MerCruiser Alpha One V6, Operation And Maintenance Manual

Page 1: ... D 2 f m a D a a a ...

Page 2: ...tenance Maroa 1 2 3 Engine Serial Number 3 Transom Assembly Serial Number The serial numbers are the manufacturer s keys to numerous engineering details which apply to your MerCruiser power package When contacting your Authorized MerCruiser Dealer about service always specify model and serial numbers 4 5 1 6 ABC12345Z123 7 TRANSOM ASSEMBLY 5 RIUNO 1 I 3 r r Length Purchase Date Boat Model SERIAL N...

Page 3: ...major accident prevention measures A WARNING WARNING Hazardsor unsafe practices which could result in severe personal injury or death A CAUTION CAUTION Hazards or unsafe practices which could result in minor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for proper operation and or maintenance A WARNING The operator driver is respon...

Page 4: ...mum See your Authorized MerCruiser Dealer for service aids BOATING SAFETY AND SEAMANSHIP Do not overload Know your boat s operating and loading limitations Check safety equipment on board addition here are suggestions of safety equipment to carry when boating Approved life jackets for each person on board Boating safety and seamanship Courses are periodically offered by the following national stat...

Page 5: ...r damaged gear housing skeg C Raised burrs or sharp edges on pro peller or gear housing VENTILATION Ventilation is caused by surface air or exhaust gases which are introduced around the propeller resulting in propeller speedUp and a reduction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missing propeller diffuser ring C A damaged propel...

Page 6: ...r Meter records engine running time MerCruiser V6 V8 9 Bilge Blower Switch must be operated for five minutes to ventilate bilge 10 Ignition Switch allows operator to start and stop engine MODELS WITH AUDIO WARNING SYSTEM Warning buzzer will sound if 1 cooling system water temperature rises too high or 2 engine oil pressure gets too low If buzzer sounds stop engine immediately If cause for warning ...

Page 7: ... 4 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle MerCruiser V6 V8 Turn screw clockwise to increase friction Do not thread screw all the way out 5 DETENT Screw controls the effort needed to move control handle out of NEUTRAL To increase tension turn screw clockwise the decrease turn screw coun terclockwise Do not thread screw all th...

Page 8: ...ed position 3A If equipped with three button con trol panel press IN button until drive unit reaches desired position In most cases reduce boat speed OPERATION Continued POWER TRIM Cause boat to accelerate and plane off slower In excess cause porpoising and or propeller ventilation 1 In most cases best overall per formance is obtained with drive unit adjusted so boat will run at a 3 to 5 angle to ...

Page 9: ...tarts If oil pressure is n01 within specified range see SPECIFICA TIONS stop engine immediately and determine cause H If engine is cold run engine for 1 or 2 minutes at fast idle 1000 1500 RPM I After engine has warmed up check water temperature gauge to ensure that engine temperature is not abnormally high If it is stop engine immediately and determine cause J Be sure charging system is functioni...

Page 10: ...h performance models are exceptions How ever gasolines containing alcohol either methyl alcohol methanol or ethyl alcohol ethanol may cause increased Corrosion of metal parts Deterioration of elastomer and plastic parts Check all fluid levels Check carburetor adjustment Inspect ignition system and timing Check for loose missing or damagel parts Check shift and throttle cable adjust ments lubricate...

Page 11: ...an APIclassification 0 SF may be used The chart below is aguide to crankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not available a multi viscosity 20W 40 SF or as a second but less preferable choice 20W 50 SF may be used IMPORTANT Theuse of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oi...

Page 12: ...RV8C 5 7 4 3 AC MR43T or Champion RV8C A MODEL Spark Plug Gap Timing Idle RPM MODEL Firing Order Spark Plug Type Electrical System Alternator Rating Recommended Battery Rating Closed Cooling I 20 U S Qts 19 3 L System Always use dipstick to determine exact quantity of oil required 2Seawater Cooling System capacity information is for winterization use only Approximately 32 fl oz 946ml 350 MAGNUM Ap...

Page 13: ...osed Portion of Steering Cable and Propeller Shaft Quicksilver Special Lubricant 101 5 Stern Drive Unit Quicksilver Gear Lube 6 All Grease Fittings Universal Joints Engine Coupler and Splined Universal Joint Shaft Quicksilver 2 4 C Marine Lubricant 7 All Exterior Surfaces Quicksilver Primer and Spray Paint and Quicksilver Corrosion Guard 8 Power Trim System Quicksilver Power Trim and Steering Flui...

Page 14: ...amage and deterioration S F Weekly 60 Days 120 Days Year Check clamps for tightness Engine Exhaust System Inspect for damage deter ioration and restrictions S F Check clamps for tightness Ignition System Check Drive Belts All Inspect condition and Ignition System Clean and inspect condition Flame Arrestor and Crankcase Ventilation Hose Clean and inspect Continuity Circuit Check components for loos...

Page 15: ...entive Closed Cooling Coolant EVERY 2 YEARS Replace Zinc Alloy Trim Tab Anodic Heads Anodic Plate and Quicksilver S F Anti Corrosion Anode Kit Optional Inspect for Gear Housing Water Pickups Check for marine growth or debris Carburetor Adjust f e cooling is in the thru hull I Closed Cooled Models a second water pickup or engm I fitting System Test output Test for alkalinity MAINTENANCE Continued M...

