MerCruiser Vazer 100, Owner'S Manual

Page 1: ...nex II ISO 8846 SAE J1171 SAE J1191 SAE J 2031 Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust when installed in a recreational craft in accordance with the manufacturers supplied instructions will meet the exhaust emissions requirements of the directive mentioned above This engine must not be put into service until the recreational craft in which it is ...

Page 2: ...printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation Mercury Marine Fond du Lac Wisconsin U S A Printed in U S A 2007 Mercury Marine Mercury Mercury Marine MerCruiser Mercury MerCruiser Mercury Racing Mercury Precision Parts Mercury Propellers...

Page 3: ...ime in order to verify and make a record of compliance with applicable standards and regulations All Mercury Marine product sold as new receives the applicable limited warranty coverage whether the engine participated in one of the test programs described above or not Read This Manual Thoroughly IMPORTANT If you don t understand any portion of this manual contact your dealer for a demonstration of...

Page 4: ...ver is responsible for the correct and safe operation of the boat the equipment aboard and the safety of all occupants aboard We strongly recommend that the operator read this Operation Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used WARNING The engine exhaust from this product contains...

Page 5: ...ge Identification 20 Engine Serial Number 20 Vazer Sterndrive Identification 20 Vazer Transom Serial Number 21 Lanyard Stop Switch 21 Instrumentation 23 Digital Gauges 23 Analog Gauges 23 Remote Controls 24 Panel Mount Features 24 Console Mount Features 25 Power Trim 25 Single Engine Trim and Trailer 27 Electrical System Overload Protection 27 Audio Warning System 30 Testing The Audio Warning Syst...

Page 6: ...ne Oil 60 Checking 60 Filling 60 Changing Oil and Filter 61 Easy Engine Oil Drain System 61 Engine Oil Drain Pump 62 Changing the Oil Filter 63 Power Assisted Steering Fluid 64 Checking 64 Filling 65 Changing 65 Engine Coolant 65 Checking 65 Filling 66 Changing 66 Sterndrive Gear Lube 67 Checking 67 Filling 67 Changing 69 Power Trim Fluid 71 Checking 71 Filling 72 Changing 72 Flame Arrestor and PC...

Page 7: ...ranks Slow 102 Engine Will Not Start Or Is Hard To Start 102 Engine Runs Rough Misses And Or Backfires 103 Poor Performance 103 Excessive Engine Temperature 103 Insufficient Engine Temperature 103 Low Engine Oil Pressure 104 Battery Will Not Come Up On Charge 104 Remote Control Operates Hard Binds Has Excessive Free play or Makes Unusual Sounds 104 Steering Wheel Turns Hard Or Jerky 104 Power Trim...

Page 8: ...Page iv 90 899883182 NOVEMBER 2007 ...

Page 9: ...y Chart 7 Commercial Application Warranty Chart 8 Government Application Warranty Chart 9 Mercury Installation Quality Certification Program 9 California Emissions Limited Warranty 10 What Is Covered 10 Duration Of Coverage 11 How To Obtain Warranty Coverage 12 What Mercury Will Do 12 What Is Not Covered 12 Components Of The Emission Control System 13 Disclaimers And Limitations 14 California Emis...

Page 10: ...urned to him for warranty service The product warranty is not effective until the product is registered at the factory NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event that a safety recall notification under the Federal Boat Safety Act is required You may change your address at any time including at time of warranty clai...

Page 11: ...ing the warranty registration card and its relationship to warranty claim processing refer to the International Warranty See Table of Contents NOTE Registration lists must be maintained by the factory and dealer on marine products sold in the United States in the event of a safety recall notification under the Federal Boat Safety Act Transfer of Warranty The limited warranty is transferable to a s...

Page 12: ...fied installations Coverage for SeaCore Sterndrive Models The Limited Warranty for SeaCore Sterndrive Models is four 4 years when installed by an Installation Quality Certified Installer or three 3 years for noncertified installations Coverage for Standard Models The Limited Warranty for Standard Models which do not include Sterndrive Models with Closed Cooling Inboard Models Scorpion 377 Models V...

Page 13: ...e purchaser cannot deliver the product to such a dealer written notice must be given to Mercury Marine Mercury Marine will then arrange for the inspection and any covered repair The purchaser in that case shall pay for all related transportation charges and travel time If the service provided is not covered by this warranty the purchaser shall pay for all related labor and material and any other e...

