Coupler Spline Grease Description Engine Coupler Spline Grease Tube Ref No.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Grease sterndrive U‑joint O‑rings. 91 Page 70 / 98 90-899883178 NOVEMBER 2007 . 91 b .U‑joint O‑rings Tube Ref No. A grease packet for this procedure is provided with the sterndrive packaging.Rubber gasket b . a a b 7853 a .

Ensure U‑joint bellows are clean and free of debris.Shift shaft b .Shift shaft coupler c .SECTION . 13. Do this by placing remote control shift lever in: FORWARD gear position for RH drive or REVERSE gear position for LH drive unit. Engage shift shaft roller into shift shaft lever. c a d b 7855 a .Shift slide d . 90-899883178 NOVEMBER 2007 Page 71 / 98 . Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft.Slot IMPORTANT: Shift slide assembly is free to rotate on core wire. Place gasket on bell housing.U‑joint bellows 11. Ensure that shift slide remains in upright position and is properly engaged with shift shaft lever roller while installing drive unit. 12.6 DRIVE SYSTEM AND ENGINE INSTALLATION 10. a 7854 a .

Guide U‑joint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into drive shaft housing. If necessary.Gasket 91‑865232 15. b. Page 72 / 98 90-899883178 NOVEMBER 2007 . Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE while simultaneously turning propeller shaft COUNTERCLOCKWISE. The LH rotation drive unit can be identified by the decal on the back side of the upper drive shaft housing. c.Roller Shift Slide Stabilizer 7859 c . a 7856 a . which states: "Alpha One ‑ Counter Rotation" 16.Shift Shaft Slide Stabilizer Tool d .Drive unit shift shaft IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dual engine installations.Shift shaft lever b . rotate propeller shaft COUNTERCLOCKWISE slightly to help align U‑joint shaft splines with engine coupler splines while sliding sterndrive into bell housing. Position trim cylinder straight back (over top of acceleration plate).6 14. a d b c c a . Be careful not to scratch acceleration plate or trim cylinders.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide. Install sterndrive unit as follows: a. Ensure that shift slide remains upright and engaged with bell housing shift shaft lever.

Locknut and continuity circuit washer (no flat washer at this location) Nm 68 lb. e. Slide sterndrive all the way into bell housing. 90-899883178 NOVEMBER 2007 Page 73 / 98 . Return remote control shift lever to the NEUTRAL position. Secure sterndrive to bell housings using fasteners as shown. in. a b 7857 a . f.6 DRIVE SYSTEM AND ENGINE INSTALLATION IMPORTANT: If drive unit will not slide into bell housing. 50 Description Sterndrive unit fasteners 17.Locknut and flat washers b . TRIM CYLINDER INSTALLATION 1. ft. b .SECTION . lb.Gasket d. a b 7858 a . Torque the fasteners. Do not force drive unit into position. Install trim cylinders on aft end of sterndrive unit with hardware as shown. ensure that the shift shaft and couplers are positioned properly.Shift slide Remove Shift Slide Stabilizer Tool and discard.

E‑ring clips e . 95 a d .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .NOTE: Upon installation of hardware apply lubricant to all components except plastic caps. Raise drive to gain access to area between gimbal housing and sterndrive. Speedometer Connection ‑ Alpha Models 1.Bushings c .Female end of speedometer tube fitting Page 74 / 98 90-899883178 NOVEMBER 2007 .Flat washers Tube Ref No. Push down to secure. Align plastic slots on male and female portions and insert.Plastic caps 7849 Description 2-4-C Marine Lubricant with Teflon Where Used Trim cylinder hardware Part No.6 2.Male end of speedometer tube fitting b . b a 4803 a . 3. Install the plastic caps by snapping in place. Position the sterndrive unit serial number decal. a b c d e b a . 2.Aft anchor pin b . immediately above the transom end of the anti‑ventilation plate. 92-802859A1 3.

Plug holes with 22‑38609 plug. 2.6 DRIVE SYSTEM AND ENGINE INSTALLATION Ensure that the speedometer tube is secured and out of the way of moving parts. A spacer can be removed from the trim cylinders to increase the trim‑in range by approximately 1‑1/2 degrees. This will improve the acceleration on some boats by forcing the bow down more quickly.SECTION ."UP" port on trim cylinder 7843 c c . Alpha Trim Cylinder Spacer Removal 1.Hydraulic connector 90-899883178 NOVEMBER 2007 Page 75 / 98 . the boat must be water tested to ensure that the increased trim‑in range does not cause any undesired boat handling characteristics (bow‑steer. The boat should be tested under all conceivable load conditions and maneuvers to ensure that the additional trim‑in does not pose a problem.Male end of speedometer tube fitting b . If the spacers are to be removed. The final decision and responsibility for use of the additional trim‑in range is left up to the boat manufacturer.) if the sterndrive is trimmed in while the boat is operated at higher speeds. ! WARNING On some boats."DOWN" hose d . Disconnect "DOWN" trim hose from hydraulic connector on gimbal housing. etc.Female end of speedometer tube fitting Alpha Notice: Increased Trim‑in Range Capability The Alpha trim cylinders provide the capability for an increased trim‑in range. increased trim‑in range can cause handling problems at high speeds. resulting in personal injury or death. Disconnect "UP" trim hose from "UP" port on trim cylinder. d b a a ."UP" hose b . b a 8029 a . We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for handling problems. chine‑walk.

Clamping the center section of the trim cylinder can cause damage. Ensure that the work area.Flat washer (port and starboard) (2) 4827 d . We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for handling problems. b d a a c e b 7844 a .E‑ring (port and starboard) (2) e . Failure of power trim or steering components can result in injury or product damage. ! CAUTION Contamination can damage the hydraulic system or cause the system to malfunction. 1.Flat washer (port and starboard) (2) d . Page 76 / 98 90-899883178 NOVEMBER 2007 .Bushing (port and starboard) (4) c . resulting in personal injury or death. IMPORTANT: During service procedures.Rear anchor pin b . Remove plug previously installed.Front anchor pin b .Bushing (port and starboard) (4) c . shop tools and all components are clean and lint free during reassembly.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .6 3. if applicable. clamp the trim cylinder on the front mounting flange.Plastic caps (port and starboard) (2) Alpha Trim Cylinder Disassembly ! WARNING On some boats. increased trim‑in range can cause handling problems at high speeds.Plastic caps (port and starboard) (2) 4. Remove rear power trim cylinder mounting hardware.E‑ring (port and starboard) (2) e . Remove front power trim cylinder mounting hardware. a c e b d a .

shop tools and all components are clean and lint free during reassembly. Description Trim cylinder shock piston bolt Nm 23 lb. Failure of power trim or steering components can result in injury or product damage. Discard spacer. and spacer.SECTION . Install washer and bolt and torque. washer. ft.6 DRIVE SYSTEM AND ENGINE INSTALLATION 2. Apply sealant to threads of shock piston bolt. Remove end cap with spanner wrench and remove piston rod assembly from cylinder. Be careful not to lose check balls. a b 7845 a . in. 17 90-899883178 NOVEMBER 2007 Page 77 / 98 . 1. Tube Ref No. Ensure that the work area.Cylinder 91‑821709T 3.Piston rod assembly Trim Cylinder End Cap Tool b . 7 Description Loctite 271 Threadlocker Where Used Trim cylinder bolt threads Part No. Remove bolt. 92-809819 2. h d e f g c 7846 a abcd- b Trim cylinder shock piston bolt Spacer Washer Springs (3) efgh- Spring pins (3) Check balls (3) Shock piston assembly O‑ring Alpha Trim Cylinder Reassembly ! CAUTION Contamination can damage the hydraulic system or cause the system to malfunction. lb.

a b c 7848 a . 2.6 IMPORTANT: During service procedures.Port trim cylinder b . 3. Replace anchor pin and install bushings and washers.End cap b .Connecting ends (offset as shown) Alpha Trim Cylinder Installation 1. 3. 92-802865Q02 lb. ft. in. a b c a . Page 78 / 98 90-899883178 NOVEMBER 2007 .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Torque end cap using the spanner wrench.Starboard trim cylinder c . 34 7847 c . 4. Clamping the center section of the trim cylinder can cause damage.Cylinder Description Special Lubricant 101 Where Used Trim cylinder end cap Nm 61 Part No. lb. Position trim cylinder rear connecting ends. 45 Description Trim cylinder end cap 5.Piston rod assembly Tube Ref No. Coat area in trim cylinder between bushings with lubricant. Apply lubricant to end cap threads and install piston rod assembly into cylinder. which could promote corrosion. Install trim cylinders forward mounting hardware. IMPORTANT: Use only 2‑4‑C with Teflon on the end cap threads. Other substances may act as an insulator and cause poor electrical continuity between the cap and cylinder. clamp the trim cylinder on the front mounting flange.

SECTION .Plastic caps (port and starboard) (2) Description 2-4-C Marine Lubricant with Teflon Where Used Trim cylinder Part No.Flat washer (port and starboard) (2) Tube Ref No. 95 4827 d .Front anchor pin b .Flat washer (port and starboard) (2) Tube Ref No. Install trim cylinders rear mounting hardware.Rear anchor pin b . 6.E‑ring (port and starboard) (2) e . b d a a c e b 7844 a . 90-899883178 NOVEMBER 2007 Page 79 / 98 . 95 d . 92-802859A1 9.E‑ring (port and starboard) (2) e .Plastic caps (port and starboard) (2) Description 2-4-C Marine Lubricant with Teflon Where Used Trim cylinder hardware Part No. Attach E‑rings and plastic caps to end of anchor pin. Coat area in trim cylinder between bushings with lubricant. 92-802859A1 5.6 DRIVE SYSTEM AND ENGINE INSTALLATION 4. Attach E‑rings and plastic caps to end of anchor pin. 8. Reconnect trim hoses after air bleeding power trim cylinders and hoses following procedures outlined in Mercury MerCruiser Service Manual 14. Replace anchor pin and install bushings and washers.Bushing (port and starboard) (4) c .Bushing (port and starboard) (4) c . a c e b d a . 7.

92-858064K01 Description High Performance Gear Lubricant Page 80 / 98 90-899883178 NOVEMBER 2007 . 87 b . (Retain elastic stop nuts and flat washers. If applicable.) a b 8993 Typical a .Trim cylinder support 2."OPERATING RANGE" line Where Used Gear Lube Monitor Part No.Gear lube monitor cap Tube Ref No.6 Bravo Sterndrive Installation 1.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Fill the gear lube monitor to the "OPERATING RANGE". remove trim cylinder support and dust cover from bell housing studs. a b 5497 Gear lube monitor a . Remove gear lube monitor cap.Dust cover b .

6 DRIVE SYSTEM AND ENGINE INSTALLATION 3. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING RANGE" (full) line with specified fluid. Release the dribble valve.Gear lube level at the "OPERATING RANGE" Tube Ref No.Dribble Valve 21440 4. Do not overtighten the cap.Gear lube level at the "ADD" mark b . a a . 92-858064K01 6. a 19962 a . 87 c . c b a 19947 Gear lube monitor a . Do not overfill. Ensure that the rubber gasket is inside the monitor cap.Cap Description High Performance Gear Lubricant Where Used Gear Lube Monitor Part No. push in on the dribble valve stem until the new gear lube appears.Gear lube monitor cap 90-899883178 NOVEMBER 2007 Page 81 / 98 .SECTION . Install the gear lube monitor cap. To purge air from the system. 5.

DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . 91 91 21442 Description Engine Coupler Spline Grease Engine Coupler Spline Grease Where Used U-joint O-rings Driveshaft splines Part No.U‑joint bellows 21456 Page 82 / 98 90-899883178 NOVEMBER 2007 . a b Bell housing of the transom assembly a .U‑joint bellows edge b .O‑rings 8. 92-802869A1 92-802869A1 9. Coat the splines on the sterndrive U‑joint with lubricant.Splines Tube Ref No.6 7. Coat the O‑rings on the sterndrive U‑joint with lubricant a a . Ensure that the U‑joint bellows are clean and free of debris. a 21441 a a .

Lubricate the shift linkage O‑ring.Tube of lubricant Where Used Part No. 92-802859A1 Description 2-4-C Marine Lubricant with Teflon Bell housing studs 11. b a a a . 95 21457 b . Lubricate the water passage seal. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the bell housing studs.Bell housing studs (6) Tube Ref No.Shift linkage O‑ring Tube Ref No. 92-802859A1 12. 95 Description 2-4-C with Teflon Where Used O-ring Part No. a 21678 a .Water passage seal 90-899883178 NOVEMBER 2007 Page 83 / 98 .SECTION .6 DRIVE SYSTEM AND ENGINE INSTALLATION 10. a 21679 a .

as shown in steps "A".6 Description Where Used Water passage seals Part No. as follows: Page 84 / 98 90-899883178 NOVEMBER 2007 .DRIVE SYSTEM AND ENGINE INSTALLATION Tube Ref No. b a a c c 5311 a . Place the driveshaft housing in position on bell housing and install the sterndrive. NOTE: As the bell housing shift cable enters the shift linkage assembly." A B C 5312 IMPORTANT: If the bell housing shift cable does not line up to properly enter the jaws of the shift linkage assembly. The jaws will open. Place remote control in NEUTRAL position. 15. 95 SECTION .Jaws open c . 14. and the jaw closes. it pushes the assembly back into the sterndrive housing.Shift linkage assembly b . use your hand to guide the cable into place while installing the sterndrive. the shift cable must be closely checked to ensure that it enters the jaws of the shift linkage assembly of the sterndrive. securing the cable. 92-802859A1 2-4-C Marine Lubricant with Teflon 13. "B" and "C. Pull out the shift linkage as far as it moves.Underside of lower lip 21471 IMPORTANT: As the sterndrive is inserted into the entry of the bell housing.

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

a.

Remove the nuts from the trim cylinders.

a

b

c

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

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

a

b

c
a - Universal joint b - Bell housing c.

d

21518

c - Shift linkage d - Shift cable

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

a

b

c
21519

a - Shift cable b - Shift linkage jaws open

c - Shift linkage jaws engage the shift cable

90-899883178 NOVEMBER 2007

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

d.

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

b a c

a - Bell housing studs b - Dribble valve

c - Shift cable

21520

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

a

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

25908

Page 86 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

17. Start from the center and torque the nuts.

a b
25909

a - Locknut (6) flat washers (4)
Description Sterndrive fasteners

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

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

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

a

b

c

d e

e

f

g

h

14326

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

efgh-

Bushing Flat washer (small I.D.) Locknut Plastic cap
Part No. 92-802859A1

Tube Ref No.
95

Where Used Trim cylinder hardware

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

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DRIVE SYSTEM AND ENGINE INSTALLATION

SECTION - 6

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

a

b

14571

a - Trim‑in limit insert Bravo One and Two (positioned forward)

b - Trim‑in limit insert Bravo Three (positioned aft)

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

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

c

b

c

a

d e

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

f
9295

d - Small ID flat washers (2) e - Locknuts (2) f - Plastic caps (2)
Where Used Trim cylinder hardware Part No. 92-802859A1

Description 2-4-C Marine Lubricant with Teflon

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

Page 88 / 98

90-899883178 NOVEMBER 2007

SECTION - 6

DRIVE SYSTEM AND ENGINE INSTALLATION

8. Install plastic caps and tighten hand‑tight only.

a b b a c

21677

a - Socket and tool b - Wrench tool

c - Plastic cap (4)

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

a

b
5319

a - Tube fitting

b - Opening

90-899883178 NOVEMBER 2007

Page 89 / 98

This test requires sufficient water supply to your engine and sterndrive. Place a block of wood between the propeller blade and the anti‑ventilation plate. place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.Drive trim switch b . 1. turn handle to left to a tightly seated position. Never operate the boat out of the water with a propeller installed. as shown.6 3. With fitting fully seated. a b 4805 Typical single handle remote control shown a . a 5320 a . Before installing or removing a propeller. Do not allow the sterndrive skeg to contact the ground. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/ IN position.Fitting installed (handle pointing forward) Trim Limit and Trim Position Settings To adjust the trim limit switch and the trim position sender see Section 9—Predelivery Preparation for the appropriate procedure. Bravo Sterndrive Shift Check (Engine Running) ! WARNING Rotating propellers can cause serious injury or death. 2. Check sterndrive for proper gear shift with boat out of water.Drive trailer button 3.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Dual Water Pick‑up Flush Gearcase Seal Kit Flushing Device 91‑881150K 1 91‑44357Q 2 Page 90 / 98 90-899883178 NOVEMBER 2007 . Connect a garden water hose between flushing attachment and water source.

7873 Proper cable bend 90-899883178 NOVEMBER 2007 Page 91 / 98 . the engine. NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of each gear FORWARD. Troubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear. NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing. DO NOT fasten any items to shift cables. ensure that the cables have enough clearance to operate. If the sterndrive will not shift: a. Check that the sterndrive propeller shaft is turning in the REVERSE direction. NOTICE Without sufficient cooling water. Remove the sterndrive and check for proper shift hook ups. Shift the remote control handle to NEUTRAL. the cables will be interfered with. When installing the control box in the side panel of the boat. Check that the sterndrive propeller shaft is not turning. 10. 8. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment. NEUTRAL. 11. and other components will overheat and suffer damage. b. idle speed position. Partially open water source until water continuously leaks out around the flushing device. Check that the shift cables are connected IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/ or contact with moving parts. Check that the sterndrive propeller shaft is turning in the FORWARD direction. Place remote control handle in NEUTRAL. 7. Shift the remote control handle to REVERSE. the water pump. this will cause very hard shifting. FORWARD‑detent‑NEUTRAL‑detent‑REVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.SECTION . 5. idle speed position. If the control box is mounted too far back toward any fiberglass structure. Provide a sufficient supply of water to the water inlets during operation. NOTE: The operator at the remote control handle should feel a slight detent before and after each gear. 12. Move the remote control handle to FORWARD. and REVERSE. at idle speed position. idle speed position.6 Flushing Kit DRIVE SYSTEM AND ENGINE INSTALLATION 91‑849996T 1 4. This is necessary because the cables move up and down when the shift handle is moved. 9. idle speed position and start engine. 6. 1.

