8m0133411 PDF

517 eng
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to
ensure operating ease and durability.
8M0133411
With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this manual.
The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready reference whenever you are on the water.
Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant!
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Name / function:
John Pfeifer, President,
Mercury Marine
Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a
8.2 MAG/H.O./SeaCore Models (ECT)

demonstration of actual starting and operating procedures.
Notice
Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the
International Hazard Symbol ! , may be used to alert the installer and user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions
while performing the service, plus common sense operation, are major accident prevention measures.
! 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.
IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard,
and the safety of all occupants aboard. We strongly recommend that the operator read this Operation and Maintenance
Manual and thoroughly understand the operational instructions for the power package and all related accessories before
the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth
defects or other reproductive harm.
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine
power package. When contacting Mercury Marine about service, always specify model and serial numbers.
© 2017 Mercury Marine
Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury
Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to
change specifications or designs without notice and without incurring obligation.
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth
in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of
damages, and other related information. Please review this important information.
Mercury Marine products are designed and manufactured to comply with our own high quality standards, applicable industry
standards and regulations, as well as certain emissions regulations. At Mercury Marine every engine is operated and tested
before it is boxed for shipment to make sure that the product is ready for use. In addition, certain Mercury Marine products are
tested in a controlled and monitored environment, for up to 10 hours of engine run time, in order to verify and make a record of
compliance with applicable standards and regulations. All Mercury Marine product, sold as new, receives the applicable limited
warranty coverage, whether the engine participated in one of the test programs described above or not.
Copyright and Trademark Information

© MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the
Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick
Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.
Identification Records
Please record the following applicable information:
MerCruiser
Engine Model and Horsepower Engine Serial Number
Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
Transmission Model (Inboard) Gear Ratio Transmission Serial Number
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
Exhaust Gas Emissions Certification Number (Europe Only)

TABLE OF CONTENTS
Section 1 - Getting to Know Your Power Package

Additional Operation Instructions for Axius Systems ................ 2 Operation...................................................................... 12
Identification............................................................................... 2 Adjustment.................................................................... 12
Information Decal................................................................ 2 Special Digital Throttle and Shift (DTS) Features............. 13
Quick Response (QR) Code............................................... 2 Dock............................................................................. 14
Engine Serial Number ........................................................ 3 Throttle Only................................................................. 14
Bravo Sterndrive Serial Number and Identification............. 3 1 Lever.......................................................................... 15
Bravo Transom Serial Number........................................... 4 Sync.............................................................................. 15
Lanyard Stop Switch.................................................................. 4 Transfer (Boats equipped with dual helms).................. 16
Keep the Lanyard Stop Switch and Lanyard Cord in Good Helm Transfer................................................................... 16
Operating Condition............................................................. 5 Zero Effort Features.......................................................... 16
Instrumentation.......................................................................... 5 Power Trim............................................................................... 17
VesselView......................................................................... 5 Single Engine Trim/Trailer............................................ 18
Front Controls................................................................. 6 Dual Engine Trim/Trailer............................................... 18
Troll Control Speed Range Specification............................ 6 Trim without Key............................................................... 18
Digital Gauges.................................................................... 6 Trim Delta......................................................................... 18
Analog Gauges................................................................... 7 Electrical System Overload Protection..................................... 18
Remote Controls (Non‑DTS Models)......................................... 8 Visual and Audio Warning Systems......................................... 22
Remote Controls................................................................. 8 Service Engine Light and OBD‑M MIL Kit......................... 22
Panel Mount Features.................................................... 8 Testing the OBD‑M Malfunction Indicator Lamp
Console Mount Features................................................ 8 (MIL)............................................................................. 22
Zero Effort Features............................................................ 9 Audio Warning System..................................................... 22
Remote Controls (DTS Models)................................................. 9 Caution......................................................................... 23
Remote Controls................................................................. 9 Critical........................................................................... 23
Panel Mount Features...................................................... 10 Nonconfigured Alarm–DTS Only.................................. 23
DTS Slim Binnacle Single Handle Console Features and Testing the Audio Warning System.............................. 23
Operation.......................................................................... 10 Guardian Strategy............................................................. 23
Special Digital Throttle and Shift (DTS) Features......... 11
Dual‑Handle Electronic Remote Control (ERC)—Operation
and Adjustment................................................................. 12
Section 2 - On the Water

Additional Operation Instructions for Axius Systems .............. 26 Stopping the Engine..................................................... 32
Safe Boating Recommendations............................................. 26 Throttle Only Operation.................................................... 32
Carbon Monoxide Exposure.................................................... 27 Trailering the Boat............................................................ 32
Be Alert To Carbon Monoxide Poisoning........................... 27 Freezing Temperature Operation..................................... 32
Stay Clear of Exhaust Areas.............................................. 27 Drain Plug and Bilge Pump............................................... 33
Good Ventilation ................................................................ 27 Protecting People in the Water................................................ 33
Poor Ventilation ................................................................. 28 While You Are Cruising...................................................... 33
Basic Boat Operation (Non‑DTS Models)................................ 28 While Boat Is Stationary..................................................... 33
Launching and Boat Operation......................................... 28 High‑Speed and High‑Performance Operation........................ 33
Operation Chart............................................................ 28 Passenger Safety in Pontoon Boats and Deck Boats.............. 33
Starting and Stopping the Engine..................................... 29 Boats Having an Open Front Deck..................................... 33
Starting the Engine....................................................... 29 Boats With Front‑Mounted, Raised Pedestal Fishing Seats
Stopping the Engine..................................................... 29 ........................................................................................... 34
Starting the Engine After It Has Been Stopped While In Wave and Wake Jumping........................................................ 34
Gear.................................................................................. 30 Impact with Underwater Hazards............................................. 34
Throttle Only Operation.................................................... 30 Drive Unit Impact Protection............................................... 35
Trailering the Boat............................................................ 30 Operating with Low Water Inlets in Shallow Water.................. 35
Freezing Temperature Operation..................................... 30 Conditions Affecting Operation................................................ 35
Drain Plug and Bilge Pump............................................... 30 Weight Distribution (Passengers and Gear) Inside the
Basic Boat Operation (DTS Models)........................................ 30 Boat.................................................................................. 35
Launching and Boat Operation......................................... 30 The Bottom of the Boat..................................................... 36
Operation Chart............................................................ 30 Cavitation.......................................................................... 36
Starting and Stopping the Engine..................................... 31 Ventilation......................................................................... 36
Starting the Engine....................................................... 31 Elevation and Climate....................................................... 36
90-8M0133411 eng MAY 2017 Page i

Propeller Selection.......................................................... 36 After the Break‑In Period................................................. 37
Getting Started....................................................................... 37 End of First Season Checkup.......................................... 37
20‑Hour Break‑In Period................................................. 37
Section 3 - Specifications
Fuel Requirements................................................................. 40 Engine Oil............................................................................... 41
Fuel Ratings...................................................................... 40 Preventing Contamination of the Emissions Control
Using Reformulated (Oxygenated) Gasoline (USA Only) System.................................................................................... 42
.......................................................................................... 40 Fluid Specifications................................................................. 42
Gasoline Containing Alcohol............................................. 40 Engine............................................................................. 42
Bu16 Butanol Fuel Blends.......................................... 40 Bravo Sterndrives............................................................ 42
Methanol and Ethanol Fuel Blends............................. 40 Power‑Assisted Steering and Power Trim Fluids............ 43
Engine Specifications............................................................. 40 Approved Power‑Assisted Steering Fluids.................. 43
8.2 MAG ECT, 8.2 MAG H.O. ECT—Including SeaCore Approved Power Trim Fluids....................................... 43
Models............................................................................. 40
Section 4 - Maintenance
Additional Operation Instructions for Axius Systems ............. 46 Cleaning the Flame Arrestor................................................... 57
Owner/Operator Responsibilities............................................ 46 Cleaning the IAC Muffler (Non‑DTS Models Only)................. 58
Dealer Responsibilities........................................................... 46 Changing the Positive Crankcase Ventilation Valve (PCV).... 59
Maintenance........................................................................... 46 Water‑Separating Fuel Filter.................................................. 59
Do‑It‑Yourself Maintenance Suggestions............................... 46 Removal and Installation................................................. 60
Inspection............................................................................... 47 Removal...................................................................... 60
MerCruiser Gas Sterndrive Inspection and Maintenance Installation................................................................... 60
Schedule................................................................................. 47 Lubrication.............................................................................. 61
Daily Checks..................................................................... 47 Steering System.............................................................. 61
After Each Use.................................................................. 47 Throttle Cable.................................................................. 62
Weekly Checks................................................................. 47 Shift Plate Control Cable Lubrication.............................. 63
Every Two Months or 50 Hours........................................ 47 Shift Cable ‑ DTS............................................................ 63
Annually or 100 Hours...................................................... 47 Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit
Three Years or 300 Hours................................................ 48 Removed)........................................................................ 63
Five Years or 500 Hours................................................... 48 Engine Coupler................................................................ 64
Engine Oil............................................................................... 48 Driveshaft Extension Models........................................... 64
Checking..................................................................... 48 Propellers............................................................................... 64
Filling........................................................................... 49 Propeller Repair.............................................................. 64
Changing Oil and Filter.................................................... 49 Bravo One Propeller Removal......................................... 65
Oil Removal with Drain Pump......................................... 49 Bravo One Propeller Installation...................................... 65
Changing the Oil Filter..................................................... 50 Bravo Two Propeller Removal......................................... 66
Power‑Assisted Steering Fluid............................................... 51 Bravo Two Propeller Installation...................................... 66
Checking......................................................................... 51 Bravo Three Propeller Removal...................................... 67
Filling............................................................................... 51 Bravo Three Propeller Installation................................... 68
Changing......................................................................... 51 Serpentine Drive Belt.............................................................. 69
Closed Cooling System.......................................................... 51 Inspection........................................................................ 69
Coolant Requirement...................................................... 51 Checking......................................................................... 70
Checking Coolant Level.................................................. 52 Replacing........................................................................ 70
.................................................................................... 52 Corrosion Protection............................................................... 71
Filling the Closed Cooling System................................... 52 Corrosion Information...................................................... 71
Draining........................................................................... 53 Maintaining Ground Circuit Continuity............................. 71
Cleaning.......................................................................... 53 MerCathode System Battery Requirements.................... 71
Sterndrive Gear Lube............................................................. 53 MerCathode Theory of Operation.................................... 71
Checking......................................................................... 53 Anodes and MerCathode System Locations................... 72
Filling............................................................................... 54 Do Not Use Caustic Cleaning Chemicals........................ 73
Changing......................................................................... 54 Power Package Exterior Surfaces................................... 74
Power Trim Fluid.................................................................... 56 Boat Bottom Care............................................................ 74
Checking........................................................................... 56 Antifouling Paint.............................................................. 74
Filling................................................................................ 56 Sterndrive Surface Care.................................................. 75
Changing.......................................................................... 56 Flushing the Seawater System—Sterndrive Models.............. 76
Battery.................................................................................... 56
Multiple EFI Engine Battery Precautions......................... 57
Page ii 90-8M0133411 eng MAY 2017

Flushing the Power Package—Bravo Models.................. 76 Alternative Water Pickups............................................ 78
Flushing Attachments................................................... 76 SeaCore Power Package Flushing Procedure................. 79
Sterndrive Water Pickups............................................. 77 Models Using the Sterndrive Water Pickup.................. 79
Section 5 - Storage
Cold Weather or Extended Storage......................................... 84 Air‑Actuated Single‑Point Drain System........................... 88
Reformulated (Oxygenated) Gasolines (U.S.A. Only)...... 84 Boat in the Water.......................................................... 88
Fuel Containing Alcohol.................................................... 84 Boat Out of the Water................................................... 89
Preparing Power Package for Storage—MPI Models....... 84 Manual Drain System....................................................... 90
Special Fuel Mix........................................................... 85 Boat in the Water.......................................................... 90
Engine and Fuel System Preparation........................... 85 Boat Out of the Water................................................... 91
Maintenance..................................................................... 86 Draining Water from the Cool Fuel Module...................... 92
Draining the Seawater System ............................................... 86 Draining the Sterndrive..................................................... 92
Drain System Identification............................................... 87 Battery Storage........................................................................ 93
Air‑Actuated Single‑Point Drain System....................... 87 Recommissioning the Power Package.................................... 93
Manual Drain System................................................... 87
Section 6 - Troubleshooting
Diagnosing EFI Problems........................................................ 96 Insufficient Engine Temperature....................................... 97
Diagnosing DTS Problems....................................................... 96 Low Engine Oil Pressure.................................................. 97
Additional Operation Instructions for Axius Systems .............. 96 Battery Will Not Recharge................................................ 98
Engine Guardian System......................................................... 96 Remote Control Is Difficult to Move, Has Excessive Play, or
Troubleshooting Charts............................................................ 96 Makes Unusual Sounds.................................................... 98
Starter Motor Will Not Crank Engine, or Cranks Slowly.... 96 Steering Wheel Jerks or Is Difficult to Turn...................... 98
Engine Will Not Start or Is Hard to Start........................... 96 Power Trim Does Not Operate (Motor Does Not
Engine Runs Rough, Misses, or Backfires....................... 97 Operate)............................................................................ 98
Poor Performance............................................................. 97 Power Trim Does Not Operate (Motor Operates but
Excessive Engine Temperature........................................ 97 Sterndrive Unit Does Not Move)....................................... 98
Section 7 - Customer Assistance Information

Owner Service Assistance..................................................... 100 Contact Information for Mercury Marine Customer Service
Local Repair Service........................................................ 100 ......................................................................................... 101
Service Away From Home................................................ 100 Customer Service Literature.................................................. 101
Stolen Power Package..................................................... 100 English Language............................................................ 101
Attention Required After Submersion............................... 100 Other Languages.............................................................. 102
Replacement Service Parts.............................................. 100 Ordering Literature................................................................. 102
Parts and Accessories Inquiries................................. 100 United States and Canada............................................... 102
Resolving a Problem........................................................ 100 Outside the United States and Canada............................ 102
Section 8 - Checklists
Predelivery Inspection (PDI).................................................. 104 Customer Delivery Inspection (CDI)...................................... 105
Section 9 - Maintenance Log

Scheduled Maintenance Log................................................. 108 Vessel Maintenance Notes.................................................... 109
90-8M0133411 eng MAY 2017 Page iii

Page iv 90-8M0133411 eng MAY 2017
Section 1 - Getting to Know Your Power Package 1

Table of Contents
Additional Operation Instructions for Axius Systems ............. 2 Dual‑Handle Electronic Remote Control (ERC)—
Identification........................................................................... 2 Operation and Adjustment............................................. 12
Information Decal............................................................. 2 Operation ............................................................... 12
Quick Response (QR) Code............................................ 2 Adjustment ............................................................ 12
Engine Serial Number ..................................................... 3 Special Digital Throttle and Shift (DTS) Features.......... 13
Bravo Sterndrive Serial Number and Identification.......... 3 Dock ...................................................................... 14
Bravo Transom Serial Number........................................ 4 Throttle Only .......................................................... 14
Lanyard Stop Switch............................................................... 4 1 Lever .................................................................. 15
Keep the Lanyard Stop Switch and Lanyard Cord in Sync ...................................................................... 15
Good Operating Condition .............................................. 5 Transfer (Boats equipped with dual helms) ........... 16
Instrumentation....................................................................... 5 Helm Transfer................................................................ 16
VesselView...................................................................... 5 Zero Effort Features....................................................... 16
Front Controls .......................................................... 6 Power Trim........................................................................... 17
Troll Control Speed Range Specification......................... 6 Single Engine Trim/Trailer ..................................... 18
Digital Gauges................................................................. 6 Dual Engine Trim/Trailer ....................................... 18
Analog Gauges................................................................ 7 Trim without Key............................................................ 18
Remote Controls (Non‑DTS Models)...................................... 8 Trim Delta...................................................................... 18
Remote Controls.............................................................. 8 Electrical System Overload Protection................................. 18
Panel Mount Features ............................................. 8 Visual and Audio Warning Systems..................................... 22
Console Mount Features ......................................... 8 Service Engine Light and OBD‑M MIL Kit...................... 22
Zero Effort Features......................................................... 9 Testing the OBD‑M Malfunction Indicator Lamp (MIL)
Remote Controls (DTS Models)............................................. 9 .............................................................................. 22
Remote Controls.............................................................. 9 Audio Warning System.................................................. 22
Panel Mount Features................................................... 10 Caution .................................................................. 23
DTS Slim Binnacle Single Handle Console Features and Critical ................................................................... 23
Operation....................................................................... 10 Nonconfigured Alarm–DTS Only ........................... 23
Special Digital Throttle and Shift (DTS) Features Testing the Audio Warning System ....................... 23
.............................................................................. 11 Guardian Strategy.......................................................... 23
90-8M0133411 eng MAY 2017 Page 1

Additional Operation Instructions for Axius Systems

If your boat has DTS engines equipped with an Axius system, refer also to the Axius Operation Manual included with the
boat.
Identification
The serial numbers are the manufacturer's key to numerous details which apply to your MerCruiser power package. When
contacting MerCruiser about service, always specify model and serial numbers.
Information Decal
The information decal is located on the coolant reservoir.
a a- Quick response code

b
b- Service point information
c- Engine serial number
d- Transom serial number
e- Sterndrive serial number
f- Specifications
d
e
f
50314
Quick Response (QR) Code

Scan the QR code link with a smartphone to access additional product information.
50444
QR code
Page 2 90-8M0133411 eng MAY 2017

Engine Serial Number

The engine serial number stamp is located on the starboard side of the engine block next to the flywheel housing cover.
a b c a - Flywheel housing cover

b - Engine serial number stamp
c - Engine block
43554
Bravo Sterndrive Serial Number and Identification

The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate on the port side
of the sterndrive.
33533
Bravo sterndrive information on ground plate
The serial number is also stamped on the driveshaft housing behind the back cover. This is used as a permanent reference for
authorized MerCruiser dealers.
44426
Bravo sterndrive serial number stamping
90-8M0133411 eng MAY 2017 Page 3

Bravo Transom Serial Number

The Bravo transom serial number is stamped in the transom assembly decal.
Transom Serial No.
53651
The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser
dealers.
44425
Serial number location on gimbal housing
Lanyard Stop Switch

A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as
may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.
A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.
ATTACH LANYARD
RUN
a - Lanyard cord clip
b b - Lanyard decal
OFF
c - Lanyard stop switch
a
c
53910
Accidental ejections, such as falling overboard, are more likely to occur in:
• Low‑sided sport boats
Page 4 90-8M0133411 eng MAY 2017

• Bass boats
• High‑performance boats
Accidental ejections can also occur from:
• Poor operating practices
• Sitting on the seat or gunwale at planing speeds
• Standing at planing speeds
• Operating at planing speeds in shallow or obstacle‑infested waters
• Releasing your grip on the steering wheel
• Carelessness caused by consuming alcohol or drugs
• High‑speed boating maneuvers
The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long when stretched out, with an element on one end made
to be inserted into the switch, and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest
condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is
made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the
operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying a knot in
the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance,
depending upon its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.
Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an
emergency.
! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the stop switch using a lanyard.
Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of
the following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the
front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.
• Loss of power and directional control in heavy seas, strong current, or high winds.
• Loss of control when docking.
! WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition
Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard
cord. If the engine does not stop, have the switch repaired before operating the boat.
Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or
wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard
cords.
Instrumentation
VesselView
Your power package may have a SmartCraft VesselView display. VesselView is a comprehensive boat information center that
can display information for up to four gasoline or diesel engines. It continuously monitors and reports basic operating data, such
as information on fuel, oil, water and waste tanks, and will alert the operator if certain problems arise.
VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible devices to
provide up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.
90-8M0133411 eng MAY 2017 Page 5