Page 14: ...nt noncommercial use purchaser upon proper re registration of the product Warranty coverage is terminated for used product repossessed from a retail customer purchased at auction from a salvage yard or from an insurance company that obtained the product as a result of an insurance claim Condition That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail cu...

Page 15: ...rands Region Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Standard SeaCore Vazer and Models with Closed Cooling Scorpion 377 Vazer Standard Models and and Models with Closed Cooling SeaCore USA and Canada 1 year 3 years 3 years 3 years 2 years 4 years 4 years 4 years 3 years 4 years Latin America 1 year 3 years 1 year 1 year 2 years 4 years 2 years 2 years 3 years 4 years Mex...

Page 16: ...1 year 1 year 1 year Europe 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand ...

Page 17: ...or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Japan 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours none none Australia and New Zealand 1 year or 500 hours 1 year or 500 hours 1 year or 500 hours 1 year or 500 h...

Page 18: ...Certification Program and communicate its benefits to consumers For a current list of MerCruiser powered boat brands that have earned Installation Quality Certification visit www mercurymarine com mercruiser_warranty California Emissions Limited Warranty NOTE Mercury Marine does not establish model years for the Mercury MerCruiser product line In order to comply with CARB warranty regulations and ...

Page 19: ...alendar year As an example 2003 model year products refers to products manufactured during calendar year 2003 This limited warranty provides coverage for the components of the emissions control systems Select emission control parts from model year 2003 2005 inboard or sterndrive engines are warranted for 2 years from either the date the product is first sold or first put into service whichever occ...

Page 20: ...mmended wide open throttle RPM range see Specifications operation of the product in a manner inconsistent with the recommended operation procedures neglect accident submersion improper installation proper installation specifications and techniques are set forth in the installation instructions for the product improper service use of an accessory or part not manufactured or sold by us jet pump impe...

Page 21: ...tem c Spark advance retard system d Ignition coil and or control module e Ignition wires 4 Lubrication System a Oil pump and internal parts b Oil injector s c Oil meter 5 Positive Crankcase Ventilation PCV System a PCV Valve b Oil filler cap 6 Exhaust System a Exhaust manifold b Exhaust elbow c Intermediate exhaust elbow d Lower exhaust pipe e Tailpipe 7 Catalysts or Thermal Reactor System a Catal...

Page 22: ...so included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists Mercury Marine will repair your inboard or sterndrive engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage For 2003 2008 spark ignition inboard and sterndrive marine engines Select emission control parts from model year1 2003 2008 inboard and...

Page 23: ...he label or the part it is affixed to before sale If modifications are necessary contact Mercury MerCruiser about the availability of replacement decals before proceeding NOTE When the CE mark is present in the lower right corner of the Emission Control Information Label on the engine the Declaration of Conformance applies Refer to the front page of this manual for further information EMISSION CON...

Page 24: ...omy burns up to 30 40 percent less gas and oil than conventional carbureted two stroke engines saving money and resources 3 Longer Emission Warranty Protects consumer for worry free operation Beginning January 1 2003 one Three Star or Four Star label will be included with each factory certified Mercury MerCruiser engine All Mercury MerCruiser engines 500 hp and below will have a Three Star Ultra L...

Page 25: ... marine engine 2004 exhaust emission standards Engines meeting these standards have 20 lower emissions than One Star Low Emission engines Three Stars Ultra Low emission A SS D mc79571 1 The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust em...

Page 26: ...Section 1 Warranty Notes Page 18 90 899883182 NOVEMBER 2007 ...

Page 27: ...ve Identification 20 Vazer Transom Serial Number 21 Lanyard Stop Switch 21 Instrumentation 23 Digital Gauges 23 Analog Gauges 23 Remote Controls 24 Panel Mount Features 24 Console Mount Features 25 Power Trim 25 Single Engine Trim and Trailer 27 Electrical System Overload Protection 27 Audio Warning System 30 Testing The Audio Warning System 31 Engine Guardian Strategy 31 Warning Horn Signals 31 2...

Page 28: ...ruiser power package When contacting Mercury Marine about service always specify model and serial numbers Engine Serial Number The engine serial number is located on a metal tag just below the alternator on the engine block 26258 a a b a Serial number tag b Serial number Vazer Sterndrive Identification Vazer models The drive serial number is located on the port side decal 26203 a a a Drive serial ...

