Mercruiser Esp

DENTRO-FUERABORDA MODELOS MOTOR GASOLINA MANUAL
Models Covered
Alpha
Models Covered 4.3 MPI 5.0 MPI 5.0 MPI DTS 350 MAG MPI 350 MAG MPI DTS Serial Number
0W650000 o superior
Bravo
Models Covered 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 Serial Number
0W650000 o superior
Notice
NOTICE
Despus de completar la instalacin, estas instrucciones se deben colocar con el producto para el uso en el futuro del dueo
NOTICE
Pre preparacin debe realizarse antes de la entrega de barco para el dueo del producto. Aviso a los fabricante de la embarcacin / instalador A lo largo de esta publicacin, Advertencias y Precauciones (acompaado por el Internacional Smbolo de peligro) se utiliza para alertar al fabricante o instalador para instrucciones especiales sobre un determinado servicio o la operacin que pueden ser peligrosos si se realizan correctamente y sin respeto. - Observarlas con cuidado!
Page i
2006 Mercury Marine
90-864196060 APRIL 2006
Estas alertas de seguridad por s solas no pueden eliminar los peligros que la seal. El estricto cumplimiento de estas instrucciones especiales al realizar el servicio, adems de la operacin de sentido comn, son las principales medidas de prevencin de accidentes.
! WARNING
indica una situacin potencialmente peligrosa que, de no evitarse, puede ocasionar la muerte o lesiones graves.
! CAUTION
indica una situacin potencialmente peligrosa que, de no evitarse, puede resultar en lesiones leves o moderadas o daos materiales. Tambin puede utilizarse para alertar contra las prcticas inseguras. IMPORTANTE: Indica la informacin o instrucciones que son necesarios para el correcto instalacin y / o operacin.
NOTA: Consulte la MerCruiser apropiado Mercurio de Producto de Aplicaciones Manual de
recomendaciones de aplicacin. Este manual de instalacin que se ha escrito y publicado por Mercury MerCruiser para ayudar a los fabricante de la embarcacin (OEM) en la instalacin de los productos descritos en este documento. Se supone que dicho personal est familiarizado con la instalacin de productos marinos. Adems, se supone que est familiarizado con, si no estn entrenados en la recomienda los procedimientos de instalacin de Mercury MerCruiser producto. No poda saber de asesoramiento o el comercio martimo de todas las instalaciones imaginables y de los posibles riesgos y / o los resultados de cada instalacin. Por lo tanto, el fabricante es responsable de cualquier instalacin que no cumpla con los requisitos de este manual. Es responsabilidad del fabricante de la embarcacin para seleccionar el motor apropiado / espejo / paquete de la unidad (incluyendo la relacin de transmisin correcta y la hlice) para un barco determinado. Mercurio MerCruiser recomienda que cualquier nuevo o nico casco / potencia combinacin 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, comunquese con la Mercury Marine ocina o distribuidor autorizado. Toda la informacin, ilustraciones y especicaciones contenidas en este manual se basan en la reciente del producto disponible en el momento de su publicacin. Mercury Marine se reserva el derecho a realizar cambios en cualquier momento y sin obligacin. Cuando sea necesario, las revisiones de este manual ser enviado a todas las compaas de barcos OEM.
Page ii
Esquema Manual 1 - Informacin Importante 2 - Construccin de embarcaciones 3 - Sistema de escape 4 - Sistema de combustible 5 - Sistema de refrigeracin 6 - Sistema de transmisin e instalacin del motor 7 - arranque y elctrico 8 - Control remoto 9 - Preparacin Preentrega y almacenamiento
Important Information
Boat Construction
Exhaust System
Fuel System
Cooling System
Drive System And Engine Installation
Starting And Electrical
Remote Controls
Predelivery Preparation And Storage
1 2 3 4 5 6 7 8 9
Page iii
Page iv
SECTION - 1
IMPORTANT INFORMATION
SECCION 1 INFORMACIN IMPORTANTE

Tabla de contenidos
Torque ................................................ .................................................. ........................................... 2 Quicksilverproductos ................................................ ........................................................................... 2 Accesorios ................................................. ........................................................................................ 2 Mandos a distancia y de instrumentacin para el sistema DTS ...................................................................... 2 Colocacin de los nmeros de serie ......................................................................................................... 3 Bravo Tres Aviso: Recortar punto Lmite de insercin .................................................................................3 Mltiples Sterndrive Directivo Acuerdos Bar .............................................................................................3 Direccin de alimentacin interna con refuerzo interno solamente ................................................................. 4 Direccin de alimentacin interna con refuerzo interno y externo....................................................................4 Direccin de alimentacin externe ............................................................................................................4 Direccin de alimentacin externa con baja Tie Bar externa ..........................................................................4 Proteccin contra la corrosin .................................................................................................................4 Pintura Anti-fouling .............................................................................................................................4 Control de Emisiones Informacin de la etiqueta ........................................................................................6 Responabilidad del propietario ................................................................................................................7 Estrella etiqueta ...................................................................................................................................7 Colgar la etiqueta .................................................................................................................................8
90-864196060 MAY 2006
Page 1 / 8
SECTION - 1
Especicaciones de Tension
NOTA: Apriete todos los tornillos no se enumeran a continuacin. NOTA: El par de la hlice se declar un valor de par mnimo. Descrpcin Tubo de escape pinza Tornillos de escape de tubera De escape de bloque tornillos de la placa Bravo Uno propulsor tuerca Bravo Two tuerca de la hlice Bravo tres frente tuerca de la hlice Bravo Tres traseros tuerca de la hlice Pernos de montaje del motor trasero De direccin por cable acoplador tuerca Pernos de direccin del sistema de pivote Dentro-fueraborda sujetadores unidad Elementos de fijacin del transom de montaje Clip de fijacin de tornillo Abrazaderas de manguera Pernos de conexin de entrada de agua Entrada de agua en bloque de tornillo de conector entrada del combustible Nm lb. in. lb.ft. T e 4 35 x 34 25 t 34 25 75 55 Alinee las pestaas con las ranuras 81 60 Alinee las pestaas con las ranuras 136 100 81 60 47 35 47 35 34 25 68 50 34 25 12,2 108 3,4 a 6,8 30 a 60 5 45 5 45 ajustada + 1 - a 2 - vueltas con una llave. No apriete 168 71-91 168
demasiado. Gen III Mdulo de combustible fresco capturado tuerca de 19 Batera de estudios 8-11 Eje de la hlice del tornillo del nodo 19
Productos quicksilver
Asesorios Relojes de Quicksilver, controles remotos, sistemas de direccin, hlices y otros accesorios
disponibles para este producto. Mercury MerCruiser recomienda el uso de piezas de Quicksilver en todos las aplicaciones. Se reeren a Mercury Precision Parts Gua de accesorios para una lista completa. Esta Gua est 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 travs del Centro de Distribucin o Distribucin.
Mandos a distancia y de instrumentacin para DTS Sistema

El acelerador digital y el sistema Shift (DTS) requiere el uso de componentes de mando especializado, incluyendo un kit de mdulo de comando y control remoto electrnico. Se reeren a la precisin de Mercury Gua y Piezas / accesorios Quicksilver.
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90-864196060 MAY 2006
SECTION - 1
Serial Number Decal Placement

There are 3 sets of engine, transom assembly, and sterndrive serial number decal strips provided with each power package. One should be used for each of the following: Engine Specification Decal Warranty Registration Card Operation, Maintenance and Warranty Manual identification page Affix engine serial number decal to specification / serial number decal.
8331
a
a - Specification/serial number decal
Bravo Three Notice: Trim-in Limit Insert

NOTE: 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) will roll up on their side under certain, specific, operating conditions. The roll can be either to port or starboard and may be experienced while moving straight ahead, or while making a turn. The roll occurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near full trim-in. While the boat will not roll completely over, the roll may be sufficient to unseat the operator or passengers, and thereby create an unsafe situation. The roll is caused by stern-lift created from excessive sterndrive unit trim-in. Under these extreme stern-lift / bow-down conditions, instability can be created, which may cause the boat to roll. Weight distribution to the stern can reduce stern-lift and, in some circumstances, help to control the condition. 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 last few degrees of full trim under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The need for this trim-in limit insert, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.
! WARNING
It is recommended that only qualified personnel adjust the trim-in limit inserts. The boat must be water tested after adjusting the trim-in limit inserts to ensure that the modified trim-in range does not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is trimmed in at higher speeds. Increased trim-in range may cause handling problems on some boats, which could result in personal injury.
Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives you must select one of several possible steering systems.
! CAUTION
Failure to observe the recommended Tie Bar Arrangements could result in serious damage to the steering and/or trim system components. This damage could adversely affect control of the boat. Observe the recommended Tie Bar Arrangements as presented in this section.
90-864196060 MAY 2006
Page 3 / 8
SECTION - 1
Internal Power Steering With Internal Tie Bar Only

At 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 the sterndrive that is directly connected to the factory power steering output. This internal tie bar is available in a variety of lengths from the sterndrive manufacturer.
Internal Power Steering With Internal and External Tie Bar

As a boat moves into the moderate performance range of 97-113 km/h. (60-70 MPH) or for a reduction in steering backlash, an external tie bar should be added. External tie bars are usually designed to attach at the aft power trim cylinder bosses. This location is an excellent choice because of its proximity to the propeller. HOWEVER, because of the potential overstress that can occur if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part Number 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 no internal tie bar when using the internal power steering system. This can cause excessive loads on 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 the steering of the boat.
External Power Steering

