mercruiser esp

Page i © 2006 Mercury Marine 90-864196060 APRIL 2006

Models CoveredAlpha

Models Covered Serial Number

4.3 MPI

5.0 MPI

5.0 MPI DTS

350 MAG MPI

350 MAG MPI DTS

BravoModels Covered Serial Number

4.3 MPI

5.0 MPI

5.0 MPI DTS

350 MAG MPI

350 MAG MPI DTS

MX 6.2 MPI

MX 6.2 MPI DTS

350 MAG MPI Horizon

350 MAG MPI Horizon DTS

MX 6.2 MPI Horizon

MX 6.2 MPI Horizon DTS

NoticeNOTICE

NOTICE

DENTRO-FUERABORDA MODELOS MOTOR GASOLINA MANUAL

0W650000 o superior

0W650000 o superior

Después de completar la instalación, estas instrucciones se deben colocar con el producto para el uso en el futuro del dueño

Pre preparación debe realizarse antes de la entrega de barco para el dueño del producto.Aviso a los fabricante de la embarcación / instalador

A lo largo de esta publicación, Advertencias y Precauciones (acompañado por el Internacional Símbolo de peligro) se utiliza para alertar al fabricante o instalador para instrucciones especiales sobre un determinado servicio o la operación que pueden ser peligrosos si se realizan correctamente y sin respeto. - Observarlas con cuidado!

Page ii

! WARNING

! CAUTION

Estas alertas de seguridad por sí solas no pueden eliminar los peligros que la señal. El estricto cumplimiento de estas instrucciones especiales al realizar el servicio, además de la operaciónde sentido común, son las principales medidas de prevención de accidentes.

indica una situación potencialmente peligrosa que, de no evitarse, puede ocasionar la muerte o lesiones graves.

indica una situación potencialmente peligrosa que, de no evitarse, puede resultar en lesiones leves o moderadas o daños materiales. También puede utilizarse para alertar contra las prácticas inseguras.

IMPORTANTE: Indica la información o instrucciones que son necesarios para el correcto instalación y / o operación.NOTA: Consulte la MerCruiser apropiado Mercurio de Producto de Aplicaciones Manual de recomendaciones de aplicación. Este manual de instalación que se ha escrito y publicado por Mercury MerCruiser para ayudar a los fabricante de la embarcación (OEM) en la instalación de los productos descritos en este documento. Se supone que dicho personal está familiarizado con la instalación de productos marinos. Además, se supone que está familiarizado con, si no están entrenados en la recomienda losprocedimientos de instalación de Mercury MerCruiser producto. No podía saber de asesoramiento o el comercio marítimo de todas las instalaciones imaginables y de los posibles riesgos y / o los resultados de cada instalación. Por lo tanto, el fabricante es responsable de cualquier instalación que no cumpla con los requisitos de este manual. Es responsabilidad del fabricante de la embarcación para seleccionar el motor apropiado / espejo / paquete de la unidad (incluyendo la relación de transmisión correcta y la hélice) para un barco determinado. Mercurio MerCruiser recomienda que cualquier nuevo o único casco / potencia combinación de paquetes se bien analizar el agua antes de su venta, para comprobar que el barco lleva a cabo como se desee, y que el motor funciona en la gama de revoluciones adecuado. Se recomienda que un Mercury MerCruiser producto Ingeniero de Aplicaciones (PAE) se contacto para obtener ayuda. Para obtener asistencia fuera de los Estados Unidos, comuníquese con la Mercury Marine oficina o distribuidor autorizado. Toda la información, ilustraciones y especificaciones contenidas en este manual se basan en la reciente del producto disponible en el momento de su publicación. Mercury Marine se reserva el derecho a realizar cambios en cualquier momento y sin obligación. Cuando sea necesario, las revisiones de este manual será enviado a todas las compañías de barcos OEM.

Page iii

Important Information 1Boat Construction 2Exhaust System 3Fuel System 4Cooling System 5Drive System And EngineInstallation 6Starting And Electrical 7Remote Controls 8Predelivery Preparation AndStorage 9

Esquema Manual

1 - Información Importante 2 - Construcción de embarcaciones 3 - Sistema de escape 4 - Sistema de combustible 5 - Sistema de refrigeración 6 - Sistema de transmisión e instalación del motor 7 - arranque y eléctrico 8 - Control remoto 9 - Preparación Preentrega y almacenamiento

Page iv

SECTION - 1 IMPORTANT INFORMATION

90-864196060 MAY 2006 Page 1 / 8

1

SECCION 1 INFORMACIÓN IMPORTANTETabla de contenidosTorque ................................................ .................................................. ........................................... 2 Quicksilverproductos ................................................ ........................................................................... 2 Accesorios ................................................. ........................................................................................ 2 Mandos a distancia y de instrumentación para el sistema DTS ...................................................................... 2 Colocación de los números de serie ......................................................................................................... 3 Bravo Tres Aviso: Recortar punto Límite de inserción .................................................................................3Múltiples Sterndrive Directivo Acuerdos Bar .............................................................................................3 Dirección de alimentación interna con refuerzo interno solamente ................................................................. 4 Dirección de alimentación interna con refuerzo interno y externo....................................................................4Dirección de alimentación externe ............................................................................................................4Dirección de alimentación externa con baja Tie Bar externa ..........................................................................4Protección contra la corrosión .................................................................................................................4Pintura Anti-fouling .............................................................................................................................4Control de Emisiones Información de la etiqueta ........................................................................................6Responabilidad del propietario ................................................................................................................7Estrella etiqueta ...................................................................................................................................7Colgar la etiqueta .................................................................................................................................8

IMPORTANT INFORMATION SECTION - 1

Page 2 / 8 90-864196060 MAY 2006

Especificaciones de Tension

NOTA: Apriete todos los tornillos no se enumeran a continuación. NOTA: El par de la hélice se declaró un valor de par mínimo.

Tubo de escape pinza 4 35 Tornillos de escape de tubería 34 25 De escape de bloque tornillos de la placa 34 25 Bravo Uno propulsor tuerca 75 55 Alinee las pestañas con las ranuras

Bravo Two tuerca de la hélice 81 60 Alinee las pestañas con las ranuras Bravo tres frente tuerca de la hélice 136 100 Bravo Tres traseros tuerca de la hélice 81 60 Pernos de montaje del motor trasero 47 35 De dirección por cable acoplador tuerca 47 35 Pernos de dirección del sistema de pivote 34 25 Dentro-fueraborda sujetadores unidad 68 50 Elementos de fijación del transom de montaje 34 25 Clip de fijación de tornillo 12,2 108Abrazaderas de manguera 3,4 a 6,8 30 a 60 Pernos de conexión de entrada de agua 5 45 Entrada de agua en bloque de tornillo de 5 45 conector entrada del combustible ajustada + 1 - ¾ a 2 - ¼ vueltas con una llave. No apriete demasiado. Gen III Módulo de combustible fresco capturado tuerca de 19 168 Batería de estudios 8-11 71-91 Eje de la hélice del tornillo del ánodo 19 168

Descrpciòn Nm lb. in. lb.ft.Text

Productos quicksilverAsesorios Relojes de Quicksilver, controles remotos, sistemas de dirección, hélices y otros accesorios

disponibles para este producto. Mercury MerCruiser recomienda el uso de piezas de Quicksilver en todos las aplicaciones. Se refieren a Mercury Precision Parts Guía de accesorios para una lista completa. Esta Guía está disponible en: Attn: Departamento de Partes Mercury Marine W6250 W. Pioneer carretera P.O. Caja de 1939 Fond du Lac, WI 54935-1939 Fuera de EE.UU., para a través del Centro de Distribución o Distribución.

Mandos a distancia y de instrumentación para DTS Sistema

El acelerador digital y el sistema Shift (DTS) requiere el uso de componentes de mando especializado, incluyendo un kit de módulo de comando y control remoto electrónico. Se refieren a la precisión de Mercury Guía y Piezas / accesorios Quicksilver.


90-864196060 MAY 2006 Page 3 / 8

Serial Number Decal PlacementThere are 3 sets of engine, transom assembly, and sterndrive serial number decal strips providedwith each power package. One should be used for each of the following:• Engine Specification Decal• Warranty Registration Card• Operation, Maintenance and Warranty Manual identification pageAffix engine serial number decal to specification / serial number decal.

a8331

a - Specification/serial number decal

Bravo Three Notice: Trim-in Limit InsertNOTE: Bravo One, Two and Three Models are equipped with a trim-in limit insert.It has been brought to our attention that some boats (predominantly deep-Vee heavy boats) willroll up on their side under certain, specific, operating conditions. The roll can be either to port orstarboard and may be experienced while moving straight ahead, or while making a turn. The rolloccurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near fulltrim-in. While the boat will not roll completely over, the roll may be sufficient to unseat the operatoror passengers, and thereby create an unsafe situation.The roll is caused by stern-lift created from excessive sterndrive unit trim-in. Under these extremestern-lift / bow-down conditions, instability can be created, which may cause the boat to roll. Weightdistribution to the stern can reduce stern-lift and, in some circumstances, help to control thecondition. Weight distribution in the bow, port or starboard, may worsen the condition.The trim-in limit insert reduces stern-lift by preventing the sterndrive unit from reaching the lastfew degrees of full trim under. While this device should reduce the rolling tendency, it may noteliminate the tendency entirely. The need for this trim-in limit insert, and its effectiveness, can onlybe determined through boat testing and is ultimately the responsibility of the boat manufacturer.

! WARNINGIt is recommended that only qualified personnel adjust the trim-in limit inserts. The boat must bewater tested after adjusting the trim-in limit inserts to ensure that the modified trim-in range doesnot cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit istrimmed in at higher speeds. Increased trim-in range may cause handling problems on someboats, which could result in personal injury.

Multiple Sterndrive Steering Tie Bar ArrangementsWith multiple sterndrives you must select one of several possible steering systems.

! CAUTIONFailure to observe the recommended Tie Bar Arrangements could result in serious damage tothe steering and/or trim system components. This damage could adversely affect control of theboat. Observe the recommended Tie Bar Arrangements as presented in this section.


Page 4 / 8 90-864196060 MAY 2006

Internal Power Steering With Internal Tie Bar OnlyAt the lower end of the performance spectrum, boats not capable of speeds in excess of 97 km/h. (60 MPH), the basic internal tie bar is recommended. It connects the slave sterndrive to thesterndrive that is directly connected to the factory power steering output. This internal tie bar isavailable in a variety of lengths from the sterndrive manufacturer.

Internal Power Steering With Internal and External Tie BarAs a boat moves into the moderate performance range of 97-113 km/h. (60-70 MPH) or for areduction in steering backlash, an external tie bar should be added. External tie bars are usuallydesigned to attach at the aft power trim cylinder bosses. This location is an excellent choicebecause of its proximity to the propeller. HOWEVER, because of the potential overstress that canoccur if one sterndrive is trimmed much differently than the other, a dual trim control kit (PartNumber 90362A3) should be installed to limit this potential tilt differential to about 20 degrees.IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with nointernal tie bar when using the internal power steering system. This can cause excessive loadson the steering components on the sterndrive connected to the internal power steering system.These increased loads can damage the steering components, resulting in increased play in thesteering of the boat.

External Power SteeringWhen boat speeds move past 113 km/h (70 MPH) or if additional steering backlash reduction isdesired, external power steering is recommended. This normally will include an external tie barmounted at the same general location as the power steering cylinders, which are generallyattached at the top of the sterndrive's drive shaft housing. With this steering system, no internaltie bar should be used. These steering cylinders can be attached either inboard (between) oroutboard of the sterndrives.

External Power Steering With Low External Tie BarFor the fastest boats, over 129 km/h (80 MPH) , or for the ultimate in steering backlash reduction,use external power steering, BUT (where mechanically possible) with the external tie bar mountedat the trim cylinder boss location (as previously described in "Internal Power Steering with Internaland External Tie Bar" statements). Again, this system does not use an internal tie bar.

Corrosion ProtectionMercury MerCruiser power packages are equipped with anodes to help protect them from galvaniccorrosion under moderate conditions. However, for severe conditions or if using a stainless steelpropeller, it is recommended that a Quicksilver Anti-Corrosion Anode Kit and/or a MerCathodeSystem with 2 additional transom mounted anode assemblies be installed (some models have aMerCathode System as standard equipment). A MerCathode Monitor also is available to allow theoperator to check the operation of the MerCathode System with the push of a button. (Refer toMercury Precision Parts Accessories Guide for part numbers.)Boats that are connected to AC shore power require additional protection to prevent destructivelow voltage galvanic currents from passing through the shore power ground wire. A QuicksilverGalvanic Isolator can be installed to block the passage of these currents while still providing a pathto ground for dangerous fault (shock) currents. (Refer to Mercury Precision Parts AccessoriesGuide for part number.)IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System andanodes may be unable to handle the increased galvanic corrosion potential.

Anti-fouling PaintIMPORTANT: Corrosion damage that results from the improper application of anti-fouling paintwill not be covered by the limited warranty.Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and boattransom but you must observe the following precautions:


90-864196060 MAY 2006 Page 5 / 8

IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System referenceelectrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.IMPORTANT: If anti-fouling protection is required for boat hull or boat transom, copper base paint,if not prohibited by law, can be used. If using copper based anti-fouling paint, observe the following:• 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.) UNPAINTEDarea on transom of the boat around these items.

8107

b

a

a - Painted boat transom b - Minimum 40 mm (1-1/2 in.) unpaintedarea around transom assembly

NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint oran anti-fouling paint that DOES NOT contain copper or any other material that could conductelectrical current. Do not paint drain holes, anodes, MerCathode system or items specified by boatmanufacturer.

! CAUTIONImproper boat-cleaning procedures can cause product damage. Washing the MerCathodeassembly, especially with a brush or high-pressure washer, will damage the MerCathodeassembly making it unable to inhibit galvanic corrosion. When cleaning the boat, do not use abrush or a high-pressure washer to wash the MerCathode assembly found on the bottom of thetransom assembly.


Page 6 / 8 90-864196060 MAY 2006

Do not wash the sterndrive unit with a power washer as this can damage the coating on thereference wire of the MerCathode assembly, if equipped, and increase corrosion.

6211

c

b

a

a - MerCathode reference electrodeb - Do not paint

c - Do not pressure wash

Emission Control Information LabelA tamper-resistant Emission Control Information label is affixed in a visible location to the engineat time of manufacture by Mercury MerCruiser. In addition to the required emissions statement,the label lists the engine serial number, family, FEL (emission level), date of manufacture (month,year), and the engine displacement. Please note that the low emissions certification will not affectthe fit, function, or performance of the engines. Boatbuilders and dealers may not remove the labelor the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiserabout the availability of replacement decals before proceeding.

EMISSION CONTROLINFORMATION

THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSIONREGULATIONS FOR SPARK IGNITION MARINE ENGINESREFER TO OWNER'S MANUAL FOR MAINTENANCESPECIFICATIONS AND ADJUSTMENTSSERIAL# OMXXXXXXXXFAMILY XXXXX_XXXXXXFEL. XX.X g/kW-hr

D.O.M. JAN. 2003DISP X.XL

11018

Emission Control Label - Non CE Marked

"SERIAL#" - Engine Serial Number"FAMILY" - Engine Family"FEL." - Family Emission Limit"D.O.M." - Date of Manufacture


90-864196060 MAY 2006 Page 7 / 8

"DISP" - Piston Displacement

OMXXXXXXDec 2004

X.XL

SERIAL#D.O.M.

DISP.FAMILY

FEL.

XXXXX XXXXXX

XX.X g/kW-hr

EMISSION CONTROL INFORMATION

THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSIONREGULATIONS FOR SPARK IGNITION MARINE ENGINES

REFER TO OWNER'S MANUAL FOR MAINTENANCESPECIFICATIONS AND ADJUSTMENTS

057510652

Emission Control Label - CE Marked

"SERIAL#" - Engine Serial Number"FAMILY" - Engine Family"FEL." - Family Emission Limit"D.O.M." - Date of Manufacture"DISP" - Piston DisplacementCE - When this 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 forfurther information.

Owner ResponsibilityThe owner/operator is required to have routine engine maintenance performed to maintainemission levels within prescribed certification standards.The owner/operator is not to modify the engine in any manner that would alter the horsepower orallow emissions levels to exceed their predetermined factory specifications.

Star LabelBeginning January 1, 2003, one Three-Star label will be included with each factory-certifiedMercury MerCruiser engine.All Mercury MerCruiser engines (500 hp and below) will have a Three-Star Ultra Low Emissionrating. The Three-Star label identifies that these engines meet the California Air Resources Board'sSterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting thesestandards have 65% lower emissions than One-Star - Low Emissions engines.The Three-Star label will be affixed on the left side of the hull as shown.

XX 1234 XX

mc79531a b

a - Recommended location b - Secondary location


Page 8 / 8 90-864196060 MAY 2006

One Star - Low emission

mc79569-1

The one-star label identifies personal watercraft, outboard,sterndrive and inboard engines that meet the AirResources Board's Personal Watercraft and Outboardmarine engine 2001 exhaust emission standards. Enginesmeeting these standards have 75% lower emissions thanconventional carbureted two-stroke engines. Theseengines are equivalent to the U.S. EPA's 2006 standardsfor marine engines.

Two Stars - Very Low emission

FO IDA

mc79570-1

The two-star label identifies personal watercraft, outboard,sterndrive and inboard engines that meet the AirResources Board's Personal Watercraft and Outboardmarine engine 2004 exhaust emission standards. Enginesmeeting these standards have 20% lower emissions thanOne Star - Low-Emission engines.

Three Stars - Ultra Low emission

ASS

D

mc79571-1

The three-star label identifies engines that meet the AirResources Board's Personal Watercraft and Outboardmarine engine 2008 exhaust emission standards or theSterndrive and Inboard marine engine 2003 exhaustemission standards. Engines meeting these standardshave 65% lower emissions than One Star - Low Emissionengines.

Four Stars - Super Ultra Low emission

RNF T

mc79572-1

The Four Star label identifies engines that meet the AirResources Board's Sterndrive and Inboard marine engine2009 exhaust emission standards. Personal Watercraftand Outboard marine engines may also comply with thesestandards. Engines meeting these standards have 90%lower emissions than One Star - Low Emission engines.

Hang TagThe Dealer must mark the appropriate box on one hang tag to match the Star label affixed to theboat. The dealer is responsible for displaying the hang tag in a visible location on the boat ondisplay in California. Failure to properly display the hang tag could result in a citation and possiblefine to the dealer from the California Air Resources Board.If in California, the dealer must place the hang tag in a visible location in the boat prior to displayingthe boat.

SECTION - 2 BOAT CONSTRUCTION

90-864196060 MAY 2006 Page 1 / 2

SECTION 2 - BOAT CONSTRUCTIONTable of ContentsBoat Construction.................................................................................................................................................... 2

Transom Thickness and Surface Plane............................................................................................................2Transom Cutout.................................................................................................................................................2Checking Transom Thickness...........................................................................................................................2Engine Bed........................................................................................................................................................2

2

BOAT CONSTRUCTION SECTION - 2

Page 2 / 2 90-864196060 MAY 2006

Boat ConstructionTransom Thickness and Surface Plane

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where thesterndrive unit mounts.

Transom Specifications

Thickness Between 51 - 57 mm (2 - 2-1/4 in.) for 203 mm (8 in.) to either side of the vertical center line

Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.)

FlatnessTransom surfaces in area where transom assembly will be mounted (includes vertical as wellas horizontal dimensions) :Inner Surface - Flat within 3 mm (1/8 in.) Outer Surface - Flat within2 mm (1/16 in.)

Angle 10 -16 degrees

ddb

e

c

a

7508

a - Transom thicknessb - Inner surfacec - Outer surface

d - Transom plate coverage -203 mm (8 in.) from center

e - Transom angle

Transom CutoutRefer to Section 6 - Drive System And Engine Mounting.

Checking Transom ThicknessRefer to Section 6 - Drive System And Engine Mounting.

Engine BedIMPORTANT: The finished boat stringer must position the front engine mount so that a minimumof 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer(structure) to obtain the 6 mm (1/4 in.) dimension.

Description Specification

Difference between starboard andport engine mount 57.2 cm (22-1/2 in.)

Mount adjustment up and down(minimum) 6 mm (1/4 in.)

NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure thatthe front and rear mount locations in the vessel are parallel and in the same plane. This may bechecked by tying a string from the left front mount location to the right rear mount location andanother from right front to left rear. The strings should touch where they cross.

SECTION - 3 EXHAUST SYSTEM

90-864196060 MAY 2006 Page 1 / 11

SECTION 3 - EXHAUST SYSTEMTable of ContentsExhaust Systems..................................................................................................................................................... 2

Preferred Exhaust System................................................................................................................................2Exhaust System Caution...................................................................................................................................2Measuring Exhaust Elbow Height.....................................................................................................................2Methods for Measuring Exhaust Elbow Height.................................................................................................5Clear Hose Method for Measuring Exhaust Elbow Height................................................................................5

Collector And Water Lift Muffler Equipped ................................................................................................. 6Through The Transom And Through The hull Exhaust System Design............................................................7Exhaust Resonator Guidelines..........................................................................................................................9

3

EXHAUST SYSTEM SECTION - 3

Page 2 / 11 90-864196060 MAY 2006

Exhaust SystemsPreferred Exhaust System

Most Mercury MerCruiser sterndrive engines were developed and tested for Y-pipe or through thepropeller exhaust systems. Using the Y-pipe system limits the potential for water intrusion due tothe exhaust system design.

Exhaust System Caution

! CAUTIONIt is the responsibility of the boat manufacturer or installing dealer to properly locate the engineand install the exhaust system. Improper installation may allow water to enter the exhaustmanifolds and combustion chambers and severely damage the engine. Damage caused bywater in the engine will not be covered by Mercury MerCruiser Warranty, unless this damage isthe result of defective parts.

Measuring Exhaust Elbow HeightThe height of the exhaust elbows and the slope of the exhaust hoses must be within the dimensionsspecified to prevent water intrusion problems. Exhaust elbow risers must be installed, if needed,to obtain the proper height and/or slope. Measurement must be taken with the boat in the water.It is important that the boat be loaded as outlined following to simulate the maximum loadingconditions likely to be encountered in normal operation.IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer.Any load distribution conditions that will affect the exhaust system height and slope compliancemust be clearly communicated to the operator in the owner's manual. For example, the numberof people that can be located on the swim platform simultaneously should be included in themanual, if this could pose a problem.1. Fill fuel, water, waste water and heater tanks to maximum capacity. People or weights can be

used to simulate these loads if desired. Refer to conversions:• 1 U.S. gallon of water = 8.3 lb• 1 liter of water = 1 kg • 1 U.S. gallon of gasoline = 6 lb• 1 liter of gasoline = 0.72 kg

2. Add maximum allowable cargo weight to boat in areas where it will be stowed, includingrefrigerator and lockers. Do not forget the PWC, if applicable.

3. Add average passenger weight in all locations where each passenger will sit during normaloperation.

4. Allow for a minimum of 2 people on the swim platform for docked conditions. Seat peoplestarting at the rear of the boat.

NOTE: ABYC specifies an average passenger weight of 64 kg (141 lb) for boat loadingcalculations. This should be used as a minimum. An average passenger weight of 86 kg (190 lb)is desirable.5. Measure exhaust elbow height as outlined under Methods For Measuring Exhaust Elbow

Height.6. Measure exhaust system slope as specified following.7. Leave fluid and cargo weights where they are, but remove passenger weights from boat.

Beginning at the bow, reload passenger weight (the equivalent of one person at a time) whileretaking readings. Use all of the available seating areas in the bow first. Continue addingpassenger weight (and taking readings), moving from the bow to the stern until the maximumpeople weight has been added back on board.

8. Repeat Step 7, but this time start at stern of boat and work toward bow.9. Measurements under all loading conditions should be within these specifications:


90-864196060 MAY 2006 Page 3 / 11

NOTE: Exhaust elbow height is measured to the waterline in the water lift muffler (instead of thewater line) on applications so equipped. Refer to the appropriate Mercury MerCruiser ProductApplications Manual for more information.

Minimum Exhaust Elbow Height

Model Specification

V6 and V8 Alpha/Bravo 330 mm (13 in.)

NOTE: Through transom exhaust applications must have an exhaust hose length of305 mm (12 in.).

a

b

9173

c

Using a universal protractor (inclinometer) to measure slopea - Protractorb - Exhaust hose or tube

c - Minimum 305 mm (12 in.).

Minimum Exhaust Hose Slope

ModelSpecification

Within 457 mm. (18 in.) ofengine Remainder of system (if applicable)

All models 10 degrees 3 degrees

10. Install risers if height is insufficient. Modify exhaust system and/or install risers, if slope isinsufficient. Refer to the Mercury Precision Parts / Quicksilver Accessory Guide for partnumbers.

Model Riser Options

V6 Sterndrive 43 mm (1.7 in.) 76 mm (3 in.) 152 mm (6 in.)

Model Riser Options

V8 Sterndrive 43 mm (1.7 in.) 76 mm (3 in.) 119 mm (4.7 in.) 152 mm (6 in.)

NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.


Page 4 / 11 90-864196060 MAY 2006

11. If measurements are less than specified, exhaust elbow risers must be installed to achieveproper dimension.

12

1

43

7

109

5

11

8

2

6

6

7932

Typical riser installation1 - Exhaust manifold bolt (4)2 - Exhaust manifold3 - Full flow gasket, with turbulator4 - Full flow gasket5 - Riser6 - Pipe plug

7 - Restrictor gasket, with turbulator8 - Block off gasket, with turbulator

(closed cooled models)9 - Exhaust elbow10 - Hose fitting11 - Washers (4)12 - Exhaust elbow bolt (4)

NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.12. Applications With Through The Propeller Exhaust: Recheck exhaust elbow height.13. Applications With Through The Hull Or Through The Transom Exhaust:

a. Move load weight to bow to simulate greatest bow-down attitude the boat will encounterin normal operation.

b. Recheck exhaust system slope.14. Move load weight and cargo weight to stern of boat to stimulate greatest stern-down attitude

the boat will encounter such as when loading.IMPORTANT: Be sure to consider swim platform loading and personal watercraft.15. Recheck exhaust system measurements.


90-864196060 MAY 2006 Page 5 / 11

Minimum Exhaust Elbow Height From Top of Elbow to Waterline

Model Measurement

V6 and V8 Sterndrive 330 mm (13 in.)

a

c

b

9141

a - Highest point on exhaust elbowb - Measurement

c - Waterline

NOTE: Additional requirements for through the hull or transom exhaust system applications:

Continuous Downward Slope From Horizontal

ModelEngine

InstallationAngle

Minimum Maximum

Sterndrive 0 degrees 9 degrees 48 mm (1-7/8 in.)per 305 mm (12 in.) 19 degrees 105 mm (4-1/8 in.) per

305 mm (12 in.)

Methods for Measuring Exhaust Elbow HeightIMPORTANT: Refer to Measuring Exhaust Elbow Height for instructions on proper loading of theboat and complete measurement instructions.

Clear Hose Method for Measuring Exhaust Elbow Height1. Obtain a 8-10 mm (5/16 - 3/8 in.) diameter hose approximately 4.5 m (15 ft) long. Put a metal

fitting or a weight on one end of the hose to keep that end of the hose below the waterline.2. Put the weighted end of the hose over the port or starboard side of the boat, keeping it in line

with the engine's exhaust elbow.3. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that

this open end section of the hose is as vertical as possible from the boat's bilge to the top ofthe exhaust elbow.

4. Coil excess hose in bilge of boat, keeping it below the water line.5. Lower open end of hose and siphon water until it starts to come out of the hose. Put a finger

over the hose and lift open end until it is at the top of the exhaust elbow.6. Slowly take finger off end of hose to let the water level stabilize. The water will seek the level

of the water outside the boat. Keep hose close to exhaust elbow and as vertical as possible.7. Make sure that the boat is level (side-to-side) using a level or inclinometer.


Page 6 / 11 90-864196060 MAY 2006

8. The measurement between water in hose and top of exhaust elbow is the exhaust elbowheight.

b

c

a

8340

e

d

9142

a - Waterlineb - Top of exhaust elbowc - Clear plastic hose

d - Weighte - Measurement - waterline to top of

exhaust elbow

COLLECTOR AND WATER LIFT MUFFLER EQUIPPEDIMPORTANT: Engine must have been operated previously to fill muffler with water.1. Attach a clear hose to the muffler drain plug or drain valve.2. If the clear hose is attached to a drain valve, open the drain valve.3. Start the engine to fill the muffler and clear hose.4. Route the remainder of the clear hose toward the engine's exhaust manifold and elbow.

Ensure that this open end section of the clear hose is as vertical as possible from the boat'sbilge to the top of the exhaust elbow.

5. Coil excess clear hose in bilge of boat, keeping it below the waterline.6. Lower open end of clear hose and siphon water until it starts to come out of the clear hose.

Put a finger over the clear hose and lift the open end until it is level with the top of the exhaustelbow.

7. Slowly take finger off the end of the clear hose to let the water level stabilize. The water willseek the level of the water inside the water lift muffler. Keep the clear hose close to exhaustelbow and as vertical as possible.

8. Make sure that the boat is level (side-to-side) using a level or inclinometer.


90-864196060 MAY 2006 Page 7 / 11

9. The measurement between the water in the clear hose and the top of the exhaust elbow isthe exhaust elbow height above the water line.

b c

d

ah

e

gi

7555

f

Typicala - Water lineb - 457 mm. (18 in.) minimum between

exhaust elbow and collectorc - 10 degree downward slope minimumd - 3 degree downward slope minimume - Collector

f - Minimum exhaust elbow height withmaximum load

g - Drain plug or drain valveh - External flappersi - Clear hose

ac

b

7556

Typical S-pipe Used With Water Lift Mufflera - Water lineb - Minimum exhaust elbow height with

maximum load

c - Drain plug or drain valve

Through The Transom And Through The hull Exhaust System DesignThese engines are equipped with a wet exhaust system in which exhaust is mixed with water inthe exhaust elbows. This cools the exhaust and allows the use of heat resistant rubber hose onthe outlet side of the system. These specifications must be observed by the OEM and mufflermanufacturer when designing and installing the exhaust system:• Through the prop exhaust utilizing the y-pipe is the desired system on all models covered in

this manual.• Heat resistant exhaust hose that complies with specifications SAE J2006 or UL 1129 should

be used (ABYC standard).• Exhaust hoses should be no smaller than the minimum sizes. Larger hoses should be used

on applications with long hose runs.


Page 8 / 11 90-864196060 MAY 2006

Minimum Exhaust Hose Size

Model Dual Outlet SystemSingle Outlet System

Dual Hose Portion Single HosePortion

All Models 102 mm (4 in.) 102 mm (4 in.) 102 mm (4 in.)

• Sharp bends in exhaust hoses should be avoided.• Exhaust hoses can be installed at up to a 5° angle relative to the exhaust elbow outlets. Refer

to Exhaust Hose Connections.• Exhaust elbows must be the prescribed distance above the water line. Install risers if needed.

See Measuring Exhaust Elbow Height.• The exhaust hose attached to exhaust elbow must have a minimum of 10° downward slope.

On longer hose applications, slope can be reduced to 3° in the portion of exhaust system thatis more than 457 mm (18 in.) away from elbow.

NOTE: Mercury MerCruiser's recommendations is more stringent than ABYC recommendation ofa minimum drop in the exhaust system of 1/2 in. per foot with an overall drop of not less than 102mm (4 in.) between the exhaust elbow outlets and the boat outlets.

Slope Conversion

Degrees Drop vs. Run Distance from Elbow

3 5/8 in. / ft 52 mm / m < 18 in.

6 1-1/4 in. / ft 105 mm / m < 18 in.

7 1-7/16 in. / ft 122 mm / m < 18 in.

10 2-1/8 in. / ft 176 mm / m < 18 in.

12 2-1/2 in. / ft 212.5 mm / m < 18 in.

14 2-15/16 in. / ft 249 mm / m < 18 in.

19 4-1/8 in. / ft 344 mm / m < 18 in.

• The drop in the exhaust hose must be continuously sloping downward so that a low spot doesnot exist at any point.

• Through the hull exhaust fittings (flanges, outlets) must be equipped with internal shutters andexternal flappers to prevent the reverse flow of water into the engine. Refer to Exhaust ThroughThe Hull Fittings.

• Exhaust outlets must be above the water line with boat at rest in the water and a full loadaboard, as well as while underway. This is necessary to minimize engine back pressure.

• Every exhaust hose connection should be secured with at least 2 hose clamps. The clampsshould be stainless steel and at least 13 mm (1/2 in.) wide. Clamps which rely solely on springtension should not be used. (ABYC Standard).

• The exhaust system must be adequately supported for proper orientation and to preventoverstressing the exhaust manifolds and elbows. The support requirements will vary withexhaust system design and the amount of G-forces to be encountered.

• The through transom exhaust system must meet the exhaust back pressure specification.• Straight through transom exhaust or silent choice exhaust must have an exhaust hose of at

least 305 mm (12 in.), have an adequately muffled tip, and meet all aforementionedspecifications.

• The system must have the capability to be serviced, reassembled, and replaced whilemaintaining all of the specifications. The boat builder must provide documentation, such asmanuals, drawings, or orientation marks on production assemblies.

• If a waterlift/collector system is used, the waterline is defined as the waterline inside thecollector. All measurements must be taken from that waterline to measure exhaust elbowheigh.


90-864196060 MAY 2006 Page 9 / 11

• in-line mufflers, collectors, and hoses must self drain after engine shut-down. See muffler/collector section.

Exhaust Resonator Guidelines

! CAUTIONAvoid severe engine damage. Water ingestion may occur in some instances without the use ofspecially designed exhaust resonators. Install exhaust resonators in the exhaust system whenspecified.

IMPORTANT: MerCruiser strongly recommends exhaust resonators on all models with throughthe transom exhaust.On sterndrive engines using through the transom or through the hull exhaust systems, specialcare must be exercised in system design and construction to prevent an adverse tuning effect onengine exhaust output.


Page 10 / 11 90-864196060 MAY 2006

• The exhaust resonator is positioned with the inside flat surface at the preferred distance of432 mm (17 in.) from the front edge of the exhaust hose but no closer than 51 mm (2 in.) tothe exhaust outlet on sterndrives. The 432 mm (17 in.) dimension can be reduced, ifnecessary, to a MINIMUM of 330 mm (13 in.). This dimension must be the same on bothexhaust outlets.

ee

ea aa abb

d d

cc

f f

gg

8232

ca a

e f

b

d

e

b c

g 8231

a - Exhaust resonatorb - Exhaust hosec - Dimension to inside flat surface of

resonator approximately432 mm (17 in.)

d - No less than 51 mm (2 in.) betweencollector and resonator

e - Clamp - positioned around center ofresonator

f - Exhaust mufflerg - Collector

Exhaust system tuning can be affected by various factors that are beyond the control of MercuryMerCruiser. Following are several factors that can affect exhaust system tuning:• Type and configuration of exhaust outlet.• Length of exhaust hose.• Amount of back-pressure in exhaust system. Refer to the appropriate Mercury MerCruiser

Product Applications Manual.