Page 29: ... decal at the top of the transom assembly 26205 a a Transom assembly serial number Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator s position as in accidental ejection from the operator s position 74608 RUN a b c a Stop switch b Lanyard c Clips to the operator Accidental ejections such as falling overboard are more lik...

Page 30: ...epending upon the velocity and degree of any turn at shut down However the boat will not complete a full circle While the boat is coasting it can cause injury to anyone in the boat s path as seriously as the boat would when under power We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required to operate the engine in an emergency e...

Page 31: ...e 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 s...

Page 32: ...ur dealer for a description and demonstration of your remote control Panel Mount Features mc77019 1 b c f a e d a Neutral lock button b Throttle only button c Lanyard stop switch d Control handle tension adjustment screw e Control handle f Trim tilt button Neutral lock button Prevents accidental shift and throttle engagement Neutral lock button must be pushed into move the control handle out of ne...

Page 33: ...e depressed only when the remote control handle is in the neutral position Control handles Operation of the the shift and throttle are controlled by the movement of the control handle Push the control handle forward from neutral with a quick firm motion to the first detent for forward gear and continue pushing forward to increase speed Pull the control handle back from neutral with a quick firm mo...

Page 34: ...rged 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 water line mc78529 Trimming sterndrive down in can Help the boat accelerate and plane off quicker Generally improve the ride in choppy water In most c...

Page 35: ...ect the cause before replacing the fuse or resetting the circuit breaker IMPORTANT Always store spare fuses in the boat for replacement NOTE In an emergency when the engine must be operated and the cause for the high current draw cannot be located and corrected turn off or disconnect all accessories connected to the engine and instrumentation wiring Reset the circuit breaker If the breaker remains...

Page 36: ...ate fuses which protect the engine wiring harness from electrical overload All of these fuses are located on the remote oil filter bracket 26206 a b c d e e e a 100 amp main fuse b Oil filter bracket c Fuse block d 15 amp fuse e 20 amp fuse 3 Two 10 amp fuses protect the O2 oxygen sensors These are located at the top of the engine near the flame arrestor 32647 ...

Page 37: ...al lead there may be a 20 amp fuse that protects the electrical system Check for a failed fuse if you turn the ignition key to the START position and nothing happens assuming the circuit breaker is not tripped mc70525 1 A power harness connected to the engine starting battery minimizes voltage drop to the electrical system This harness is protected by a 5 amp fuse a b c 32206 a Fuse cover b 5 amp ...

Page 38: ... Trim Control Panel mc70527 1 A 20 amp in line fuse protects the Quicksilver MerCathode System if equipped The fuse is located in the wire connecting the positive terminal on the controller If the fuse fails the system will not operate and corrosion protection will be disabled mc79977 Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System The Audio ...

Page 39: ...by the ECM Engine Guardian monitors Oil pressure Coolant temperature Engine overspeed Exhaust Manifold Temperature Also the Engine Guardian Strategy will reduce engine power to 90 percent of maximum if any sensor on the power package fails For example if the water inlet becomes partially blocked Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage fro...

Page 40: ...Section 2 Getting to Know Your Power Package Notes Page 32 90 899883182 NOVEMBER 2007 ...

Page 41: ...9 Drain Plug and Bilge Pump 39 Protecting People In The Water 39 While You Are Cruising 39 While Boat Is Stationary 40 High Speed and High Performance Boat Operation 40 Passenger Safety in Pontoon Boats and Deck Boats 40 Boats Having An Open Front Deck 40 Boats With Front Mounted Raised Pedestal Fishing Seats 40 Wave And Wake Jumping 41 Impact with Underwater Hazards 41 Sterndrive Impact Protectio...

Page 42: ... instructions Water proof storage containers Spare operating equipment batteries bulbs and fuses Compass and map or chart of the area Personal flotation device 1 per person on board Watch for signs of weather change and avoid foul weather and rough sea boating Tell someone where you are going and when you expect to return Passenger boarding Stop the engine whenever passengers are boarding unloadin...

Page 43: ...fallen skiers When using your boat for water skiing or similar activities always keep a fallen or down skier on the operator s side of the boat while returning to attend to the skier The operator should always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boat...