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

For 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 mounted at the trim cylinder boss location (as previously described in "Internal Power Steering with Internal and External Tie Bar" statements). Again, this system does not use an internal tie bar.
Corrosion Protection
Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions or if using a stainless steel propeller, it is recommended that a Quicksilver Anti-Corrosion Anode Kit and/or a MerCathode System with 2 additional transom mounted anode assemblies be installed (some models have a MerCathode System as standard equipment). A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. (Refer to Mercury Precision Parts Accessories Guide for part numbers.) Boats that are connected to AC shore power require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while still providing a path to ground for dangerous fault (shock) currents. (Refer to Mercury Precision Parts Accessories Guide for part number.) IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and anodes may be unable to handle the increased galvanic corrosion potential.
Anti-fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the limited warranty. Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and boat transom but you must observe the following precautions:
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90-864196060 MAY 2006
SECTION - 1
IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System reference electrode 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.) UNPAINTED area on transom of the boat around these items.
b
8107
a - Painted boat transom
b - Minimum 40 mm (1-1/2 in.) unpainted area around transom assembly
NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint or an anti-fouling paint that DOES NOT contain copper or any other material that could conduct electrical current. Do not paint drain holes, anodes, MerCathode system or items specified by boat manufacturer.
! CAUTION
Improper boat-cleaning procedures can cause product damage. Washing the MerCathode assembly, especially with a brush or high-pressure washer, will damage the MerCathode assembly making it unable to inhibit galvanic corrosion. When cleaning the boat, do not use a brush or a high-pressure washer to wash the MerCathode assembly found on the bottom of the transom assembly.
90-864196060 MAY 2006
Page 5 / 8
SECTION - 1
Do not wash the sterndrive unit with a power washer as this can damage the coating on the reference wire of the MerCathode assembly, if equipped, and increase corrosion.
b
6211
a - MerCathode reference electrode b - Do not paint
c - Do not pressure wash
Emission Control Information Label

A tamper-resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. 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 affect the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser about the availability of replacement decals before proceeding.
THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS SERIAL# OMXXXXXXXX D.O.M. JAN. 2003 FAMILY XXXXX_XXXXXX DISP X.XL FEL. XX.X g/kW-hr
11018
EMISSION CONTROL INFORMATION
Emission Control Label - Non CE Marked "SERIAL#" - Engine Serial Number "FAMILY" - Engine Family "FEL." - Family Emission Limit "D.O.M." - Date of Manufacture
Page 6 / 8
90-864196060 MAY 2006
SECTION - 1
"DISP" - Piston Displacement
EMISSION CONTROL INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION REGULATIONS FOR SPARK IGNITION MARINE ENGINES REFER TO OWNER'S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS
SERIAL# OMXXXXXX D.O.M. DISP.
FAMILY XXXXX XXXXXX FEL. XX.X g/kW-hr
Dec 2004 X.XL

0575
10652
Emission Control Label - CE Marked "SERIAL#" - Engine Serial Number "FAMILY" - Engine Family "FEL." - Family Emission Limit "D.O.M." - Date of Manufacture "DISP" - Piston Displacement CE - 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 for further information.
Owner Responsibility
The owner/operator is required to have routine engine maintenance performed to maintain emission levels within prescribed certification standards. The owner/operator is not to modify the engine in any manner that would alter the horsepower or allow emissions levels to exceed their predetermined factory specifications.
Star Label
Beginning January 1, 2003, one Three-Star label will be included with each factory-certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three-Star Ultra Low Emission rating. The Three-Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards 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
a
a - Recommended location
b
mc79531
b - Secondary location
90-864196060 MAY 2006
Page 7 / 8
IMPORTANT INFORMATION One Star - Low emission
SECTION - 1
mc79569-1
The one-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPA's 2006 standards for marine engines.
Two Stars - Very Low emission The two-star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star - Low-Emission engines.
FO
IDA
mc79570-1
Three Stars - Ultra Low emission The three-star label identifies engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2008 exhaust emission standards or the Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star - Low Emission engines.
SS
mc79571-1
Four Stars - Super Ultra Low emission The Four Star label identifies engines that meet the Air Resources Board's Sterndrive and Inboard marine engine 2009 exhaust emission standards. Personal Watercraft and Outboard marine engines may also comply with these standards. Engines meeting these standards have 90% lower emissions than One Star - Low Emission engines.
FN R
mc79572-1
Hang Tag
The Dealer must mark the appropriate box on one hang tag to match the Star label affixed to the boat. The dealer is responsible for displaying the hang tag in a visible location on the boat on display in California. Failure to properly display the hang tag could result in a citation and possible fine 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 displaying the boat.
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90-864196060 MAY 2006
SECTION - 2
BOAT CONSTRUCTION
SECTION 2 - BOAT CONSTRUCTION

Table of Contents
Boat Construction.................................................................................................................................................... 2 Transom Thickness and Surface Plane............................................................................................................2 Transom Cutout.................................................................................................................................................2 Checking Transom Thickness...........................................................................................................................2 Engine Bed........................................................................................................................................................2
90-864196060 MAY 2006
Page 1 / 2
BOAT CONSTRUCTION
SECTION - 2
Boat Construction
Transom Thickness and Surface Plane
IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive 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.) Flatness Angle Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface - Flat within 3 mm (1/8 in.) Outer Surface - Flat within 2 mm (1/16 in.) 10 -16 degrees
e d b d
c
a - Transom thickness b - Inner surface c - Outer surface
7508
d - Transom plate coverage 203 mm (8 in.) from center e - Transom angle
Transom Cutout
Refer to Section 6 - Drive System And Engine Mounting.
Checking Transom Thickness

Refer to Section 6 - Drive System And Engine Mounting.
Engine Bed
IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 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 Difference between starboard and port engine mount Mount adjustment up and down (minimum) Specification 57.2 cm (22-1/2 in.) 6 mm (1/4 in.)
NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure that the front and rear mount locations in the vessel are parallel and in the same plane. This may be checked by tying a string from the left front mount location to the right rear mount location and another from right front to left rear. The strings should touch where they cross.
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90-864196060 MAY 2006
SECTION - 3
EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Exhaust Systems..................................................................................................................................................... 2 Preferred Exhaust System................................................................................................................................2 Exhaust System Caution...................................................................................................................................2 Measuring Exhaust Elbow Height.....................................................................................................................2 Methods for Measuring Exhaust Elbow Height.................................................................................................5 Clear Hose Method for Measuring Exhaust Elbow Height................................................................................5 Collector And Water Lift Muffler Equipped ................................................................................................. 6 Through The Transom And Through The hull Exhaust System Design............................................................7 Exhaust Resonator Guidelines..........................................................................................................................9
90-864196060 MAY 2006
Page 1 / 11
EXHAUST SYSTEM
SECTION - 3
Exhaust Systems
Preferred Exhaust System
Most Mercury MerCruiser sterndrive engines were developed and tested for Y-pipe or through the propeller exhaust systems. Using the Y-pipe system limits the potential for water intrusion due to the exhaust system design.
Exhaust System Caution

! CAUTION
It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine and install the exhaust system. Improper installation may allow water to enter the exhaust manifolds and combustion chambers and severely damage the engine. Damage caused by water in the engine will not be covered by Mercury MerCruiser Warranty, unless this damage is the result of defective parts.
Measuring Exhaust Elbow Height

The height of the exhaust elbows and the slope of the exhaust hoses must be within the dimensions specified 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 loading conditions 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 compliance must be clearly communicated to the operator in the owner's manual. For example, the number of people that can be located on the swim platform simultaneously should be included in the manual, if this could pose a problem. 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, including refrigerator and lockers. Do not forget the PWC, if applicable. 3. Add average passenger weight in all locations where each passenger will sit during normal operation. 4. Allow for a minimum of 2 people on the swim platform for docked conditions. Seat people starting at the rear of the boat. NOTE: ABYC specifies an average passenger weight of 64 kg (141 lb) for boat loading calculations. 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) while retaking readings. Use all of the available seating areas in the bow first. Continue adding passenger weight (and taking readings), moving from the bow to the stern until the maximum people 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:
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90-864196060 MAY 2006
SECTION - 3
EXHAUST SYSTEM
NOTE: Exhaust elbow height is measured to the waterline in the water lift muffler (instead of the water line) on applications so equipped. Refer to the appropriate Mercury MerCruiser Product Applications Manual for more information.
Minimum Exhaust Elbow Height Model V6 and V8 Alpha/Bravo Specification 330 mm (13 in.)
NOTE: Through transom exhaust applications must have an exhaust hose length of 305 mm (12 in.).
c a
b
9173
Using a universal protractor (inclinometer) to measure slope a - Protractor c - Minimum 305 mm (12 in.). b - Exhaust hose or tube
Minimum Exhaust Hose Slope Specification Model All models Within 457 mm. (18 in.) of engine 10 degrees Remainder of system (if applicable) 3 degrees
10. Install risers if height is insufficient. Modify exhaust system and/or install risers, if slope is insufficient. Refer to the Mercury Precision Parts / Quicksilver Accessory Guide for part numbers.
Model V6 Sterndrive Model V8 Sterndrive 43 mm (1.7 in.) 43 mm (1.7 in.) Riser Options 76 mm (3 in.) Riser Options 76 mm (3 in.) 119 mm (4.7 in.) 152 mm (6 in.) 152 mm (6 in.)
NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.
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Page 3 / 11
EXHAUST SYSTEM
SECTION - 3
11. If measurements are less than specified, exhaust elbow risers must be installed to achieve proper dimension.
12 11 9 7 5 6 3 2 4 6 10 8
1
7932
123456-
Typical riser installation Exhaust manifold bolt (4) Exhaust manifold Full flow gasket, with turbulator Full flow gasket Riser Pipe plug
7 - Restrictor gasket, with turbulator 8 - Block off gasket, with turbulator (closed cooled models) 9 - Exhaust elbow 10 - Hose fitting 11 - 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 encounter in 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.
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90-864196060 MAY 2006
SECTION - 3 Minimum Exhaust Elbow Height From Top of Elbow to Waterline Model V6 and V8 Sterndrive
EXHAUST SYSTEM
Measurement 330 mm (13 in.)
c
9141
a - Highest point on exhaust elbow b - Measurement
c - Waterline
NOTE: Additional requirements for through the hull or transom exhaust system applications:
Continuous Downward Slope From Horizontal Model Sterndrive Engine Installation Angle 0 degrees 9 degrees Minimum 48 mm (1-7/8 in.) 19 degrees per 305 mm (12 in.) Maximum 105 mm (4-1/8 in.) per 305 mm (12 in.)
Methods for Measuring Exhaust Elbow Height