Page 16: ...r Trim pump Reset circuit breaker If breaker remains open electrical overload has not been eliminated Further checks mustbe made on electrical system In an emergency when engine must be operated and cause for high current draw cannot be located and corrected turn OFF or disconnect all accessories connected to engine and instrumentation wiring OVERLOAD PROTECTION ELECTRICAL SYSTEM If an electrical ...

Page 17: ...ump Place drive unit in full down in position MerCruiser V6 V8 5 Remove fill cap from reservoir check that caplug is removed from filler neck and observe oil level Level must be up to but not over bottom of filler neck Add Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor oil if required to bring level to bottom offiller neck Replace cap SA The fill cap is vented frequently check that ...

Page 18: ...ft grease fittings at engine end with 2 4 C Marine Lubri cant MAINTENANCE Continued On dual engine boats lubricate all pivot points including tie bar pivot points with SAE 30W motor oil 3 Lubricate control valve fitting with 2 4 C Marine Lubricant 4 Lubricate steering system pivot points with SAE 30W motor oil If steering cable does not have grease fitting inner wire of cable cannot be greased 2 W...

Page 19: ... MerCruiser V6 V8 Repair Somedamagedpropellerscan be repaired See your dealer Installation IMPORTANT If reusing tab washer carefully inspecttabs for cracks or other damage Replace tab washer if condition is questionable 4 Apply a liberal coat of one of the fol lowing Quicksilver lubricants to propeller shaft Anti Corrosion Grease Special Lub ricant 101 or 2 4 C Marine Lubricant 5 Slide thrust hub ...

Page 20: ...lates onto heat exchanger Install bolts and tighten securely Start engine and inspect cooling system for leaks it CAUTION Do not run engine above 1500 RPM when flushing Suction created by sea water pickup pump may collapse flushing hose causing engine and or drive unit to overheat it CAUTION Watch temperature gauge on dash to ensure that engine does not overheat MAINTENANCE Continued To prevent si...

Page 21: ...pressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 1 Alternator Drive Belt Inspect drive belt for excessive wear or damage If any drive belts need replacement or tension needs adjustment see your Authorized MerCruiser Dealer All drive belts must be periodically in spected for condition and tension Perform the following inspections of alter nator drive belt power steering p...

Page 22: ...aling ring and filter by turning clockwise to right Tighten filter securely Do not overtighten 3 Removeoil filler cap Add correct type oil see SPECIFICATIONS page 18 to MerCruiser V6 V8 bring level up to but not over FULL mark on dipstick IMPORTANT Always use dipstick to determine exactly how much oil is required Drive Unit Oil IMPORTANT Use only specified gear lubricant in drive unit See SPECIFI ...

Page 23: ...cket and discard Coat sealing rings on new filter with motor oil Thread filter clockwise onto bracket and tighten securely by hand Do not use a filter wrench MerCruiser V6 V8 Start and run engine Check filter con nection for gasoline leaks If leaks exist recheckfilter installation If leakscontinue stop engine immediately and contact your Authorized MerCruiser Dealer A WARNING Make sure no leaks ex...

Page 24: ...he paint Corro sion damage that results from the improper application of copper base paint will not be covered by the limited warranty IMPORTANT Do not paint zinc anodes or MerCathode system Spray power package components on inside of boat every 2 3 weeks with MerCruiser V6 V8 Quicksilver Corrosion Guard to protect finish from dulling and corrosion Ex ternal power package components may also be sp...

Page 25: ...en tial problems before they occur The entire power package should be checked care fully including all accessible engine parts Check for loose damaged or missing parts hosesand clamps tighten or replace as required Check plug leads and electrical leads for damage Remove and inspect propeller If badly nicked bent or cracked see your dealer Repair nicks and corrosion damage on power packageexterior ...

Page 26: ...ORTANT Drain seawater section of closed cooling system only 7 Remove drain plugs from both exhaust elbows MerCruiser V6 V8 OUT OF SEASON STORAGE Continued DRAINING INSTRUCTIONS ACAUTION If boat is to remain in water after draining seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses IMPORTANT Ob...

Page 27: ...t NEGATIVE battery cable to NEGATIVE battery terminal and POSITIVE battery cable to POSITIVE battery terminal If battery cables are reversed electrical system damage will result Install fully charged battery Clean bat tery cable clamps and terminals and recon nect cables Tighten clamps securely Coat terminals with a battery terminal anti corrosion spray to help retard corrosion Perform all checks ...

Page 28: ...harge restricted or Clean exhaust elbows plugged Faulty seawater pickup pump Closed cooling section dirty Coolant level low in closed cooling Check for cause of low coolant level section and repair Fill systemwith proper coolant I solution _ e Heat exchanger cores plugged with Clean heat exchanger foreign material e Loss of pressure in closed cooling Check for leaks Clean inspect and section test ...

Page 29: ...S UNUSUAL SOUNDS Loose or missing shift and throttle Check all linkages If any are l oose or linkage fasteners missing see Authorized MerCruiser Dealer immediately Obstruction in shift or throttle linkages Remove obstruction Loose or dirty electrical connections or Check all associated electrical connec damaged wiring tions and wires especially battery cables Clean and tighten faulty connections R...

Page 30: ... ...