Engine end Tube Ref No. Ensure that when the shift cable from the control box is led through the side gunnel of the hull.). 4000 GEN II Series Panel Mount Remote Control Description Mounting surface maximum thickness Minimum cable bend radius at any point Specification 25 mm (1 in.) 305 mm (12 in. Page 92 / 98 90-899883178 NOVEMBER 2007 .) thickness. 95 7874 c . it does not have any extremely sharp bends in it as this will cause stiff shifting. b c a d a . 92-802859A1 Description 2-4-C Marine Lubricant with Teflon NOTE: Allow for clearance of cables directly behind panel mount remote control.Adjusting barrel d .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION . Both conditions place extra stress on the cables. 3.4 cm (3 ft) of the control box. extend the stainless rod eye end of the cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.) 4. Cable radius at any one point must not be less than 305 mm (12 in.6 7872 Improper cable bend 2.Remote control end b . IMPORTANT: Shift cable/throttle cable lubrication points use 2‑4‑C with Teflon. The 4000 GEN II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in. sharp bends on too‑short cables result in kinks and too‑long cables require unnecessary bends or loops. IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH. Do not strap or clamp the control cables to any other cables or rigid structure within 91. Before installing the shift cable into the control box.Lubricating point Where Used Shift cable end Part No.

b. The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE. a. Ensure that the engine was not set down on the intermediate shift cable during installation. 9. 6. NOTE: Lubricate attaching points with engine oil. 10. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.5 m (5 ft) of the shift plate. where it is connected to the anchor points on the shift plate. The cable should come through the transom. Refer to 90‑865523 Instruction Sheet for more information. If this cannot be done or is not done at your manufacturing facility. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Following this routing will prevent the engine coupler from damaging the cable.5 m (5 ft) of the shift plate. The cable should then go up behind the power steering valve and loop over to the shift plate on the engine. above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. Ensure that the cable is not permanently kinked. 90-899883178 NOVEMBER 2007 Page 93 / 98 . 8. c. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1. 8995 Through prop exhaust shown NOTE: NOTE: A final check of the adjustments should be made with the boat in the water and engine running. Description SAE 30W Engine Oil Where Used Shift cable pivot points Part Number Obtain Locally 11.SECTION . The cable should then be routed under the starboard rear engine mount and turn toward the transom.6 DRIVE SYSTEM AND ENGINE INSTALLATION 5. arrangement should be made with the dealer to do this as part of the pre‑delivery inspection 12. Ensure that there is proper clearance for cable movement when the control box is installed in the side panel. 7. as this will crush the inner cable tubing and cause improper and / or stiff shifting. Barrel and cable end must be free to rotate on the mounting stud. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows: NOTE: Cable route is the same for through transom and through prop exhaust. Do not fasten the shift cable with straps or clamps to any other cable within 1.

13° transom angle b . Usually the right (starboard) side to minimize cavitation.6 Paddle Wheel Speed Sensor Installation (If Equipped) PARTS PROVIDED e a b ABCD d c h f g abcdeSpare pin yoke Wire retainer Connector Bracket Paddle wheel fghij- i i j 29269 Flat washer (2) #10 ‑ 19 mm (3/4 in. ribs. heavier displacement boats.DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .) beyond the swing radius of the propeller.) screw (4) Clamp (2) SELECTING LOCATION Single engine installation ‑ Mount paddle wheel on the transom where the propeller blade is rotating downward. TRANSOM ANGLE REQUIREMENTS Standard 13° to 20° transoms ‑ No special adjustment required. intakes or outlets for live wells or any protrusion that may cause turbulence or cavitation.20° transom angle Stepped or undercut transom with 3 angles ‑ A small shim of tapered plastic. positioning it farther from the keel is acceptable. Mount the paddle wheel on the step for best performance. however. On slower. mount at least 50 mm (2 in.) screw (4) Cable cap #6 ‑ 12 mm (1/2 in. If feasible. a b 29272 a . metal or wood must be fabricated and installed as shown.Shim Page 94 / 98 90-899883178 NOVEMBER 2007 . a 29276 a . Dual engine installation ‑ Mount the paddle wheel between the engines as close to the center line (keel) of the boat as possible. NOTE: Do not mount the paddle wheel directly behind any stakes.

Template b . 5.) c . 2. 4.Flat washer (2) e . Using a 2.) deep.) from the point end of drill bit. Drill a 15 mm (5/8 in. NOTE: The mounting template provided is located on the last page of this instruction sheet. 4. wrap masking tape around the drill bit 22 mm (7/8 in. Using the washer provided.) bit. a b e c a .8 mm (7/64 in.5 mm (1/16 in. drill holes for the clamps and cap approximately 13 mm (1/2 in. To prevent water seepage into the transom. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads.) diameter hole. Using a #28 or 9/64 in. Seal the transom hole with silicone (RTV) or a comparable marine sealer after the cable has been routed through. tape the template to the transom. 3. attach and tighten the bracket to the hull making sure the bracket is flush with the underside of the hull. as shown.#10 screw d 29282 d . Fill any gap between the housing and the transom with a caulking material.) above the paddle wheel.) deep holes where indicated on the template.6 DRIVE SYSTEM AND ENGINE INSTALLATION INSTALLING BRACKET 1.Caulking ROUTING THE CABLE DRILLING HOLE THROUGH TRANSOM (OPTIONAL) 1. Select a transom location for the hole above the water line that does not interfere with other cables and controls. smooth the surface to ensure proper water flow.) deep to prevent surface cracks. At the location selected. install the cable clamps and feed the cable through cable cap.50 mm (2 in. first chamfer the gelcoat using a 6 mm (1/4 in.) drill. Cut out the template. bit. NOTE: The hole for the first clamp should be 25 mm (1 in. drilling about 1. To prevent drilling too deeply. 90-899883178 NOVEMBER 2007 Page 95 / 98 . The hole for the second clamp should be positioned halfway between the first clamp and the cap covering the transom hole drilled for the cable.SECTION . apply a marine sealer (such as RTV) to the two #10 screws provided. Make sure the black dotted line on the template is aligned with the transom bottom edge. Route the cable through the drilled hole. NOTE: In fiberglass hulls. drill two 22 mm (7/8 in. 3. 2. Using a putty knife. as shown.

a b a . make sure wires are routed through the transom. Removal ‑ squeeze open (unlock) the tabs and pull on the paddle wheel. a b c e d 29285 abcde- Splash well drain hole Cable cap Cable clamp Paddle wheel assembly Distance between first cable clamp and top of paddle wheel ‑ 25. Page 96 / 98 90-899883178 NOVEMBER 2007 .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .) INSTALLING AND REMOVING THE PADDLE WHEEL Installation ‑ Slide the pins into the slots in the bracket and snap the tabs into place.Tabs b .6 WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL) Route the cable over the transom or through a drain hole that is above the water line.0 in.Pins 29288 WIRING CONNECTIONS IMPORTANT: Before making wire connections.4 mm (1.

SECTION . DC BA WHT YEL BL U BL K D C BA 29289 b a . Have the wiring routed through the transom. Secure wires into connector with the wire retainer. Align the wire terminal with the tabs inside the connector.Connector a b b .Drill holes here b . Push wire in until they snap into place.6 DRIVE SYSTEM AND ENGINE INSTALLATION NOTE: Wires can only be pushed into the connector one way. Push each wire terminal into its respective location in the connector.PADDLE WHEEL SPEED SENSOR a b 29291 a .Align dotted line with the transom bottom edge and fold under 90-899883178 NOVEMBER 2007 Page 97 / 98 .Wire retainer TEMPLATE .

6 NOTES: Page 98 / 98 90-899883178 NOVEMBER 2007 .DRIVE SYSTEM AND ENGINE INSTALLATION SECTION .

................................................................ 15 Wiring Diagrams.......................... 10 Additional Relay Kit ..........................................................18 Drawing ..........................................................................................................................3 Power Trim Electrical Connection.............5 Boat Wiring.............................................................. 18 Diagram ........................................................................................................................................................................... 25 Connectors ............................................................................................................................................................................25 DTS Battery Specifications.......... 25 Junction Box (if Equipped)............................................................................................................................................................................................24 Installation Guidelines for DTS System Components.............................................. 6 Boat Harness Installation Guidelines—MPI Sterndrive.... 25 Weather Caps....................................................... 6 Dual Station ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ 12 CAN V (CAN 3) Connection ........................................................21 Power Trim System .......................................................................................................................................................................................................................17 Boat Harness............................................................................................................................................ 6 Key Switch Connector ................................................................................................................................................................................................................5 Single Station ............................................................................................................................................................................. 3 Boat Harness and Accessories Information.........................................................20 Drawing ............................................................................................................................................................... 24 14‑Pin Engine Harness Connector.... 12 General Repower Information ............................................. 20 Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly)................................................................................................... 7 Trim Switch .....................26 7 90-899883178 NOVEMBER 2007 Page 1 / 38 ..................................... 16 Transom Harness—MPI .....................................................................................ELECTRICAL SYSTEM Table of Contents General Information................................................................................................................................................................................................................................................................. 24 Special Tools ‑ DTS Installation.............................................................................................................................................................................................4 Multiple MPI Engine Battery Information...................................................................................................................................... 19 Analog Gauge Harness.................................... 5 Engine Harness and Accessory Power Supply.......................................... 12 Transom Harness—MPI ......................................................................................6 Boat Harness Deutsch Connector to Engine ..............................................................................................................................................................................................................................16 Transom Harness—DTS....................................... 8 Neutral Switch ...........................................................................................................................................................................................................SECTION .................................................................................... 9 Lanyard Stop Switch .......... 20 Diagram ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 10 Gauge Connection ................................................................4 Battery Cables....................................................................... 10 Accessory Relay Connection ............................................................................................................................................................................................................23 Adaptor Harness for Power Trim Pump—DTS..................................................5 Boat Harness and Installation Connections...................3 Batteries........................................................................................................................................................................................................24 DTS Information and Installation........................................................ 9 Optional E Stop ...............................................................7 ELECTRICAL SYSTEM SECTION 7 ......................................................24 Data Harness ......................................................................................................................................................................................................................................................................................................... 14 Transom Ground Connection ............................................... 10 Warning Horn ................................ 10 CAN P (CAN 1) Connections ................................................................................................ 4 Battery.................................................................................................................... 13 Transom Harness—DTS .................................

... 31 Installing DTS Command Module and Harness ‑ Dual Engine................................................................................................................................................................................................................................................................. 27 Data Harness Pulling Procedure.........................................................................................7 Data Harness Installation.............. 35 Analog Gauge Interface (AGI) Installation..............................................................29 Single Helm .....................................................................30 Harness Installation ...........................................................................................................27 Connecting 14 Pin Data Harness ‑ Single Engine........................................ 35 Configuring Analog/Digital Tachometer Signal through PCM............................................................................................................................................. 28 Dual Helm ...........................................36 PCM Configuration with CDS ............................................................................................................................................ 32 Module Installation .............ELECTRICAL SYSTEM SECTION .................................................................................................................................................. 30 Installing DTS Command Module and Harness ‑ Single Engine... 34 Analog Gauge Interface (AGI)................................................................ 29 Dual Helm ................................................................................................................................................................................................................................. 28 Single Helm ..................................................................................................................... 36 Page 2 / 38 90-899883178 NOVEMBER 2007 .................................................................................................................................................................................................................................................................................................................................................................................................................................................. 29 DTS Command Module and Harness Installation........................................32 Harness Installation ....................................... 28 Connecting 14 Pin Data Harness ‑ Dual Engine......................................................................................................... 30 Module Installation ..............................

4618 General Information • • • • Fuel injected MerCruiser engine models are "SmartCraft" ready and may be rigged using the SmartCraft instrumentation. If SmartCraft instruments and analog instruments are desired on the same boat. 6. MerCruiser has developed three methods to facilitate compliance with ABYC recommendations. These come in the form of one standard production and two accessory kits. 4. an analog gauge interface (AGI) adapter to power the analog gauges. An accessory kit is available to provide accessory power up to 40 amps. A separate harness is required to connect the control or dash mounted power trim switch to the power trim pump. Ensure that the 14‑pin boat harness is the correct length to properly route from the boat dash to the locking 14‑pin electrical connector on the engine. Up to 15 amps of accessory power can be supplied through the 14‑pin wiring harness. It must be connected to the switched side of the battery switch. Prevents damage to DTS data harness. the power trim pump may not be connected to the continuously energized circuit (battery). A remote control can have a lanyard stop switch and will connect directly to the boat harness or a separate stop switch can be installed and connected to the boat harness c. The remote control must be compatible with MerCruiser applications b. Power Trim Electrical Connection NOTE: ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. • Boat Harness and Accessories Information Refer to the Mercury Precision Parts and Accessories Guide or the OEM Rigging and Accessories Guide for part number information 1. A power trim switch can be part of the remote control or a separate dash mounted power trim switch can be installed. A key switch assembly plugs into the 14‑pin boat harness (both 3‑position and 4‑position available) 5. Wire length requirements and location of circuit protection are also specified. If an adapter is used the accessory current through the boat harness is limited to 15 amps even if the boat has a 10 pin harness that in the past has been capable of handling larger accessory loads. 2. 90-899883178 NOVEMBER 2007 Page 3 / 38 . The SmartCraft data is carried in the 14 pin system without the use of a special data harness.7 ELECTRICAL SYSTEM Special Tools Data Cable Puller 91‑888462A1 Attaches to end of DTS data harness to aid in pulling harness through boat. (Do not use the connector in the 14‑pin boat harness labeled power trim. Adapters have been made to adapt a 14 pin connector engine to a 10 pin connector boat and from a 14 pin boat to a 10 pin engine. or a combination of both.SECTION . SmartCraft data is not supported across the adapters so a separate CAN line will be needed on a boat using SmartCraft instrumentation and an adapter harness. Select a remote control assembly a. An analog gauge dash harness or a SmartCraft junction box plugs into the 14‑pin boat harness 3. This connection is for outboard only) 7. (See ABYC for additional information) ABYC further recommends: if a boat is equipped with a battery switch. analog instrumentation.

Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery. provided with circuit protection within 7 inches of the power source or ii.ELECTRICAL SYSTEM SECTION . 1000 mca or 180 AH Battery Cables Select proper size positive (+) and negative (‑) battery cables. This will require the use of an accessory kit. IMPORTANT: Engine electrical system is negative (‑) ground. • The battery should have a capacity rating of at least: Engine (Cyl. • Add the positive (+) and negative (‑) battery cable lengths together. sheathed the entire length of wire from the point of connection to the source and the circuit protection device. Using the following chart. Refer to regulations for your area. 950 mca or 180 AH 800 cca./Type) V6 and V8 MPI models V8 DTS models Minimum Required Cranking Battery Size 750cca. IMPORTANT: It is recommended (required in some states) that battery be installed in an enclosed case. 2. IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Select a battery that meets all of the following specifications: • 12‑volt marine type cranking battery • Deep cycle batteries are not recommended for cranking applications • Tapered post connectors or side terminal connectors. Provided with circuit protection within 40 inches of the point of connection with the power source. • Spray terminals with a battery connection sealant to retard corrosion. BIA. battery should be located as close to engine as possible. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: Do not use a battery with wing nut connectors. federal standards and Coast Guard regulations must be adhered to when installing the battery. • Battery cables should always be tightened with a wrench. 1.). Do not use acid flux solder as it may cause corrosion and a subsequent failure. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: The red current conductor (for the trim pump) must be: a. Part Number 8M2000587 8M2000588 Description Cable Assembly – Trim Pump Cable Assembly – Trim Pump Color Red Red Length 72 inches 40 inches Type Fused Sheathed Batteries Battery IMPORTANT: Boating industry standards (NMMA. Use electrical grade (resin flux) solder only. ABYC. • Divide by 2 to obtain the average cable length. Connected to the switched side of the battery switch and either: i.7 1. Page 4 / 38 90-899883178 NOVEMBER 2007 . etc.

blower. 2 battery banks.5 ft. 120 amps (maximum alternator output). 2. 2 charging sources. NOTE: Sure Power Industries Inc. 1.3m (6 ‑ 7.9 ‑ 3. either engine's alternator could be charging either bank of batteries through the Model 32023A battery isolator. Relay kits are available to provide additional accessory power at the helm. 4.8m (3. In an emergency.SECTION . 90-899883178 NOVEMBER 2007 Page 5 / 38 . This maximum is fuse‑protected and must be observed. Boat Wiring NOTE: Twin engines are treated as two single engines in the same boat. Do not operate engines with switches in BOTH or ALL position. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.6m (12 ‑ 15 ft. another engine's battery can be used to start an engine with a dead battery.) 1.8 ‑ 2.) 3.5 ft. The Model 32023A battery isolator is connected to 2 banks of batteries. 5. No twin engine disconnect is required.7 ‑ 4. The Model 32023A battery isolator is designed for this type of use. the maximum accessory power available on the 14‑pin wiring harness is 15 amps. pumps.7m (9..) 2.1m (3.5 ft.3 ‑ 2.) ELECTRICAL SYSTEM Cable Gauge 25 mm2 (4) 35 mm2 (2) 50mm2 (1) 50mm2 (0) 70mm2 (00) 95mm2 (000) 120mm2 (0000) Both positive (+) and negative (-) cables Multiple MPI Engine Battery Information Batteries: Boats with multi‑engine MPI power packages require each engine be connected to its own battery. If the fuse opens. the engine will stop and will not restart until the fuse is corrected. Generators: The generator's battery should be considered another engine's battery. or any other electrical device using the engine wiring harness for power). Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.) 4.1 ‑ 1. The boat may have 2 engines connected to a single Model 32023A battery isolator.8m (15 ‑ 19 ft. When the engines are operating. The second battery in each bank is connected in parallel to the cranking battery.5 ‑ 9. stereo. Boat Harness and Installation Connections Engine Harness and Accessory Power Supply If the engine harness is used to supply power for boat accessories (lights.5 ‑ 6 ft. 6. Model 32023A meets this design specification. This ensures that the engine's Electronic Control Module (ECM) has a stable voltage source.9m (7. Battery isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. Battery switches: Battery switches should always be positioned so each engine is operating off its own battery.) 2.6 ‑ 5.7 Cable Length Less than or equal to 1. 3.) 1.. Any other manufacturer's battery isolator that is the same type as the Sure Power Inc. Model 32023A could also be used.5 ‑ 12 ft.

Page 6 / 38 90-899883178 NOVEMBER 2007 . Use the proper length harness from the Y to the lower station. Use the Y‑adapter to connect the upper and lower stations. use the extension harness from the engine to the lower station.7 SINGLE STATION 25043 DUAL STATION 25041 • • • • On dual helm installations. Use the proper length harness from the Y to the upper station.ELECTRICAL SYSTEM SECTION . 25132 Y‑adapter for dual helm installations Boat Harness Installation Guidelines—MPI Sterndrive BOAT HARNESS DEUTSCH CONNECTOR TO ENGINE Select the boat harness by length.

90-899883178 NOVEMBER 2007 Page 7 / 38 . 25045 25044 Typical four position key switch (off/accessory/run/start) NOTE: When installing the ignition verify that the drain hole in the barrel of the switch is positioned downward for proper drainage. both key switches used must be modified to operate independently. IMPORTANT: Cutting the black / yellow stripe wire disconnects the E stop circuit incorporated in the the key switch.) 7. A mounting bezel is not available for the three position key switch.SECTION .8 m (29 ft.) 6. IMPORTANT: For dual helm installation. The key switches must operate independently. a key switch is used at the upper and lower station. 3.) 12. 25046 Typical three position key switch (off/run/start) 2.7 Boat Harness Length of the Boat Harness 61 cm (02 ft.) Boat Harness and Key Switch Three Position (off/run/start) 84‑896537 K02 84‑896537 K15 84‑896537 K20 84‑896537 K24 84‑896537 K29 84‑896537 K40 ELECTRICAL SYSTEM Boat Harness (key switch is not included) 84‑896537 A02 84‑896537 A15 A84‑896537 20 84‑896537 A24 84‑896537 A29 84‑896537 A40 NOTE: Extension harnesses are available if longer length is needed.0 m (20 ft. KEY SWITCH CONNECTOR 1. NOTE: 899203A01 Decal and washer kit is available for the three position key switch if needed. The four position key switch is available with mounting hardware.3 m (24 ft.) 8.) 4. For dual helm installation.6 m (15 ft.2 m (40 ft.