Page 44: ...t is moored in a confined space b Mooring close to another boat with its engine operating 2 Examples of poor ventilation while a boat is moving mc79556 1 a b a Operating the boat with the trim angle of the bow too high b Operating the boat with no forward hatches open station wagon effect Basic Boat Operation Launching and Boat Operation IMPORTANT Install the bilge drain plug prior to launching bo...

Page 45: ...ff valve if equipped Open fuel shut off valve if equipped Flush the seawater cooling circuit if operating in saltwater brackish water or polluted water Place sterndrive in full down in position Drain the bilge Check the engine oil Perform all other checks specified by your dealer and boat builder Listen for the Audio Warning Alarm to sound when the ignition switch is in the ON position Warm up the...

Page 46: ...ust leaks 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 7 Move the control handle with a firm quick motion forward to shift into forward gear or backward to shift into reverse After shifting advance the throttle to the desired setting STOPPING THE ENGINE 1 Move the remote control handle to the ...

Page 47: ...ts IMPORTANT The seawater section of the Vazer 100 is self draining and will drain when the boat is removed from the water If there is a chance of ice forming on the water remove the boat from the water and allow the seawater section to drain completely of water If ice should form at the water level inside the sterndrive or engine it will block water flow to the engine causing possible engine and ...

Page 48: ...m 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 ...

Page 49: ... 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 cont...

Page 50: ...rwater 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 Marin...

Page 51: ... 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 b...

Page 52: ...ting with increased load additional passengers pulling skiers causes a loss of RPM For better acceleration such as is needed for water skiing 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 i...

Page 53: ... to Engine Oil in the Maintenance section 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 fi...

Page 54: ...Section 3 On The Water Notes Page 46 90 899883182 NOVEMBER 2007 ...

Page 55: ...uel Ratings 48 Using Reformulated Oxygenated Gasoline USA Only 48 Gasoline Containing Alcohol 48 Engine Oil 49 Engine Specifications 50 Fluid Specifications 50 Engine 50 Sterndrives 50 Power Assisted Steering and Power Trim Fluids 50 Approved Power Assisted Steering Fluids 50 Approved Power Trim Fluids 51 Approved Paints 51 4 ...

Page 56: ...enate that is used in the gasoline in your area refer to Gasoline Containing Alcohol These Reformulated Gasoline Gasoline Containing Alcohol If the gasoline in your area contains either methanol methyl alcohol or ethanol ethyl alcohol be aware of possible adverse effects These adverse effects are more severe with methanol and worsen according to the percentage of alcohol in the fuel Alcohol in gas...

Page 57: ...cation requirements for catalyzed engines differ from the requirements for non catalyzed engines Some marine grade lubricants contain high levels of phosphorus which can damage the catalyst system on MerCruiser engines Although these high phosphorus lubricants may allow for acceptable engine performance exposure over time will damage the catalyst Catalysts damaged by lubricants containing high lev...

Page 58: ...CA 90 Ah Alternator rating 65 A Firing order 1 3 4 2 Spark plug type Champion RN2C Spark plug gap 0 9 mm 0 1 mm 0 035 in 0 004 in Fluid Specifications Engine IMPORTANT All capacities are approximate fluid measures Vazer 100 with Emissions Control Capacity Fluid Type Engine oil with filter 4 L 4 25 US qt Mercury Full Synthetic MerCruiser 20W 40 Closed cooling system 7 8 L 8 24 US qt Mercury Extende...

Page 59: ...PROVED POWER TRIM FLUIDS Description Part Number Power Trim and Steering Fluid 92 858074K01 SAE Engine Oil 10W 30 Obtain locally SAE Engine Oil 10W 40 Approved Paints Description Part Number Mercury Light Gray Primer 92 802878 52 Mercury Phantom Black 92 802878Q 1 ...

Page 60: ...Section 4 Specifications Notes Page 52 90 899883182 NOVEMBER 2007 ...

Page 61: ...3 Positive Crankcase Ventilation Valve PCV 74 Changing 74 Fuel Filters 74 Removal 74 Installation 76 Flushing the Power Package 77 General Information 77 Sterndrive Water Pickup 78 Flushing Attachments Non Running Flush 78 Quick Connect Flush Non Running Flush 78 Flushing Attachments Running Flush 79 Vazer Sterndrive Connection 80 Flushing the Power Package Running Flush 80 Lubrication 81 Steering...