Front Controls
a c d
b f
g
52293
a- Touch screen
b- Mark–Menu button
c- Standby–Auto button
d- Exit button
e- Rotary knob (press for enter function)
f- Goto–Pages button
g- In/out zoom, man overboard (MOB) button
h- Power/brightness
i- Card reader door
Troll Control Speed Range Specification

Troll Control Speed Range Specification
DTS Engine Model RPM
8.2 Mag with Emissions Control 650–1200
8.2 Mag H.O. with Emissions Control 650–1200
Digital Gauges
A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument
package will display are engine RPM, coolant temperature, oil pressure (requires a SmartCraft oil pressure sender kit), battery
voltage, fuel consumption, and engine operating hours.
Page 6 90-8M0133411 eng MAY 2017

SmartCraft digital gauges also feature troll control. This allows a vessel to maintain a constant speed with an engine speed
between the specified RPM range.
a b SmartCraft gauges
a - Tachometer
b - Speedometer
c - LCD system view display
c
26238
The SmartCraft instrument package also aids in Engine Guardian diagnostics. The SmartCraft instrument package displays
critical engine alarm data and potential problems.
Refer to the manual with your gauge package for the warning functions monitored by and basic operation of the SmartCraft
instrument package.
Analog Gauges
The following is a brief explanation of the instrumentation typically found on some boats. The owner and operator should be
familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should
have your boat dealer explain the particular gauges and normal readings for your boat.
50 60 4
3 5
90
80 100
40 70 110 70 2 6
60
50 120 C H
30 40
L H 10 16
30 1 7
KPH
20
80 X 1000
10 0 8 BATT TEMP
MPH RPM OIL
a b c d e
0
4
4
4
0 0 0 0 0
CRUISELOG
FUEL
TRIM
f g h i j 14671
Reference Gauge Function

a Speedometer Indicates boat speed.
b Tachometer Indicates engine RPM.
c Oil pressure gauge Indicates engine oil pressure.
d Voltmeter Indicates battery voltage.
e Coolant temperature gauge Indicates engine operating temperature.
f Fuel gauge Indicates quantity of fuel in tank.
g Hour meter Records engine operating time.
h Bilge blower switch Operates the bilge blower.
i Ignition switch Allows the operator to start and stop engine.
j Power trim gauge Indicates sterndrive angle (trim up [out] and down [in]).
90-8M0133411 eng MAY 2017 Page 7

Remote Controls (Non‑DTS Models)

Remote Controls
Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features
shown. Consult your dealer for a description and/or demonstration of your remote control.
Panel Mount Features
a e a- Neutral lock button

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

b b- Control handle
d c c- Power trim switch
d- Trailer switch
a d
a c mc79503-1
Page 8 90-8M0133411 eng MAY 2017

Throttle only button ‑ Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the
neutral position.
Control handles ‑ Operation of the shift and throttle are controlled by the movement of the control handle. Push the control
handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to
increase speed. Pull the control handle back from neutral with a quick firm motion to the first detent for reverse gear and
continue pushing back to increase speed.
Control handle tension adjustment screw (not visible) ‑ This screw is used to adjust the effort required to move the remote
control handle. Refer to instructions provided with remote control for complete adjustment instructions.
Power trim switch ‑ See Power Trim section for detailed power trim operating procedures.
Trailer switch ‑ Used to raise drive unit for trailering, launching, beaching or shallow water operation. See Power Trim for
detailed trailer switch operation.
Zero Effort Features
c a - Shift lever
b b - Throttle lever
a c - Trim/tilt switch
5656
Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its
aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its
forward position.
Throttle lever ‑ Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle
lever forward. Achieve wide‑open throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by
moving the throttle lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.
Trim/tilt switch ‑ Refer to Power Trim.
Remote Controls (DTS Models)

Remote Controls
IMPORTANT: Your boat must be equipped with a Mercury Marine electronic remote control. Start in gear protection is provided
by this control system and prevents the engine from starting when the control is actuated in forward or reverse. Refer to the
Mercury Precision Parts/Quicksilver Accessories Guide.
The digital throttle and shift (DTS) system required to operate this engine package provides start and stop functions, throttle
control, shift control, start in gear protection, and emergency lanyard stop functions. The DTS system works with specialized
helm components such as a command module kit and electronic remote control. Consult your dealer for a description and/or
demonstration of your remote control.
90-8M0133411 eng MAY 2017 Page 9

Panel Mount Features
d a- Lanyard stop switch

c b- Control handle
e c- Shift lock
- +
b d- Trim/tilt switch
f
e- Throttle only button
h f- Start/stop button
g- Detent tension adjustment screw
a h- Control handle friction adjustment screw
3409
g
Lanyard stop switch ‑ Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away
from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.
Control handle ‑ Operation of the shift and throttle are controlled by the movement of the control handle. Push the control
handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase
speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue
pushing back to increase speed.
Shift lock ‑ Pressing the shift lock allows the engine to shift. The shift lock must always be pressed when moving the control
handle out of the neutral position.
Trim/tilt switch (if equipped) ‑ Refer to Power Trim.
Throttle only button ‑ Allows engine throttle advancement without shifting the engine. The throttle only button can be
depressed only when the remote control is in the neutral position, and should only be used to assist in starting or warming up
the engine.
Start/stop button ‑ Allows the boat operator to start or stop the engine without using the ignition key.
Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort required to move the control
handle out of the detent positions (cover must be removed). Turning the screw clockwise will increase tension.
Control handle friction adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control
handle (cover must be removed). This will help prevent unwanted motion of the handle in rough water. Turn the screw
clockwise to increase tension and counterclockwise to decrease tension.
DTS Slim Binnacle Single Handle Console Features and Operation

1. Operation of shift and throttle is controlled by the movement of the control handle. Push the control handle forward from
neutral to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from
neutral to the first detent for reverse gear. Continue pushing back to increase speed.
2. Trim switch (if equipped) ‑ When the power trim switch is activated on the ERC handle, the DTS command module senses
a closed circuit for either up or down trim. The DTS command module formulates a signal and sends it to the PCM. The
PCM closes the ground circuit to the up or down trim relay.
b a- Forward
b- Neutral
c- Reverse
d- Trim switch
a c
d
52360
3. Detent tension adjustment screw ‑ This screw can be adjusted to increase or decrease the effort to move control handle
out of detent positions. Turning screw clockwise will increase tension. Adjust to tension desired.
Page 10 90-8M0133411 eng MAY 2017

4. Control handle tension adjustment screw ‑ This screw can be adjusted to increase or decrease the tension on the control
handle. This will help prevent unwanted motion of the remote control handle in rough water. Turn screw clockwise to
increase tension and counterclockwise to decrease tension. Adjust to tension desired.
a - Caps (2)
b - Detent tension adjustment
c - Control handle tension adjustment
a
b c
52313
NOTE: The control handle tension and detent tension screws may require periodic maintenance adjustment.
Special Digital Throttle and Shift (DTS) Features
The DTS system features several alternate operational modes for the electronic remote control (ERC) levers.
a
STOP/
START b
h N
g DOCK TRANSFER
c
THROTTLE - ONLY d
f e
52365
Slim binnacle ERC
Item Control Function

Raises and lowers the engine for best efficiency, or for conditions such as shallow water,
a Trim control (handle)
trailering, etc.
Allows the operator to start or stop the engine without the use of the key switch. The key switch
b "Stop/Start"
must be in the run position for the start/stop switch to function.
c "Transfer" Allows boat control to be transferred to a different helm.
Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission
d "Throttle‑only"
into gear.
e "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.
f "–" Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.
Reduces control lever operation throttle capacity to approximately 50% of normal control lever
g "Dock"
throttle demand.
Illuminates when the drive is in the neutral gear position. The lights flash when the engine is in
h Neutral light
throttle only mode.
90-8M0133411 eng MAY 2017 Page 11

Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment

Operation
The electronic remote control (ERC) handle controls the shift and throttle operation. Push the control handle forward from
neutral to the first detent for forward gear. Continue pushing the handle forward to increase speed. Pull the control handle from
the forward position to the neutral position to decrease speed and eventually stop. Pull the control handle back from neutral to
the first detent for reverse gear. Continue pulling the handle back to increase speed in reverse.
NOTE: In certain modes, the gear position is determined by the electronic shift control (ESC), not the position of the ERC
levers. When using the joystick or while in Skyhook, the computer controls the shifting in and out of gears even though the
handles are in neutral.
b a - Forward
b - Neutral
c - Reverse
c a
51902
The amount of force needed to move the handles and to move the handles through the detents is adjustable to help prevent
unwanted motion.
Adjustment
NOTE: The control handle tension and detent tension may require periodic maintenance using the adjustment screws.
To adjust the handle detent tension:
1. Remove the side cover plugs of the handle that needs adjustment.
2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.
3. Adjust to the tension desired.
To adjust handle tension:
1. Remove the side cover plugs of the handle that needs adjustment.
2. Turn the adjustment screw clockwise to increase tension on the control handle and counterclockwise to decrease tension.
3. Adjust to the tension desired.
a - Detent tension adjustment screw

b - Handle tension adjustment screw
a b
51901
Page 12 90-8M0133411 eng MAY 2017

Special Digital Throttle and Shift (DTS) Features

The DTS system features several alternate operational modes for the electronic remote control (ERC) levers. Any of the listed
features can operate simultaneously.
a c
j d
i e
h f
g
51853
Dual-engine ERC
Item Control Function

Raises and lowers the engines for best efficiency, or for conditions such as shallow water,
a Trim control (handle)
trailering, etc.
Trim control (CAN
b Raises and lowers all the engines.
pad)
Illuminate when the drive is in the neutral gear position. The lights flash when the engine is in
c "NEUTRAL" lights
throttle only mode.
d "TRANSFER" Allows boat control to be transferred to a different helm. Refer to Helm Transfer.
Available with joystick operation and the control levers.
Joystick operation reduces throttle capacity to approximately 70% of normal joystick throttle
e "DOCK" demand.
Control lever operation reduces throttle capacity to approximately 50% of normal control lever
throttle demand.
f "+" Increases brightness settings for CAN pad, VesselView and SmartCraft gauges.
Allows the boat operator to increase engine RPM for warm‑up without shifting the transmission
g "THROTTLE ONLY"
into gear.
h "–" Decreases brightness settings for CAN pad, VesselView and SmartCraft gauges.
i "1 LEVER" Enables the throttle and shift functions of both engines to be controlled by the port lever.
j "SYNC" Turns off or on the auto‑synchronization feature.
NOTE: Not all functions may be active.
90-8M0133411 eng MAY 2017 Page 13

Dock
Dock mode is available with joystick operation and remote control lever operation. Dock mode reduces throttle capacity to
approximately 70% of normal joystick throttle demand, allowing finer control of engine power in close quarter situations. If more
power is needed for vessel maneuvering when environmental conditions require more thrust, use the electronic remote control
levers.
51854
"DOCK" button
Throttle Only
NOTE: The joystick can become active when it is moved any time the engines are running and the ERC levers are in the
neutral position. Throttle only mode should be used to disable the joystick if the captain is not in command at the helm. Placing
the ERC in throttle only will avoid unintended gear engagement. The engines will turn using the steering wheel or the joystick
and the RPM of the engines can be increased while in the throttle only mode, but the gear position will remain in neutral.
51855
"THROTTLE ONLY" button
To engage throttle only mode:

1. Place both ERC levers in neutral.
2. Press the "THROTTLE ONLY" button. The button light will turn on and the neutral lights will blink.
3. Place either ERC lever into gear. The warning horn will beep each time the levers are moved in and out of gear while in
throttle only, but will remain in neutral.
4. The RPM of the engines can be increased.
5. Throttle only mode also affects the joystick. The engines will move and the RPM can be increased, but will remain in
neutral.
NOTE: Pressing the "THROTTLE ONLY" button while the ERC levers are not in the neutral position, turns the button light off
and remains in throttle only mode. You must place the ERC levers into the neutral position to disengage throttle only mode.
To disengage throttle only mode:
1. Place both ERC levers into neutral. Throttle only will not disengage unless the ERC levers are in neutral.
2. Press the "THROTTLE ONLY" button. The button light will turn off.
3. The neutral lights stop flashing and remain illuminated. The joystick can now be used.
Page 14 90-8M0133411 eng MAY 2017

1 Lever
The outboard joystick system features the ability to command both engines with a single lever on a dual‑engine application.
This feature simplifies engine management during rough sea conditions by allowing you to use a single lever to command both
engines simultaneously. It has no affect on the joystick function. It is not the same as the system feature called Sync.
51856
"1 LEVER" button
To engage 1 Lever mode:

2. Press the "1 LEVER" button. The button light will turn on.
3. Place the starboard ERC lever into gear.
4. When the handle is moved, the engines RPM and gear position is synchronized.
To disengage 1 lever mode:
2. Press the "1 LEVER" button. The button light turns off.
Sync
Sync is an automatic engine synchronization feature that is always on unless it is turned off. Sync monitors the position of both
ERC levers. When both levers are within 10% of one another, the port engine synchronizes to the starboard engine's RPM. The
SmartCraft system will automatically disengage sync after 95% of throttle position range to allow each engine the ability to
reach maximum available RPM. Sync cannot engage until the engines are at a minimum speed.
The indicator light on the "SYNC" button is on when both engines are on. The light is yellow at idle and 95% of throttle and
when the engines are not synchronized. The light turns red when the engines are synchronized.
51857
"SYNC" button
The RPM display of VesselView also shows an orange icon under the RPM numbers if the engines RPMs differ more than 10%
of each other, and the icon turns red when they are synchronized.
To disengage sync mode:
1. Place the ERC levers in any detent.
2. Press the "SYNC" button. The button light turns off.
To engage Sync mode, press the "SYNC" button at any time.
90-8M0133411 eng MAY 2017 Page 15

Transfer (Boats equipped with dual helms)

The "TRANSFER" button allows the boat operator to transfer control of the boat from the active helm to the inactive helm on
boats equipped with dual helms. Refer to Helm Transfer.
51858
"TRANSFER" button
Helm Transfer
Some boats are designed to allow control of the vessel from more than one location. These locations are commonly referred to
as helms or stations. Helm transfer is a term used to describe the method of transferring control from one helm (or station) to
another helm.
! WARNING
Avoid serious injury or death from loss of boat control. The boat operator should never leave the active station while engine is
in gear. Helm transfer should only be attempted while both stations are manned. One‑person helm transfer should only be
performed while engine is in neutral.
The helm transfer function allows the boat operator to select which helm is in control of the vessel. Before a transfer can be
initiated the ERC levers at the active helm and at the helm intended for the transfer must be in the neutral position.
NOTE: If you attempt to transfer helm control when the ERC levers are not in neutral, a beep will sound and the helm transfer
will not succeed until the levers at the helms are moved to neutral and transfer is requested again.
Some fault codes may appear on VesselView if other control or navigation functions are attempted after the helm transfer
procedure is started. To remove the fault codes it may be necessary to cycle the key switch off and on, and then restart the
helm transfer procedure. Ensure that other control and navigation inputs are performed after helm transfer is complete to avoid
setting fault codes.
NOTICE
The ERC levers must be in neutral to perform a helm transfer. While in neutral your vessel could drift and collide with objects
nearby resulting in damage. Keep an adequate look out while performing the helm transfer.
To avoid damage, use extra care when attempting a helm transfer while the vessel is close to docks, piers, or other fixed items
or when near other vessels.
Zero Effort Features
c a - Shift lever
b b - Throttle lever
a c - Trim/tilt switch
5656
Page 16 90-8M0133411 eng MAY 2017

Shift lever ‑ Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its
aft position. Shift into neutral by moving the shift lever to its center position. Shift into forward by moving the shift lever to its
forward position.
Throttle lever ‑ Throttle functions are controlled by the movement of the throttle lever. Increase the RPM by moving the throttle
lever forward. Achieve wide‑open throttle (WOT) by placing the throttle lever in its full forward position. Decrease RPM by
moving the throttle lever back. Achieve minimum RPM (idle) by placing the throttle lever in its full aft position.
Trim/tilt switch ‑ Refer to Power Trim.
Power Trim
Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load
and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering,
beaching, launching, low speed (below 1200 RPM engine speed), and shallow water operation.
! WARNING
Excessive trim can cause serious injury or death at high speeds. Use caution when trimming the sterndrive, and never trim
out beyond the gimbal ring support flanges while the boat is underway or at engine speeds above 1200 RPM.
For best performance trim the sterndrive unit so that the boat bottom is at a 3–5° angle to the water.
3-5
mc79528
Trimming sterndrive unit up/out can:

• Generally increase top speed
• Increase clearance over submerged objects or a shallow bottom
• Cause boat to accelerate and plane off slower
• In excess, cause boat porpoising (bouncing) or propeller ventilation
• Cause engine overheating if trimmed up/out to a point where any cooling water intake holes are above the waterline
mc78529
Trimming sterndrive unit down/in can:

• Help the boat accelerate and plane off quicker
• Generally improve the ride in choppy water
• In most cases, reduce boat speed
90-8M0133411 eng MAY 2017 Page 17

• If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane.
This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a
significant wave is encountered.
mc79530
Single Engine Trim/Trailer

Single engine applications will have a button that can be pressed to trim the sterndrive unit up or down.
To raise the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM), and shallow water operation push
the trim button to raise the sterndrive unit to the full up/out position.
Some controls also have a trailer button that trims the sterndrive to a position suitable for trailer purposes only.
NOTE: The DTS control system limits the extent to which the sterndrive unit can be trimmed up/out when engine speed is
above 3500 RPM.
Dual Engine Trim/Trailer
NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering
systems. If using an external tie bar, raise and lower all drives together as a unit.
Dual engine applications may have a single integral button to operate both sterndrive units simultaneously or may have
separate buttons for each sterndrive unit.
Some controls also have a trailer button that trims the sterndrives to a position suitable for trailer purposes only.
Trim without Key

Trim without key is a method of allowing trim operation after the ignition key switch is turned off. The command module and
PCM remain powered and are able to process trim requests for up to 15 minutes after the key switch is turned off. The
command module does not process any requests other than trim during this period. Once the 15 minute period expires, the
command module sends a command through the CAN lines to shut down the PCM. On multi‑engine applications, the timeout is
managed separately for each engine.
The trim without key period may be ended at any time by moving the control handle to wide‑open throttle reverse (WOTR) with
the key off. To end the 15 minute period for the center engine in a shadow mode application, ensure all ignition key switches
are in the "OFF" position and both remote control handles are in the wide‑open throttle reverse (WOTR) position.
Trim Delta
Trim delta controls the distance between the individual adjacent drive angles when trimming. The trim delta limit is preset, and
will not allow extreme drive angle differences that could damage tie bars. If the maximum trim delta limit is met, the drive
furthest in the trim process "up or down", will stop trimming until the adjacent drive is back within the delta limit. Once the drive
or drives are back within this delta window, the trim process will continue.
Electrical System Overload Protection