90-864196060 MAY 2006 Page 11 / 11

Exhaust Resonator Kit use on Sterndrive Models:

CAN Be Used With: CANNOT Be Used With:

Transom mounted muffler tips Silent Choice Exhaust System

Waterlift mufflers or other mufflers that are mountedoutboard of exhaust elbows Below swim platform exhaust

Open exhaust Mufflers that mount between exhaust elbow andexhaust tip


NOTES:

Page 12 / 11 90-864196060 MAY 2006

SECTION - 4 FUEL SYSTEM

90-864196060 MAY 2006 Page 1 / 3

SECTION 4 - FUEL SYSTEMTable of ContentsFuel Delivery System .............................................................................................................................................. 2

4

FUEL SYSTEM SECTION - 4

Page 2 / 3 90-864196060 MAY 2006

Fuel Delivery SystemThe fuel delivery system must be designed to deliver the fuel to the engine with minimal restrictionand at the lowest temperature. Gasoline is extremely sensitive to vaporizing if placed under avacuum (low pressure) and exposed to moderate or high temperatures. This is particularly true ifwinter blend fuels with a high RVP (Reid Vapor Pressure) are encountered in warmer temperatureareas. Excessive restriction in the fuel delivery system may cause a condition known as vaporlocking. This typically occurs after the engine has been operated at high RPM and then shut offand allowed to sit for 15 minutes to 2 hours. During this time the engine heat soaks, causing thetemperature of the fuel system to increase. Upon restart, the combination of heat and vacuum inthe fuel system causes the fuel to vaporize. The fuel system cannot handle this vapor andtherefore, fuel starvation results when the boater attempts to resume operation. Depending uponthe degree of vapor locking, this can range from a hesitation or bog when accelerating to acomplete stalling of the engine. To minimize the potential for this problem, the guidelines shouldbe observed to limit fuel delivery restriction to 6.9 kPa (2 in. Hg) or less and fuel inlet temperatureto 44 C (110 F) or less.The fuel delivery system is an integral part of the boat. Mercury MerCruiser makes no attempt inthis manual to cover all aspects of design and integration of the fuel delivery system, due to abroad range of possible configurations and the numerous regulations and standards that coverthis area. The applicable standards and regulations for the markets where your product will besold should be observed, along with any information from the fuel system componentmanufacturers. The following general guidelines are provided:

! WARNINGAvoid serious injury or death and property damage due to improper boat design andconstruction. Always adhere to all applicable Marine Regulations (United States Coast Guard[USCG], European Union - Recreational Craft Directive [EU-RCD], and so on) and the standardsthey reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers[SAE], International Standards Organization [ISO], and so on) when designing and constructingthe boat and the boat components, such as the engine compartment, fuel delivery system andexhaust system.

The main concern of a boat's fuel system is safety; this must be achieved through a technicallysound installation and constant inspection.The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.The fuel tank is an integrated component of the boat. Refer to the special information on serviceand maintenance, which you have received from the tank manufacturer.Only a few points related to function and safety are listed here [Refer to boating standards (NMMA,ABYC, etc.) and Coast Guard regulations for complete guidelines]:• All connections should be on the upper side of the tank.• The drain plug at the lowest point on the tank serves to permit the removal of water and

sediment.• The tank breather pipe must have an inner diameter of at least 13 mm (1/2 in.) and must be

fitted with a swan neck to prevent water from entering the tank.It is recommended that the exact route and length of the fuel lines be established at the firstinstallation of the engine to prevent problems later in connecting them to the engine.All fuel lines must be well secured. The holes where the lines run through the bulkheads shouldbe carefully rounded off or protected with rubber grommets. This prevents damage to the linesfrom abrasion.The following, but not limited to the following, additional fuel connection related points, applyingto all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA,ABYC, etc.) and Coast Guard regulations for complete guidelines]:1. Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up

impurities.

SECTION - 4 FUEL SYSTEM

90-864196060 MAY 2006 Page 3 / 3

2. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg)through out engine operating range.

IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today'sfuels. It can also cause poor engine performance because of fuel starvation.3. Fuel lines used must be Coast Guard approved (USCG Type A1).


Minimum Fuel Line Diameter 10 mm (3/8 in.) minimum

4. On Multi-Engine Gasoline Installations: It is best to use a fuel pickup and supply line foreach engine. If a single pickup and line is used, line must be 13 mm (1/2 in.) ID or larger.

5. On installations that require long lines or numerous fittings: The fuel lines and fittings IDmust be greater than 10 mm (3/8 in.).

6. Fuel lines should be installed free of stress and firmly secured to prevent vibration and/orchafing.

7. Sharp bends in fuel lines must be avoided.8. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to

absorb deflection when engine is running.

FUEL SYSTEM SECTION - 4

NOTES:

Page 4 / 3 90-864196060 MAY 2006

SECTION - 5 COOLING SYSTEM

90-864196060 MAY 2006 Page 1 / 17

SECTION 5 - COOLING SYSTEMTable of ContentsSeawater Connections - General Information......................................................................................................... 2

Specifications....................................................................................................................................................2Seawater Pickup...............................................................................................................................................2Seawater Pickup Requirements........................................................................................................................2

Seawater Pickup - General Information ..................................................................................................... 3Seacock - General Information .................................................................................................................. 4Sea Strainer - General Information ............................................................................................................ 4

Y-Fitting................................................................................................................................................................... 5Hot Water Heater Hose Connections - MPI Models ............................................................................................... 6

Supply Hose Connection .................................................................................................................................. 6Return Hose Connection .................................................................................................................................. 7

Water Flow Diagrams.............................................................................................................................................. 8V-6 and V-8.......................................................................................................................................................8

V-8 Closed Cooled Bravo Models with Risers ........................................................................................... 8V6 Closed Cooled Alpha Models with Risers ............................................................................................ 9V8 Closed Cooled Bravo Models ............................................................................................................. 10V6 Closed Cooled Sterndrive Models ...................................................................................................... 11V6 Seawater Cooled Bravo MPD Models ................................................................................................ 12V8 Seawater Cooled Bravo MPD Models ................................................................................................ 13V8 Seawater Cooled Bravo Models Except MPD Models ....................................................................... 14V6 Seawater Cooled Bravo Models Except MPD Models ....................................................................... 15V6 And V8 Seawater Cooled Alpha MPD Models ................................................................................... 16V6 And V8 Seawater Cooled Alpha Models Except MPD Models ........................................................... 17

5

COOLING SYSTEM SECTION - 5

Page 2 / 17 90-864196060 MAY 2006

Seawater Connections - General InformationSpecifications


Minimum flow (closed cooled models only) 114 liters per minute (30 gallons per minute) at 4000 rpm

Minimum pressure (closed cooled modelsonly) 138 kPa (20 psi) at 4000 rpm

Water pickup 32 mm (1-1/4 in.) ID wire reinforced

Water inlet hose

32 mm (1-1/4 in.) connectionsSeacock

Seawater strainer

Seawater PickupThis section covers through the hull and through the transom water inlets only. For information onsterndrive water inlet connections, refer to the appropriate section after engine installation.

Seawater Pickup RequirementsIMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suctionis created by seawater pump impeller.

g

d

a

b

c

b

f

be

7924

Typical installation shown with a through the hull water pick upa - Quicksilver seawater pickup and

seacockb - Hose clampc - Seawater hose to seawater strainerd - Quicksilver seawater strainer

e - Seawater hose to enginef - Seawater pump hose connector (if

equipped)g - Below seawater pump level

IMPORTANT: Do not install the water pickup directly in line with the propeller, as the pickup maycreate turbulence and allow air to flow into the propeller slipstream. This will cause propellerventilation and will adversely affect boat performance.IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not comein contact with steering system components, engine coupler, or drive shaft.• The seawater pickup must be large enough to permit sufficient water flow to engine seawater

pickup pump for adequate engine cooling.


90-864196060 MAY 2006 Page 3 / 17

• The seawater pickup also must supply a positive head while underway.• The seawater pickup should be located as close to the seawater pump inlet as possible and

in an area where an uninterrupted, solid stream of water will flow past when the boat isunderway.

• Refer to appropriate Mercury MerCruiser Product Applications Manual.SEAWATER PICKUP - GENERAL INFORMATION

A transom seawater pick up or a through the hull seawater pickup can be used.IMPORTANT: Seawater pickup must have an integral seacock.IMPORTANT: Follow seawater pickup manufacturer's installation instructions.

7542

Typical through hull seawater pickup with seacock

8619

Typical transom seawater pickup installed on boat transom

• Pickup location should be selected to minimize water inlet hose length, while providing anoptimum location for water pickup.

• Location should be in an area that will provide a solid, air-free flow of water under all operatingconditions.

• Avoid areas with a disturbed water flow, such as those behind, or in close proximity to, thepropeller.

• Locations that are too far forward or outboard should also be avoided as these are prone toaeration problems at high boat trim angles and in turns.

• Check for aeration as outlined under Water Supply Test.• Provisions should be made to minimize galvanic corrosion, given the hull material being used

and the composition of the surrounding components. Some industry standards and regulationsalso require that the pickup be connected into the boat's bonding system to minimize straycurrent corrosion. Refer to applicable standards and regulations for more details.


Page 4 / 17 90-864196060 MAY 2006

• Refer to appropriate Mercury MerCruiser Product Applications Manual.SEACOCK - GENERAL INFORMATION

The ABYC and other industry standards / regulations require the use of a seacock on certain typesof applications to stop the entry of water in the event of a leak in the cooling system.IMPORTANT: Follow seacock manufacturer's installation instructions.

7532

Typical seacock shown with a through the hull water pick up

• Refer to applicable standards / regulations for specific requirements. The seacock also allowsthe water to be shut off when servicing the engine.

• Seacock must provide minimum restriction to water flow (refer to Specifications).• A ball or gate valve is recommended.• The ball valve is most common and is typically equipped with a lever type handle that operates

in a 90 degree arc. This design gives a clear indication of whether the valve is open or shut.• Industry standards / requirements typically require that the seacock be rigidly attached to the

hull at the water pickup.• Seacock location should be readily accessible for quick, easy operation.• Refer to appropriate Mercury MerCruiser Product Applications Manual.

SEA STRAINER - GENERAL INFORMATIONA sea strainer is recommended if the boat is to be operated in an area with a high debris content.


90-864196060 MAY 2006 Page 5 / 17

IMPORTANT: Follow sea strainer manufacturer's installation instructions.

7533

Typical sea strainer

• Sea strainer must be sized to minimize restriction (Refer to Specifications) and to provide areasonable service interval.

• Locate strainer in an area that will be easily accessible for servicing.• If boat is not equipped with a seacock, strainer should be located above the waterline to

prevent water entry into boat when servicing.• Strainer must have provision to allow draining in freezing temperature periods.• Refer to appropriate Mercury MerCruiser Product Applications Manual.

Y-FittingNOTE: All closed cooled models require a through the hull or through the transom pickup inaddition to the sterndrive water inlets in order to meet the minimum flow specifications.When additional water inlets are used, a Y-fitting is installed to the engine seawater pump.

a

bc

d 8485

a - Engine seawater pumpb - Hose from seawater pump inlet port

to Y-fitting

c - Y- fitting port to Bravo drived - Y-fitting port to additional water inlet


Page 6 / 17 90-864196060 MAY 2006

Hot Water Heater Hose Connections - MPI ModelsIMPORTANT: When connecting a cabin heater or hot water heater:• Supply hose (from engine to heater) and return hose (from heater to engine) Must Not Exceed

16 mm (5/8 in.) inside diameter (ID).• Make heater connections only at locations shown.• Refer to manufacturers' instructions for complete installation information and procedures.• Do not reposition engine temperature switch.

! CAUTIONAvoid a performance loss and/or possible engine damage. Engine coolant must flowcontinuously from the engine intake manifold to the engine water circulating pump. Never closeoff or block the engine coolant flow to or from a hot water heater using coolant supplied by theengine intake manifold and returned to the engine water circulating pump.

! CAUTIONAvoid engine overheating which could result in engine damage. On models equipped withClosed Cooling, an air pocket may form in the closed cooling system if some coolant is lost fromthe system and the cabin heater or hot water is mounted higher than the fill cap on the heatexchanger. Heater must be mounted lower than the fill cap of the heat exchanger on models soequipped.

Supply Hose ConnectionNOTE: Some models may be equiped with additional fittings.

a 9255

Seawater cooled models with air or manual draina - Supply hose connection locations


90-864196060 MAY 2006 Page 7 / 17

a

9256

Closed cooled modelsa - Supply hose connection locations

a9257

Seawater cooled models with multi-point draina - Supply hose connection locations

Return Hose Connection

a

b

9258

a - Return hose connection for hot waterheater

b - Water circulating pump housing


Page 8 / 17 90-864196060 MAY 2006

Water Flow DiagramsV-6 and V-8V-8 CLOSED COOLED BRAVO MODELS WITH RISERS

a

b

cd

e

f

g

h

ij

k

l

m

cn

o

8182

a - Seawater inletb - Power steering coolerc - Gen III cool fuel moduled - Exhaust and seawater outlete - Exhaust manifoldf - Distribution housingg - Water circulating pumph - Thermostat housing

i - Exhaust elbowj - Seawater pumpk - Heat exchangerl - To power steering pumpm - From seawater pumpn - Seawatero - Ethylene glycol mixp - Check valve


90-864196060 MAY 2006 Page 9 / 17

V6 CLOSED COOLED ALPHA MODELS WITH RISERS

a

b

c

d

e

f

g

h

i

jk

l

m

n

9393

a - Seawater inletb - Power steering coolerc - Check valved - Fuel coolere - Exhaust and seawater outletf - Exhaust manifoldg - Distribution housing

h - Water circulating pumpi - Thermostat housingj - Exhaust elbowk - Seawater pumpl - Heat exchangerm - Seawatern - Ethylene glycol mix


Page 10 / 17 90-864196060 MAY 2006

V8 CLOSED COOLED BRAVO MODELS

a

b

c

d

e

f

g

h

i

j

k

l

m

n

o

c

9385

a - Y-fittingb - Power steering coolerc - Gen III cool fuel moduled - Exhaust and seawater outlete - Exhaust manifoldf - Distribution housingg - Water circulating pumph - Thermostat housing

i - Exhaust elbowj - Seawater pumpk - Heat exchangerl - To power steering coolerm - From seawater pumpn - Seawatero - Ethylene glycol mixp - Check valve


90-864196060 MAY 2006 Page 11 / 17

V6 CLOSED COOLED STERNDRIVE MODELS

a

b

c

d

e

f

g

h

ij

k

l

9386

m

na - Y-fittingb - Power steering coolerc - Check valved - Fuel coolere - Exhaust and seawater outletf - Exhaust manifoldg - Distribution housing

h - Water circulating pumpi - Thermostat housingj - Exhaust elbowk - Seawater pumpl - Heat exchangerm - Seawatern - Ethylene glycol mix


Page 12 / 17 90-864196060 MAY 2006

V6 SEAWATER COOLED BRAVO MPD MODELS

ab

c

d

e

fgh

i

j

k

9388

a - Seawater inletb - Power steering coolerc - Fuel coolerd - Exhaust and seawater outlete - Exhaust manifold

f - Check valveg - Water circulating pumph - Thermostat housingi - Exhaust elbowj - Seawater pump


90-864196060 MAY 2006 Page 13 / 17

V8 SEAWATER COOLED BRAVO MPD MODELS

a

b

c

d

e

fgh

i

j

k

m

l

d

9387

a - Seawater inletb - Power steering coolerc - Gen III Cool Fuel Moduled - Exhaust and seawater outlete - Exhaust manifoldf - Check valve

g - Water circulating pumph - Thermostat housingi - Exhaust elbowj - Seawater pumpk - To power steering coolerl - From seawater pump


Page 14 / 17 90-864196060 MAY 2006

V8 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS

a

b

c

d

e

f

g

h

i

j

k

l

m

c

9389

a - Seawater inletb - Power steering coolerc - Gen III cool fuel moduled - Exhaust and seawater outlete - Exhaust manifoldf - Distribution housingg - Water circulating pump

h - Thermostat housingi - Exhaust elbowj - Seawater pumpk - Drain from starboard exhaust manifoldl - To power steering coolerm - From seawater pumpn - Check valve


90-864196060 MAY 2006 Page 15 / 17

V6 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS

a

b

c

d

e

f

g

h

i

j

k

9390

a - Seawater inletb - Power steering coolerc - Check valved - Fuel coolere - Exhaust and seawater outletf - Exhaust manifold

g - Distribution housingh - Water circulating pumpi - Thermostat housingj - Exhaust elbowk - Seawater pump


Page 16 / 17 90-864196060 MAY 2006

V6 AND V8 SEAWATER COOLED ALPHA MPD MODELS

a

b

c

d

e

fh

i

j

9391

a - Seawater inlet (from transom)b - Power steering coolerc - Drain plugd - Fuel coolere - Exhaust and seawater outlet

f - Exhaust manifoldg - Check valveh - Water circulating pumpi - Thermostat housingj - Exhaust elbow


90-864196060 MAY 2006 Page 17 / 17

V6 AND V8 SEAWATER COOLED ALPHA MODELS EXCEPT MPD MODELS

a

b

c

d

e

f

g

h

i

j

9392

a - Seawater inlet (from transom)b - Power steering coolerc - Check valved - Fuel coolere - Exhaust and seawater outlet

f - Exhaust manifoldg - Distribution housingh - Water circulating pumpi - Thermostat housingj - Exhaust elbow


NOTES:

Page 18 / 17 90-864196060 MAY 2006

SECTION - 6 DRIVE SYSTEM AND ENGINE INSTALLATION

90-864196060 MAY 2006 Page 1 / 113

SECTION 6 - DRIVE SYSTEM AND ENGINEINSTALLATION

Table of ContentsTransom Cutout....................................................................................................................................................... 6

Finding The Crankshaft Vertical Center Line....................................................................................................6Single Engine ............................................................................................................................................. 6Dual Engine ............................................................................................................................................... 6

Finding Crankshaft Horizontal Center Line (X-dimension)................................................................................790 Degree Tool Method ............................................................................................................................. 7Tape Measure Method ............................................................................................................................... 8

Cutting Out The Transom..................................................................................................................................8Checking The Transom Thickness..................................................................................................................10

Preliminary Connections........................................................................................................................................ 11Drive Shaft Extension Models.........................................................................................................................11Engine Mounts................................................................................................................................................11Air Pump..........................................................................................................................................................11

Special Information................................................................................................................................................ 12Transom Thickness and Surface.....................................................................................................................12All Bravo Models.............................................................................................................................................12Rear Engine Mounts........................................................................................................................................13Drive Shaft Extension Models.........................................................................................................................14Bravo Models Exhaust Preparation.................................................................................................................14

Transom Assembly Installation.............................................................................................................................. 15Installing Inner Transom Plate ........................................................................................................................15Trim Position Sender Connections..................................................................................................................17Sensor Steering Assembly..............................................................................................................................17Connecting Speedometer Pickup....................................................................................................................18Exhaust Preparation........................................................................................................................................18Seawater Inlet Fitting Installation....................................................................................................................20Water Inlet Block-Off Plate Installation............................................................................................................20

Alternative Water Pickups ........................................................................................................................ 20Bravo Models ........................................................................................................................................... 21

Gear Lube Monitor Connection At Gimbal Housing........................................................................................23Alternative Mounting Of Gear Lube Monitor On Transom...............................................................................24Transom Exhaust Connections.......................................................................................................................24

Models With Alpha Sterndrive and Alternative Water Pickups.............................................................................. 25Alpha Models .................................................................................................................................................. 25

Models With Bravo Sterndrive and Alternative Water pickups.............................................................................. 27Alternative Water Pickups .............................................................................................................................. 27Bravo Models ................................................................................................................................................. 28

Power Trim Pump Installation................................................................................................................................ 30Power Trim Electrical Connection...................................................................................................................30Power Trim Pump............................................................................................................................................31Power Trim Pump Connections and Filling.....................................................................................................31

Filling ....................................................................................................................................................... 32Trim Limit Switch Connection..........................................................................................................................33

Steering System Installation.................................................................................................................................. 33Hydraulic (Helm) Steering...............................................................................................................................33Steering Helm and Cable................................................................................................................................33Steering Cable Specifications.........................................................................................................................34Installing Steering System...............................................................................................................................34Shift Cable Routing.........................................................................................................................................38Transom Harness............................................................................................................................................39

6

DRIVE SYSTEM AND ENGINE INSTALLATION SECTION - 6

Page 2 / 113 90-864196060 MAY 2006

Engine Installation................................................................................................................................................. 39Transom Preparation.......................................................................................................................................39Shift Cable Routing.........................................................................................................................................42Engine Preparation .........................................................................................................................................42Fuel Inlet Fitting...............................................................................................................................................43Engine Installation...........................................................................................................................................44Exhaust System Hose / Tube Connections.....................................................................................................47Engine Alignment Sterndrive Models..............................................................................................................49

Electrical Connections........................................................................................................................................... 51Instrumentation Connections-MPI Engines.....................................................................................................51

SmartCraft Product .................................................................................................................................. 52Audio Warning System Connections...............................................................................................................52MerCathode Connections (If Equipped)..........................................................................................................53Power Trim Electrical Connection...................................................................................................................54Battery Cables Connection..............................................................................................................................55Power Trim Pump Connections.......................................................................................................................55

Transom Connections........................................................................................................................................... 55Gear Lube Monitor Connection.......................................................................................................................55Power-Assisted Steering Hoses......................................................................................................................56Seawater Inlet Fitting Connection...................................................................................................................56

Alpha Shift Cable Installation................................................................................................................................ 60Alpha Sterndrive Shift Cable Installation.........................................................................................................60

Shift Cable Travel .................................................................................................................................... 60Separate Shift and Throttle Controls ....................................................................................................... 61Installation ................................................................................................................................................ 62

Bravo Shift Cable Installation and Adjustment...................................................................................................... 65Bravo Models Shift Cable Installation..............................................................................................................65Bravo Models Shift Cable Adjustment.............................................................................................................65Shift Cable Installation For DTS System.........................................................................................................68

Throttle Cable Installation and Adjustment............................................................................................................ 69Alpha Sterndrive Installation.................................................................................................................................. 70

Alpha Notice: Increased Trim-in Range Capability..........................................................................................70Alpha Trim Cylinder Spacer Removal.............................................................................................................70Alpha Trim Cylinder Disassembly...................................................................................................................72Alpha Trim Cylinder Reassembly....................................................................................................................73Alpha Trim Cylinder Installation.......................................................................................................................74Alpha Sterndrive Installation............................................................................................................................76

Trim Cylinder Installation ......................................................................................................................... 80Speedometer Connection - Alpha Models.......................................................................................................81

Bravo Installation................................................................................................................................................... 82Engine Alignment Check.................................................................................................................................82Bravo Sterndrive Installation...........................................................................................................................84

Trim Cylinder Installation ......................................................................................................................... 91Speedometer Connections - Bravo Models.....................................................................................................93Bravo Sterndrive Shift Check (Engine Running).............................................................................................94Troubleshooting Shift Problems......................................................................................................................96Bravo Trim Limit Switch Adjustment - Analog Gauges ...................................................................................98Trim Position Sender Adjustment - Analog Gauges......................................................................................100Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method.................................................101Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method.................................................102Bravo Sterndrive Propeller Installation..........................................................................................................103

Bravo One Models ................................................................................................................................. 103Bravo Two Models ................................................................................................................................. 105Bravo Three ........................................................................................................................................... 106

Bravo Sterndrive Propeller Installation..........................................................................................................107Bravo One Models ................................................................................................................................. 107Bravo Two Models ................................................................................................................................. 109


90-864196060 MAY 2006 Page 3 / 113

Bravo Three ........................................................................................................................................... 110DTS System Installation...................................................................................................................................... 111Shift Cable Installation For DTS System............................................................................................................. 111


Page 4 / 113 90-864196060 MAY 2006

Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

Liquid soap Exhaust tubes Obtain Locally

7 Loctite 271 Threadlocker Trim cylinder bolt threads 92-809819

9 Loctite 567 PST Pipe Sealant Fuel inlet fitting 92-809822

25 Liquid Neoprene

Battery terminalsAll electrical connectionsMerCathode connections

Battery Terminals

92-25711-3

27 Bellows Adhesive Exhaust bellows mounting surface 92-86166Q1

34 Special Lubricant 101

Power steering bushingsUpper and lower pivot bolts

Clevis pinSteering cable end

Shift cable studTrim cylinder end capPropeller shaft splines

92-802865A1

80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally

87 High Performance Gear Lubricant Gear lube monitorGear Lube Monitor 92-802854A1

91 Engine Coupler Spline Grease

Coupler splinesUjoint O-rings

Drive shaft splinesU-joint O-rings

Driveshaft splines

92-802869A1

94 Anti-Corrosion Grease Propeller shaft splines 92-802867A1

95 2-4-C Marine Lubricant with Teflon

Trim cylinder hardwareTrim cylinder

Bell housing studsO-ring

Water passage sealsAnchor pin threads

Shift cable endPropeller shaft splines

92-802859A1

114 Power Trim and Steering Fluid Power trim pump 92-802880A1

Special ToolsTapered insert tool 91-43579

9197

Removes and installs the tapered insert retainer into the waterinlet hose.

Alignment Tool Assembly 91-805475A 1

9183

Aligns the engine and the sterndrive unit during installation.


90-864196060 MAY 2006 Page 5 / 113

Shift Cable Adjustment Tool 91-12427

9186

Attaches over the shift cable, and aids in proper shift cableadjustment at the shift plate.

Trim Cylinder End Cap Tool 91-821709T

9191

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

Shift Slide Stabilizer 91-865232

9184

Holds the shift slide in the proper position as the sterndrive isinstalled onto the bell housing studs.

Dual Water Pick-up Flush Gearcase Seal Kit 91-881150K 1

9194

Blocks off the front water inlet holes on the dual water inletgearcases.

Flushing Device 91-44357Q 2

9192

Attaches to the water intakes; provides a fresh waterconnection when flushing the cooling system or operating theengine.

Flushing Kit 91-849996T 1

9195

Use for flushing gearcases with low water inlets.

Propeller Nut Tool 91-805457T 1

10677

Aids in the removal and installation of the front propeller nut.


Page 6 / 113 90-864196060 MAY 2006

Transom CutoutFinding The Crankshaft Vertical Center LineSINGLE ENGINE

1. Locate and mark the vertical center line on the transom, if known. This is also the crankshaftvertical center line.

2. If unknown, a compass can be used to locate the vertical center line:a. Mark identical locations on each side of the boat 304 mm (12 in.) from the bottom of the

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

bba

ce

de

7687

Single engine installationa - 304 mm (12 in.)b - Identical side marksc - Compass arc

d - Arc intersection pointse - Crankshaft vertical center line

DUAL ENGINE1. Locate and mark the vertical center line on the transom. Refer to Single Engine procedure.2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical center

lines on either side of the vertical center line.

Minimum Distance Between Crankshaft Vertical Center lines (Dual Side-By-Side)

Model Measurement

V6 and V8 Sterndrive 838 mm (33 in.)

IMPORTANT: Crankshaft vertical center lines must be an equal distance from boat vertical centerline.


90-864196060 MAY 2006 Page 7 / 113

3. Draw the 2 crankshaft vertical center lines through the intersection of the marks.

bc

7688

cb

aDual installation

a - Vertical center lineb - 1/2 minimum distance between

crankshaft center line marks

c - Crankshaft vertical center lines

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

90 DEGREE TOOL METHOD1. Construct the 90 degree tool.

90a

b 7689

a - 34.5 cm (13-9/16 in.) b - 1.2 m (4 ft)

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

line. This is the crankshaft horizontal center line or X-dimension.


Page 8 / 113 90-864196060 MAY 2006

4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

7690

b

c

a 7691

cb

aSingle engine Dual engine

a - 90 degree tool along boat bottom atvertical center line

b - Contact point

c - Crankshaft horizontal center line

TAPE MEASURE METHOD1. Determine the X-dimension from the following chart.IMPORTANT: This dimension should only be raised or lowered after proper testing.

Transom Angle (degrees) X-dimension

16 36.4 cm (14-5/16 in.)

15 36.2 cm (14-1/4 in.)

14 36.0 cm (14-3/16 in.)

13 35.9 cm (14-1/8 in.)

12 35.7 cm (14-1/16 in.)

11 35.6 cm (14 in.)

10 35.4 cm (13-15/16 in.)

2. On the vertical crankshaft center line, measure up from the bottom of the transom to theX-dimension selected previously. This is the crankshaft horizontal center line at theX-dimension.

3. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.

7692

c

a

b7693

a

bc

Single engine Dual enginea - Vertical center lineb - X-dimension that corresponds to

transom angle

c - Crankshaft horizontal center line

Cutting Out The TransomIMPORTANT: The following instructions will provide a sterndrive unit mounting location that issuitable for most boats. Best mounting location for a particular boat, however, can be determinedonly by testing.


90-864196060 MAY 2006 Page 9 / 113

1. Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from X-Dimension.2. Heavy duty applications: Subtract 25 mm (1 in.) from X-Dimension.3. Above 40 km/h (25 mph): Use X-Dimension shown.4. Above 80 km/h (50 mph): The X-Dimension can be increased to improve performance in

some applications. However, pulling power for skiing will decrease. During testing,X-Dimension should be increased 13 mm (1/2 in.) at a time until desired performance isachieved but in no case should it ever be increased by more than:

Maximum Increase In X-Dimension

Bravo One and Three 76 mm (3 in.)

Bravo Two 25 mm (1 in.)

Extreme care should be taken when raising drive unit to ensure that water supply does not becomeaerated. Use clear water inlet hose to monitor incoming water and monitor engine temperaturegauge to ensure engine does not overheat.In applications where cooling water to the engine is supplied by a through the hull orthrough the transom fitting, the sterndrive height will not cause cooling water aeration.IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed heightwill not be covered by Mercury MerCruiser warranty.1. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately).

7893 7694

Transom cutout template Transom drilling fixture kit2. Follow instructions indicated on template or provided with drilling fixture.3. Ensure that centerline on either the template or transom drilling fixture align with lines

previously marked on transom.4. Drill two 6 mm (1/4 in.) pilot holes at a 60 degree angle for hole saw guides.


Page 10 / 113 90-864196060 MAY 2006

5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole sawcutout is made incorrectly, drive unit steering lever may contact transom causing limitedsteering travel.

b

a

7695

a - 51 mm (2 in.) hole saw holes(steering lever cutout)

b - 60 degrees versus transom angle

6. Cut the transom on the cut line at a 90 degree angle. If the transom cutout is made incorrectlythe gimbal housing or exhaust system may improperly contact the boat transom causingtransom mounting problems.

7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent waterabsorption and deterioration of the transom.

b

d

a

7696

c

a - Cut lineb - 90 degrees to transom

c - Exhaust pipe aread - Mounting holes perpendicular to

transom (8)

Checking The Transom ThicknessIMPORTANT: Transom thickness and surface plane (flatness) must be controlled where thesterndrive unit mounts.1. Ensure that transom thickness and surface conform to specifications.


90-864196060 MAY 2006 Page 11 / 113

Transom Specifications

Thickness Between 51 - 57 mm (2 - 2-1/4 in.) for 203 mm (8 in.) to either side of the vertical center line


FlatnessTransom surfaces in area where transom assembly will be mounted (includes vertical as wellas horizontal dimensions) :Inner Surface - Flat within 3 mm (1/8 in.) Outer Surface - Flat within2 mm (1/16 in.)

Angle 10 -16 degrees

a

c

b

7697

a - Measuring thicknessb - Measuring flatness

c - Suitable mandrel to check for uniformtransom thickness

Preliminary ConnectionsDrive Shaft Extension Models

If your power package is equipped with a drive shaft extension, refer to the Drive Shaft ExtensionInstallation Instructions (90-866039) included with your engine package.You will also need to order extensions for the gear lube monitor and MerCathode quick connects.Refer to your parts catalog for current part numbers.

Engine MountsNOTE: On offshore boats or boats which will be used in rough water areas, Mercury MerCruiserrecommends the use of a solid plate engine mount.

Air PumpNOTE: Some models have air pump mounted on the engine and other models have the air pumpin a parts bag.1. Select an easily accessible mounting location for the air pump.2. Mount the air pump.

8992


Page 12 / 113 90-864196060 MAY 2006

Special InformationTransom Thickness and Surface

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where thesterndrive mounts.Transom thickness and surface must conform to the following:

Transom specifications

Thickness Between 51 - 57 mm (2 - 2-1/4 in.)


Flatness

Transom surfaces in area where transom assembly will be mounted(includes vertical as well as horizontal dimensions):Inner Surface - Flat within 3 mm (1/8 in.)Outer Surface - Flat within 2 mm (1/16 in.)

Angle 10 - 16 Degrees

ddb

e

c

a

7508

a - Transom thicknessb - Inner surfacec - Outer surface

d - Transom plate coveragee - Transom angle

a

c

b

7682

a - Measuring thicknessb - Measuring surface flatness

c - Suitable mandrel to check for uniformtransom thickness

All Bravo ModelsIMPORTANT: The trim-in limit insert must be properly positioned before installing the trim cylinderanchor pin.NOTE: When removing the sterndrive, note the position of the insert for reference when reinstallingthe sterndrive.


90-864196060 MAY 2006 Page 13 / 113

1. Ensure that the trim-in limit insert is positioned correctly for the appropriate Bravo model.

a

8548

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

a

8557

Bravo Three (positioned aft)a - Trim-in limit insert

IMPORTANT: The position of the trim-in limit insert on the Bravo Three sterndrive should only bechanged after the boat has been properly tested. Contact the boat manufacturer if you are notsure of the original position for a particular boat application.

Rear Engine MountsA fiber washer is cemented to the transom plate where the rear engine mount is attached to thetransom plate. Verify the washer is in place before installing the engine.Normally the engine attaches to the transom plate with only the fiber washer in place. If the frontengine mounts cannot be adjusted low enough to achieve proper engine alignment, spacer kit(12-892619A01) can be ordered and installed as shown to raise the rear of the engine. Do not usethe spacer unless alignment cannot be achieved with the front engine mount adjustment.IMPORTANT: The fiber washer must be used.NOTE: Engine alignment is usually obtained using only the rear engine mount and the fiberwasher.


Page 14 / 113 90-864196060 MAY 2006

1. Ensure that the fiber washer is in place.

16584

ba

a - Transom plate b - Fiber washer

2. Place the stainless steel washer on top of the transom plate mount only if needed to obtainproper alignment.

16583

a a

c

bb

c

a - Transom plateb - Stainless steel washer

c - Stainless steel washer position to raiseengine

Drive Shaft Extension ModelsIf the power package is equipped with a drive shaft extension, refer to the Drive Shaft ExtensionInstallation Instructions (90-866039) included with the engine package.Extensions for the gear lube monitor and MerCathode quick connects are used with drive shaftextention installations. Refer to your parts catalog for replacement part numbers.

Bravo Models Exhaust PreparationIMPORTANT: When installing through the transom exhaust, it is recommended that the exhaustbellows on the transom assembly be removed. This is necessary to avoid creating a vacuum atthe exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propellerperformance on some boats.1. If required, remove and discard clamps and bellows from gimbal housing.


90-864196060 MAY 2006 Page 15 / 113

IMPORTANT: When installing through the propeller exhaust:• With Bravo One and Bravo Two Sterndrives, an exhaust tube MAY BE INSTALLED for a slight

increase in performance.• With most Bravo Three Sterndrive Models, an exhaust tube MAY BE INSTALLED for a slight

increase in performance.• With a Silent Choice Exhaust System, the exhaust bellows must be removed and an exhaust

tube MUST BE INSTALLED.• With any application, installation of an exhaust tube will increase exhaust noise.2. If required, install exhaust tube on gimbal housing as follows:

a. Remove and discard clamps and exhaust bellows.