IMPORTANT: Refer to Measuring Exhaust Elbow Height for instructions on proper loading of the boat and complete measurement instructions.
Clear Hose Method for Measuring Exhaust Elbow Height

1. 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 of the 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.
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EXHAUST SYSTEM
SECTION - 3
8. The measurement between water in hose and top of exhaust elbow is the exhaust elbow height.
c a d
8340
9142
a - Waterline b - Top of exhaust elbow c - Clear plastic hose
d - Weight e - Measurement - waterline to top of exhaust elbow
COLLECTOR AND WATER LIFT MUFFLER EQUIPPED

IMPORTANT: 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's bilge 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 exhaust elbow. 7. Slowly take finger off the end of the clear hose to let the water level stabilize. The water will seek the level of the water inside the water lift muffler. Keep the clear hose close to exhaust elbow and as vertical as possible. 8. Make sure that the boat is level (side-to-side) using a level or inclinometer.
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SECTION - 3
EXHAUST SYSTEM
9. The measurement between the water in the clear hose and the top of the exhaust elbow is the exhaust elbow height above the water line.
b c
d e f
a g
Typical a - Water line b - 457 mm. (18 in.) minimum between exhaust elbow and collector c - 10 degree downward slope minimum d - 3 degree downward slope minimum e - Collector
7555
f - Minimum exhaust elbow height with maximum load g - Drain plug or drain valve h - External flappers i - Clear hose
a c
7556
Typical S-pipe Used With Water Lift Muffler a - Water line c - Drain plug or drain valve b - Minimum exhaust elbow height with maximum load
Through The Transom And Through The hull Exhaust System Design
These engines are equipped with a wet exhaust system in which exhaust is mixed with water in the exhaust elbows. This cools the exhaust and allows the use of heat resistant rubber hose on the outlet side of the system. These specifications must be observed by the OEM and muffler manufacturer 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.
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EXHAUST SYSTEM Minimum Exhaust Hose Size
SECTION - 3
Single Outlet System Model All Models Dual Outlet System 102 mm (4 in.) Dual Hose Portion 102 mm (4 in.) Single Hose Portion 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 that is more than 457 mm (18 in.) away from elbow. NOTE: Mercury MerCruiser's recommendations is more stringent than ABYC recommendation of a minimum drop in the exhaust system of 1/2 in. per foot with an overall drop of not less than 102 mm (4 in.) between the exhaust elbow outlets and the boat outlets.
Slope Conversion Degrees 3 6 7 10 12 14 19 5/8 in. / ft 1-1/4 in. / ft 1-7/16 in. / ft 2-1/8 in. / ft 2-1/2 in. / ft 2-15/16 in. / ft 4-1/8 in. / ft Drop vs. Run 52 mm / m 105 mm / m 122 mm / m 176 mm / m 212.5 mm / m 249 mm / m 344 mm / m Distance from Elbow < 18 in. < 18 in. < 18 in. < 18 in. < 18 in. < 18 in. < 18 in.
The drop in the exhaust hose must be continuously sloping downward so that a low spot does not exist at any point. Through the hull exhaust fittings (flanges, outlets) must be equipped with internal shutters and external flappers to prevent the reverse flow of water into the engine. Refer to Exhaust Through The Hull Fittings. Exhaust outlets must be above the water line with boat at rest in the water and a full load aboard, 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 clamps should be stainless steel and at least 13 mm (1/2 in.) wide. Clamps which rely solely on spring tension should not be used. (ABYC Standard). The exhaust system must be adequately supported for proper orientation and to prevent overstressing the exhaust manifolds and elbows. The support requirements will vary with exhaust 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 aforementioned specifications. The system must have the capability to be serviced, reassembled, and replaced while maintaining all of the specifications. The boat builder must provide documentation, such as manuals, drawings, or orientation marks on production assemblies. If a waterlift/collector system is used, the waterline is defined as the waterline inside the collector. All measurements must be taken from that waterline to measure exhaust elbow heigh.
Page 8 / 11
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SECTION - 3
EXHAUST SYSTEM
in-line mufflers, collectors, and hoses must self drain after engine shut-down. See muffler/ collector section.
Exhaust Resonator Guidelines

! CAUTION
Avoid severe engine damage. Water ingestion may occur in some instances without the use of specially designed exhaust resonators. Install exhaust resonators in the exhaust system when specified. IMPORTANT: MerCruiser strongly recommends exhaust resonators on all models with through the transom exhaust. On sterndrive engines using through the transom or through the hull exhaust systems, special care must be exercised in system design and construction to prevent an adverse tuning effect on engine exhaust output.
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EXHAUST SYSTEM
SECTION - 3
The exhaust resonator is positioned with the inside flat surface at the preferred distance of 432 mm (17 in.) from the front edge of the exhaust hose but no closer than 51 mm (2 in.) to the exhaust outlet on sterndrives. The 432 mm (17 in.) dimension can be reduced, if necessary, to a MINIMUM of 330 mm (13 in.). This dimension must be the same on both exhaust outlets.
c a e d g g a e b a
b e d
c a
8232
b c a d g
a - Exhaust resonator b - Exhaust hose c - Dimension to inside flat surface of resonator approximately 432 mm (17 in.) d - No less than 51 mm (2 in.) between collector and resonator
b e
a f
8231
e - Clamp - positioned around center of resonator f - Exhaust muffler g - Collector
Exhaust system tuning can be affected by various factors that are beyond the control of Mercury MerCruiser. 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.
Page 10 / 11
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SECTION - 3
EXHAUST SYSTEM
Exhaust Resonator Kit use on Sterndrive Models:

CAN Be Used With: Transom mounted muffler tips Waterlift mufflers or other mufflers that are mounted outboard of exhaust elbows Open exhaust CANNOT Be Used With: Silent Choice Exhaust System Below swim platform exhaust Mufflers that mount between exhaust elbow and exhaust tip
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EXHAUST SYSTEM
SECTION - 3
NOTES:
Page 12 / 11
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SECTION - 4
FUEL SYSTEM
SECTION 4 - FUEL SYSTEM

Table of Contents
Fuel Delivery System .............................................................................................................................................. 2
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FUEL SYSTEM
SECTION - 4
Fuel Delivery System

The fuel delivery system must be designed to deliver the fuel to the engine with minimal restriction and at the lowest temperature. Gasoline is extremely sensitive to vaporizing if placed under a vacuum (low pressure) and exposed to moderate or high temperatures. This is particularly true if winter blend fuels with a high RVP (Reid Vapor Pressure) are encountered in warmer temperature areas. Excessive restriction in the fuel delivery system may cause a condition known as vapor locking. This typically occurs after the engine has been operated at high RPM and then shut off and allowed to sit for 15 minutes to 2 hours. During this time the engine heat soaks, causing the temperature of the fuel system to increase. Upon restart, the combination of heat and vacuum in the fuel system causes the fuel to vaporize. The fuel system cannot handle this vapor and therefore, fuel starvation results when the boater attempts to resume operation. Depending upon the degree of vapor locking, this can range from a hesitation or bog when accelerating to a complete stalling of the engine. To minimize the potential for this problem, the guidelines should be observed to limit fuel delivery restriction to 6.9 kPa (2 in. Hg) or less and fuel inlet temperature to 44 C (110 F) or less. The fuel delivery system is an integral part of the boat. Mercury MerCruiser makes no attempt in this manual to cover all aspects of design and integration of the fuel delivery system, due to a broad range of possible configurations and the numerous regulations and standards that cover this area. The applicable standards and regulations for the markets where your product will be sold should be observed, along with any information from the fuel system component manufacturers. The following general guidelines are provided:
! WARNING
Avoid serious injury or death and property damage due to improper boat design and construction. Always adhere to all applicable Marine Regulations (United States Coast Guard [USCG], European Union - Recreational Craft Directive [EU-RCD], and so on) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], and so on) when designing and constructing the boat and the boat components, such as the engine compartment, fuel delivery system and exhaust system. The main concern of a boat's fuel system is safety; this must be achieved through a technically sound 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 service and 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 first installation 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 should be carefully rounded off or protected with rubber grommets. This prevents damage to the lines from abrasion. The following, but not limited to the following, additional fuel connection related points, applying to 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.
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SECTION - 4
FUEL SYSTEM
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's fuels. It can also cause poor engine performance because of fuel starvation. 3. Fuel lines used must be Coast Guard approved (USCG Type A1).
Description Minimum Fuel Line Diameter Specification 10 mm (3/8 in.) minimum
4. On Multi-Engine Gasoline Installations: It is best to use a fuel pickup and supply line for each 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 ID must be greater than 10 mm (3/8 in.). 6. Fuel lines should be installed free of stress and firmly secured to prevent vibration and/or chafing. 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.
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FUEL SYSTEM
SECTION - 4
NOTES:
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SECTION - 5
COOLING SYSTEM
SECTION 5 - COOLING SYSTEM