If an electrical overload occurs, a fuse will open or the circuit breaker will open. The cause must be found and corrected before
replacing the fuse or resetting the circuit breaker.
NOTE: In an emergency, when you must operate the engine and cannot locate the cause for the high current draw, turn off or
disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker. If the breaker remains
open, the electrical overload has not been eliminated. Contact your authorized dealer as soon as possible.
Page 18 90-8M0133411 eng MAY 2017

The circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. To reset the circuit
breaker, push the red button. The circuit breaker is located at the starboard rear of the engine in the electrical center.
51332
A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload
occurs.
43202
Four fuses protect the main power, fuel pump, ignition, and accessory circuits. Four 10‑amp fuses protect the O2 sensors.
These fuses are located near the 14‑pin harness connector.
a- Good fuse
b- Bad fuse
c- Alternator and fuel pump circuit ‑ 20‑amp fuse
d- Power to 14‑pin helm harness ‑ 20‑amp fuse
e- ECM driver power, fuel pump relay, coils, and start relay
(DTS) ‑ 20‑amp fuse
f - Trim down relay (DTS), trim up relay, and injectors circuit ‑
20‑amp fuse
g - Spare fuse
e c a
20 20
f
20
20 20
g d 50401
90-8M0133411 eng MAY 2017 Page 19

The clean power harness connected to the engine starting battery minimizes voltage drop to the electrical system and is
protected by a 5‑amp fuse.
a b c d e a- Paddle wheel and tank level connector

b- Diagnostic connector
c- 14‑pin harness connector
d- Clean power harness connector
e- Transom harness connector
43057
A 15‑amp accessory fuse protects the accessory circuits. This fuse is located on the rear of the engine.
c
a - Fuse cover
a b b - 15‑amp fuse
c - Accessory harness
32206
The emissions control system is protected by a 5‑amp fuse located in the clean power harness.
a - 5‑amp fuse
b - Positive (+) battery terminal (harness lead with fuse)
c - Negative (–) battery terminal
a b c
43608
Page 20 90-8M0133411 eng MAY 2017

A 20‑amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for an open fuse or
an open circuit breaker if the ignition key is turned to the "START" position and nothing happens.
mc70525-1
The power trim system is protected from overload by both a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump.
The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or
battery connection.
a - 20‑amp spade fuse

b - 110‑amp fuse
b 9208
The power trim control panel is protected by a 20‑amp in‑line fuse.
53673
90-8M0133411 eng MAY 2017 Page 21

The MerCathode has a 5‑amp fuse that connects to the positive (+) terminal on the controller. If the fuse is open, the system
will not operate, resulting in a loss of corrosion protection.
a
a - MerCathode
b - Red/purple wire
c - 5‑amp fuse
50534
Visual and Audio Warning Systems

Service Engine Light and OBD‑M MIL Kit
Boats powered by emissions control technology (ECT) catalyzed engines must be equipped with a SmartCraft‑enabled gauge
capable of displaying the service engine icon, or a dash‑mounted service engine light. Malfunction indicator lamp (MIL) kits
containing a dash‑mounted service engine light and a special harness that connects to the engine harness may be purchased
separately.
The service engine icon or MIL will provide a visual indication of a malfunction with the engine's emission control system and
will remain illuminated while the OBD‑M fault is active.
47594
SC 1000 gauge and service engine light
Testing the OBD-M Malfunction Indicator Lamp (MIL)

1. Turn the ignition switch to the on position without cranking the engine.
2. The service engine icon and MIL will remain illuminated for four seconds if the visual indication system is functioning
correctly.
Audio Warning System

IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the engine from
damage.
Most faults cause the warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.
There are two warning horn states:
• Caution
• Critical
There is also an alarm that sounds if the helm has not been properly configured using the G3 service tool.
Page 22 90-8M0133411 eng MAY 2017

Caution
If a caution state is detected, the audio warning system will sound for six one‑second intervals.
ON ON ON ON ON ON
1 1 1 1 1 1
a - Horn (on or off)
a 1 1 1 1 1 b - Time (in seconds)
OFF OFF OFF OFF OFF OFF
b
33402
Critical
If a critical state is detected, the audio warning system sounds for six seconds and then turns off.
ON

a 6
b - Time (in seconds)
OFF
b 53403
Nonconfigured Alarm–DTS Only

If the helm has not been properly configured using the G3 service tool, the audio warning system will sound for five one‑second
intervals.
ON ON ON ON ON
1 1 1 1 1
a 1 1 1 1 b - Time (in seconds)
OFF OFF OFF OFF OFF
b 53402
Testing the Audio Warning System

1. Turn the key switch to the on position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
Guardian Strategy
The MerCruiser Engine Guardian system reduces the potential for engine damage by restricting engine power when the PCM
detects a potential problem. Below are some examples of what Engine Guardian monitors:
• Oil pressure
• Engine overspeed
• Exhaust manifold temperature
IMPORTANT: Engine Guardian can reduce power anywhere from 100% to idle, depending on the severity of the problem. If
forced to idle, boat speed might not respond to throttle operation.
The PCM stores the fault for diagnostics. For example, if the water inlet becomes partially blocked, Engine Guardian reduces
the available power level of the engine to help prevent damage from decreased water flow to the engine. If the debris passes
through, and full water flow is restored, Engine Guardian restores engine power to normal.
90-8M0133411 eng MAY 2017 Page 23

Notes:
Page 24 90-8M0133411 eng MAY 2017


Table of Contents
Additional Operation Instructions for Axius Systems ........... 26
Safe Boating Recommendations.......................................... 26
Freezing Temperature Operation.................................. 32
Drain Plug and Bilge Pump............................................ 33
2
Carbon Monoxide Exposure................................................. 27 Protecting People in the Water............................................. 33
Be Alert To Carbon Monoxide Poisoning ..................... 27 While You Are Cruising ................................................ 33
Stay Clear of Exhaust Areas ........................................ 27 While Boat Is Stationary ............................................... 33
Good Ventilation .......................................................... 27 High‑Speed and High‑Performance Operation..................... 33
Poor Ventilation ........................................................... 28 Passenger Safety in Pontoon Boats and Deck Boats.......... 33
Basic Boat Operation (Non‑DTS Models)............................. 28 Boats Having an Open Front Deck ............................... 33
Launching and Boat Operation...................................... 28 Boats With Front‑Mounted, Raised Pedestal Fishing
Operation Chart ..................................................... 28 Seats ............................................................................ 34
Starting and Stopping the Engine.................................. 29 Wave and Wake Jumping..................................................... 34
Starting the Engine ................................................ 29 Impact with Underwater Hazards......................................... 34
Stopping the Engine .............................................. 29 Drive Unit Impact Protection ......................................... 35
Starting the Engine After It Has Been Stopped While In Operating with Low Water Inlets in Shallow Water............... 35
Gear............................................................................... 30 Conditions Affecting Operation............................................. 35
Throttle Only Operation................................................. 30 Weight Distribution (Passengers and Gear) Inside the
Trailering the Boat......................................................... 30 Boat............................................................................... 35
Freezing Temperature Operation.................................. 30 The Bottom of the Boat.................................................. 36
Drain Plug and Bilge Pump............................................ 30 Cavitation....................................................................... 36
Basic Boat Operation (DTS Models).................................... 30 Ventilation...................................................................... 36
Launching and Boat Operation...................................... 30 Elevation and Climate.................................................... 36
Operation Chart ..................................................... 30 Propeller Selection......................................................... 36
Starting and Stopping the Engine.................................. 31 Getting Started..................................................................... 37
Starting the Engine ................................................ 31 20‑Hour Break‑In Period................................................ 37
Stopping the Engine .............................................. 32 After the Break‑In Period............................................... 37
Throttle Only Operation................................................. 32 End of First Season Checkup........................................ 37
Trailering the Boat......................................................... 32
90-8M0133411 eng MAY 2017 Page 25


boat.
Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions
and consider the following suggestions.
Know and obey all nautical rules and laws of the waterways.
• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary,
the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For
more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).
Perform safety checks and required maintenance.
• Follow a regular schedule and ensure that all repairs are properly made.
Check safety equipment onboard.
• Here are some suggestions of the types of safety equipment to carry when boating:
Approved fire extinguishers
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Tools necessary for minor repairs
Anchor and extra anchor line
Manual bilge pump and extra drain plugs
Drinking water
Radio
Paddle or oar
Spare propeller, thrust hubs, and an appropriate wrench
First aid kit and instructions
Waterproof storage containers
Spare operating equipment, batteries, bulbs, and fuses
Compass and map or chart of the area
Personal flotation device (one per person onboard)
Watch for signs of weather change and avoid foul weather and rough‑sea boating.
Tell someone where you are going and when you expect to return.
Passenger boarding.
• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive
unit into neutral is not sufficient.
Use personal flotation devices.
• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and
readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life
jacket at all times while in the boat.
Prepare other boat operators.
• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver
becomes disabled or falls overboard.
Do not overload your boat.
• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your
boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your
authorized Mercury Marine dealer or the boat manufacturer.
Ensure that everyone in the boat is properly seated.
• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of
seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride
anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat
movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat
and are in it before any boat movement.
Page 26 90-8M0133411 eng MAY 2017

Never operate a boat while under the influence of alcohol or drugs. It is the law.
• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.
Know your boating area and avoid hazardous locations.
Be alert.
• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have
an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when
the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.
Never drive your boat directly behind a water‑skier.
• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.
Watch fallen skiers.
• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the
boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to
the skier or anyone in the water.
Report accidents.
• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when
their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable
loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other
property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from
local law enforcement.
Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning
Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the
engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless,
but if you can smell or taste engine exhaust, you are inhaling CO.
Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include
headache, dizziness, drowsiness, and nausea.
! WARNING
Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage,
or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.
Stay Clear of Exhaust Areas

co
co
co
co co
co
co co co
co co
co co
co
co co
co co
co co
41127
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines
are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While
underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This
dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the
possibility of injury from the boat propeller.
Good Ventilation
Ventilate the passenger area, open side curtains or forward hatches to remove fumes.
90-8M0133411 eng MAY 2017 Page 27

Example of desired air flow through the boat:
43367
Poor Ventilation
Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient
ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that
contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:
a a - Operating the engine when the boat

b is moored in a confined space
b - Mooring close to another boat that
has its engine operating
21626
2. Examples of poor ventilation while the boat is moving:
a a - Operating the boat with the

b
trim angle of the bow too
high
b - Operating the boat with no
forward hatches open
43368 (station wagon effect)
Basic Boat Operation (Non‑DTS Models)

Launching and Boat Operation
IMPORTANT: Install the bilge drain plug prior to launching the boat.
Follow these guidelines when operating your boat to avoid possible water ingestion:
• Do not turn the key off when the engine is above idle speed.
• Do not use the lanyard stop switch to shut off the engine when operating above idle speed.
• Enter the water slowly when launching your boat from a steep ramp.
• Do not shift into reverse while on plane.
• When coming off plane, avoid impact with large following waves by applying short, light bursts of power to minimize the
wave action against the stern of the boat.
• Do not come off plane quickly and immediately shut of the engine.
Operation Chart
Operation Chart
Before Starting After Starting While Underway After Stopping
Observe all gauges to Observe all gauges
check condition of engine. to check condition of Turn the ignition key to the
Install the bilge drain plug.
If not normal, stop the engine. If not normal, "OFF" position.
engine. stop the engine.
Check for fuel, oil, water, Listen for the audio Turn battery switch to the
Open engine hatch.
fluid and exhaust leaks. alarm. "OFF" position.
Page 28 90-8M0133411 eng MAY 2017

Operation Chart
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Close seacock, if
Operate bilge blowers. Check steering operation.
equipped.
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if equipped. Drain bilge.
Close the drain system.
Place sterndrive unit in full down (in)
position.
Check the engine oil.
Perform all other checks specified by your
dealer or boat builder.
Listen for audio warning alarm to sound
when the ignition switch is in the "ON"
position.
Starting and Stopping the Engine

NOTE: Only perform those functions applicable to your power package.
Starting the Engine
1. Check all items listed in the Operation Chart.
2. Place the remote control handle in neutral.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before
starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes.
3. Turn ignition key to "START." Release key when engine starts and allow switch to return to "ON" position. Allow engine to
warm up (6–10 minutes on first start of the day).
4. If engine does not start after three attempts:
a. Push the throttle only button and position the remote control handle/throttle lever to the 1/4 throttle position.
b. Turn ignition key to "START." Release key when engine starts and allow switch to return to "ON" position.
5. If engine does not start after step 4:
a. Move the remote control handle/throttle lever to full throttle position, then return to 1/4 throttle.
b. Turn ignition key to "START." Release key when engine starts and allow switch to return to "ON" position.
6. Inspect the power package for fuel, oil, water, and exhaust leaks.
7. Move control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After shifting,
advance throttle to desired setting.
NOTICE
Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is
operating at idle.
Stopping the Engine

1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at
high speed for a long period of time, allow the engine to cool at idle speed for 3–5 minutes.
2. Turn ignition key to the "OFF" position.
90-8M0133411 eng MAY 2017 Page 29

Starting the Engine After It Has Been Stopped While In Gear

IMPORTANT: Avoid stopping the engine if the sterndrive unit is in gear. If the engine does stop, refer to the following
procedure:
1. Push and pull repeatedly on the remote control handle until handle returns to the neutral/idle position. This may take
several tries if the power package was operating above idle RPM when the engine stopped.
2. After the handle returns to the neutral/idle position, resume normal starting procedures.
Throttle Only Operation

1. Refer to Remote Controls section for remote control features.
2. Move the control lever to the idle/neutral position.
3. Depress and hold the throttle only button, and move the control lever to the idle/forward or idle/reverse position.
4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase.
IMPORTANT: Moving the control lever back to the idle/neutral position will disengage the throttle only button and allow the
engine to shift into gear.
5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position. Moving the control lever from the
idle/neutral position to the idle/forward or idle/reverse position without pressing the throttle only button will shift the unit into
the chosen gear.
Trailering the Boat

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

IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze
damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty.
Drain Plug and Bilge Pump

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

Launching and Boat Operation
IMPORTANT: Install the bilge drain plug prior to launching the boat.
Follow these guidelines when operating your boat to avoid possible water ingestion:
• Do not turn the key off when the engine is above idle speed.
• Do not use the lanyard stop switch to shut off the engine when operating above idle speed.
• Enter the water slowly when launching your boat from a steep ramp.
• Do not shift into reverse while on plane.
• When coming off plane, avoid impact with large following waves by applying short, light bursts of power to minimize the
wave action against the stern of the boat.
• Do not come off plane quickly and immediately shut of the engine.
Operation Chart
Operation Chart
Observe all gauges to Observe all gauges
check condition of engine. to check condition of Turn the ignition key to the
Install the bilge drain plug.
If not normal, stop the engine. If not normal, "OFF" position.
engine. stop the engine.
Check for fuel, oil, water, Listen for the audio Turn battery switch to the
Open engine hatch.
fluid and exhaust leaks. alarm. "OFF" position.
Page 30 90-8M0133411 eng MAY 2017

Operation Chart
Check shift and throttle
Turn battery switch on. Close fuel shut off valve.
control operation.
Close seacock, if
Operate bilge blowers. Check steering operation.
equipped.
Flush cooling system if in
Open fuel shut off valve.
saltwater.
Open seacock, if equipped. Drain bilge.
Close the drain system.
Place sterndrive unit in full down (in)
position.
Check the engine oil.
Perform all other checks specified by your
dealer or boat builder.
Listen for audio warning alarm to sound
when the ignition switch is in the "ON"
position.
Starting and Stopping the Engine

NOTE: Perform only those functions applicable to your power package.
Starting the Engine
1. Check all items listed in the Operation Chart.
2. Place the remote control handle in neutral.
NOTICE
! WARNING
Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion. Before
starting the engine, operate the bilge blower or vent the engine compartment for at least five minutes.
NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting.
Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts,
SmartStart completely controls the starting process. When the start button is pushed, the DTS system signals the engine
PCM to start the engine. If the engine does not start, the starting process times out after eight seconds or when the engine
reaches 400 RPM. Attempting to start the engine with the engine already running will turn the engine off.
3. Turn ignition key to "RUN" position.
4. Turn the ignition key switch to the "START" position then release, or depress the start/stop button and release. If the
engine is cold, allow the engine to operate at idle for 6‑10 minutes or until the engine temperature reaches 60 °C (140 °F).
5. If the engine does not start after three attempts:
a. Push the throttle‑only button and position the remote control handle or throttle lever to the 1/4 throttle position.
b. Turn the ignition key to "START." Release key when the engine starts and allow the switch to return to the "ON"
position.
6. If the engine does not start after step 5:
a. Move the remote control handle throttle lever to the full throttle position, then return to 1/4 throttle.
b. Turn the ignition key to "START." Release key when the engine starts and allow the switch to return to the "ON"
position.
7. Inspect the power package for fuel, oil, water, and exhaust leaks.
8. Move the control handle with a firm, quick motion forward to shift to forward gear, or backward to shift to reverse. After
shifting, advance throttle to desired setting.
90-8M0133411 eng MAY 2017 Page 31

NOTICE
Shifting into gear at engine speeds above idle will damage the drive system. Shift the drive into gear only when the engine is
operating at idle.
Stopping the Engine

1. Move the remote control handle to neutral/idle and allow the engine to slow to idle speed. If engine has been operated at
high speed for a long period of time, allow the engine to cool at idle speed for 3 to 5 minutes.
2. The engine can be stopped by any one of the following 4 methods:
a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop and the control system will
be deactivated.
b. Depress the start/stop button, if equipped. The engine will stop and the control system will remain active.
c. Momentarily move the ignition key switch to the "START" position, then release immediately. The control system will
recognize that the engine is running and will stop the engine. The control system will remain active. Moving the
ignition key switch to the "START" position again will issue a start request to the control system and the control
system will start the engine, if appropriate.
d. Activate the lanyard stop switch, if equipped. The engine will stop, but the control system will remain active. The
control system will not allow the engine to start if the lanyard stop switch is activated.
Throttle Only Operation

NOTE: When operating in throttle only (neutral) mode, the DTS control system will not allow the engine speed to increase
above 3500 RPM.
Zero effort remote controls: Zero effort remote controls have separate throttle control and shift control levers. Advancing the
throttle control lever beyond the idle position while the shift control lever is in the neutral position will cause engine speed to
increase, but only up to the maximum neutral engine speed of 3500 RPM.
! WARNING
The Digital Throttle and Shift (DTS) Zero Effort control can shift the engine or transmission at speeds greater than idle,
causing unexpected boat movement, which may result in injury, death, or property damage due to loss of boat control.
Always place the throttle control lever in the idle position before moving the shift control lever into forward or reverse gear
position.
Panel mount and console mount remote controls: Panel mount and console mount remote controls are equipped with a
throttle only button. To activate throttle only mode:
1. Refer to Remote Controls section for remote control features.
2. Move the control lever to the idle/neutral position.
3. Depress the throttle only button, and move the control lever to the idle/forward or idle/reverse position. The DTS control
system will sound two beeps on the audio warning horn to indicate throttle only mode is active. On console mount remote
controls, the neutral light will begin to blink.
4. Advancing the control lever beyond the idle/forward or idle/reverse position will cause engine speed to increase.
IMPORTANT: Moving the control lever back to the idle/neutral position will deactivate the throttle only mode and allow the
engine to shift into gear.
5. Throttle only mode is deactivated by moving the control lever to the idle/neutral position. Moving the control lever from the
idle/neutral position to the idle/forward or idle/reverse position without pressing the throttle only button will shift the unit into
the chosen gear.
Trailering the Boat