! CAUTIONExhaust tube clamp may corrode if grounding clip is not installed.

b. Install grounding clip on tube.c. Apply adhesive to exhaust bellows/tube mounting surface.

Tube Ref No. Description Where Used Part No.

27 Bellows Adhesive Exhaust bellows mountingsurface 92-86166Q1

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

a

e

bc

d

8406

a - Exhaust tubeb - Clampc - "SIDE" marking

d - Exhaust tubee - Grounding clip

Description Nm lb. in. lb. ft.

Exhaust tube clamp 4 35

Transom Assembly InstallationInstalling Inner Transom Plate

1. Insert wires, hoses, and shift cable through appropriate openings in inner transom plate.2. Position gimbal housing on transom and hold in place.IMPORTANT: Tighten the transom assembly fasteners using an X-pattern torque sequence,starting from the middle fasteners. Tighten in small increments and go around the pattern severaltimes until the proper torque is achieved.


Page 16 / 113 90-864196060 MAY 2006

3. Secure transom assembly with fasteners. Torque the fasteners.


Transom assembly hardware 34 25

IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressingwire when steering lever moves.IMPORTANT: Transom harness ground must be attached as shown.

23138

a a

a

c

b

a

1

8 6

4

23

5 7

f

e

gd

a - Locknuts and flat washers (8)b - Hydraulic hoses and MerCathode

wirec - Steering lever continuity wiresd - Transom plate continuity wires

e - Torque sequencef - Trim sender and trim limit wiresg - Ground from transom harness


90-864196060 MAY 2006 Page 17 / 113

Trim Position Sender ConnectionsNOTE: MerCruiser engines are shipped with the transom harness.1. Connect trim position sender wires (from transom assembly) to engine harness. Use the ORG/

GRY wire for analog gauges and the ORG/WHT wire for digital gauges.

BLKBLK

a b

a

b

BLK

ORG/WHT

ORG/GRY

9292

a - Engine harness bullet connector b - Transom assembly bullet connector

Sensor Steering Assembly1. Remove nuts from upper 2 transom studs.2. Remove cotter pin and clevis pin from steering lever.3. Install new clevis pin and secure with existing cotter pin.

gb

ah

d

e

f

a

c

8403

a - Transom stud holesb - Pitot tube connectionc - Plugd - Guide

e - Cotter pinf - Clevis ping - Tie straph - Alignment mark

4. Slide guide onto the groove in the clevis pin.5. Bolt the steering assembly to the transom.6. Remove the brass plug from the transom.7. Install pitot barbed fitting.8. Attach pitot tube to barbed fitting and secure with a tie strap.9. Plug sensor into transom harness.


Page 18 / 113 90-864196060 MAY 2006

Connecting Speedometer Pickup

! CAUTIONExcess water in bilge can damage engine or cause boat to sink. Do not remove plug fromspeedometer pickup tube fitting unless connection is to be utilized.

1. Remove the protective cap from the male quick connect.2. Connect a 4 mm (5/32 in.) speedometer hose (not provided) from speedometer to barb fitting.

Secure hose with tie strap.

ab

c

7703

c ed

b

Typicala - Male quick connectb - Female quick connectc - Barbed fitting

d - Hosee - Tie strap

! CAUTIONAvoid water leaking into boat. Speedometer hose is filled with water, especially during boatoperation. Hose contact with moving or rotating engine parts could cause damage to the hoseresulting in water leaking into boat. Do not let speedometer hose contact steering systemcomponents, engine coupler or drive shaft.

3. Secure the hose to the transom with the hose clip and screw that are provided in the partsbag. Ensure that the hose does not contact the steering system components or the enginecoupler and drive shaft.

Exhaust PreparationIMPORTANT: When installing through the transom exhaust, it is recommended that the exhaustbellows on the transom assembly be removed. This is necessary to avoid creating a vacuum atthe exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propellerperformance on some boats.1. If required, remove and discard clamps and bellows from gimbal housing.IMPORTANT: When installing through the propeller exhaust:• With Bravo One and Bravo Two Sterndrives, an exhaust tube MAY BE INSTALLED for a slight

increase in performance.• With most Bravo Three Sterndrive Models, an exhaust tube MAY BE INSTALLED for a slight

increase in performance.• With a Silent Choice Exhaust System, the exhaust bellows must be removed and an exhaust

tube MUST BE INSTALLED.• With any application, installation of an exhaust tube will increase exhaust noise.


90-864196060 MAY 2006 Page 19 / 113

2. If required, install exhaust tube on gimbal housing as follows:a. Remove and discard clamps and exhaust bellows.

! CAUTIONExhaust tube clamp may corrode if grounding clip is not installed.

b. Install grounding clip on tube.c. Apply adhesive to exhaust bellows/tube mounting surface.


27 Bellows Adhesive Exhaust bellows mountingsurface 92-86166Q1

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

a

e

bc

d

8406

a - Exhaust tubeb - Clampc - "SIDE" marking

d - Exhaust tubee - Grounding clip


Exhaust tube clamp 4 35


Page 20 / 113 90-864196060 MAY 2006

Seawater Inlet Fitting Installation1. Install a new gasket, seawater inlet fitting, and screws. Torque screws.

a

21634

c

a

b

d

Seawater inlet fitting shown with gear lube hose J-clipa - Seawater inlet fittingb - Screw (2)

c - Gasketd - Star washers


Seawater inlet fitting screws 5 45

Water Inlet Block-Off Plate InstallationALTERNATIVE WATER PICKUPS

A water inlet block-off kit must be used if the sterndrive unit water pickup will not be used to supplywater to the engine. When installing the block-off plate, it is necessary to cut the water hose thatis located between the bell housing and the gimbal housing. This allows water to continue tocirculate through the sterndrive unit for cooling.

! CAUTIONAvoid overheating the sterndrive. The seawater inlet holes must be allowed to flow water withoutbeing obstructed or damage to the sterndrive will result. Do not dead-end the seawater hosefrom bell housing. Cut hose as recommended in procedures.


90-864196060 MAY 2006 Page 21 / 113

BRAVO MODELS1. Remove the tapered insert in the gimbal housing using the tapered insert tool. Discard the

insert.

17857

c

d

b

a

a - Tapered insert location in the gimbalhousing

b - Rachet and extension

c - Tapered insertd - Tapered insert tool

Tapered insert tool 91-43579

2. Install the block-off plate with new gasket. Secure with screws and lockwashers. Torque thescrews.

a

21683

a

b

dc

a - Block-off plateb - Gasket

c - Screwd - Lockwasher


Water inlet block off screw 5 45


Page 22 / 113 90-864196060 MAY 2006

3. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbalhousing and the bell housing and detach the water hose from the gimbal housing where thetapered insert was removed in Step 2.

a

b

ec

d

8489

a - Trim limit switch wiresb - Speedometer hosec - Gimbal housing

d - Water hosee - Tapered insert

! WARNINGAvoid water leakage into the boat. If the U-joint bellows is damaged, water will enter the boat.Be careful not to damage the U-joint bellows when removing the section of the water hoseattached between the gimbal housing and the bell housing.

NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them whencutting the water hose. The existing tie strap and clip can be reused if they are moved andrepositioned after the hose is cut.4. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where

it is fitted into the bell housing in the area shown. Do not damage the U-joint bellows.5. Discard loose hose piece.6. Secure the trim limit switch wires and speedometer hose to the remaining section of water

hose using existing tie strap and clip.

c e

ab

d

f

8490

a - Tie strapb - Clipc - Water inlet hose

d - Speedometer hosee - Trim limit wire harnessf - Cutting area

7. Install a through the hull or through the transom seawater pickup, seawater strainer, andseacock.

8. Connect the seawater inlet hose between seawater pump and seawater strainer.9. Secure all hoses with hose clamps.


90-864196060 MAY 2006 Page 23 / 113

Gear Lube Monitor Connection At Gimbal Housing

! CAUTIONAvoid sterndrive unit damage. The quick release button on the gear lube monitor 90 degree hosefitting may not lock on the gimbal housing fitting if touching or depressed by the water inlet fitting,or block-off plate if equipped. Failure to lock the 90 degree hose fitting on the gimbal housingfitting could result in a loose 90 degree hose fitting causing a loss of gear lube and damage tothe sterndrive unit. Ensure the 90 degree hose fitting is locked on the gimbal housing fitting.

1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbalhousing.

a

a

b

c

d

21623

Model with block-off platea - Hoseb - Quick release 90 degree fitting

c - Seawater inlet fittingd - J-clip

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

not contact water fitting.

a

21624

b

cModel with Quick connect seawater inlet fitting

a - Gear lube monitor hoseb - Seawater inlet fitting

c - Quick release button

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


Page 24 / 113 90-864196060 MAY 2006

Alternative Mounting Of Gear Lube Monitor On TransomIMPORTANT: The mounting location specified must be above the steering lever on the transomassembly. Hose must be positioned to avoid moving parts (steering system, engine coupler).1. Install the gear lube monitor bracket in the specified location and secure with lag screws and

flat washers.2. Install the gear lube monitor in the bracket. Secure the monitor with the retaining strap.

a

b

c

d

7706

a - Bracketb - Lag screw and flat washer

c - Gear lube monitor and capd - Retaining strap

Transom Exhaust ConnectionsIMPORTANT: Exhaust pipe or block-off plate and gimbal housing mating surface must be cleanand free of nicks and scratches and O-ring must be properly seated in groove or water may leakinto boat.

a

21630

a - Seal

1. Through The Transom Exhaust Models: Install block-off plate using 4 bolts andlockwashers. Torque bolts.

a21625

b

c

a

a - Block-off plateb - Bolts

c - Lockwashers


90-864196060 MAY 2006 Page 25 / 113


Exhaust block-off plate bolts 34 25

2. Through The Propeller Exhaust Models: Install exhaust pipe. Torque bolts.

a18976

a16231

a - Engine exhaust pipe


Exhaust pipe to gimbal housing bolts 34 25

Models With Alpha Sterndrive and Alternative Water PickupsA water inlet block-off kit must be used if the sterndrive unit water pickup will not be used to supplywater to the engine. When installing the block-off plate, it is necessary to cut the water hose thatis located between the bell housing and the gimbal housing. This allows water to continue tocirculate through the sterndrive unit for cooling.


Alpha Models1. Cut water tube off close to cover. Remove and discard the screws and cover.

9260

a

cb

a

b

a - Water Tube Coverb - Screws

c - Water Tube


Page 26 / 113 90-864196060 MAY 2006

2. Remove rubber grommet from cavity around tube.

ba

9283

a - Water Tube (Cut Off In PreviousStep)

b - Rubber Grommet

3. Remove and discard bell housing sta-strap and clip that retains wires and speedometer hose.

c

f

a

be

d

9281

a - Sta-Strapb - Clipc - Bell Housing Hose

d - Bell Housing Assemblye - Speedometer Hosef - Trim Limit Switch Wire Harness

4. Cut the bell housing hose close to the bell housing as shown.

a

b

9285

a - Bell Housing Hose b - Cut Line


90-864196060 MAY 2006 Page 27 / 113

5. Pull on hose to withdraw water tube through gimbal housing opening. Remove hose withremaining piece of water tube from gimbal housing.

9286

a

ab

a - Bell Housing Hose b - Water Tube (Cut Off Previously)

6. Sta-strap (obtain locally) speedometer hose and trim limit switch wire harness together ontopiece of hose remaining on bell housing.


a

b

dc

7262







Models With Bravo Sterndrive and Alternative Water pickupsAlternative Water Pickups

A water inlet block-off kit must be used if the sterndrive unit water pickup will not be used to supplywater to the engine. When installing the block-off plate, it is necessary to cut the water hose thatis located between the bell housing and the gimbal housing. This allows water to continue tocirculate through the sterndrive unit for cooling.


Page 28 / 113 90-864196060 MAY 2006


Bravo Models1. Remove the existing water fitting and gasket. Discard the screws and washers.

a

b

8486

Bravo showna - Water inlet fitting b - Screws and lockwashers

2. Remove the tapered insert in the gimbal housing using the Tapered Insert Tool. Discard theinsert.

a

c

b

a

8487

a - Tapered insertb - Tapered Insert Tool

c - Gimbal housing cross-sectional view

Tapered Insert Tool 91-43579


90-864196060 MAY 2006 Page 29 / 113


ca

d

b

8488





4. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbalhousing and the bell housing and detach the water hose from the gimbal housing where thetapered insert was removed in Step 2.

a

b

ec

d

8489

a - Trim limit switch wiresb - Speedometer hosec - Gimbal housing

d - Water hosee - Tapered insert

! WARNINGAvoid water leakage into the boat. If the U-joint bellows is damaged, water will enter the boat.Be careful not to damage the U-joint bellows when removing the section of the water hoseattached between the gimbal housing and the bell housing.

NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them whencutting the water hose. The existing tie strap and clip can be reused if they are moved andrepositioned after the hose is cut.5. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where

it is fitted into the bell housing in the area shown. Do not damage the U-joint bellows.6. Discard loose hose piece.


Page 30 / 113 90-864196060 MAY 2006

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

c e

ab

d

f

8490

a - Tie strapb - Clipc - Water inlet hose

d - Speedometer hosee - Trim limit wire harnessf - Cutting area



Power Trim Pump InstallationPower Trim Electrical Connection

ABYC (American Boat and Yacht Council) installation recommends installing a battery switch inthe positive conductor of any battery or battery bank with CCA rating greater than 800 amperes.(See ABYC for additional information)ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump maynot be connected to the continuously energized circuit (battery). It must be connected to theswitched side of the battery switch. Wire length requirements and location of circuit protection arealso specified.MerCruiser has developed three methods to facilitate compliance with ABYC recommendations.These come in the form of one standard production and two accessory kits.• Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold

Cranking Amps (CCA) and without battery switches: The trim pump may be installed usingthe wires supplied with the power trim pump and should be connected directly to the battery.

• Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a batteryswitch) or any boat with a battery switch:a. The red current conductor (for the trim pump) must be connected to the switched side

of the battery switch and either:• provided with circuit protection within 7 inches of the power source or• Provided with circuit protection within 40 inches of the point of connection with the

power source and sheathed the entire length of wire from the point of connection tothe source and the circuit protection device. This will require the use of an Accessorycable kit.

Accessory Part Numbers

Part Number Description Color Length Type

8M2000587 Cable Assembly – Trim Pump Red 72 inches Fused

8M2000588 Cable Assembly – Trim Pump Red 40 inches Sheathed


90-864196060 MAY 2006 Page 31 / 113

Power Trim Pump1. Select an appropriate mounting location (floor or transom) for the trim pump that:

• Is within length limits of BLACK and GRAY hydraulic hoses coming from gimbal housingassembly.

• Is close to the battery so that trim pump battery leads can be connected.• Allows easy access to trim pump oil fill and vent locations.• Is in an area where pump will not be exposed to water.• Prevents the power steering booster cylinder from coming in contact with the trim pump

when the steering wheel is turned in either direction (right or left).NOTE: Template 90-863152 provides mounting hole location for floor or transom mounting.2. Mount the pump in the desired location.

Power Trim Pump Connections and FillingIMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking fromthe system.1. Connect hydraulic hoses to the trim pump. Ensure that the quickconnect fittings completely

seat when connecting the hoses.

a

b

c

ed

g

f

h

7698

a - Positive battery leadb - Negative battery leadc - Harness connectord - BLACK hydraulic hose (UP hose)

e - GRAY hydraulic hose (DOWN hose)f - Fill/vent capg - Dual mount trim pump bracketh - Trim limit switch connected and

secured


Page 32 / 113 90-864196060 MAY 2006

2. Connect power trim pump control harness to trim pump.

b

a

7699

a - Control harness b - Trim pump connector

FILLING1. If the oil level is below the "MIN" line specified fluid must be added.2. Remove the fill cap from the reservoir.NOTE: Fill cap is vented.

a b

7701

Power tim pump reservoir showes the oil level is below "MIN" linea - Fill cap assembly b - Fill cap installed

3. Add lubricant to bring level to the within the "MIN" and "MAX" lines on the reservoir.

a b7876

a - Reservoir b - "MIN" and "MAX" lines




90-864196060 MAY 2006 Page 33 / 113

4. Install the fill cap.

Trim Limit Switch Connection1. Connect the trim limit switch wires and secure with a wire retainer and tie strap.

a

b 7700

a - Trim limit switch wires b - Wire retainer and cable tie

Steering System InstallationHydraulic (Helm) Steering

If your power package is equipped with Compact Hydraulic Steering, refer to the CompactHydraulic (Helm) Steering Installation Instructions .

Steering Helm and CableTransom assembly is shipped with the steering cable guide tube preset for cables with enddimensions that comply with ABYC standards as outlined in the NMMA certification handbook.The steering cable coupler nut must also have a means of locking it to the guide tube, as specifiedin ABYC requirements.

! WARNINGFailure to use a steering cable locking device could cause loss of steering, causing possibledamage to the boat or injury.

NOTE: All current production Quicksilver RideGuide steering cables have a self-locking couplernut and do not require an external locking device. (Other cable manufacturers also make cableswith self-locking coupler nut.)

7255

a

a - Quicksilver RideGuide steering cable self-locking coupler nut (identified by groove)

IMPORTANT: If using a steering cable that does not have a self-locking coupler nut, an externallocking device such as a locking sleeve must be used.

! CAUTIONIf steering cable with improper dimensions is installed, severe damage to transom assemblyand/or steering system may result.

1. Steering cable must be the correct length, particularly when installed in larger boats.2. Avoid sharp bends, kinks, or loops in cable.


Page 34 / 113 90-864196060 MAY 2006

3. Fully extended steering cable end dimension must be as specified.

Steering Cable SpecificationsIMPORTANT: Power-assisted steering pump lugging (squealing) in a hard right turn (against lock)may mean a steering cable has been installed that does not have the correct dimensions.

CL

ab

c

de

fg

hi

jk

l

7254

a - Coupler nut - 7/8 - 14 UNF - 28 threadb - 298 mm (11-3/4 in.) minimumc - Interface pointd - 12.7 mm (1/2 in.) maximume - 10.7 mm (27/64 in.) minimum flatf - 3.1 mm (7/64 in.) minimum radius

g - 15.9 mm (5/8 in.) maximum diameterend fitting

h - 9.5 mm (3/8 in.)i - 9.8 mm (3/8 in.) diameter through hole

(chamfered each side)j - 34.9 mm (1-3/8 in.) maximumk - 15.9 mm (5/8 in.) diameter tubel - Cable travel: mid-travel position -

429 mm (16-7/8 in.) total travel to be203 mm (8 in.) minimum to228 mm (9 in.) maximum travel eachside of mid-travel position -102 mm (4 in.) minimum to114 mm (4-1/2 in.) maximum

Installing Steering SystemNOTE: For dual installations, power-assisted steering unit can be mounted on port or starboardtransom assembly. Measure exact distance between power package center lines. Select a tie barfrom Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar installationinstructions before proceeding.1. Remove the protective shipping caps.2. Inspect the bushings for debris. Lubricate the power steering bushings.3. a

7709

a - Bushings


34 Special Lubricant 101 Power steering bushings 92-802865A1


90-864196060 MAY 2006 Page 35 / 113

4. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.

a

b21631

a - Upper pivot bolt b - Lower pivot bolt


34 Special Lubricant 101 Upper and lower pivot bolts 92-802865A1

5. Position the steering assembly so that the pivot bolts will enter the bushings in thepower-assisted steering control valve.

6. Install the upper and lower pivot bolts along with tab washers. Ensure that the tab washertangs straddle the ridge on the inner transom plate.

a

b

ba

a 21632

Upper Pivot Bolt And Tab Washer Shown (Lower Similar)a - Tab washer tang b - Ridge

7. Turn the pivot bolts all the way in, by hand, to ensure proper steering assembly alignment.8. Ensure that the steering assembly pivots freely.9. Torque the pivot bolts. Bend the tab washer tabs against the corresponding flats on the

bolt heads.


Page 36 / 113 90-864196060 MAY 2006

NOTE: It may be necessary to tighten the pivot bolts further to align the flats on bolt head with thetabs on the washer.

a

a

b b

21691

a - Pivot bolt b - Bent tab


Upper and lower pivot bolt 34 25

! CAUTIONMOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid from thecontrol valve ports. Wear eye protection.

10. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tubeas shown, so that it will be less difficult to pull it out or push it in during connection.

a ab

b

8496

a - Port b - Control valve cable guide tube

11. Connect the clevis to the steering lever.a. Lubricate the clevis pin.


34 Special Lubricant 101 Clevis pin 92-802865A1


90-864196060 MAY 2006 Page 37 / 113

b. Insert the clevis pin.

ba

20396

a - Clevis b - Clevis pin

c. Insert the cotter pin.d. Spread both ends of the cotter pin.

c

b

aa

c

20399

a - Cotter pinb - Clevis pin

c - Steering lever

IMPORTANT: Quicksilver RideGuide steering cable has a self-locking coupler nut and does notrequire an external locking sleeve or locking plate.

7255

a

a - Self-locking coupler nut


Page 38 / 113 90-864196060 MAY 2006

! CAUTIONProper steering system function requires that the steering cable and outer casing must be freeto move back and forth. Items fastened to the steering cable and outer casing prevent freemovement. Do not fasten any items to the steering cable and outer casing.

7827

a

a - Steering cable and outer casing

12. Connect the steering cable as follows:a. Coat the steering cable end with a liberal amount of lubricant.


34 Special Lubricant 101 Steering cable end 92-802865A1

b. Install the steering cable and secure with hardware as shown.IMPORTANT: Cable guide tube flat surfaces must be positioned vertically or slight feedback inthe steering system could be encountered.

c. Using a suitable wrench hold the flat surfaces on the cable guide tube in the verticalposition. Torque the coupler nut. Ensure that the flat surfaces are still aligned verticallyafter torque is applied to the coupler nut.

d

h

d

cba

g

fe

7830

a - Steering cableb - Grease fittingc - Cable coupler nutd - Cable guide tube

e - Steering cable endf - Clevisg - Clevis pinh - Cotter pin

Shift Cable Routing1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:


90-864196060 MAY 2006 Page 39 / 113

a. The cable should come through the transom, above the exhaust pipe and make a turntoward the starboard side of the boat between the exhaust pipe and the engine flywheelhousing.

b. The cable should then be routed under the starboard rear engine mount and turn towardthe transom.

c. The cable should then go up behind the power-assisted steering valve and loop over tothe shift actuator on the engine.

NOTE: Following this routing will prevent the engine coupler from damaging the cable.

8995

Refer to Section 8 - Remote Control.

Transom HarnessMerCruiser engines are shipped with a separate transom harness. This harness allows forconnection to various electrical components that occur behind the engine such as trim sendersand the Mercathode, and provides the continuity ground to the transom and sterndrive for corrosionprotection. The harness is labeled with the sensors that will connect to it. The sensor needed foryour installation should be connected and the wiring secured with clamps and stay straps toprevent damage to the wiring as the engine is installed and later as the boat is used. The engineconnector should be tied back so as not to interfere with the engine installation. After the engineis installed, the single connector will be connected.NOTE: The black ground wire on the transom harness must be connected under the bolt on theport side of the transom plate that has the bonding strap and j-clamp already attached. See"Installing inner Transom Plate" for details.

Engine InstallationTransom Preparation

IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicksand scratches and O-ring must be properly seated in groove or water and exhaust may leak intoboat.1. Ensure the exhaust pipe and gimbal housing mating surfaces are clean and free of nicks and

scratches.


Page 40 / 113 90-864196060 MAY 2006

2. Ensure the O-ring is properly seated in the groove.

a

b

6638

a - Gimbal housing mating surface b - O-ring

3. Loosen hose clamps and remove exhaust pipe and bellows from engine.4. Remove the shipping plug from the engine coupler.

a 7767

a - Shipping plug

5. Through The Propeller Exhaust Models: Install exhaust pipe assembly using 4 bolts andlockwashers. Torque bolts.

ab

8499

a - Exhaust pipe b - Bolts and lockwashers (4)


Exhaust pipe bolts 34 25


90-864196060 MAY 2006 Page 41 / 113

6. Through The Transom Exhaust Models: Install block-off plate using 4 bolts andlockwashers. Torque bolts.

a b

8404

a - Block-off plate b - Bolts and lockwashers (4)


Exhaust block-off plate bolts 34 25

NOTE: Through the transom exhaust fittings can be installed at this time.

! CAUTIONAvoid product damage caused by improper engine alignment. Improper engine alignment canbe caused by mismatched flywheel housing mounts and inner transom plate mounting hardware.Ensure that the flywheel housing mounts and the inner transom plate mounting hardware, portand starboard, are the correct parts and match before installing the engine.

7. These models have new design mounts - knurled bottom surface: Use the fiber washer only.Do not use the double-wound lockwasher.

a

b

7960

Typical flywheel housing, all similara - Late style mount - knurled surface b - Fiber washer


Page 42 / 113 90-864196060 MAY 2006

8. Position rear engine mount attaching hardware on inner transom plate mounts as shown.

a

b

7839

a - Fiber Washer (2) b - Locknut (2)

Shift Cable Routing1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:



c. The cable should then go up behind the power steering valve and loop over to the shiftactuator on the engine.


8995

Refer to Section 8 - Remote Control.

Engine Preparation1. Remove and read all tags attached to engine.2. Remove all hardware that secures engine to shipping container.3. Connect battery cables to engine. Observe the following:

a. Ensure that the grounding stud and starter solenoid terminal are free of paint or any othermaterial that could cause a poor electrical connection.

b. Install battery positive (+) wire directly to the large starter solenoid stud.c. After battery cables are connected, apply a thin coat of sealant to the terminals.


90-864196060 MAY 2006 Page 43 / 113


Battery stud 8-11 71-97


25 Liquid Neoprene Battery terminals 92-25711-3

d. Slide rubber boot over positive (+) terminal after making connection.4. Drape battery cables over top of engine to prevent interference during installation.IMPORTANT: There is a fuse located at the starter solenoid. Do not remove this fuse.

b

ca

8501

a - Positive (+) battery cable locationb - Starter solenoid

c - 90 amp fuse - Do not remove

5. If not already done, remove shipping plug from coupler and lubricate splines.

a 7767

Typicala - Shipping plug


91 Engine Coupler Spline Grease Coupler splines 92-802869A1

Fuel Inlet FittingIMPORTANT: The following information is provided to ensure proper installation of brass fittingsor plugs installed into fuel pump system.• Use Loctite 565 Pipe Sealant with Teflon on threads of fuel inlet fittings or plugs. DO NOT

USE TEFLON TAPE.


Page 44 / 113 90-864196060 MAY 2006

! WARNINGAvoid serious injury or death and property damage due to improper boat design andconstruction. Always adhere to all applicable Marine Regulations (United States Coast Guard[USCG], European Union - Recreational Craft Directive [EU-RCD], and so on) and the standardsthey reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers[SAE], International Standards Organization [ISO], and so on) when designing and constructingthe boat and the boat components, such as the engine compartment, fuel delivery system andexhaust system.

! WARNINGAvoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump orfuel filter base can crack casting and/or cause a fuel leak.

1. Remove plastic plug from fuel inlet hole.2. Apply sealant to threads of fuel inlet fitting. DO NOT USE TEFLON TAPE.

! WARNINGOvertightening the fuel inlet fitting can lead to fuel leaks, avoid severe personal injury or deathfrom a gasoline fire or explosion. Do not use a power tool (i.e. impact wrench) to tighten the fuelinlet fitting.

3. Install fuel inlet fitting in fuel pump or filter base. To prevent cracking the casting or causingfuel leaks, turn fuel inlet fitting in by hand until finger-tight. Tighten the fitting an additional 1-3/4to 2-1/4 turns with wrench. DO NOT OVERTIGHTEN.

IMPORTANT: Hold brass fittings with a suitable wrench while tightening fuel inlet fittings.


9 Loctite 567 PST Pipe Sealant Fuel inlet fitting 92-809822

Description Procedure

Fuel inlet fitting Finger-tight + 1-3/4 to 2-1/4 turns with a wrench. Do not overtighten.

! CAUTIONEngine compartment size may require the removal of additional components.

NOTE: An installation jig (91-806794A02) can be used to align and adjust engine mounts. Referto instructions with fixture for proper use.


90-864196060 MAY 2006 Page 45 / 113

1. Remove the engine cover, if equipped.

9289

b

a

Closed cool model shown, seawater cooled similara - Engine cover knob b - Engine cover

2. Attach a suitable sling to the front and rear lifting eyes on engine and adjust so that engine islevel when suspended.

! CAUTION

ab

b

9375

a - Center lifting eye (engine alignmentonly)

b - Lifting eye

c -

3. Lift engine into position (in boat) using an overhead hoist.4. Align rear engine mounts with inner transom plate mounts while simultaneously aligning

exhaust tube with exhaust pipe bellows.


Liquid soap Exhaust tubes Obtain Locally

5. To help with installation, apply lubricant into the exhaust tubes.IMPORTANT: The quick drain oil fitting clearance must be greater than 13 mm (1/2 in.) from theengine compartment and boat bottom.6. If equipped with quick drain oil: Ensure that the quick drain oil fitting has a clearance of

more than 13 mm (1/2 in.) from the engine compartment and boat bottom.7. If clearance is 13 mm (1/2 in.) or less:Remove the quick drain oil fitting and install the oil

drain plug from parts bag directly into the engine oil pan.


Page 46 / 113 90-864196060 MAY 2006

8. If clearance is greater than 13 mm (1/2 in.):

c

d

e

a b f7771

a - Bilge drain plugb - Tetherc - Quick oil drain hose plug

d - Flangee - Toward interior of boatf - Clip

a. Push end of oil drain hose out of boat hull through flange.b. Pull oil drain hose out until it is 304 mm (12 in.) from flange.c. Move alignment clip on the oil drain hose and squeeze to position it on the hose just

inside of the boat hull against the flange.d. Connect bilge drain plug to oil drain hose plug using clip.

bc

a

d

7618

a - Oil drain hoseb - Alignment clip

c - Clipd - Bilge drain plug

e. Push oil drain hose through flange into boat hull.f. Install bilge drain plug in hull.

9. Install both rear engine mounting bolts and hardware and torque. Do not relieve hoist tension.


90-864196060 MAY 2006 Page 47 / 113

NOTE: Normally the engine attaches to the transom plate with only the fiber washer in place. Ifthe front engine mounts cannot be adjusted low enough to achieve proper engine alignment,spacer kit (12-892619A01) can be ordered and installed as shown to raise the rear of the engine.Do not use the spacer unless alignment cannot be achieved with the front engine mountadjustment.

a

c

f

b

e

7961

d

f

g a

b

c

e

7772

a - Rear engine mountb - Inner transom plate mountc - Boltd - Washer

e - Spacerf - Fiber washerg - Stainless steel washer (optional

spacer kit)


Rear engine mounting bolts 47 35

10. Loosen both adjusting nuts on front engine mounts to allow for adjustment during alignment.11. Attach the front mounts to the stringers.12. Remove the engine hoist.

Exhaust System Hose / Tube Connections

! CAUTIONAvoid exhaust hose failure which could cause exhaust or discharge water to enter the boat.Discharge water from the exhaust elbow must flow without restriction around the entire insidediameter of the exhaust hose to avoid causing hot spots, which could eventually burn throughthe exhaust hose. Connect the exhaust hoses and tubes to the exhaust elbows so that they donot restrict the flow of discharge water from the exhaust elbows.

Exhaust hoses must be properly installed on exhaust elbow outlets. Discharge water from theexhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots thatcould burn through the hose.

7628 7629

Correct Incorrect


Page 48 / 113 90-864196060 MAY 2006

e

a

b

cd

9290

Exhaust connectiona - Maximum misalignment +/- 5

degreesb - Exhaust outlet centerline (14

degrees vs. crankshaft centerline)c - Exhaust hose centerline

d - Angle vs. horizontale - Horizontal (level surface)

IMPORTANT: Exhaust hoses/tubes should be secured at each connection with at least 2 hoseclamps.All exhaust connections, including those at the exhaust elbow, should be secured with 2 hoseclamps. ABYC standards also specify the use of stainless steel clamps with a minimum13 mm (1/2 in.) band width. Do not use spring tension clamps.1. Torque all exhaust hose and/or exhaust tube clamps.

a7631

a - Hose clamps


Exhaust tube clamps 4 35

Hose clamps 3.4-6.8 30-60


90-864196060 MAY 2006 Page 49 / 113

Engine Alignment Sterndrive Models1. If applicable, open perforated area in bell housing dust cover.

a

8378

a - Dust cover

! CAUTIONDo not use an alignment tool from another manufacturer. Alignment tools other than QuicksilverAlignment Tool may cause improper alignment and damage to gimbal bearing and/or enginecoupler.

! CAUTIONTo avoid damage to gimbal bearing, engine coupler, or alignment tool:Do not attempt to force Quicksilver alignment tool.Do not raise or lower engine with alignment tool inserted (or partially inserted) in gimbal bearingor engine coupler.Do not raise engine mount bracket above top of engine mount stud.

2. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into theengine coupler splines.


3. If the alignmet tool does not fit, remove it and carefully raise or lower the front end of the engineas necessary.

4. If applicable, attach the engine hoist to the engine aligment hook to raise or lower the frontend of engine.

NOTE: Models not equipped with engine alingment hooks; require adjusting the front enginemounts equally to raise and lower the front end of the engine.5. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the

engine coupler splines.NOTE: It may be necessary to hit the Alignment Tool with a synthane hammer to set the gimbalbearing to the coupler.


Page 50 / 113 90-864196060 MAY 2006

6. If necessary, firmly strike the sides of the Alignment Tool at 90 degree increments to help alignthe gimbal bearing.

a

d

e

cb

a

7784

a - Alignment Toolb - Gimbal bearingc - Engine coupler

d - Hammere - 90 degree increments

7. Repeat step 4. until the Alignment Tool installs easily (SLIDES FREELY WITH MINIMALEFFORT) all the way into and out of engine coupler splines. Do not check by turning thealignment tool.

IMPORTANT: The finished boat stringer must position the front engine mount so that a minimumof 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer(structure) to obtain the 6 mm (1/4 in.) dimension.IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction requiredto align engine.8. Adjust front engine mounts until they rest on boat stringers.9. Relieve hoist tension entirely and fasten both front mounts to boat stringer using

9 mm (3/8 in.) lag bolts.10. Recheck alignment with Alignment Tool. Tool must enter coupling splines freely. If not,

readjust front mounts.

ba

8503

a - Alignment Tool (use onlyrecommended Alignment Tool)

b - End to be inserted through gimbalhousing assembly

11. When alignment is correct, tighten locknut securely. Recheck alignment.


90-864196060 MAY 2006 Page 51 / 113

12. Bend tab down on adjusting nut.

d

ab

c

8504

a - Nut and lockwasherb - Adjustment nut

c - Direction (counterclockwise) to raisefront of engine

d - Tab washer

13. Remove Alignment Tool. If not installing drive, fold bell housing dust cover flap back into placeand tape shut for boat shipment. Dust cover flap will have to be removed before operatingengine.

14. Remove the engine alignment hook from the engine.

Electrical Connections! CAUTION

Avoid damage to the electrical system components caused by improper work or diagnosticpractices. Observe the following precautions when working on or around an electrical harness,or when adding electrical accessories:• Do not tap electrical accessories into the engine electrical harness.• Do not puncture (probe) wires for testing.• Do not reverse battery leads.• Do not splice wires into the electrical harness.• Do not attempt diagnostics without proper, approved service tools.