A Y‑harness is available with adapters to connect the dual helm power trim harnesses together to connect to the power trim pump. DTS models do not need the separate trim harness. Connect the black wire and the black/yellow stripe wire eye terminals to a momentary switch. Cover cut wire ends with heat shrink tubing. MerCruiser models require a separate trim harness from the trim control to the power the trim pump connection.Black/yellow stripe wire with eye terminals. cut the black / yellow stripe wire at each key switch and cover both open wire ends with heat shrink tubing. Cut the black wire at the key switch and cover the cut wire at the key switch with heat shrink tubing. the black wire and black/yellow stripe wire can be clipped at the key switch and connected to a normally open momentary button switch. a 25136 Typical key switch a .Momentary switch TRIM SWITCH The trim switch connection is only used on Mercury outboards. a d b c 25137 Typical key switch with momentary "stop" switch for MPI models a . Page 8 / 38 90-899883178 NOVEMBER 2007 . c. d . b. 5. Install an eye terminal on the black/yellow stripe wire from the connector side.ELECTRICAL SYSTEM SECTION . d. 6. rocker style or toggle switch could be utilized to create the "stop" switch. If both station key switches are in the "run" position the engine cannot be turned off with the key switch and the lanyard stop switches will not function. To modify the key switches.Black/yellow stripe wire IMPORTANT: The key switch at the station being used should be the only key switch in the "run" position. Any marine momentary push button.7 4. 7.Black wire with eye terminals c . To Install a momentary "stop" switch: a. If a momentary stop switch is added. Install an eye terminal on the black wire from the connector side.Eye terminals connected to momentary switch b . Cover cut wire ends with heat shrink tubing. the "stop" switch will override the key switch and the engine will shut off when the stop switch is activated. If a stop button is desired on a dual helm installation. Label the switch on the dash after installation.

On dual‑helm installations. If a lanyard stop switch is not used. the lower and the upper station controls need a neutral safety switch. 25166 Power trim adapter harness For dual helm installation. ECM. or ignition system is interrupted and the engine is shut off. 90-899883178 NOVEMBER 2007 Page 9 / 38 . the circuit is opened and the power to the engine. 25171 25172 Power trim Y‑harness Power trim adapter harness NEUTRAL SWITCH The neutral switch connects to the remote control. (The original hog nose Y‑harness).SECTION . these two wires must be plugged together for the engine to run. 25168 Power trim extention harness An adapter connects the Y‑harness to the power trim pump. use a power trim extention harness from the upper and lower helm to a Y‑harness. or an E stop switch is used. When the lanyard is pulled and the switch is tripped. LANYARD STOP SWITCH PPL and PPL/WHT wires are connected together through a normally closed stop switch.7 ELECTRICAL SYSTEM Use the power trim adapter harness for the single helm harness connection the remote control to the power trim pump.

(Another horn is also supplied with the engine for those using custom wiring systems. The black and black/yellow wires are connected together through a lanyard switch that is normally open. This multiplies out on dual engine and dual helm applications as long as the power wires to the helm are adequate to carry the total current demand.ELECTRICAL SYSTEM SECTION . the wires should be kept separate and capped. This location will power up with the key in the "run" position only. When this connection is not used. Page 10 / 38 90-899883178 NOVEMBER 2007 . 25048 Relay With Power Harness ADDITIONAL RELAY KIT An additional 40‑amp relay kit can be installed and connected to a junction box at the dash gauge connection location. If SmartCraft instrumentation is used. WARNING HORN The audio warning horn and connections are included with the Mercury harness assemblies. If the fuse is blown. connect to a a SmartCraft junction box. 25144 Accessory relay harness GAUGE CONNECTION The gauge connection of the boat harness connects to the analog gauge harness. When the lanyard is pulled and the switch is is tripped.7 OPTIONAL E STOP The E stop lanyard switch connection is used on Mercury outboards and can be used on MerCruiser MPI engines. The key switch will power‑up the relay in the "accessory" position and "run" position. The use of both relay kits will result in a maximum of 80 amps of key controlled power at the helm.) ACCESSORY RELAY CONNECTION Accessory relay kit connection. This harness is fuse protected on the engine with a 15‑amp fuse on the engine. The 14-pin wiring system is able to provide up to 15 amps of accessory power to the helm through the purple wire (key controlled) or the red wire (constant on) circuit. An accessory relay kit connected to this location can provide up to 40 amps of accessory power. the circuit will close and ground the ECM to shut the engine off. the engine will not start or continue to run.

6 m (15 ft. unless the SmartCraft and an AGI kit are used.5 m (5 ft. The AGI harness connects to the junction box along with the SmartCraft connection. h i j f e d c b a g 25052 abcde- Analog gauge harness Connector to boat harness Trim Tach Key on (+) Temp fghij- Oil Ground (–) Can (+) or spare Can (–) or spare 12V (+) 90-899883178 NOVEMBER 2007 Page 11 / 38 .SECTION . IMPORTANT: The AGI requires setting the tachometer signal to digital with CDS or DDT.0 m (10 ft. the oil pressure sender and the cooling temperature sender must be changed to special dual‑helm senders. AGI (Analog Gauge Interface) Length of the Harness 1. an AGI (analog gauge interface) kit is used to provide analog instrumentation.) 4.) Analog Gauge Harness (14 pin) 84‑892990T01 84‑892990T10 84‑892990T15 IMPORTANT: On dual‑helm installations.7 ELECTRICAL SYSTEM If a combination of SmartCraft and analog is used.) 3.

• If the boat is dual engine and dual helm.14‑pin engine connection Page 12 / 38 90-899883178 NOVEMBER 2007 . The jumper harness is installed at the upper station.10‑pin boat harness connection b .7 A system link adapter can be used to connect SmartCraft link gauges without a System Gauge (requires resetting tach signal to digital with CDS or DDT) fuel tank and trim gauge setting will be defaulted. Leave the protective cap in place.ELECTRICAL SYSTEM SECTION . GENERAL REPOWER INFORMATION Harness adapters are used for installing 14‑pin engines into boats with 10‑pin wiring harnesses and 10‑pin engines into boats with 14‑pin wiring harnesses. the terminator resistor is removed and a jumper harness connects the CAN P (CAN 1) lines together so that the engines will share SmartCraft data. There is no provision with link gauge to calibrate these gauges. 25147 System Link SC 100 adapter CAN P (CAN 1) CONNECTIONS CAN P (CAN 1) connection with a terminator resistor in place: • If a this is a dual engine and the SmartCraft instrumentation is used. 25149 Two pin link harness—CAN CAN V (CAN 3) CONNECTION CAN V (CAN 3) connection is not currently used by MerCruiser. • The resistors on the engines are the required terminator resistors for the SmartCraft‑equipped dual engine applications. the terminator resistor at the lower helm is removed from the connector. a b 25054 14‑pin engine to 10‑pin boat wiring harness 25054 a .

Connections made before the engine is installed are: • Mercathode connection • Trim connections • Ground connection 90-899883178 NOVEMBER 2007 Page 13 / 38 .7 ELECTRICAL SYSTEM NOTE: The adapter used with 10‑pin engine to 14‑pin boat wiring harness includes a 15‑amp fuse.14‑pin connector b .10‑pin engine connection c .50‑amp circuit breaker Part Number 84‑859743T03 Qty. a c b 25055 10‑pin engine to 14‑pin boat wiring harness a . boat accessories may need to be rewired to meet the new amperage load limitation. and paddle wheel harness TRANSOM HARNESS—MPI This transom harness is designed so that connections can be made after the transom is installed in the boat but before the engine is installed. • Accessory kits are available to provide additional amperage to the helm. a separate CAN (blue data cable) harness is required for SmartCraft instrumentation. The new harness is needed to replace the original harness for any 10‑pin engine installation using SmartCraft fuel level or paddle wheel. auxiliary tank. a f b c e d 25150 Typical MPI engine a . • The fuel tank. and paddle wheel harness has been changed on MerCruiser to match the harness used by Mercury Outboard.15‑amp fuse For repower of the original 10‑pin engines with the 14‑pin engines: • If adapters are used.DLC and depth transducer connector d . 1 Description Fuel tank.SECTION .14‑pin boat harness connection b . Remove the terminator resistor on the engine and connect the CAN harness • If a 14‑pin engine (limited to 15 amps of current draw) is installed into a 10‑pin wired boat. auxiliary tank.Standard terminator resistor (remove and connect CAN harness if necessory for repower) f .16‑pin transom harness connector c .Fuel – paddle wheel connector e .

Trim gauge sender for digital gauges i .Trim gauge sender ground (black is common) g .DTS power trim harness connects to transom DTS harness Page 14 / 38 90-899883178 NOVEMBER 2007 . After the engine is in place.7 • SmartCraft sensor connections Secure the wiring and position the engine connector out of the way until the engine is installed.Transom ground (to the transom bonding screw) TRANSOM HARNESS—DTS DTS engines are shipped with an adapter to connect the transom harness to the power trim pump.Trim gauge sender (orange with white stripe is for analog gauges) f .MerCathode g . make the single connection between the transom and the engine.Transom ground (to the transom bonding strap screw) h . b a h 25155 c g f abcd- d e Transom harness—MPI 16‑pin connector to engine harness SmartCraft steering sensor SmartCraft petot sensor MerCathode e .ELECTRICAL SYSTEM SECTION .Trim gauge sender (orange with pink stripe is for digital gauges) h . b c d e f j g a i abcdeTransom Harness—DTS 16‑pin connector to engine harness Power trim connects to power trim harness (color coded) SmartCraft steering sensor SmartCraft pitot sensor Trim gauge sender for analog gauges h 25154 f .DTS power trim harness connects to power trim pump j .

Bonding strap screw b . NOTE: In some cases. This ground wire is not needed with the transom harness.SECTION .7 ELECTRICAL SYSTEM TRANSOM GROUND CONNECTION The ground wire for the transom is incorporated into the transom harness included with the engine. Use the ground studs on the flywheel housing for other grounding needs.Ground wire from transom harness 90-899883178 NOVEMBER 2007 Page 15 / 38 . a ground wire to connect to the flywheel housing may be attached to the bonding screw on the transom.but can be connected to the flywheel housing or removed. a b 25173 Ground wire from the transom harness to the transom bonding strap screw a . Do not connect any other ground wires here. In any case the grounding wire in the transom harness must be connected to the bonding strap screw. Connect the ground wire in the transom harness under the bonding strap screw on the transom.

ELECTRICAL SYSTEM SECTION .7 Wiring Diagrams Transom Harness—MPI a C B A BLK-PNK PNK-DK BLU L R GRA-BLK BLK-PNK GRA-BLK R A C B b L WHT-LT BLU c 1 ORN-PNK A B C D E F G H J K L M N P R S GRA-BLK BLK-PNK WHT-LT BLU PNK-DK BLU ORN-PNK ORN-WHT ORN BRN BLK BLK L R ORN-WHT ORN BRN B A d e BLK 1 1 h 1 BLK g abcdSteering Pitot Analog trim Mercathode efgh- f 23812 Analog trim Ground Digital Trim 16 pin connector Page 16 / 38 90-899883178 NOVEMBER 2007 .

7 ELECTRICAL SYSTEM Transom Harness—DTS b BLK-PNK ORN-PNK GRA-BLK A C B a C B A BLK-PNK PNK-DK BLU L R GRA-BLK BLK-PNK GRA-BLK R A C B c L WHT-LT BLU d 1 A B C D E F G H J K L M N P R S GRA-BLK BLK-PNK WHT-LT BLU PNK-DK BLU ORN-PNK ORN-WHT ORN BRN BLK BLK L R ORN-WHT e ORN BRN B A BLK 1 f GRN DK BLU BLK 1 PPL k 1 1 1 g j abcdef- 23810 i h ghijkGround Trim down Relay power Trim up 16 pin connector Steering Digital trim Pitot Analog trim Mercathode Analog trim 90-899883178 NOVEMBER 2007 Page 17 / 38 .SECTION .

7 Boat Harness DRAWING 2 7 1 11 10 4 3 8 5 9 1234514‑pin Deutsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 .Warning horn 8 .Accessory relay connection (15‑amp) 9 .CAN P (CAN 1) with resistor cap 11 .Lanyard (outboard) or E Stop connection 12340 6 7 .ELECTRICAL SYSTEM SECTION .Gauge connector/CAN connector for SmartCraft 10 .CAN V (CAN 3) with weather cap Page 18 / 38 90-899883178 NOVEMBER 2007 .

NOTE: The lanyard stop switch (PPL and PPL/WHT wires) breaks power to the ECM or ignition to stop the engine. Wires must be separate unless connected through E Stop Switch. The switch is normally open. The switch is normally closed until activated. Therefore the PPL and PPL/WHT wires must be connected together if Lanyard Stop Switch is not used. on purple wire (switched) and the red wire (continuous power). or if the E Stop Switch is used. Up to 15 amps total accessory power can be provided.SECTION . the circuit closes when switch is activated. An accessory relay kit can be used for loads up to 40‑amps.Lanyard (outboard) or E Stop connection 78910 11 - Warning horn Accessory relay connection (15‑amp) Gauge connector CAN P (CAN 1) with resistor cap CAN V (CAN 3) with weather cap NOTE: Dual engines are treated as two singles in the same boat and are not connected together. NOTE: E Stop Switch (BLK and BLK/YEL wires) connects ground to ECM to stop engine.7 ELECTRICAL SYSTEM DIAGRAM A B A B ORG GRN WHT DKBLU 11 A B A B 10 RED BLK ORG GRN PPL GRY YEL WHT DKBLU PPL_WHT BLK RED A B C D E F G H J K A B C 9 8 7 1 1 PPL 1 BRN 5 1 PPL_WHT PPL A B C D E F G H J K L M N P GRN YEL_RED GRY BRN YEL GRN_WHT BLU_WHT DKBLU WHT ORG BLK_YEL PPL BLK RED BLK BLK_YEL BLK BLK 1 6 1 PPL 1 YEL_RED YEL_RED 1 4 1 RED RED BLU_WHT GRN_WHT RED BLK PPL_WHT PPL BLK_YEL YEL_RED 3 2 12339 A B C A B C D E F 12345- 14‑pin Deutsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 . Refer to the MerCruiser Parts and Accessory Guide or MerCruiser Rigging Guide 90-899883178 NOVEMBER 2007 Page 19 / 38 .

ELECTRICAL SYSTEM SECTION .7 Analog Gauge Harness DRAWING 8 9 10 2 3 4 5 6 7 12312 1 12345- Connector to boat harness Trim Tach Key on (+) Temp 678910 - Oil Ground (–) CAN (+) or spare CAN (–) or spare 12V (+) DIAGRAM BRN_WHT 2 3 4 5 6 7 GRY PPL A B C D E F G H J K DK_BLU WHT BRN_WHT GRY PPL TAN LTBLU BLK RED TAN LTBLU BLK 1 WHT 8 9 10 12318 DK_BLU RED 12345- Connector to boat harness Trim Tach Key on (+) Temp 678910 - Oil Ground (–) CAN (+) or spare CAN (–) or spare 12V (+) Page 20 / 38 90-899883178 NOVEMBER 2007 .

Connection to trim pump 12323 c .SECTION .Connections to trim limit switch 90-899883178 NOVEMBER 2007 Page 21 / 38 .Connection to control box b .7 ELECTRICAL SYSTEM Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly) a b c a .

7 b A C1 B DK BLU-WHT RED GRN-WHT RED 3 1 C2 4 2 PPL-WHT DK BLU-WHT a 1 T2 T1 c a .Connections to trim limit switch Page 22 / 38 90-899883178 NOVEMBER 2007 GRN-WHT C .ELECTRICAL SYSTEM SECTION .Connection to control box b .Connection to trim pump 1 12322 c .

7 ELECTRICAL SYSTEM Power Trim System BLU/WHT BLK GRN/WHT RED BLK a RED/PPL b c BLU/WHT RED BLK e YEL/RED YEL/RED RED/PPL GRN/WHT PPL/WHT BLU/WHT GRN/WHT d g f BLU/WHT h BLK BLK 7866 abcd- 20 A fuse Ground bolt (floor mount) UP solenoid DOWN solenoid e .Neutral switch to instrument wiring harness h .SECTION .Y‑harness (optional) g .Trim limit switch 90-899883178 NOVEMBER 2007 Page 23 / 38 BLK .110 A fuse f .

7 Adaptor Harness for Power Trim Pump—DTS a A B C PPL DK BLU GRN a .Not used on DTS 14‑Pin Engine Harness Connector Mechanical 14‑Pin Connector Pin‑Out Pin A B C D E F G H J K L M N P PINK BLACK PURPLE DK GREEN/YELLOW DK BLUE WHITE LT BLUE Open Open ORANGE/WHITE BROWN/DK BLUE GRAY/WHITE YELLOW/BLACK TAN Wire Color + 12 Volt Ground (‑) Wake E‑Stop Analog oil pressure CAN 1+ CAN 1‑ Spare Spare Analog trim position Audio warning horn Tachometer/Link gauge Crank Analog coolant temperature Function DTS Information and Installation Special Tools ‑ DTS Installation Data Cable Puller 91‑888462A1 Installation Guidelines for DTS System Components ! WARNING Splicing or probing will damage the wire insulation allowing water to enter the wiring. Page 24 / 38 90-899883178 NOVEMBER 2007 . do not splice or probe into any wire insulation of the DTS system.To transom DTS harness d .To transom DTS harness 1 1 d 23809 b c 1 c .To power trim pump b . Water intrusion may lead to wiring failure and loss of throttle and shift control.ELECTRICAL SYSTEM SECTION . To avoid the possibility of serious injury or death from loss of boat control.