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

IMPORTANT: If the boat is operated during periods of freezing temperature, precautions must be taken to prevent freeze
damage to the power package. Damage caused by freezing is not covered by Mercury MerCruiser Limited Warranty.
Page 32 90-8M0133411 eng MAY 2017

Drain Plug and Bilge Pump

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

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

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

If your boat is considered a high‑speed or high‑performance boat and you are unfamiliar with its operation, we recommend that
you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your
dealer or an operator experienced with your boat. For additional information, refer to Hi‑Performance Boat Operation booklet
(90‑849250R03) from your dealer, distributor, or Mercury Marine.
Passenger Safety in Pontoon Boats and Deck Boats

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

No one should ever be on the deck in front of the fence while the boat is in motion. Keep all passengers behind the front fence
or enclosure.
Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their
legs caught by a wave and pulled into the water.
mc79555-1
! WARNING
Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
90-8M0133411 eng MAY 2017 Page 33

Boats With Front‑Mounted, Raised Pedestal Fishing Seats

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

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

Reduce speed and proceed with caution whenever you're driving a boat in shallow water or in areas where the waters are
suspected of having underwater obstacles that could be struck by the underwater drive components, rudder, or the boat
bottom.
mc79679-1
IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or
underwater object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of
24–40 km/h (15–25 mph).
Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could result in the
following:
Page 34 90-8M0133411 eng MAY 2017

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

The power trim hydraulic system is designed to provide impact protection for the sterndrive unit. If a submerged object is struck
while the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive unit as it clears the object,
reducing damage to the unit. After the sterndrive unit has cleared the object, the hydraulic system allows the sterndrive unit to
return to its original operating position, preventing loss of steering control and engine overspeed.
Use extreme caution when operating in shallow water or where underwater objects are known to be present. No impact
protection is provided in reverse; use extreme care to prevent striking submerged objects while operating in reverse.
IMPORTANT: Impact protection system cannot be designed to ensure total protection from impact damage under all
conditions.
Operating with Low Water Inlets in Shallow Water
a - Low water inlets
mc75827-1
a
NOTICE
Operating in shallow water can cause severe engine damage due to clogged water inlets. Ensure that the water inlets on the
gearcase do not ingest sand, silt, or other debris, which can restrict or stop cooling water supply to the engine.
Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water.
Also, avoid beaching a boat with the engine operating.
Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to rear (stern):
• Generally increases speed and engine RPM
• Causes bow to bounce in choppy water
• Increases danger of following wave splashing into the boat when coming off plane
• At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
90-8M0133411 eng MAY 2017 Page 35

• Improves ease of planing
• Improves rough water ride
• At extremes, can cause the boat to veer back and forth (bow steer)
The Bottom of the Boat

To maintain maximum speed, the boat bottom should be:
• Clean, free of barnacles and marine growth
• Free of distortion; nearly flat where it contacts the water
• Straight and smooth, fore and aft
Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog the
water inlets and cause the engine to overheat.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the
gear housing or the propeller. Common causes of cavitation are:
• Weeds or other debris snagged on the propeller
• Bent propeller blade
• Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up
and a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to
continue, eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
• Drive unit trimmed out too far
• A missing propeller diffuser ring
• A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing
• Drive unit installed too high on transom
Elevation and Climate

Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by:
• Higher elevations
• Higher temperatures
• Low barometric pressures
• High humidity
For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to
allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your
normal boating weather conditions.
In most cases, recommended RPM can be achieved by changing to a lower pitch propeller.
Propeller Selection
IMPORTANT: The engines covered in this manual are equipped with an RPM rev‑limiter that is set to an upper RPM limit. This
limit, which is slightly above the normal operating range of the engine, helps prevent damage from excessive engine RPM.
Once the RPM returns to the recommended operating RPM range, normal engine operation resumes.
The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propeller. Refer
to Mercury Marine's web page https://www.mercurymarine.com/en/us/propellers/selector/#/step‑one.
Select a propeller that will allow the engine power package to operate at or near the top end of the recommended WOT
operating RPM range with a normal load.
If full‑throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and
possible engine damage. On the other hand, operating an engine above the recommended operating RPM range will cause
higher than normal wear and damage.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch.
• Warmer weather and greater humidity cause a loss of RPM.
• Operating in a higher elevation causes a loss of RPM.
• Operating with a dirty boat bottom causes a loss of RPM.
Page 36 90-8M0133411 eng MAY 2017

• Operating with increased load (additional passengers, pulling skiers) causes a loss of RPM.
For better acceleration, such as is needed for waterskiing, use the next lower pitch propeller. When not pulling skiers, do not
operate at full throttle when using the lower pitch propeller.
Getting Started
20‑Hour Break‑In Period
IMPORTANT: The first 20 hours of operation is the engine break‑in period. Correct break‑in is essential to obtain minimum oil
consumption and maximum engine performance. During this break‑in period, the following rules must be observed:
• Do not operate below 1500 RPM for extended periods of time for the first 10 hours. Shift into gear as soon as possible after
starting and advance the throttle above 1500 RPM if conditions permit safe operation.
• Do not operate at one speed consistently for extended periods.
• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is
permissible (five minutes at a time maximum).
• Avoid full throttle acceleration from idle speed.
• Do not operate at full throttle until the engine reaches normal operating temperature.
• Frequently check engine oil level. Add oil as needed. It is normal for oil consumption to be high during the break‑in period.
After the Break‑In Period

To help extend the life of your Mercury MerCruiser power package, follow these recommendations:
• Ensure that the propeller allows the engine to operate at or near the top of the specified wide‑open throttle (WOT) RPM
range. Refer to Specifications and Maintenance.
• Operate the engine at 3/4 throttle or lower. Refrain from prolonged operation at WOT RPM.
End of First Season Checkup

At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss or perform scheduled
maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your
dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
90-8M0133411 eng MAY 2017 Page 37

Notes:
Page 38 90-8M0133411 eng MAY 2017

Table of Contents
Fuel Requirements............................................................... 40 Engine Oil............................................................................. 41
Fuel Ratings ................................................................. 40 Preventing Contamination of the Emissions Control System
Using Reformulated (Oxygenated) Gasoline (USA Only) .............................................................................................. 42
...................................................................................... 40 Fluid Specifications............................................................... 42
Gasoline Containing Alcohol ........................................ 40
Bu16 Butanol Fuel Blends ..................................... 40
Engine............................................................................ 42
Bravo Sterndrives.......................................................... 42 3
Methanol and Ethanol Fuel Blends ....................... 40 Power‑Assisted Steering and Power Trim Fluids.......... 43
Engine Specifications........................................................... 40 Approved Power‑Assisted Steering Fluids ............ 43
8.2 MAG ECT, 8.2 MAG H.O. ECT—Including SeaCore Approved Power Trim Fluids ................................. 43
Models........................................................................... 40
90-8M0133411 eng MAY 2017 Page 39

Fuel Requirements
NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.
IMPORTANT: Use of improper gasoline can damage your engine. Engine damage resulting from the use of improper
gasoline is considered misuse of the engine and will not be covered under the limited warranty.
Fuel Ratings
Mercury MerCruiser engines will operate satisfactorily with any major brand of unleaded gasoline that meets the following
specifications:
USA and Canada ‑ A posted pump octane rating of 87 (R+M)/2, minimum, for all models. Premium gasoline 91 (R+M)/2
octane is also acceptable for all models. Do not use leaded gasoline.
Outside USA and Canada ‑ A posted pump octane rating of 91 RON, minimum, for all models. Premium gasoline (95 RON) is
also acceptable for all models. Do not use leaded gasoline.
Using Reformulated (Oxygenated) Gasoline (USA Only)

Reformulated gasoline is required in certain areas of the USA and is acceptable for use in your Mercury Marine engine. The
only oxygenate currently in use in the USA is alcohol (ethanol, methanol, or butanol).
Gasoline Containing Alcohol

Bu16 Butanol Fuel Blends
Fuel blends of up to 16.1% butanol (Bu16) that meet the published Mercury Marine fuel rating requirements are an acceptable
substitute for unleaded gasoline. Contact your boat manufacturer for specific recommendations on your boat's fuel system
components (fuel tanks, fuel lines, and fittings).
Methanol and Ethanol Fuel Blends
IMPORTANT: The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol (methanol or
ethanol) content in the gasoline. Your boat's fuel system may not be capable of withstanding the same percentage of alcohol.
Contact your boat manufacturer for specific recommendations on your boat's fuel system components (fuel tanks, fuel lines,
and fittings).
Be aware that gasoline containing methanol or ethanol may cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through the rubber fuel lines
• Likelihood of phase separation (water and alcohol separating from the gasoline in the fuel tank)
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
IMPORTANT: If you use gasoline that contains or might contain methanol or ethanol, you must increase the frequency of
inspection for leaks and abnormalities.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing methanol or ethanol, do not store the gasoline
in the fuel tank for long periods. Cars normally consume these blended fuels before they can absorb enough moisture to cause
trouble; boats often sit idle long enough for phase separation to take place. Internal corrosion may occur during storage if
alcohol has washed protective oil films from internal components.
Engine Specifications
8.2 MAG ECT, 8.2 MAG H.O. ECT—Including SeaCore Models
NOTE: Performance specifications are obtained and corrected in accordance with SAE J1228/ISO 8665 Crankshaft Power.
All measurements are taken with the engine at normal operating temperature.
RPM range is measured using an accurate service tachometer with the engine at normal operating temperatures.
Oil pressure must be checked with the engine at normal operating temperature.
NOTE: Oil pressure specifications are for reference and may vary.
Page 40 90-8M0133411 eng MAY 2017

8.2 MAG ECT 8.2 MAG H.O. ECT

Propeller shaft power 279 kW (380 hp) 316 kW (430 hp)
Displacement 8.2L (502 cid)
Hot 72 A
Alternator amperage
Cold 65 A
WOT 4600–5000
RPM
Rev limiter 5150 5150
Mechanical
Idle RPM 650
DTS
At 2000 RPM 207 kPa (30 psi)
Minimum oil pressure
At idle 103 kPa (15 psi)
Thermostat 76 °C (170 °F)
Timing at idle Not adjustable
Firing order 1‑8‑4‑3‑6‑5‑7‑2
Non‑DTS models 750 CCA, 950 MCA, 180 Ah
Minimum battery rating
DTS models 800 CCA, 1000 MCA, 190 Ah
Spark plug type NGK BPR6ES
Spark plug gap 0.83 mm (0.033 in.)
Electronic engine control (EC), heated oxygen sensor
Emission control system
(HO2S), catalyst
Engine Oil
For optimum engine performance and maximum protection, use the following oil:
Application Recommended Oil

All MerCruiser engines Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil, NMMA FC‑W Catalyst Compatible rated
IMPORTANT: Lubrication requirements for catalyzed engines differ from the requirements for noncatalyzed engines. Some
marine‑grade lubricants contain high levels of phosphorus. Although these high‑phosphorus lubricants may allow acceptable
engine performance, exposure over time will damage the catalyst. Catalysts damaged by lubricants containing high levels of
phosphorus may not be covered by the MerCruiser Limited Warranty.
If Mercury/Quicksilver 25W‑40 Synthetic Blend Engine Oil is unavailable, use the following lubricants, listed in order of
recommendation.
1. Mercury/Quicksilver 25W‑40 Mineral NMMA FC‑W Catalyst Compatible.
IMPORTANT: If you are servicing a catalyst engine, use the following oils for short periods of time only.
2. Other recognized brands of NMMA FC‑W Catalyst Compatible rated 4‑cycle oil.
3. Other recognized brands of NMMA FC‑W rated 4‑cycle oils.
4. A good‑grade, straight‑weight detergent automotive oil according to the last row of the operating chart below.
NOTE: We do not recommend nondetergent oils, multi‑viscosity oils (other than as specified), non‑FC‑W rated synthetic oils,
low‑quality oils, or oils that contain solid additives.
90-8M0133411 eng MAY 2017 Page 41

Use the following information for selecting the type of oil according to the order of preference.
Mercury/Quicksilver 25W-40 Synthetic Blend, NMMA FC-W Catalyst Compatible rated 4-cycle oil
ORDER OF PREFERENCE
Mercury/Quicksilver 25W-40 Mineral NMMA FC-W Catalyst Compatible rated 4-cycle oil
Other recognized brands of NMMA FC-W Catalyst Compatible rated 4-cycle oil
Other recognized brands of NMMA FC-W rated 4-cycle oil
SAE40W
SAE30W
SAE 20W
0° C 10° C
(32° F) (50° F) 53574
AIR TEMPERATURE
Preventing Contamination of the Emissions Control System

Catalysts and oxygen sensors can become contaminated, leading to component failure. Phosphorus, found in some
marine‑grade oils, and other compounds will damage or destroy a catalyst's ability to clean the exhaust. Catalyst‑friendly oils,
like Mercury Synthetic Blend Engine Oil or Mercury 25W‑40 mineral oil, prevents this damage. Approved oils must be used in
MerCruiser engines with emissions control.
Acetoxy silicone sealants and other compounds in the exhaust stream can damage oxygen sensors and catalysts. Do not use
nonapproved compounds and sealants. Oxime silicone sealants and Loctite 587 High Performance Blue can be safely used
with catalyzed engines.
Fiberglass, a silica‑based material, can contaminate the catalyst and the oxygen sensors. To reduce the possibility that the
engine will ingest harmful fiberglass and thereby poison the emission control components, protect the engine from fiberglass
dust and debris during construction and clean‑up.
Fluid Specifications
Engine
IMPORTANT: All capacities are approximate fluid measures.
All Models Capacity Fluid Type

Mercury/Quicksilver 25W‑40 Synthetic Blend NMMA FC‑W
Engine oil (with filter) 6.5 L (7 US qt)
Catalyst Compatible
Seawater cooling system
20 L (21 US qt) Propylene glycol and purified water
(winterization use only)
Mercury Extended Life Coolant Antifreeze or extended life
Closed cooling system 17.4 L (18.4 US qt)
ethylene glycol 5/100 antifreeze mixed 50/50 with purified water
NOTICE
Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed
cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be
exposed.
Bravo Sterndrives
NOTE: Oil capacity includes gear lube monitor.
Page 42 90-8M0133411 eng MAY 2017

Model Capacity Fluid Type

Bravo One 3209 ml (108‑1/2 oz)
Bravo Two 3682 ml (124‑1/2 oz)
High Performance Gear Lubricant
Bravo Three (single seawater pickup) 3445 ml (116‑1/2 oz)
Bravo Three (dual seawater pickup) 3209 ml (108‑1/2 oz)
Power‑Assisted Steering and Power Trim Fluids

Approved Power-Assisted Steering Fluids
Description Part Number
Power Trim and Steering Fluid 92‑858074K01
Approved Power Trim Fluids

Power Trim and Steering Fluid 92‑858074K01
SAE Engine Oil 10W‑30
Obtain locally
SAE Engine Oil 10W‑40
90-8M0133411 eng MAY 2017 Page 43

Notes:
Page 44 90-8M0133411 eng MAY 2017

Table of Contents
Additional Operation Instructions for Axius Systems ........... 46 Changing the Positive Crankcase Ventilation Valve (PCV).. 59
Owner/Operator Responsibilities.......................................... 46 Water‑Separating Fuel Filter................................................ 59
Dealer Responsibilities......................................................... 46 Removal and Installation............................................... 60
Maintenance......................................................................... 46 Removal ................................................................ 60
Do‑It‑Yourself Maintenance Suggestions............................. 46 Installation ............................................................. 60
Inspection............................................................................. 47 Lubrication............................................................................ 61
MerCruiser Gas Sterndrive Inspection and Maintenance Steering System............................................................ 61
Schedule............................................................................... 47 Throttle Cable................................................................ 62
4
Daily Checks ................................................................. 47 Shift Plate Control Cable Lubrication............................. 63
After Each Use ............................................................. 47 Shift Cable ‑ DTS........................................................... 63
Weekly Checks ............................................................. 47 Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit
Every Two Months or 50 Hours .................................... 47 Removed)...................................................................... 63
Annually or 100 Hours .................................................. 47 Engine Coupler.............................................................. 64
Three Years or 300 Hours ............................................ 48 Driveshaft Extension Models......................................... 64
Five Years or 500 Hours ............................................... 48 Propellers............................................................................. 64
Engine Oil............................................................................. 48 Propeller Repair............................................................. 64
Checking ............................................................... 48 Bravo One Propeller Removal....................................... 65
Filling ..................................................................... 49 Bravo One Propeller Installation.................................... 65
Changing Oil and Filter.................................................. 49 Bravo Two Propeller Removal....................................... 66
Oil Removal with Drain Pump........................................ 49 Bravo Two Propeller Installation.................................... 66
Changing the Oil Filter................................................... 50 Bravo Three Propeller Removal.................................... 67
Power‑Assisted Steering Fluid............................................. 51 Bravo Three Propeller Installation................................. 68
Checking........................................................................ 51 Serpentine Drive Belt............................................................ 69
Filling............................................................................. 51 Inspection...................................................................... 69
Changing....................................................................... 51 Checking........................................................................ 70
Closed Cooling System........................................................ 51 Replacing....................................................................... 70
Coolant Requirement..................................................... 51 Corrosion Protection............................................................. 71
Checking Coolant Level................................................. 52 Corrosion Information.................................................... 71
.............................................................................. 52 Maintaining Ground Circuit Continuity........................... 71
Filling the Closed Cooling System................................. 52 MerCathode System Battery Requirements.................. 71
Draining......................................................................... 53 MerCathode Theory of Operation.................................. 71
Cleaning......................................................................... 53 Anodes and MerCathode System Locations................. 72
Sterndrive Gear Lube........................................................... 53 Do Not Use Caustic Cleaning Chemicals...................... 73
Checking........................................................................ 53 Power Package Exterior Surfaces................................. 74
Filling............................................................................. 54 Boat Bottom Care.......................................................... 74
Changing....................................................................... 54 Antifouling Paint............................................................. 74
Power Trim Fluid.................................................................. 56 Sterndrive Surface Care................................................ 75
Checking ....................................................................... 56 Flushing the Seawater System—Sterndrive Models............ 76
Filling ............................................................................ 56 Flushing the Power Package—Bravo Models............... 76
Changing ...................................................................... 56 Flushing Attachments ............................................ 76
Battery.................................................................................. 56 Sterndrive Water Pickups ...................................... 77
Multiple EFI Engine Battery Precautions....................... 57 Alternative Water Pickups ..................................... 78
Cleaning the Flame Arrestor................................................. 57 SeaCore Power Package Flushing Procedure.............. 79
Cleaning the IAC Muffler (Non‑DTS Models Only)............... 58 Models Using the Sterndrive Water Pickup ........... 79
90-8M0133411 eng MAY 2017 Page 45