IMPORTANT: When routing all wire harnesses and hoses, ensure that they are routed andsecured to avoid coming in contact with hot spots on engine and to avoid contact with movingparts.


25 Liquid Neoprene All electrical connections 92-25711-3

Instrumentation Connections-MPI EnginesWe recommend the use of Quicksilver Instrumentation and Wiring Harnesses. On dual stationapplications, oil pressure and water temperature senders (on engine) must be changed. Refer toMercury Precision Parts Accessories Guide for selection.The 4 basic gauges that must be used with the engine are:• Tachometer• Oil pressure• Water temperature


Page 52 / 113 90-864196060 MAY 2006

• VoltmeterIMPORTANT: Maximum accessory load on the engine harness is 15 amps. If additional accessoryload is needed, an accessory kit is available.1. Route instrumentation wiring harness back to engine, ensuring that harness does not rub or

get pinched. If an extension harness is required, be sure to secure connection properly.2. Fasten harnesses to boat at least every 46 cm (18 in.) using appropriate fasteners.3. Connect the instrumentation wiring harness to engine harness plug at location shown.

23135

a

Typicala - Engine harness plug

4. Connect 14-pin harness to engine. Turn locking ring until firm snap is felt.

23136

1

2

SMARTCRAFT PRODUCTA Mercury SmartCraft System instrument package can be purchased for this product. A few of thefunctions the instrument package will display are engine rpm, coolant temperature, water pressure,battery voltage, fuel consumption, and engine operating hours. The Smartcraft instrumentpackage will also aid in engine diagnostics.The SmartCraft instrument package will display critical engine alarm data and potential problems.Refer to the Mercury SmartCraft Operator's Supplement (90-10229023) for the warning functionsmonitored and basic operation of the SmartCraft Instrument package. Refer to the instructionsincluded with the instruments for installation instructions.

Audio Warning System Connections

! WARNINGAvoid serious injury or death from a gasoline fire or explosion. Engine or fuel tank compartmentsmay have gasoline or gasoline vapors present that could be ignited by components that are notexternal ignition proof. The audio warning alarm is not external ignition-proof. Do not mount theaudio warning alarm in the engine or fuel tank compartments.


90-864196060 MAY 2006 Page 53 / 113

1. Select a location for audio warning alarm that meets all of the following:• Alarm can be easily heard, yet is out of sight• Alarm can be easily accessed for installation and maintenance• Alarm will remain dry• Alarm is within length limits of the 46 cm (18 in.) purple alarm wire that connects to the

"I" terminal or 12 volt source on switched side of ignition switch.NOTE: The terminal to which wire is attached must have no voltage when ignition switch is in theOFF position.2. Place alarm in desired location and secure to wire bundle with tie strap provided.3. Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge or

ignition switch. Tighten connection securely.4. Connect TAN/BLUE wire from alarm to TAN/ BLUE wire from instrument harness.5. Place the small (transparent) decals on the bottom of the water temperature and the oil

pressure gauges.6. Place the large decal on the instrument panel or other appropriate location easily viewed by

the operator.

ALARM INDICATES LOW OIL OR OVERHEATING

APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION:

AUDIO WARNING HORN WILL SOUND WHEN: 1. ENGINE OIL PRESSURE IS TOO LOW 2. ENGINE TEMP. IS TOO HIGH, OR 3. DRIVE OIL LEVEL IS TOO LOW

TO TEST AUDIO WARNING HORN:TURN KEY TO "ON" POSITION (ENGINE OFF)

a

b

7799

a - Small decal (transparent) b - Larger decal

7. Test audio warning system during Predelivery Preparation section.

MerCathode Connections (If Equipped)The MerCathode controller assembly is located on the back of the front lifting eye.1. The Mercathode attachment to the anode on the transom is accomplished through the transom

harness that should already be connected.IMPORTANT: Opposite end of RED/PURPLE wire must be connected directly to battery positive(+) terminal. Do not connect it to a switched positive (+) circuit. MerCathode system must functioncontinuously for proper corrosion protection.


Page 54 / 113 90-864196060 MAY 2006

2. Connect the Mercathode Red/Purple wire directly to the battery positive lead.

da

bc

8507

a - ORANGE lead - from anode ontransom assembly (part of quickconnect)

b - RED/PURPLE wire - to positive (+)battery terminal

c - BLACK wire - from engine harnessd - BROWN wire - from electrode on

transom assembly(part of quickconnect)


25 Liquid Neoprene MerCathode connections 92-25711-3

Power Trim Electrical ConnectionABYC (American Boat and Yacht Council) installation recommends installing a battery switch inthe positive conductor of any battery or battery bank with CCA rating greater than 800 amperes.(See ABYC for additional information)ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump maynot be connected to the continuously energized circuit (battery). It must be connected to theswitched side of the battery switch. Wire length requirements and location of circuit protection arealso specified.MerCruiser has developed three methods to facilitate compliance with ABYC recommendations.These come in the form of one standard production and two accessory kits.• Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold

Cranking Amps (CCA) and without battery switches: The trim pump may be installed usingthe wires supplied with the power trim pump and should be connected directly to the battery.

• Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a batteryswitch) or any boat with a battery switch:a. The red current conductor (for the trim pump) must be connected to the switched side

of the battery switch and either:• provided with circuit protection within 7 inches of the power source or• Provided with circuit protection within 40 inches of the point of connection with the

power source and sheathed the entire length of wire from the point of connection tothe source and the circuit protection device. This will require the use of an Accessorycable kit.

Accessory Part Numbers





90-864196060 MAY 2006 Page 55 / 113

Battery Cables ConnectionIMPORTANT: Engine electrical system is negative (-) ground.1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal.2. Connect engine negative (-) battery cable (usually BLACK) to negative (-) battery terminal.

Power Trim Pump Connections1. Connect power trim pump BLACK (-) battery cable to negative (-) battery terminal and pump

RED (+) battery cable to positive (+) battery terminal.

a

b6842

a - Positive battery lead b - Negative battery lead


25 Liquid Neoprene Battery Terminals 92-25711-3

Transom ConnectionsGear Lube Monitor Connection

IMPORTANT: Avoid using excessive hose when routing it to gear lube monitor. Hose should berouted directly to oil reservoir in as straight a line as possible to avoid low spots (traps) in thesystem.

! CAUTIONEnsure that hose is not kinked when connecting in the following step. If hose is kinked, gear lubemonitor will not function properly and damage to sterndrive unit could occur.

1. Locate the gear lube monitor quick connect at the rear of the engine.2. Locate the gear lube monitor quick connect at transom.IMPORTANT: Hose must not come in contact with steering system components, engine coupler,U-joint shaft, or drive shaft.


Page 56 / 113 90-864196060 MAY 2006

3. Fasten the quick connect.

7800

bc a

a - Gear lube monitor hose assemblyfrom transom

b - Gear lube monitor hose assemblyfrom gear lube monitor

c - Quick connect fitting

Power-Assisted Steering HosesIMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks.1. Disconnect the quick connect fittings on the power-assisted steering hoses.2. Connect the power-assisted steering hoses to the control valve. Ensure that the quick

connects snap into place.3. Route hoses as appropriate to avoid contact with the steering system components.4. Use extra hose clips to secure hose to transom.

a

b

a

b

a

a

16225

a - Hydraulic lines b - Power-assisted steering control valve

NOTE: Steering Fluid can be added at this time if desired.

Seawater Inlet Fitting Connection

! CAUTIONExcess water in the bilge can damage the engine or cause the boat to sink. An improperlyconnected seawater inlet hose could result in excess water in the bilge. Ensure that the seawaterinlet hose is connected properly by performing the specified pull test.

NOTE: The retainer clip must be in the closed position prior to installation.1. Install the seawater inlet hose assembly to the water inlet fitting.


90-864196060 MAY 2006 Page 57 / 113

a. Position the retainer clip in the closed position.

8512

a

b

c

Seawater inlet hose assemblya - Retainer clip closedb - Quick connect fitting

c - Hose decal

b. Position the seawater inlet hose assembly with the center of the retainer clip and thehose decal toward the engine.

IMPORTANT: Tabs and slots are sized to only mate at the correct orientation. Mate the small tabwith the small slot.

c. Align the slots of the quick connect fitting to the tabs of the water inlet fitting.

g

b

ca

h

e

fd

8513

a - Quick connect fittingb - Small slotc - Large slotd - Seawater inlet fitting

e - Small tabf - Large tabg - Center of retainer clip (toward engine)h - Centerline of water inlet fitting (toward

engine)

d. Ensure that the center line of the water inlet fitting and the center of the retainer clip arepositioned toward the engine.

2. Push the seawater inlet hose assembly onto the water inlet fitting until connected.


Page 58 / 113 90-864196060 MAY 2006

NOTE: The retainer clip snaps into place and resumes the closed position when properlyconnected.

8514

ac

b

Shown with engine removed for visual claritya - Centerline of water inlet fittingb - Retainer clip in closed position

c - Hose decal


IMPORTANT: A pull test must be performed at the seawater inlet connection.3. Perform a pull test on the water hose quick connection.

a. Pull on the seawater inlet hose near the connection point with an approximate force of111 N (25 lbf). If the seawater inlet hose does not become separated from the seawaterinlet fitting when force is applied, the seawater inlet hose is connected and sealedproperly.

bca

8515

Shown with engine removed for visual claritya - Seawater inlet hoseb - Quick connect fitting

c - Seawater inlet fitting

b. If the seawater inlet hose does become separated from the seawater inlet fitting, reinstallas specified.

c. When all steps have been completed, check for any leaks at this connection.4. Connect the seawater inlet hose to the engine seawater pump.


90-864196060 MAY 2006 Page 59 / 113

NOTE: The seawater inlet hose connects to the engine and the transom.

a

c

8516

e bd

e

Seawater inlet hose assemblya - Seawater inlet hoseb - To enginec - Quick connect fitting

d - Seawater inlet fittinge - Hose clamps

5. Models Using The Seawater Extension Hose Assembly:NOTE: The seawater inlet hose connects to the engine and the transom, the seawater extensionhose assembly connects to the transom and the seawater inlet hose.

a. When connecting the seawater extension hose assembly to the seawater inlet hoseassembly, position the center of the retainer clip away from the engine.

b

c

e

d

a8517

Shown with engine removed for visual claritya - Retainer clip position (away from

engine)b - Seawater extension hosec - Seawater inlet hose (to engine

seawater pump)

d - Quick connect fitting (to seawater inletfitting)

e - Seawater inlet fitting (to transom)


b. Perform a pull test and ensure that the requirements for checking the integrity of theconnection are met.


Page 60 / 113 90-864196060 MAY 2006

NOTE: The seawater extension hose assembly connects to the transom and the seawater inlethose.

d

ab c

e f

gg

g

g

8518

a - Seawater inlet hoseb - Quick connect fitting to extension

hosec - Quick connect male fittingd - Extension hose

e - Quick connect fitting to seawater inletfitting

f - Seawater inlet fittingg - Hose clamp

Alpha Shift Cable InstallationAlpha Sterndrive Shift Cable Installation

IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in theremote control.• If shift cable end guide moves in direction "A" when control lever is placed in FORWARD,

remote control is set up for RIGHT-HAND (RH) propeller rotation.• If shift cable end guide moves in direction "B" when control lever is placed in FORWARD,

remote control is set up for LEFT-HAND (LH) propeller rotation.

B

A

6614

Arrow indicates direction of motion

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoidsharp bends and/or contact with moving parts. Do not fasten any items to shift cables.

SHIFT CABLE TRAVELWe recommend the use of a Quicksilver remote control and cable. Refer to Mercury PrecisionParts Accessories Guide for selection. However, if a control other than Quicksilver is to be used,control must provide specified shift cable travel (at the shift plate end).


Shift cable travel1 73 mm (2-7/8 in.)-80 mm (3-1/8 in.)2

1 At the shift plate end

2 With a 6.8-9 kg (15-20 lb) load applied to the cable end guide

NOTE: On engines with Alpha drives, the measurement indicated above can be taken by installingthe remote control shift cable and using the shift assist assembly (provided) to place the properload on the shift cable.


90-864196060 MAY 2006 Page 61 / 113

1. Place a mark on the tube against the edge of the cable end guide.

d

a

b c

a

e

7809

a - Shift assist assemblyb - Remote control shift cable - in

FORWARD gear positionc - Edge of cable end guide

d - Remote control shift cable - inREVERSE gear position

e - Measurement taken from mark to edgeof cable end guide

SEPARATE SHIFT AND THROTTLE CONTROLSIMPORTANT: If boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATESHIFT AND THROTTLE LEVERS, the shift assist assembly that is shipped with the engine shouldnot be used. The use of the shift assist assembly with this type of remote control can cause theshift lever to move out of gear unexpectedly.The Spacer Kit (23-11284A1) will have to be ordered to connect remote control shift cable whenshift assist assembly is not used.

b

c

a

d 7810

a - Clevis pinb - Washer

c - Spacerd - Cotter pin


Page 62 / 113 90-864196060 MAY 2006

NOTE: Do not discard shift assist assembly until after it is used below.IMPORTANT: Shift cable must be connected at the remote control for the appropriate rotation (LHor RH) drive unit, as explained following:RIGHT-HAND ROTATION - Control cable will have to be installed in remote control so that cableend will move in direction "A" when shift handle is placed in the FORWARD position.LEFT-HAND ROTATION - Control cable will have to be installed in remote control so that cableend will move in direction "B" when shift handle is placed in the FORWARD position.

B

A

6614

INSTALLATION1. Remove shift assist assembly.2. Remove shift cable attaching hardware.

b

a

7812

a - Shift assist b - Shift plate

3. Install intermediate cable.

7813

4. Secure the brass barrel retainer with the cotter pin.


90-864196060 MAY 2006 Page 63 / 113

5. Secure the cable end guide with washers (one on each end of the end guide) and cotter pin.6. Locate center of remote control and control cable play (backlash).IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making thefollowing adjustment.

a. a. Shift remote control to NEUTRAL.b. Push in on control cable end with enough pressure to remove play and mark position "a"

on tube.c. Pull out on control cable end with enough pressure to remove play and mark position "b"

on tube.d. Measure distance between marks "a" and "b" and mark position "c" half-way between

marks "a" and "b."

a

c

b7815

7. Temporarily install control cable end guide into shift lever and insert anchor pin.8. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure

that backlash center mark is aligned with edge of control cable end guide.

! CAUTIONDo not attempt to install or remove control cable barrel from stud without first removing end guideanchor pin from shift lever and removing cable. Attempting to bend control cable to install orremove barrel will place undue stress on cable end guide and shift lever and damage to bothcould occur.

9. Place remote control and and sterndrive unit in FORWARD gear.10. Install the remote control shift cable.11. Place remote control handle in NEUTRAL.12. Install the shift assist assembly. Ensure that it fits over the clevis pin and barrel stud with no

resistance.


Page 64 / 113 90-864196060 MAY 2006

13. Install the fastening hardware. If shift assist assembly attaching points will not align, verifycontroller is in NEUTRAL. Remove the shift cable and reposition the adjustment barrel asrequired to allow the shift assembly to be installed with no effort.

a

b

c

e

d

7818

With shift assist assemblya - Remote control shift cableb - Shift assist assemblyc - Clevis pin (and cotter pin not shown)

d - Large ID washere - Small ID washer and cotter pin

c

7841

a gfd

e

b

hi

Without shift assist assemblya - Remote control shift cableb - Clevis pinc - Cotter pin (existing) (not shown)d - Spring (existing) (not shown)e - Washer (existing)

f - Washerg - Spacerh - Washer (existing)i - Cotter pin (existing)


90-864196060 MAY 2006 Page 65 / 113

Bravo Shift Cable Installation and AdjustmentBravo Models Shift Cable Installation

NOTE: Bravo Models Only: Using shift cable adjustment tool (91-12427), shift cables can beadjusted with or without the sterndrive installed, using the following procedure.

Shift Cable Adjustment Tool 91-12427

IMPORTANT: Sterndrive propeller rotation is determined by the shift cable installation in theremote control.• Bravo One/Two - If shift cable end guide moves in direction A when control lever is placed in

FORWARD, remote control is set up for RIGHT-HAND (RH) propeller rotation.• Bravo One/Two - If shift cable end guide moves in direction B when control lever is placed in

FORWARD, remote control is set up for LEFT-HAND (LH) propeller rotation.

A

B 21620

Arrow indicates direction of motion• Bravo Three - Front propeller on sterndrive is always LH Rotation and rear propeller is always

RH Rotation. Shift cable end guide must move in direction A, when control lever is placed inFORWARD gear position.

A

21621

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoidsharp bends and/or contact with moving parts. Do not fasten any items to shift cables.

Bravo Models Shift Cable Adjustment1. Remove the adjustment tool.

a

21611

a - Adjustment tool


Page 66 / 113 90-864196060 MAY 2006

2. Loosen the adjustable stud and move it to dimension, as shown. Retighten stud.

a

21612

b

a - Adjustable stud b - 76 mm (3 in.) (center of pivot bolt tocenter of stud)

3. Install sterndrive shift cable.4. Install cotter pin.5. Insert cotter pin from top and spread ends fully.

a

21616

b

c

a - Sterndrive shift cableb - Long cotter pin

c - Short cotter pin

6. Place adjustment tool over sterndrive shift cable, as shown. Hold tool in place using a pieceof tape over the barrel retainer.

a

21615

b

a - Adjustment tool b - Sterndrive shift cable


90-864196060 MAY 2006 Page 67 / 113

7. Locate center of remote control and control cable play (backlash).IMPORTANT: Keep center mark "C" aligned with control cable end guide edge when making thefollowing adjustment.

a. Shift remote control to NEUTRAL.b. Push in on control cable end with enough pressure to remove play and mark position "a"

on tube.c. Pull out on control cable end with enough pressure to remove play and mark position "b"

on tube.d. Measure distance between marks "a" and "b" and mark position "c" half-way between

marks "a" and "b."

a

c

b7815

8. Temporarily install control cable end guide into shift lever and insert anchor pin.9. Adjust control cable barrel so that hole in barrel centers with vertical center line of stud. Ensure

that backlash center mark is aligned with edge of control cable end guide.

! CAUTIONDo not attempt to install or remove control cable barrel from stud without first removing end guideanchor pin from shift lever and removing cable. Attempting to bend control cable to install orremove barrel will place undue stress on cable end guide and shift lever and damage to bothcould occur.

10. Remove control cable end guide from shift lever by removing clevis pin.

c d

e

ba

c d

21613

a - Control cable end guideb - Clevis pinc - Backlash center

d - Control cable barrele - Stud, washer and cotter pin

11. Install the control cable.12. Install the washer and cotter pin to secure the barrel.13. Install the clevis pin.


Page 68 / 113 90-864196060 MAY 2006

14. Install the cotter pin into the clevis pin from the top and spread the ends.15. Remove the adjustment tool.16. Shift remote control lever into FORWARD position. Place end of adjustment tool in barrel

retainer. If slot does not fit over stud, loosen shift lever stud and slide stud up or down untilslot in tool fits over stud. When adjustment is correct, retighten stud.

17. Lift the adjustment tool so that the slot is above the stud.18. Shift the remote control into REVERSE and repeat the adjustment process.

b a21614

a - RH rotation Bravo One, Two, ThreeFORWARD, LH rotation Bravo Oneand Two REVERSE slot

b - LH rotation Bravo One and TwoFORWARD, RH rotation Bravo One,Two and Three REVERSE slot

19. Remove adjustment tool.20. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180

degrees.21. Lubricate shift cable pivot points.


80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally

Shift Cable Installation For DTS SystemIMPORTANT: Do not move the shift cable stud on the shift arm.IMPORTANT: The shift cable barrel is preset and CANNOT be adjusted.1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:



c. The cable should then go up behind the power-assisted steering valve and loop over tothe shift actuator on the engine.


8995


90-864196060 MAY 2006 Page 69 / 113

NOTE: A final check of the adjustments should be made with the boat in the water and enginerunning. If this cannot be done or is not done at your manufacturing facility, arrangement shouldbe made with the dealer to do this as part of the pre-delivery inspection.2. SeaCore Models: Apply lubricant to the threads of the shift cable stud.


34 Special Lubricant 101 Shift cable stud 92-802865A1

3. Install the intermediate shift cable to the shift actuator on the engine.4. Tighten locknut until it contacts and then loosen 1/2 turn.

a

b

c

f

e

d

8996

a - Shift actuatorb - Shift cablec - Locknut

d - Shift cable stude - Shift cable barrelf - Washers

5. Insert cotter pin from top and spread ends.

a

8997

a - Cotter pin

Throttle Cable Installation and Adjustment1. Place remote control handles in NEUTRAL/IDLE position.IMPORTANT: Ensure that cable is routed to avoid sharp bends and/or contact with moving parts.Do not fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.2. Adjust cable so that it can be placed on both studs simultaneously.


Page 70 / 113 90-864196060 MAY 2006

3. Place cable over studs. Do not adjust cable after installation.4. Secure throttle cable with hardware as shown. Do not overtighten as cable must pivot freely.

Tighten until nut contacts, then loosen 1/2 turn.5. Place remote control throttle lever in the wide open throttle (WOT) position. Ensure that throttle

shutters are completely open.6. Return remote control throttle lever to idle position and ensure that throttle lever contacts idle

speed adjustment screw.

ab

c

de

g

h

i

j

f

9378

a - Cable end guideb - Throttle lever screwc - Locknut and flat washer (small)d - Throttle levere - Idle speed adjustment screw

f - Idle camg - Throttle bracketh - Cable barreli - Flat washer and locknut (large)j - Throttle cable anchor stud

Alpha Sterndrive InstallationAlpha Notice: Increased Trim-in Range Capability

The Alpha trim cylinders provide the capability for an increased trim-in range. A spacer can beremoved from the trim cylinders to increase the trim-in range by approximately 1-1/2 degrees. Thiswill improve the acceleration on some boats by forcing the bow down more quickly. If the spacersare to be removed, the boat must be water tested to ensure that the increased trim-in range doesnot cause any undesired boat handling characteristics (bow-steer, chine-walk, etc.) if thesterndrive is trimmed in while the boat is operated at higher speeds. The boat should be testedunder all conceivable load conditions and maneuvers to ensure that the additional trim-in does notpose a problem. The final decision and responsibility for use of the additional trim-in range is leftup to the boat manufacturer.

! WARNINGIt is recommended that only qualified personnel adjust the trim-in limit inserts. The boat must bewater tested after adjusting the trim-in limit inserts to ensure that the modified trim-in range doesnot cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit istrimmed in at higher speeds. Increased trim-in range may cause handling problems on someboats, which could result in personal injury.

Alpha Trim Cylinder Spacer Removal1. Disconnect "UP" trim hose from "UP" port on trim cylinder.


90-864196060 MAY 2006 Page 71 / 113

2. Disconnect "DOWN" trim hose from hydraulic connector on gimbal housing. Plug holes with22-38609 plug.

cd

ab

7843

a - "UP" hoseb - "UP" port on trim cylinder

c - "DOWN" hosed - Hydraulic connector

3. Remove front power trim cylinder mounting hardware.

bd

ac

e

4827

a - Front anchor pinb - Bushing (port and starboard) (4)c - Flat washer (port and starboard) (2)

d - E-ring (port and starboard) (2)e - Plastic caps (port and starboard) (2)

4. Remove rear power trim cylinder mounting hardware.

c ea

b da

b 7844

a - Rear anchor pinb - Bushing (port and starboard) (4)c - Flat washer (port and starboard) (2)



Page 72 / 113 90-864196060 MAY 2006

Alpha Trim Cylinder Disassembly

! WARNINGIt is recommended that only qualified personnel perform the adjustment to the trim cylinders.The boat must be water tested after removing the spacers from the trim cylinders to ensure thatthe increased trim range does not cause the boat to exhibit an undesirable boat handlingcharacteristic if the drive is trimmed in at higher speeds. The increased trim-in range may causehandling problems on some boats which could result in personal injury.

! CAUTIONEnsure work area is clean before disassembling power trim cylinders. Cylinder parts can bedamaged by dirt entering into power trim system.

! CAUTIONTrim cylinders can be damaged by improper clamping. Clamping the center section of the trimcylinder during service procedures can cause damage that could result in a loss of trim control.Clamp the trim cylinder only on the front mounting flange.

1. Remove plug previously installed, if applicable.2. Remove end cap with spanner wrench and remove piston rod assembly from cylinder.

b

a

7845

a - Piston rod assembly b - Cylinder

Trim Cylinder End Cap Tool 91-821709T


90-864196060 MAY 2006 Page 73 / 113

3. Remove bolt, washer, and spacer. Be careful not to lose check balls. Discard spacer.

acb

g

hf

ed

7846

a - Trim cylinder shock piston boltb - Spacerc - Washerd - Springs (3)

e - Spring pins (3)f - Check balls (3)g - Shock piston assemblyh - O-ring

Alpha Trim Cylinder Reassembly

! CAUTIONEnsure that work area and all components are clean before reassembling trim cylinders. Powertrim components can become damaged if dirt gets into system.

1. Apply sealant to threads of shock piston bolt.


7 Loctite 271 Threadlocker Trim cylinder bolt threads 92-809819

2. Install washer and bolt and torque.


Trim cylinder shock piston bolt 23 17

! CAUTIONTrim cylinders can be damaged by improper clamping. Clamping on the trim cylinder centersection during service procedures can cause damage that could result in a loss of some trim-inor trim-out. Clamp the trim cylinder only on the front mounting flange.

! CAUTIONPrevent trim cylinder damage caused by corrosion. Always apply Special Lubricant 101 to theend cap threads before assembly.

3. Apply lubricant to end cap threads and install piston rod assembly into cylinder.


Page 74 / 113 90-864196060 MAY 2006

4. Torque end cap using the spanner wrench.

c

b

a

7847

a - End capb - Piston rod assembly

c - Cylinder


34 Special Lubricant 101 Trim cylinder end cap 92-802865A1


Trim cylinder end cap 61 45

5. Position trim cylinder rear connecting ends.

a b

c

7848

a - Port trim cylinderb - Starboard trim cylinder

c - Connecting ends (offset as shown)

Alpha Trim Cylinder Installation1. Install trim cylinders forward mounting hardware.2. Coat area in trim cylinder between bushings with lubricant.3. Replace anchor pin and install bushings and washers.


90-864196060 MAY 2006 Page 75 / 113

4. Attach E-rings and plastic caps to end of anchor pin.

bd

ac

e

4827

a - Front anchor pinb - Bushing (port and starboard) (4)c - Flat washer (port and starboard) (2)



95 2-4-C Marine Lubricant withTeflon Trim cylinder hardware 92-802859A1

5. Install trim cylinders rear mounting hardware.6. Coat area in trim cylinder between bushings with lubricant.7. Replace anchor pin and install bushings and washers.8. Attach E-rings and plastic caps to end of anchor pin.

c ea

b da

b 7844

a - Rear anchor pinb - Bushing (port and starboard) (4)c - Flat washer (port and starboard) (2)



95 2-4-C Marine Lubricant withTeflon Trim cylinder 92-802859A1

9. Reconnect trim hoses after air bleeding power trim cylinders and hoses following proceduresoutlined in Mercury MerCruiser Service Manual 14.


Page 76 / 113 90-864196060 MAY 2006

1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nutsand flat washers.)

a

7713

b

Typicala - Dust cover b - Trim cylinder support

2. Remove gear lube monitor cap. Fill with lubricant.

5497

ba

a - - Gear lube monitor cap b - "OPERATING RANGE" line


87 High Performance GearLubricant Gear lube monitor 92-802854A1

3. Push dribble valve stem in until gear lube appears.

a

7851

a - Dribble valve stem


90-864196060 MAY 2006 Page 77 / 113

4. Once gear lube appears, release dribble valve stem.5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING

RANGE" (full) line with specified fluid. Do not overfill.


87 High Performance GearLubricant Gear lube monitor 92-802854A1

6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Donot overtighten the cap.

IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installingdrive unit or water may leak into boat.7. Ensure that rubber gasket and water passage O-ring are properly positioned in bell housing.8. Coat bell housing studs with lubricant.

a

7852

cc

b

a - Rubber gasketb - Water passage O-ring

c - Studs (6)


95 2-4-C Marine Lubricant withTeflon Bell housing studs 92-802859A1

9. Grease sterndrive U-joint O-rings, and drive shaft splines. A grease packet for this procedureis provided with the sterndrive packaging.

a

a

b

7853

a - U-joint O-rings b - Drive shaft splines


Page 78 / 113 90-864196060 MAY 2006


91 Engine Coupler Spline Grease Ujoint O-rings 92-802869A1


91 Engine Coupler Spline Grease Drive shaft splines 92-802869A1

10. Ensure U-joint bellows are clean and free of debris.

a

7854

a - U-joint bellows

11. Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore andaft. Do this by placing remote control shift lever in: FORWARD gear position for RH driveor REVERSE gear position for LH drive unit.

c

a

b

d

7855

a - Shift shaftb - Shift shaft coupler

c - Shift slided - Slot

IMPORTANT: Shift slide assembly is free to rotate on core wire. Ensure that shift slide remains inupright position and is properly engaged with shift shaft lever roller while installing drive unit.12. Engage shift shaft roller into shift shaft lever.13. Place gasket on bell housing.


90-864196060 MAY 2006 Page 79 / 113

14. Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide.

a

b

7859cc

d

a - Shift shaft leverb - Roller

c - Shift Shaft Slide Stabilizer Toold - Gasket

Shift Slide Stabilizer 91-865232

15. Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISEwhile simultaneously turning propeller shaft COUNTERCLOCKWISE.

a

7856

a - Drive unit shift shaft

IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dualengine installations. The LH rotation drive unit can be identified by the decal on the back side ofthe upper drive shaft housing, which states: "Alpha One - Counter Rotation"16. Install sterndrive unit as follows:

a. Position trim cylinder straight back (over top of acceleration plate). Be careful not toscratch acceleration plate or trim cylinders.

b. Guide U-joint shaft through gimbal bearing and into engine coupler while simultaneouslyguiding shift slide into drive shaft housing. Ensure that shift slide remains upright andengaged with bell housing shift shaft lever.

c. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align U-jointshaft splines with engine coupler splines while sliding sterndrive into bell housing.


Page 80 / 113 90-864196060 MAY 2006

IMPORTANT: If drive unit will not slide into bell housing, ensure that the shift shaft and couplersare positioned properly. Do not force drive unit into position.

a

b7857

a - Gasket b - Shift slide

d. Remove Shift Slide Stabilizer Tool and discard.e. Slide sterndrive all the way into bell housing.f. Secure sterndrive to bell housings using fasteners as shown. Torque the fasteners.

b

a

7858

a - Locknut and flat washers b - Locknut and continuity circuit washer(no flat washer at this location)


Sterndrive unit fasteners 68 50

17. Return remote control shift lever to the NEUTRAL position.TRIM CYLINDER INSTALLATION

1. Install trim cylinders on aft end of sterndrive unit with hardware as shown.


90-864196060 MAY 2006 Page 81 / 113

2. Install the plastic caps by snapping in place.NOTE: Upon installation of hardware applylubricant to all components except plastic caps.

a

b

b

a

c d e

7849

a - Aft anchor pinb - Bushingsc - Flat washers

d - E-ring clipse - Plastic caps



3. Position the sterndrive unit serial number decal.

Speedometer Connection - Alpha Models1. Raise drive to gain access to area between gimbal housing and sterndrive, immediately above

the transom end of the anti-ventilation plate.2. Align plastic slots on male and female portions and insert.3. Push down to secure.

a

b

4803

a - Male end of speedometer tube fitting b - Female end of speedometer tubefitting


Page 82 / 113 90-864196060 MAY 2006

Ensure that the speedometer tube is secured and out of the way of moving parts.

a

b

8029

a - Male end of speedometer tube fitting b - Female end of speedometer tubefitting

Bravo InstallationEngine Alignment Check

The engine alignment tool must slide in and out of the engine coupler and the gimbal bearing withlittle or no friction.

! CAUTIONDamage to engine and sterndrive can result from improper engine alignment. Align your engineas specified in the Mercury MerCruiser Installation Manual for your engine package.

! CAUTIONDo not use an alignment tool from another manufacturer. Alignment tools other than QuicksilverAlignment Tool may cause improper alignment and damage to gimbal bearing and/or enginecoupler.

1. Check the engine alignment as follows.a. Insert the solid end of the alignment tool through the gimbal bearing and into the engine

coupler splines.

a21671

a - Alignment tool



90-864196060 MAY 2006 Page 83 / 113

b. Hit the sides of the alignment tool with a synthane hammer at 90 degree increments tohelp align the gimbal bearing to the coupler as shown in the following steps:

ad

cb

4889

a - Alignment toolb - Gimbal bearing

c - Engine couplerd - 90 degree increments

c. Hit the alignment tool upward and downward.

a

b

a

b

21672

a - Synthane hammer b - Alignment tool

d. Hit the alignment tool on the port side and on the starboard side.

a ba

b21673

a - Synthane hammer b - Alignment tool

e. Pull the tool out and insert it through the gimbal bearing and into the engine couplersplines.

f. If the alignment tool does not fit, or is very tight, remove the tool.


Page 84 / 113 90-864196060 MAY 2006

NOTE: Apply grease to the alignment tool before checking alignment. When the tool is removedthe tool is wiped clean on the tight side. This can help determine where the engine adjustment isneeded.

• Adjust the engine mounts as necessary: Refer to the appropriate MercuryMerCruiser Engine Service Manual.

• Perform the Engine Alignment Check.g. The engine alignment is good when the alignment tool can slide in and out of the engine

coupler and the gimbal bearing with little or no friction.IMPORTANT: Engine alignment tool must slide in and out of the engine coupler and the gimbalbearing with little or no friction.

4781a

b

c

a - Alignment toolb - Gimbal housing

c - Gimbal bearing

Bravo Sterndrive Installation1. If applicable, remove trim cylinder support and dust cover from bell housing studs. (Retain

elastic stop nuts and flat washers.)

8993

b

a

Typicala - Dust cover b - Trim cylinder support


90-864196060 MAY 2006 Page 85 / 113

2. Remove gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE".

5497

ba

Gear lube monitora - Gear lube monitor cap b - "OPERATING RANGE" line


87 High Performance GearLubricant Gear Lube Monitor 92-802854A1

3. To purge air from the system, push in on the dribble valve stem until the new gear lube appears.

a

21440

a - Dribble Valve

4. Release the dribble valve.


Page 86 / 113 90-864196060 MAY 2006

5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATINGRANGE" (full) line with specified fluid. Do not overfill.