Table of Contents
Seawater Connections - General Information......................................................................................................... 2 Specifications....................................................................................................................................................2 Seawater Pickup...............................................................................................................................................2 Seawater Pickup Requirements........................................................................................................................2 Seawater Pickup - General Information ..................................................................................................... 3 Seacock - General Information .................................................................................................................. 4 Sea Strainer - General Information ............................................................................................................ 4 Y-Fitting................................................................................................................................................................... 5 Hot Water Heater Hose Connections - MPI Models ............................................................................................... 6 Supply Hose Connection .................................................................................................................................. 6 Return Hose Connection .................................................................................................................................. 7 Water Flow Diagrams.............................................................................................................................................. 8 V-6 and V-8.......................................................................................................................................................8 V-8 Closed Cooled Bravo Models with Risers ........................................................................................... 8 V6 Closed Cooled Alpha Models with Risers ............................................................................................ 9 V8 Closed Cooled Bravo Models ............................................................................................................. 10 V6 Closed Cooled Sterndrive Models ...................................................................................................... 11 V6 Seawater Cooled Bravo MPD Models ................................................................................................ 12 V8 Seawater Cooled Bravo MPD Models ................................................................................................ 13 V8 Seawater Cooled Bravo Models Except MPD Models ....................................................................... 14 V6 Seawater Cooled Bravo Models Except MPD Models ....................................................................... 15 V6 And V8 Seawater Cooled Alpha MPD Models ................................................................................... 16 V6 And V8 Seawater Cooled Alpha Models Except MPD Models ........................................................... 17
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COOLING SYSTEM
SECTION - 5
Seawater Connections - General Information

Specifications
Description Minimum flow (closed cooled models only) Minimum pressure (closed cooled models only) Water pickup Water inlet hose Seacock Seawater strainer 32 mm (1-1/4 in.) connections Specification 114 liters per minute (30 gallons per minute) at 4000 rpm 138 kPa (20 psi) at 4000 rpm 32 mm (1-1/4 in.) ID wire reinforced
Seawater Pickup
This section covers through the hull and through the transom water inlets only. For information on sterndrive water inlet connections, refer to the appropriate section after engine installation.
Seawater Pickup Requirements

IMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction is created by seawater pump impeller.
c f b e b d a
7924
Typical installation shown with a through the hull water pick up a - Quicksilver seawater pickup and e - Seawater hose to engine seacock f - Seawater pump hose connector (if b - Hose clamp equipped) c - Seawater hose to seawater strainer g - Below seawater pump level d - Quicksilver seawater strainer IMPORTANT: Do not install the water pickup directly in line with the propeller, as the pickup may create turbulence and allow air to flow into the propeller slipstream. This will cause propeller ventilation and will adversely affect boat performance. IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come in 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.
Page 2 / 17
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SECTION - 5
COOLING SYSTEM
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 is underway. 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 an optimum location for water pickup. Location should be in an area that will provide a solid, air-free flow of water under all operating conditions. Avoid areas with a disturbed water flow, such as those behind, or in close proximity to, the propeller. Locations that are too far forward or outboard should also be avoided as these are prone to aeration problems at high boat trim angles and in turns. 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 regulations also require that the pickup be connected into the boat's bonding system to minimize stray current corrosion. Refer to applicable standards and regulations for more details.
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COOLING SYSTEM
SECTION - 5
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 types of 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 allows the 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 INFORMATION

A sea strainer is recommended if the boat is to be operated in an area with a high debris content.
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COOLING SYSTEM
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 a reasonable 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-Fitting
NOTE: All closed cooled models require a through the hull or through the transom pickup in addition to the sterndrive water inlets in order to meet the minimum flow specifications. When additional water inlets are used, a Y-fitting is installed to the engine seawater pump.
c b d
a - Engine seawater pump b - Hose from seawater pump inlet port to Y-fitting
8485
c - Y- fitting port to Bravo drive d - Y-fitting port to additional water inlet
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COOLING SYSTEM
SECTION - 5
Hot Water Heater Hose Connections - MPI Models

IMPORTANT: When connecting a cabin heater or hot water heater: Supply hose (from engine to heater) and return hose (from heater to engine) Must Not Exceed 16 mm (5/8 in.) 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.
! CAUTION
Avoid a performance loss and/or possible engine damage. Engine coolant must flow continuously from the engine intake manifold to the engine water circulating pump. Never close off or block the engine coolant flow to or from a hot water heater using coolant supplied by the engine intake manifold and returned to the engine water circulating pump.
! CAUTION
Avoid engine overheating which could result in engine damage. On models equipped with Closed Cooling, an air pocket may form in the closed cooling system if some coolant is lost from the system and the cabin heater or hot water is mounted higher than the fill cap on the heat exchanger. Heater must be mounted lower than the fill cap of the heat exchanger on models so equipped.
Supply Hose Connection

NOTE: Some models may be equiped with additional fittings.
9255
Seawater cooled models with air or manual drain a - Supply hose connection locations
Page 6 / 17
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SECTION - 5
COOLING SYSTEM
a
9256
Closed cooled models a - Supply hose connection locations
a
9257
Seawater cooled models with multi-point drain a - Supply hose connection locations
Return Hose Connection
9258
a - Return hose connection for hot water heater
b - Water circulating pump housing
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COOLING SYSTEM
SECTION - 5
Water Flow Diagrams

V-6 and V-8
V-8 CLOSED COOLED BRAVO MODELS WITH RISERS
j k
a c
i d
e g n o
c l m
abcdefgh-
8182
Seawater inlet Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump Thermostat housing
i - Exhaust elbow j - Seawater pump k - Heat exchanger l - To power steering pump m - From seawater pump n - Seawater o - Ethylene glycol mix p - Check valve
Page 8 / 17
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SECTION - 5
COOLING SYSTEM
V6 CLOSED COOLED ALPHA MODELS WITH RISERS
a j e c
d f h m g
abcdefgSeawater inlet Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold Distribution housing
9393
n
h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - Heat exchanger m - Seawater n - Ethylene glycol mix
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COOLING SYSTEM
SECTION - 5
V8 CLOSED COOLED BRAVO MODELS
i a h b
j k
e g c f n o
l m
abcdefghY-fitting Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump Thermostat housing
9385
i - Exhaust elbow j - Seawater pump k - Heat exchanger l - To power steering cooler m - From seawater pump n - Seawater o - Ethylene glycol mix p - Check valve
Page 10 / 17
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SECTION - 5
COOLING SYSTEM
V6 CLOSED COOLED STERNDRIVE MODELS
a j i b
d f h m n
9386
g
abcdefgY-fitting Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold Distribution housing
h - Water circulating pump i - Thermostat housing j - Exhaust elbow k - Seawater pump l - Heat exchanger m - Seawater n - Ethylene glycol mix
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COOLING SYSTEM
SECTION - 5
V6 SEAWATER COOLED BRAVO MPD MODELS
j b a
k i c d h g f e
9388
abcde-
Seawater inlet Power steering cooler Fuel cooler Exhaust and seawater outlet Exhaust manifold
fghij-
Check valve Water circulating pump Thermostat housing Exhaust elbow Seawater pump
Page 12 / 17
90-864196060 MAY 2006
SECTION - 5
COOLING SYSTEM
V8 SEAWATER COOLED BRAVO MPD MODELS
b a k
h d
l m
abcdefSeawater inlet Power steering cooler Gen III Cool Fuel Module Exhaust and seawater outlet Exhaust manifold Check valve ghijkl-
9387
Water circulating pump Thermostat housing Exhaust elbow Seawater pump To power steering cooler From seawater pump
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COOLING SYSTEM
SECTION - 5
V8 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS
c a h j c k l m
abcdefgSeawater inlet Power steering cooler Gen III cool fuel module Exhaust and seawater outlet Exhaust manifold Distribution housing Water circulating pump
f
9389
h - Thermostat housing i - Exhaust elbow j - Seawater pump k - Drain from starboard exhaust manifold l - To power steering cooler m - From seawater pump n - Check valve
Page 14 / 17
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SECTION - 5
COOLING SYSTEM
V6 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS
j b
a i k h d f c e
g
abcdefSeawater inlet Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet Exhaust manifold ghijk-
9390
Distribution housing Water circulating pump Thermostat housing Exhaust elbow Seawater pump
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COOLING SYSTEM
SECTION - 5
V6 AND V8 SEAWATER COOLED ALPHA MPD MODELS
i c e
d h f
9391
abcde-
Seawater inlet (from transom) Power steering cooler Drain plug Fuel cooler Exhaust and seawater outlet
fghij-
Exhaust manifold Check valve Water circulating pump Thermostat housing Exhaust elbow
Page 16 / 17
90-864196060 MAY 2006
SECTION - 5
COOLING SYSTEM
V6 AND V8 SEAWATER COOLED ALPHA MODELS EXCEPT MPD MODELS
a j b
d f
9392
g
abcdeSeawater inlet (from transom) Power steering cooler Check valve Fuel cooler Exhaust and seawater outlet fghijExhaust manifold Distribution housing Water circulating pump Thermostat housing Exhaust elbow
90-864196060 MAY 2006
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COOLING SYSTEM
SECTION - 5
NOTES:
Page 18 / 17
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SECTION - 6
DRIVE SYSTEM AND ENGINE INSTALLATION
SECTION 6 - DRIVE SYSTEM AND ENGINE INSTALLATION