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

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

Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery.
Electronic ignition, special fuel delivery and exhaust systems provide greater performance, fuel economy, and lower exhaust
emissions. but also are more complex for the untrained mechanic.
If you are one of those persons who likes to do it yourself, here are some suggestions for you.
• Do not attempt any repairs unless you are aware of the Cautions, Warnings and procedures required. Your safety is our
concern.
Page 46 90-8M0133411 eng MAY 2017

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

New sterndrive installations may require as much as 470 mL (16 fl oz) of gear lube added to the monitor bottle during the
break‑in period (20 hours of running time). It is important to monitor and maintain the gear lube level during the break‑in period.
During the initial drive installation, air may be trapped in the top of the driveshaft housing. This void is filled from the gear lube
monitor during the sterndrive break‑in period. As the air is purged from the sterndrive through the monitor bottle, the lube level
in the bottle will drop.
Daily Checks
• Check the engine oil level
• Check the power steering fluid level
• Check the power trim pump fluid level
• Check the sterndrive gear oil level
• Check the lanyard stop switch
After Each Use

• Flush the engine with fresh water, brackish or saltwater use only
Weekly Checks
• Check the seawater inlets for marine growth
• Clean the seawater strainer, if equipped
• Check the coolant level, if equipped
• Inspect the anodes
• Verify the operation of the MerCathode module, if equipped
Every Two Months or 50 Hours

• Lubricate the engine coupler 1.
Annually or 100 Hours

• Lubricate the engine coupler 1.
• Lubricate the propeller shaft splines
• Clean the gauges and check wire connection—dealer item
• Check the torque of the propeller nut
1. Power packages that are used extensively at idle or trolling speeds must have the coupler lubricated every 50 hours.
90-8M0133411 eng MAY 2017 Page 47

• Check the battery condition and connections—dealer item

• Touch up any paint nicks and spray the power package with Corrosion Guard
• Change the engine oil and filter
• Change the sterndrive gear oil
• Check the closed cooling fluid level and concentration for freeze protection, if equipped
• Replace the water‑separating fuel filter
• Clean the crankcase vent—8.2L only
• Clean the IAC muffler—8.2L only
• Clean the flame arrestor—8.2L only
• Inspect the condition of the accessory drive belt—dealer item
• Tighten the connection of the gimbal ring to the steering shaft—dealer item
• Check the steering system for loose components—dealer item
• Check the remote control system for loose components—dealer item
• Check the MerCathode module operation for proper protection and check the continuity circuit—dealer item
• Replace the PCV valve
• Jackshaft models—check U‑joints and tailstock bearings—dealer item
• Spray the power package with Corrosion Guard
• Inspect anodes, if equipped
Three Years or 300 Hours

• Inspect the spark plugs and spark plug wires 2.
• Clean the flame arrestor and crankcase vent hoses
• Check the engine mount fasteners for tightness and tighten to the specified torque—dealer item
• Check the electrical system for loose, damaged, or corroded fasteners—dealer item
• Check the exhaust and cooling system hose clamps for tightness. Inspect for damage or leaks—dealer item.
• Inspect and clean seawater side of closed cooling system, if equipped—dealer item
• Clean, inspect, and test the closed cooling pressure cap, if equipped—dealer item
• Inspect seawater pump. Replace worn components—dealer item.
• Inspect the exhaust system. If the power package is equipped with water shutters, verify they are not missing or damaged
—dealer item.
• Check the engine alignment—dealer item
• Inspect the gimbal housing bellows and verify clamp tightness—dealer item
• Inspect the gimbal bearing for roughness—dealer item
• Lubricate the engine coupler—dealer item
• Replace the vent valve on each exhaust elbow, port and starboard, if equipped—dealer item
Five Years or 500 Hours

• Replace the antifreeze—replace the antifreeze every two years if not using extended life antifreeze—dealer item
Engine Oil
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
Checking
1. Stop the engine. Allow approximately five minutes for the oil to drain into the oil pan. The boat must be at rest in the water.
2. Inspect the condition of the spark plugs and spark plug wires. Replace as necessary. If the condition of these components is satisfactory, repeat the inspection every 100 hours or once a year,
whichever occurs first.
Page 48 90-8M0133411 eng MAY 2017

2. Remove the dipstick. Wipe clean and install fully into the dipstick tube. Wait 60 seconds to allow trapped air to vent.
a - Oil dipstick handle

b - Operating range
b
50315
3. Remove the dipstick and observe the oil level. Oil level must be in the operating range. Install the dipstick into the dipstick
tube.
Filling
IMPORTANT: Do not overfill the engine with oil.
IMPORTANT: Always use the dipstick to determine the exact quantity of oil required.
1. Remove oil fill cap.
a a - Oil fill cap
50316
2. Add the specified engine oil to bring the level up to, but not over, the operating range mark on the dipstick. Check the oil
level.
3. Replace the fill cap.

Mercury 25W‑40 Synthetic Blend 4‑Stroke
Engine oil (with filter) 6.5 Liter (7 US qt)
Engine Oil
Changing Oil and Filter

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

1. Loosen the oil filter to vent the system.
90-8M0133411 eng MAY 2017 Page 49

2. Remove the dipstick.
3. Install the oil drain pump onto the dipstick tube.
b a - Oil drain hose

a
b - Oil drain pump
50335
4. Insert the hose end of the crankcase oil pump onto an appropriate container and use the handle to pump until the
crankcase is empty.
5. Remove the pump.
6. Install the dipstick.
Changing the Oil Filter

NOTE: Keep oil off the exhaust manifold and also the serpentine belt.
1. Remove and discard the oil filter. If any oil escapes from the oil filter, it will exit the oil drain slot. Place a container below
the oil drain slot to catch any oil.
a a - Oil fill cap

b - Oil filter
c - Oil drain slot
50318
2. Coat the sealing ring on the new filter with engine oil.
3. Install and tighten the oil filter securely following the filter manufacturer's instructions. Do not overtighten.
4. Remove the oil fill cap.
5. Use the dipstick to determine the amount of engine oil required. Replace the dipstick.
6. Add the required amount of the recommended oil to bring the level up to the bottom of the OK range on the dipstick.
7. With the boat at rest in the water, repeat steps 5 and 6 if necessary.
NOTE: Adding 0.95 L (1 US qt) of engine oil raises the level from the bottom of the operating range to the top of the
operating range.

Engine oil (with filter) 6.5 L (7 US qt) Mercury 25W‑40 Synthetic Blend 4‑Stroke Engine Oil
8. Start the engine and operate for three minutes, checking for leaks.
9. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes with the boat at rest in the water.
Page 50 90-8M0133411 eng MAY 2017

Power‑Assisted Steering Fluid

Checking
1. Stop the engine and center the sterndrive unit.
IMPORTANT: If fluid is not visible on the fill cap dipstick, contact your authorized Mercury MerCruiser dealer.
2. Remove the fill cap from the power steering fluid reservoir and observe the level. The oil level should be at the full mark on
the dipstick.
a- Fill cap
a b- Full mark (engine hot)
c- Full mark (engine cold)
d- Add mark
b HOT
c COLD
d ADD
50317
3. Add the specified fluid if necessary. Refer to Filling.
Filling
1. Remove the fill cap and dipstick and observe the fluid level.
2. Add the specified fluid to bring the fluid level up to the proper level.
Tube Ref No. Description Where Used Part No.
114 Power Trim and Steering Fluid Power-assisted steering system 92-858074K01
Dexron III Automatic

28 Power-assisted steering system Obtain Locally
Transmission Fluid
3. Install the fill cap and dipstick.
Changing
Power‑assisted steering fluid does not require changing unless it becomes contaminated with water or debris. Contact your
authorized Mercury MerCruiser dealer.
Closed Cooling System

Coolant Requirement
NOTICE
exposed.
NOTE: All factory‑installed closed cooling systems come filled with Extended Life Coolant. This antifreeze requires draining and
replacing every five years or 1000 hours of operation, whichever comes first. The color of this antifreeze is orange. Any "top‑off"
fluid used must be Extended Life Coolant.
122 Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1
90-8M0133411 eng MAY 2017 Page 51

Checking Coolant Level

! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently, resulting in serious injury from burns. Allow
the engine to cool down before removing the coolant pressure cap.
IMPORTANT: When reinstalling the coolant reservoir cap, ensure that it is tightened securely.
The coolant level should be at the full mark on the coolant reservoir with the engine cold.
a- Coolant reservoir cap

b- Coolant reservoir
c- Sight window
a b d- Full mark (engine hot)
e- Full mark (engine cold)
HOT d
FILL
COLD e 50319
Filling the Closed Cooling System

IMPORTANT: The engine must be cooled to ambient temperature to correctly perform the following procedure.
NOTICE
exposed.
The coolant section of the closed cooling system must be filled with a 50/50 mixture of Extended Life Antifreeze/Coolant and
distilled water.
122 Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1
NOTE: The coolant section capacity is approximately 17.4 Liter (18.4 US qt).
8.2 (502 cid)

Closed cooling system 17.4 Liter (18.4 US qt)
! CAUTION
IMPORTANT: When filling the coolant section after it has been completely drained, the engine should be level or slightly lower
at the flywheel end.
1. Remove the coolant reservoir cap from the coolant reservoir.
2. Fill the reservoir to the full mark with the recommended coolant solution.
Page 52 90-8M0133411 eng MAY 2017

3. Replace the pressure cap.
NOTICE
4. Supply cooling water to the engine.
5. With the engine running, check the hose connections, fittings, and gaskets for leaks. Also observe the engine temperature
gauge to ensure that the engine operating temperature is normal. If the gauge indicates excessive temperature, stop the
engine immediately and determine the cause.
! CAUTION
6. After the engine has cooled completely, recheck the coolant level and add coolant, if necessary.
7. If the reservoir was completely emptied of coolant, a significant amount of air remains in the cooling system. Refill the
reservoir to the full mark, repeat the warm‑up/cool‑down cycle, and check the coolant level again.
8. Maintain the coolant level in the reservoir at or near the full mark with the engine cold.
Draining
Contact your authorized Mercury MerCruiser dealer.
Cleaning
Contact your authorized Mercury MerCruiser dealer.
Sterndrive Gear Lube

Checking
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil,
coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing
the disposal or recycling of waste, and contain and dispose of fluids as required.
NOTE: The oil level fluctuates during operation, so check with the engine cold before starting.
1. Check the gear lube level. Keep the gear lube at the recommended level.
90-8M0133411 eng MAY 2017 Page 53

2. Inspect the lubricant condition. If any water is visible at the bottom of the gear lube monitor, if water appears at the fill and
drain plug hole, or if the gear lube appears discolored, contact your authorized Mercury MerCruiser dealer immediately.
These conditions can indicate a water leak in the sterndrive.
a - Gear lube monitor

b - Recommended gear lube level
b
COLD FILL
50333
Filling
New installations may require as much as 470 mL (16 fl oz) of gear lube added to the monitor bottle during the break‑in period
(20 hours of running time). It is important to monitor and maintain the gear lube level during the break‑in period.
IMPORTANT: The gear lube monitor must be checked and filled if necessary at the beginning of each day when the engine is
cold. If the gear lube alarm sounds during the day's activity, add the appropriate amount of gear lube to the monitor bottle.
NOTE: If filling the entire sterndrive, see Changing.
1. Remove the gear lube monitor cap.
2. Fill the monitor with the specified fluid until the gear lube is at the recommended level. Do not overfill.
87 High Performance Gear Lubricant Gear lube monitor 92-858064K01
3. Replace the cap.
Changing
1. Remove the gear lube monitor from the bracket.
2. Empty the contents into a suitable container.
3. Install the gear lube monitor in the bracket.
4. Bravo One models:
a. Remove the propeller.
b. Position the sterndrive unit to the full down position.
c. Remove the oil fill and drain screw and sealing washer.
Page 54 90-8M0133411 eng MAY 2017

d. Drain the fluid into a suitable container.
a - Oil fill and drain screw

b - Sealing washer
b mc79506-1
5. All other models:

a. Place the sterndrive unit in full trim out position.
b. Remove the oil fill and drain screw and sealing washer.
c. Drain the fluid into a suitable container.
a - Oil fill and drain screw

b - Sealing washer
b
a
mc79507-1
6. Remove the oil vent screw and sealing washer. Allow the oil to drain completely.
a - Oil vent screw

b - Sealing washer
a b
mc77106-1
IMPORTANT: If any water drains from the unit, or if the fluid appears milky, the sterndrive unit is leaking. See your
authorized Mercury MerCruiser dealer.
7. Lower the sterndrive unit so the propeller shaft is level.
IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lubricant in the sterndrive unit.
8. Fill the sterndrive unit through the oil fill and drain hole with specified gear lubricant until an air‑free stream of lubricant
flows from the oil vent hole.
87 High Performance Gear Lubricant Sterndrive unit 92-858064K01
9. Install the oil vent screw and sealing washer.

10. Continue to pump gear lubricant into the drive through the oil fill and drain hole until gear lubricant appears in the gear lube
monitor.
11. Fill the monitor so that the oil level is in the operating range. Do not overfill.
12. Ensure that the rubber gasket is inside the cap and install. Do not overtighten.
90-8M0133411 eng MAY 2017 Page 55

NOTE: Oil capacities include the gear lube monitor.
Model Capacity Fluid Type

Bravo One 3209 ml (108‑1/2 oz)
Bravo Two 3682 ml (124‑1/2 oz)
High Performance Gear Lubricant
Bravo Three (single seawater pickup) 3445 ml (116‑1/2 oz)
Bravo Three (dual seawater pickup) 3209 ml (108‑1/2 oz)
13. Remove the pump from the oil fill and drain hole. Quickly install the sealing washer and screw. Tighten securely.
14. Install the propeller. Refer to Propellers.
15. Check the oil level after the first use.
IMPORTANT: Oil level in the gear lube monitor rises and falls during operation. Always check the oil level when the sterndrive
is cool and the engine is off.
Power Trim Fluid

Checking
IMPORTANT: Check the oil level with the sterndrive unit in the full down/in position only.
1. Place the sterndrive unit in full down/in position.
2. Observe the oil level. Level must be between the "MIN" and "MAX" lines on the reservoir.
a - Reservoir
b - "MIN" and "MAX" lines
a b
7876
3. Fill as necessary with the specified fluid.
114 Power Trim and Steering Fluid Power trim pump 92-858074K01
Filling
1. Remove the fill cap from the reservoir.
NOTE: Fill cap is vented.
2. Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir.
114 Power Trim and Steering Fluid Power trim pump 92-858074K01
3. Install the cap.
Changing
Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized
Mercury MerCruiser dealer.
Battery
Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following
precautions when handling a battery.
Page 56 90-8M0133411 eng MAY 2017

! WARNING
Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious
injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away
from sparks or flames.
! WARNING
An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause
severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.
Multiple EFI Engine Battery Precautions

Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is
mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for
both batteries. Normally, the other engine's alternator will not be required to supply any charging current.
EFI electronic control module (ECM): The ECM requires a stable voltage source. During multiple engine operation, an
onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may go below the ECMs
minimum required voltage. Also, the alternator on the other engine may now start charging. This could cause a voltage spike in
the engine's electrical system.
In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself,
and the engine will operate normally. The ECM shuts off and resets itself so quickly that the engine may only seem to have an
ignition miss.
Batteries: Boats with multiengine EFI power packages require each engine be connected to its own battery. This ensures that
the engine's ECM has a stable voltage source.
Battery switches: Battery switches should always be positioned so each engine is operating off of its own battery. Do not
operate engines with switches in both or all position. In an emergency, another engine's battery can be used to start an engine
with a dead battery.
Battery isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should
not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this
purpose.
Generators: The generator's battery should be considered another engine's battery.
Cleaning the Flame Arrestor

! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot
start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated
and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any
spilled fuel immediately.
1. Gently lift the top back edge of the silencer and pull forward to remove.
a - Silencer
b - Flame arrestor
50395
90-8M0133411 eng MAY 2017 Page 57

2. Loosen the flame arrestor clamp and remove the flame arrestor.
a - Flame arrestor
b - Flame arrestor clamp
a
b
50396
3. Clean the flame arrestor with solvent and dry with compressed air or set aside and allow to air dry completely.
4. Install the flame arrestor and tighten the clamp to the specified torque.
Description Nm lb‑in. lb‑ft

Flame arrestor clamp 6.2 55 –
5. Install the silencer.
Cleaning the IAC Muffler (Non‑DTS Models Only)

! WARNING
1. Locate the idle air control valve (IAC) on the rear of the engine.
2. Remove the IAC muffler from the slot in the plenum.
a b a - IAC muffler
b - Plenum
c - IAC
44887
3. Inspect the muffler for holes, cracks, or deterioration. Replace if damaged.
IMPORTANT: Do not use a cleaner that contains methyl ethyl ketone and do not use cleaner on electrical connections.
4. Clean the muffler with warm water and mild detergent. Replace if necessary.
5. Allow the IAC muffler to dry completely before use.
6. Install the IAC muffler.
Page 58 90-8M0133411 eng MAY 2017

Changing the Positive Crankcase Ventilation Valve (PCV)

This engine is equipped with a positive crankcase ventilation valve (PCV). We recommend changing it every 100 hours of
operation or at least once a year, whichever occurs first.
1. Pull the PCV valve out of the intake manifold and remove the PCV valve from the hose.
a - Hose from plenum to PCV valve

a b - PCV valve
43215
2. Inspect the PCV valve and replace if necessary.
3. Install the PCV valve into the intake manifold.
4. Ensure that the PCV valve is tightly seated into the intake manifold.
We recommend the use of Mercury MerCruiser replacement parts.
Water‑Separating Fuel Filter

! WARNING
! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.
90-8M0133411 eng MAY 2017 Page 59

Removal and Installation
a a- Filter assembly retaining screw

b- Filter cap
g b c- Fuel filter element
d- O‑ring
e- Filter cup
c f- Cool Fuel Module
g- Cool Fuel Module harness
d
e
f
50405
Removal
1. Allow the engine to cool down.
NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal.
2. Close fuel supply valve, if equipped.
3. Disconnect the Cool Fuel Module harness from the engine wiring harness.
4. Turn the key switch to the start position and allow the starter to operate for five seconds.
5. Turn key switch to off position.
6. Loosen each filter assembly retaining screw until the screw is disengaged from the Cool Fuel Module. Do not remove the
filter assembly retaining screws from the filter cap.
7. Unseat the filter assembly by grasping the filter cap handle and pulling upward. Do not remove the filter assembly from the
Cool Fuel Module at this time.
8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool
Fuel Module filter reservoir.
9. Remove the filter cup from the filter cap by grasping the filter cap and rotating it in a clockwise direction while holding the
filter cup stationary.
10. Remove the used water‑separating fuel filter element from the filter cup, place it in a clean, approved container.
11. Dispose of any water or debris that may be in the filter cup.
Installation
1. Install a new water‑separating fuel filter element into the filter cup. Push the element into the cup until completely seated.
2. Install new O‑ring on the filter cup.
3. Attach the filter cap to the filter cup by grasping the filter cap and rotating it in a counterclockwise direction while holding
the filter cup stationary, until the filter cap locks securely into place.
4. Install the fuel filter assembly slowly into the Cool Fuel Module to prevent spilling fuel, and align the screws retained in the
filter cap with the screw holes in the Cool Fuel Module. Tighten the filter assembly retaining screws until hand‑tight.
5. Ensure that the filter cap is firmly seated against the Cool Fuel Module and torque each filter assembly retaining screw.