CCA. 90-899883178 NOVEMBER 2007 Page 25 / 38 .2 pin cap DTS Battery Specifications IMPORTANT: Do not use deep cycle batteries for the main engine starting battery. CONNECTORS IMPORTANT: Connectors should never have to be forced into the receptacle. Typical weather caps are as follows: 4958 a a . etc.10 pin cap b . Do not pull on cable connectors when pulling cables through the boat. IMPORTANT: It is recommended (required in some states) that the battery be installed in an enclosed case. ABYC. it will only take a small amount of pressure to insert it into the receptacle. If a data harness is too short. Do not allow cables to flex at connection points. or Ah specification that will be equal to or greater than the SAE Standard J537 specified previously. ratings and physical battery sizes will vary.7 ELECTRICAL SYSTEM DATA HARNESS ! WARNING Prevent serious injury or death from a loss of boat control. Pulling on or flexing connectors can loosen terminals and cause open or intermittent electrical connections. Ensure that connectors are free of any lubricant or dielectric grease before installation. IMPORTANT: Boating industry standards (BIA. federal standards and Coast Guard regulations must be adhered to when installing the battery. Weather Caps Weather caps are to be used whenever there are any unused connectors on a harness. do not connect multiple harnesses together to make up the required length.).SECTION . For installations requiring a data harness length longer than 12.) of any connection. Rotate the locking collar to secure the electrical connection. which will interrupt control of throttle and shifting.).5 pin cap b c d c . Verify all connections are tight to prevent moisture or corrosion occurring inside the connections. Check with the manufacturer for a starting battery with a MCA.2 m (40 ft. contact Mercury Marine for more information. Refer to regulations for your area. Fasten all electrical harnesses within 25. When the connector is properly aligned. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. NOTE: Connect only one data harness of the required length between the engine and helm.3 pin cap d . Minimum SAE Starting Battery Requirements ‑ BCI GRP 24 MCA CCA Ah 1000 800 180 (International Rating) NOTE: Due to the wide variety of battery manufacturers throughout the world.4 cm (10 in.

or 180 Ah. Spray terminals with a battery connection sealant to help retard corrosion. Mount in an area that is accessible for troubleshooting and servicing the system. in. Ensure the DTS command module harness will reach all the connection points. it is recommended that the junction box be mounted in an area that stays relatively dry. it is recommended that an auxiliary battery or batteries be installed. Metric hex nuts not supplied. rating. 800 CCA. hex nut are supplied per battery for wing nut replacement. Description Hex nuts Nm 13. hex nuts must be used to secure battery leads to battery posts. If your boat application requires additional battery loads for boat accessories or marine electronics. and one 3/8 in. Page 26 / 38 90-899883178 NOVEMBER 2007 .) IMPORTANT: Battery cable size and length is critical.5Nm (120 lbs. IMPORTANT: Battery cable size and length is critical. 37-895387 Place decal on or near battery box for future service reference. Refer to engine installation manual for size requirements. One 5/16 in. leading to serious injury or death due to loss of boat control. ft.DTS & Optimax Engines DO NOT USE DEEP CYCLE BATTERIES! DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA. When connecting engine battery. NOTICE .) of the junction box. Refer to Battery Cable Size tables or engine installation manual for size requirements.7 IMPORTANT: For DTS products. 120 lb. Metric hex nuts are not supplied. Decal needs to be placed on or near battery box for future service reference.ELECTRICAL SYSTEM SECTION . 13. 3486 Junction Box (if Equipped) • • • • • Although the junction box connections are watertight. ! WARNING Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS) system.5 lb. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Fasten all junction box connections within 25. Torque nuts to specifications. each engine must be equipped with its own starting battery. DO NOT USE WING NUTS. Secure the battery leads to the battery posts with hex nuts to avoid loose connections. Mount in an area where the wiring connection will not get stepped on or disturbed. in.4 cm (10 in.

3. or radios. Minimum bend radius should be 7.Weather cap (859318T 2) c . IMPORTANT: Avoid sharp bends in the data harness. Secure pulling tool with two cable ties.7 ELECTRICAL SYSTEM • Seal all unused connections with weather caps. b a d c e 29220 a . 3836 Data Cable Puller 91‑888462A1 IMPORTANT: Carefully inspect data harness pins to ensure all pins are securely fastened to data harness connector end following installation. high power VHF coax. hot surfaces.25. IMPORTANT: The cable ties must be tight to prevent any slipping during installation.DTS command module harness Data Harness Installation Data Harness Pulling Procedure IMPORTANT: Do not route data harness near engine ignition components (coils. Fasten cables away from any sharp edges. 2.) for the final wiring installation. and spark plugs). fasteners.SECTION . IMPORTANT: Do not route data harness near sharp edges. Install cable pulling tool to data harness. NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.4 cm (10 in. or objects that could wear into the harness.6 cm (3 in. An electrical field generated from these components could cause interference with data transmission.Junction box d .) e . or moving parts. 90-899883178 NOVEMBER 2007 Page 27 / 38 .Clamp b . spark plug leads. 1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs that could cut the harness.

Clamp or cable tie DUAL HELM b a c d e a .Dual helm adapter (Y harness) e .7 Connecting 14 Pin Data Harness ‑ Single Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness.14 pin data harness b .Helm 2 (upper helm) ‑ auxilary c .Helm 1 (lower helm) ‑ primary 3682 d .6 cm (3 in.).14 pin data harness b .Clamp or cable tie Page 28 / 38 90-899883178 NOVEMBER 2007 .ELECTRICAL SYSTEM SECTION . Minimum bend radius should be 7. b a 3619 a .

).Helm 1 (lower helm) c .Clamp or cable tie DUAL HELM a c b c d e a .14 pin data harness 3977 b .6 cm (3 in.Dual helm adapter (Y harness) e .14 pin data harness 3978 d .Clamp or cable tie 90-899883178 NOVEMBER 2007 Page 29 / 38 . Minimum bend radius should be 7.SECTION .7 ELECTRICAL SYSTEM Connecting 14 Pin Data Harness ‑ Dual Engine SINGLE HELM IMPORTANT: Avoid sharp bends in the harness.Helm 2 (upper helm) b . a b a .

Clamp or cable tie Page 30 / 38 90-899883178 NOVEMBER 2007 . Fasten and support the harness with clamps or cable ties along the routing path.ELECTRICAL SYSTEM SECTION .DTS command module harness b . a b 3622 Single Helm Application a . Make sure all connections are tight and seal all unused connectors with weather caps.7 DTS Command Module and Harness Installation Installing DTS Command Module and Harness ‑ Single Engine HARNESS INSTALLATION • • • • Locate a routing path for the harness connections so they reach their installation points. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness.

Ensure the wiring harness connected to the command module will reach all the connection points. blue (CAN P and CAN X) MODULE INSTALLATION • • • • Although the Command Module connection is watertight. Mount in an area where the wiring connection will not get stepped on or disturbed. a c Terminator CAN 1 Terminator CAN 2 e f d h g b c d 3677 abcd- Dual Helm Application Helm 2 (upper helm) Helm 1 (lower helm) DTS command module harness Clamp or cable tie efgh- CAN P (CAN 1) connector CAN X (CAN 2) connector Weather caps Terminator resistors. and seal connectors with weather caps.SECTION . Mount in an area that is accessible for troubleshooting and servicing the system. 90-899883178 NOVEMBER 2007 Page 31 / 38 .7 ELECTRICAL SYSTEM NOTE: For dual helm application ‑ Remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm closest to the engine). it is recommended that it be mounted in an area that stays relatively dry.

7 • Mounting the Command Module with the supplied rubber grommets/bushings to minimize vibration. Page 32 / 38 90-899883178 NOVEMBER 2007 .DTS Command Module Installing DTS Command Module and Harness ‑ Dual Engine HARNESS INSTALLATION • • • Locate a routing path for the harness connections so they reach their installation points. Fasten and support the harness with clamps or cable ties along the routing path. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness. a 3939 a .ELECTRICAL SYSTEM SECTION .

SECTION .Clamp or cable tie e .CAN P (CAN 1) connectors e 3689 d . c a Terminator CAN 2 Terminator CAN 1 b Terminator CAN 2 c Terminator CAN 1 d Single Helm Application a .7 ELECTRICAL SYSTEM • Make sure all connections are tight and seal all unused connectors with weather caps.DTS command module harness 90-899883178 NOVEMBER 2007 Page 33 / 38 .CAN link harness b .CAN X (CAN 2) Terminator resistors ‑ do not remove c .

Helm 1 MODULE INSTALLATION • • • Although the Command Module connection is watertight. Page 34 / 38 90-899883178 NOVEMBER 2007 .DTS Command Module harness e .Helm 2 d . Mount in an area where the wiring connection will not get stepped on or disturbed.ELECTRICAL SYSTEM SECTION .CAN link harness c . it is recommended that it be mounted in an area that stays relatively dry.Weather caps b . b c e a d 2 f d 1 4079 Dual helm application a . Mount in an area that is accessible for troubleshooting and servicing the system.Termination resistors ‑ do not remove from helm 2 f . and seal connectors with weather caps.7 NOTE: For dual helm application ‑ Remove CAN P (CAN 1) and CAN X (CAN 2) terminator resistors from helm 1 (helm closest to the engine).

2. 2 helms maximum. Tape back any unused terminals. Secure connections per gauge manufacturers specifications. mount the AGI module securely under dash or helm in close proximity to gauges being used. Route and secure all wires and harnesses away from hot or moving parts. 1. and tape back any unused terminals.SECTION . use 3 pin System Link connection on AGI harness. For SmartCraft System Link gauges. With screws and washers supplied in kit.7 ELECTRICAL SYSTEM • Ensure the wiring harness connected to the command module will reach all the connection points. For analog gauges. The AGI system can support 10 System Link gauges per helm. use ring terminals on AGI harness to connect to analog sender inputs on gauge backs.DTS Command Module Analog Gauge Interface (AGI) Analog Gauge Interface (AGI) Installation NOTE: This Analog Gauge Interface (AGI) can only be used with the 14 pin Digital Throttle and Shift (DTS) system to drive analog and/or SmartCraft System Link gauges. a 4080 a . IMPORTANT: Mount AGI module with wires coming out of potting facing downward to prevent moisture from collecting at base of wires and wicking into module. Analog Gauge Type Tachometer Oil Pressure/Oil Level Water Temperature Trim Positions AGI Harness Wire Color Gray Blue Tan Brown/White 90-899883178 NOVEMBER 2007 Page 35 / 38 . Refer to the following table for AGI harness wire color/analog gauge sender input connections.

ELECTRICAL SYSTEM Analog Gauge Type Fuel Level AGI Harness Wire Color Pink/Black

SECTION - 7

a

b

c

GRY PNK/BLK BRN/WHT TAN BLU

d

f
a - AGI module b - 14 pin connection c - AGI harness

e

3688

d - Analog gauge terminal connections e - System Link 3 pin connection f - 10 pin CAN data connection

3. Route and connect wire from key switched 12 volt positive power source to analog gauges. Secure connections per gauge manufacturers specifications. 4. Route and connect ground wire from analog gauges to a common ground. Secure connections per gauge manufacturers specifications. 5. Connect any SmartCraft System Link gauges to 3 pin System Link connection. The AGI system can support 10 System Link gauges per helm, 2 helms maximum. 6. Plug 14 pin AGI harness connection into AGI module. 7. Connect 10 pin CAN data harness connection on command module harness to AGI harness. a. If SmartCraft System View is not being used, plug 10 pin CAN data connection on AGI harness directly into 10 pin CAN data connection on command module harness. b. If SmartCraft System View is being used, a junction box and harness adaptor will be required. Plug 10 pin CAN data connection on command module harness, 10 pin CAN data connection on System View harness, and one end of harness adaptor into junction box. Plug 10 pin CAN data connection on AGI harness into other end of harness adaptor. Insulate any unused connection ports on junction box with weather caps.

Configuring Analog/Digital Tachometer Signal through PCM
IMPORTANT: The engine Propulsion Control Module (PCM) tachometer configuration factory default has been set to an analog. This will allow the operation of one analog tachometer. Depending on the desired use of analog/digital gauges, the PCM set‑up may have to be configured from analog to a digital. Following are optional uses of analog and digital gauges and the setting for the tachometer configuration in the PCM necessary to run them.
Gauge Configuration Analog Tachometer Only System Link Gauges used with System View, System Monitor, or System Tach System Link Gauges used in conjunction with System Link Adaptor Harness and Command Module Harness without the use of System View, System Monitor or System Tach AGI used with or without System View, System Monitor or System Tachometer, to run analog and System Link Gauges Analog Digital X X X

The Digital Diagnostic Tool (DDT) or Computer Diagnostic System (CDS) can be used to select analog or digital PCM tachometer configuration.

PCM CONFIGURATION WITH CDS
1. Attach CDS to engine. Refer to on‑line help if needed. 2. From Logon screen, navigate to Engine Select screen.

Page 36 / 38

90-899883178 NOVEMBER 2007

SECTION - 7

ELECTRICAL SYSTEM

3. 4. 5. 6.

From Engine Select screen fill in engine type information and select Tool Box. From Tool Box screen, select Active Diagnostics. From Active Diagnostics screen, scroll down and select Tach Link Config. To change PCM configuration from default of analog to digital, select Enable and then select Run. 7. To change PCM configuration from digital to analog, select Disable and then select Run.

90-899883178 NOVEMBER 2007

Page 37 / 38

ELECTRICAL SYSTEM

SECTION - 7

NOTES:

Page 38 / 38

90-899883178 NOVEMBER 2007

SECTION - 8

REMOTE CONTROLS

SECTION 8 - REMOTE CONTROLS
Table of Contents
Remote Control Installation..................................................................................................................................... 4 Locating and Drilling Mounting Area.................................................................................................................4 Installing DTS Panel Mount Control..................................................................................................................4 Installing DTS Single Handle Console Control..................................................................................................6 Installing DTS Dual Handle Console Control....................................................................................................9 Installing DTS Zero Effort Control...................................................................................................................12 Steering System Information................................................................................................................................. 14 High Speed Or Twin Engine Applications Steering Recommendation ...........................................................14 Steering Helm and Cable................................................................................................................................15 Steering Cable Specifications.........................................................................................................................16 Hydraulic (Helm) Steering...............................................................................................................................16 Sterndrive Shift Cable Information........................................................................................................................ 17 Propeller Rotation............................................................................................................................................17 Checking Alpha Shift Cable Installation and Adjustment................................................................................17 Bravo Sterndrive Shift Check (Engine Running).............................................................................................21 Troubleshooting Shift Problems......................................................................................................................22 DTS Remote Control ‑ Sterndrive...................................................................................................................25 DTS Calibration..................................................................................................................................................... 25 Special Tools ‑ DTS Calibration......................................................................................................................25 Methods of Calibration....................................................................................................................................25 Setting Trailer and Trim Limit................................................................................................................................ 25 Setting Trailer Limit with CDS.........................................................................................................................25 Setting Trim Limit with CDS............................................................................................................................26 Troubleshooting Procedure................................................................................................................................... 26 Troubleshooting Information............................................................................................................................26 Default Sensor Values ............................................................................................................................. 26 Fault Conditions ....................................................................................................................................... 27 Sticky/Non‑Sticky Faults .......................................................................................................................... 27 Engine Guardian ...................................................................................................................................... 27 Warning Horn Signals .............................................................................................................................. 27 Special Tools ‑ DTS Troubleshooting.............................................................................................................. 27

8

90-899883178 NOVEMBER 2007

Page 1 / 28

REMOTE CONTROLS

SECTION - 8

Lubricant, Sealant, Adhesives
Tube Ref No.
95

Description 2-4-C Marine Lubricant with Teflon

Where Used Shift cable end

Part No. 92-802859A1

Special Tools
Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1

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

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

Flushing Kit

91‑849996T 1

Use for flushing gearcases with low water inlets.
9195

Male to Male 10 Pin Adapter

84‑892452A01 Allows connection between CAN 1 communications cable and Computer Diagnostic System in applications where a junction box is not used. 84‑892663

4621

Can 1 Diagnostic Cable

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

Adapter Harness

84‑822560A13 Data link harness between engine and Computer Diagnostic System (CDS) or Digital Diagnostic Terminal (DDT).
5826

Page 2 / 28

90-899883178 NOVEMBER 2007

4679 90-899883178 NOVEMBER 2007 Page 3 / 28 . For additional information. or to order the Computer Diagnostic System contact: SPX Corporation 28635 Mound Rd. May be used with Computer Diagnostic System (CDS). 5974 Terminal Test Probe Kit SPX P/N MM‑46523 Test probes adapt test meter leads to harness connections without damaging harness terminals. MI 48092 or call: USA ‑ 1‑800‑345‑2233 Canada ‑ 800‑345‑2233 Europe ‑ 49 6182 959 149 Australia ‑ (03) 9544‑6222 SPX P/N MM‑46225 4520 Breakout Box Connects to Propulsion Control Module (PCM) to test engine circuits and components without probing wires. pricing. diagnostics. and calibration purposes. 8036 Adapter Harness 84‑822560A5 Data link harness between engine and Digital Diagnostic Terminal (DDT).SECTION . 7915 12 Volt Shunt Connector 889675A01 Connects to data harness allowing operation of the DTS system with the Digital Diagnostic Terminal. Warren. 4009 2 to 4 Pin Harness Adapter 84‑822560A12 Adapts the 2 pin Digital Diagnostic Terminal harness to the 4 pin connector on the engine. May be used with Computer Diagnostic System (CDS).8 Computer Diagnostic System (CDS) REMOTE CONTROLS Order through SPX Monitors all electrical systems for proper function.

Allow sufficient clearance for handle movement and clearance for the wiring. Page 4 / 28 90-899883178 NOVEMBER 2007 .8 H z TEMP mA V Hz mV OFF A IG IP TEMP Measures RPM.REMOTE CONTROLS DMT 2004 Digital Multimeter 91‑892647A01 SECTION . Select the correct template for mounting application. make sure opening is free of sharp edges. 2. Locate area of boat where the remote control is to be mounted. amperes. Ensure opening is free of sharp edges. 26744 3.Template Installing DTS Panel Mount Control 1. cut and drill as instructed on template. IMPORTANT: After cutting mounting area. Place template over mounting area. 2. Route wiring for the remote control into opening. records maximums and minimums simultaneously. and accurately reads in high RFI environments. Connect trim harness and lever harness. ohms. AC and DC voltages. a 3600 a . 3. Hz A mA COM V 4516 Remote Control Installation Locating and Drilling Mounting Area 1.

Mounting screw (3) 7.Lever harness 3250 6. a a 3251 a . Turn screw towards "+" to increase tension or towards "–" to decrease tension. This will help prevent the handle from unwanted motion in rough water. This will prevent connector from pulling out.25 in. Place the remote control into the opening. b a 5086 a . Fasten the remote control with three #12 x 1. Control Handle Tension Adjustment – This screw can be adjusted to increase or decrease the overall effort to move the control handle. IMPORTANT: Allow slack in the trim harness.8 REMOTE CONTROLS 4.SECTION . 90-899883178 NOVEMBER 2007 Page 5 / 28 . Insert the bayonet end into bracket hole. b . long screws. Harness will flex and move during control handle movement.Trim harness 5.

Install front and back bezel covers with attaching screws. 2.Screw ‑ (2) M4 x 12 Installing DTS Single Handle Console Control 1. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. 3509 3. This will prevent connector from pulling out. Page 6 / 28 90-899883178 NOVEMBER 2007 . lever and trackpad harnesses.REMOTE CONTROLS SECTION .8 8.Detent tension adjustment screw 9. Turn screw towards "+" to increase tension or towards "–" to decrease tension.Front cover b .Control handle tension adjustment screw b . Ensure opening is free of sharp edges. Connect trim. 4. Route wiring for the remote control into opening. a b c 3254 a . b a 3252 a . Insert the bayonet end of the lever harness into bracket hole.Back cover c .

Trackpad harness 3296 90-899883178 NOVEMBER 2007 Page 7 / 28 . b c a 5098 a . c .Trim harness b .Lever harness 5. Place the remote control into the opening. Harness will flex and move during control handle movement.SECTION .8 REMOTE CONTROLS IMPORTANT: Allow slack in the trim harness.

a b c a . Turn screw towards "+" to increase tension or towards "–" to decrease tension. Fasten the remote control with four M6 x 40 long screws.REMOTE CONTROLS SECTION . Control Handle Tension Adjustment Screw – This screw can be adjusted to increase or decrease the overall effort to move the control handle.Detent tension adjustment b .Mounting screw (4) M6 x 40 b . Turn screw towards "+" to increase tension or towards "–" to decrease tension.8 6. This will help prevent the handle from unwanted motion in rough water. 8.Control handle tension adjustment Page 8 / 28 90-899883178 NOVEMBER 2007 .Nut ‑ nylon insert ! CAUTION Overtightening the detent tension adjustment screw can damage the control module. 7. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position.Washer 3297 c . a b 5102 a . Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket.