Page 62: ...mum efficiency Familiarize the customer with the on board equipment Explain and demonstrate the operation of the power package and boat Provide you with a copy of a Predelivery Inspection Checklist Your selling dealer should fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product Maintenance WARNING Performing service or maintenance wi...

Page 63: ...rive 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 p...

Page 64: ...cover horizontally to the port side to detach from the starboard side mounts 26210 Starboard side horizontal mounts Port side vertical mounts To install the engine cover 1 Install the cover horizontally and attach it to the starboard side horizontal mounts 2 Set the port side of the engine cover over the port mounts and press the cover down in the mount areas Maintenance Schedule Sterndrive Models...

Page 65: ...every 25 hours or 30 days whichever occurs first Scheduled Maintenance NOTE Only perform maintenance which applies to your particular power package Task Interval Maintenance to Be Performed After the initial 20 hour break in period Change the engine oil and filter Every 100 hours or annually whichever occurs first Touch up the paint on the power package Change the engine oil and filter Change the ...

Page 66: ... inspect the seawater pump and replace worn components Clean the seawater section of the closed cooling system Clean inspect and test the pressure cap Inspect the exhaust system components If the package was equipped with water shutters flapper valves verify that they are not missing or worn Check the engine alignment Inspect the U joints the splines the bellows and check the clamps Lubricate the ...

Page 67: ...Section 5 Maintenance 90 899883182 NOVEMBER 2007 Page 59 Date Maintenance Performed Engine Hours ...

Page 68: ...se of fluids as required Checking 1 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 2 Remove the dipstick wipe it clean and install it into the dipstick tube Wait 60 seconds to allow trapped air to vent 32706 b c a a Dipstick b Maximum mark c Minimum mark 3 Remove the dipstick and observe the oil level which must be betw...

Page 69: ... 25 U S Quart Mercury Full Synthetic MerCruiser 20W 40 3 Check the oil level See Checking 4 Replace the fill cap 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 engin...

Page 70: ...9 Replace the engine oil filter See Changing the Oil Filter Engine Oil Drain Pump NOTE This is an alternate method to utilize the Easy Engine Oil Drain System hose IMPORTANT The oil drain pump can only be used if the Easy Engine Oil Drain System is not connected to the bilge drain plug 1 Loosen the oil filter to vent the system 2 Allow sufficient time for the oil to drain from the filter down into...

Page 71: ...ontainer until the crankcase is empty 8 Remove the pump and the fitting 9 Install the drain plug in the oil drain hose 10 Replace the engine oil filter See Changing the Oil Filter Changing the Oil Filter NOTE Allow the oil in the oil filter to drain back into the engine block prior to removing it will prevent oil spillage when removing the filter 1 Remove and discard the old oil filter and sealing...

Page 72: ...l the engine with oil See Filling 6 Supply cooling water to the engine See Supplying Cooling Water to the Engine 7 Start the engine run the engine for three minutes and check for leaks Stop the engine 8 Check the oil level See Checking Power Assisted Steering Fluid IMPORTANT Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid ATF in the power assisted stee...

Page 73: ...dealer 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 pump 92 858074K01 Tube Ref No Description Where Used Part No 28 Dexron III Automatic Transmission Fluid Power assisted steering system Obtain Local...

Page 74: ...amage the cooling system or the engine Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed NOTICE 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 NOTE Add coolant only ...

Page 75: ...onitor to determine the gear lube level Keep the gear lube level within the recommended operating range See Filling 26282 a b Gear lube level shown is at the correct operating range a ADD mark b OPERATING RANGE mark IMPORTANT If any water is visible at the bottom of the gear lube monitor or appears at the fill and drain plug hole or if the gear lube appears discolored contact your authorized Mercu...

Page 76: ... Gear lube level at the ADD mark b Gear lube level at the OPERATING RANGE mark c Gear lube monitor cap Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Gear lube monitor 92 858064K01 3 Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap Do not overtighten 26217 a a Gear lube monitor cap NOTE When filling the entire sterndrive see Chang...

Page 77: ...ar lube monitor b Retaining strap 2 Empty the contents into a suitable container 3 Install the gear lube monitor in the bracket 4 Place the sterndrive in full trim limit up out position 5 Remove the oil fill and drain screw and the sealing washer 6 Drain the gear lube into a suitable container 26215 a a Oil fill and drain screw ...