Filter assembly retaining screw 6 53 –
6. Open the fuel supply valve, if equipped.
7. Reconnect the Cool Fuel Module harness to the engine wiring harness.
8. Properly ventilate the engine compartment.
Page 60 90-8M0133411 eng MAY 2017

NOTICE
9. Supply cooling water to the engine.
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately.
Check the filter installation, clean spilled fuel, and properly ventilate the engine compartment. If leaks continue, stop engine
immediately and contact your authorized Mercury MerCruiser dealer.
Lubrication
Steering System
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
NOTE: If the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased.
1. If the steering cable has grease fittings: Turn the steering wheel until the steering cable is fully retracted into the cable
housing. Apply approximately three pumps of grease from a typical hand‑operated grease gun.
a - Steering cable grease fitting
6221
Extreme Grease Steering cable grease fitting 8M0071842
2. Turn the steering wheel until the steering cable is fully extended. Lightly lubricate the exposed part of the cable.
a - Extended steering cable
6222
Extreme Grease Steering cable 8M0071842
90-8M0133411 eng MAY 2017 Page 61

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

Mercury 25W-40 Synthetic Blend
139 Steering pin 92-8M0078629
4-Stroke Engine Oil
4. On dual engine boats: Lubricate the tie bar pivot points.

139 Tie bar pivot points 92-8M0078629
4-Stroke Engine Oil
5. After starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering
system operates properly before getting underway.
Throttle Cable
Lubricate the pivot points and the guide contact surfaces.
a - Pivot points
b - Guide contact surfaces
a a
b 43552

139 Throttle cable pivot points and guide contact surfaces 92-8M0078629
4-Stroke Engine Oil
Page 62 90-8M0133411 eng MAY 2017

Shift Plate Control Cable Lubrication

Lubricate the points shown in the following illustration with oil at least once a year, more often if the product is operated in
saltwater.
Alpha shift plate shown,

Bravo shift plate similar
a - Remote control shift
cable
a b - Shift assist assembly
b c - Intermediate shift cable
c
57220
Shift Cable ‑ DTS

Lubricate the pivot points and the guide contact surfaces.
a b a - Pivot points
b - Guide contact surfaces
43662

139 Shift cable pivot points and guide contact surfaces 92-8M0078629
4-Stroke Engine Oil
Driveshaft U‑joint Splines and O‑Rings (Sterndrive Unit Removed)

1. Apply grease to the driveshaft U‑joint splines and O‑rings.
a - Driveshaft U‑joint splines

b b - O‑rings (3)
8591
Extreme Grease Driveshaft U-joint splines and O-rings 8M0071842
2. For propeller shaft lubrication, refer to Propellers.
90-8M0133411 eng MAY 2017 Page 63

Engine Coupler
Lubricate the engine coupler splines through grease fittings on the coupler by applying approximately 8–10 pumps of grease
from a typical hand‑operated grease gun.
NOTE: If the boat is operated at idle for prolonged periods of time, the coupler should be lubricated every 50 hours.
Bravo drive coupler

a - Grease fitting
6212
Extreme Grease Engine coupler splines 8M0071842
NOTE: The coupler and shaft splines can be lubricated without removing the sterndrive unit. Apply lubricant from a typical
hand‑operated grease gun until a small amount of grease begins to push out.
Driveshaft Extension Models

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

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

Transom end grease fitting, engine end grease fitting, driveshaft grease
Extreme Grease 8M0071842
fittings
Propellers
Propeller Repair
Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.
Page 64 90-8M0133411 eng MAY 2017

Bravo One Propeller Removal

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

IMPORTANT: The selected propeller's rotation must match the forward gear direction of propeller shaft rotation.
1. Liberally lubricate the propeller shaft spline with one of the following Quicksilver lubricants.
95 2-4-C with PTFE Propeller shaft splines 92-802859A 1
Extreme Grease Propeller shaft splines (saltwater only) 8M0071842
NOTE: Extreme Grease is for saltwater applications only.

2. Install the propeller with the attaching hardware as shown.
3. Tighten the propeller nut to the specified torque.
Typical Bravo One models

a - Propeller shaft splines
d
b - Forward thrust hub
c - Flo‑Torque II drive hub
d - Propeller
e - Drive sleeve adapter
e f
a f - Tab washer
g g - Propeller nut
b
c
5301
NOTE: The specified torque is a minimum torque value.
Description Nm lb‑in. lb ft
136 – 100
Bravo One propeller nut
Then align tabs with grooves
4. Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align
with the grooves on the spline washer.
5. Bend the three tabs down into the grooves.
b c a- Propeller
b- Tab washer
a d c- Drive sleeve adapter
e d- Tab bent down
e- Propeller nut
4750
90-8M0133411 eng MAY 2017 Page 65

Bravo Two Propeller Removal

! WARNING
1. Place a wood block between the propeller blade and anti‑ventilation plate to prevent rotation. Straighten bent tabs on tab
washer.
2. Turn propeller shaft nut counterclockwise to remove nut.
3. Slide tab washer, spline washer, propeller, and thrust hub off propeller shaft.
Bravo Two Propeller Installation

IMPORTANT: The selected propeller's rotation must match the forward gear direction of propeller shaft rotation.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.
95 2-4-C with PTFE Propeller shaft splines 92-802859A 1
Extreme Grease Propeller shaft splines (saltwater only) 8M0071842
NOTE: Extreme Grease is for saltwater applications only.

2. Install the propeller with the attaching hardware as shown.
3. Tighten the propeller nut to the specified torque.
c Bravo Two
a - Propeller shaft splines
d b - Forward thrust hub
f c - Propeller
a d - Spline washer
e - Tab washer
b f - Propeller nut
8566
e
NOTE: The torque stated is a minimum torque value.
Description Nm lb‑in. lb ft
81 – 60
Bravo Two propeller nut
Then align tabs with grooves
4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.
5. Bend the three tabs down into the grooves.
b c a- Propeller
b- Tab washer
a d c- Drive sleeve adapter
e d- Tab bent down
e- Propeller nut
4750
Page 66 90-8M0133411 eng MAY 2017

Bravo Three Propeller Removal

! WARNING
1. Place a wood block between the propeller blades and the anti‑ventilation plate to prevent rotation.
2. Remove the bolt and washers securing the propeller shaft anode.
3. Remove the propeller shaft anode.
a- Propeller
b- Rear propeller nut
c- Propeller shaft anode
d- Propeller shaft anode screw
b e- Flat washer
c f- Star washer
d a
e f
5303
4. Turn the rear propeller nut 37 mm (1‑7/16 in.) counterclockwise to remove the nut.
5. Slide the propeller and thrust hub off the propeller shaft.
6. Turn the front propeller nut 70 mm (2‑3/4 in.) counterclockwise to remove the nut.
7. Slide the propeller and thrust hub off the propeller shaft.
NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer.
e a- Rear propeller nut

b- Rear propeller
f c- Rear propeller thrust hub
b d- Front propeller nut
d e- Front propeller
c
f- Front propeller thrust hub
a g- Propeller shaft anode screw
i h- Flat washer
j i- Star washer
g h j- Propeller shaft anode
5304
90-8M0133411 eng MAY 2017 Page 67

Bravo Three Propeller Installation

NOTICE
Operating the engine with a loose propeller can damage the propeller, the drive, or drive components. Always tighten the
propeller nut or nuts to specification and check for tightness periodically and at the required maintenance interval.
e a- Rear propeller nut

b- Rear propeller
f c- Rear propeller thrust hub
b d- Front propeller nut
d e- Front propeller
c
f- Front propeller thrust hub
a g- Propeller shaft anode screw
i h- Flat washer
j i- Star washer
g h j- Propeller shaft anode
5304
1. Slide the front propeller thrust hub onto the propeller shaft with the outside taper facing toward the propeller hub (toward
end of propeller shaft).
2. Apply a liberal amount of one of the following lubricants to the propeller shaft.
Extreme Grease Propeller shaft 8M0071842
95 2-4-C with PTFE Propeller shaft 92-802859A 1
3. Align the splines and install the front propeller onto the propeller shaft.
4. Install the front propeller nut and tighten to the specified torque. Check the propeller every 20 hours of operation and
tighten to the specified torque as needed.

Front propeller nut 136 – 100
5. Slide the rear thrust hub onto the propeller shaft with the outside taper facing toward the propeller hub (toward end of
propeller shaft).
6. Align the splines and install the rear propeller onto the propeller shaft.
7. Install the rear propeller nut and tighten to the specified torque. Check the propeller every 20 hours of operation and tighten
to the specified torque as needed.

Rear propeller nut 81 – 60
8. Install the propeller shaft anode over the rear propeller nut.
9. Place the flat washer onto the propeller shaft anode screw.
10. Place the star washer onto the propeller shaft anode screw.
Page 68 90-8M0133411 eng MAY 2017

11. Apply Loctite 271 Threadlocker onto the propeller shaft anode screw threads.
a- Propeller
b- Rear propeller nut
c- Propeller shaft anode
d- Propeller shaft anode screw
b e- Flat washer
c f- Star washer
d a
e f
5303
7 Loctite 271 Threadlocker Propeller shaft anode screw threads 92-809819
12. Secure the propeller shaft anode to the propeller shaft with the propeller shaft anode screw and washers. Tighten the
anode screw to the specified torque.

Propeller shaft anode screw 38 mm (0.3125‑18 x 1.5 in.) long 27 – 20
Serpentine Drive Belt

Inspection
! WARNING
Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition
key before inspecting the belts.
a- Alternator pulley
b- Idler pulley
c- Power steering pump pulley
b d- Water circulating pump pulley
a e- Crankshaft pulley
f- Tensioner pulley
f g- Seawater pump pulley
d
h- Belt routing diagram
e
g
50406
90-8M0133411 eng MAY 2017 Page 69

Checking
Inspect the drive belt for:
• Proper belt tension deflection
• Excessive wear
• Cracks
• Fraying
• Glazed surfaces
• Proper tension
Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys.
Description
Deflection 13 mm (1/2 in.)
NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length)
that join transverse cracks are not acceptable.
21062
Replacing
IMPORTANT: If reusing a belt, install it in the same direction of rotation as before.
The belt tensioner operates within the limits of movement provided by the cast stops when the belt length and geometry are
correct. If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length.
Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the
tensioner to contact the cast stops. See your authorized MerCruiser dealer for service if these conditions exist.
! CAUTION
Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage.
Relieve the spring tension slowly.
1. Use a breaker bar and appropriate socket to relieve the tensioner. Rotate the tensioner away from the belt until it stops.
2. Remove the belt from the idler pulley and slowly relieve the tension on the breaker bar.
d a- Tensioner pulley
b- Socket and breaker bar
c- Water circulating pump pulley
d- Idler pulley
a
c
b
43776
3. Remove the belt and route the replacement belt according to the belt routing diagram.
4. Carefully release the tensioner and ensure that the belt stays positioned properly.
5. Check the belt tension.
Page 70 90-8M0133411 eng MAY 2017

NOTE: Proper tension is a measurement of deflection with moderate thumb pressure on the belt at the location that has
the longest distance between two pulleys.
50920
Deflection measurement point
Description
Deflection 13 mm (½ in.)
Corrosion Protection
Corrosion Information
Whenever two or more dissimilar metals are submerged in a conductive solution, such as saltwater, polluted water or water
with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical
current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more
information contact your authorized Mercury MerCruiser dealer.
Maintaining Ground Circuit Continuity

The transom assembly and sterndrive are equipped with a ground wire circuit to ensure good electrical continuity between the
engine, transom assembly, and sterndrive components. Good continuity is essential for the MerCathode System to function
effectively.
MerCathode System Battery Requirements

The Mercury MerCruiser MerCathode system requires a minimum battery charge of 12.6 volts at all times to maintain
functionality.
Boats equipped with a MerCathode system that use shore power, and are not run for a long period of time, must use a battery
charger to maintain a minimum battery charge of 12.6 volts or above.
Boats equipped with a MerCathode system that do not have access to shore power must be operated often enough to maintain
a minimum battery charge of 12.6 volts or above at all times.
MerCathode Theory of Operation

The MerCathode system provides corrosion protection by impressing a reverse blocking current that stops the destructive flow
of galvanic currents. The MerCathode controller will regulate output to maintain 0.94 volts at the reference electrode.
90-8M0133411 eng MAY 2017 Page 71

A constant LED indicates that the system is operating correctly. A flashing LED indicates that a fault has occurred, or that an
abnormal condition exists.
a a - LED
57169
IMPORTANT: When a boat or new drive is first put into service the LED may initially indicate that the protective current is not
being supplied through the MerCathode anode. This condition is normal, and, in such cases, the LED may flash for a period.
The light from the LED will become steady after the boat is moored for a period of eight hours without operation.
MerCathode LED Codes

MerCathode LED Definition Required Action
No fault. The controller is No action is necessary. This is the normal LED indication for a
On (no flash)
working properly. properly functioning MerCathode system.
This may be normal. Monitor the LED over time. If the flashing
Reference voltage is below
2 flashes per second continues, contact your local Mercury Service dealer for
0.84 V.
assistance.
Reference voltage is above
1 flash every 4 seconds Contact your local Mercury Service dealer for assistance.
1.04 V.
1 long flash every 10 Shorted or open reference
Contact your local Mercury Service dealer for assistance.
seconds terminal.
2 long flashes every 10 Shorted or open anode
Contact your local Mercury Service dealer for assistance.
seconds terminal.
• If the boat is out of the water, no action is necessary; this is a
Open anode and reference normal LED flash sequence.
1 long flash every 60
terminals, or the boat is out of
seconds • If the boat is in the water, contact your local Mercury Service
the water/dry docked.
dealer for assistance.
• Check the battery voltage; it must be 12.6 V or higher.
Controller is not operating or • Check the 5‑amp fuse in the controller wire harness.
LED not on
is faulty. • If further assistance is required, contact your local Mercury
Service dealer.
Anodes and MerCathode System Locations

IMPORTANT: Replace sacrificial anodes if eroded 50 percent or more.
The following sacrificial anodes are installed at different locations on your power package. These anodes help protect against
galvanic corrosion by sacrificing their metal to be slowly eroded instead of the metal components on the power package.
MerCathode system—Electrode assembly replaces the anode block. System should be tested to ensure adequate output. The
test should be performed where boat is moored, using Quicksilver reference electrode and test meter.
Page 72 90-8M0133411 eng MAY 2017

Description Location Figure
Mounted on the underside of the

Gearcase anode plate
lower gearcase.
20336
Ventilation plate anode Mounted on the front of the gearcase.
20338
The MerCathode electrode is

mounted to the underside of the
gimbal housing. The MerCathode
MerCathode system controller is mounted on the engine or
on the boat transom. The controller
harness connects to the electrode 20340
harness.
Anode kit (if equipped) Mounted to the boat transom.
20341
Trim cylinder anodes Mounted on each of the trim cylinders.
20342
Located in front of the propeller,

Bearing carrier anode (Bravo One) between the front side of the propeller
and the gear housing.
20343
Propshaft anode (Bravo Three) Located behind the aft propeller.
20344
Do Not Use Caustic Cleaning Chemicals

IMPORTANT: Do not use caustic cleaning chemicals on any part of the MerCruiser power package. Some cleaning products
contain strong caustic agents. For example, some hull cleaners contain hydrochloric acid. These cleaners can degrade some of
the components they contact, including critical steering fasteners.
Damage to steering fasteners may not be obvious during visual inspection, and this damage may lead to catastrophic failure.
Some caustic cleaning chemicals may cause or accelerate corrosion. Exercise caution when using cleaning chemicals around
the power package, and follow the recommendations on the packaging of the cleaning product.
90-8M0133411 eng MAY 2017 Page 73

Power Package Exterior Surfaces

1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for
proper application.
120 Corrosion Guard Painted surfaces 92-802878 55
2. Clean the entire power package. External surfaces that have become bare should be repainted with the recommended
primer and spray paint at recommended intervals.