19947

b

a

c

Gear lube monitora - Gear lube level at the "ADD" markb - Gear lube level at the "OPERATING

RANGE"

c - Cap



6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Donot overtighten the cap.

a

19962

a - Gear lube monitor cap

7. Coat the O-rings on the sterndrive U-joint with lubricant

a a21441

a - O-rings


90-864196060 MAY 2006 Page 87 / 113

8. Coat the splines on the sterndrive U-joint with lubricant.

a21442

a - Splines


91 Engine Coupler Spline Grease U-joint O-rings 92-802869A1

91 Engine Coupler Spline Grease Driveshaft splines 92-802869A1

9. Ensure that the U-joint bellows are clean and free of debris.

a b

21456

Bell housing of the transom assemblya - U-joint bellows edge b - U-joint bellows

10. Lubricate the bell housing studs.

a

b

a

21457

a - Bell Housing Studs (6) b - Tube of lubricant


95 2-4-C Marine Lubricant withTeflon Bell housing studs 92-802859A1


Page 88 / 113 90-864196060 MAY 2006

11. Lubricate the shift linkage O-ring.

21678

a

a - Shift linkage O-ring


95 2-4-C with Teflon O-ring 92-802859A1

12. Lubricate the water passage seal.

21679a

a - Water passage seal


95 2-4-C Marine Lubricant withTeflon Water passage seals 92-802859A1


90-864196060 MAY 2006 Page 89 / 113

13. Pull out the shift linkage as far as it moves. Jaws will open.

a

b

c

c

531121471

a

a - Shift linkage assemblyb - Jaws open

c - Underside of lower lip

IMPORTANT: As the sterndrive is inserted into the entry of the bell housing, the shift cable mustbe closely checked to ensure that it enters the jaws of the shift linkage assembly of the sterndrive.14. Place remote control in NEUTRAL position.NOTE: As bell housing shift cable enters the shift linkage assembly, it pushes the assembly backinto the sterndrive housing, and the jaw closes, securing the cable, as shown in steps "A", "B" and"C."

A

B

C 5312

IMPORTANT: If bell housing shift cable does not line up to properly enter jaws of shift linkageassembly, use your hand to guide the cable into place while installing the sterndrive.15. Place driveshaft housing in position on bell housing and install sterndrive, as follows:


Page 90 / 113 90-864196060 MAY 2006

a. Remove the nuts from the trim cylinders.

21521

a bc

de

a - Socketb - Wrenchc - Anchor pin

d - Ground wirese - Trim cylinders

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

a b

cd 21518

a - Universal jointb - Bell housing

c - Shift linkaged - Shift cable

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

a b c

21519

a - Shift cableb - Shift linkage jaws open

c - Shift linkage jaws engage the shiftcable


90-864196060 MAY 2006 Page 91 / 113

d. If necessary, rotate the propeller shaft COUNTERCLOCKWISE slightly (using apropeller) to align U-joint shaft splines with splines in engine coupling, then slidesterndrive all the way into bell housing.

b

ca

21520

a - Bell housing studsb - Dribble valve

c - Shift cable

16. Secure sterndrive to bell housing with 5 flat washers and 6 locknuts. Start from the center andtorque the nuts.

c

ba

21680

a - Locknut (6) flat washers (5)b - Ground plate (washer not used here)

c - Torque wrench


Sterndrive fasteners 68 50

TRIM CYLINDER INSTALLATION1. Install the mounting hardware of the trim cylinder forward as shown2. Lubricate anchor pin threads to prevent threads from galling.


Page 92 / 113 90-864196060 MAY 2006

3. Hand thread locknuts onto the pin. Do not tighten at this time.

a b c d e e f g h

14326

Fronta - Anchor pinb - Retainer clip groovec - Flat washer (large I.D.)d - Retainer clip

e - Bushingf - Flat washer (small I.D.)g - Locknuth - Plastic cap


95 2-4-C Marine Lubricant withTeflon Anchor pin threads 92-802859A1

IMPORTANT: On Bravo One, Two, and Three Models the trim-in limit insert must be properlypositioned before installing the trim cylinder anchor pin in the following steps.NOTE: Ensure that the trim-in limit insert is reinstalled in the same position as before removal ofthe sterndrive. If you are not sure of the original position, contact the boat manufacturer for theirrecommendation. Refer to Special Information at the front of this section before reinstalling thetrim-in limit insert.

b

14571

a

a - Trim-in limit insert Bravo One andTwo (positioned forward)

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

4. Install the mounting hardware of the trim cylinder aft as shown.5. Lubricate anchor pin threads to prevent the threads from galling.6. Hand-thread locknuts onto the anchor pin.


90-864196060 MAY 2006 Page 93 / 113

IMPORTANT: The position of the trim-in limit insert on the Bravo Three sterndrive should only bechanged after the boat has been properly tested. Contact the boat manufacturer if you are notsure of the original position for a particular boat application.

a

c f

edcc b

9295

a - Aft anchor pinb - Larger flat washers (2)c - Bushings (4)

d - Small ID flat washers (2)e - Locknuts (2)f - Plastic caps (2)



7. Tighten the locknuts until the washer and locknut contact the shoulder on the anchor pin.8. Install plastic caps and tighten hand-tight only.NOTE: Upon installation of hardware apply lubricant to all components except plastic caps.

a

b ab

c

21677

a - Socket and toolb - Wrench tool

c - Plastic cap (4)

Speedometer Connections - Bravo Models1. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately

atop the transom end of the anti-ventilation plate.


Page 94 / 113 90-864196060 MAY 2006

2. Insert speedometer tube fitting into opening on topside of anti-ventilation plate, in positionshown.

a

5319

b

a - Tube fitting b - Opening

3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.

a

5320

a - Fitting installed (handle pointing forward)

Bravo Sterndrive Shift Check (Engine Running)

! WARNINGContact with moving sterndrive components and the propeller can cause personal injury ordeath. To avoid possible injury , remove the propeller and ensure that no people or animals arein the area of the sterndrive.

This test requires sufficient water supply to your engine and sterndrive.1. Check sterndrive for proper gear shift with boat out of water.


90-864196060 MAY 2006 Page 95 / 113

2. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/IN position. Do not allow the sterndrive skeg to contact the ground.

4805

b

a

Typical single handle remote control showna - Drive trim switch b - Drive trailer button

3. Connect a garden water hose between flushing attachment and water source.




4. Partially open water source until water continuously leaks out around the flushing device.

! CAUTIONOverheating from insufficient cooling water will cause engine and drive system damage. Ensurethat there is sufficient water always available at water inlet holes during operation.

IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and usinga through the hull water inlet need a supply of cooling water available to both the sterndrive andto the engine during operation.5. Place remote control handle in NEUTRAL, idle speed position and start engine.

! CAUTIONEngine overheating can cause engine damage. To avoid, observe the water temperature gaugeand ensure that the engine is operating in the normal range.

! CAUTIONSterndrive not shifting properly can cause engine and sterndrive damage. Contact yourauthorized Mercury MerCruiser dealer for proper adjustment.

NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and outof each gear FORWARD, NEUTRAL, and REVERSE, at idle speed position.NOTE: The operator at the remote control handle should feel a slight detent before and after eachgear. FORWARD-detent-NEUTRAL-detent-REVERSEIMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttleis engaged. Consult your authorized Mercury MerCruiser dealer/representative for properadjustment.6. Move the remote control handle to FORWARD, idle speed position.7. Check that the sterndrive propeller shaft is turning in the FORWARD direction.8. Shift the remote control handle to NEUTRAL, idle speed position.


Page 96 / 113 90-864196060 MAY 2006

9. Check that the sterndrive propeller shaft is not turning.10. Shift the remote control handle to REVERSE, idle speed position.11. Check that the sterndrive propeller shaft is turning in the REVERSE direction.12. If the sterndrive will not shift:

a. Remove the sterndrive and check for proper shift hook ups.b. Check that the shift cables are connected

IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to shift cables.

Troubleshooting Shift ProblemsNOTE: The following information is provided to assist an installer in troubleshooting if hard shiftingor chucking/racheting is encountered when shifting into FORWARD gear.1. When installing the control box in the side panel of the boat, ensure that the cables have

enough clearance to operate. This is necessary because the cables move up and down whenthe shift handle is moved. If the control box is mounted too far back toward any fiberglassstructure, the cables will be interfered with; this will cause very hard shifting.

NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.

7873

Proper cable bend

7872

Improper cable bend2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull,

it does not have any extremely sharp bends in it as this will cause stiff shifting.IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends ontoo-short cables result in kinks and too-long cables require unnecessary bends or loops. Bothconditions place extra stress on the cables.IMPORTANT: Shift cable/throttle cable lubrication points use 2-4-C with Teflon.


90-864196060 MAY 2006 Page 97 / 113

3. Before installing the shift cable into the control box, extend the stainless rod eye end of thecable and lubricate it. Move it back and forth to allow even distribution of the lubricant.

b

c

d

a

7874

a - Remote control endb - Engine end

c - Adjusting barreld - Lubricating point


95 2-4-C Marine Lubricant withTeflon Shift cable end 92-802859A1

NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GENII Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.) thickness.Cable radius at any one point must not be less than 305 mm (12 in.).

4000 GEN II Series Panel Mount Remote Control


Mounting surface maximum thickness 25 mm (1 in.)

Minimum cable bend radius at any point 305 mm (12 in.)

4. Do not strap or clamp the control cables to any other cables or rigid structure within91.4 cm (3 ft) of the control box.

5. Ensure that the cable is not permanently kinked.6. Ensure that there is proper clearance for cable movement when the control box is installed in

the side panel. The cables must have room to move up and down when the control handle isshifted into either FORWARD or REVERSE.

7. Ensure that the engine was not set down on the intermediate shift cable during installation,as this will crush the inner cable tubing and cause improper and / or stiff shifting.

8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of theshift plate.

9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within1.5 m (5 ft) of the shift plate.

10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cableend must be free to rotate on the mounting stud.

NOTE: Lubricate attaching points with engine oil.

Description Where Used Part Number

SAE 30W Engine Oil Shift cable pivot points Obtain Locally

11. Check the intermediate shift cable routing from the transom assembly to the shift plate asfollows:


Page 98 / 113 90-864196060 MAY 2006

NOTE: Cable route is the same for through transom and through prop exhaust.a. The cable should come through the transom, above the exhaust pipe and make a turn

toward the starboard side of the boat between the exhaust pipe and the engine flywheelhousing.


c. The cable should then go up behind the power steering valve and loop over to the shiftplate on the engine, where it is connected to the anchor points on the shift plate.

Following this routing will prevent the engine coupler from damaging the cable.

8995

Through prop exhaust shown

NOTE: NOTE: A final check of the adjustments should be made with the boat in the water andengine running. If this cannot be done or is not done at your manufacturing facility, arrangementshould be made with the dealer to do this as part of the pre-delivery inspection12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.Refer to 90-865523 Instruction Sheet for more information.

Bravo Trim Limit Switch Adjustment - Analog Gauges

! WARNINGWhen adjusting trim limit switch, use extreme care that the engine is not started and keep clearof the area near the propeller. Use care to prevent placing hands in an area where injury couldoccur because of drive unit movement.

! CAUTIONTrim limit switch MUST BE adjusted exactly as outlined. If switch is adjusted incorrectly, driveunit could move out beyond the gimbal ring support flanges and cause damage to sterndriveunit.

IMPORTANT: All Bravo models must have the trim-in-limit insert positioned properly beforeperforming the trim position sender adjustment.


90-864196060 MAY 2006 Page 99 / 113

1. Ensure that the trim-in-limit insert is positioned as shown for the appropriate Bravo model.

a

8548

a

8557

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

2. Bravo sterndrive, adjust trim limit switch as follows:a. Loosen screws and turn trim limit switch clockwise to end of slots.

16524

a

Trim limit switcha - Screws

b. Ensure drive unit is in the full DOWN/IN position.c. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE

TRAILER BUTTON.


Page 100 / 113 90-864196060 MAY 2006

d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimensionshown.

21675

a

Trim limit switcha - Rotate Counterclockwise To Adjust

a8558

Bravo trim cylinder extendeda - Trim Limit Dimension 21-3/4 in. (552 mm)

e. Retighten screws when adjustment is correct.

Trim Position Sender Adjustment - Analog Gauges1. Loosen both trim position sender retaining screws.

21676

a

b

a - Retaining screws b - Trim position sender

! CAUTIONDo not start engine in the following step or damage to sterndrive unit and engine could resultfrom lack of cooling water.

2. Turn ignition key to RUN position.3. Trim sterndrive unit to the full DOWN/IN position.


90-864196060 MAY 2006 Page 101 / 113

4. Rotate trim position sender as required to show full DOWN/IN position on dashboardinstrument as shown.

a7883

a - Trim gauge needle

5. Tighten retaining screws and turn ignition key to the OFF position.

21674

a

b


Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method

a

b

21076

a - Trim position sender b - Retaining screws

1. Trim the sterndrive unit to the full DOWN/IN position.2. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool.


Page 102 / 113 90-864196060 MAY 2006

3. Turn ignition key switch to the RUN position.4. Set the scan tool to display TRIM POS counts and note the value displayed.5. TRIM POS counts must be between 20 and 24 counts.6. If TRIM POS counts are within specified range, proceed to step 6. Otherwise:

a. Loosen both trim position sender retaining screws.b. Rotate the trim position sender until TRIM POS counts are within the specified range,

preferably near the middle of the range.c. Tighten the trim position sender retaining screws.d. Verify TRIM POS counts are still within the specified range. Repeat steps "a" through

"c" if necessary.7. Turn the ignition key switch to the OFF position, disconnect the scan tool from the Diagnostic

Link connector, and install the weather cap in the Diagnostic Link connector.

Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method

a

b

21076


1. Trim the sterndrive unit to the full DOWN/IN position.2. Disconnect trim position sender wires from engine wiring harness connections.3. Connect Multimeter leads to trim position sender wires and set Multimeter to display resistance

(Ohms).4. Note resistance reading. Resistance must be between 16 and 20 Ohms.5. If resistance reading is within specified range, proceed to step 6. Otherwise:

a. Loosen both trim position sender retaining screws.b. Rotate the trim position sender until resistance reading is within the specified range,

preferably near the middle of the range.c. Tighten the trim position sender retaining screws.d. Verify resistance reading is still within the specified range. Repeat steps "a" through "c"

if necessary.6. Disconnect the trim position sender wires from the multimeter leads and reconnect trim

position sender wires to engine wiring harness connections.7. Refer to Mercury SmartCraft Operator's Manual for final Trim Calibration procedure.


90-864196060 MAY 2006 Page 103 / 113

Bravo Sterndrive Propeller Installation

! WARNINGEnsure that remote control is in NEUTRAL position and ignition key is removed from switch priorto installing propeller.

! WARNINGPlace a block of wood between the anti-ventilation plate and propeller to protect hands frompropeller blades and to prevent propeller from turning when tightening propeller nut.

a

b

c

4826

a - Wood blockb - Propeller

c - Propeller nut under socket

BRAVO ONE MODELSIMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the directionof rotation of the propeller shaft.1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.


34 Special Lubricant 101 Propeller shaft splines 92-802865A1

95 2-4-C Marine Lubricant withTeflon Propeller shaft splines 92-802859A1


NOTE: Anti-corrosion grease is for salt water applications only.2. Install the propeller with the attaching hardware as shown.


Page 104 / 113 90-864196060 MAY 2006

3. Torque the propeller nut.

ab c

d

e f

g 5301

Typical Bravo One modelsa - Propeller shaft splinesb - Forward thrust hubc - Flo-Torque II drive hubd - Propeller

e - Drive sleeve adapterf - Tab washerg - Propeller nut

ab

c

d ef g

19816

Bravo One XR modelsa - Propeller shaftb - Propeller hub insert with snubbersc - Propellerd - Thick washer

e - Washerf - Washerg - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.NOTE: Some special use Bravo One props utilizing the centering bushing require different torquevalues. Refer to the literature supplied with the prop to verify the proper prop nut torque.


Bravo One propeller nut75 55

Then align tabs with grooves

NOTE: Bravo One XR models do not use the tab washer.4. Models equipped with the tab washer: Continue to tighten the propeller nut until the 3 tabs

on the tab washer align with the grooves on the spline washer.


90-864196060 MAY 2006 Page 105 / 113

5. Bend the 3 tabs down into the grooves.

e

c

d

ba

4750

a - Propb - Tab washerc - Drive sleeve adapter

d - Tab bent downe - Propeller nut

BRAVO TWO MODELSIMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the directionof rotation of the propeller shaft.1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.





NOTE: Anti-corrosion grease is for salt water applications only.2. Install the propeller with the attaching hardware as shown.3. Torque the propeller nut.

8566

ab

c

fd

eBravo Two

a - Propeller shaft splinesb - Forward thrust hubc - Propeller

d - Spline washere - Tab washerf - Propeller nut

NOTE: The propeller torque stated is a minimum torque value.


Page 106 / 113 90-864196060 MAY 2006


Bravo Two propeller nut81 60

Then align tabs with groves

4. Continue to tighten the propeller nut until the 3 tabs on the tab washer align with the grooveson the spline washer.


e

c

d

ba

4750



BRAVO THREE1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.





NOTE: Anti-corrosion grease is for salt water applications only.2. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.3. Align splines and place front propeller on propeller shaft.4. Install front propeller locknut and torque using the Propeller Nut Tool.



Bravo Three front propeller nut 136 100

5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub6. Align splines and install aft propeller.7. Install propeller nut and torque.NOTE: The propeller torque stated is a minimum torque value.


Bravo Three rear propeller nut 81 60


90-864196060 MAY 2006 Page 107 / 113

8. Install propeller shaft anode and screw and torque.

ef

a

bc d

5304

g h

i j

Bravo Threea - Rear propeller nutb - Rear propellerc - Rear propeller thrust hubd - Front propeller nute - Front propeller

f - Front propeller thrust hubg - Propeller shaft anode screwh - Flat washeri - Star washerj - Propeller shaft anode


Propeller shaft anode screw 19 168




a

b

c

4826

a - Wood blockb - Propeller

c - Propeller nut under socket

BRAVO ONE MODELSIMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the directionof rotation of the propeller shaft.


Page 108 / 113 90-864196060 MAY 2006

1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.






ab c

d

e f

g 5301

Typical Bravo One modelsa - Propeller shaft splinesb - Forward thrust hubc - Flo-Torque II drive hubd - Propeller


ab

c

d ef g

19816

Bravo One XR modelsa - Propeller shaftb - Propeller hub insert with snubbersc - Propellerd - Thick washer

e - Washerf - Washerg - Propeller nut






90-864196060 MAY 2006 Page 109 / 113

NOTE: Bravo One XR models do not use the tab washer.4. Models equipped with the tab washer: Continue to tighten the propeller nut until the 3 tabs

on the tab washer align with the grooves on the spline washer.5. Bend the 3 tabs down into the grooves.

e

c

d

ba

4750



BRAVO TWO MODELSIMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the directionof rotation of the propeller shaft.1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.






8566

ab

c

fd

eBravo Two





Page 110 / 113 90-864196060 MAY 2006



Then align tabs with groves

4. Continue to tighten the propeller nut until the 3 tabs on the tab washer align with the grooveson the spline washer.


e

c

d

ba

4750



BRAVO THREE1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.





NOTE: Anti-corrosion grease is for salt water applications only.2. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.3. Align splines and place front propeller on propeller shaft.4. Install front propeller locknut and torque using the Propeller Nut Tool.



Bravo Three front propeller nut 136 100

5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub6. Align splines and install aft propeller.7. Install propeller nut and torque.NOTE: The propeller torque stated is a minimum torque value.


Bravo Three rear propeller nut 81 60


90-864196060 MAY 2006 Page 111 / 113

8. Install propeller shaft anode and screw and torque.

ef

a

bc d

5304

g h

i j





DTS System InstallationRefer to DTS System Installation section 7 - Electrical System

Shift Cable Installation For DTS SystemIMPORTANT: Do not move the shift cable stud on the shift arm.IMPORTANT: The shift cable barrel is preset and CANNOT be adjusted.1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:



c. The cable should then go up behind the power steering valve and loop over to the shiftactuator on the engine.


Page 112 / 113 90-864196060 MAY 2006


8995

NOTE: A final check of the adjustments should be made with the boat in the water and enginerunning. If this cannot be done or is not done at your manufacturing facility, arrangement shouldbe made with the dealer to do this as part of the pre-delivery inspection.2. Install the intermediate shift cable to the shift actuator on the engine.3. Tighten locknut until it contacts and then loosen 1/2 turn.

a

b

c

f

e

d

8996

a - Shift actuatorb - Shift cablec - Locknut

d - Shift cable stude - Shift cable barrelf - Washers


90-864196060 MAY 2006 Page 113 / 113

4. Insert cotter pin from top and spread ends.

a

8997

a - Cotter pin


NOTES:

Page 114 / 113 90-864196060 MAY 2006

SECTION - 7 STARTING AND ELECTRICAL

90-864196060 MAY 2006 Page 1 / 43

SECTION 7 - STARTING AND ELECTRICALTable of ContentsGeneral Information................................................................................................................................................. 3

Information and Checklist—Installation Using 14-Pin Connection....................................................................3Power Trim Electrical Connection.....................................................................................................................3

Batteries.................................................................................................................................................................. 4Battery Specifications........................................................................................................................................4Battery Cables...................................................................................................................................................4Multiple MPI Engine Battery Information...........................................................................................................5Electrical System Precautions...........................................................................................................................5

DTS System Installation.......................................................................................................................................... 6SC5000 Data Cable ......................................................................................................................................... 6Data Cable Routing - New Installations ........................................................................................................... 6

Wiring Diagrams...................................................................................................................................................... 7Wire Color Code Abbreviations.........................................................................................................................714 Pin Engine Harness - Boat Harness - Single Engine - Single Station..........................................................714 Pin Engine - Analog Gauge Harness...........................................................................................................9Non-DTS Single Station Instrumentation Installation - Typical........................................................................10Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly).................11Power Trim System.........................................................................................................................................13MerCathode System .......................................................................................................................................14ECM 555 MPI System Engine Wiring Diagrams.............................................................................................15

CAN, Fuel Level, Paddle Wheel and Temperature Circuit ...................................................................... 15Typical DTS Control System...........................................................................................................................16

Panel mount ERC and Smartcraft instrumentation .................................................................................. 1614 Pin Engine Harness Connector..................................................................................................................164.3L MPI Engine Wiring Diagram with 14 Pin.................................................................................................185.0L and 5.7L MCM Alpha Engine Wiring Diagrams with 14 Pin....................................................................205.0L and 5.7L MCM Bravo Engine Wiring Diagrams with 14 Pin....................................................................22

DTS Installation..................................................................................................................................................... 23Special Tools - DTS Installation......................................................................................................................23Installation Guidelines for DTS System Components.....................................................................................23

Data Harness ........................................................................................................................................... 23Connectors .............................................................................................................................................. 24

Weather Caps.................................................................................................................................................24Battery Harness Information and Installation........................................................................................................ 24

DTS Battery Specifications..............................................................................................................................24Data Harness Pulling Procedure........................................................................................................................... 25Connecting 14 Pin Data Harness - Single Engine................................................................................................. 26

Single Helm .................................................................................................................................................... 26Dual Helm ....................................................................................................................................................... 26

Connecting 14 Pin Data Harness - Dual Engine................................................................................................... 27Single Helm .................................................................................................................................................... 27Dual Helm ....................................................................................................................................................... 27

Installing DTS Command Module and Harness - Single Engine........................................................................... 28Harness Installation ........................................................................................................................................ 28Module Installation ......................................................................................................................................... 29

Installing DTS Command Module and Harness - Dual Engine............................................................................. 30Harness Installation ........................................................................................................................................ 30Module Installation ......................................................................................................................................... 32

Junction Box (If Equipped).................................................................................................................................... 33Analog Gauge Interface (AGI)............................................................................................................................... 34

Analog Gauge Interface (AGI) Installation.......................................................................................................34Typical AGI Application with System View .............................................................................................. 35

7

STARTING AND ELECTRICAL SECTION - 7

Page 2 / 43 90-864196060 MAY 2006

Configuring Analog/Digital Tachometer Signal through PCM.........................................................................35PCM Configuration with DDT ................................................................................................................... 36PCM Configuration with CDS .................................................................................................................. 36

Typical 14 Pin DTS Wiring Diagrams.................................................................................................................... 37DTS Panel Control Wiring...............................................................................................................................37DTS Single Console Control Wiring................................................................................................................38DTS Single Console Control Wiring with Dual Helm.......................................................................................39DTS Dual Console Control Wiring...................................................................................................................40DTS Dual Console Control Wiring with Dual Helm..........................................................................................41DTS Zero Effort Control Wiring - Single Engine..............................................................................................42DTS Zero Effort Control Wiring - Dual Engine ................................................................................................43


90-864196060 MAY 2006 Page 3 / 43

Special ToolsData Cable Puller 91-888462A1

4618

Attaches to end of DTS data harness to aid in pulling harnessthrough boat. Prevents damage to DTS data harness.

General Information• Fuel injected MerCruiser engine models are "SmartCraft" ready and may be rigged using the

SmartCraft instrumentation, analog instrumentation, or a combination of both.• The SmartCraft data is carried in the 14 pin system without the use of a special data harness.• Adapters have been made to adapt a 14 pin connector engine to a 10 pin connector boat and

from a 14 pin boat to a 10 pin engine.• If an adapter is used the accessory current through the boat harness is limited to 15 amps

even if the boat has a 10 pin harness that in the past has been capable of handling largeraccessory loads.

• SmartCraft data is not supported across the adapters so a separate CAN line will be neededon a boat using SmartCraft instrumentation and an adapter harness.

Information and Checklist—Installation Using 14-Pin ConnectionRefer to Mercury Precision Parts and Accessories Guide or OEM Rigging and Accessories Guidefor part number information1. Ensure that the 14 pin boat harness is the correct length to properly route from the boat dash

to the locking 14 pin electrical connector on the engine.2. An analog gauge dash harness or a SmartCraft junction box plugs into the 14 pin boat harness3. If SmartCraft instruments and analog instruments are desired on the same boat, An Analog

Gauge Interface (AGI) Adapter needs to be used to power the analog gauges.4. A key switch assembly plugs into the 14 pin boat harness (both 3position and 4 position

available)5. Select a remote control assembly

a. The remote control must be compatible with MerCruiser applicationsb. A remote control can have a lanyard stop switch and will connect directly to the boat

harness or a separate stop switch can be installed and connected to the boat harnessc. A power trim switch can be part of the remote control or a separate dash mounted power

trim switch can be installed.6. A separate harness is required to connect the control or dash mounted power trim switch to

the power trim pump. (Do not use the connector in the 14 pin boat harness labeled power trim.This connection is for outboard only)

7. Up to 15 amps of accessory power can be supplied through the 14 pin wiring harness. Anaccessory kit is available to provide accessory power up to 40 amps.

Power Trim Electrical ConnectionNOTE: ABYC (American Boat and Yacht Council) installation recommends installing a batteryswitch in the positive conductor of any battery or battery bank with CCA rating greater than 800amperes. (See ABYC for additional information)ABYC further recommends: if a boat is equipped with a battery switch, the power trim pump maynot be connected to the continuously energized circuit (battery). It must be connected to theswitched side of the battery switch. Wire length requirements and location of circuit protection arealso specified.MerCruiser has developed three methods to facilitate compliance with ABYC recommendations.These come in the form of one standard production and two accessory kits.


Page 4 / 43 90-864196060 MAY 2006

1. Installations with the batteries (or battery banks) rated at less than or equal to 800 ColdCranking Amps (CCA) and without battery switches: The trim pump may be installed usingthe wires supplied with the power trim pump and should be connected directly to the battery.

2. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a batteryswitch) or any boat with a battery switch: The red current conductor (for the trim pump) mustbe:a. Connected to the switched side of the battery switch and either:

i. provided with circuit protection within 7 inches of the power source orii. Provided with circuit protection within 40 inches of the point of connection with the

power source, sheathed the entire length of wire from the point of connection to thesource and the circuit protection device.

This will require the use of an accessory kit.




BatteriesBattery Specifications

IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guardregulations must be adhered to when installing the battery. Ensure that battery cable installationmeets the pull test requirements and that positive battery terminal is properly insulated inaccordance with regulations.IMPORTANT: It is recommended (required in some states) that the battery be installed in anenclosed case. Refer to regulations for your area.IMPORTANT: Engine electrical system is negative (-) ground.Select a battery that meets all of the following specifications:• 12-volt marine type.• Tapered post connectors or side terminal connectors.IMPORTANT: Do not use a battery with wing nut connectors.IMPORTANT: Battery cables should always be tightened with a wrench• Battery capacity rating of at least:

Model Minimum required cranking battery size

V6 and V8 MPI models 750 cca, 950 mca, 180 Ah

V8 DTS models 800 cca, 1000 mca, 180 Ah

Battery CablesSelect proper size positive (+) and negative (-) battery cables. Using the following chart, batteryshould be located as close to engine as possible.• Add the positive (+) and negative (-) battery cable lengths together.• Divide by 2 to obtain the average cable length.IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Useelectrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion anda subsequent failure.


90-864196060 MAY 2006 Page 5 / 43

Cable Length Cable Gauge

Less than or equal to 1.1m (3.5 ft.) 25 mm2 (4)

1.1 - 1.8m (3.5 - 6 ft.) 35 mm2 (2)

1.8 - 2.3m (6 - 7.5 ft.) 50mm2 (1)

2.3 - 2.9m (7.5 - 9.5 ft.) 50mm2 (0)

2.9 - 3.7m (9.5 - 12 ft.) 70mm2 (00)

3.7 - 4.6m (12 - 15 ft.) 95mm2 (000)

4.6 - 5.8m (15 - 19 ft.) 120mm2 (0000)

Both positive (+) and negative (-) cables

Multiple MPI Engine Battery InformationBatteries: Boats with multi-engine MPI power packages require each engine be connected to itsown battery. This ensures that the engine's Electronic Control Module (ECM) has a stable voltagesource.Battery switches: Battery switches should always be positioned so each engine is operating offits 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 poweringaccessories in the boat. They should not be used to charge the battery of another engine in theboat unless the type of isolator is specifically designed for this purpose.NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.1. The boat may have 2 engines connected to a single Model 32023A battery isolator.2. The Model 32023A battery isolator is connected to 2 banks of batteries.3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.4. The second battery in each bank is connected in parallel to the cranking battery.5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2 charging

sources, 120 amps (maximum alternator output).6. When the engines are operating, either engine's alternator could be charging either bank of

batteries through the Model 32023A battery isolator.Any other manufacturer's battery isolator that is the same type as the Sure Power Inc., Model32023A could also be used.Generators: The generator's battery should be considered another engine's battery.

Electrical System PrecautionsThe following precautions apply to all engines:

! CAUTIONAvoid damage to the electrical system, and components. Refer to the following precautions whenworking on or around the electrical harness or when adding other electrical accessories:• Do not tap accessories into engine harness.• Do not puncture wires for testing (probing).• Do not reverse battery leads.• Do not splice wires into harness.• Do not attempt diagnostics without proper, approved Service Tools.

Battery isolators: Isolators can be used to charge an auxiliary battery used for poweringaccessories in the boat. They should not be used to charge the battery of another engine in theboat unless the type of isolator is specifically designed for this purpose.NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.


Page 6 / 43 90-864196060 MAY 2006

• The boat may have 2 engines connected to a single Model 32023A battery isolator.• The Model 32023A battery isolator is connected to the 2 banks of batteries.• Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.• The second battery in each bank is connected in parallel to the cranking battery• The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2 charging

sources, 120 amps (maximum alternator output)• When the engines are operating, either engine’s alternator could be charging either bank of

batteries through the Model 32023A battery isolator.Any other manufacturer’s battery isolator that is the same type as the Sure Power Inc., Model32023A could also be used.Generators: The generator’s battery should be considered another engine’s battery.

DTS System Installation! WARNING

To avoid the possibility of serious injury or death from loss of boat control, do not splice or probeinto any wire insulation of the DTS system. Splicing or probing will damage the wire insulationallowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttleand shift control.

SC5000 Data Cable

! WARNINGTo avoid the possibility of serious injury or death from loss of boat control, do not pull on cableconnectors when pulling cable into boat. Observe correct pulling procedure. Pulling onconnectors can loosen terminals resulting in open or poor electrical connections. Open or poorelectrical connections may result in loss of throttle and shift control.

IMPORTANT: Do not route cable near engine ignition components (coils, spark plug leads, andspark plugs). An electrical field generated from these components could cause a problem withdata transmission.IMPORTANT: Do not route cables near sharp edges, hot surfaces or moving parts. Fasten cablesaway from any sharp edge, fastener or object that could wear into the cable.IMPORTANT: Avoid sharp bends in the cable. Minimum bend radius MUST be 3 inches.

Data Cable Routing - New Installations1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs.2. Route the cable.

7943

3. Fasten the cable to the boat with tie straps or clips.


90-864196060 MAY 2006 Page 7 / 43

Wiring DiagramsWire Color Code Abbreviations

Wire Color Abbreviations

BLK Black

BLU Blue

BRN Brown GRY Gray

GRN Green ORN or ORG Orange

PNK Pink PPL or PUR Purple

RED Red TAN Tan

WHT White YEL Yellow

LT or LIT Light DK or DRK Dark

14 Pin Engine Harness - Boat Harness - Single Engine - Single StationNOTE: Dual engines are treated as 2 singles in the same boat and are not connected together.

12340

1

7

8

1011

9

2

3

4

56

1 - 14 pin Duetsch connector2 - Key switch connector3 - Trim switch (outboard only)4 - Neutral switch5 - Lanyard switch (sterndrive) or key

switch + connection6 - Lanyard (outboard) or E Stop

connection

7 - Warning horn8 - Accessory load (10 AMP)9 - Gauge connector/can connector for

SmartCraft10 - Can 1 with resistor cap11 - Can 3 with weather cap

NOTE: The lanyard stop switch (PPL and PPL/WHT wires) breaks power to the ECM to stopengine. The switch is normally closed until activated. Therefore the PPL and PPL/WHT wires mustbe connected together if Lanyard Stop Switch is not used, or if the E Stop Switch is used.


Page 8 / 43 90-864196060 MAY 2006

NOTE: E Stop Switch (BLK and BLK/YEL wires) connects ground to ECM to stop engine. Theswitch is normally open, the circuit closes when switch is activated. Wires must be separate unlessconnected through E Stop Switch.

1

RED

RED

RED

RED

RED

RED

BLK

BLK

BLK

BLK

BLK

PPL

PPL

BLK_YEL

BLK_YEL

ORG

ORG

WHT

WHT

DKBLU

DKBLU

BLU_WHT

BLU_WHT

GRN_WHT

GRN_WHT

YEL

YEL

BRN

BRN

GRY

GRY

YEL_RED

YEL_RED

GRN

GRN

BLKBLK

PPL

PPL

BLK_YEL

PPL_WHT

PPL_WHT

YEL_RED

YEL_RED

PPL

PPL

PPL_WHT

GRN

ORG

WHT

DKBL

U

AB

CD

EF

GH

JK

LM

NP

AB

CD

EF

GH

JK

AB

C

AB

CD

EF

AB

C1

1

1

1

1

A B A B

A B A B

1

1

1

2

3

5

5

8

9

1011

4

6

7

12339

1 - 14 pin Duetsch connector2 - Key switch connector3 - Trim switch (outboard only)4 - Neutral switch5 - Lanyard switch (sterndrive) or key

switch + connection6 - lanyard (outboard) or E Stop

connection

7 - Warning horn8 - Accessory load (10 AMP)9 - Gauge connector10 - Can 1 with resistor cap11 - Can 3 with weather cap


90-864196060 MAY 2006 Page 9 / 43

14 Pin Engine - Analog Gauge Harness

12312

8

910

23456

71

1 - Connector to boat harness2 - Trim3 - Tach4 - Key on (+)5 - Temp

6 - Oil7 - Ground (-)8 - Can (+) or spare9 - Can (-) or spare10 - 12V (+)

RED

RED

DK_BLU

DK_BLU

WHT

WHT

BLK BLKLTBLU

LTBLUTAN

TAN

PPL

PPL

GRY

GRY

BRN_WHT

BRN_WHT

AB

CD

EF

GH

JK

12318

1

234567

8

9

10

1 - Connector to boat harness2 - Trim3 - Tach4 - Key on (+)5 - Temp

6 - Oil7 - Ground (-)8 - Can (+) or spare9 - Can (-) or spare10 - 12V (+)

Accessory power can be provided up to 15 amps total; on purple wire (switched) and red wire(continuous power.)An accessory relay kit can be used for loads up to 40 amps. Refer to MerCruiser Parts andAccessory Guide or MerCruiser Rigging Guide


Page 10 / 43 90-864196060 MAY 2006

Non-DTS Single Station Instrumentation Installation - Typical

1 - Ignition (key) switch2 - Not used on MerCruiser products3 - Neutral start switch4 - Lanyard stop5 - Audio warning alarm6 - 10 pin 150 GT Female7 - Can 3 line (not used)8 - 120 ohm resister9 - Oil pressure (Can 3+)10 - Water temperature(Can 3-)11 - Trim position12 - Horn13 - Can 1+14 - Can 1-15 - Spare16 - Spare17 - Tachometer/Link18 - Crank

19 - E-stop20 - Wake21 - Ground22 - 12 volts23 - 3-pin metri pack (Female)24 - 3-pin metri pack (Male)25 - Ground26 - 12 volt continuous27 - 12 volt switched28 - 6 pin connector (Male)29 - Relay30 - 6 pin connector (Female)31 - Accessory32 - +12 volts33 - Ground34 - Run35 - E-Stop36 - Crank

NOTE: Refer to gauge manufacturer's instructions for specific connections.