Insert the bayonet ends into bracket holes.SECTION .Side cover (2) Installing DTS Dual Handle Console Control 1. 2. 90-899883178 NOVEMBER 2007 Page 9 / 28 . b a 3298 a .8 REMOTE CONTROLS 9. Make sure opening is free of sharp edges. This will prevent connectors from pulling out. Route wiring for the remote control into opening.Attaching screws (4) M4 x 20 b . Install the side cover with attaching screws. 3606 3.

Blue paint dot 4.Port engine 3305 3306 Page 10 / 28 90-899883178 NOVEMBER 2007 . Place the remote control into the opening.Bayonet ends b . b c d e f a a .8 IMPORTANT: Allow slack in the trim button harness going to the control handle.Starboard engine f .Trim button harness c . d . This harness will flex and move during control handle movement.REMOTE CONTROLS SECTION .Yellow paint dot e .

Turn screw towards "+" to increase tension or towards "–" to decrease tension.Washer 3307 c .Nut ‑ nylon insert ! CAUTION Overtightening the detent tension adjustment screw can damage the control module. a b c a . Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket.8 REMOTE CONTROLS 5. Fasten the remote control with four M6 x 40 screws. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–" to decrease tension.Control handle tension adjustment 90-899883178 NOVEMBER 2007 Page 11 / 28 . 7. Do not turn this screw more than 11 turns from the initial point of hex head contact with bracket. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase or decrease the overall effort to move the control handle.Detent tension adjustment b . Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. 6.Mounting Screw (4) M6 x 40 b . ! CAUTION Overtightening the detent tension adjustment screw can damage the control module. a b 5102 a .SECTION .

Install the side cover with attaching screws.Lever 1 harness (blue) f . Connect trim. G RN/W HT G RN/WHT B LU/W HT B LU/W HT b R ED c LEVER 1 f 5181 a .Throttle adaptor harness b .Side cover (2) b .Attaching screws (4) M4 x 20 Installing DTS Zero Effort Control 1.Trim harness R ED a e d d . 3.Trim adaptor harness Page 12 / 28 90-899883178 NOVEMBER 2007 .Remote control c . 2. Ensure opening is free of sharp edges. a b 3308 a . Route wiring for the remote control into opening.8 8.REMOTE CONTROLS SECTION .Trackpad ‑ not used e . lever and adaptor harnesses.

Always install a nylon washer between each screw and the control plate. a b c d 5184 a b c d a b c d 5182 Forward Cant Models a .Forward d . d d a b c a .Throttle lever b .8 REMOTE CONTROLS 4.Reverse b .F‑N‑R decal location 5."F‑N‑R" label a 4749 NOTICE Chipped paint can lead to rapid corrosion.Trim switch c b c . 90-899883178 NOVEMBER 2007 Page 13 / 28 .Neutral Aft Cant Models c .Shift lever d . Ensure the control is position so the forward‑neutral‑reverse ("F‑N‑R") decal is in the correct orientation.SECTION . Ensure the control is positioned so the forward‑neutral‑reverse (F‑N‑R) decal is in the correct orientation.

more firm steering control. Mercury MerCruiser recommends the use of an external power steering system where the power steering cylinders connect directly to the sterndrive unit on the outside of the boat. a b c d 5192 a . and is recommended for the following applications: • High speed single or twin engine applications and/or boats with unusual handling characteristics.Nylon washer (4) c .REMOTE CONTROLS SECTION . Mayfair Marine Machine 12890 N. Because of the many variables involved. External power steering and hydraulic helm systems can be obtained from the following after market suppliers: Latham Marine. W. If there is any question whether or not external power steering is necessary. Inc. the final decision as to whether or not external power steering is required rests with the boat manufacturer and must be made after a thorough test and evaluation of each specific boat. 32nd Court Ft. however. as this varies from boat design to boat design. On certain applications. This arrangement gives additional support for even tighter. 280 S. Page 14 / 28 90-899883178 NOVEMBER 2007 . 30th Avenue Opalocka. Mercury MerCruiser recommends that it be installed.W. self tapping screws and nylon washers. External power steering systems are generally either mechanical cable actuated or hydraulic actuated. Lauderdale.Control quadrant assembly d . • Any Hi‑Performance sport boat powered by three or more engines.Console Steering System Information High Speed Or Twin Engine Applications Steering Recommendation Mercury MerCruiser power packages come standard with Mercury MerCruiser's internal power steering. There are boats which operate at 60 mph that would benefit from the use of external power steering. • Offshore boats or other applications where the boat and sterndrive units may come out of the water occasionally. This durable system provides precise effortless steering control and is recommended for most sport boat applications. NOTE: It is virtually impossible to give a specific recommendation as to when external power steering should be used. Secure control to the console using the 8 X 1‑1/4 in. Mercury MerCruiser recommends using external power steering on boats which operate in excess of 70 mph. self tapping screw (4) b .8 6. FL 33315 Phone: (305) 462-3055 Fax: (305) 462-3081.8 X 1‑1/4 in. FL 33054 Phone: (305) 681-1815.

as specified in ABYC requirements.SECTION . or loops in cable. ! WARNING Failure to use a steering cable locking device can cause serious injury or death due to loss of boat control.) a 7255 a . 2. 90-899883178 NOVEMBER 2007 Page 15 / 28 .8 REMOTE CONTROLS Steering Helm and Cable Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. such as a self‑locking coupler or external locking device when installing steering controls. The steering cable coupler nut must also have a means of locking it to the guide tube. kinks. Use a locking device. NOTE: All current production Quicksilver RideGuide steering cables have a self‑locking coupler nut and do not require an external locking device. Avoid sharp bends. Refer to Steering Cable Specifications for fully extended steering cable and dimensions. an external locking device such as a locking sleeve must be used. Use only approved or required components when installing steering systems. (Other cable manufacturers also make cables with self‑locking coupler nuts. 1. 3.Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove) IMPORTANT: If using a steering cable that does not have a self‑locking coupler nut. particularly when installed in larger boats. Steering cable must be the correct length. ! WARNING Failure to use the correct cables or other steering system components can cause serious injury or death due to loss of boat control.

) minimum radius g .9.) maximum diameter end fitting h .9 mm (5/8 in.7 mm (27/64 in.) diameter through hole (chamfered each side) j .15.) maximum Hydraulic (Helm) Steering If your power package is equipped with Compact Hydraulic Steering.8 Steering Cable Specifications IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.) minimum to 22.15.) total travel to be20. Page 16 / 28 90-899883178 NOVEMBER 2007 .3 cm (8 in. a b e f c d g C L k l j i h 7254 abcdef- Coupler nut ‑ 7/8 ‑ 14 UNF ‑ 28 thread 29.9 mm (5/8 in.) maximum k . refer to the Compact Hydraulic (Helm) Steering Installation Instructions .02 cm (4 in.) maximum travel each side of mid‑travel position ‑ 1.8 mm (3/8 in.) maximum 10.1 mm (7/64 in.) minimum to 114 mm (4‑1/2 in.9 cm (16‑7/8 in.9 mm (1‑3/8 in.) minimum flat 3.) minimum Interface point 12.5 mm (3/8 in.Cable travel: mid‑travel position ‑ 42.9.8 cm (11‑3/4 in.7 mm (1/2 in.34.8 cm (9 in.REMOTE CONTROLS SECTION .) diameter tube l .) i .

Gasoline Alpha Models Only: Excessive force would be indicated by movement of the V‑notch of the actuator lever assembly. as viewed from the aft (rear) end of the propeller. into WOT position. Right-hand (RH) rotation drive unit ‑ Verify remote control travel for FORWARD gear. Place the remote control in FORWARD gear. 7807 90-899883178 NOVEMBER 2007 Page 17 / 28 . 1.SECTION . past detent.8 REMOTE CONTROLS Sterndrive Shift Cable Information Propeller Rotation Propeller rotation for sterndrive can be clockwise or counterclockwise. a. 4802 4747 Clockwise rotation Counterclockwise rotation Checking Alpha Shift Cable Installation and Adjustment IMPORTANT: Do not use excessive force when holding pressure on the drive unit shift cable.

Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable). Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. a. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable). Place the remote control in FORWARD gear. Page 18 / 28 90-899883178 NOVEMBER 2007 .REMOTE CONTROLS SECTION . Right-hand (RH) rotation drive unit ‑ Verify remote control travel for REVERSE gear. into WOT position. a. past detent.8 2. 7817 3. Left-hand (LH) rotation drive unit ‑ Verify remote control travel for FORWARD gear. 7807 4. 7870 5. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotating propeller shaft clockwise until shaft stops to ensure full clutch engagement.

into WOT position. Left-hand (LH) rotation drive unit ‑ Verify remote control travel for REVERSE gear. into WOT position. a. past detent. 7870 7.8 REMOTE CONTROLS a. 7869 6. Place the remote control in REVERSE gear.SECTION . past detent. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotating propeller shaft clockwise until shaft stops to ensure full clutch engagement. 7869 90-899883178 NOVEMBER 2007 Page 19 / 28 . Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable). Place the remote control in REVERSE gear.

loosen adjustable stud on shift lever and move it up in slot until clutch engages with REVERSE gear. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement.8 8. Pin must be centered. 10. Clutch should engage and cause propeller shaft to lock. Clutch should engage before shift lever comes to a stop. move remote control shift handle into full REVERSE position. a. b. Retighten stud. Pin must be centered.While turning propeller shaft CLOCKWISE. If clutch does not engage. If drive unit is installed and the package is equipped with a single lever shift/throttle control: Right-hand (RH) propeller rotation drive unit ‑ Shift remote control into REVERSE gear.REMOTE CONTROLS SECTION . Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).Shift remote control into FORWARD gear. If drive unit is installed and the package is equipped with a two lever remote control with separate shift and throttle levers: a. Right-hand (RH) propeller rotation drive unit . Retighten stud. 9. Clutch should engage and cause propeller shaft to lock. WOT position while simultaneously rotating propeller shaft CLOCKWISE. Retighten stud. Page 20 / 28 90-899883178 NOVEMBER 2007 . or if the remote control has inadequate output travel. WOT position while simultaneously rotating propeller shaft CLOCKWISE. Left-hand (LH) propeller rotation drive unit . if there are a lot of bends in the cable. If clutch does not engage. If clutch does not engage. Pin must be centered. Shift remote control several times and stop in REVERSE to recheck shift cutout switch position. loosen adjustable stud on shift lever and move it up in slot until clutch engages with REVERSE gear. Shift remote control several times and stop in FORWARD to recheck shift cutout switch position. loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear. Shift remote control several times and stop in REVERSE to recheck shift cutout switch position. 7817 IMPORTANT: It may be necessary to make additional adjustments if using extra long remote control shift cable.

1. Clutch should engage before shift lever comes to a stop. place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. If clutch does not engage.Adjustable stud b . Check sterndrive for proper gear shift with boat out of water. Left-hand (LH) propeller rotation drive unit . Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/ IN position. 2. Do not allow the sterndrive skeg to contact the ground. Retighten stud. move remote control shift handle into full FORWARD position. Before installing or removing a propeller.Drive trailer button 3. a b 7871 a . Never operate the boat out of the water with a propeller installed.SECTION .While turning propeller shaft CLOCKWISE. This test requires sufficient water supply to your engine and sterndrive. Connect a garden water hose between flushing attachment and water source. Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1 90-899883178 NOVEMBER 2007 Page 21 / 28 .Shift interrupt switch plunger Bravo Sterndrive Shift Check (Engine Running) ! WARNING Rotating propellers can cause serious injury or death. a b 4805 Typical single handle remote control shown a . Shift remote control several times and stop in FORWARD to recheck shift cutout switch position.Drive trim switch b . loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear.8 REMOTE CONTROLS b. Pin must be centered. Place a block of wood between the propeller blade and the anti‑ventilation plate.

This is necessary because the cables move up and down when the shift handle is moved. ensure that the cables have enough clearance to operate. 11. Check that the sterndrive propeller shaft is not turning. Place remote control handle in NEUTRAL. 5. 7873 Proper cable bend Page 22 / 28 90-899883178 NOVEMBER 2007 . 7. Check that the shift cables are connected IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/ or contact with moving parts. the cables will be interfered with. idle speed position and start engine. 12. the water pump. idle speed position. b. NOTE: The operator at the remote control handle should feel a slight detent before and after each gear. Troubleshooting Shift Problems NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear. at idle speed position. 1. idle speed position.8 4. If the control box is mounted too far back toward any fiberglass structure. the engine. and REVERSE. Provide a sufficient supply of water to the water inlets during operation. Remove the sterndrive and check for proper shift hook ups. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.REMOTE CONTROLS Flushing Device Flushing Kit 91‑44357Q 2 91‑849996T 1 SECTION . NEUTRAL. Check that the sterndrive propeller shaft is turning in the FORWARD direction. 9. NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing. If the sterndrive will not shift: a. 8. Move the remote control handle to FORWARD. and other components will overheat and suffer damage. Shift the remote control handle to REVERSE. idle speed position. NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of each gear FORWARD. DO NOT fasten any items to shift cables. this will cause very hard shifting. FORWARD‑detent‑NEUTRAL‑detent‑REVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. Check that the sterndrive propeller shaft is turning in the REVERSE direction. Partially open water source until water continuously leaks out around the flushing device. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment. 6. 10. Shift the remote control handle to NEUTRAL. When installing the control box in the side panel of the boat. NOTICE Without sufficient cooling water.

SECTION . Do not strap or clamp the control cables to any other cables or rigid structure within 91. Both conditions place extra stress on the cables. The 4000 GEN II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in. Cable radius at any one point must not be less than 305 mm (12 in. 95 7874 c .4 cm (3 ft) of the control box. 90-899883178 NOVEMBER 2007 Page 23 / 28 . IMPORTANT: Shift cable/throttle cable lubrication points use 2‑4‑C with Teflon.Remote control end b .) 4. 3. extend the stainless rod eye end of the cable and lubricate it. b c a d a . Before installing the shift cable into the control box. 92-802859A1 Description 2-4-C Marine Lubricant with Teflon NOTE: Allow for clearance of cables directly behind panel mount remote control. 4000 GEN II Series Panel Mount Remote Control Description Mounting surface maximum thickness Minimum cable bend radius at any point Specification 25 mm (1 in.).8 REMOTE CONTROLS 7872 Improper cable bend 2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull. sharp bends on too‑short cables result in kinks and too‑long cables require unnecessary bends or loops.Engine end Tube Ref No. Move it back and forth to allow even distribution of the lubricant.Adjusting barrel d . IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH. it does not have any extremely sharp bends in it as this will cause stiff shifting.Lubricating point Where Used Shift cable end Part No.) thickness.) 305 mm (12 in.

arrangement should be made with the dealer to do this as part of the pre‑delivery inspection 12.8 5. Barrel and cable end must be free to rotate on the mounting stud. above the exhaust pipe and make a turn toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing. 8. 6. Page 24 / 28 90-899883178 NOVEMBER 2007 . Refer to 90‑865523 Instruction Sheet for more information.5 m (5 ft) of the shift plate. 8995 Through prop exhaust shown NOTE: NOTE: A final check of the adjustments should be made with the boat in the water and engine running. c. b. NOTE: Lubricate attaching points with engine oil. The cable should come through the transom. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1. Following this routing will prevent the engine coupler from damaging the cable.REMOTE CONTROLS SECTION . Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of the shift plate. The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE. 7. The cable should then be routed under the starboard rear engine mount and turn toward the transom. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows: NOTE: Cable route is the same for through transom and through prop exhaust. Do not overtighten the throttle or shift cable attaching nuts at the engine end. a. The cable should then go up behind the power steering valve and loop over to the shift plate on the engine. If this cannot be done or is not done at your manufacturing facility. as this will crush the inner cable tubing and cause improper and / or stiff shifting. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls. 10. Ensure that the cable is not permanently kinked. Description SAE 30W Engine Oil Where Used Shift cable pivot points Part Number Obtain Locally 11. where it is connected to the anchor points on the shift plate. 9. Ensure that there is proper clearance for cable movement when the control box is installed in the side panel. Ensure that the engine was not set down on the intermediate shift cable during installation.

90-899883178 NOVEMBER 2007 Page 25 / 28 . Always set the trailer limit before setting the trim limit. command module kit and electronic remote control. DTS Calibration Special Tools ‑ DTS Calibration Male to Male 10 Pin Adapter Can 1 Diagnostic Cable Adapter Harness Computer Diagnostic System (CDS) 84‑892452A01 84‑892663 84‑822560A13 Order through SPX Methods of Calibration NOTE: DTS system calibration must be performed following complete system installation.8 REMOTE CONTROLS DTS Remote Control ‑ Sterndrive IMPORTANT: Boat must be equipped with Mercury electronic remote control. start in gear protection and emergency lanyard stop function. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in FORWARD or REVERSE. T R I M SO CL R L SE ET L C F R RN U 8994 The Digital Throttle and Shift System (DTS) required to operate this engine package provides start. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide. shift control. stop. • Mercury Marine Computer Diagnostic System (CDS) ‑ Connect the CDS to the CAN bus circuit and follow the helm configuration setup on the computer diagnostic screen. or if an error is made during the calibration setup. A DTS system reset must be performed prior to calibration. Setting Trailer and Trim Limit Setting Trailer Limit with CDS IMPORTANT: Incorrectly configuring the trim limit using a DDT or CDS can create a programming error in the engine's PCM.SECTION . It must also be completed after an accessory or replacement part is added to the system that requires new configuration codes. contact the Mercury Marine Technical Service Department for further instructions. The Digital Throttle and Shift system (DTS) works with specialized helm component. throttle. If you configure the limit incorrectly.