Page 78: ... level 9 Fill the sterndrive through the oil fill and drain hole with specified gear lubricant until an air free stream of lubricant flows from oil vent hole Tube Ref No Description Where Used Part No 87 High Performance Gear Lubricant Sterndrive 92 858064K01 IMPORTANT Use only Mercury Quicksilver High Performance Gear Lubricant in sterndrive 10 Install the oil vent screw and sealing washer 11 Con...

Page 79: ...ely 16 Recheck the gear lube level after the first use See Checking IMPORTANT Oil level in the gear lube monitor will rise and fall during sterndrive operation always check the oil level when the sterndrive is cool and the engine is shut down Power Trim Fluid Checking IMPORTANT Check the oil level with the sterndrive in the full down in position only 1 Place the sterndrive in full down in position...

Page 80: ...pecified fluid to bring the fluid level to within the MIN and MAX lines on the reservoir 26313 a b b Power trim pump reservoir with fluid level between the MIN and MAX lines a Reservoir b MIN and MAX lines Tube Ref No Description Where Used Part No 114 Power Trim and Steering Fluid Power trim pump 92 858074K01 3 Install the fill cap Changing Power trim fluid does not require changing unless it bec...

Page 81: ...e the flame arrestor 26218 a b c a Flame arrestor b Crankcase ventilation hose c Clamp IMPORTANT Do not use an acidic based cleaner as it can deteriorate portions of the flame arrestor 4 Clean the flame arrestor with warm soapy water 5 Inspect the flame arrestor for holes cracks or deterioration Replace if necessary 6 Allow the flame arrestor to air dry completely before use 7 Clean the crankcase ...

Page 82: ...ON 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 26239 a c d e b Fuel filters a Water separating fuel filter b Fuel filter mounting bracket c Pre engine fu...

Page 83: ...pre engine fuel filter from the fuel boost pump 26260 a b c c a Fuel boost pump b Pre engine fuel filter c Wrench IMPORTANT Do not discard the fuel inlet fitting unless it is to be replaced 7 Remove and save the fuel inlet fitting from the fuel filter Discard the used fuel filter and O ring 26261 a b d c d a Fuel inlet fitting b Fuel filter c O ring d Wrench ...

Page 84: ...E Engine Oil 30W Water separating fuel filter sealing ring Obtain Locally 2 Install the new water separating fuel filter Tighten securely by hand 3 Install the fuel inlet fitting on the new pre engine fuel filter 4 Install the new O ring and coat it with engine oil 26261 a b d c d a Fuel inlet fitting b Fuel filter c O ring d Wrench Tube Ref No Description Where Used Part No 80 SAE Engine Oil 30W ...

Page 85: ... Supplying Cooling Water to the Engine 9 Start the engine Check for gasoline leaks around the fuel filter assemblies If leaks exist stop the engine immediately Recheck 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 Flushing the Power Package General Information ...

Page 86: ...ts Non Running Flush Quick Connect Flushing Attachment Contained in parts bag 26222 Connects to the attachment mounted on the engine Provides flushing water to the power package Do not operate the engine while using this flushing attachment This is a static flushing attachment only Quick Connect Flush Non Running Flush IMPORTANT This is a static flushing procedure Do not operate the engine while f...

Page 87: ...racket 26223 a b d c d a Water supply hose b Female quick connect fitting c Release button d Male quick connect fitting 4 Completely open the water source to provide maximum water supply 5 Flush the system for a minimum of 10 minutes 6 For power packages operated in saltwater brackish water mineral laden water or polluted water continue to flush the power package until the discharge water is clear...

Page 88: ...Hose attachment 4 Connect a water supply hose to the flushing attachment 5 Lower the sterndrive to the full down in position 6 Flush the power package See Flushing the Power Package Running Flush Flushing the Power Package Running Flush NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system damaging the engine Do not supply flush water for more th...

Page 89: ...e sterndrive to the trailer position 13 Remove the flushing attachment from the sterndrive 14 On models that were flushed out of the water reinstall the propeller See Propellers 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 lubrica...

Page 90: ...teering pin 26289 a a a Steering pin Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Steering pin 92 883725K01 4 On dual engine boats Lubricate the tie bar pivot points Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Tie bar pivot points 92 883725K01 5 Upon first starting engine turn the steering wheel several ti...