90-864196060 MAY 2006 Page 11 / 43

Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control HarnessAssembly)

a b

c 12323

a - Connection to control boxb - Connection to trim pump

c - Connections to trim limit switch


Page 12 / 43 90-864196060 MAY 2006

C1

T2 T1

C2

DK

BLU-

WHT

DK BLU-WHT

PPL-WHT

RED

RED

GRN-

WHT

GRN-WHT

1 2

3 4

11A B C

12322

a

b

ca - Connection to control boxb - Connection to trim pump

c - Connections to trim limit switch


90-864196060 MAY 2006 Page 13 / 43

Power Trim SystemY

EL/

RE

DY

EL/

RE

D

BLU/WHT

BLU/WHT

BLU/WHT

BLU

/WH

T

PPL/WHTGRN/WHT

GRN/WHT

GRN/WHT

RED/PPL

RE

D/P

PL

RE

D

RE

D

BLK

BLK

BLK

BLK

BLK

BLK

7866

c

ba

f

h

g

d

e

a - 20 amp fuseb - Ground bolt (floor mount)c - UP solenoidd - 110 amp fuse

e - DOWN solenoidf - Y-harness (optional)g - Neutral switch to instrument wiring

harnessh - Trim limit switch

ABYC (American Boat and Yacht Council) installation recommends installing a battery switch inthe positive conductor of any battery or battery bank with CCA rating greater than 800 amperes.(See ABYC for additional information)


Page 14 / 43 90-864196060 MAY 2006

ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump maynot be connected to the continuously energized circuit (battery). It must be connected to theswitched side of the battery switch. Wire length requirements and location of circuit protection arealso specified.

MerCathode System

d

a

b

c8526

a - Controllerb - 20 amp fuse

c - Electroded - BLACK wire - with engine harness


90-864196060 MAY 2006 Page 15 / 43

ECM 555 MPI System Engine Wiring DiagramsCAN, FUEL LEVEL, PADDLE WHEEL AND TEMPERATURE CIRCUIT

BLK

/PN

K

A

10 11 12 13 14 15 161 2 3 4 5 6 7 8

917 18 19 20 21 22 23 24

B

10 11 12 13 14 15 161 2 3 4 5 6 7 8

917 18 19 20 21 22 23 24

A B CB

LK/P

NK

BLK

GR

Y/B

LK

GR

Y

LT B

LU

D

LT BLU/BLK

SPLICE 100

LT B

LU/O

RN

DK

GR

N/Y

EL

WH

T

PP

L

SPLICE 102

a

b

c

d

e

f

PPL

BLK/PNK

A B C

SPLICE 104

A B C D E

FGHK J

GRY

7993

a - ECM 555b - Fuel level connectorc - ECM 555

d - Paddle wheel/seawater tempconnector

e - To 10-pin connector key switchf - CAN connector


Page 16 / 43 90-864196060 MAY 2006

Typical DTS Control SystemPANEL MOUNT ERC AND SMARTCRAFT INSTRUMENTATION

NOTE: Refer to the Command Module Installation Kit.

BLK

-YEL

BLK

BLK

-YEL

BLK

BLK/ORGPUR/YELGRN/YELGRN/ORGGRN/RED

WH

ITE

BLU

E

8010

Shown with panel mount ERC, Smartcraft instrumentation, foot throttle, accessory relay, and start/stop button.

14 Pin Engine Harness ConnectorMechanical 14-Pin Connector Pin-Out

Pin Wire Color Function

A PINK + 12 Volt

B BLACK Ground (-)

C PURPLE Wake

D DK GREEN/YELLOW E-Stop

E DK BLUE Analog oil pressure

F WHITE CAN 1+

G LT BLUE CAN 1-

H Open Spare

J Open Spare

K ORANGE/WHITE Analog trim position

L BROWN/DK BLUE Audio warning horn

M GRAY/WHITE Tachometer/Link gauge

N YELLOW/BLACK Crank

P TAN Analog coolant temperature


NOTES:

90-864196060 MAY 2006 Page 17 / 43


Page 18 / 43 90-864196060 MAY 2006

4.3L MPI Engine Wiring Diagram with 14 Pin


90-864196060 MAY 2006 Page 19 / 43

1 - Idle Air Control Valve2 - Digital Coolant3 - Injector 54 - Injector 35 - Injector 16 - Lube7 - Connector A8 - Connector B9 - Main power relay10 - Fuel pump relay11 - Fuses12 - Resistor13 - Fuel pump14 - 50A circuit breaker15 - Analog coolant16 - 14 pin17 - Analog oil pressure18 - Starter relay19 - Slave output20 - Chassis ground21 - Alternator ground22 - Alternator excitation23 - TMAP

24 - Throttle positioning sensor25 - Neutral safety26 - Crank POS sensor27 - Shift switch28 - Alternator output29 - Starter fuse30 - 50A circuit breaker ('90A')31 - Mercathode anode32 - Mercathode electrode33 - Transom harness34 - Digital oil pressure35 - Paddle / fuel level36 - Sea pump37 - Ignition coil38 - Coil driver39 - Injector 640 - Injector 441 - Injector 242 - Tachometer lead43 - Mercathode ground44 - Lube ground45 - Knock even sensor46 - Diagnostic


Page 20 / 43 90-864196060 MAY 2006

5.0L and 5.7L MCM Alpha Engine Wiring Diagrams with 14 Pin


90-864196060 MAY 2006 Page 21 / 43

1 - Idle Air Control Valve2 - Digital Coolant3 - Injector 14 - Injector 85 - Knock sensor odd6 - Connector A7 - Connector B8 - Lube9 - Main power relay10 - Injector 411 - Injector 712 - Fuel pump relay13 - Fuses14 - Resistor15 - Fuel pump16 - 50A circuit breaker17 - Analog coolant18 - 14 pin19 - Analog oil pressure20 - Slave output21 - Starter relay22 - Cam sensor23 - TMAP24 - Alternator excitation25 - Throttle positioning sensor

26 - Neutral safety27 - Crank POS sensor28 - Chassis ground29 - Alternator ground30 - Shift switch31 - Alternator output32 - Starter fuse33 - 50A circuit breaker ('90A')34 - Mercathode anode35 - Mercathode electrode36 - Transom harness37 - Digital oil pressure38 - Paddle / fuel level39 - Sea pump40 - Ignition coil41 - Coil driver42 - Injector 243 - Injector 544 - Injector 345 - Injector 646 - Tachometer lead47 - Mercathode ground48 - Lube ground49 - Knock even sensor50 - Diagnostic


Page 22 / 43 90-864196060 MAY 2006

5.0L and 5.7L MCM Bravo Engine Wiring Diagrams with 14 Pin


90-864196060 MAY 2006 Page 23 / 43

1 - Idle Air Control Valve2 - Digital Coolant3 - Injector 14 - Injector 85 - Knock sensor odd6 - Connector A7 - Connector B8 - Lube9 - Main power relay10 - Injector 411 - Injector 712 - Fuel pump relay13 - Fuses14 - Resistor15 - Fuel pump16 - 50A circuit breaker17 - Analog coolant18 - 14 pin19 - Analog oil pressure20 - Starter relay21 - Slave output22 - Chassis ground23 - Alternator ground24 - Alternator excitation25 - TMAP

26 - Cam sensor27 - Throttle positioning sensor28 - Neutral safety29 - Crank POS sensor30 - Shift switch31 - Alternator output32 - 50A circuit breaker ('90A')33 - Starter fuse34 - Mercathode anode35 - Mercathode electrode36 - Transom harness37 - Digital oil pressure38 - Paddle / fuel level39 - Sea pump40 - Ignition coil41 - Coil driver42 - Injector 243 - Injector 544 - Injector 345 - Injector 646 - Tachometer lead47 - Mercathode ground48 - Lube ground49 - Knock even sensor50 - Diagnostic

DTS InstallationSpecial Tools - DTS Installation

Data Cable Puller 91-888462A1

Installation Guidelines for DTS System Components

! WARNINGTo avoid the possibility of serious injury or death from loss of boat control, do not splice or probeinto any wire insulation of the DTS system. Splicing or probing will damage the wire insulationallowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttleand shift control.

DATA HARNESS

! WARNINGTo avoid the possibility of serious injury or death from loss of boat control, do not pull on cableconnectors when pulling cable into boat. Observe correct pulling procedure. Pulling onconnectors can loosen terminals resulting in open or poor electrical connections. Open or poorelectrical connections may result in loss of throttle and shift control.


Page 24 / 43 90-864196060 MAY 2006

CONNECTORSIMPORTANT: Connectors should never have to be forced into the receptacle. Ensure thatconnectors are free of any lubricant or dielectric grease before installation. When the connectoris properly aligned, it will only take a small amount of pressure to insert it into the receptacle. Rotatethe locking collar to secure the electrical connection.NOTE: Connect only one data harness of the required length between the engine and helm. If adata harness is too short, do not connect multiple harnesses together to make up the requiredlength. For installations requiring a data harness length longer than 12.2 m (40 ft.), contact MercuryMarine for more information.

Weather CapsWeather caps are to be used whenever there are any unused connectors on a harness. Verify allconnections are tight to prevent moisture or corrosion occurring inside the connections.Typical weather caps are as follows:

4958

a b c d

a - 10 pin capb - 5 pin cap

c - 3 pin capd - 2 pin cap

NOTE: A complete listing of weather caps with part numbers is not available at the time of thepublication.

Battery Harness Information and InstallationDTS Battery Specifications

IMPORTANT: Do not use deep cycle batteries for the main engine starting battery.IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guardregulations must be adhered to when installing the battery. Ensure that battery cable installationmeets the pull test requirements and that positive battery terminal is properly insulated inaccordance with regulations.IMPORTANT: It is recommended (required in some states) that the battery be installed in anenclosed case. Refer to regulations for your area.

Minimum SAE Starting Battery Requirements - BCI GRP 24

MCA 1000

CCA 800

Ah 180 (International Rating)

NOTE: Due to the wide variety of battery manufacturers throughout the world, ratings and physicalbattery sizes will vary. Check with the manufacturer for a starting battery with a MCA, CCA, or Ahspecification that will be equal to or greater than the SAE Standard J537 specified previously.IMPORTANT: For DTS products, each engine must be equipped with its own starting battery. Ifyour boat application requires additional battery loads for boat accessories or marine electronics,it is recommended that an auxiliary battery or batteries be installed.


90-864196060 MAY 2006 Page 25 / 43

! CAUTIONHex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power.

When connecting engine battery, hex nuts must be used to secure battery leads to battery posts.Torque nuts to specifications.


Hex nuts 13.5 120

IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engineinstallation manual for size requirements.Decal needs to be placed on or near battery box for future service reference. One 5/16 in. andone 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are notsupplied.

Place decal on or near battery box for future service reference. 5/16" and 3/8" hex nuts supplied for wing nut replacement. Metric hex nuts not supplied.

NOTICE - DTS & Optimax Engines

37-895387

IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.

DO NOT USE WING NUTS.

DO NOT USE DEEP CYCLE BATTERIES!

13.5Nm (120 lbs. in.)

DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah.rating.

3486

Data Harness Pulling ProcedureIMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads,and spark plugs), high power VHF coax or radios. An electrical field generated from thesecomponents could cause interference with data transmission.IMPORTANT: Do not route data harness near sharp edges, hot surfaces or moving parts. Fastencables away from any sharp edges, fasteners or objects that could wear into the harness.IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be7.6 cm (3 in.) for the final wiring installation.1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs that could cut

the harness.2. Install cable pulling tool to data harness.3. Secure pulling tool with two cable ties.IMPORTANT: The cables ties must be tight to prevent any slipping during installation.

3836

Data Cable Puller 91-888462A1

IMPORTANT: Carefully inspect data harness pins to ensure all pins are securely fastened to dataharness connector end following installation.


Page 26 / 43 90-864196060 MAY 2006

NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.

Connecting 14 Pin Data Harness - Single EngineSingle Helm

IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).

ab

3619

a - 14 pin data harness b - Clamp or cable tie

Dual Helm

3682

a

b

c

d

e

a - 14 pin data harnessb - Helm 2 (upper helm) - auxilaryc - Helm 1 (lower helm) - primary

d - Dual helm adapter (Y harness)e - Clamp or cable tie


90-864196060 MAY 2006 Page 27 / 43

Connecting 14 Pin Data Harness - Dual EngineSingle Helm

IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).

3977

a

b

a - 14 pin data harness b - Clamp or cable tie

Dual Helm

3978

a

b

c

d

e

c

a - Helm 2 (upper helm)b - Helm 1 (lower helm)c - 14 pin data harness

d - Dual helm adapter (Y harness)e - Clamp or cable tie


Page 28 / 43 90-864196060 MAY 2006

Installing DTS Command Module and Harness - Single EngineHarness Installation

• Locate a routing path for the harness connections so they reach their installation points.• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could

cut the harness.• Fasten and support the harness with clamps or cable ties along the routing path.• Make sure all connections are tight and seal all unused connectors with weather caps.

3622

a

b

Single Helm Applicationa - DTS command module harness b - Clamp or cable tie


90-864196060 MAY 2006 Page 29 / 43

NOTE: For dual helm application - Remove CAN 1 and CAN 2 terminator resistors from helm 1(helm closest to the engine), and seal connectors with weather caps.

3677

a

c

c

b

d

d

e f

g

h

TerminatorCAN 1

TerminatorCAN 2

Dual Helm Applicationa - Helm 2 (upper helm)b - Helm 1 (lower helm)c - DTS command module harnessd - Clamp or cable tie

e - CAN 1 connectorf - CAN 2 connectorg - Weather capsh - Terminator resistors, blue (CAN1 &

CAN2)

Module Installation• Although the Command Module connection is watertight, it is recommended that it be mounted

in an area that stays relatively dry.• Mount in an area where the wiring connection will not get stepped on or disturbed.• Mount in an area that is accessible for troubleshooting and servicing the system.• Ensure the wiring harness connected to the command module will reach all the connection

points.


Page 30 / 43 90-864196060 MAY 2006

• Mounting the Command Module with the supplied rubber grommets/bushings to minimizevibration.

3939

a

a - DTS Command Module

Installing DTS Command Module and Harness - Dual EngineHarness Installation

• Locate a routing path for the harness connections so they reach their installation points.• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could

cut the harness.• Fasten and support the harness with clamps or cable ties along the routing path.


90-864196060 MAY 2006 Page 31 / 43

• Make sure all connections are tight and seal all unused connectors with weather caps.

Term

inat

or

CA

N 1

Term

inat

or

CA

N 1

Terminator CAN 2

Terminator CAN 2

a

b

d3689

c

c

e

Single Helm Applicationa - CAN link harnessb - CAN 2 Terminator resistors - do not

removec - CAN 1 connectors

d - Clamp or cable tiee - DTS command module harness


Page 32 / 43 90-864196060 MAY 2006

NOTE: For dual helm application - Remove CAN 1 and CAN 2 terminator resistors from helm 1(helm closest to the engine), and seal connectors with weather caps.

1

2

b

a

c

ed

d

4079

f

Dual helm applicationa - Weather capsb - CAN link harnessc - Helm 2

d - DTS Command Module harnesse - Termination resistors - do not remove

from helm 2f - Helm 1

Module Installation• Although the Command Module connection is watertight, it is recommended that it be mounted

in an area that stays relatively dry.• Mount in an area where the wiring connection will not get stepped on or disturbed.• Mount in an area that is accessible for troubleshooting and servicing the system.


90-864196060 MAY 2006 Page 33 / 43

• Ensure the wiring harness connected to the command module will reach all the connectionpoints.

4080

a

a - DTS Command Module

Junction Box (If Equipped)• Although the junction box connections are watertight, it is recommended that the junction box

be mounted in an area that stays relatively dry.• Mount in an area where the wiring connection will not get stepped on or disturbed.• Mount in an area that is accessible for troubleshooting and servicing the system.• Ensure the DTS command module harness will reach all the connection points.• Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.• Seal all unused connections with weather caps.

a

d

ob01481

b c

e

a - Clampb - Weather cap (859318T 2)c - Junction box

d - 25.4 cm (10 in.)e - DTS command module harness


Page 34 / 43 90-864196060 MAY 2006

Analog Gauge Interface (AGI)Analog Gauge Interface (AGI) Installation

NOTE: This Analog Gauge Interface (AGI) can only be used with the 14 pin Digital Throttle andShift (DTS) system to drive analog and/or SmartCraft System Link gauges. For analog gauges,use ring terminals on AGI harness to connect to analog sender inputs on gauge backs, and tapeback any unused terminals. For SmartCraft System Link gauges, use 3 pin System Link connectionon AGI harness. The AGI system can support 10 System Link gauges per helm, 2 helms maximum.IMPORTANT: Mount AGI module with wires coming out of potting facing downward to preventmoisture from collecting at base of wires and wicking into module. Route and secure all wires andharnesses away from hot or moving parts.1. With screws and washers supplied in kit, mount the AGI module securely under dash or helm

in close proximity to gauges being used.2. Refer to the following table for AGI harness wire color/analog gauge sender input connections.

Tape back any unused terminals. Secure connections per gauge manufacturersspecifications.

Analog Gauge Type AGI Harness Wire Color

Tachometer Gray

Oil Pressure/Oil Level Blue

Water Temperature Tan

Trim Positions Brown/White

Fuel Level Pink/Black

GRYPNK/BLKBRN/WHT

TANBLU

a c

d

b

f e 3688

a - AGI moduleb - 14 pin connectionc - AGI harness

d - Analog gauge terminal connectionse - System Link 3 pin connectionf - 10 pin CAN data connection

3. Route and connect wire from key switched 12 volt positive power source to analog gauges.Secure connections per gauge manufacturers specifications.

4. Route and connect ground wire from analog gauges to a common ground. Secure connectionsper gauge manufacturers specifications.

5. Connect any SmartCraft System Link gauges to 3 pin System Link connection. The AGIsystem can support 10 System Link gauges per helm, 2 helms maximum.

6. Plug 14 pin AGI harness connection into AGI module.7. Connect 10 pin CAN data harness connection on command module harness to AGI harness.

a. If SmartCraft System View is not being used, plug 10 pin CAN data connection on AGIharness directly into 10 pin CAN data connection on command module harness.

b. If SmartCraft System View is being used, a junction box and harness adaptor will berequired. Plug 10 pin CAN data connection on command module harness, 10 pin CANdata connection on System View harness, and one end of harness adaptor into junctionbox. Plug 10 pin CAN data connection on AGI harness into other end of harness adaptor.Insulate any unused connection ports on junction box with weather caps.


90-864196060 MAY 2006 Page 35 / 43

TYPICAL AGI APPLICATION WITH SYSTEM VIEW

3957

OFF ON

GRYPNK/BLKBRN/WHT

TANBLU

a

b

cd

e

f

g

h

a - System View displayb - 10 pin CAN data connection on

System View harnessc - SmartCraft Junction Boxd - Weather Cap

e - Harness Adaptorf - 10 pin CAN data connection on AGI

harnessg - AGI moduleh - 10 pin CAN data connection on

Command Module harness

Configuring Analog/Digital Tachometer Signal through PCMIMPORTANT: The engine Propulsion Control Module (PCM) tachometer configuration factorydefault has been set to an analog. This will allow the operation of one analog tachometer.Depending on the desired use of analog/digital gauges, the PCM set-up may have to be configuredfrom analog to a digital.Following are optional uses of analog and digital gauges and the setting for the tachometerconfiguration in the PCM necessary to run them.

Gauge Configuration Analog Digital

Analog Tachometer Only X

System Link Gauges used with System View, System Monitor, or System Tach - -

System Link Gauges used in conjunction with System Link Adaptor Harness and CommandModule Harness without the use of System View, System Monitor or System Tach X


Page 36 / 43 90-864196060 MAY 2006

Gauge Configuration Analog Digital

AGI used with or without System View, System Monitor or System Tachometer, to runanalog and System Link Gauges X

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

PCM CONFIGURATION WITH DDTIMPORTANT: The use of DDT cartridge 1.3.1 or above must be used for PCM configuration.1. Attach DDT to engine and power up. Refer to DDT Owners Manual if needed.2. Press 1. "MERCURY MARINE"3. Press 1. "TO CONTINUE"4. Press 2. "MANUAL TEST"5. Arrow down and Press 5. "SPECIAL FUNCTION"6. Arrow down and Press 9. "TACH LINK CONFIG"7. "CONFIGURE TACH SOFTWARE DRIVER?" - Press 1. "YES"8. "TACH LINK CONFIG" - Press 1. "FOR LINK" (Digital) - Press 2. "FOR ANALOG"9. After task completion confirmation, Press "MODE" to Exit

PCM CONFIGURATION WITH CDS1. Attach CDS to engine. Refer to on-line help if needed.2. From Logon screen, navigate to Engine Select screen.3. From Engine Select screen fill in engine type information and select Tool Box.4. From Tool Box screen, select Active Diagnostics.5. From Active Diagnostics screen, scroll down and select Tach Link Config.6. To change PCM configuration from default of analog to digital, select Enable and then select

Run.7. To change PCM configuration from digital to analog, select Disable and then select Run.


90-864196060 MAY 2006 Page 37 / 43

Typical 14 Pin DTS Wiring DiagramsDTS Panel Control Wiring

5104W

HIT

EB

LUE


BLK

/YE

LB

LK/Y

EL

BLK

BLK

OFF ON

-+

a

b

c d e

f

g

h

i

jk

l

m

np

qr o

a - Remote controlb - Remote control connectionsc - Key switchd - Start/stop switch (optional)e - SmartCraft System View (optional)f - SmartCraft Link Gauge (optional)g - Display harnessh - Horni - Horn

j - GPS connectionk - Cable adaptor (male to female)l - Weather capsm - Junction box (optional)n - DTS Command Module harnesso - Terminator resistorsp - DTS Command Moduleq - Accessory power relay (optional)r - Foot throttle (optional)


Page 38 / 43 90-864196060 MAY 2006

DTS Single Console Control Wiring

5103

WH

ITE

BLU

E


BLK

/YE

LB

LK/Y

EL

BLK

BLK

OFF ON

-+

a

b

c

d

e f

g

h

i

j

kl

m

no

pq

rs

a - Remote controlb - Remote control connectionsc - Lanyard stop switchd - Key switche - Start/stop switch (optional)f - SmartCraft System View (optional)g - SmartCraft Link Gauge (optional)h - Display harnessi - Hornj - Horn

k - GPS connectionl - Cable adaptorm - Weather capsn - Junction box (optional)o - Terminator resistorp - DTS Command Module harnessq - DTS Command Moduler - Accessory power relay (optional)s - Foot throttle (optional)


90-864196060 MAY 2006 Page 39 / 43

DTS Single Console Control Wiring with Dual Helm

ce

l

n

r

ij

dg

p

m

f

h

k

qa

b

s

t

u

g

h

ij

n

d

m

3588

o

a - Helm 1b - Helm 2c - Clamps (use as required)d - Remote controle - Key switch connector not used – seal

with weather capf - Start/stop switch (2 required at helm )g - Lanyard stop switchh - System View (optional)i - Hornj - Foot throttle connectork - Accessory power relay connector

(optional, not used at second helm)

l - Terminator resistors (helm 2 only)m - DTS Command Modulen - DTS Command Module harnesso - Data harnessp - Start/stop switch (optional at helm 1)q - Key switchr - Accessory power relays - Terminator resistors not used – seal

connectors with weather capst - Dual helm adaptor harnessu - Data harness to engine


Page 40 / 43 90-864196060 MAY 2006

DTS Dual Console Control WiringNOTE: Optional foot throttle is not compatible in multiple engine applications.

–+

12112j

b ba c

h

f

l

h

d

n

k

h

n

f

e

k

l

k

g g

g

i

hh

a - DTS Controlb - Key Switchc - Lanyard Stop Switchd - System View (optional)e - Air Temp Sensorf - Command module

g - Hornh - Clampi - To starboard enginej - To port enginek - Connector, Start/Stop Switch

(optional)l - Accessory Power Relay (optional)


90-864196060 MAY 2006 Page 41 / 43

DTS Dual Console Control Wiring with Dual HelmNOTE: Optional foot throttle is not compatible in multiple engine applications.

b

cd

e

j k l

n

q

r

h

i

jko

c

fg

d

g

t

p

d

d dm

a

3310

d

s

idd

p

o

om

n

ii

f

t

ou u

r

j jv

a - Helm 1 (primary)b - Helm 2 (auxiliary)c - Remote controld - Connector not used – seal with

weather cape - Start/stop switch (required at helm

#2)f - Lanyard stop switchg - System View (optional)h - Clamps (use as required)i - DTS Command Modulej - Junction box connection (optional)k - Terminator resistor (required at helm

#2)

l - CAN link harnessm - Hornn - DTS Command Module harnesso - Data harnessp - Key switchq - Start/stop switch (optional at helm 1)r - Dual helm adaptor harnesss - Data harness to starboard enginet - Accessory power relayu - Remove terminator resistor and seal

with weather capv - Data harness to port engine


Page 42 / 43 90-864196060 MAY 2006

DTS Zero Effort Control Wiring - Single Engine

BLK

/YE

LB

LK/Y

EL

BLK

BLK

OFF ON

WH

ITE

BLU

E

-+

RE

D

RE

D

GR

N/W

HT

GR

N/W

HT

BLU

/WH

T B

LU/W

HT

l

k

a b

c

d

e

f

gh

i

j

7731

a - Start/stop switch (optional)b - System View (optional)c - SmartCraft Link gauged - GPS Connectione - Display harnessf - Cable adaptor

g - Weather capsh - Junction boxi - DTS Command Modulej - Accessory power relay (optional)k - DTS Command Module harnessl - Adaptor


90-864196060 MAY 2006 Page 43 / 43

DTS Zero Effort Control Wiring - Dual Engine

RE

D

RE

D

GR

N/W

HT

GR

N/W

HT

BLU

/WH

T B

LU/W

HT

�+

WH

TB

LU7725

b

cd

e

gg

h

e

d

c

b

j

i f

k k

a

a - System View (optional)b - Hornc - Junction box connection (optional)d - Accessory power relay (optional)e - DTS Command Modulef - To starboard engine

g - Terminator resistorh - CAN link harnessi - To port enginej - DTS Command Module harnessk - Connector - Start/stop switch

(optional)


NOTES:

Page 44 / 43 90-864196060 MAY 2006

SECTION - 8 REMOTE CONTROLS

90-864196060 MAY 2006 Page 1 / 34

SECTION 8 - REMOTE CONTROLSTable of ContentsRemote Control Installation..................................................................................................................................... 4

Locating and Drilling Mounting Area.................................................................................................................4Installing DTS Panel Mount Control..................................................................................................................4Installing DTS Single Handle Console Control..................................................................................................6Installing DTS Dual Handle Console Control....................................................................................................9Installing DTS Zero Effort Control...................................................................................................................12

Steering System Information................................................................................................................................. 14High Speed Or Twin Engine Applications Steering Recommendation ...........................................................14Steering Helm and Cable................................................................................................................................15Steering Cable Specifications.........................................................................................................................16Hydraulic (Helm) Steering...............................................................................................................................16

Sterndrive Shift Cable Information........................................................................................................................ 17Propeller Rotation............................................................................................................................................17Checking Alpha Shift Cable Installation and Adjustment................................................................................17Bravo Sterndrive Shift Check (Engine Running).............................................................................................21Troubleshooting Shift Problems......................................................................................................................22DTS Remote Control - Sterndrive...................................................................................................................25

DTS Calibration..................................................................................................................................................... 25Special Tools - DTS Calibration......................................................................................................................25Methods of Calibration....................................................................................................................................26System View Display Connection....................................................................................................................26DTS System Reset..........................................................................................................................................26Calibration Setup.............................................................................................................................................27

Special Instructions for Dual Helm Vessels ............................................................................................. 27Calibration ................................................................................................................................................ 27Console Mount and Panel Mount Controls .............................................................................................. 29Console Mount and Panel Mount Controls with Foot Throttle ................................................................. 29Zero Effort Controls ................................................................................................................................. 29Zero Effort Controls with Foot Throttle ..................................................................................................... 30

Setting Trailer and Trim Limit................................................................................................................................ 30Setting Trailer Limit with DDT..........................................................................................................................30Setting Trailer Limit with CDS.........................................................................................................................31Setting Trim Limit with DDT.............................................................................................................................31Setting Trim Limit with CDS............................................................................................................................32

Troubleshooting Procedure................................................................................................................................... 32Troubleshooting Information............................................................................................................................32

Default Sensor Values ............................................................................................................................. 32Fault Conditions ....................................................................................................................................... 32Sticky/Non-Sticky Faults .......................................................................................................................... 33Engine Guardian ...................................................................................................................................... 33Warning Horn Signals .............................................................................................................................. 33

Special Tools - DTS Troubleshooting..............................................................................................................33

8

REMOTE CONTROLS SECTION - 8

Page 2 / 34 90-864196060 MAY 2006


95 2-4-C Marine Lubricant with Teflon Shift cable end 92-802859A1

Special ToolsDual Water Pick-up Flush Gearcase Seal Kit 91-881150K 1

9194

Blocks off the front water inlet holes on the dual water inletgearcases.


9192



9195


Male to Male 10 Pin Adapter 84-892452A01

4621

Allows connection between CAN 1 communications cableand Computer Diagnostic System in applications where ajunction box is not used.

Can 1 Diagnostic Cable 84-892663

4680

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

Adapter Harness 84-822560A13

5826

Data link harness between engine and Computer DiagnosticSystem (CDS) or Digital Diagnostic Terminal (DDT).


90-864196060 MAY 2006 Page 3 / 34

Computer Diagnostic System (CDS) Order through SPX

4520

Monitors all electrical systems for proper function,diagnostics. and calibration purposes. For additionalinformation, pricing, or to order the Computer DiagnosticSystem contact:SPX Corporation28635 Mound Rd.Warren, MI 48092or call:USA - 1-800-345-2233Canada - 800-345-2233Europe - 49 6182 959 149Australia - (03) 9544-6222

Breakout Box SPX P/N MM-46225

5974

Connects to Propulsion Control Module (PCM) to test enginecircuits and components without probing wires. May be usedwith Computer Diagnostic System (CDS).

Terminal Test Probe Kit SPX P/N MM-46523

7915

Test probes adapt test meter leads to harness connectionswithout damaging harness terminals. May be used withComputer Diagnostic System (CDS).

12 Volt Shunt Connector 889675A01

8036

Connects to data harness allowing operation of the DTSsystem with the Digital Diagnostic Terminal.


4009

Data link harness between engine and Digital DiagnosticTerminal (DDT).

2 to 4 Pin Harness Adapter 84-822560A12

4679

Adapts the 2 pin Digital Diagnostic Terminal harness to the 4pin connector on the engine.


Page 4 / 34 90-864196060 MAY 2006

DMT 2004 Digital Multimeter 91-892647A01

A C O M m A V H z

mV

V

H z TEMPm A

A

IG

IPOFF

H z

TEMP

4516

Measures RPM, ohms, amperes, AC and DC voltages;records maximums and minimums simultaneously, andaccurately reads in high RFI environments.

Remote Control InstallationLocating and Drilling Mounting Area

1. Locate area of boat where the remote control is to be mounted. Allow sufficient clearance forhandle movement and clearance for the wiring.

2. Select the correct template for mounting application.3. Place template over mounting area; cut and drill as instructed on template.IMPORTANT: After cutting mounting area, make sure opening is free of sharp edges.

a

3600

a - Template

Installing DTS Panel Mount Control1. Ensure opening is free of sharp edges.2. Route wiring for the remote control into opening.

ob00040

3. Connect trim harness and lever harness.


90-864196060 MAY 2006 Page 5 / 34

4. Insert the bayonet end into bracket hole. This will prevent connector from pulling out.IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handlemovement.

5086

a

b

a - Trim harness b - Lever harness

5. Place the remote control into the opening.

3250

6. Fasten the remote control with three #12 x 1.25 in. long screws.

3251

a

a

a - Mounting screw (3)

7. Control Handle Tension Adjustment – This screw can be adjusted to increase or decrease theoverall effort to move the control handle. This will help prevent the handle from unwantedmotion in rough water. Turn screw towards "+" to increase tension or towards "–" to decreasetension.


Page 6 / 34 90-864196060 MAY 2006

8. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease theeffort to move control handle into or out of detent position. Turn screw towards "+" to increasetension or towards "–" to decrease tension.

3252

ab

a - Control handle tension adjustment screwb - Detent tension adjustment screw

9. Install front and back bezel covers with attaching screws.

3254

a b

c

a - Front coverb - Back cover

c - Screw - (2) M4 x 12

Installing DTS Single Handle Console Control1. Ensure opening is free of sharp edges.2. Route wiring for the remote control into opening.

3509

3. Connect trim, lever and trackpad harnesses.4. Insert the bayonet end of the lever harness into bracket hole. This will prevent connector from

pulling out.


90-864196060 MAY 2006 Page 7 / 34

IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handlemovement.

a

bc

5098

a - Trim harnessb - Lever harness

c - Trackpad harness


3296


Page 8 / 34 90-864196060 MAY 2006

6. Fasten the remote control with four M6 x 40 long screws.

a

b

c 3297

a - Mounting screw (4) M6 x 40b - Washer

c - Nut - nylon insert

! CAUTIONDo not turn control handle tension adjustment screw clockwise more than 11 turns from the initialpoint of hex head contact with bracket. Damage to the module may occur.

! CAUTIONDo not turn detent tension adjustment screw clockwise more than 11 turns from full out position.Damage to the module may occur.

7. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase ordecrease the overall effort to move the control handle. This will help prevent the handle fromunwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–"to decrease tension.


5102

a b

a - Detent tension adjustment b - Control handle tension adjustment


90-864196060 MAY 2006 Page 9 / 34

9. Install the side cover with attaching screws.

3298

a

b

a - Attaching screws (4) M4 x 20 b - Side cover (2)

Installing DTS Dual Handle Console Control1. Make sure opening is free of sharp edges.2. Route wiring for the remote control into opening.