Table of Contents
Transom Cutout....................................................................................................................................................... 6 Finding The Crankshaft Vertical Center Line....................................................................................................6 Single Engine ............................................................................................................................................. 6 Dual Engine ............................................................................................................................................... 6 Finding Crankshaft Horizontal Center Line (X-dimension)................................................................................7 90 Degree Tool Method ............................................................................................................................. 7 Tape Measure Method ............................................................................................................................... 8 Cutting Out The Transom..................................................................................................................................8 Checking The Transom Thickness..................................................................................................................10 Preliminary Connections........................................................................................................................................ 11 Drive Shaft Extension Models.........................................................................................................................11 Engine Mounts................................................................................................................................................11 Air Pump..........................................................................................................................................................11 Special Information................................................................................................................................................ 12 Transom Thickness and Surface..................................................................................................................... 12 All Bravo Models.............................................................................................................................................12 Rear Engine Mounts........................................................................................................................................13 Drive Shaft Extension Models.........................................................................................................................14 Bravo Models Exhaust Preparation.................................................................................................................14 Transom Assembly Installation.............................................................................................................................. 15 Installing Inner Transom Plate ........................................................................................................................ 15 Trim Position Sender Connections..................................................................................................................17 Sensor Steering Assembly..............................................................................................................................17 Connecting Speedometer Pickup....................................................................................................................18 Exhaust Preparation........................................................................................................................................18 Seawater Inlet Fitting Installation....................................................................................................................20 Water Inlet Block-Off Plate Installation............................................................................................................20 Alternative Water Pickups ........................................................................................................................ 20 Bravo Models ........................................................................................................................................... 21 Gear Lube Monitor Connection At Gimbal Housing........................................................................................23 Alternative Mounting Of Gear Lube Monitor On Transom...............................................................................24 Transom Exhaust Connections.......................................................................................................................24 Models With Alpha Sterndrive and Alternative Water Pickups.............................................................................. 25 Alpha Models .................................................................................................................................................. 25 Models With Bravo Sterndrive and Alternative Water pickups.............................................................................. 27 Alternative Water Pickups .............................................................................................................................. 27 Bravo Models ................................................................................................................................................. 28 Power Trim Pump Installation................................................................................................................................ 30 Power Trim Electrical Connection...................................................................................................................30 Power Trim Pump............................................................................................................................................ 31 Power Trim Pump Connections and Filling.....................................................................................................31 Filling ....................................................................................................................................................... 32 Trim Limit Switch Connection..........................................................................................................................33 Steering System Installation.................................................................................................................................. 33 Hydraulic (Helm) Steering...............................................................................................................................33 Steering Helm and Cable................................................................................................................................33 Steering Cable Specifications.........................................................................................................................34 Installing Steering System...............................................................................................................................34 Shift Cable Routing.........................................................................................................................................38 Transom Harness............................................................................................................................................39
90-864196060 MAY 2006
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SECTION - 6
Engine Installation................................................................................................................................................. 39 Transom Preparation.......................................................................................................................................39 Shift Cable Routing.........................................................................................................................................42 Engine Preparation .........................................................................................................................................42 Fuel Inlet Fitting...............................................................................................................................................43 Engine Installation...........................................................................................................................................44 Exhaust System Hose / Tube Connections.....................................................................................................47 Engine Alignment Sterndrive Models..............................................................................................................49 Electrical Connections........................................................................................................................................... 51 Instrumentation Connections-MPI Engines.....................................................................................................51 SmartCraft Product .................................................................................................................................. 52 Audio Warning System Connections...............................................................................................................52 MerCathode Connections (If Equipped)..........................................................................................................53 Power Trim Electrical Connection...................................................................................................................54 Battery Cables Connection..............................................................................................................................55 Power Trim Pump Connections....................................................................................................................... 55 Transom Connections........................................................................................................................................... 55 Gear Lube Monitor Connection.......................................................................................................................55 Power-Assisted Steering Hoses......................................................................................................................56 Seawater Inlet Fitting Connection...................................................................................................................56 Alpha Shift Cable Installation................................................................................................................................ 60 Alpha Sterndrive Shift Cable Installation.........................................................................................................60 Shift Cable Travel .................................................................................................................................... 60 Separate Shift and Throttle Controls ....................................................................................................... 61 Installation ................................................................................................................................................ 62 Bravo Shift Cable Installation and Adjustment...................................................................................................... 65 Bravo Models Shift Cable Installation.............................................................................................................. 65 Bravo Models Shift Cable Adjustment.............................................................................................................65 Shift Cable Installation For DTS System.........................................................................................................68 Throttle Cable Installation and Adjustment............................................................................................................ 69 Alpha Sterndrive Installation.................................................................................................................................. 70 Alpha Notice: Increased Trim-in Range Capability.......................................................................................... 70 Alpha Trim Cylinder Spacer Removal.............................................................................................................70 Alpha Trim Cylinder Disassembly...................................................................................................................72 Alpha Trim Cylinder Reassembly....................................................................................................................73 Alpha Trim Cylinder Installation....................................................................................................................... 74 Alpha Sterndrive Installation............................................................................................................................76 Trim Cylinder Installation ......................................................................................................................... 80 Speedometer Connection - Alpha Models.......................................................................................................81 Bravo Installation................................................................................................................................................... 82 Engine Alignment Check.................................................................................................................................82 Bravo Sterndrive Installation...........................................................................................................................84 Trim Cylinder Installation ......................................................................................................................... 91 Speedometer Connections - Bravo Models..................................................................................................... 93 Bravo Sterndrive Shift Check (Engine Running).............................................................................................94 Troubleshooting Shift Problems......................................................................................................................96 Bravo Trim Limit Switch Adjustment - Analog Gauges ................................................................................... 98 Trim Position Sender Adjustment - Analog Gauges......................................................................................100 Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method.................................................101 Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method.................................................102 Bravo Sterndrive Propeller Installation..........................................................................................................103 Bravo One Models ................................................................................................................................. 103 Bravo Two Models ................................................................................................................................. 105 Bravo Three ........................................................................................................................................... 106 Bravo Sterndrive Propeller Installation..........................................................................................................107 Bravo One Models ................................................................................................................................. 107 Bravo Two Models ................................................................................................................................. 109
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SECTION - 6
Bravo Three ........................................................................................................................................... 110 DTS System Installation...................................................................................................................................... 111 Shift Cable Installation For DTS System............................................................................................................. 111
90-864196060 MAY 2006
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SECTION - 6
Lubricant, Sealant, Adhesives

Tube Ref No. Liquid soap
7 9
Description
Where Used Exhaust tubes Trim cylinder bolt threads Fuel inlet fitting Battery terminals All electrical connections MerCathode connections Battery Terminals Exhaust bellows mounting surface Power steering bushings Upper and lower pivot bolts Clevis pin Steering cable end Shift cable stud Trim cylinder end cap Propeller shaft splines Shift cable pivot points Gear lube monitor Gear Lube Monitor Coupler splines Ujoint O-rings Drive shaft splines U-joint O-rings Driveshaft splines Propeller shaft splines Trim cylinder hardware Trim cylinder Bell housing studs O-ring Water passage seals Anchor pin threads Shift cable end Propeller shaft splines Power trim pump
Part No. Obtain Locally 92-809819 92-809822
Loctite 271 Threadlocker Loctite 567 PST Pipe Sealant
25
Liquid Neoprene
92-25711-3
27
Bellows Adhesive
92-86166Q1
34
Special Lubricant 101
92-802865A1
80 87
SAE Engine Oil 30W High Performance Gear Lubricant
Obtain Locally 92-802854A1
91
Engine Coupler Spline Grease
92-802869A1
94
Anti-Corrosion Grease
92-802867A1
95
2-4-C Marine Lubricant with Teflon
92-802859A1
114
Power Trim and Steering Fluid
92-802880A1
Special Tools
Tapered insert tool 91-43579 Removes and installs the tapered insert retainer into the water inlet hose.
9197
Alignment Tool Assembly
91-805475A 1
Aligns the engine and the sterndrive unit during installation.

9183
Page 4 / 113
90-864196060 MAY 2006
SECTION - 6 Shift Cable Adjustment Tool
DRIVE SYSTEM AND ENGINE INSTALLATION 91-12427 Attaches over the shift cable, and aids in proper shift cable adjustment at the shift plate. 91-821709T
9186
Trim Cylinder End Cap Tool
Allows easy removal of the trim cylinder end caps. Required if tilt limit spacers are to be installed or if the trim in limit spacer is to be removed (to allow additional trim in range).
9191
Shift Slide Stabilizer
91-865232
Holds the shift slide in the proper position as the sterndrive is installed onto the bell housing studs.
9184
Dual Water Pick-up Flush Gearcase Seal Kit
91-881150K 1
Blocks off the front water inlet holes on the dual water inlet gearcases.
9194
Flushing Device
91-44357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine.
9192
Flushing Kit
91-849996T 1
Use for flushing gearcases with low water inlets.