Page 91: ...re Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Throttle cable pivot points guide contact surfaces 92 883725K01 Shift Cable 1 Lubricate the pivot points and the guide contact surfaces 26267 a a a a b b a a Pivot points b Guide contact surfaces Tube Ref No Description Where Used Part No Synthetic Blend MerCruiser Engine Oil SAE25W 40 Shift cable pivot points guide contact surfaces 9...

Page 92: ...s through grease fittings on coupler by applying approximately 8 to 10 pumps of grease from a typical hand operated grease gun NOTE If the boat is operated at idle for prolonged periods of time coupler should be lubricated every 150 hours 26269 a Engine coupler shown with drive removed for clarity only a Engine coupler grease fitting Tube Ref No Description Where Used Part No 91 Engine Coupler Spl...

Page 93: ... 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 Straighten the bent tabs on the tab washer e c d b a 4750 a Prop b Tab washer c Drive sleeve adapter d Tab bent down e Propeller nut 2 Place a wood block between the propeller blade and anti ventilatio...

Page 94: ...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 IMPORTANT If reusing the tab washer carefully inspect tabs for cracks or ...

Page 95: ... Propeller e Drive sleeve f Locking tab washer g Propeller nut 3 Install and torque the propeller nut a b c 4826 a Wood block b Propeller c Propeller nut under socket NOTE The propeller torque stated is a minimum torque value Description Nm lb in lb ft Propeller nut 75 55 4 Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer ...

Page 96: ...ltwater polluted water or water with a high mineral content a chemical reaction takes place causing electrical current to flow between metals The electrical current flow causes the metal that is most chemically active or anodic to erode This is known as galvanic corrosion and if not controlled it will in time cause the need for replacement of power package components exposed to water Refer to the ...

Page 97: ...rine Corrosion Protection Guide 26235 3 5 1 2 4 6 1 Front trim cylinder anodes 2 2 Rear Trim cylinder anodes 2 3 Gearcase anodic plate 4 Bearing carrier anode 5 Gimbal housing anode 6 Anode kit if equipped IMPORTANT Replace sacrificial anodes if eroded 50 or more The following sacrificial anodes are installed at different locations on your power package These anodes help protect against galvanic c...

Page 98: ... to the boat transom on opposite sides of the sterndrive The MerCathode controller is mounted on the engine or on the inside of the boat transom 26234 Anode kit if equipped Mounted to the boat transom 26300 In addition to the corrosion protection devices take the following steps to inhibit corrosion 1 Paint the power package See Painting Your Power Package 2 Annually spray the power package compon...

Page 99: ...ure wash the MerCathode assembly Doing so will damage the coating on the reference electrode wire and decrease the corrosion protection 26236 a b The MerCathode is mounted on the boat transom port and starboard sides of the drive a MerCathode anode b MerCathode reference electrode The system should be tested to ensure adequate output The test should be performed where the boat is moored using a Qu...

Page 100: ...sed anti fouling paints observe the following Avoid any electrical interconnection between the paint and the Mercury MerCruiser product anodic blocks or MerCathode system by allowing a minimum of 40 mm 1 1 2 in unpainted area on the transom of the boat around these items 26265 a b a Painted boat transom b Unpainted area on transom 2 Painting the sterndrive or transom assembly The sterndrive and tr...

Page 101: ...Fraying Glazed surfaces 21062 Proper tension Deflection with moderate thumb pressure on the belt at the location that has the longest distance between two pulleys Description Deflection 6 mm 1 4 in Replacing IMPORTANT If a belt is to be reused it should be installed in the same direction of rotation as before The belt tensioner is designed to operate within the limits of movement provided by the c...

Page 102: ...ned properly 4 Check the tension of the serpentine belt Description Deflection 6 mm 1 4 in Battery Refer to specific instructions and warnings accompanying your battery If this information is not available observe the following precautions when handling a battery WARNING Recharging a weak battery in the boat or using jumper cables and a booster battery to start the engine can cause serious injury ...

Page 103: ...ler blade and the anti ventilation plate 1 Remove the propeller See Propellers 2 Place the sterndrive in the full down in position 3 Connect the appropriate attachment to the seawater inlets See Flushing Attachments Running Flush NOTICE Flushing the engine when it is not operating will result in water collecting in the exhaust system damaging the engine Do not supply flush water for more than 15 s...

Page 104: ...the full down in position 2 Ensure that the external water level is above the seawater inlets 3 Start the engine 4 Depress the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM 100 RPM 5 Observe the water temperature gauge to ensure that the engine is operating in the normal range 6 After specified operating time is complete slowly return the throttle to neutra...