3606

3. Insert the bayonet ends into bracket holes. This will prevent connectors from pulling out.


Page 10 / 34 90-864196060 MAY 2006

IMPORTANT: Allow slack in the trim button harness going to the control handle. This harness willflex and move during control handle movement.

bc d

e

3305a

f

a - Bayonet endsb - Trim button harnessc - Blue paint dot

d - Yellow paint dote - Starboard enginef - Port engine


3306


90-864196060 MAY 2006 Page 11 / 34

5. Fasten the remote control with four M6 x 40 screws.

3307

a

bc

a - Mounting Screw (4) M6 x 40b - Washer

c - Nut - nylon insert

! CAUTIONDo not turn control handle tension adjustment screw clockwise more than 11 turns from the initialpoint of hex head contact with bracket. Damage to the module may occur.

! CAUTIONDo not turn detent tension adjustment screw clockwise more than 11 turns from full out position.Damage to the module may occur.

6. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase ordecrease the overall effort to move the control handle. This will help prevent the handle fromunwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–"to decrease tension.


5102

a b

a - Detent tension adjustment b - Control handle tension adjustment


Page 12 / 34 90-864196060 MAY 2006

8. Install the side cover with attaching screws.

3308

a

b

a - Side cover (2) b - Attaching screws (4) M4 x 20

Installing DTS Zero Effort Control1. Ensure opening is free of sharp edges.2. Route wiring for the remote control into opening.3. Connect trim, lever and adaptor harnesses.

RED

RED

GRN

/WHT

GRN

/WHT

BLU

/WHT

BLU

/WHT

LEVER 1

a

bc

de

f5181

a - Throttle adaptor harnessb - Remote controlc - Trim harness

d - Trackpad - not usede - Lever 1 harness (blue)f - Trim adaptor harness


90-864196060 MAY 2006 Page 13 / 34

4. Ensure the control is positioned so the forward-neutral-reverse (F-N-R) decal is in the correctorientation.

a bc

d

5184

a

ab b

c

c

d d

5182

Forward Cant Models Aft Cant Modelsa - Reverseb - Neutral

c - Forwardd - F-N-R decal location

5. Ensure the control is position so the forward-neutral-reverse ("F-N-R") decal is in the correctorientation.

4749

a c

d

ba

b

c

d

a - Throttle leverb - Trim switch

c - Shift leverd - "F-N-R" label

! CAUTIONTo avoid possible corrosion damage, always install nylon washer between each screw and thecontrol quadrant plate. Improper installation may result in chipped paint, triggering corrosion.


Page 14 / 34 90-864196060 MAY 2006

6. Secure control to the console using the 8 X 1-1/4 in. self tapping screws and nylon washers.

a

b

c

d5192

a - 8 X 1-1/4 in. self tapping screw (4)b - Nylon washer (4)

c - Control quadrant assemblyd - Console

Steering System InformationHigh Speed Or Twin Engine Applications Steering Recommendation

Mercury MerCruiser power packages come standard with Mercury MerCruiser's internal powersteering. This durable system provides precise effortless steering control and is recommended formost sport boat applications. On certain applications, however, Mercury MerCruiser recommendsthe use of an external power steering system where the power steering cylinders connect directlyto the sterndrive unit on the outside of the boat. This arrangement gives additional support for eventighter, more firm steering control, and is recommended for the following applications:• High speed single or twin engine applications and/or boats with unusual handling

characteristics.NOTE: It is virtually impossible to give a specific recommendation as to when external powersteering should be used, as this varies from boat design to boat design. Mercury MerCruiserrecommends using external power steering on boats which operate in excess of 70 mph. Thereare boats which operate at 60 mph that would benefit from the use of external power steering.Because of the many variables involved, the final decision as to whether or not external powersteering is required rests with the boat manufacturer and must be made after a thorough test andevaluation of each specific boat. If there is any question whether or not external power steering isnecessary, Mercury MerCruiser recommends that it be installed.• Any Hi-Performance sport boat powered by three or more engines.• Offshore boats or other applications where the boat and sterndrive units may come out of the

water occasionally.External power steering systems are generally either mechanical cable actuated or hydraulicactuated.External power steering and hydraulic helm systems can be obtained from the following aftermarket suppliers:Latham Marine, Inc.280 S.W. 32nd CourtFt. Lauderdale, FL 33315Phone: (305) 462-3055Fax: (305) 462-3081,Mayfair Marine Machine12890 N. W. 30th AvenueOpalocka, FL 33054Phone: (305) 681-1815,


90-864196060 MAY 2006 Page 15 / 34

Steering Helm and CableTransom assembly is shipped with the steering cable guide tube preset for cables with enddimensions that comply with ABYC standards as outlined in the NMMA certification handbook.The steering cable coupler nut must also have a means of locking it to the guide tube, as specifiedin ABYC requirements.

! WARNINGFailure to use a steering cable locking device could cause loss of steering, causing possibledamage to the boat or injury.

NOTE: All current production Quicksilver RideGuide steering cables have a self-locking couplernut and do not require an external locking device. (Other cable manufacturers also make cableswith self-locking coupler nuts.)

7255

a

a - Quicksilver RideGuide steering cable self-locking coupler nut (identified by groove)

IMPORTANT: If using a steering cable that does not have a self-locking coupler nut, an externallocking device such as a locking sleeve must be used.

! CAUTIONIf steering cable with improper dimensions is installed, severe damage to transom assemblyand/or steering system may result.

1. Steering cable must be the correct length, particularly when installed in larger boats.2. Avoid sharp bends, kinks, or loops in cable.3. Refer to Steering Cable Specifications for fully extended steering cable and dimensions.


Page 16 / 34 90-864196060 MAY 2006

Steering Cable SpecificationsIMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) maymean a steering cable has been installed that does not have the correct dimensions.

CL

ab

c

de

fg

hi

jk

l

7254

a - Coupler nut - 7/8 - 14 UNF - 28 threadb - 29.8 cm (11-3/4 in.) minimumc - Interface pointd - 12.7 mm (1/2 in.) maximume - 10.7 mm (27/64 in.) minimum flatf - 3.1 mm (7/64 in.) minimum radius

g - 15.9 mm (5/8 in.) maximum diameterend fitting

h - 9.5 mm (3/8 in.)i - 9.8 mm (3/8 in.) diameter through hole

(chamfered each side)j - 34.9 mm (1-3/8 in.) maximumk - 15.9 mm (5/8 in.) diameter tubel - Cable travel: mid-travel position -

42.9 cm (16-7/8 in.) total travel tobe20.3 cm (8 in.) minimum to22.8 cm (9 in.) maximum travel eachside of mid-travel position -1.02 cm (4 in.) minimum to114 mm (4-1/2 in.) maximum

Hydraulic (Helm) SteeringIf your power package is equipped with Compact Hydraulic Steering, refer to the CompactHydraulic (Helm) Steering Installation Instructions .


90-864196060 MAY 2006 Page 17 / 34

Sterndrive Shift Cable InformationPropeller Rotation

Propeller rotation for sterndrive can be clockwise or counterclockwise, as viewed from the aft (rear)end of the propeller.

4802 4747

Clockwise rotation Counterclockwise rotation

Checking Alpha Shift Cable Installation and AdjustmentIMPORTANT: Do not use excessive force when holding pressure on the drive unit shift cable.Gasoline Alpha Models Only: Excessive force would be indicated by movement of the V-notch ofthe actuator lever assembly.1. Right-hand (RH) rotation drive unit - Verify remote control travel for FORWARD gear.

a. Place the remote control in FORWARD gear, past detent, into WOT position.

7807


Page 18 / 34 90-864196060 MAY 2006

2. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotatingpropeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintaina light pressure on the drive unit shift cable to hold it at the end of its travel (this removes allslack from the cable).

7817

3. Left-hand (LH) rotation drive unit - Verify remote control travel for FORWARD gear.a. a. Place the remote control in FORWARD gear, past detent, into WOT position.

7807

4. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotatingpropeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a lightpressure on the drive unit shift cable to hold it at the end of its travel (this removes all slackfrom the cable).

7870

5. Right-hand (RH) rotation drive unit - Verify remote control travel for REVERSE gear.


90-864196060 MAY 2006 Page 19 / 34

a. Place the remote control in REVERSE gear, past detent, into WOT position.

7869

6. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotatingpropeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a lightpressure on the drive unit shift cable to hold it at the end of its travel (this removes all slackfrom the cable).

7870

7. Left-hand (LH) rotation drive unit - Verify remote control travel for REVERSE gear.a. Place the remote control in REVERSE gear, past detent, into WOT position.

7869


Page 20 / 34 90-864196060 MAY 2006

8. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotatingpropeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintaina light pressure on the drive unit shift cable to hold it at the end of its travel (this removes allslack from the cable).

7817

IMPORTANT: It may be necessary to make additional adjustments if using extra long remotecontrol shift cable, if there are a lot of bends in the cable, or if the remote control has inadequateoutput travel.9. If drive unit is installed and the package is equipped with a single lever shift/throttle

control:a. Right-hand (RH) propeller rotation drive unit - Shift remote control into REVERSE

gear, WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutchshould engage and cause propeller shaft to lock. If clutch does not engage, loosenadjustable stud on shift lever and move it up in slot until clutch engages with REVERSEgear. Retighten stud. Shift remote control several times and stop in REVERSE to recheckshift cutout switch position. Pin must be centered.

b. Left-hand (LH) propeller rotation drive unit - Shift remote control into FORWARDgear, WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutchshould engage and cause propeller shaft to lock. If clutch does not engage, loosenadjustable stud on shift lever and move it up in slot until clutch engages with FORWARDgear. Retighten stud. Shift remote control several times and stop in FORWARD torecheck shift cutout switch position. Pin must be centered.

10. If drive unit is installed and the package is equipped with a two lever remote controlwith separate shift and throttle levers:a. Right-hand (RH) propeller rotation drive unit - While turning propeller shaft

CLOCKWISE, move remote control shift handle into full REVERSE position. Clutchshould engage before shift lever comes to a stop. If clutch does not engage, loosenadjustable stud on shift lever and move it up in slot until clutch engages with REVERSEgear. Retighten stud. Shift remote control several times and stop in REVERSE to recheckshift cutout switch position. Pin must be centered.


90-864196060 MAY 2006 Page 21 / 34

b. Left-hand (LH) propeller rotation drive unit - While turning propeller shaftCLOCKWISE, move remote control shift handle into full FORWARD position. Clutchshould engage before shift lever comes to a stop. If clutch does not engage, loosenadjustable stud on shift lever and move it up in slot until clutch engages with FORWARDgear. Retighten stud. Shift remote control several times and stop in FORWARD torecheck shift cutout switch position. Pin must be centered.

ab

7871

a - Adjustable stud b - Shift interrupt switch plunger

Bravo Sterndrive Shift Check (Engine Running)

! WARNINGContact with moving sterndrive components and the propeller can cause personal injury ordeath. To avoid possible injury , remove the propeller and ensure that no people or animals arein the area of the sterndrive.

This test requires sufficient water supply to your engine and sterndrive.1. Check sterndrive for proper gear shift with boat out of water.2. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/

IN position. Do not allow the sterndrive skeg to contact the ground.

4805

b

a

Typical single handle remote control showna - Drive trim switch b - Drive trailer button

3. Connect a garden water hose between flushing attachment and water source.



Page 22 / 34 90-864196060 MAY 2006



4. Partially open water source until water continuously leaks out around the flushing device.


IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and usinga through the hull water inlet need a supply of cooling water available to both the sterndrive andto the engine during operation.5. Place remote control handle in NEUTRAL, idle speed position and start engine.


! CAUTIONSterndrive not shifting properly can cause engine and sterndrive damage. Contact yourauthorized Mercury MerCruiser dealer for proper adjustment.

NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and outof each gear FORWARD, NEUTRAL, and REVERSE, at idle speed position.NOTE: The operator at the remote control handle should feel a slight detent before and after eachgear. FORWARD-detent-NEUTRAL-detent-REVERSEIMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttleis engaged. Consult your authorized Mercury MerCruiser dealer/representative for properadjustment.6. Move the remote control handle to FORWARD, idle speed position.7. Check that the sterndrive propeller shaft is turning in the FORWARD direction.8. Shift the remote control handle to NEUTRAL, idle speed position.9. Check that the sterndrive propeller shaft is not turning.10. Shift the remote control handle to REVERSE, idle speed position.11. Check that the sterndrive propeller shaft is turning in the REVERSE direction.12. If the sterndrive will not shift:

a. Remove the sterndrive and check for proper shift hook ups.b. Check that the shift cables are connected

IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to shift cables.

Troubleshooting Shift ProblemsNOTE: The following information is provided to assist an installer in troubleshooting if hard shiftingor chucking/racheting is encountered when shifting into FORWARD gear.1. When installing the control box in the side panel of the boat, ensure that the cables have

enough clearance to operate. This is necessary because the cables move up and down whenthe shift handle is moved. If the control box is mounted too far back toward any fiberglassstructure, the cables will be interfered with; this will cause very hard shifting.


90-864196060 MAY 2006 Page 23 / 34

NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.

7873

Proper cable bend

7872

Improper cable bend2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull,

it does not have any extremely sharp bends in it as this will cause stiff shifting.IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends ontoo-short cables result in kinks and too-long cables require unnecessary bends or loops. Bothconditions place extra stress on the cables.IMPORTANT: Shift cable/throttle cable lubrication points use 2-4-C with Teflon.3. Before installing the shift cable into the control box, extend the stainless rod eye end of the

cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.

b

c

d

a

7874

a - Remote control endb - Engine end

c - Adjusting barreld - Lubricating point


Page 24 / 34 90-864196060 MAY 2006


95 2-4-C Marine Lubricant withTeflon Shift cable end 92-802859A1

NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GENII Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.) thickness.Cable radius at any one point must not be less than 305 mm (12 in.).

4000 GEN II Series Panel Mount Remote Control


Mounting surface maximum thickness 25 mm (1 in.)

Minimum cable bend radius at any point 305 mm (12 in.)

4. Do not strap or clamp the control cables to any other cables or rigid structure within91.4 cm (3 ft) of the control box.

5. Ensure that the cable is not permanently kinked.6. Ensure that there is proper clearance for cable movement when the control box is installed in

the side panel. The cables must have room to move up and down when the control handle isshifted into either FORWARD or REVERSE.

7. Ensure that the engine was not set down on the intermediate shift cable during installation,as this will crush the inner cable tubing and cause improper and / or stiff shifting.

8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of theshift plate.

9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within1.5 m (5 ft) of the shift plate.

10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cableend must be free to rotate on the mounting stud.

NOTE: Lubricate attaching points with engine oil.

Description Where Used Part Number

SAE 30W Engine Oil Shift cable pivot points Obtain Locally

11. Check the intermediate shift cable routing from the transom assembly to the shift plate asfollows:

NOTE: Cable route is the same for through transom and through prop exhaust.a. The cable should come through the transom, above the exhaust pipe and make a turn

toward the starboard side of the boat between the exhaust pipe and the engine flywheelhousing.


c. The cable should then go up behind the power steering valve and loop over to the shiftplate on the engine, where it is connected to the anchor points on the shift plate.


90-864196060 MAY 2006 Page 25 / 34

Following this routing will prevent the engine coupler from damaging the cable.

8995

Through prop exhaust shown

NOTE: NOTE: A final check of the adjustments should be made with the boat in the water andengine running. If this cannot be done or is not done at your manufacturing facility, arrangementshould be made with the dealer to do this as part of the pre-delivery inspection12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.Refer to 90-865523 Instruction Sheet for more information.

DTS Remote Control - SterndriveIMPORTANT: Boat must be equipped with Mercury electronic remote control. Start in gearprotection is provided by this control system and prevents the engine from starting when the controlis actuated in FORWARD or REVERSE.

RUN

F R

SELECTSCROLL

TRIM

8994

The Digital Throttle and Shift System (DTS) required to operate this engine package provides start,stop, throttle, shift control, start in gear protection and emergency lanyard stop function. Refer tothe Mercury Precision Parts/Quicksilver Accessories Guide.The Digital Throttle and Shift system (DTS) works with specialized helm component, commandmodule kit and electronic remote control. Refer to the Mercury Precision Parts/QuicksilverAccessories Guide.

DTS CalibrationSpecial Tools - DTS Calibration


Can 1 Diagnostic Cable 84-892663


Page 26 / 34 90-864196060 MAY 2006



Methods of CalibrationNOTE: DTS system calibration must be performed following complete system installation. It mustalso be completed after an accessory or replacement part is added to the system that requiresnew configuration codes. A DTS system reset must be performed prior to calibration, or if an erroris made during the calibration setup.• Method 1 - Mercury Marine Computer Diagnostic System (CDS) - Connect the CDS to the

CAN bus circuit and follow the helm configuration setup on the computer diagnostic screen.• Method 2 - Mercury Marine SmartCraft System View display - If the boat is not equipped

with a System View display, temporarily connect a System View display to the helm harnessshown in the following diagrams. Follow the System View calibration setup instructions for theDTS. If the DTS system was previously calibrated, perform a DTS system reset to restore thefactory default settings.

System View Display ConnectionIf the boat is not equipped with a System View display, temporarily connect a System View displayto the DTS command module harness as shown. After calibration, remove System View andharness, seal harness connections with weather caps.

a b

c

d

e

f

g

c

d

g

f

5003

h

i

ONON

OFF OFF

OFF

RUN

BLK

/WH

T

BLK

/WH

T

BLK

/YE

L

BLK

/YE

LB

LK

BLK

BLK

/YE

L

BLK

/YE

L

BLU

BLU W

HT

WH

T

a - Single engine connectionb - Dual engine connectionc - System Viewd - System View harnesse - Cable adapter (male to male)

f - 14 pin data harness from engineg - DTS Command Module harnessh - Weather capsi - Junction box

DTS System ResetThe DTS system reset will restore the engine setup and remote control menus to factory defaultsettings. DTS reset must be completed prior to system calibration, after an error is made duringthe calibration setup, or an accessory has been added or replaced.NOTE: If the boat does not have a System View installed, temporarily connect a System View tothe DTS command module harness.


90-864196060 MAY 2006 Page 27 / 34

1. Use the trackpad on the System View and highlight the "SETTINGS" directory on the homescreen.

2. Press and hold in the bottom arrow on the trackpad for 10 seconds. Continue holding after 10seconds then press in the top arrow. This will bring up the warning screen.

3. The warning screen will ask the question "DO YOU WANT TO CONTINUE". Highlight "YES"and press "SELECT" button to accept. This will bring up the reset screen.

4. Use the trackpad and highlight "RESTORE VESSEL CONFIGURATION TO FACTORYDEFAULTS" selection on the reset screen. Press "SELECT" button to accept. The resetscreen will ask the question "ARE YOU SURE YOU WANT TO RESTORE VESSELCONFIGURATION TO FACTORY DEFAULTS". Highlight "YES" and press "SELECT" buttonto accept.

5. DTS system reset is complete. The engine setup and remote control menus have beenrestored back to the factory defaults.

Calibration SetupSPECIAL INSTRUCTIONS FOR DUAL HELM VESSELS

• Perform the calibration setup at each helm using the System View. After setup is complete atone helm, repeat setup on the second helm.

• If only one System View is installed in the vessel, the System View must be temporarilyconnected to the second helm. An extra System View can temporarily be connected at thesecond helm. This will eliminate the need to move the System View between helms.

• If one System View is used between helms for calibration setup, a DTS system reset will haveto be performed each time it is moved to a different helm. Refer to DTS System Resetprocedure.

• Calibration can be started at either helm. However, if one System View is being used, it is bestto start at helm 2 (helm with the start/stop switch) and then move to helm 1.

• Calibration setup requires remote control lever movement at both helms.NOTE: Helm 1 is always the helm with the ignition key switch. Helm 2 has the start/stop switch.

CALIBRATIONNOTE: The following calibration procedure is for using method 2, using a System View displayscreen. If method 1, using a Mercury Marine Computer Diagnostic System is used, follow theon-screen instructions on the diagnostic computer to calibrate the system.1. The first screen will ask if the module initialization has been completed on another station.

Select "NO" on single helm vessels and on dual helm vessels if calibration has not yet beencompleted on the another helm. Select "YES" on dual helm vessels if calibration has alreadybeen completed on the other helm.

NOTE: If "YES" is selected, module initialization was completed at the other station. Calibrationwill advance to step 7.2. The next screen should read "HOW MANY HELMS AND ENGINES ARE THERE ON THE

VESSEL?" Select the number of helms and engines the vessel has. Use the up and downarrows to change the number of engines or helms. Use the left or right arrow to change fromthe engine to helm selection. After making selections, press "SELECT" button to continue.

3. The next screen should read, "PLEASE MOVE ALL LEVERS ON ALL HELMS TO NEUTRALIDLE". Press "SELECT" to continue.

NOTE: On dual helm vessels, helm identified as 1 is the helm with the ignition key switch. Helmidentified as 2 is the helm with the start/stop switch. On dual engine installations, engine identifiedas 1 is the starboard engine, engine identified as 2 is the port engine.4. The next screen should read, "PLEASE MOVE LEVER FOR HELM 1 ENGINE 1 TO

REVERSE MAXIMUM". Press "SELECT" button when completed to continue.5. The next screen should read, "HELM MODULE INITIALIZATION IS COMPLETE". Press

"SELECT" button to continue calibration.


Page 28 / 34 90-864196060 MAY 2006

6. The next screen should read, "ASSIGN STATION IDENTIFICATION FOR THIS SYSTEMVIEW". Assign "1" for System View connected at helm 1. When applicable, assign "2" forSystem View connected at helm 2. Press "SELECT" button to continue.

7. The next screen should read, "SELECT THE ENGINE CONFIGURATION THE SYSTEMVIEW IS CONNECTED TO". Press "SELECT" button to continue.

a

b

c

d

a

b

a

c a

b 5290

a - Engine 1 starboard "STBD"b - Engine 2 port "PORT"

c - Engine 1 starboard 2 "STBD 2"d - Engine 2 port 2 "PORT 2"

8. The next screen should read, "IS THIS AN ELECTRONIC THROTTLE AND SHIFT SYSTEM".Select "YES". Press "SELECT" button to continue.

9. The next screen should read, "DO YOU HAVE FOOT THROTTLE INSTALLED?" (singleengines only). Press "SELECT" button to continue.


90-864196060 MAY 2006 Page 29 / 34

IMPORTANT: All Verado engines shift as a standard rotation, right hand. All OptiMax andMerCruiser engines must be selected as either standard rotation or counter rotation.10. Depending on engine type, propeller rotation screen may be displayed. The screen should

read, select prop shaft rotation for each engine. Consult engine installation manual for details."STND/RH" = standard rotation/right hand, "CNTR/LH" = counter rotation/left hand. Press"SELECT" button to continue.

11. The next screen should read, "HOW MANY HELMS AND ENGINES ARE THERE ON THISVESSEL?" Press "SELECT" button to continue.

12. The next screen should read, "PLEASE SELECT FROM THE FOLLOWING CONTROLTYPES": Select the control type used: 1) "PANEL MOUNT", 2) "CONSOLE MOUNT", 3)"ZERO EFFORT". Press "SELECT" button when completed to continue.

Calibration procedure will advance to adapting the type of control selected.CONSOLE MOUNT AND PANEL MOUNT CONTROLS

NOTE: On dual lever console controls, move and position both levers together.Move the control lever to the selected positions as instructed on the System View display, in orderfor the command module to learn all the lever positions.1. Move control lever to maximum reverse. Press "SELECT" when the lever is in position.2. Move control lever to reverse detent. Press "SELECT" when lever is in position.3. Move control lever to neutral. Press "SELECT" when lever is in position.4. Move control lever to forward detent. Press "SELECT" when lever is in position.5. Move control lever to maximum forward. Press "SELECT" when lever is in position.6. Move control lever to neutral. Press "SELECT" when lever is in position.7. You have successfully completed the adaptation process. Do you accept the results. Select

"YES" and press "SELECT" to accept.8. Initial calibration is complete. Turn the power off to the System View. Once the unit is turned

off, turn the power back on again for the settings to take effect.CONSOLE MOUNT AND PANEL MOUNT CONTROLS WITH FOOT THROTTLE

Move the control lever and foot throttle to the selected positions as instructed on the System Viewdisplay, in order for the command module to learn all the lever positions.1. Move control lever to maximum reverse and push foot throttle to WOT. Press "SELECT" when

lever is in position.2. Move control lever to reverse detent and return foot throttle to idle. Press "SELECT" when

lever is in position.3. Move control lever to neutral and keep foot throttle at idle. Press "SELECT" when lever is in

position.4. Move control lever to forward detent and keep foot throttle at idle. Press "SELECT" when lever

is in position.5. Move control lever to maximum forward position and push foot throttle to WOT. Press

"SELECT" when lever is in position.6. Move control lever to neutral and return foot throttle to idle. Press "SELECT" when lever is in

position.7. You have successfully completed the adaptation process. Select "YES" and press "SELECT"

to accept.8. Initial calibration is complete. Turn the power off to the System View. Once the unit is turned

off, turn the power back on again for the settings to take effect.ZERO EFFORT CONTROLS

NOTE: On multiple engine applications, move and position levers together.Move the control levers to the selected positions as instructed on the System View display, in orderfor the command module to learn all the lever positions.


Page 30 / 34 90-864196060 MAY 2006

1. Move shift lever to reverse position and move throttle lever to WOT. Press "SELECT" whenlevers are in position.

2. Keep shift lever in reverse and move throttle lever to idle. Press "SELECT" when levers arein position.

3. Move shift lever to neutral and keep throttle lever at idle. Press "SELECT" when levers are inposition.

4. Move shift lever to forward and keep throttle lever at idle. Press "SELECT" when levers arein position.

5. Move shift lever to forward and move throttle lever to WOT. Press "SELECT" when levers arein position.

6. Move shift lever to neutral and move throttle lever to idle. Press "SELECT" when levers arein position.

7. You have successfully completed the adaptation process. Select "YES" and press "SELECT"to accept.

8. Initial calibration is complete. Turn the power off to the System View. Once the unit is turnedoff, turn the power back on again for the settings to take effect.

ZERO EFFORT CONTROLS WITH FOOT THROTTLEMove the control lever and foot throttle to the selected positions as instructed on the System Viewdisplay, in order for the command module to learn all the lever positions.1. Move shift lever to reverse position and push foot throttle to WOT. Press "SELECT" when

levers are in position.2. Keep shift lever in reverse position and return foot throttle to idle. Press "SELECT" when levers

are in position.3. Moved shift lever to neutral position and keep foot throttle at idle. Press "SELECT" when levers

are in position.4. Move shift lever to forward and keep foot throttle at idle. Press "SELECT" when levers are in

position.5. Move shift lever to forward position and push foot throttle to WOT. Press "SELECT" when

levers are in position.6. Move shift lever to neutral and return foot throttle to idle. Press "SELECT" when levers are in

position.7. You have successfully completed the adaptation process. Select "YES" and press "SELECT"

to accept.8. Initial calibration is complete. Turn the power off to the System View. Once the unit is turned

off, turn the power back on again for the settings to take effect.

Setting Trailer and Trim LimitSetting Trailer Limit with DDT

! CAUTIONThe trailer limit must be set before setting the trim limit. Failure to set the trailer limit prior tosetting the trim limit, will create a programming error in the engine PCM. The PCM must bereprogrammed to correct the error. Contact Mercury Marine Technical Service Department forinstruction on reprogramming the PCM.

The function of the trailer limit:• Outboard - To limit the maximum tilt up position, preventing damage to the cowl.• MerCruiser - To limit the maximum trailer up position, preventing damage to swim platforms

etc.NOTE: It the DDT display is blank, the interface and/or adaptor cables are not installed properly.


90-864196060 MAY 2006 Page 31 / 34

1. Connect the DDT to the DLC/Depth transducer connector on the engine.2. Power up the DDT by turning the ignition to the ON position. On the "SELECT FUNCTION"

screen, press 2 - "MANUAL TEST".3. The "SELECT FUNCTION" screen will appear. Press 5 - "SPECIAL FUNCTIONS".4. The "SELECT FUNCTION" screen will appear. Press 8 - "TRAILER LIMIT".5. The "TRAILER LIMIT" screen will appear. To set the maximum trailer limit, press 1 - "YES".6. Trim the engine/drive up to the desired trailer position. To "CONTINUE" press 1 "YES".7. The maximum trailer limit setting is stored in the PCM. To "CONTINUE" press 1 "YES".8. Turn key off for 10 seconds, then back to run, for the PCM to accept the new limit. Press

"MODE" to exit the trailer limit calibration.NOTE: If the trailer limit update failed, press 1 "TO RETRY", or "MODE" to exit.

Setting Trailer Limit with CDS


The function of the trailer limit:• Outboard - To limit the maximum tilt up position, preventing damage to the cowl.• MerCruiser - To limit the maximum trailer up position, preventing damage to swim platforms

etc.1. Connect the CDS to the engine data link harness.2. Turn the ignition key to the "RUN" position.3. Select the correct engine location.4. Open the Tool Box icon in the CDS.5. Open the Active Diagnostics Icon.6. Scroll down the Active Diagnostics window and highlight "Trailer Limit".7. Run the trim system completely in (down) and hold the trim button in for 3-4 seconds. This will

configure the PCM to recognize the maximum trim in position according to the trim positionsensor.

8. Run the test.9. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to

store the current position in the ECU."10. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.

Setting Trim Limit with DDT


The trim limit configures the PCM to control the maximum up trim limit. The trim limit function isonly supported if the PCM has input for the three wire trim sensor.1. Power up the DDT by turning the ignition to the ON position. On the "SELECT FUNCTION"

screen, press 2 - "MANUAL TEST".2. Connect the DDT to the DLC/Depth transducer connector on the engine.


Page 32 / 34 90-864196060 MAY 2006

3. The "SELECT FUNCTION" screen will appear. Press 5 - "SPECIAL FUNCTIONS".4. The "SELECT FUNCTION" screen will appear. Press 7 - "TRIM LIMIT".5. The "TRIM LIMIT" screen will appear. To set the maximum up trim limit, press 1 - "YES".6. Trim the engine/drive to the desired trim position. To "CONTINUE" press 1 - "YES".7. The maximum trim limit setting is stored in the PCM. To "CONTINUE" press 1 "YES".8. Turn key off for 10 seconds, then back to run, for the PCM to accept the new limit. Press

"MODE" to exit the trailer limit calibration.If the trim limit update failed, press 1 "TO RETRY", or "MODE" to exit.

Setting Trim Limit with CDS


IMPORTANT: The engine must be running above 2000 RPM in gear to initiate the trim limit.The trim limit configures the PCM to control the maximum up trim limit. The trim limit function isonly supported if the PCM has input for the three wire trim sensor.1. Connect the CDS to the engine data link harness.2. Turn the ignition key to the "RUN" position.3. Open the Tool Box icon in the CDS.4. Open the Active Diagnostics Icon.5. Scroll down the Active Diagnostics window and highlight "Trim Limit".6. Run the test.7. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to

store the current position in the ECU."8. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.

Troubleshooting ProcedureTroubleshooting Information

NOTE: All of the following are determined by the calibration of the PCM. Upgrading the calibrationcan result in changes to these settings.

DEFAULT SENSOR VALUESDefault sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignitionvalues, when the sensor in question has exceeded its preprogrammed diagnostic limits. Defaultsensor values typically are used when the sensor has a circuit high or circuit low fault.Most temperature sensors default to 0 °C (32 °F). This can be verified by unplugging the sensorin question and watching the data stream value with the CDS or the DDT.Most pressure sensors default to a preprogrammed number also. MAP sensors usually default to100 kPa (29.5 in. Hg). This can be verified by unplugging the sensor in question and watching thedata stream value. Other pressure sensors will have their own default values which may bedetermined as described previously.

FAULT CONDITIONSMost faults can be detected with the engine running, or key-on, engine off. However, some faultsrequire the presence of engine RPM, and cannot be detected key-on, engine off. Examples of thistype of fault are EST (cylinders 1 through 8) shorted circuit and all injector faults (fuel and direct).Some faults are only detected in the key-on, engine off mode. Examples of the type of fault wouldbe EST (cylinders 1 through 8) open circuit.


90-864196060 MAY 2006 Page 33 / 34

In addition, some faults are programmed to ignore certain engine speeds. For example, the lowblock pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled untilenough RPM has been achieved to develop a reasonable amount of water pressure. Therefore,this fault will not be set at idle.Faults also take a certain time to set. The time it takes to set a fault varies greatly and can alsovary with engine RPM. Faults generally set faster at higher engine speed.

STICKY/NON-STICKY FAULTSAll faults are classified as either sticky or non-sticky. Sticky means that the fault, once set, willcontinue to show up as active, even if the circuit or problem has corrected itself. A key switch cycleis required to reset a sticky fault.A non-sticky fault is a fault that will change it's status from active to inactive without requiring akey switch cycle.The diagnostic tools (CDS or DDT) will continue to display a sticky fault as active, even thoughthe cause of the fault has been corrected. Cycle the key to reset all faults if there is difficultycorrecting a fault.

ENGINE GUARDIANAlmost every fault will cause the guardian program (within the PCM) to become active. The amountof guardian protection is expressed as a percentage. The higher the percentage, the more powerthe engine is allowed to produce. If available power (on the CDS or DDT) is showing 100%, thenguardian is not currently active and the engine is capable of producing full power. On a DTS engine,guardian closes the ETC to reduce engine power. Non-DTS engine reduce engine power bychanging injector and ignition operation.Guardian is always accompanied by another fault or faults that actually caused the guardian tobecome active. The more severe the fault, the more the guardian reduces available power. A smallproblem, such as a non-critical sensor going circuit high or circuit low, will result in available powerof 90% depending on product line. A severe problem such as low oil pressure, or a DTS shift orthrottle actuator failing, will result in forced idle which is usually displayed as 5-6% available power.Several minor faults occurring at the same time will cause the PCM to treat the faults as a moresevere situation.

WARNING HORN SIGNALSMost faults will cause the warning horn circuit to activate. How the warning horn activates dependson how serious the problem is. There are four warning horn states:• Caution - horn signal varies with product line and calibration. Minimal guardian.• Warning - horn signal varies with product line and calibration.• Severe - horn is beeping constantly.• Critical - horn is beeping constantly and guardian will be at forced idle.In addition, depending on the gauge package, there will be warning icons and fault messages onthe dash mounted gauges.