9195
Propeller Nut Tool
91-805457T 1
Aids in the removal and installation of the front propeller nut.

10677
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SECTION - 6
Transom Cutout
Finding The Crankshaft Vertical Center Line
SINGLE ENGINE
1. Locate and mark the vertical center line on the transom, if known. This is also the crankshaft vertical center line. 2. If unknown, a compass can be used to locate the vertical center line: a. Mark identical locations on each side of the boat 304 mm (12 in.) from the bottom of the hull. 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.
b d
e c b e
7687
Single engine installation a - 304 mm (12 in.) b - Identical side marks c - Compass arc
d - Arc intersection points e - Crankshaft vertical center line
DUAL ENGINE
1. Locate and mark the vertical center line on the transom. Refer to Single Engine procedure. 2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical center lines on either side of the vertical center line.
Minimum Distance Between Crankshaft Vertical Center lines (Dual Side-By-Side) Model V6 and V8 Sterndrive Measurement 838 mm (33 in.)
IMPORTANT: Crankshaft vertical center lines must be an equal distance from boat vertical center line.
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90-864196060 MAY 2006
SECTION - 6
3. Draw the 2 crankshaft vertical center lines through the intersection of the marks.
b b
a
Dual installation a - Vertical center line b - 1/2 minimum distance between crankshaft center line marks
7688
c - Crankshaft vertical center lines
Finding Crankshaft Horizontal Center Line (X-dimension)

X-dimension can be measured by the 90 Degree Tool Method or by the Tape Measure Method.
90 DEGREE TOOL METHOD

1. Construct the 90 degree tool.
90
b
a - 34.5 cm (13-9/16 in.)
7689
b - 1.2 m (4 ft)
IMPORTANT: The 34.5 cm (13-9/16 in.) dimension should only be raised or lowered after proper testing. -To lower drive unit - Subtract from dimension "a". To raise drive unit - Add to dimension "a". 2. Place the 90 degree tool along the boat bottom at the vertical center line. 3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical center line. This is the crankshaft horizontal center line or X-dimension.
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SECTION - 6
4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.
c b c a
7690
7691
Single engine a - 90 degree tool along boat bottom at vertical center line b - Contact point
Dual engine c - Crankshaft horizontal center line
TAPE MEASURE METHOD

1. Determine the X-dimension from the following chart. IMPORTANT: This dimension should only be raised or lowered after proper testing.
Transom Angle (degrees) 16 15 14 13 12 11 10 X-dimension 36.4 cm (14-5/16 in.) 36.2 cm (14-1/4 in.) 36.0 cm (14-3/16 in.) 35.9 cm (14-1/8 in.) 35.7 cm (14-1/16 in.) 35.6 cm (14 in.) 35.4 cm (13-15/16 in.)
2. On the vertical crankshaft center line, measure up from the bottom of the transom to the X-dimension selected previously. This is the crankshaft horizontal center line at the X-dimension. 3. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.
a c c
7692
7693
Single engine a - Vertical center line b - X-dimension that corresponds to transom angle
Dual engine c - Crankshaft horizontal center line
Cutting Out The Transom

IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is suitable for most boats. Best mounting location for a particular boat, however, can be determined only by testing.
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SECTION - 6
1. 2. 3. 4.
Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from X-Dimension. Heavy duty applications: Subtract 25 mm (1 in.) from X-Dimension. Above 40 km/h (25 mph): Use X-Dimension shown. Above 80 km/h (50 mph): The X-Dimension can be increased to improve performance in some applications. However, pulling power for skiing will decrease. During testing, X-Dimension should be increased 13 mm (1/2 in.) at a time until desired performance is achieved but in no case should it ever be increased by more than:
Maximum Increase In X-Dimension
Bravo One and Three Bravo Two
76 mm (3 in.) 25 mm (1 in.)
Extreme care should be taken when raising drive unit to ensure that water supply does not become aerated. Use clear water inlet hose to monitor incoming water and monitor engine temperature gauge to ensure engine does not overheat. In applications where cooling water to the engine is supplied by a through the hull or through the transom fitting, the sterndrive height will not cause cooling water aeration. IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed height will not be covered by Mercury MerCruiser warranty. 1. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately).
7893
7694
Transom cutout template Transom drilling fixture kit 2. 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.
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SECTION - 6
5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole saw cutout is made incorrectly, drive unit steering lever may contact transom causing limited steering travel.
a b
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 incorrectly the gimbal housing or exhaust system may improperly contact the boat transom causing transom mounting problems. 7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water absorption and deterioration of the transom.
a c
7696
d
a - Cut line b - 90 degrees to transom
c - Exhaust pipe area d - Mounting holes perpendicular to transom (8)
Checking The Transom Thickness

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts. 1. Ensure that transom thickness and surface conform to specifications.
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SECTION - 6
DRIVE SYSTEM AND ENGINE INSTALLATION 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.) Flatness Angle Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions) :Inner Surface - Flat within 3 mm (1/8 in.) Outer Surface - Flat within 2 mm (1/16 in.) 10 -16 degrees
c
7697
a - Measuring thickness b - Measuring flatness
c - Suitable mandrel to check for uniform transom thickness
Preliminary Connections
Drive Shaft Extension Models
If your power package is equipped with a drive shaft extension, refer to the Drive Shaft Extension Installation 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 Mounts
NOTE: On offshore boats or boats which will be used in rough water areas, Mercury MerCruiser recommends the use of a solid plate engine mount.
Air Pump
NOTE: Some models have air pump mounted on the engine and other models have the air pump in a parts bag. 1. Select an easily accessible mounting location for the air pump. 2. Mount the air pump.
8992
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SECTION - 6
Special Information
Transom Thickness and Surface
IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive mounts. Transom thickness and surface must conform to the following:
Transom specifications Thickness Parallelism Flatness Angle Between 51 - 57 mm (2 - 2-1/4 in.) Inner and outer surfaces must be parallel within 3 mm (1/8 in.) 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.) 10 - 16 Degrees
e d b d
c
a - Transom thickness b - Inner surface c - Outer surface
7508
d - Transom plate coverage e - Transom angle
c
7682
a - Measuring thickness b - Measuring surface flatness
c - Suitable mandrel to check for uniform transom thickness
All Bravo Models

IMPORTANT: The trim-in limit insert must be properly positioned before installing the trim cylinder anchor pin. NOTE: When removing the sterndrive, note the position of the insert for reference when reinstalling the sterndrive.
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90-864196060 MAY 2006
SECTION - 6
1. Ensure that the trim-in limit insert is positioned correctly for the appropriate Bravo model.
8548
Bravo One and Two (positioned forward) a - Trim-in limit insert
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 be changed after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a particular boat application.
Rear Engine Mounts

A fiber washer is cemented to the transom plate where the rear engine mount is attached to the transom 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 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 mount adjustment. IMPORTANT: The fiber washer must be used. NOTE: Engine alignment is usually obtained using only the rear engine mount and the fiber washer.
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SECTION - 6
1. Ensure that the fiber washer is in place.
16584
a - Transom plate
b - Fiber washer
2. Place the stainless steel washer on top of the transom plate mount only if needed to obtain proper alignment.
a c
b c
16583
a - Transom plate b - Stainless steel washer
c - Stainless steel washer position to raise engine
Drive Shaft Extension Models

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

IMPORTANT: When installing through the transom exhaust, it is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats. 1. If required, remove and discard clamps and bellows from gimbal housing.
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90-864196060 MAY 2006
SECTION - 6
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.
! CAUTION
Exhaust tube clamp may corrode if grounding clip is not installed. b. c. Install grounding clip on tube. Apply adhesive to exhaust bellows/tube mounting surface.
Description Bellows Adhesive Where Used Exhaust bellows mounting surface Part No. 92-86166Q1
Tube Ref No.

27
d. e. f.
Allow bellows adhesive to dry until no longer tacky (approximately 10 minutes). Position tube so that "SIDE" markings on tube are facing toward the right and left sides. Install and torque the clamp.
c a
a - Exhaust tube b - Clamp c - "SIDE" marking
Description Exhaust tube clamp
b
8406
d - Exhaust tube e - Grounding clip
Nm 4
lb. in. 35
lb. ft.
Transom Assembly Installation

Installing 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 several times until the proper torque is achieved.
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SECTION - 6
3. Secure transom assembly with fasteners. Torque the fasteners.

Description Transom assembly hardware Nm 34 lb. in. lb. ft. 25
IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves. IMPORTANT: Transom harness ground must be attached as shown.
g d c a
a
3 2 4 8 6
23138
b
1
e
a - Locknuts and flat washers (8) b - Hydraulic hoses and MerCathode wire c - Steering lever continuity wires d - Transom plate continuity wires
e - Torque sequence f - Trim sender and trim limit wires g - Ground from transom harness
Page 16 / 113
90-864196060 MAY 2006
SECTION - 6
Trim Position Sender Connections

NOTE: 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.
ORG/GRY
ORG/WHT BLK
BLK BLK
b
9292
a - Engine harness bullet connector
b - Transom assembly bullet connector
Sensor Steering Assembly

1. 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.
c a h d e a f
b
abcd4. 5. 6. 7. 8. 9. Transom stud holes Pitot tube connection Plug Guide
8403
efgh-
Cotter pin Clevis pin Tie strap Alignment mark
Slide guide onto the groove in the clevis pin. Bolt the steering assembly to the transom. Remove the brass plug from the transom. Install pitot barbed fitting. Attach pitot tube to barbed fitting and secure with a tie strap. Plug sensor into transom harness.
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Page 17 / 113
SECTION - 6
Connecting Speedometer Pickup

! CAUTION
Excess water in bilge can damage engine or cause boat to sink. Do not remove plug from speedometer 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.
b c c e
7703
Typical a - Male quick connect b - Female quick connect c - Barbed fitting d - Hose e - Tie strap
! CAUTION
Avoid water leaking into boat. Speedometer hose is filled with water, especially during boat operation. Hose contact with moving or rotating engine parts could cause damage to the hose resulting in water leaking into boat. Do not let speedometer hose contact steering system components, engine coupler or drive shaft. 3. Secure the hose to the transom with the hose clip and screw that are provided in the parts bag. Ensure that the hose does not contact the steering system components or the engine coupler and drive shaft.
Exhaust Preparation
IMPORTANT: When installing through the transom exhaust, it is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats. 1. If required, remove and discard clamps and bellows from gimbal housing. IMPORTANT: When installing through the propeller exhaust: With Bravo One and Bravo Two Sterndrives, an exhaust tube MAY BE INSTALLED for a slight increase in performance. With most Bravo Three Sterndrive Models, an exhaust tube MAY BE INSTALLED for a slight increase in performance. With a Silent Choice Exhaust System, the exhaust bellows must be removed and an exhaust tube MUST BE INSTALLED. With any application, installation of an exhaust tube will increase exhaust noise.
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90-864196060 MAY 2006
SECTION - 6
2. If required, install exhaust tube on gimbal housing as follows: a. Remove and discard clamps and exhaust bellows.
! CAUTION
Exhaust tube clamp may corrode if grounding clip is not installed. b. c. Install grounding clip on tube. Apply adhesive to exhaust bellows/tube mounting surface.
Description Bellows Adhesive Where Used Exhaust bellows mounting surface Part No. 92-86166Q1
Tube Ref No.