Page 26 / 28 90-899883178 NOVEMBER 2007 . Most pressure sensors default to a preprogrammed number also.5 in. preventing damage to swim platforms etc. preventing damage to the cowl. Scroll down the Active Diagnostics window and highlight "Trailer Limit".REMOTE CONTROLS SECTION . then to "RUN" for the PCM to accept new limit. 10. Open the Active Diagnostics Icon. This can be verified by unplugging the sensor in question and watching the data stream value. contact the Mercury Marine Technical Service Department for further instructions. 3. 5. • 1. 4. 2. Turn the ignition key to the "RUN" position. Troubleshooting Procedure Troubleshooting Information NOTE: All of the following are determined by the calibration of the PCM. 9. 6. 6. 7. This will configure the PCM to recognize the maximum trim in position according to the trim position sensor. Other pressure sensors will have their own default values which may be determined as described previously. Turn the ignition key to the "RUN" position. Connect the CDS to the engine data link harness. Turn the ignition key "OFF". The CDS screen will read "Adjust the engine/outdrive to the desired position. If you configure the limit incorrectly. Always set the trailer limit before setting the trim limit. Hg). Open the Active Diagnostics Icon. Upgrading the calibration can result in changes to these settings. Scroll down the Active Diagnostics window and highlight "Trim Limit". MerCruiser . The trim limit function is only supported if the PCM has input for the three wire trim sensor. Run the trim system completely in (down) and hold the trim button in for 3‑4 seconds. then to "RUN" for the PCM to accept new limit. 2. The CDS screen will read "Adjust the engine/outdrive to the desired position. DEFAULT SENSOR VALUES Default sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignition values. 1.To limit the maximum trailer up position. This can be verified by unplugging the sensor in question and watching the data stream value with the CDS. Open the Tool Box icon in the CDS. Select OK to store the current position in the ECU. MAP sensors usually default to 100 kPa (29. Setting Trim Limit with CDS IMPORTANT: Incorrectly configuring the trim limit using a DDT or CDS can create a programming error in the engine's PCM. Select the correct engine location. IMPORTANT: The engine must be running above 2000 RPM in gear to initiate the trim limit." 8.8 The function of the trailer limit: • Outboard . 7. Open the Tool Box icon in the CDS.To limit the maximum tilt up position. 4. Most temperature sensors default to 0 °C (32 °F). 8. Select OK to store the current position in the ECU. when the sensor in question has exceeded its preprogrammed diagnostic limits. The trim limit configures the PCM to control the maximum up trim limit. Connect the CDS to the engine data link harness. 5. 3. Run the test." Turn the ignition key "OFF". Run the test. Default sensor values typically are used when the sensor has a circuit high or circuit low fault.

will continue to show up as active. The time it takes to set a fault varies greatly and can also vary with engine RPM. then guardian is not currently active and the engine is capable of producing full power. even though the cause of the fault has been corrected. some faults are programmed to ignore certain engine speeds. How the warning horn activates depends on how serious the problem is. On a DTS engine. engine off. Some faults are only detected in the key‑on. Cycle the key to reset all faults if there is difficulty correcting a fault. Sticky means that the fault. engine off mode. Non‑DTS engine reduce engine power by changing injector and ignition operation. The higher the percentage. • Critical ‑ horn is beeping constantly and guardian will be at forced idle. There are four warning horn states: • Caution ‑ horn signal varies with product line and calibration. • Severe ‑ horn is beeping constantly. STICKY/NON-STICKY FAULTS All faults are classified as either sticky or non‑sticky. once set. Guardian is always accompanied by another fault or faults that actually caused the guardian to become active. Examples of the type of fault would be EST (cylinders 1 through 8) open circuit. will result in available power of 90% depending on product line. However. the more the guardian reduces available power. there will be warning icons and fault messages on the dash mounted gauges. A small problem. this fault will not be set at idle. WARNING HORN SIGNALS Most faults will cause the warning horn circuit to activate. TheCDS will continue to display a sticky fault as active. A key switch cycle is required to reset a sticky fault. will result in forced idle which is usually displayed as 5‑6% available power. the more power the engine is allowed to produce. Several minor faults occurring at the same time will cause the PCM to treat the faults as a more severe situation. A severe problem such as low oil pressure. or key‑on. In addition. For example. A non‑sticky fault is a fault that will change it's status from active to inactive without requiring a key switch cycle. depending on the gauge package.SECTION .8 REMOTE CONTROLS FAULT CONDITIONS Most faults can be detected with the engine running. If available power is showing 100%. • Warning ‑ horn signal varies with product line and calibration. The amount of guardian protection is expressed as a percentage. such as a non‑critical sensor going circuit high or circuit low. ENGINE GUARDIAN Almost every fault will cause the guardian program (within the PCM) to become active. Therefore. some faults require the presence of engine RPM. guardian closes the ETC to reduce engine power. Faults also take a certain time to set. and cannot be detected key‑on. The more severe the fault. Examples of this type of fault are EST (cylinders 1 through 8) shorted circuit and all injector faults (fuel and direct). In addition. the low block pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled until enough RPM has been achieved to develop a reasonable amount of water pressure. Special Tools ‑ DTS Troubleshooting Computer Diagnostic System (CDS) Breakout Box Terminal Test Probe Kit Order through SPX SPX P/N MM‑46225 SPX P/N MM‑46523 90-899883178 NOVEMBER 2007 Page 27 / 28 . or a DTS shift or throttle actuator failing. Minimal guardian. engine off. even if the circuit or problem has corrected itself. Faults generally set faster at higher engine speed.

REMOTE CONTROLS 12 Volt Shunt Connector Adapter Harness 2 to 4 Pin Harness Adapter Adapter Harness Male to Male 10 Pin Adapter DMT 2004 Digital Multimeter 889675A01 84‑822560A5 84‑822560A12 84‑822560A13 84‑892452A01 91‑892647A01 SECTION .8 Page 28 / 28 90-899883178 NOVEMBER 2007 .

....25 Models Using The Sterndrive Water Pickup .........................................................................PREDELIVERY PREPARATION AND STORAGE Table of Contents Predelivery Preparation..............................................14 Bravo One Models ............................................... 32 Three Point Manual Drain System .......................................................................................................................................................................................... 30 Draining the Seawater System................................................. 22 Flushing Attachments ..................................................... 32 Manual Single Point Drain System .................................................................................................... 15 Bravo Two Models ...............................................................................................................................................................................19 Boat Out Of the Water ...................................................................................................................................................................................................................................................6 Filling Coolant Recovery Bottle ................................................................................................................................ 23 Alternative Water Pickups ....................................................................................................................................................................................................................................... 4 Adding Engine Oil ........................................ 25 Cold Weather or Extended Storage..........................................................................................................11 Trim Position Sender Adjustment ‑ SmartCraft Gauges Multimeter Method.............................................................................................................................................13 Alpha Models .......................................................................................................................... 21 Boat In The Water Tests........................................................................... 22 Sterndrive Water Pickups .................................................. 34 9 90-899883178 NOVEMBER 2007 Page 1 / 46 ..................................................................18 Priming the Fuel System...............12 Propeller Selection............................................................................................................................................................................................................................................................................................................................................................................................... 32 Air Actuated Single Point Drain System ......................... 14 Bravo Sterndrive Propeller Installation....................................................................................................... 5 Drive unit gear lube monitor..............................................7 Alpha Trim Limit Switch Adjustment.................................................................................................................................................................................................................................................................. 21 Checking Shift Operation .......................21 Engine Idle Speed ..........................................................................................................................................................................................................................................................29 Engine and Fuel System Preparation ............................................................................. 8 Trim Position Sender Adjustment ‑ Analog Gauges......................................................................................................................................................................9 PREDELIVERY PREPARATION AND STORAGE SECTION 9 ....... 34 Boat in the Water ................................................. 33 Multi‑Point Drain (MPD) System ..............................................................................................................................................................................7 Analog Guages .................................................................................................................................................................... 24 SeaCore Power Package Flushing Procedure............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4 Engine Oil............................................................................................................................................................ 19 Boat In the Water ........4 Checking ....................................................................................................................................................................... 19 Testing Preparation ... 31 Drain System Identification..................................................................... 33 Air‑Actuated Single‑Point Drain System....................................................................................................... 16 Bravo Three .............................................................................................................................................................10 Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method............................................................................................................ 22 Flushing the Power Package............ 7 Bravo Trim Limit Switch Adjustment ‑ Analog Gauges ...................................................................................12 Alpha Sterndrive Propeller Installation ..........................5 Power Trim Pump............................................................................ 29 Preparing Power Package for Storage.................................18 Test Running Engine ............................................................................................................................................................................................................................................................................ 17 Battery Connection.................................................................................................................................... 4 Power Steering Fluid........................................................................................ 20 Testing .............................................................................................................. 21 Wide Open Throttle Test ........SECTION ..............................................................................................

..........................................................................................................................................................................9 Boat out of the Water ...............................40 Boat in the Water ..................................................................... 46 Power Package Recommissioning............................................................................................................. 42 Boat in the Water ................. 39 Three Point Manual Drain System........................................................................................................................ 38 Boat out of the Water ..........................................................................................PREDELIVERY PREPARATION AND STORAGE SECTION ........................ 41 Multi‑Point Drain (MPD) System.......................................................................................................................................................................................................................................... 46 Page 2 / 46 90-899883178 NOVEMBER 2007 ...................................................................................................................................................................................................................................... 38 Boat in the Water ........................................................................... 44 Battery Storage.......................................... 36 Manual Single‑Point Drain System...................................................................................................................................42 Boat out of the Water ................................................ 40 Boat out of the Water ......................................................................................................................................

10677 Flushing Device 91‑44357Q 2 Attaches to the water intakes. 9192 Flushing Kit 91‑849996T 1 Use for flushing gearcases with low water inlets. provides a fresh water connection when flushing the cooling system or operating the engine. 34 80 87 94 95 114 115 124 Description Special Lubricant 101 SAE Engine Oil 30W High Performance Gear Lubricant Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon Power Trim and Steering Fluid Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer Where Used Propeller shaft splines Power trim pump Gear Lube Monitor Propeller shaft splines Propeller shaft splines Power steering pump Power trim pump Fuel system Fuel system Part No. 9195 Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases. 92-802865Q02 Obtain Locally 92-858064K01 92-802867Q 1 92-802859A1 92-858074K01 92-858026K01 858071K01 Special Tools Propeller Nut Tool 91‑805457T 1 Aids in the removal and installation of the front propeller nut.SECTION .9 PREDELIVERY PREPARATION AND STORAGE Lubricant. Sealant. 9194 90-899883178 NOVEMBER 2007 Page 3 / 46 . Adhesives Tube Ref No.

and contain and dispose of fluids as required. Add the specified engine oil to bring the level up to. Fill as necessary with specified fluid. the full or OK range mark on the dipstick. Be aware of the local restrictions governing the disposal or recycling of waste. coolant. but not over. 2. IMPORTANT: Add the specified engine oil to bring the level up to. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and add. Wait 60 seconds to allow trapped air to vent. ADDING ENGINE OIL IMPORTANT: Do not overfill the engine with oil. Engine Oil NOTICE Discharge of oil.95 liters (1 quart) of engine oil will raise the level from the ADD mark to the top of the OK range. Stop the engine. the full or OK range mark on the dipstick. but not over. coolant. a 6077 a . The boat must be at rest in the water. Remove the dipstick. Use caution not to spill oil. the full or OK range mark on the dipstick. NOTE: Adding 0. Page 4 / 46 90-899883178 NOVEMBER 2007 . Allow approximately 5 minutes for the oil to drain into the oil pan. or other engine/drive fluids into the environment is restricted by law. but not over. Remove oil fill cap. NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine (flywheel end).PREDELIVERY PREPARATION AND STORAGE SECTION .Oil fill cap IMPORTANT: Add the specified engine oil to bring the level up to. CHECKING 1. 1. 2. the following final steps should be taken to prepare power package for delivery to the customer. or other fluids into the environment when using or servicing your boat. It is the boat manufacturer's responsibility to perform these procedures or to make arrangement with the dealer to have these procedures completed. Wipe clean and reinstall fully into the dipstick tube.9 Predelivery Preparation Once the power package installation is complete. 3.

90-899883178 NOVEMBER 2007 Page 5 / 46 . NOTE: Be prepared to add fluid to pump when first starting engine. Replace the fill cap.Dipstick Description Where Used Power steering pump Where used Power steering pump Part No. Always check steering fluid levels before operating the boat. Add fluid as required. 92-858074K01 Part Number Obtain locally Power Trim and Steering Fluid Description Dexron III ‑ Automatic Transmission Fluid Power Trim Pump 1.SECTION .9 PREDELIVERY PREPARATION AND STORAGE 3. 114 b . Power Steering Fluid IMPORTANT: Use only specified lubricant. Position sterndrive unit so that it is straight back. IMPORTANT: Use only specified lubricant.Fill cap Tube Ref No. IMPORTANT: Running the pump dry will damage the pump. Remove fill cap from power steering pump and check fluid level using dipstick. 2. a b 9356 a . 1. Check oil level with sterndrive unit in the full DOWN/IN position.

Remove the gear lube monitor cap. Fill the gear lube monitor to the Operating Range (full) line. 1. 80 3. a b c 8539 a . Oil level should be maintained within the "MIN" and "MAX" lines on the reservoir. (with drive unit in the full DOWN/IN position).Gear lube monitor cap Tube Ref No.Reservoir fill neck Tube Ref No.Operating Range (full) line Where Used Gear Lube Monitor Part No. Check the power trim pump hose fittings for leaks. Raise and lower sterndrive unit (to the full UP/OUT position) 6 to 10 times to purge air from system. Obtain Locally Tube Ref No.Fill cap (top and underneath side views) b . Check oil level visually.9 2. 114 c . 2.PREDELIVERY PREPARATION AND STORAGE SECTION . 92-858074K01 Part No. 92-858064K01 Description High Performance Gear Lubricant Page 6 / 46 90-899883178 NOVEMBER 2007 . If fluid is visible at the fittings."MIN" and "MAX" lines Description Power Trim and Steering Fluid Description SAE Engine Oil 30W Where Used Power trim pump Where Used Power trim pump Part No. 87 b . always check oil level when drive is cool and engine is shut down. a b 7884 Typical a . Drive unit gear lube monitor IMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation. check connections.

IMPORTANT: Follow these procedures exactly as outlined below.SECTION . Filling Coolant Recovery Bottle NOTE: This section applies to Closed Cooled models only. a b b 7879 Trim limit switch a . DO NOT USE TRAILER BUTTON. Reinstall cap. Recheck coolant level after first WOT boat test and add coolant. b . trim drive unit UP/OUT. 3.Screws b. 1. Incorrect switch adjustment can cause the drive unit to move beyond the gimbal ring support flanges.9 PREDELIVERY PREPARATION AND STORAGE 3. Using the Trim button on the remote control. 2. c. Do not overtighten. 90-899883178 NOVEMBER 2007 Page 7 / 46 . causing product damage. Alpha Trim Limit Switch Adjustment ANALOG GUAGES ! CAUTION Trimming the sterndrive creates pinch points. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution. which can cause personal injury. Alpha sterndrive. a. Stay clear from the sterndrive when trimming or tilting. Ensure that the rubber gasket is inside the gear lube monitor cap. 4. Recheck gear lube level after first use. Loosen screws and turn trim limit switch clockwise to end of slots. adjust trim limit switch as follows: NOTE: Trim limit switch is located on the port side of gimbal ring. 1.Slots Ensure drive unit is in the full DOWN/IN position. Maintain coolant level in coolant recovery reservoir between ADD and FULL marks with engine at normal operating temperature. if necessary. 5. Install the gear lube monitor cap.

a 7880 Trim limit switch a . Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown. IMPORTANT: Follow these procedures exactly as outlined below. Bravo Trim Limit Switch Adjustment ‑ Analog Gauges ! CAUTION Trimming the sterndrive creates pinch points.) e.Maximum520 mm (20‑3/4 in. Stay clear from the sterndrive when trimming or tilting. Page 8 / 46 90-899883178 NOVEMBER 2007 . causing product damage. Incorrect switch adjustment can cause the drive unit to move beyond the gimbal ring support flanges.9 d.PREDELIVERY PREPARATION AND STORAGE SECTION . which can cause personal injury. IMPORTANT: All Bravo models must have the trim‑in‑limit insert positioned properly before performing the trim position sender adjustment. Retighten screws when adjustment is correct.Rotate Counterclockwise To Adjust a 7881 Alpha trim cylinder extended a .

a a 8548 8557 Bravo One and Two (positioned forward) a .SECTION .9 PREDELIVERY PREPARATION AND STORAGE 1. a Trim limit switch a . trim drive unit UP/OUT.Trim‑in‑limit insert Bravo Three (positioned aft) 2. c. DO NOT USE TRAILER BUTTON. 90-899883178 NOVEMBER 2007 Page 9 / 46 . 16524 Ensure drive unit is in the full DOWN/IN position. Ensure that the trim‑in‑limit insert is positioned as shown for the appropriate Bravo model. Bravo sterndrive.Screws b. Loosen screws and turn trim limit switch clockwise to end of slots. Using the Trim button on the remote control. adjust trim limit switch as follows: a.

Page 10 / 46 90-899883178 NOVEMBER 2007 . 2.Trim position sender IMPORTANT: Do not start the engine during this procedure.PREDELIVERY PREPARATION AND STORAGE SECTION . Loosen both trim position sender retaining screws. 3. Trim Position Sender Adjustment ‑ Analog Gauges 1.9 d.Rotate Counterclockwise To Adjust 21675 a 8558 Bravo trim cylinder extended a . Turn ignition key to RUN position. Retighten screws when adjustment is correct. a Trim limit switch a . (552 mm) e. Trim sterndrive unit to the full DOWN/IN position. b a a .Trim Limit Dimension 21‑3/4 in.Retaining screws 21676 b . Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.

b a a . a 7883 a .SECTION .9 PREDELIVERY PREPARATION AND STORAGE 4. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool. 90-899883178 NOVEMBER 2007 Page 11 / 46 .Trim position sender 21076 b . Trim the sterndrive unit to the full DOWN/IN position.Trim gauge needle 5.Retaining screws 21674 b .Trim position sender Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method a b a . 2. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown.Retaining screws 1. Tighten retaining screws and turn ignition key to the OFF position.

proceed to step 6. TRIM POS counts must be between 20 and 24 counts. Verify TRIM POS counts are still within the specified range. Trim the sterndrive unit to the full DOWN/IN position. proceed to step 6.9 3. 3. c. b. 2. Repeat steps "a" through "c" if necessary. d. b. Turn the ignition key switch to the OFF position. Page 12 / 46 90-899883178 NOVEMBER 2007 . c. d. Loosen both trim position sender retaining screws. Turn ignition key switch to the RUN position. Trim Position Sender Adjustment ‑ SmartCraft Gauges Multimeter Method a b a . 7. Note resistance reading. 4. 5.PREDELIVERY PREPARATION AND STORAGE SECTION . Connect Multimeter leads to trim position sender wires and set Multimeter to display resistance (Ohms). Tighten the trim position sender retaining screws. 7. 6.Trim position sender 21076 b . Loosen both trim position sender retaining screws. Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum WOT rpm. preferably near the middle of the range. Disconnect the trim position sender wires from the multimeter leads and reconnect trim position sender wires to engine wiring harness connections. If TRIM POS counts are within specified range. Refer to Mercury SmartCraft Operator's Manual for final Trim Calibration procedure. preferably near the middle of the range. Tighten the trim position sender retaining screws. Rotate the trim position sender until TRIM POS counts are within the specified range. Disconnect trim position sender wires from engine wiring harness connections. Otherwise: a. 6. Set the scan tool to display TRIM POS counts and note the value displayed. Otherwise: a. Verify resistance reading is still within the specified range. Resistance must be between 16 and 20 Ohms. Use an accurate service tachometer to verify engine operating rpm. Repeat steps "a" through "c" if necessary.Retaining screws 1. disconnect the scan tool from the Diagnostic Link connector. If resistance reading is within specified range. and install the weather cap in the Diagnostic Link connector. Rotate the trim position sender until resistance reading is within the specified range. 5. 4.

Available propellers are listed in the Mercury Precision Parts Accessories Guide. Place a block of wood between the propeller blade and the anti‑ventilation plate.SECTION . For better acceleration. place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. such as is needed for water skiing. liberally coat propeller shaft splines with lubricant. the propeller must be changed to prevent loss of performance and possible engine damage. the following common problems may require that the propeller be changed to a lower pitch. Place a block of wood between the propeller blade and the anti‑ventilation plate. • Operating in a higher elevation causes a loss of rpm. Because of the many variables of boat design.9 PREDELIVERY PREPARATION AND STORAGE It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller. 92-802865Q02 90-899883178 NOVEMBER 2007 Page 13 / 46 . • Operating with increased load (additional passengers. pulling skiers) causes a loss of rpm. Maximum RPM Test at the back of this manual. only testing will determine the best propeller for a particular application. place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Specified engine WOT and operating rpm range are listed in the Mercury MerCruiser Operation. On the other hand. Never operate the boat out of the water with a propeller installed. Never operate the boat out of the water with a propeller installed. After initial propeller selection. To aid in future removal of the propeller. • Warmer weather and greater humidity cause a loss of rpm. Do not operate at full throttle when using the lower pitch propeller but not pulling skiers. use the next lower pitch propeller. 7885 1. 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. See BOAT IN THE WATER TESTS. Before installing or removing a propeller. 34 Description Special Lubricant 101 Where Used Propeller shaft splines Part No. ! WARNING Rotating propellers can cause serious injury or death. operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage. Alpha Sterndrive Propeller Installation ! WARNING Rotating propellers can cause serious injury or death. Before installing or removing a propeller. Maintenance and Warranty Manual attached to the engine. Tube Ref No.