Special Tools - DTS Troubleshooting


Breakout Box SPX P/N MM-46225

Terminal Test Probe Kit SPX P/N MM-46523

12 Volt Shunt Connector 889675A01


2 to 4 Pin Harness Adapter 84-822560A12


Page 34 / 34 90-864196060 MAY 2006



DMT 2004 Digital Multimeter 91-892647A01

SECTION - 9 PREDELIVERY PREPARATION AND STORAGE

90-864196060 MAY 2006 Page 1 / 37

SECTION 9 - PREDELIVERY PREPARATION ANDSTORAGE

Table of ContentsPredelivery Preparation........................................................................................................................................... 3

Engine Oil..........................................................................................................................................................3Checking .................................................................................................................................................... 4Adding Engine Oil ...................................................................................................................................... 4

Power Steering Fluid.........................................................................................................................................4Power Trim Pump..............................................................................................................................................5Drive unit gear lube monitor..............................................................................................................................6Filling Coolant Recovery Bottle ........................................................................................................................6Alpha Trim Limit Switch Adjustment..................................................................................................................6

Analog Guages .......................................................................................................................................... 6Bravo Trim Limit Switch Adjustment - Analog Gauges .....................................................................................8Trim Position Sender Adjustment - Analog Gauges........................................................................................10Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method...................................................11Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method...................................................12Propeller Selection..........................................................................................................................................12Alpha Sterndrive Propeller Installation ...........................................................................................................13

Alpha Models ........................................................................................................................................... 13Bravo Sterndrive Propeller Installation............................................................................................................14

Bravo One Models ................................................................................................................................... 14Bravo Two Models ................................................................................................................................... 15Bravo Three ............................................................................................................................................. 16

Battery Connection..........................................................................................................................................17Priming The Fuel System................................................................................................................................17Test Running Engine ......................................................................................................................................18

Boat Out Of the Water ............................................................................................................................. 18Boat In the Water ..................................................................................................................................... 18Testing Preparation ................................................................................................................................. 18Testing .................................................................................................................................................... 19

Boat In The Water Tests.................................................................................................................................20Engine Idle Speed ................................................................................................................................... 20Wide Open Throttle Test .......................................................................................................................... 20Checking Shift Operation ......................................................................................................................... 20

Cold Weather and Extended Storage.................................................................................................................... 21Cold Weather or Extended Storage ...............................................................................................................21Seawater Section............................................................................................................................................21Closed Cooling Section...................................................................................................................................21Preparing Power Package For Storage...........................................................................................................21

Fuel System ............................................................................................................................................. 22Battery ..................................................................................................................................................... 22

Draining Instructions.............................................................................................................................................. 23Identification....................................................................................................................................................23

Manual Single Point Drain System .......................................................................................................... 23Air Actuated Single Point Drain System .................................................................................................. 233 Point Manual Drain System .................................................................................................................. 24Multi-Point Drain (MPD) System .............................................................................................................. 24

Boat In Water..................................................................................................................................................25Manual Single Point Drain System .......................................................................................................... 25Air Actuated Single Point Drain System .................................................................................................. 263 Point Manual Drain System .................................................................................................................. 28

Boat Out Of The Water....................................................................................................................................29

9

PREDELIVERY PREPARATION AND STORAGE SECTION - 9

Page 2 / 37 90-864196060 MAY 2006

Manual Single Point Drain System .......................................................................................................... 29Air Actuated Single Point Drain System ................................................................................................. 303 Point Manual Drain System .................................................................................................................. 32Multi-Point Drain (MPD) System .............................................................................................................. 33

Power Package Recommissioning..................................................................................................................35Predelivery Inspection.....................................................................................................................................37


90-864196060 MAY 2006 Page 3 / 37



80 SAE Engine Oil 30W Power trim pump Obtain Locally

87 High Performance Gear Lubricant Gear Lube Monitor 92-802854A1


95 2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A1

114 Power Trim and Steering Fluid Power steering pumpPower trim pump 92-802880A1

115 Premium Plus 2-cycle TC-W3 Outboard Oil Fuel system 92-802824A1

124 Fuel System Treatment & Stabilizer Fuel system 802875A1

Special ToolsFlushing Device 91-44357Q 2

9192



9195


Predelivery PreparationOnce the power package installation is complete, the following final steps should be taken toprepare power package for delivery to the customer. It is the boat manufacturer's responsibility toperform these procedures or to make arrangement with the dealer to have these procedurescompleted.

Engine Oil

! CAUTIONENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted bylaw. Do not spill oil or oil waste into the environment when using or servicing your boat. Containand dispose of oil or oil waste as directed by local authorities.


Page 4 / 37 90-864196060 MAY 2006

CHECKING1. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat

must be at rest in the water.2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to

allow trapped air to vent.NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine(flywheel end).IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OKrange mark on the dipstick.3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and

add. Fill as necessary with specified fluid.NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the ADD mark to the topof the OK range.

ADDING ENGINE OILIMPORTANT: Do not overfill the engine with oil.1. Remove oil fill cap.

a

6077

a - Oil fill cap

IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OKrange mark on the dipstick.2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on

the dipstick.3. Replace the fill cap.

Power Steering FluidIMPORTANT: Use only specified lubricant.

! CAUTIONDo not RUN POWER STEERING DRY or pump will be damaged.

1. Position sterndrive unit so that it is straight back.2. Remove fill cap from power steering pump and check fluid level using dipstick. Add fluid as

required.


90-864196060 MAY 2006 Page 5 / 37

NOTE: Be prepared to add fluid to pump when first starting engine.

a b

9356

a - Fill cap b - Dipstick


114 Power Trim and Steering Fluid Power steering pump 92-802880A1

Description Where used Part Number

Dexron III - AutomaticTransmission Fluid Power steering pump Obtain locally

Power Trim Pump1. Check oil level with sterndrive unit in the full DOWN/IN position.IMPORTANT: Use only specified lubricant.2. Raise and lower sterndrive unit (to the full UP/OUT position) 6 to 10 times to purge air from

system. Check oil level visually, (with drive unit in the full DOWN/IN position). Oil level shouldbe maintained within the "MIN" and "MAX" lines on the reservoir.

a b

8539

c

a - Fill cap (top and underneath sideviews)

b - Reservoir fill neck

c - "MIN" and "MAX" lines




Page 6 / 37 90-864196060 MAY 2006


80 SAE Engine Oil 30W Power trim pump Obtain Locally

3. Check the power trim pump hose fittings for leaks. If fluid is visible at the fittings, checkconnections.

Drive unit gear lube monitorIMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always checkoil level when drive is cool and engine is shut down.1. Remove the gear lube monitor cap.2. Fill the gear lube monitor to the Operating Range (full) line.

b

a

7884

Typicala - Gear lube monitor cap b - Operating Range (full) line



3. Ensure that the rubber gasket is inside the gear lube monitor cap.4. Install the gear lube monitor cap. Do not overtighten.5. Recheck gear lube level after first use.

Filling Coolant Recovery BottleNOTE: This section applies to Closed Cooled models only.1. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution.

Reinstall cap.2. Recheck coolant level after first WOT boat test and add coolant, if necessary.3. Maintain coolant level in coolant recovery reservoir between ADD and FULL marks with engine

at normal operating temperature.

Alpha Trim Limit Switch AdjustmentANALOG GUAGES



90-864196060 MAY 2006 Page 7 / 37


1. Alpha sterndrive, adjust trim limit switch as follows:NOTE: Trim limit switch is located on the port side of gimbal ring.

a. Loosen screws and turn trim limit switch clockwise to end of slots.

a b

b

7879

Trim limit switcha - Screws b - Slots


TRAILER BUTTON.d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension

shown.

7880

a



Page 8 / 37 90-864196060 MAY 2006

a7881

Alpha trim cylinder extendeda - Maximum520 mm (20-3/4 in.)


Bravo Trim Limit Switch Adjustment - Analog Gauges



IMPORTANT: All Bravo models must have the trim-in-limit insert positioned properly beforeperforming the trim position sender adjustment.1. Ensure that the trim-in-limit insert is positioned as shown for the appropriate Bravo model.

a

8548

a

8557

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

2. Bravo sterndrive, adjust trim limit switch as follows:NOTE: Trim position sender is located on the starboard side of gimbal ring.


90-864196060 MAY 2006 Page 9 / 37

a. Loosen screws and turn trim limit switch clockwise to end of slots.

a b

b

7879

Trim limit switcha - Screws b - Slots


TRAILER BUTTON.d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension

shown.

7880

a


a8558

Bravo trim cylinder extendeda - Trim Limit Dimension 21-3/4 in. (552 mm)



Page 10 / 37 90-864196060 MAY 2006

Trim Position Sender Adjustment - Analog GaugesNOTE: Trim position sender is located on the starboard side of gimbal ring.1. Loosen both trim position sender retaining screws.

a

b

7882


! CAUTIONDo not start engine in the following step or damage to sterndrive unit and engine could resultfrom lack of cooling water.

2. Turn ignition key to RUN position.3. Trim sterndrive unit to the full DOWN/IN position.4. Rotate trim position sender as required to show full DOWN/IN position on dashboard

instrument as shown.

a7883

a - Trim gauge needle

5. Tighten retaining screws and turn ignition key to the OFF position.

a

b

7882



90-864196060 MAY 2006 Page 11 / 37

Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool MethodNOTE: Trim position sender is located on the starboard side of gimbal ring.

a

b

21076


1. Trim the sterndrive unit to the full DOWN/IN position.2. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool.3. Turn ignition key switch to the RUN position.4. Set the scan tool to display TRIM POS counts and note the value displayed.5. TRIM POS counts must be between 20 and 24 counts.6. If TRIM POS counts are within specified range, proceed to step 6. Otherwise:

a. Loosen both trim position sender retaining screws.b. Rotate the trim position sender until TRIM POS counts are within the specified range,

preferably near the middle of the range.c. Tighten the trim position sender retaining screws.d. Verify TRIM POS counts are still within the specified range. Repeat steps "a" through

"c" if necessary.7. Turn the ignition key switch to the OFF position, disconnect the scan tool from the Diagnostic

Link connector, and install the weather cap in the Diagnostic Link connector.


Page 12 / 37 90-864196060 MAY 2006

Trim Position Sender Adjustment - SmartCraft Gauges Multimeter MethodNOTE: Trim position sender is located on the starboard side of gimbal ring.

a

b

21076


1. Trim the sterndrive unit to the full DOWN/IN position.2. Disconnect trim position sender wires from engine wiring harness connections.3. Connect Multimeter leads to trim position sender wires and set Multimeter to display resistance

(Ohms).4. Note resistance reading. Resistance must be between 16 and 20 Ohms.5. If resistance reading is within specified range, proceed to step 6. Otherwise:

a. Loosen both trim position sender retaining screws.b. Rotate the trim position sender until resistance reading is within the specified range,

preferably near the middle of the range.c. Tighten the trim position sender retaining screws.d. Verify resistance reading is still within the specified range. Repeat steps "a" through "c"

if necessary.6. Disconnect the trim position sender wires from the multimeter leads and reconnect trim

position sender wires to engine wiring harness connections.7. Refer to Mercury SmartCraft Operator's Manual for final Trim Calibration procedure.

Propeller SelectionIMPORTANT: Installed propeller must allow engine to run at its specified maximum WOT rpm.Use an accurate service tachometer to verify engine operating rpm.It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power packagewith the correct propeller. Specified engine WOT and operating rpm range are listed in the MercuryMerCruiser Operation, Maintenance and Warranty Manual attached to the engine.Select a propeller that will allow the engine power package to operate at or near the top end ofthe recommended WOT operating rpm range with a normal load.If full throttle operation is below the recommended range, the propeller must be changed to preventloss of performance and possible engine damage. On the other hand, operating an engine abovethe recommended operating rpm range will cause higher than normal wear and/or damage.After initial propeller selection, the following common problems may require that the propeller bechanged 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 increased load (additional passengers, pulling skiers) causes a loss of rpm.


90-864196060 MAY 2006 Page 13 / 37

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Donot operate at full throttle when using the lower pitch propeller but not pulling skiers.Because of the many variables of boat design, only testing will determine the best propeller for aparticular application. Available propellers are listed in the Mercury Precision Parts AccessoriesGuide.See BOAT IN THE WATER TESTS, Maximum RPM Test at the back of this manual.

Alpha Sterndrive Propeller Installation



7885

1. To aid in future removal of the propeller, liberally coat propeller shaft splines with lubricant.



IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed throughpropeller nut after torquing it.

ALPHA MODELS1. Install propeller with attaching hardware as shown.2. Torque the nut, then continue to tighten until 3 tabs on the tab washer align with grooves on

spline washer.


Page 14 / 37 90-864196060 MAY 2006

3. Bend the 3 tabs down into grooves.

ab c

d

e f

g 5301

a - Propeller shaft splinesb - Forward thrust hubc - Flo-torque II drive hubd - Propeller

e - Drive sleeve adapterf - Locking tab washerg - Propeller nut


Alpha propeller nutAlpha propeller nut1.75 55

Then align tabs with grooves.




7885

BRAVO ONE MODELSIMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft.1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.



1. The propeller torque stated is the minimum torque value.


90-864196060 MAY 2006 Page 15 / 37





NOTE: Anti-corrosion grease is for salt water applications only.2. Install propeller with attaching hardware as shown.3. Torque the propeller nut, then continue to tighten until 3 tabs on the tab washer align with

grooves on spline washer. Bend the 3 tabs down into grooves.

ab c

d

e f

g 5301

Bravo Onea - Propeller shaft splinesb - Forward thrust hubc - Flo-Torque II drive hubd - Propeller





NOTE: The propeller torque stated is a minimum torque value.BRAVO TWO MODELS

IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft.1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.







NOTE: Anti-corrosion grease is for salt water applications only.2. Install propeller with attaching hardware as shown.


Page 16 / 37 90-864196060 MAY 2006

3. Torque the propeller nut, then continue to tighten until 3 tabs on the tab washer align withgrooves on spline washer. Bend the 3 tabs down into grooves.

8566

ab

c

fd

eBravo Two






NOTE: The propeller torque stated is a minimum torque value.BRAVO THREE

1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.







NOTE: Anti-corrosion grease is for salt water applications only.2. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.3. Align splines and place front propeller on propeller shaft.4. Install front propeller locknut and torque.


Front dual propeller nut 136 100

NOTE: The propeller torque stated is a minimum torque value.5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub6. Align splines and install aft propeller.7. Install propeller nut and torque.


Rear dual propeller nut 81 60


90-864196060 MAY 2006 Page 17 / 37

NOTE: The propeller torque stated is a minimum torque value.8. Install propeller shaft anode and screw and torque.

ef

a

bc d

5304

g h

i j





Battery ConnectionIMPORTANT: Engine electrical system is negative (-) ground.1. Ensure that all battery terminal connections are tight.

Priming The Fuel SystemIMPORTANT: Use a portable fuel tank with a primer bulb fuel line.

! WARNINGBe careful when working on fuel system. Gasoline is extremely flammable and highly explosiveunder certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilledfuel immediately.

1. Disconnect the fuel line from the fuel tank to the fuel inlet fitting and plug the line, if attachedto the engine.

2. Attach portable fuel tank to the fitting and secure tightly.3. Squeeze the primer bulb until the bulb becomes firm.4. Turn the ignition switch to the "RUN" position for 3 seconds and then turn OFF.NOTE: Do not turn the key switch to the "START" position during the priming.5. Repeat Step 3. and Step 4. three more times.IMPORTANT: Before disconnecting the fuel line primer bulb, ensure that the bulb is soft and doesnot still have fuel in it to prevent spilling fuel.6. Disconnect the primer bulb fuel line from the fuel inlet fitting.7. Remove the plug from the fuel tank fuel line.8. Attach the fuel line from the fuel tank to the fuel inlet and tighten securely.


Page 18 / 37 90-864196060 MAY 2006

Test Running Engine

! WARNINGAvoid Injury: If engine is to be tested with the boat out of the water, the propeller must be removedto avoid injury.


BOAT OUT OF THE WATERFor engine operation tests with the boat out of the water:IMPORTANT: If using a flushing attachment over the water inlet holes with a water hose, do notuse full water source pressure.1. Install a flushing attachment over the sterndrive water inlet holes.2. Connect a hose between the flushing attachment and a water source.3. Open the water source about 1/2 maximum. Do not use full water pressure.IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and usinga through the hull water inlet, need a supply of cooling water available to both the sterndrive unitand to the engine during operation.4. On Engines With Through The Hull Water Inlet, supply sufficient cooling water to the

engine.5. Proceed to Testing Preparation.

BOAT IN THE WATERFor engine operation tests with the boat in the water:IMPORTANT: If using a test tank the water level must be above the water inlet holes on thesterndrive unit or the through the hull pickup.1. Ensure that the water level is above the water inlet holes on the sterndrive or the through the

hull pickup.2. Proceed to Testing Preparation.

TESTING PREPARATION

! WARNINGDo not leave the helm unattended when performing tests with the boat in the water.

1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight.NOTE: Refer to appropriate Mercury MerCruiser Operation, Maintenance and Warranty Manualfor operating specifications. Refer to appropriate Mercury MerCruiser Service Manual for fluidcapacity information.2. Check crankcase oil level.IMPORTANT: Oil level in monitor will rise and lower during sterndrive operation. Always check oillevel when sterndrive is cool and engine is shut down.3. Check sterndrive unit oil level in the monitor.4. Check drive belt tension.5. Test Audio Warning system in accordance with instructions on instrumentation panel decal.6. Supply water to the engine either by putting boat in the water or by using the correct flush

device.IMPORTANT: If using a test tank, ensure water level is above water intake holes.


90-864196060 MAY 2006 Page 19 / 37

! CAUTIONIf using flush test device, install over water intake holes and connect a water hose as shown.Do not use full water tap pressure. Also, do not operate engine above 1500 rpm, as suctioncreated could cause water hose to collapse causing water supply to be cut off.

! WARNINGIf engine is to be tested with boat out of water, the propeller must be removed to avoid injury.

5752 5773

Low water pickup Side pickup

IMPORTANT: Engines may also use a through the hull or through the transom inlet. If so, watermust be provided to these inlets or air flow must be blocked. If a block-off plate is used, the throughthe transom or through the hull fitting is the only water inlet to the engine.



TESTING1. Place sterndrive in neutral , idle speed and start engine.2. Slowly advance throttle until engine reaches 1300 rpm (+/-100 rpm).


3. Watch all gauges for normal readings.4. Turn steering wheel RIGHT/STARBOARD, then LEFT/PORT, and ensure drive unit turns the

correct way.5. Inspect engine compartment for water, oil, fuel, and exhaust leaks.6. Turn steering wheel PORT until it stops and continue to apply pressure. If pump lugs (engine

rpm drops and/or power steering pump tone changes):a. Check for an obstruction between gimbal ring and gimbal housing and all moving steering

componentsb. Ensure that steering lever is not contacting cutout in transom. If contact is being made,

modify cutoutc. Check steering cable end dimension with cable FULLY EXTENDED.

7. Turn steering wheel STARBOARD until it stops and continue to apply pressure. If pump lugs(engine rpm drops and/or power steering pump tone changes):


Page 20 / 37 90-864196060 MAY 2006

a. Turn off engine.b. Remove cap/dipstick from power steering pump. Check fluid level and add if necessary.

a7890

a - Dipstick (full when hot line)

Boat In The Water TestsENGINE IDLE SPEED

Engine should idle at RPM as specified in appropriate Mercury MerCruiser Operation,Maintenance, and Warranty Manual with boat in the water, drive unit in FORWARD gear andengine at normal operating temperature. If idle speed is incorrect, proceed as follows:1. Ensure that throttle cable has been adjusted properly.

WIDE OPEN THROTTLE TESTIMPORTANT: To operate engine at full throttle before the break-in period is complete, follow thisprocedure.1. Place remote control in neutral , idle speed and start engine.2. Slowly advance throttle until engine reaches 1300 rpm (+/-100 rpm).


3. Watch all gauges for normal readings.4. When engines reaches mornal operating temperature, run the boat up on plane.5. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM.6. To test if the correct propeller has been installed, operate boat (with normal load on board) at

WOT and check RPM with an accurate tachometer. Engine RPM should be near top of thespecified range so that, under a heavy load, engine speed will not fall below specifications. Ifengine speed is too high, replace propeller with a higher pitch propeller. Normally a25 mm (1 in.) propeller pitch change causes an RPM change of 150 RPM.

7. Return to idle speed.8. Shut off engine.9. Check coolant level and add coolant if necessary.

CHECKING SHIFT OPERATIONWith sterndrive unit installed and engine operating, ensure that drive unit shifts properly, asexplained following:1. Shift into FORWARD and REVERSE gear, ensuring that clutch engages before engine begins

to accelerate.2. Accelerate engine while in FORWARD and REVERSE gear to ensure that engine does not

stop.3. If the proper results are not achieved in the previous steps, shift cables must be readjusted.


90-864196060 MAY 2006 Page 21 / 37

4. Shifting from FORWARD and REVERSE to NEUTRAL: ensure drive unit is in NEUTRALbefore remote control shift lever comes to the NEUTRAL detent position. Perform this checkusing various shifting rates to ensure that the drive unit shifts the same whether shifting fastor slow.

Cold Weather and Extended StorageCold Weather or Extended Storage

! CAUTIONSterndrive unit should be stored in full down position. Universal Joint bellows may develop a setif unit is stored in raised position and may fail when unit is returned to service.

Seawater SectionIMPORTANT: Drain seawater section of closed cooling system only.IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.

! CAUTIONSeawater section of cooling system must be completely drained for winter storage, orimmediately after cold weather use, if the possibility of freezing temperatures exist. Failure tocomply may result in trapped water causing freeze and/or corrosion damage to engine. Damagecaused by freezing is not covered by the Mercury MerCruiser Limited Warranty.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.

Closed Cooling Section

! CAUTIONIf engine will be exposed to freezing temperatures, ensure closed cooling section is filled withan ethylene glycol antifreeze and water solution properly mixed to protect engine to lowesttemperature to which it will be exposed.

IMPORTANT: Closed cooling section must be kept filled year-round with recommended coolant.IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine.NOTE: If recommended coolant is unavailable, any type of ethylene glycol based antifreeze maybe used, but it will require replacement every two years.

! CAUTIONEnsure that boat is out of the water or seacock is closed and that bilge pump is operating. Excesswater in the bilge can damage engine or cause boat to sink.

Preparing Power Package For Storage1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount

of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline. Follow instructionson the container.

2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuelwithout alcohol is not available): Fuel tanks should be drained as low as possible andQuicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank.Refer to Fuel Requirements for additional information.


Page 22 / 37 90-864196060 MAY 2006

NOTE: If desired, a portable fuel tank can be used to perform the remainder of the power packagelay up procedures. Be sure to add an appropriate amount of Gasoline Stabilizer to the portabletank.3. Flush the cooling system.4. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel

with Quicksilver Gasoline Stabilizer to circulate through the fuel system. Shut off engine.5. Change the oil and oil filter.6. Store boat with drive unit in full down/in position.7. For additional assurance against freezing and rust, after draining fill the cooling system with

a mixture of propylene glycol and tap water mixed to manufacturer's recommendation toprotect engine to the lowest temperature to which it will be exposed during cold weather orextended storage.

FUEL SYSTEM

! WARNINGThe fuel injection system is pressurized. Avoid serious injury from an explosion. Use care whenremoving water separating fuel filter. Allow engine to cool down before removing the waterseparating fuel filter. Also, hold a clean shop towel over the water separating fuel filter whenremoving it, to help avoid fuel spraying on the engine.

! WARNINGFuel vapors can be present in the engine compartment. Avoid injury or power package damagecaused by fuel vapors or explosion. Always ventilate the engine compartment prior to servicingthe power package.

1. In a 23 liter (6 U.S. gal.) remote fuel tank mix:a. 19 liter (5 U.S. gal) regular unleaded 87 octane (90 RON) gasolineb. 1.89 liter (2 U.S. qts.) Premium Plus 2-Cycle TC-W3 Outboard Oilc. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System

Treatment and Stabilizer Concentrate.


115 Premium Plus 2-cycle TC-W3Outboard Oil Fuel system 92-802824A1

124 Fuel System Treatment &Stabilizer Fuel system 802875A1

2. Allow the engine to cool down.IMPORTANT: Immediately wipe up any fuel spills or sprays.3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not

equipped with a fuel shut off valve.4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting.IMPORTANT: Supply cooling water to the engine.5. Start and operate the engine at 1300 rpm for 5 minutes.6. After specified operating time is complete, slowly return throttle to idle rpm and shut engine

off.IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the engine'sfuel system to become completely dry.7. Remove and discard the water separating fuel filter.8. Install a new filter.

BATTERYFollow the battery manufacturer's instructions for storage.


90-864196060 MAY 2006 Page 23 / 37

Draining Instructions! CAUTION

Excess water in bilge can damage engine or cause boat to sink. Ensure that the boat is out ofthe water or the seacock is closed and bilge pump is operating before beginning procedure.

! CAUTIONDo not operate engine with drain system open. Excess water in bilge can damage engine orcause boat to sink.

IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.Your power package is equipped with a drain system. Refer to Identification on the following pageto determine which instructions apply to your power package.The power package should be drained before flushing or prior to extended or cold weather storage.IMPORTANT: The engine must not be operating at any point during this procedure.

IdentificationMANUAL SINGLE POINT DRAIN SYSTEM

a

b

9326

b

a - Blue handle b - Blue drain plug location

AIR ACTUATED SINGLE POINT DRAIN SYSTEM

ab c

d

9336

ab

c

d

9327

Closed cooled models Seawater cooled modelsa - Blue drain plug locationb - Blue air pump

c - Air manifoldd - Green indicators


Page 24 / 37 90-864196060 MAY 2006

3 POINT MANUAL DRAIN SYSTEM

9328

aa

a - Blue drain plug

MULTI-POINT DRAIN (MPD) SYSTEM

10226 M110050

93235672

b

aa

b

9330

a - Side of cylinder block b - Bottom of exhaust manifolds

a a

9331

a - Drain plug


90-864196060 MAY 2006 Page 25 / 37

a

9332

a - Drain plug

Boat In WaterMANUAL SINGLE POINT DRAIN SYSTEM

1. Close the seacock.2. Rotate blue handle COUNTERCLOCKWISE until it stops (approximately 2 turns). The red on

the handle shaft indicates that the drain system is open. Do not force handle as this will createnew threads.

3. Immediately remove the blue drain plug from the side of the thermostat housing. This mustbe removed within 30 seconds to properly vent the cooling system.

a

b

9333

a - Blue handle b - Blue drain plug location

4. Visually verify that water is draining. If water does not drain, remove blue drain plug fromdistribution housing and drain manually.

ab

9334

a - Drain location - orange or red b - Blue drain plug


Page 26 / 37 90-864196060 MAY 2006

5. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommendsleaving the drain system open while transporting the boat or while performing othermaintenance.

6. Reinstall the blue drain plug in the thermostat housing.7. Close the drain system by rotating the blue handle CLOCKWISE until it stops and install the

blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtightenthe handle as this will create new threads.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.8. Open the seacock prior to operating the engine.

AIR ACTUATED SINGLE POINT DRAIN SYSTEMNOTE: This procedure is written for the air pump that is attached to the engine. However, any airsource can be used.1. Close the seacock.2. Remove the blue air pump from the engine or remote mounting location.3. Ensure that lever on top of pump is flush with the handle (horizontal).4. Install air pump on the fitting in the air manifold.

a

8223

a - Green indicators

5. Pull lever on air pump up (vertical) to lock pump on the fitting.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.


90-864196060 MAY 2006 Page 27 / 37

7. Immediately remove the blue drain plug from the side of the thermostat housing or the heatexchanger. This must be removed within 30 seconds to properly vent the cooling system.

ab c

d

9336

ab

c

d

9327



8. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain Systeminstructions.

b

a9335

a - Port side drain location b - Starboard side drain location

9. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the greenindicators extended.

10. Crank engine over slightly with starter motor to purge any water trapped in seawater pump.Do not allow engine to start.

11. Reinstall the blue drain plug in the thermostat housing.12. Remove the air pump from the air manifold 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.IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.


Page 28 / 37 90-864196060 MAY 2006

14. Before launching boat, pull up on manual release valve. Verify that green indicators are nolonger extended.

a6135


15. Open the seacock prior to operating the engine.3 POINT MANUAL DRAIN SYSTEM

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drainsystem or if the single point drain system fails.1. Close the seacock.2. Remove the blue drain plug from the distribution housing (lower front, port side).

a 9348

a - Blue drain plug

3. Immediately remove the blue drain plug from the side of the thermostat housing. This mustbe removed within 30 seconds to properly vent the cooling system.

a

8219

a - Blue drain plug location


90-864196060 MAY 2006 Page 29 / 37

4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).

9349

a

a - Blue drain plug location

5. Verify that water is draining from each opening.6. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends

leaving the drain system open while transporting the boat or while performing othermaintenance.

7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickuppump. Do not allow engine to start.

8. Prior to launching boat or starting the engine, close the drain system by installing the 4 bluedrain plugs.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.9. Open the seacock prior to operating the engine.

Boat Out Of The WaterMANUAL SINGLE POINT DRAIN SYSTEM

1. Place the boat on a level surface to ensure complete draining of system.


Page 30 / 37 90-864196060 MAY 2006

2. Rotate blue handle COUNTERCLOCKWISE until rotation stops (approximately 2 turns). Thered on the handle shaft indicates that the drain system is open. Do not force handle as thiswill create new threads.

a

9347

a - Blue handle

3. Visually verify that water is draining. If water does not drain, remove blue drain plug fromdistribution housing and allow to drain manually.

ab

9334

a - Drain location - orange or red b - Blue drain plug

4. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommendsleaving the plugs out while transporting the boat or while performing other maintenance toensure that all water is drained.

5. Close the drain system by rotating the blue handle CLOCKWISE until it stops or installing theblue drain plug. The handle is fully seated when no red is visible. Do not overtighten handleas this will create new threads.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.

AIR ACTUATED SINGLE POINT DRAIN SYSTEMNOTE: This procedure is written for the air pump that is attached to the engine. However, any airsource can be used.1. Place the boat on a level surface to ensure complete draining of system.2. Remove the blue air pump from the engine or remote mounting location.3. Ensure that lever on top of pump is flush with the handle (horizontal).


90-864196060 MAY 2006 Page 31 / 37

4. Install air pump on the fitting in the air manifold.

a

8223


5. Pull lever on air pump up (vertical) to lock pump on the fitting.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.

ab c

d

9336

ab

c

d

9327




Page 32 / 37 90-864196060 MAY 2006

7. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System.

b

a9335

a - Port side drain location b - Starboard side drain location

8. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the greenindicators extended.

9. Crank engine over slightly with starter motor to purge any water trapped in seawater pump.Do not allow engine to start.

10. Remove the air pump from the air manifold and return it to the mounting bracket.11. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while

performing other maintenance to ensure that all water is drained.IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.12. Before launching boat, pull up on the manual release valve. Verify that the green indicators

are no longer extended.

a6135


3 POINT MANUAL DRAIN SYSTEMNOTE: Use this procedure if your engine is not equipped with an air actuated single point drainsystem or if the single point drain system fails.1. Place the boat on a level surface to ensure complete draining of system.


90-864196060 MAY 2006 Page 33 / 37

2. Remove 3 blue drain plugs: 1 from the distribution housing (lower front, port side) and 2 fromthe seawater pickup pump (front, starboard side).

a 9348

9349

a

a - Blue drain plug

3. Verify that water is draining from each opening.4. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends

leaving the plugs out while transporting the boat or while performing other maintenance toensure that all water is drained.


IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.6. Prior to launching boat or starting the engine, close the drain system by re-installing the 3 blue

drain plugs.MULTI-POINT DRAIN (MPD) SYSTEM

1. Place the boat on a level surface to ensure complete draining of system.2. Remove blue drain plugs from the following locations. It may be necessary to clean out drain

holes using a stiff piece of wire. Do so until the entire system is drained.a. Port and starboard side of cylinder block.b. Bottom of exhaust manifolds.

10226 M110050

93235672

b

aa

b

9330

a - Side of cylinder block b - Bottom of exhaust manifolds


Page 34 / 37 90-864196060 MAY 2006

c. Water circulating pump hose.

9350

a

a - Water circulating pump drain plug

d. Fuel cooler to thermostat housing hose.

a

9352

a - Drain plug

e. Check valve.

a

9332

a - Drain plug


90-864196060 MAY 2006 Page 35 / 37

3. On models with seawater pickup pump, remove the 2 blue drain plugs. If your seawater pickuppump does not have blue drain plugs or you are unable to access them, loosen clamps andremove both hoses.

9354

b

9353

a

a - Hose clamps b - Blue drain plugs

4. Using a piece of wire, check water drain holes in sterndrive unit to ensure that they are open.

cf

be

d

a

9355

Sterndrive unit water drain holesa - Speedometer pitot tubeb - Trim tab cavity vent holec - Trim tab cavity drain passage

d - Gear housing water drain hole (1each - port and starboard)

e - Gear housing cavity vent holef - Gear housing cavity drain hole


6. After cooling system has been drained completely, install drain plugs, reconnect hoses andtighten all hose clamps securely.

IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic andenvironmentally safe) antifreeze be used in the seawater section of the cooling system for coldweather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitorand is recommended for use in marine engines. Follow the propylene glycol manufacturer'srecommendations.

Power Package Recommissioning1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.


Page 36 / 37 90-864196060 MAY 2006

! CAUTIONAvoid electrical system damage. When installing the battery, be sure to connect the negative (-)battery cable to the negative (-) battery terminal and the positive (+) battery cable to the positive(+) battery terminal.

2. Install a fully-charged battery. Clean the battery cable clamps and terminals and reconnectcables (see CAUTION listed above). Tighten each cable clamp securely when connecting.

3. Coat the terminal connections with a battery terminal anti-corrosion agent.4. Perform all the checks in the BEFORE STARTING column of the Operations Chart.


5. Start the engine and closely observe instrumentation to ensure that all systems are functioningcorrectly.

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.


90-864196060 MAY 2006 Page 37 / 37

Predelivery Inspection

Not Applicable Check /Adjust CHECK BEFORE RUNNING Not Applicable Check /

Adjust ON THE WATER TEST

⃞ ⃞ Drain plug in and petcocks closed ⃞ ⃞ Engine alignment (Inboards only)

⃞ ⃞ Seawater inlet valve open ⃞ ⃞ Starter neutral safety switchoperation

⃞ ⃞ Engine mounts tight ⃞ ⃞ Water pump operation⃞ ⃞ Engine alignment ⃞ ⃞ Instruments(s) operation⃞ ⃞ Drive unit fasteners torqued ⃞ ⃞ Fuel leaks⃞ ⃞ Power trim cylinders fasteners tight ⃞ ⃞ Oil leaks⃞ ⃞ Battery fully charged and secured ⃞ ⃞ Water leaks⃞ ⃞ All electrical connections tight ⃞ ⃞ Exhaust leaks⃞ ⃞ Exhaust system hose clamps tight ⃞ ⃞ Ignition timing

⃞ ⃞ All fuel connections tight ⃞ ⃞ Idle________ rpm, withinspecifications

⃞ ⃞ Correct rotation propeller (installedand torqued) ⃞ ⃞ Forward - Neutral - Reverse gear

operation

⃞ ⃞ Throttle, shift and steering systemfasteners tightened properly ⃞ ⃞ Steering operation throughout

range

⃞ ⃞ Throttle plates open and closecompletely ⃞ ⃞ Acceleration from idle rpm

⃞ ⃞ Crankcase oil level ⃞ ⃞WOT________ rpm withinspecifications (in FORWARDgear)

⃞ ⃞ Power trim oil level ⃞ ⃞ Power trim operation

⃞ ⃞ Sterndrive unit oil level ⃞ ⃞ Trim tab adjustmentBoathandling

⃞ ⃞ Power steering fluid level AFTER ON WATER TEST⃞ ⃞ Closed cooling level ⃞ ⃞ Propeller nut torque

⃞ ⃞ Transmission fluid level ⃞ ⃞ Fuel, oil, coolant, water and fluidleaks

⃞ ⃞ Alternator belt tension ⃞ ⃞ Oil and fluid levels

⃞ ⃞ Seawater pickup pump belt tension ⃞ ⃞ Apply Quicksilver CorrosionGuard to engine package

⃞ ⃞ Power steering pump belt tension ⃞ ⃞C.A.R.B. Hang Tag and OwnersManual in boat1.

⃞ ⃞ Audio warning system operation ⃞ ⃞C.A.R.B. Decal properly affixedto boat hull1.

1. If registered to a CA resident.


NOTES:

Page 38 / 37 90-864196060 MAY 2006

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