Page 105: ...rage Table of Contents Cold Weather Freezing Temperature and Extended Storage 98 Draining the Vazer 100 Seawater System 98 Preparing the Power Package for Extended Storage 98 Engine and Fuel System Preparation 99 Battery Storage 100 Power Package Recommissioning 100 6 ...

Page 106: ...of 5 minutes Preparing the Power Package for Extended Storage IMPORTANT Mercury MerCruiser recommends performing all scheduled maintenance before proceeding with the Extended Storage procedure Refer to the Maintenance section 1 Flush the seawater cooling system Refer to Flushing the Seawater System in the Maintenance section 2 Fill the fuel tanks with fresh gasoline that does not contain alcohol a...

Page 107: ...RON gasoline 19 L 5 gal Premium Plus 2 Cycle TC W3 Outboard Oil 1 89 L 2 US qt Fuel System Treatment and Stabilizer or Fuel System Treatment and Stabilizer Concentrate 150 mL 5 oz or 30 mL 1 oz Tube Ref No Description Where Used Part No 115 Premium Plus 2 cycle TC W3 Outboard Oil Fuel system 92 858026K01 124 Fuel System Treatment Stabilizer Fuel system 858071K01 2 Allow the engine to cool 3 Close ...

Page 108: ...cal shock or can damage the electrical system Always disconnect the negative battery cable first and connect it last 3 Install a fully charged battery Clean the battery cable clamps and terminals and reconnect cables Tighten each cable clamp securely when connecting 4 Coat the terminal connections with a battery terminal anti corrosion agent 5 Perform all the checks in the before starting column o...

Page 109: ...o Start 102 Engine Runs Rough Misses And Or Backfires 103 Poor Performance 103 Excessive Engine Temperature 103 Insufficient Engine Temperature 103 Low Engine Oil Pressure 104 Battery Will Not Come Up On Charge 104 Remote Control Operates Hard Binds Has Excessive Free play or Makes Unusual Sounds 104 Steering Wheel Turns Hard Or Jerky 104 Power Trim Does Not Operate Motor Does Not Operate 104 Powe...

Page 110: ...off Turn the switch on Remote control not in neutral position Position the control lever in neutral Open circuit breaker or fuse Check and reset the main power circuit breaker or replace the fuse Check the 5 amp fuse on the power harness connected to the battery and replace if necessary Loose or dirty electrical connections or damaged wiring Check all electrical connections and wires especially ba...

Page 111: ... 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 EFI System fault Have EFI System checked by an authorized Mercury MerCruiser dealer Excessive Engine Temperature Possible Cause Remedy Water inlet or ...

Page 112: ... Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift and throttle linkage fasteners Lubricate Obstruction in shift or throttle linkages Remove obstruction Loose or missing shift and throttle linkages Check all throttle linkages If any are loose or missing see authorized Mercury MerCruiser dealer immediately Shift or throttle cable kinked Straighten cable or have authorized...

Page 113: ...899883182 NOVEMBER 2007 Page 105 Power Trim Does Not Operate Motor Operates But Sterndrive Unit Does Not Move Possible Cause Remedy Trim pump oil level low Fill pump with oil Drive unit binding in gimbal ring Check for obstruction ...

Page 114: ...Section 7 Troubleshooting Notes Page 106 90 899883182 NOVEMBER 2007 ...

Page 115: ... Assistance 108 Local Repair Service 108 Service Away From Home 108 Stolen Power Package 108 Attention Required After Submersion 108 Replacement Service Parts 108 Parts And Accessories Inquiries 109 Resolving A Problem 109 Mercury Marine Service Offices 109 Ordering Literature 110 United States and Canada 110 Outside The United States and Canada 110 8 ...

Page 116: ...acement 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...

Page 117: ...es manager or service manager If this has already been done then contact the owner of the dealership 2 Should you have a question concern or problem that cannot be resolved by your dealership please contact Mercury Marine Service Office for assistance Mercury Marine will work with you and your dealership to resolve all problems The following information will be needed by the service office Your na...

Page 118: ...ited States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P O Box 1939 Fond du Lac WI 54936 1939 920 929 5110 Fax 920 929 4894 Outside The United States and Canada Contact your nearest dealer or Marine Power Service Center ...