Drive sleeve adapter f . place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. Never operate the boat out of the water with a propeller installed. Bravo Sterndrive Propeller Installation ! WARNING Rotating propellers can cause serious injury or death. The propeller torque stated is the minimum torque value. in. 3.Wood block b .Propeller nut Nm 75 lb. Place a block of wood between the propeller blade and the anti‑ventilation plate.PREDELIVERY PREPARATION AND STORAGE SECTION . d e a b c g abcdDescription Alpha propeller nutAlpha propeller nut1.Propeller nut under socket 1. 55 Then align tabs with grooves. Torque the nut. Before installing or removing a propeller. Install propeller with attaching hardware as shown.9 IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed through propeller nut after torquing it.Propeller c . then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer.Locking tab washer g . lb. ALPHA MODELS 1. 5301 f Propeller shaft splines Forward thrust hub Flo‑torque II drive hub Propeller e . ft. Page 14 / 46 90-899883178 NOVEMBER 2007 . a b c 4826 a . Bend the 3 tabs down into grooves. 2.

Propeller nut NOTE: The propeller torque stated is a minimum torque value.Propeller nut Propeller a b c d e f g 19816 abcd- Bravo One XR models Propeller shaft Propeller hub insert with snubbers Propeller Thick washer e .SECTION .Washer f . The propeller rotation must match the direction of rotation of the propeller shaft. 92-802865Q02 92-802859A1 92-802867Q 1 NOTE: Anti‑corrosion grease is for salt water applications only. 34 95 94 Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon Anti-Corrosion Grease Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines Part No.9 PREDELIVERY PREPARATION AND STORAGE BRAVO ONE MODELS IMPORTANT: Use the correct rotation propeller. Install the propeller with the attaching hardware as shown. 3.Tab washer Flo‑Torque II drive hub g .Washer g . 2. Tube Ref No. d e a b c g abcd5301 f Typical Bravo One models Propeller shaft splines e .Drive sleeve adapter Forward thrust hub f . 1. 90-899883178 NOVEMBER 2007 Page 15 / 46 . Coat the propeller shaft spline with one of the following Quicksilver lubricants. Torque the propeller nut.

– SECTION . 1. Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer. in. 4. The propeller rotation must match the direction of rotation of the propeller shaft. 5.PREDELIVERY PREPARATION AND STORAGE Description Bravo One propeller nut Nm 75 lb. 55 NOTE: Bravo One XR models do not use the tab washer.Tab washer c . Install the propeller with the attaching hardware as shown. Tube Ref No.Tab bent down e .Prop b . ft. Page 16 / 46 90-899883178 NOVEMBER 2007 .Propeller nut BRAVO TWO MODELS IMPORTANT: Use the correct rotation propeller. a b c d e 4750 a . 92-802865Q02 92-802859A1 92-802867Q 1 NOTE: Anti‑corrosion grease is for salt water applications only. Coat the propeller shaft spline with one of the following Quicksilver lubricants. Bend the three tabs down into the grooves. 34 95 94 Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon Anti-Corrosion Grease Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines Part No.9 lb.Drive sleeve adapter d . 2.

Propeller nut NOTE: The propeller torque stated is a minimum torque value.Prop b . Torque the propeller nut.Propeller shaft splines b . ft. 92-802865Q02 92-802859A1 92-802859A1 NOTE: Anti‑corrosion grease is for salt water applications only. 34 95 95 Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon 2-4-C Marine Lubricant with Teflon Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines Part No. Description Bravo Two propeller nut Nm 81 lb.Tab bent down e .9 PREDELIVERY PREPARATION AND STORAGE 3. a b c d e 4750 a .Tab washer c . Bend the three tabs down into the grooves.Forward thrust hub c . in. 90-899883178 NOVEMBER 2007 Page 17 / 46 .Propeller nut BRAVO THREE 1.Propeller 8566 d .SECTION .Drive sleeve adapter d .Spline washer e . Tube Ref No. 5.Tab washer f . – lb. 60 4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer. c d f a b e Bravo Two a . Coat the propeller shaft spline with one of the following Quicksilver lubricants.

Install front propeller locknut and torque using the Propeller Nut tool. with tapered side toward propeller hub. 168 lb. Propeller Nut Tool Description Bravo Three front propeller nut 91‑805457T 1 Nm 136 lb. Priming the Fuel System IMPORTANT: Use a portable fuel tank with a primer bulb fuel line. 1. 100 5. Install propeller shaft anode and screw and torque. Slide forward thrust hub onto propeller shaft. Align splines and place front propeller on propeller shaft. in. Keep the work area well ventilated and avoid prolonged exposure to vapors. Description Bravo Three rear propeller nut Nm 81 lb.PREDELIVERY PREPARATION AND STORAGE SECTION . ft. Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately. in. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Page 18 / 46 90-899883178 NOVEMBER 2007 . 60 8. Do not smoke or allow sources of spark or open flame in the area while servicing. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 6. ft. ft. in. – lb. Align splines and install aft propeller. 3. 4. 7. Ensure that all battery terminal connections are tight. – Propeller shaft anode screw Battery Connection IMPORTANT: Engine electrical system is negative (‑) ground.9 2. Install propeller nut and torque. – lb. e f b a j 5304 c d i g h abcdeDescription Bravo Three Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller fghij- Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode Nm 19 lb. ! WARNING Fuel is flammable and explosive.

if attached to the engine. IMPORTANT: Before disconnecting the fuel line primer bulb. 2. 8. Disconnect the primer bulb fuel line from the fuel inlet fitting. 7. Test Running Engine ! WARNING Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death.SECTION . do not use full water source pressure. Ensure that the water level is above the water inlet holes on the sterndrive or the through the hull pickup. BOAT IN THE WATER For engine operation tests with the boat in the water: IMPORTANT: If using a test tank the water level must be above the water inlet holes on the sterndrive unit or the through the hull pickup. BOAT OUT OF THE WATER For engine operation tests with the boat out of the water: IMPORTANT: If using a flushing attachment over the water inlet holes with a water hose. 4. Repeat Step 3. NOTICE Without sufficient cooling water. three more times. 2. Remove the plug from the fuel tank fuel line. Use caution when performing a test that requires the engine running.9 PREDELIVERY PREPARATION AND STORAGE 1. Attach portable fuel tank to the fitting and secure tightly. Do not use full water pressure. 6. Proceed to Testing Preparation. the engine. the water pump. need a supply of cooling water available to both the sterndrive unit and to the engine during operation. Squeeze the primer bulb until the bulb becomes firm. Disconnect the fuel line from the fuel tank to the fuel inlet fitting and plug the line. and remove the propeller to avoid injury. 90-899883178 NOVEMBER 2007 Page 19 / 46 . and other components will overheat and suffer damage. 5. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through the hull water inlet. 1. 3. ensure that the bulb is soft and does not still have fuel in it to prevent spilling fuel. 5. 4. and Step 4. On Engines With Through The Hull Water Inlet. supply sufficient cooling water to the engine. 2. Open the water source about 1/2 maximum. Provide a sufficient supply of water to the water inlets during operation. NOTE: Do not turn the key switch to the "START" position during the priming. 3. Attach the fuel line from the fuel tank to the fuel inlet and tighten securely. Turn the ignition switch to the "RUN" position for 3 seconds and then turn OFF. Proceed to Testing Preparation. Connect a hose between the flushing attachment and a water source. 1. Install a flushing attachment over the sterndrive water inlet holes.

Flushing Device Flushing Kit 91‑44357Q 2 91‑849996T 1 Page 20 / 46 90-899883178 NOVEMBER 2007 . ensure water level is above water intake holes. Use caution when performing a test that requires the engine running. NOTE: Refer to appropriate Mercury MerCruiser Operation. 5. petcocks and hoses are installed and tight. water must be provided to these inlets or air flow must be blocked. 6. Refer to appropriate Mercury MerCruiser Service Manual for fluid capacity information. Maintenance and Warranty Manual for operating specifications.PREDELIVERY PREPARATION AND STORAGE SECTION . 1. IMPORTANT: If using a flush test device. During operation. and remove the propeller to avoid injury. Ensure someone is at the helm at all times. If so. 3. Check crankcase oil level. 4. do not use full water tap pressure. Check drive belt tension. Ensure that cooling system drain plugs. Supply water to the engine either by putting boat in the water or by using the correct flush device. Test Audio Warning system in accordance with instructions on instrumentation panel decal. Check sterndrive unit oil level in the monitor. 5752 5773 Low water pickup Side pickup IMPORTANT: Engines may also use a through the hull or through the transom inlet. the through the transom or through the hull fitting is the only water inlet to the engine. do not operate the engine above 1500 RPM to ensure the engine seawater pump suction does not collapse the hose to the water source causing the engine water supply to stop. IMPORTANT: Oil level in monitor will rise and lower during sterndrive operation. 2. ! WARNING Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. IMPORTANT: If using a test tank. If a block‑off plate is used.9 TESTING PREPARATION ! WARNING Leaving the helm unattended while performing tests with the boat in the water may result in loss of boat control causing serious injury or death. Always check oil level when sterndrive is cool and engine is shut down. unless the boat is secured to a dock.

Ensure that steering lever is not contacting cutout in transom. and ensure drive unit turns the correct way. 4. 3.SECTION . then LEFT/PORT. idle speed and start engine. If pump lugs (engine rpm drops and/or power steering pump tone changes): a. operate boat (with normal load on board) at WOT and check RPM with an accurate tachometer. 6. idle speed and start engine. Turn steering wheel STARBOARD until it stops and continue to apply pressure. Place remote control in neutral . engine speed will not fall below specifications. 6. If pump lugs (engine rpm drops and/or power steering pump tone changes): a. To test if the correct propeller has been installed. Turn off engine. follow this procedure. 4.) propeller pitch change causes an RPM change of 150 RPM. Place sterndrive in neutral . Ensure that throttle cable has been adjusted properly. and Warranty Manual with boat in the water. 2. Turn steering wheel RIGHT/STARBOARD. run the boat up on plane. under a heavy load. replace propeller with a higher pitch propeller. Remove cap/dipstick from power steering pump. Watch all gauges for normal readings. When engines reaches mornal operating temperature. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM. drive unit in FORWARD gear and engine at normal operating temperature. Check fluid level and add if necessary. Slowly advance throttle until engine reaches 1300 rpm (+/‑100 rpm). and exhaust leaks. 90-899883178 NOVEMBER 2007 Page 21 / 46 . Check for an obstruction between gimbal ring and gimbal housing and all moving steering components b. If engine speed is too high. Engine RPM should be near top of the specified range so that. Inspect engine compartment for water. Watch all gauges for normal readings.Dipstick (full when hot line) Boat In The Water Tests ENGINE IDLE SPEED Engine should idle at RPM as specified in appropriate Mercury MerCruiser Operation. If idle speed is incorrect. proceed as follows: 1. Check steering cable end dimension with cable FULLY EXTENDED. 7. Maintenance. 5. WIDE OPEN THROTTLE TEST IMPORTANT: To operate engine at full throttle before the break‑in period is complete. 1. oil.9 PREDELIVERY PREPARATION AND STORAGE TESTING 1. 2. b. modify cutout c. Normally a 25 mm (1 in. 7890 a a . If contact is being made. Turn steering wheel PORT until it stops and continue to apply pressure. 5. fuel. 3. Slowly advance throttle until engine reaches 1300 rpm (+/‑100 rpm).

8. and through the sterndrive. Shift into FORWARD and REVERSE gear. CHECKING SHIFT OPERATION With sterndrive unit installed and engine operating.Dual water pickup flush gearcase seal kit 91‑44357Q 2 91‑881150K 1 21515 Page 22 / 46 90-899883178 NOVEMBER 2007 . Return to idle speed. Shifting from FORWARD and REVERSE to NEUTRAL: ensure drive unit is in NEUTRAL before remote control shift lever comes to the NEUTRAL detent position. 4.Flushing device b . ensure that drive unit shifts properly.9 7. Accelerate engine while in FORWARD and REVERSE gear to ensure that engine does not stop. as explained following: 1. Check coolant level and add coolant if necessary. through the transom. 3. FLUSHING ATTACHMENTS a a b b c Flushing attachments for dual water pickup a . ensuring that clutch engages before engine begins to accelerate. Shut off engine. shift cables must be readjusted. Flushing the Power Package The boat can be equipped with a combination of any of three different types of water pickups: through the hull. Perform this check using various shifting rates to ensure that the drive unit shifts the same whether shifting fast or slow. IMPORTANT: Engines that require dual water pickups require a through‑the‑hull or through‑the‑transom pickup in addition to the sterndrive water inlets.PREDELIVERY PREPARATION AND STORAGE SECTION .Hose attachment Flushing Device Dual Water Pick‑up Flush Gearcase Seal Kit 21514 Flushing attachments for side water pickup c . If the proper results are not achieved in the previous steps. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through‑the‑hull or through‑the‑transom pickup need a supply of cooling water available to both the sterndrive and to the engine during operation. 2. The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. 9.

resulting in engine damage. On seawater cooled models: Proceed to Step 4. brackish.9 PREDELIVERY PREPARATION AND STORAGE STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water. disconnect the hose from the alternative water pickup and plug both ends. NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine. 2. 5. Never operate the boat out of the water with a propeller installed. If flushing the cooling system with the boat out of the water: a. close the seacock in the hose from the alternative water pickup. mineral laden or polluted water applications. Raise sterndrive to trailer position. Lower sterndrive to full down (in) position. If flushing the cooling system with the boat in the water: a. or Step 5.SECTION . c. 5752 5773 Dual water pickup Side water pickup NOTE: Flushing is needed only for salty. If equipped with a seacock. refer to Alternative Water Pickups. Keep the seacock closed until starting the engine. If there is not a hose running to the transom. ! WARNING Rotating propellers can cause serious injury or death. Place a block of wood between the propeller blade and the anti‑ventilation plate. supply water to only the sterndrive by taking the following steps to block. Lower sterndrive to full down (in) position. supply water to the sterndrive and to the engine. and side water pickups require the flushing attachment (44357Q 2). Flushing is recommended after each outing for best results. 3. If not equipped with a seacock. or disconnect and block. and side water pickups. b. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1). place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting. 1. 4. Before installing or removing a propeller. c. On models with the sterndrive seawater inlet blocked. a. 90-899883178 NOVEMBER 2007 Page 23 / 46 . See Alternative Water Pickups. the hose from the alternative seawater pickup pump inlet Y‑fitting. Close the seacock before flushing the engine. Install the appropriate flushing attachment over the water inlet holes in the gear housing. On models using the sterndrive seawater inlet and a through‑hull or through‑transom alternative water pickup. b.

IMPORTANT: Models with the sterndrive water inlet blocked off at the gimbal housing and using a through‑hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation. ALTERNATIVE WATER PICKUPS IMPORTANT: Two water sources are needed for this procedure. Never operate the boat out of the water with a propeller installed. c. NOTICE Operating the engine out of the water at high speeds creates suction. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 3. Raise sterndrive to trailer position. Place the remote control in the neutral idle speed position and start engine. c. c. Stop engine. NOTE: Flushing is needed only for salty. to prevent water from siphoning into the engine or boat. if equipped. Flushing is recommended after each outing for best results. If flushing the cooling system with the boat in the water: a. Connect hose between flushing attachment and water source. 12. Lower sterndrive unit to full down (in) position. Page 24 / 46 90-899883178 NOVEMBER 2007 . Remove propeller. ! WARNING Rotating propellers can cause serious injury or death. Observe the water temperature gauge to ensure that the engine is operating in the normal range. Close the seacock. Lower sterndrive to full down (in) position. 7. 16. Install the appropriate flushing attachment over the water inlet holes in the gear housing. Depress the throttle‑only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM). Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine. b. 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. 2. 14. mineral laden or polluted water applications. 6. open the water source fully. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine. If flushing the cooling system with the boat out of the water: a. Place a block of wood between the propeller blade and the anti‑ventilation plate.9 b. Remove propeller. Slowly return throttle to idle speed position. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. 1. b. Install the appropriate flushing attachment over the water inlet holes in the gear housing. 9. Connect hose between flushing attachment and water source. 4. 8. 11. Before installing or removing a propeller. 13. With sterndrive in normal operating position. brackish. 15. 10.PREDELIVERY PREPARATION AND STORAGE SECTION . Shut off water and remove flushing attachment. place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.

Using a suitable adapter. NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: Refer to Alternative Water Pickups. Flushing the SeaCore power package is most effective when performed with the boat and sterndrive out of the water. NOTICE Operating the engine out of the water at high speeds creates suction.9 PREDELIVERY PREPARATION AND STORAGE 5. such as on a boat lift or trailer. Operate engine with sterndrive in neutral for about 10 minutes or until discharge water is clear. Slowly advance throttle until engine reaches 1300 RPM (+/‑100 RPM). and other components will overheat and suffer damage. NOTICE Without sufficient cooling water. Slowly return throttle to idle speed position. mineral laden or polluted water applications. brackish.SECTION . IMPORTANT: Flushing the SeaCore power package with the boat and sterndrive in the water is less effective. 7. Flushing is recommended after each outing for best results. With sterndrive in normal operating position. 90-899883178 NOVEMBER 2007 Page 25 / 46 . Shut off the water and remove flushing attachments. Remove the seawater inlet hose from the seawater pump and plug the hose to prevent water from siphoning into the engine or boat. the engine. 8. 13. Provide a sufficient supply of water to the water inlets during operation. Do not block or remove the inlet water hose from the sterndrive to the engine. If the boat is out of the water: Install the water inlet hose to the aft side of the seawater pump. connect the flushing hose from the water source to the water inlet of the seawater pump. 16. 9. 14. which can collapse the water supply hose and overheat the engine. Observe the water temperature gauge to ensure that the engine is operating in the normal range. Place the remote control in neutral idle speed position and start engine. Tighten the hose clamp securely. the water pump. 11. Stop engine. 12. 6147 6. open the water source fully. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply. 10. SeaCore Power Package Flushing Procedure NOTE: Flushing is needed only for salt. MODELS USING THE STERNDRIVE WATER PICKUP IMPORTANT: The system is designed to flush the Bravo sterndrive and the engine with one water source. If the boat is in the water: Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be reconnected prior to operating engine. 15.