27
d. e. f.
Allow bellows adhesive to dry until no longer tacky (approximately 10 minutes). Position tube so that "SIDE" markings on tube are facing toward the right and left sides. Install and torque the clamp.
c a
a - Exhaust tube b - Clamp c - "SIDE" marking
Description Exhaust tube clamp
b
8406
d - Exhaust tube e - Grounding clip
Nm 4
lb. in. 35
lb. ft.
90-864196060 MAY 2006
Page 19 / 113
SECTION - 6
Seawater Inlet Fitting Installation

1. Install a new gasket, seawater inlet fitting, and screws. Torque screws.
a b
c d
21634
Seawater inlet fitting shown with gear lube hose J-clip a - Seawater inlet fitting c - Gasket b - Screw (2) d - Star washers
Description Seawater inlet fitting screws Nm 5 lb. in. 45 lb. ft.
Water Inlet Block-Off Plate Installation

ALTERNATIVE WATER PICKUPS
A water inlet block-off kit must be used if the sterndrive unit water pickup will not be used to supply water to the engine. When installing the block-off plate, it is necessary to cut the water hose that is located between the bell housing and the gimbal housing. This allows water to continue to circulate through the sterndrive unit for cooling.
! CAUTION
Avoid overheating the sterndrive. The seawater inlet holes must be allowed to flow water without being obstructed or damage to the sterndrive will result. Do not dead-end the seawater hose from bell housing. Cut hose as recommended in procedures.
Page 20 / 113
90-864196060 MAY 2006
SECTION - 6
BRAVO MODELS
1. Remove the tapered insert in the gimbal housing using the tapered insert tool. Discard the insert.
a
c
b
d
17857
a - Tapered insert location in the gimbal housing b - Rachet and extension

Tapered insert tool
c - Tapered insert d - Tapered insert tool
91-43579
2. Install the block-off plate with new gasket. Secure with screws and lockwashers. Torque the screws.
a d c
21683
a - Block-off plate b - Gasket

Description Water inlet block off screw
c - Screw d - Lockwasher
Nm 5 lb. in. 45 lb. ft.
90-864196060 MAY 2006
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SECTION - 6
3. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2.
a d e c b
8489
a - Trim limit switch wires b - Speedometer hose c - Gimbal housing
d - Water hose e - Tapered insert
! WARNING
Avoid 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 hose attached between the gimbal housing and the bell housing. NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. The existing tie strap and clip can be reused if they are moved and repositioned 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.
f b d
a - Tie strap b - Clip c - Water inlet hose
a
8490
d - Speedometer hose e - Trim limit wire harness f - Cutting area
7. Install a through the hull or through the transom seawater pickup, seawater strainer, and seacock. 8. Connect the seawater inlet hose between seawater pump and seawater strainer. 9. Secure all hoses with hose clamps.
Page 22 / 113
90-864196060 MAY 2006
SECTION - 6
Gear Lube Monitor Connection At Gimbal Housing

! CAUTION
Avoid sterndrive unit damage. The quick release button on the gear lube monitor 90 degree hose fitting 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 housing fitting could result in a loose 90 degree hose fitting causing a loss of gear lube and damage to the 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 gimbal housing.
d a c
b
21623
Model with block-off plate a - Hose b - Quick release 90 degree fitting c - Seawater inlet fitting d - J-clip
NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting, or block-off plate if equipped. Release button must not contact water fitting or block-off plate, if equipped. 2. Position quick release button on hose fitting away from water inlet fitting. Release button must not contact water fitting.
21624
Model with Quick connect seawater inlet fitting a - Gear lube monitor hose c - Quick release button b - Seawater inlet fitting NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.
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Page 23 / 113
SECTION - 6
Alternative Mounting Of Gear Lube Monitor On Transom

IMPORTANT: The mounting location specified must be above the steering lever on the transom assembly. 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 c d b
a - Bracket b - Lag screw and flat washer
7706
c - Gear lube monitor and cap d - Retaining strap
Transom Exhaust Connections

IMPORTANT: Exhaust pipe or block-off plate and gimbal housing mating surface must be clean and free of nicks and scratches and O-ring must be properly seated in groove or water may leak into boat.
a
21630
a - Seal 1. Through The Transom Exhaust Models: Install block-off plate using 4 bolts and lockwashers. Torque bolts.
b c a a
a - Block-off plate b - Bolts
21625
c - Lockwashers
Page 24 / 113
90-864196060 MAY 2006
SECTION - 6 Description Exhaust block-off plate bolts
DRIVE SYSTEM AND ENGINE INSTALLATION Nm 34 lb. in. lb. ft. 25
2. Through The Propeller Exhaust Models: Install exhaust pipe. Torque bolts.
a
18976
16231
a - Engine exhaust pipe

Description Exhaust pipe to gimbal housing bolts Nm 34 lb. in. lb. ft. 25
Models With Alpha Sterndrive and Alternative Water Pickups

! CAUTION
Alpha Models
1. Cut water tube off close to cover. Remove and discard the screws and cover.
b c a b
9260
a - Water Tube Cover b - Screws
c - Water Tube
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Page 25 / 113
SECTION - 6
2. Remove rubber grommet from cavity around tube.
a
a - Water Tube (Cut Off In Previous Step)
b
9283
b - Rubber Grommet
3. Remove and discard bell housing sta-strap and clip that retains wires and speedometer hose.
f c a b e
a - Sta-Strap b - Clip c - Bell Housing Hose
9281
d - Bell Housing Assembly e - Speedometer Hose f - Trim Limit Switch Wire Harness
4. Cut the bell housing hose close to the bell housing as shown.
b
9285
a - Bell Housing Hose
b - Cut Line
Page 26 / 113
90-864196060 MAY 2006
SECTION - 6
5. Pull on hose to withdraw water tube through gimbal housing opening. Remove hose with remaining piece of water tube from gimbal housing.
9286
a - Bell Housing Hose
b - Water Tube (Cut Off Previously)
6. Sta-strap (obtain locally) speedometer hose and trim limit switch wire harness together onto piece of hose remaining on bell housing. 7. Install the block-off plate with new gasket. Secure with screws and lockwashers. Torque the screws.
7262

Models With Bravo Sterndrive and Alternative Water pickups

Alternative Water Pickups
90-864196060 MAY 2006
Page 27 / 113
SECTION - 6
! CAUTION
Bravo Models
1. Remove the existing water fitting and gasket. Discard the screws and washers.
8486
Bravo shown a - Water inlet fitting b - Screws and lockwashers
2. Remove the tapered insert in the gimbal housing using the Tapered Insert Tool. Discard the insert.
c a
a b
8487
a - Tapered insert b - Tapered Insert Tool

Tapered Insert Tool
c - Gimbal housing cross-sectional view
91-43579
Page 28 / 113
90-864196060 MAY 2006
SECTION - 6
3. Install the block-off plate with new gasket. Secure with screws and lockwashers. Torque the screws.
8488

4. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2.
a d e c b
8489
a - Trim limit switch wires b - Speedometer hose c - Gimbal housing
d - Water hose e - Tapered insert
! WARNING
Avoid 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 hose attached between the gimbal housing and the bell housing. NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when cutting the water hose. The existing tie strap and clip can be reused if they are moved and repositioned 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.
90-864196060 MAY 2006
Page 29 / 113
SECTION - 6
7. Secure the trim limit switch wires and speedometer hose to the remaining section of water hose using existing tie strap and clip.
f b d
a - Tie strap b - Clip c - Water inlet hose
a
8490
d - Speedometer hose e - Trim limit wire harness f - Cutting area
Power Trim Pump Installation

Power Trim Electrical Connection
ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information) ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also 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 using the 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 battery switch) 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 to the source and the circuit protection device. This will require the use of an Accessory cable kit. Accessory Part Numbers
Part Number 8M2000587 8M2000588 Description Cable Assembly Trim Pump Cable Assembly Trim Pump Color Red Red Length 72 inches 40 inches Type Fused Sheathed
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SECTION - 6
Power Trim Pump

1. Select an appropriate mounting location (floor or transom) for the trim pump that: Is within length limits of BLACK and GRAY hydraulic hoses coming from gimbal housing assembly. 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 Filling

IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking from the system. 1. Connect hydraulic hoses to the trim pump. Ensure that the quick- connect fittings completely seat when connecting the hoses.
a c g
h f b
abcd-
d
Positive battery lead Negative battery lead Harness connector BLACK hydraulic hose (UP hose)
7698
e
efghGRAY hydraulic hose (DOWN hose) Fill/vent cap Dual mount trim pump bracket Trim limit switch connected and secured
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SECTION - 6
2. Connect power trim pump control harness to trim pump.
a b
7699
a - Control harness
b - Trim pump connector
FILLING
1. 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.
7701
Power tim pump reservoir showes the oil level is below "MIN" line a - 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
a - Reservoir
Tube Ref No.
114
b
7876
b - "MIN" and "MAX" lines

Description Where Used Power trim pump Part No. 92-802880A1
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SECTION - 6
4. Install the fill cap.
Trim Limit Switch Connection

1. Connect the trim limit switch wires and secure with a wire retainer and tie strap.
b
a - Trim limit switch wires
7700
b - Wire retainer and cable tie
Steering System Installation