Mercury Light Gray Primer 92‑802878 52
Painted surfaces
Mercury Phantom Black 92‑802878Q 1
Boat Bottom Care

To achieve maximum performance and fuel economy, the boat bottom must be kept clean. Accumulation of marine growth or
other foreign matter can greatly reduce boat speed and increase fuel consumption. To ensure best performance and efficiency,
periodically clean the boat bottom in accordance with manufacturer's recommendations.
In some areas, it may be advisable to paint the bottom to help prevent marine growth. Refer to the following information for
special notes about the use of antifouling paints.
Antifouling Paint
IMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited
warranty.
You may apply antifouling paint to the boat hull and boat transom but you must observe the following precautions:
IMPORTANT: Do not paint or pressure‑wash the anodes or the MerCathode system reference electrode and anode. Doing so
will render them ineffective as inhibitors of galvanic corrosion.
IMPORTANT: If antifouling protection is required for the boat hull or boat transom, you can use copper‑based paint if it is not
prohibited by law. If you are using copper based antifouling paint, observe the following precaution:
• Avoid an electrical interconnection between the Mercury MerCruiser product, anodic blocks, or MerCathode system and
the paint by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on transom of the boat around these items.
a - Painted boat transom

b - Minimum 40 mm (1‑1/2 in.) unpainted area around
transom assembly
8107
NOTE: Sterndrive and transom assembly can be painted with a good marine paint or an antifouling paint that does not
contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, the
MerCathode system, or items specified by the boat manufacturer.
Page 74 90-8M0133411 eng MAY 2017

NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning
equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.
Do not power‑wash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of
the MerCathode assembly and increase corrosion.
a a - Reference electrode
b - Anode plate
b
21563
Sterndrive Surface Care

c Standard Bravo sterndrive
a - Sacrificial trim cylinder anode
d b - Sacrificial anodic plate
c - Steering lever ground wire
a d - Ground wire between the gimbal ring and bell housing
e - Stainless steel hoses
e f - Ground wire between the gimbal housing and trim cylinder
g - Ground wire between the gimbal ring and gimbal housing
f
g
b
21083
We recommend the following maintenance items to help keep your sterndrive corrosion‑free:
• Maintain a complete paint covering on the sterndrive.
• Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only
tin‑based antifouling paint or its equivalent on or near aluminum surfaces below the waterline.
• If bare metal is showing, apply two coats of paint.
Description Where used Part number

Mercury Phantom Black Bare metal 92‑ 802878‑1
• Spray all electrical connections with sealant.
25 Liquid Neoprene All electrical connections 92- 25711 3
• Inspect the sacrificial trim tab or anode plate if equipped, at regular intervals and replace it before it is half gone. If a
stainless steel propeller is installed, additional anodes or a MerCathode system will be required.
• Inspect the propeller shaft for fishing line, which can cause corrosion on a stainless steel shaft.
90-8M0133411 eng MAY 2017 Page 75

• Remove the propeller at least every 60 days and lubricate the propeller shaft.
• Do not use lubricants containing graphite on or near the aluminum in saltwater.
• Do not paint trim tabs or the mounting surface.
Flushing the Seawater System—Sterndrive Models

Flushing the Power Package—Bravo Models
The boat can be equipped with a combination of any of three different types of water pickups: through‑the‑hull,
through‑the‑transom, and through‑the‑sterndrive. The flushing procedures for these systems are separated into two categories:
sterndrive water pickups and alternative water pickups.
IMPORTANT: Flushing the power package with the boat and sterndrive in the water is less effective. Flushing the power
package is most effective when performed with the boat and sterndrive out of the water, such as on a boat lift or trailer.
Flushing Attachments
a Flushing attachments for side water pickup

a - Flushing device
b - Hose attachment
21515
a Flushing attachments for dual water pickup

a - Flushing device
b - Hose attachment
c - Dual water pickup flush gearcase seal kit
b
c
21514
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
Page 76 90-8M0133411 eng MAY 2017

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
Sterndrive Water Pickups

There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side water pickups. Dual
water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side water pickups require
the flushing attachment (44357Q 2).
5752
5773
Dual water pickup Side water pickup
NOTE: Flushing is only required after operation in salty, brackish, mineral‑laden, or polluted water. Flushing is required after
each outing for best results.
1. On models with the sterndrive seawater inlet blocked, supply water to the sterndrive and to the engine. Refer to
Alternative Water Pickups.
2. On models using the sterndrive seawater inlet and a through‑the‑hull or through‑the‑transom alternative water pickup,
supply water only to the sterndrive by taking the following steps to block off, or disconnect and plug the hose from the
alternative seawater pickup pump inlet Y‑fitting.
a. If equipped with a seacock, close the seacock on the hose from the alternative water pickup.
b. If not equipped with a seacock, disconnect the hose from the alternative water pickup and plug both ends.
3. On models using the sterndrive water pickups for water supply: proceed to Step 4 or Step 5.
4. If flushing the cooling system with the boat in the water:
a. Raise the sterndrive to the trailer position.
b. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
c. Lower the sterndrive to the full down (in) position.
5. If flushing the cooling system with the boat out of the water:
! WARNING
a. Engage the E‑stop switch and remove the propeller.

b. Lower the sterndrive to the full down (in) position.
c. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
90-8M0133411 eng MAY 2017 Page 77

6. Connect the hose between the flushing attachment and the water source.
7. With the sterndrive in a normal operating position, open the water source fully.
8. Disengage the E‑stop switch, place the remote control in the neutral idle speed position and start the engine.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat
the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
9. Press the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
10. Observe the water temperature gauge to ensure that the engine is operating in the normal range.
11. With the sterndrive in neutral, operate the engine for at least 10 minutes.
12. Slowly return the throttle to the idle speed position.
13. Stop the engine.
14. Shut off the water.
15. If the boat is moored in the water, remove the seawater inlet hose from the seawater pump and plug the hose to prevent
water from siphoning into the engine.
16. Remove the flushing attachment.
17. Tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be connected prior to operating the
engine.
18. Install the propeller.
Alternative Water Pickups
IMPORTANT: Two water sources are needed for this procedure.
IMPORTANT: When flushing Bravo model engines out of the water, you must have a supply of cooling water available to both
the sterndrive and to the engine during operation.
1. If flushing the cooling system with the boat in the water:
a. Raise the sterndrive to the trailer position.
b. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
c. Lower the sterndrive unit to full down (in) position.
2. If flushing the cooling system with the boat out of the water:
! WARNING
a. Engage the lanyard stop switch and remove the propeller.

b. Lower the sterndrive to full down (in) position.
c. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
3. Connect the hose between the flushing attachment and the water source.
4. Close the seacock, if equipped, to prevent water from siphoning into the engine or boat.
Page 78 90-8M0133411 eng MAY 2017

5. Remove the seawater inlet hose from the seawater pump at the location shown. Plug the hose to prevent water from
siphoning into the engine or boat.
55049
Seawater inlet hose connection
6. Use a suitable adapter to connect the flushing hose from the water source to the water inlet of the seawater pump.
NOTICE
7. With the sterndrive in a normal operating position, open the water source fully.
8. Place the remote control in the neutral idle speed position and start the engine.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat
the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
9. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
12. Slowly return the throttle to the idle speed position.
13. Stop the engine.
14. Shut off the water and remove the flushing attachments.
15. If the boat is out of the water, install the water inlet hose to the aft side of the seawater pump. Tighten the hose clamp
securely.
17. If the boat is moored in the water, tag the ignition switch with an appropriate tag requiring the seawater inlet hose to be
connected prior to operating the engine.
SeaCore Power Package Flushing Procedure

IMPORTANT: Flushing the SeaCore power package with the boat and sterndrive in the water is less effective. Flushing the
SeaCore power package is most effective when performed with the boat and sterndrive out of the water, such as on a boat lift
or trailer.
Models Using the Sterndrive Water Pickup
IMPORTANT: The system is designed to flush the Bravo sterndrive and the engine with one water source. Do not block or
remove the inlet water hose from the sterndrive to the engine.
IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the flushing
procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends.
1. Remove the boat from the water.
90-8M0133411 eng MAY 2017 Page 79

! WARNING
2. Engage the lanyard stop switch and remove the propeller.
3. Remove the quick‑connect fitting from the parts bag supplied with the engine.
4. Attach the quick‑connect fitting to a water hose.
a a - Quick‑connect fitting (water hose end)

b
b - Water hose
18487
5. Snap the quick‑connect fitting with the water hose into the flush socket on the engine.
a - Water hose
b - Quick‑connect fitting (water hose end)
a
c - Flush socket
18489
6. Open the water source of the water hose to a full flow.

7. Allow the water to flush the sterndrive for 30 seconds.
8. Place the remote control in neutral idle speed position.
9. Disengage the lanyard stop switch and start the engine.
NOTICE
10. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
13. Slowly return the throttle to the idle speed position, shut off the engine, and engage the lanyard stop switch.
14. Allow the water to flush the sterndrive for 10 seconds.
15. Turn off the water source.
Page 80 90-8M0133411 eng MAY 2017

16. Press the release button on the flush socket to disconnect the quick‑connect fitting and water hose from the engine.
a - Quick‑connect fitting (water hose end)

a b - Flush socket release button
18488
17. Remove the quick‑connect fitting from the water hose.
a a - Quick‑connect fitting (water hose end)

b
b - Water hose
18487
18. Store the quick‑connect fitting on the boat for easy access.
IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater
pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not
covered by Mercury MerCruiser Warranty.
63788
Quick-connect fitting: store on the boat, NOT the engine
19. Insert the dust cover in the flush socket on the engine.
a Dust cover installed in the flush socket

a - Dust cover
b - Flush socket
b
18490
90-8M0133411 eng MAY 2017 Page 81

Notes:
Page 82 90-8M0133411 eng MAY 2017

Section 5 - Storage
Section 5 - Storage
Table of Contents
Cold Weather or Extended Storage...................................... 84 Air‑Actuated Single‑Point Drain System........................ 88
Reformulated (Oxygenated) Gasolines (U.S.A. Only)... 84 Boat in the Water ................................................... 88
Fuel Containing Alcohol................................................. 84 Boat Out of the Water ............................................ 89
Preparing Power Package for Storage—MPI Models.... 84 Manual Drain System.................................................... 90
Special Fuel Mix .................................................... 85 Boat in the Water ................................................... 90
Engine and Fuel System Preparation .................... 85 Boat Out of the Water ............................................ 91
Maintenance.................................................................. 86 Draining Water from the Cool Fuel Module................... 92
Draining the Seawater System ............................................ 86 Draining the Sterndrive.................................................. 92
Drain System Identification............................................ 87 Battery Storage..................................................................... 93
Air‑Actuated Single‑Point Drain System ................ 87 Recommissioning the Power Package................................. 93
Manual Drain System ............................................ 87
90-8M0133411 eng MAY 2017 Page 83

Section 5 - Storage
Cold Weather or Extended Storage

Reformulated (Oxygenated) Gasolines (U.S.A. Only)
This type of gasoline is required throughout most of the U.S.A. There are two types of oxygenates used in fuels: alcohol
(ethanol) or ether (MTBE or ETBE). Gasoline containing ethanol is especially subject to absorbing atmospheric moisture,
forming gums or solids, or it may separate into a layer of fuel floating on top of a layer of water and alcohol. To reduce the
potential for separation, storage should be in containers that prevent oxidation or water vapors mixing. If ethanol is used in the
gasoline in your area, refer to Fuel Containing Alcohol.
Fuels for your Mercury Marine engine may contain up to 10% of ethanol or ether.
Fuel Containing Alcohol

Fuels containing either methanol (methyl alcohol) or ethanol (ethyl alcohol) may cause certain adverse effects. These adverse
effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb moisture from the air, resulting in a
separation (phase) of the water/alcohol from the gasoline in the fuel tank.
The fuel system components on your Mercury Marine engine will withstand up to 10% alcohol content in the gasoline. We do
not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations
on the boat's fuel system components (fuel tanks, fuel lines, and fittings). Be aware that gasolines containing alcohol may
cause increased:
• Corrosion of metal parts
• Deterioration of rubber or plastic parts
• Fuel permeation through rubber fuel lines
• Starting and operating difficulties
! WARNING
Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system
components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or
deterioration requires replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, only alcohol‑free gasoline should be used. If only fuel containing
alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is
required.
IMPORTANT: When operating a Mercury Marine engine on gasoline containing alcohol, storage of gasoline in the fuel tank for
long periods should be avoided. Long periods of storage, common to boats, create unique problems. In cars, alcohol‑blend
fuels normally are consumed before they can absorb enough moisture to cause problems. Conversely, boats may not be used
for days, weeks, or months, long enough for phase separation to take place. In addition, internal corrosion may take place
during storage if alcohol has washed protective oil films from internal components.
IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury
MerCruiser dealer. Damage caused by freezing temperatures is not covered by the Mercury MerCruiser Limited Warranty.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open
the seacock or unplug and reconnect the water inlet hose before starting the engine.
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's instructions, be used
in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the propylene glycol
antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol
manufacturer's recommendations.
Preparing Power Package for Storage—MPI Models

Multipoint fuel injection (MPI) systems must have a special mix of fuel, stabilizer, and lubricant, completely fill the fuel delivery
system. This fuel mix stabilizes the fuel and lubricates the fuel pumps, fuel pressure regulator, fuel injectors and, reduces
internal oxidation of the fuel system metal components.
IMPORTANT: This special fuel mix can be used on Mercury Marine catalyzed gasoline engines.
Page 84 90-8M0133411 eng MAY 2017

Section 5 - Storage
Special Fuel Mix

! WARNING
! WARNING
1. Fill a 23 liter (6 US gal) remote fuel tank with 19 L (5 US gal) regular unleaded 87 octane (90 RON) gasoline.
2. Pour into the remote fuel tank 1.89 L (2 US qt) of Premium Plus 2‑Cycle TC‑W3 Outboard Oil and 29.5 ml (1 oz) of
Mercury Quickstor Fuel Stabilizer.

Premium Plus 2-Cycle TC-W3
115 Fuel system 92-858026K01
Outboard Oil
124 Quickstor Fuel Stabilizer Fuel system 92-8M0047932
3. Install the remote fuel tank cap and ensure the added ingredients are thoroughly mixed with the fuel.
Engine and Fuel System Preparation
! WARNING
! WARNING
NOTICE
Running out of fuel can damage catalyst components. Do not allow the fuel tanks to become empty during operation.
1. Check the antifreeze concentration where applicable. Refer to the Specifications section.
2. Before adding Mercury Quickstor Fuel Stabilizer to the fuel in the tank, determine the type of fuel that is in the fuel tanks
and proceed with the following:
a. Vessels using fuel without alcohol—fill the vessel fuel tanks with fresh gasoline that does not contain alcohol and add
a sufficient amount of Mercury Quickstor Fuel Stabilizer to treat the gasoline. Follow the instructions on the container.
b. Vessels using fuel containing alcohol—drain the fuel tanks as low as possible and add a sufficient amount of Mercury
Quickstor Fuel Stabilizer to treat the remaining gasoline. Follow the instructions on the container.
3. Flush the cooling system. Refer to the Maintenance section.
4. Supply cooling water to the engine. Refer to the Maintenance section.
5. Close the fuel shut off valve, if equipped, or disconnect and plug the boat fuel tank hose.
6. Connect the remote fuel tank with the special fuel mix to the fuel inlet fitting.
7. Start the engine and run the engine at 1300 RPM for five minutes. This is usually enough time for the special fuel mix to
circulate through the fuel system. Check to ensure there are no oil leaks. Shut the engine off.
IMPORTANT: Do not allow the engine to run out of fuel.
8. Disconnect the special fuel mix hose from the inlet fitting. Connect the boat fuel tank hose to the inlet fitting. Open the fuel
shut off valve, if equipped.
9. Change the oil and oil filter.
10. Replace the water‑separating fuel filter element where applicable.
11. Drain the engine seawater cooling system. Refer to Draining the Seawater System.
90-8M0133411 eng MAY 2017 Page 85

Section 5 - Storage
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater
section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat
is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.
12. Fill the seawater cooling system with propylene glycol mixed to the manufacturer's recommendation to protect the engine
to the lowest temperature to which it will be exposed during freezing temperatures or extended storage. This will also
prevent the formation of exfoliating rust in the cooling system passages.
13. Tilt the sterndrive to the full down position.
14. Store the battery according to the manufacturer's instructions.
Maintenance
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing engine or drive components.
! WARNING
IMPORTANT: Refer to the maintenance schedule for the complete listing of all scheduled maintenance to be performed. A
repair shop or person of the owner's choosing may maintain, replace, or repair emission control devices and systems. Certain
other items should be performed only by an authorized Mercury MerCruiser dealer. Before attempting maintenance or repair
procedures not covered in this manual, we recommend that you purchase a Mercury MerCruiser service manual and read it
thoroughly.
NOTE: Maintenance points are color‑coded for ease of identification.
Maintenance Point Color Codes

Yellow Engine oil
Black Drive lube
Brown Power steering fluid
Blue Drain or flush
Draining the Seawater System

! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat
from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational
before draining. Do not operate the engine with the drain system open.
IMPORTANT: Only drain the seawater section of the closed cooling system.
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system.
Your power package is equipped with a drain system. Refer to Drain System Identification to determine which instructions
apply to your power package.
IMPORTANT: The engine must not be operating at any point during the draining procedure.
Page 86 90-8M0133411 eng MAY 2017

Section 5 - Storage
Drain System Identification

Air-Actuated Single-Point Drain System
a b a - Manual pressure release valve

b - Threaded cap for air connection
c - Green indicators
50399
c
a
b
50407
a - Starboard side air‑actuated drain location

b - Port side air‑actuated drain location
Manual Drain System
a
b
50408
a - Starboard side blue drain plugs

b - Port side blue drain plug
90-8M0133411 eng MAY 2017 Page 87

Section 5 - Storage
Air‑Actuated Single‑Point Drain System

Boat in the Water
NOTE: This procedure is written for the air pump that was shipped with the engine from the factory. However, any air source
can be used.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Obtain the air pump.
3. Remove the threaded cap from the air connection.
4. Ensure that the lever on top of the air pump is against the handle (horizontal).
5. Install the air pump on the air connection.
6. Pull the lever on the air pump (vertical) to seal the pump to the connection.
7. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side
will begin draining before the starboard side.
b a- Manual release valve

c b- Air pump lever (locked)
c- Air pump
a d- Air connection
e- Green indicators extended
50409
e
8. Verify that water is draining from each opening. If not, use the Manual Drain System instructions.
a
b
50407

9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.
10. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit by pulling the fuse marked "CD."
11. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow the
engine to start.
12. Remove the air pump from the air connection and return it to the mounting bracket.
13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other
maintenance. This helps ensure that all water is drained.
Page 88 90-8M0133411 eng MAY 2017

Section 5 - Storage
14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

50399
c
15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Boat Out of the Water
NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used.
1. Place the boat on a level surface and ensure that the boat is level.
2. Obtain the air pump.
3. Ensure that the lever on top of the pump is flush with the handle (horizontal).
4. Install the air pump on the air connection.
5. Pull the lever on the air pump (vertical) to seal the pump to the air connection.
6. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side
will begin draining before the starboard side.
b a- Manual release valve

c b- Air pump lever (locked)
c- Air pump
a d- Air connection
e- Green indicators extended
50409
e
90-8M0133411 eng MAY 2017 Page 89

Section 5 - Storage
7. Verify that water is draining from each opening. If not, use the Manual Drain System instructions.
a
b
50407

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.
10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do not allow the
engine to start.
11. Remove the air pump from the air manifold and return it to the mounting bracket.
12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other
maintenance. This helps ensure that all water is drained.
13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.