Close the seacock.Hose fitting to engine c . Never operate the boat out of the water with a propeller installed. Remove the boat from the water.Handle (closed position) b . disconnect the water hose from the alternative water pickup and plug both ends. c a b d For visual clarity.9 ! WARNING Rotating propellers can cause serious injury or death. If equipped with an alternative water pickup and not equipped with a seacock. Before installing or removing a propeller. Remove the quick‑connect fitting from the parts bag supplied with the engine. excluding the Bravo sterndrive. 6. If equipped.Seacock d . 1.PREDELIVERY PREPARATION AND STORAGE SECTION . Attach the quick‑connect fitting to a water hose. ensure that all alternative water inlet hoses are plugged at both ends. 4. 18510 a b 18487 a . Place a block of wood between the propeller blade and the anti‑ventilation plate. the secock shown is not installed a . 5.Water hose Page 26 / 46 90-899883178 NOVEMBER 2007 . Ensure that the inlet water hose from the sterndrive to the engine is connected. IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing procedure.Quick connect fitting (water hose end) b . if equipped. 2. place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.To water source pickup attachment 3.

Turn off the water source. 16. Allow the water to flush the sterndrive for 30 seconds.9 PREDELIVERY PREPARATION AND STORAGE 7. 14. Place the remote control in neutral idle speed position and start engine. 9. a b c a . Open the water source of the water hose to a full flow. 15. Snap the quick‑connect fitting with the water hose into the flush socket on the engine. 13. and other components will overheat and suffer damage. Do not exceed 1200 RPM.Flush socket 8. 12. Monitor the engine temperature while operating the engine.Water hose b . 10. Flush the engine for 5 to 10 minutes or until discharge water is clear. Provide a sufficient supply of water to the water inlets during operation. Shut off the engine.SECTION . the water pump. Allow the water to flush the sterndrive for 10 seconds.Quick‑connect fitting (water hose end) 18489 c . the engine. 90-899883178 NOVEMBER 2007 Page 27 / 46 . 11. NOTICE Without sufficient cooling water. Operate the engine at idle speed in neutral gear.

9 17. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem.PREDELIVERY PREPARATION AND STORAGE SECTION .Quick‑connect fitting (water hose end) b . Retain the quick‑connect fitting with the water hose end for repeated use by storing it separately in a storage compartment on the boat for easy access. a b a . IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. a 25900 Quick‑connect fitting stored in the boat a . a b 18487 a .Water hose 19. Disconnect the quick‑connect fitting and water hose from the flush socket on the engine by pressing the release button on the flush socket.Flush socket release button 18. Remove the quick‑connect fitting from the water hose.Quick‑connect fitting (water hose end) Page 28 / 46 90-899883178 NOVEMBER 2007 .Quick‑connect fitting (water hose end) 18488 b .

Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. be used in the seawater section of the cooling system for freezing temperatures or extended storage. Insert the dust cover in the flush socket on the engine. Be certain to follow the propylene glycol manufacturer's recommendations. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. leave the water inlet hose disconnected and plugged. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. Refer to Fuel Requirements for additional information. 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. the seacock should remain closed until time of usage. 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. IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze. or reconnect the alternative water inlet source prior to operating the engine.SECTION . open the seacock. If unit is to be stored out of the water. Preparing Power Package for Storage 1. 2. 18490 Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Open the seacock. 21. keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. 90-899883178 NOVEMBER 2007 Page 29 / 46 . mixed to the manufacturers instructions. if equipped. Follow instructions on the container. If the boat is not fitted with a seacock. a b Dust cover installed in the flush socket a .Dust cover b . 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.9 PREDELIVERY PREPARATION AND STORAGE 20. NOTE: As a precautionary measure.Flush socket IMPORTANT: If the unit is to be stored in the water. If the boat is in the water.

4. 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. causing the bellows to fail when returned to service and allowing water to enter the boat. ! WARNING Fuel vapors trapped in the engine compartment may be an irritant. Refer to Engine and Fuel System Preparation. Always check for leaks before attempting to start the engine and wipe up any spilled fuel immediately. 11. Keep the work area well ventilated and avoid prolonged exposure to vapors. If the boat is not fitted with a seacock. leave the water inlet hose disconnected and plugged. Drain the seawater section of the cooling system immediately after operation or before any length of storage in cold weather. Refer to Draining the Seawater System. or may ignite resulting in a fire or explosion. Flush the cooling system. If the boat is in the water. 5. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System Treatment and Stabilizer Concentrate Page 30 / 46 90-899883178 NOVEMBER 2007 . Store the sterndrive in the full down position. In a 23 liter (6 U. keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. Ensure the key switch is off and the lanyard is positioned so that the engine cannot start. Shut off the engine. 9. 1. Drain the engine seawater cooling system. 8. after draining.89 liter (2 U. Prepare the engine and fuel system for storage. IMPORTANT: In order to run the engine as required in the remainder of the storage preparation procedure.gal. ENGINE AND FUEL SYSTEM PREPARATION ! WARNING Fuel is flammable and explosive. qts.S.) remote fuel tank mix: a. NOTICE The universal joint bellows may develop a set when stored in a raised or up position.S. 7.9 3. Store boat with drive unit in full down/in position.PREDELIVERY PREPARATION AND STORAGE SECTION . Perform this operation.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil c. Refer to the Maintenance section. Ensure that the sterndrive vent holes and water drain holes and passages are unobstructed and open (refer to Draining Instructions). cause difficulty breathing. Provide cooling water to the engine as done in the previous step. 1. NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. For additional assurance against freezing and rust. Do not smoke or allow sources of spark or open flame in the area while servicing. gal) regular unleaded 87 octane (90 RON) gasoline b. Store the battery according to the manufacturer's instructions. 6. 10. 19 liter (5 U. water must be supplied to the engine as described in the flushing procedure. Always ventilate the engine compartment before servicing the power package.S. 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.

IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze. Be certain to follow the propylene glycol manufacturer's recommendations. 90-899883178 NOVEMBER 2007 Page 31 / 46 .9 Tube Ref No. Replace the water separating fuel filter element. Disconnect and plug the fuel inlet fitting if not equipped with a fuel shut off valve. Do not operate the engine with the drain system open.SECTION . After specified operating time is complete. IMPORTANT: Supply cooling water to the engine. 115 124 PREDELIVERY PREPARATION AND STORAGE Description Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer Where Used Fuel system Fuel system Part No. if equipped. Remove the boat from the water or close the seacock. be used in the seawater section of the cooling system for freezing temperatures or extended storage. Refer to Drain System Identification to determine which instructions apply to your power package. IMPORTANT: Ensure that some fogging mixture remains in the engine. Close the fuel shut off valve. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Draining the Seawater System ! CAUTION Water can enter the bilge when the drain system is open. IMPORTANT: The engine must not be operating at any point during the draining procedure. 7. IMPORTANT: Only drain the seawater section of the closed‑cooling system. Your power package is equipped with a drain system. 5. 4. Do not allow the engines fuel system to become completely dry. IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system. Refer to Section 5 for proper procedure. IMPORTANT: Immediately wipe up any fuel spills or sprays. 6. and ensure the bilge pump is operational before draining. 3. Start and operate the engine at 1300 rpm for 5 minutes. Allow the engine to cool down. disconnect and plug the seawater inlet hose. slowly return throttle to idle rpm and shut engine off. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting. 92-858026K01 858071K01 2. damaging the engine or causing the boat to sink. mixed to the manufacturer's instructions.

PREDELIVERY PREPARATION AND STORAGE SECTION .9 Drain System Identification AIR ACTUATED SINGLE POINT DRAIN SYSTEM c a b c a b d d 6124 6125 Closed Cooled Models a .Blue air pump Seawater Cooled Models c .Air manifold d .Blue air pump b .Blue drain plug location Page 32 / 46 90-899883178 NOVEMBER 2007 .Air manifold c .Blue drain plug locations 21125 MANUAL SINGLE POINT DRAIN SYSTEM b a b 6128 a .Green indicators a b c d d Scorpion Models a .Blue drain plug location b .Green indicators d .Blue handle b .

Fuel cooler to thermostat housing 90-899883178 NOVEMBER 2007 Page 33 / 46 .9 PREDELIVERY PREPARATION AND STORAGE THREE POINT MANUAL DRAIN SYSTEM a a .Water circulating pump hose b .Bottom of exhaust manifolds b a 6130 a .Blue drain plug a 6126 MULTI-POINT DRAIN (MPD) SYSTEM b a 93235672 b a 10226 M110050 6129 a .Side of cylinder block b .SECTION .

PREDELIVERY PREPARATION AND STORAGE SECTION . Close the seacock (if equipped) or remove and plug the water inlet hose. Install the air pump on the actuator fitting.Green indicators c . c e a d b a .Lever (locking) 6.Manual release valve 8293 d .Actuator fitting b . 4. Page 34 / 46 90-899883178 NOVEMBER 2007 . Pull lever on air pump (vertical) to lock pump on the fitting. Pump air into the system until both green indicators extend and water drains from both sides of the engine.Check valve (if equipped) Air‑Actuated Single‑Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. Remove the air pump from the engine. 5. 3.9 a 6131 a . However. any air source can be used. 2.Air pump e . The port side will begin draining before the starboard side. 1. Ensure that the lever on top of the pump is flush with the handle (horizontal).

Verify that water is draining from each opening.SECTION . If not.Green indicators a b c d d Scorpion Models a .9 PREDELIVERY PREPARATION AND STORAGE 7.Blue drain plug locations 21125 8. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger.Air manifold c .Starboard side drain location 90-899883178 NOVEMBER 2007 Page 35 / 46 . a a . c a b c a b d d 6124 6125 Closed Cooled Models a .Air manifold d .Blue air pump Seawater Cooled Models c . This must be removed within 30 seconds to properly vent the cooling system.Blue drain plug location b . use the Three Point Manual Drain System instructions.Port side drain location b 6133 b .Blue air pump b .Green indicators d .

13. 14. Pump air as necessary to keep the green indicators extended. 10. Open the seacock. Verify that the green indicators are no longer extended.Manual release valve 8293 d . c e a d b a . Place the boat on a lever surface to ensure complete draining of system.PREDELIVERY PREPARATION AND STORAGE SECTION . BOAT OUT OF THE WATER NOTE: This procedure is written for the air pump that is attached to the engine.Green indicators 15. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Install the air pump on the actuator fitting. 2.Green indicators c . Do not allow engine to start. 12.Air pump e . Remove the air pump from the engine. Ensure that the lever on top of the pump is flush with the handle (horizontal). 1. if equipped. pull up on the manual release valve. 4. This helps ensure that all water is drained. any air source can be used.9 9. or unplug and reconnect the water inlet hose prior to operating the engine. Allow the system to drain for a minimum of five minutes. Pull lever on air pump (vertical) to lock pump on the fitting. 11. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. Reinstall the blue drain plug in the thermostat housing or heat exchanger. 3. a 6135 a .Lever (locking) Page 36 / 46 90-899883178 NOVEMBER 2007 .Actuator fitting b . 5. Before launching the boat. Remove the air pump from the air manifold and return it to the mounting bracket. However.

Green indicators d .Air manifold d . If not.Blue air pump b .Blue drain plug location b .Blue drain plug locations 21125 7.SECTION . Pump air into the system until both green indicators extend and water drains from both sides of the engine.Port side drain location b 6133 b . use the Three Point Manual Drain System instructions.Air manifold c .Starboard side drain location 90-899883178 NOVEMBER 2007 Page 37 / 46 . The port side will begin draining before the starboard side.Green indicators a b c d d Scorpion Models a .Blue air pump Seawater Cooled Models c . a a . c a b c a b d d 6124 6125 Closed Cooled Models a .9 PREDELIVERY PREPARATION AND STORAGE 6. Verify that water is draining from each opening.

Rotate the blue handle counterclockwise until it stops (approximately two turns). Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. 10. This helps ensure that all water is drained. The red on the handle shaft indicates that the drain system is open. Do not allow engine to start. Do not force the handle as this will create new threads. Close the seacock (if equipped) or remove and plug the water inlet hose. 9. 2.Blue drain plug location Page 38 / 46 90-899883178 NOVEMBER 2007 .Green indicators Manual Single‑Point Drain System BOAT IN THE WATER 1. Allow the system to drain for a minimum of five minutes. b a 6136 a . Verify that the green indicators are no longer extended. This must be removed within 30 seconds to properly vent the cooling system. Pump air as necessary to keep the green indicators extended. a 6135 a .PREDELIVERY PREPARATION AND STORAGE SECTION . Before launching the boat. Immediately remove the blue drain plug from the side of the thermostat housing. 3. pull up on the manual release valve. 11. 12.Blue handle b . Crank the engine over slightly with starter motor to purge any water trapped in the seawater pump.9 8. Remove the air pump from the air manifold and return it to the mounting bracket.

The handle is fully seated when no red is visible. Do not overtighten the handle. Close the drain system by rotating the blue handle clockwise until it stops and install the blue drain plug. Open the seacock (if equipped) or unplug and reconnect the water inlet hose before operating the engine. BOAT OUT OF THE WATER 1. Do not overtighten the handle. as this action will create new threads. The red on the handle shaft indicates that the drain system is open. a 6141 a .SECTION . 6. as this action will create new threads.Blue drain plug 5. Rotate the blue handle counterclockwise until it stops (approximately two turns). if removed. Place the boat on a level surface to ensure complete draining of system. 8. Allow the system to drain for a minimum of five minutes. Visually verify that water is draining. Reinstall the blue drain plug in the thermostat housing. We recommend leaving the drain system open while transporting the boat or performing other maintenance. 2. b a a . 7.Blue handle 90-899883178 NOVEMBER 2007 Page 39 / 46 .Drain location ‑ orange or red 6137 b . If water does not drain. remove the blue drain plug from the distribution housing and drain manually.9 PREDELIVERY PREPARATION AND STORAGE 4.

remove the blue drain plug from the distribution housing and drain manually. 5. Three Point Manual Drain System BOAT IN THE WATER NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the air actuated single point drain system fails. as this action will create new threads.Blue drain plug Page 40 / 46 90-899883178 NOVEMBER 2007 . We recommend leaving the plugs out while transporting the boat or performing other maintenance to ensure that all water is drained. Remove the blue drain plug from the distribution housing (lower front. Do not overtighten handle. a 6138 a . b a a . Close the drain system by rotating the blue handle clockwise until it stops or installing the blue drain plug. 1. The handle is fully seated when no red is visible. port side). Visually verify that water is draining.PREDELIVERY PREPARATION AND STORAGE SECTION . If water does not drain.Drain location ‑ orange or red 6137 b .9 3. Close the seacock (if equipped) or remove and plug the water inlet hose. 2. Allow the system to drain for a minimum of five minutes.Blue drain plug 4.

starboard side). a 6139 a .SECTION . Verify that water is draining from each opening. a a . 6. 9. To properly vent the cooling system. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.9 PREDELIVERY PREPARATION AND STORAGE 3. 1. 8.Blue drain plug location 4. Open the seacock. Do not allow the engine to start. if equipped. Allow the system to drain for a minimum of five minutes. BOAT OUT OF THE WATER NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 90-899883178 NOVEMBER 2007 Page 41 / 46 . Prior to launching the boat or starting the engine. Remove the two blue drain plugs from the seawater pickup pump (front.Blue drain plugs 6140 5. remove the blue drain plug from the side of the thermostat housing within 30 seconds. Place the boat on a level surface to ensure complete draining of the system. or unplug and reconnect the water inlet hose prior to operating the engine. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump. close the drain system by installing the four blue drain plugs. 7.

Allow the system to drain for a minimum of five minutes. Do not allow the engine to start. Place the boat on a level surface to ensure complete draining of the system. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained. Bottom of exhaust manifolds b a 93235672 b a 10226 M110050 6129 a . port side) and two from the seawater pickup pump (front. If necessary.Blue drain plug 3. clean out the drain holes using a stiff piece of wire. 2. Verify that water is draining from each opening. Do so until the entire system is drained.PREDELIVERY PREPARATION AND STORAGE SECTION .Exhaust manifold drain plug Page 42 / 46 90-899883178 NOVEMBER 2007 . 6. Remove the blue drain plugs from the following locations. Remove three blue drain plugs: one from the distribution housing (lower front.Cylinder block drain plug b . Prior to launching the boat or starting the engine.9 2. Port and starboard side of cylinder block b. close the drain system by installing the three blue drain plugs. 5. a a 6142 a . starboard side). Multi‑Point Drain (MPD) System BOAT OUT OF THE WATER 1. a. 4. Crank the engine over slightly with starter motor to purge any water trapped in the seawater pickup pump.

Drain plug (if equipped) 90-899883178 NOVEMBER 2007 Page 43 / 46 . Fuel‑cooler‑to‑thermostat‑housing hose a 6144 a .Drain plug e. Water‑circulating pump hose a 6143 a .Drain plug d.9 PREDELIVERY PREPARATION AND STORAGE c.SECTION . Check valve a 6131 a .

Bottom of exhaust manifolds b a 93235672 b a 10226 M110050 6129 a .Blue drain plugs 4.PREDELIVERY PREPARATION AND STORAGE SECTION . Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. 5. Remove the blue drain plugs from the following locations. Close the seacock (if equipped) or remove and plug the water inlet hose. After the cooling system has been drained completely. clean out the drain holes using a stiff piece of wire. 2. reconnect the hoses. If the seawater pickup pump does not have blue drain plugs. BOAT IN THE WATER 1. If necessary. On models with a seawater pickup pump. a. remove the two blue drain plugs. install the drain plugs. or you are unable to access them.9 3. Port and starboard side of cylinder block b. loosen the clamps and remove both hoses.Cylinder block drain plug b .Hose clamps b . Do not allow the engine to start.Exhaust manifold drain plug Page 44 / 46 90-899883178 NOVEMBER 2007 . and tighten all hose clamps securely. a 6145 b a . Do so until the entire system is drained.

9 PREDELIVERY PREPARATION AND STORAGE c. Fuel‑cooler‑to‑thermostat‑housing hose a 6144 a .SECTION .Drain plug e.Drain plug d. Water‑circulating pump hose a 6143 a .Drain plug (if equipped) 90-899883178 NOVEMBER 2007 Page 45 / 46 . Check valve a 6131 a .

or unplug and reconnect the water inlet hose before operating the engine. remove the two blue drain plugs. Do not allow the engine to start.9 3. Power Package Recommissioning 1. 2. Provide a sufficient supply of water to the water inlets during operation. It should be clean and free of leaks. Tighten each cable clamp securely when connecting. Open the seacock. be sure the cells are full of water and the battery is fully charged and in good operating condition. If the seawater pickup pump does not have blue drain plugs. 4. if equipped.Blue drain plugs 4. Always disconnect the negative (‑) battery cable first and connect it last. or you are unable to access them. NOTICE Without sufficient cooling water. 6.PREDELIVERY PREPARATION AND STORAGE SECTION . Ensure that all cooling system hoses are connected properly and hose clamps are tight. On models with a seawater pickup pump. Coat the terminal connections with a battery terminal anti‑corrosion agent. the engine. 7. Follow the battery manufacturer's instructions for storage. Clean the battery cable clamps and terminals and reconnect cables. and other components will overheat and suffer damage. Before launching the boat or starting the engine. 6. 5. shift and throttle control for proper operation. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly. oil. Inspect the steering system. fluid. loosen the clamps and remove both hoses. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. close the drain system by installing the blue drain plugs. a 6145 b a . ! CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. the water pump. 5. 3. Perform all the checks in the before starting column of the Operation Chart. Battery Storage Whenever the battery will be stored for an extended period of time.Hose clamps b . water and exhaust leaks. Install a fully charged battery. Page 46 / 46 90-899883178 NOVEMBER 2007 . Carefully inspect the engine for fuel.

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