50399
c
Manual Drain System

Boat in the Water
NOTE: Use this procedure if the air‑actuated single‑point drain system fails.
NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are disconnected.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
Page 90 90-8M0133411 eng MAY 2017

Section 5 - Storage
2. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
a
b
50408

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open
while transporting the boat or while performing other maintenance to ensure that all water is drained.
6. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow
the engine to start.
7. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain plugs.
8. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Boat Out of the Water
NOTE: Use this procedure if the air‑actuated single‑point drain system fails.
NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are disconnected.
1. Place the boat on a level surface to ensure complete draining of the system.
2. Remove the port side blue drain plug.
3. Remove two blue drain plugs from the seawater pickup pump (front, starboard side).
a
b
50408

4. Verify that water is draining from each opening.

5. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open
while transporting the boat or while performing other maintenance to ensure that all water is drained.
7. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup pump. Do not allow
the engine to start.
8. Prior to launching the boat or starting the engine, close the drain system by installing the two blue drain plugs.
90-8M0133411 eng MAY 2017 Page 91

Section 5 - Storage
Draining Water from the Cool Fuel Module

Mercury MerCruiser recommends draining the Gen 3 Cool Fuel Module if it is equipped with a drain plug.
1. Remove the drain plug from the Gen 3 Cool Fuel Module and allow the water to completely drain from the module.
2. Inspect the drain plug and the O‑ring for damage. Replace if needed.
3. Place the O‑ring on the drain plug and apply Perfect Seal to the threads. Install the drain plug in the module drain hole.
Tighten the drain plug to finger‑tight.
a - Gen 3 Cool Fuel Module

b - Drain plug
c - O‑ring
b 50410
19 Perfect Seal Drain plug threads 92-34227Q02
Draining the Sterndrive

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

a - Speedometer pitot tube
b - Trim tab cavity vent hole
c - Trim tab cavity drain passage
d - Gear housing water drain hole (1 each ‑ port and starboard)
e - Gear housing cavity vent hole
f - Gear housing cavity drain hole
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when
returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.
Page 92 90-8M0133411 eng MAY 2017

Section 5 - Storage
2. Lower the sterndrive unit to the full down/in position.
3. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol mixed to the
manufacturer's recommendation to protect 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, mixed to the manufacturer's instructions, be
used in the seawater section of the cooling system for freezing temperatures or extended storage. Ensure that the
propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the
propylene glycol manufacturer's recommendations.
Battery Storage
Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the battery is fully
charged and in good operating condition. It should be clean and free of leaks. Follow the battery manufacturer's instructions for
storage.
Recommissioning the Power Package

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage
the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable
clamp securely when connecting.
3. Coat the terminal connections with a battery terminal anticorrosion agent.
4. Perform all the checks in the Operation Chart.
NOTICE
5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly.
6. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.
7. Inspect the steering system, shift and throttle control for proper operation.
90-8M0133411 eng MAY 2017 Page 93

Section 5 - Storage
Notes:
Page 94 90-8M0133411 eng MAY 2017

Table of Contents
Diagnosing EFI Problems..................................................... 96 Insufficient Engine Temperature.................................... 97
Diagnosing DTS Problems................................................... 96 Low Engine Oil Pressure............................................... 97
Additional Operation Instructions for Axius Systems ........... 96 Battery Will Not Recharge............................................. 98
Engine Guardian System...................................................... 96 Remote Control Is Difficult to Move, Has Excessive Play,
Troubleshooting Charts........................................................ 96 or Makes Unusual Sounds............................................. 98
Starter Motor Will Not Crank Engine, or Cranks Slowly Steering Wheel Jerks or Is Difficult to Turn................... 98
....................................................................................... 96 Power Trim Does Not Operate (Motor Does Not Operate)
Engine Will Not Start or Is Hard to Start........................ 96 ....................................................................................... 98
Engine Runs Rough, Misses, or Backfires.................... 97 Power Trim Does Not Operate (Motor Operates but
Poor Performance.......................................................... 97 Sterndrive Unit Does Not Move).................................... 98
Excessive Engine Temperature..................................... 97
90-8M0133411 eng MAY 2017 Page 95

Diagnosing EFI Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on electronic fuel injection
(EFI) systems. The engine control module (ECM) on these engines has the ability to detect some problems with the system
when they occur, and store a Trouble Code in the ECMs memory. This code can then be read later by a service technician
using a special diagnostic tool.
Diagnosing DTS Problems

Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on digital throttle and shift
(DTS) systems. The engine control module (ECM)/propulsion control module (PCM) on these engines has the ability to detect
some problems with the system when they occur, and store a Trouble Code in the ECM/PCMs memory. This code can then be
read later by a service technician using a special diagnostic tool.

boat.
Engine Guardian System

The Engine Guardian System monitors the critical sensors on the engine for any early indications of problems. The system will
respond to a problem by emitting a continuous beep and/or reducing engine power in order to provide engine protection.
If Guardian System has been activated, reduce throttle speed. The horn will turn off when throttle speed is within the allowable
limit. Consult an authorized Mercury MerCruiser dealer for assistance.
Troubleshooting Charts
Starter Motor Will Not Crank Engine, or Cranks Slowly
Possible Cause Remedy
Battery switch turned off. Turn the switch on.
Remote control not in neutral position. Position the control lever in neutral.
Check and reset the main power circuit breaker or replace the fuse. Check the
Open circuit breaker or fuse. 5‑amp fuse on the power harness connected to the battery, and replace if
necessary.
Loose or dirty electrical connections or Check all electrical connections and wires (especially battery cables). Clean
damaged wiring. and tighten all faulty connections.
Bad battery or low battery voltage. Test the battery and charge if necessary; replace if bad.
Lanyard stop switch activated. Check the lanyard stop switch.
Engine Will Not Start or Is Hard to Start

Lanyard stop switch activated. Check the lanyard stop switch.
Improper starting procedure. Read the starting procedure.
Insufficient fuel supply. Fill fuel tank or open valve.
Faulty ignition system component. Service the ignition system.
Clogged fuel filter. Replace fuel filter.
Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to remove
Fuel line or tank vent line kinked or clogged.
obstruction.
Faulty wire connections. Check wire connections.
EFI system fault. Have EFI system checked by an authorized Mercury MerCruiser dealer.
Page 96 90-8M0133411 eng MAY 2017

Engine Runs Rough, Misses, or Backfires

Clogged fuel filter. Replace filter.
Stale or contaminated fuel. Drain fuel tank. Fill with fresh fuel.
Replace kinked lines or blow out lines with compressed air to remove
Kinked or clogged fuel line or fuel tank vent line.
obstruction.
Flame arrestor dirty. Clean the flame arrestor.
Faulty ignition system component. Service ignition system.
Idle speed too low. Have EFI system checked by an authorized Mercury MerCruiser dealer.
Poor Performance
Throttle not fully open. Inspect the throttle cable and linkages for proper operation.
Damaged or improper propeller. Replace the propeller.
Excessive bilge water. Drain and check for cause of entry.
Boat overloaded or load improperly distributed. Reduce load or redistribute load more evenly.
Flame arrestor dirty. Clean the flame arrestor.
Boat bottom fouled or damaged. Clean or repair as necessary.
Ignition problem. See Engine Runs Rough, Misses, or Backfires.
Engine overheating. See Excessive Engine Temperature.
Excessive Engine Temperature

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

Faulty thermostat. Replace.
Low Engine Oil Pressure

Insufficient oil in crankcase. Check and add oil.
Excessive oil in crankcase (causing it to Check and remove required amount of oil. Check for cause of excessive oil
become aerated). (improper filling).
Change oil and oil filter, using correct grade and viscosity oil. Determine
Diluted or improper viscosity oil.
cause for dilution (excessive idling).
90-8M0133411 eng MAY 2017 Page 97

Battery Will Not Recharge

Excessive current draw from battery. Turn off nonessential accessories.
Alternator drive belt loose or in poor condition. Replace and/or adjust.
Unacceptable battery condition. Test battery, replace if necessary.
Check all associated electrical connections and wires (especially
Loose or dirty electrical connections or damaged
battery cables). Clean and tighten faulty connections. Repair or
wiring.
replace damaged wiring.
Faulty alternator. Test alternator output, replace if necessary.
Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds
Insufficient lubrication on shift and throttle linkage
Lubricate.
fasteners.
Obstruction in shift or throttle linkages. Remove obstruction.
Check all linkages. If any are loose or missing, see authorized
Loose or missing shift and throttle linkages.
Mercury MerCruiser dealer immediately.
Straighten cable or have authorized Mercury MerCruiser dealer
Shift or throttle cable kinked.
replace cable if damaged beyond repair.
Steering Wheel Jerks or Is Difficult to Turn

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

Replace fuse. Fuses may be located near the dash trim switch, at the trim pump, in the
Blown fuse.
positive (red) power trim battery lead near the battery switch, or a combination of these.
Loose or dirty electrical
Check all associated electrical connections and wires (especially battery cables). Clean and
connections or damaged
tighten faulty connection. Repair or replace wiring.
wiring.
Power Trim Does Not Operate (Motor Operates but Sterndrive Unit Does Not Move)
Trim pump oil level low. Fill pump with oil.
Drive unit binding in gimbal ring. Check for obstruction.
Page 98 90-8M0133411 eng MAY 2017


Table of Contents
Owner Service Assistance.................................................. 100 Contact Information for Mercury Marine Customer
Local Repair Service .................................................. 100 Service ....................................................................... 101
Service Away From Home .......................................... 100 Customer Service Literature............................................... 101
Stolen Power Package ............................................... 100 English Language ....................................................... 101
Attention Required After Submersion ......................... 100 Other Languages ........................................................ 102
Replacement Service Parts ........................................ 100 Ordering Literature............................................................. 102
Parts and Accessories Inquiries .......................... 100 United States and Canada ......................................... 102
Resolving a Problem .................................................. 100 Outside the United States and Canada ...................... 102
90-8M0133411 eng MAY 2017 Page 99

Owner Service Assistance

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

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. If, for any reason,
you cannot obtain service, contact the nearest regional service center. Outside the United States and Canada, contact the
nearest Marine Power International service center.
Stolen Power Package

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

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

! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with
federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system
components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and
tighten all components.
Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both
fresh and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine
engine parts because specifications are different from those of the standard automotive engine. For example, one of the most
important special replacement parts is the cylinder head gasket. Marine engines cannot use steel‑type automotive head
gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.
Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve
springs, valve lifters, pistons, bearings, camshafts, and other heavy‑duty moving parts.
Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.
Parts and Accessories Inquiries
Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has
the necessary information to order parts and accessories for you. Only authorized dealers can purchase genuine Quicksilver
parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When
inquiring about parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.
Resolving a Problem
Satisfaction with your Mercury MerCruiser product is important to your dealer and to us. If you ever have a problem, question,
or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need
additional assistance:
1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and
service manager have been unable to resolve the problem.
2. If your question, concern, or problem cannot be resolved by your dealership, please contact a Mercury Marine Service
Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.
The following information will be needed by Customer Service:
• Your name and address
• Daytime telephone number
• Model and serial numbers for your power package
• The name and address of your dealership
Page 100 90-8M0133411 eng MAY 2017

• Nature of the problem
Contact Information for Mercury Marine Customer Service

For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.
United States, Canada

English +1 920 929 5040 Mercury Marine
Telephone
Français +1 905 636 4751 W6250 Pioneer Road
English +1 920 929 5893 P.O. Box 1939
Fax Fond du Lac, WI 54936-1939
Français +1 905 636 1704
Website www.mercurymarine.com
Australia, Pacific
Telephone +61 3 9791 5822 Brunswick Asia Pacific Group
41–71 Bessemer Drive
Fax +61 3 9706 7228 Dandenong South, Victoria 3175
Australia
Europe, Middle East, Africa

Telephone +32 87 32 32 11 Brunswick Marine Europe
Parc Industriel de Petit-Rechain
Fax +32 87 31 19 65 B-4800 Verviers,
Belgium
Mexico, Central America, South America, Caribbean

Telephone +1 954 744 3500 Mercury Marine
11650 Interchange Circle North
Fax +1 954 744 3535 Miramar, FL 33025
U.S.A.
Japan
Telephone +072 233 8888 Kisaka Co., Ltd.
4-130 Kannabecho Sakai-shi Sakai-ku
Fax +072 233 8833 5900984 Osaka,
Japan
Asia, Singapore
Telephone +65 65466160 Brunswick Asia Pacific Group
T/A Mercury Marine Singapore Pte Ltd
Fax +65 65467789 29 Loyang Drive
Singapore, 508944
Customer Service Literature

English Language
English language publications are available from:
Mercury Marine
Attn: Publications Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for
further information.
When ordering be sure to:
• List your product, model, year, and serial numbers.
• Check the literature and quantities you want.
• Enclose full remittance in check or money order (NO COD).
90-8M0133411 eng MAY 2017 Page 101

Other Languages
To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine
Power International Service Center for information. A list of part numbers for other languages is provided with your power
package.
Ordering Literature
Before ordering literature, have the following information about your power package available:
Model Serial Number

Horsepower Year
United States and Canada

For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:
Mercury Marine
Telephone Fax Mail
Mercury Marine
(920) 929‑5110 (920) 929‑4894 Attn: Publications Department
(USA only) (USA only) P.O. Box 1939
Outside the United States and Canada

Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular
power package.
Mercury Marine
Submit the following Attn: Publications Department
order form with payment W6250 Pioneer Road
to: P.O. Box 1939
Ship To: (Copy this form and print or type–This is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country
Quantity Item Stock Number Price Total

. .
. .
. .
. .
. .
Total Due .
Page 102 90-8M0133411 eng MAY 2017

Table of Contents
Predelivery Inspection (PDI)............................................... 104 Customer Delivery Inspection (CDI)................................... 105
90-8M0133411 eng MAY 2017 Page 103

Predelivery Inspection (PDI)

IMPORTANT: This checklist is for packages that are not equipped with Axius. For engine packages equipped with Axius, use
the Axius‑specific checklist, which appears in Section 5 of the Axius Operation Manual.
Perform these tasks before the Customer Delivery Inspection (CDI).
Check/
N/A Item
Adjust
⃞ ⃞ Service bulletin updates or repairs completed
⃞ Drain plug installed and drain valves closed
⃞ ⃞ Seawater inlet valve open
⃞ Engine mounts tight
⃞ ⃞ Engine alignment
⃞ ⃞ Drive unit fasteners tightened to specifications
⃞ ⃞ Power trim cylinders fasteners tight
⃞ Battery of proper rating, fully charged, secured, with protective covers in place
⃞ All electrical connections tight
⃞ Exhaust system hose clamps tight
⃞ All fuel connections tight
⃞ Correct propeller selected, installed, and tightened to specifications
⃞ Throttle, shift, and steering system fasteners tightened to specifications
⃞ ⃞ Test OBDM warning system and MIL (light) operation (EC models only)
⃞ Steering operation throughout range
⃞ Throttle plates open and close completely
⃞ Crankcase oil level
⃞ ⃞ Power trim oil level
⃞ ⃞ Sterndrive unit oil level
⃞ ⃞ Power steering fluid level
⃞ ⃞ Closed cooling fluid level
⃞ ⃞ Transmission fluid level
⃞ ⃞ V‑engines: serpentine belt tension
⃞ ⃞ Alternator belt tension (3.0L)
⃞ ⃞ Power steering pump belt tension (3.0L)
⃞ ⃞ SmartCraft gauges calibrated, if equipped
⃞ ⃞ Warning system operation
⃞ ⃞ Trim limit switch operation
Page 104 90-8M0133411 eng MAY 2017

Predelivery Inspection Checklist, Continued
Check/
N/A Item
Adjust
On‑the‑Water Test
⃞ ⃞ Engine alignment (Inboard models only)
⃞ Starter neutral safety switch operation
⃞ E‑stop switch/lanyard stop switch operation (all helms)
⃞ Seawater pump operation
⃞ Operation of instruments
⃞ Fuel, oil, and water leaks
⃞ Exhaust leaks
⃞ Ignition timing
⃞ Forward, neutral, and reverse gear operation
⃞ Steering operation throughout range
⃞ Acceleration from idle RPM is normal
⃞ WOT________ RPM within specification (in forward gear)
⃞ ⃞ EC models: run two full operating cycles (key on/off) to WOT with engine at normal operating temperature
while monitoring engine with G3 CDS to verify engine goes into closed‑loop engine control.
⃞ ⃞ Power trim operation
⃞ ⃞ Boat handling
After On‑the‑Water Test
⃞ Propeller nut tightened to specification
⃞ Fuel, oil, coolant, water, and fluid leaks
⃞ Oil and fluid levels
⃞ Apply Quicksilver Corrosion Guard to engine package
⃞ Operation, Maintenance & Warranty manual in boat
If Boat Is Registered to a Resident of California
⃞ ⃞ CARB hang tag in boat
⃞ ⃞ CARB decal properly affixed to boat hull
Customer Delivery Inspection (CDI)

IMPORTANT: This checklist is for packages that are not equipped with joystick piloting. For engine packages equipped with
joystick piloting, use the checklist included with the joystick piloting operation manual.
Perform these tasks after the Predelivery Inspection (PDI).
This inspection must take place in the presence of the customer.
N/A Completed Item

⃞ Operation and Maintenance manual—provide and review with customer. Emphasize the importance of safety
warnings and Mercury engine testing procedures.
⃞ Approve the external appearance of the product (paint, cowl, decals, etc.)
⃞ Warranty—provide and explain the limited warranty to the customer. Explain dealer services.
⃞ ⃞ Explain the optional Mercury Product Protection Plan (North America only)
Operation of equipment—explain and demonstrate:
⃞ E‑stop switch/lanyard stop switch operation (all helms)
⃞ Cause and effect of steering torque or pull; instruct on using a firm steering grip; explain boat spin‑out and
how to trim for neutral steering
⃞ Explain the warning horn strategy—caution and critical
⃞ ⃞ U.S. Coast Guard capacity plate
⃞ Proper seating
⃞ Importance of personal flotation devices (PFDs or life vests) and throwable PFDs (throw cushions)
⃞ ⃞ Functions of SmartCraft accessories (if applicable)
⃞ Off‑season storage and maintenance schedule
⃞ Explain the power package flushing procedure
⃞ Engine (starting, stopping, shifting, using throttle)
90-8M0133411 eng MAY 2017 Page 105

N/A Completed Item
⃞ Boat (lights, battery switch location, fuses/breakers)
⃞ ⃞ Trailer (if applicable)
Registration:
⃞ Complete and submit warranty registration—provide the customer with a copy
Page 106 90-8M0133411 eng MAY 2017


Table of Contents
Scheduled Maintenance Log.............................................. 108 Vessel Maintenance Notes................................................. 109
90-8M0133411 eng MAY 2017 Page 107

Scheduled Maintenance Log

100 Hours
Actual Hours
Service Notes
Dealer Name Signature Date
200 Hours
Actual Hours
Service Notes
300 Hours
Actual Hours
Service Notes
400 Hours
Actual Hours
Service Notes
500 Hours
Actual Hours
Service Notes
600 Hours
Actual Hours
Service Notes
Page 108 90-8M0133411 eng MAY 2017

Vessel Maintenance Notes

Record all general maintenance performed on your power package here. Save all work orders and receipts.
Engine
Date Maintenance Completed Servicing Dealer
Hours
90-8M0133411 eng MAY 2017 Page 109

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517 eng

Read This Manual Thoroughly

8.2 MAG/H.O./SeaCore Models (ECT)

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

Copyright and Trademark Information

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

Section 1 - Getting to Know Your Power Package

Section 2 - On the Water

90-8M0133411 eng MAY 2017 Page i

Page ii 90-8M0133411 eng MAY 2017

Section 7 - Customer Assistance Information

Section 9 - Maintenance Log

90-8M0133411 eng MAY 2017 Page iii

Section 1 - Getting to Know Your Power Package 1

90-8M0133411 eng MAY 2017 Page 1

Additional Operation Instructions for Axius Systems

a a- Quick response code

Quick Response (QR) Code

Page 2 90-8M0133411 eng MAY 2017

Engine Serial Number

a b c a - Flywheel housing cover

Bravo Sterndrive Serial Number and Identification

Bravo sterndrive information on ground plate

Bravo sterndrive serial number stamping

90-8M0133411 eng MAY 2017 Page 3

Bravo Transom Serial Number

Transom Serial No.

Serial number location on gimbal housing

Lanyard Stop Switch

Page 4 90-8M0133411 eng MAY 2017

90-8M0133411 eng MAY 2017 Page 5

Troll Control Speed Range Specification

Page 6 90-8M0133411 eng MAY 2017

Reference Gauge Function

90-8M0133411 eng MAY 2017 Page 7

Remote Controls (Non‑DTS Models)

a e a- Neutral lock button

b a- Throttle only button

Page 8 90-8M0133411 eng MAY 2017

Zero Effort Features

Remote Controls (DTS Models)

90-8M0133411 eng MAY 2017 Page 9

Panel Mount Features

d a- Lanyard stop switch

DTS Slim Binnacle Single Handle Console Features and Operation

Page 10 90-8M0133411 eng MAY 2017

Slim binnacle ERC

Item Control Function

90-8M0133411 eng MAY 2017 Page 11

Dual‑Handle Electronic Remote Control (ERC)—Operation and Adjustment

a - Detent tension adjustment screw

Page 12 90-8M0133411 eng MAY 2017

Special Digital Throttle and Shift (DTS) Features

Item Control Function

NOTE: Not all functions may be active.