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

Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. The steering cable coupler nut must also have a means of locking it to the guide tube, as specified in ABYC requirements.
! WARNING
Failure to use a steering cable locking device could cause loss of steering, causing possible damage to the boat or injury. NOTE: All current production Quicksilver RideGuide steering cables have a self-locking coupler nut and do not require an external locking device. (Other cable manufacturers also make cables with self-locking coupler nut.)
7255
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 external locking device such as a locking sleeve must be used.
! CAUTION
If steering cable with improper dimensions is installed, severe damage to transom assembly and/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.
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SECTION - 6
3. Fully extended steering cable end dimension must be as specified.
Steering Cable Specifications

IMPORTANT: Power-assisted steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.
a b e f
c d g
C L
k l
j i
7254
abcdef-
Coupler nut - 7/8 - 14 UNF - 28 thread 298 mm (11-3/4 in.) minimum Interface point 12.7 mm (1/2 in.) maximum 10.7 mm (27/64 in.) minimum flat 3.1 mm (7/64 in.) minimum radius
g - 15.9 mm (5/8 in.) maximum diameter end 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.) maximum k - 15.9 mm (5/8 in.) diameter tube l - Cable travel: mid-travel position 429 mm (16-7/8 in.) total travel to be 203 mm (8 in.) minimum to 228 mm (9 in.) maximum travel each side of mid-travel position 102 mm (4 in.) minimum to 114 mm (4-1/2 in.) maximum
Installing Steering System

NOTE: For dual installations, power-assisted steering unit can be mounted on port or starboard transom assembly. Measure exact distance between power package center lines. Select a tie bar from Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar installation instructions before proceeding. 1. Remove the protective shipping caps. 2. Inspect the bushings for debris. Lubricate the power steering bushings. 3. a
7709
a - Bushings
Tube Ref No.
34
Description Special Lubricant 101
Where Used Power steering bushings
Part No. 92-802865A1
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SECTION - 6
4. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.
b
21631
a - Upper pivot bolt

Tube Ref No.
34
b - Lower pivot bolt

Where Used Upper and lower pivot bolts Part No. 92-802865A1
5. Position the steering assembly so that the pivot bolts will enter the bushings in the power-assisted steering control valve. 6. Install the upper and lower pivot bolts along with tab washers. Ensure that the tab washer tangs straddle the ridge on the inner transom plate.
a b
b
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.
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SECTION - 6
NOTE: It may be necessary to tighten the pivot bolts further to align the flats on bolt head with the tabs on the washer.
a
21691
a - Pivot bolt
Description Upper and lower pivot bolt
b - Bent tab
Nm 34 lb. in. lb. ft. 25
! CAUTION
MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid from the control valve ports. Wear eye protection. 10. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tube as shown, so that it will be less difficult to pull it out or push it in during connection.
b b
8496
a - Port 11. Connect the clevis to the steering lever. a. Lubricate the clevis pin.
Tube Ref No.
34
b - Control valve cable guide tube
Where Used Clevis pin
Part No. 92-802865A1
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90-864196060 MAY 2006
SECTION - 6
b.
Insert the clevis pin.
b a
20396
a - Clevis c. d. Insert the cotter pin. Spread both ends of the cotter pin.
b - Clevis pin
b c
a
a - Cotter pin b - Clevis pin
20399
c - Steering lever
IMPORTANT: Quicksilver RideGuide steering cable has a self-locking coupler nut and does not require an external locking sleeve or locking plate.
7255
a - Self-locking coupler nut
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SECTION - 6
! CAUTION
Proper steering system function requires that the steering cable and outer casing must be free to move back and forth. Items fastened to the steering cable and outer casing prevent free movement. Do not fasten any items to the steering cable and outer casing.
7827
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.
Tube Ref No.
34
Where Used Steering cable end
Part No. 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 in the steering system could be encountered. c. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical position. Torque the coupler nut. Ensure that the flat surfaces are still aligned vertically after torque is applied to the coupler nut.
d g
h e f c
a b
d
7830
abcd-
Steering cable Grease fitting Cable coupler nut Cable guide tube
efgh-
Steering cable end Clevis Clevis pin Cotter pin
Shift Cable Routing

1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:
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SECTION - 6
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 flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power-assisted steering valve and loop over to the shift actuator on the engine. NOTE: Following this routing will prevent the engine coupler from damaging the cable.
a.
8995
Refer to Section 8 - Remote Control.
Transom Harness
MerCruiser engines are shipped with a separate transom harness. This harness allows for connection to various electrical components that occur behind the engine such as trim senders and the Mercathode, and provides the continuity ground to the transom and sterndrive for corrosion protection. The harness is labeled with the sensors that will connect to it. The sensor needed for your installation should be connected and the wiring secured with clamps and stay straps to prevent damage to the wiring as the engine is installed and later as the boat is used. The engine connector should be tied back so as not to interfere with the engine installation. After the engine is installed, the single connector will be connected. NOTE: The black ground wire on the transom harness must be connected under the bolt on the port side of the transom plate that has the bonding strap and j-clamp already attached. See "Installing inner Transom Plate" for details.
Engine Installation
Transom Preparation
IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches and O-ring must be properly seated in groove or water and exhaust may leak into boat. 1. Ensure the exhaust pipe and gimbal housing mating surfaces are clean and free of nicks and scratches.
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SECTION - 6
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
a - Shipping plug
7767
5. Through The Propeller Exhaust Models: Install exhaust pipe assembly using 4 bolts and lockwashers. Torque bolts.
b
a - Exhaust pipe
Description Exhaust pipe bolts
a
8499
b - Bolts and lockwashers (4)

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SECTION - 6
6. Through The Transom Exhaust Models: Install block-off plate using 4 bolts and lockwashers. Torque bolts.
8404
a - Block-off plate
Description Exhaust block-off plate bolts
b - Bolts and lockwashers (4)

NOTE: Through the transom exhaust fittings can be installed at this time.
! CAUTION
Avoid product damage caused by improper engine alignment. Improper engine alignment can be 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, port and 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
7960
Typical flywheel housing, all similar a - Late style mount - knurled surface b - Fiber washer
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SECTION - 6
8. Position rear engine mount attaching hardware on inner transom plate mounts as shown.
b
7839
a - Fiber Washer (2)
b - Locknut (2)
Shift Cable Routing

1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows: 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 flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power steering valve and loop over to the 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.
Engine Preparation
1. 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 other material 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.
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SECTION - 6 Description Battery stud Tube Ref No.

25
DRIVE SYSTEM AND ENGINE INSTALLATION Nm 8-11 Description Liquid Neoprene Where Used Battery terminals lb. in. 71-97 Part No. 92-25711-3 lb. ft.
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.
8501
a - Positive (+) battery cable location b - Starter solenoid
c - 90 amp fuse - Do not remove
5. If not already done, remove shipping plug from coupler and lubricate splines.
a
Typical a - Shipping plug
Tube Ref No.
91
7767
Description Engine Coupler Spline Grease
Where Used Coupler splines
Part No. 92-802869A1
Fuel Inlet Fitting

IMPORTANT: The following information is provided to ensure proper installation of brass fittings or 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.
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SECTION - 6
! WARNING
Avoid serious injury or death and property damage due to improper boat design and construction. Always adhere to all applicable Marine Regulations (United States Coast Guard [USCG], European Union - Recreational Craft Directive [EU-RCD], and so on) and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers [SAE], International Standards Organization [ISO], and so on) when designing and constructing the boat and the boat components, such as the engine compartment, fuel delivery system and exhaust system.
! WARNING
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump or fuel 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.
! WARNING
Overtightening the fuel inlet fitting can lead to fuel leaks, avoid severe personal injury or death from a gasoline fire or explosion. Do not use a power tool (i.e. impact wrench) to tighten the fuel inlet fitting. 3. Install fuel inlet fitting in fuel pump or filter base. To prevent cracking the casting or causing fuel leaks, turn fuel inlet fitting in by hand until finger-tight. Tighten the fitting an additional 1-3/4 to 2-1/4 turns with wrench. DO NOT OVERTIGHTEN. IMPORTANT: Hold brass fittings with a suitable wrench while tightening fuel inlet fittings.
Tube Ref No.
9
Description Loctite 567 PST Pipe Sealant
Where Used Fuel inlet fitting Procedure
Part No. 92-809822
Description Fuel inlet fitting
Finger-tight + 1-3/4 to 2-1/4 turns with a wrench. Do not overtighten.
! CAUTION
Engine compartment size may require the removal of additional components. NOTE: An installation jig (91-806794A02) can be used to align and adjust engine mounts. Refer to instructions with fixture for proper use.
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SECTION - 6
1. Remove the engine cover, if equipped.
a b
9289
Closed cool model shown, seawater cooled similar a - 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 is level when suspended.
! CAUTION
9375
a - Center lifting eye (engine alignment only) 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.
Tube Ref No. Description Liquid soap Where Used Exhaust tubes Part No. 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 the engine 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.
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SECTION - 6
8. If clearance is greater than 13 mm (1/2 in.):
d e
7771
a - Bilge drain plug b - Tether c - Quick oil drain hose plug a. b. c. d.
d - Flange e - Toward interior of boat f - Clip
Push end of oil drain hose out of boat hull through flange. Pull oil drain hose out until it is 304 mm (12 in.) from flange. 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. Connect bilge drain plug to oil drain hose plug using clip.
b c d
7618
a - Oil drain hose b - Alignment clip
c - Clip d - 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.
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SECTION - 6
NOTE: Normally the engine attaches to the transom plate with only the fiber washer in place. If the 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 mount adjustment.
c c e d e a f
7961
g b f
7772
b
abcdDescription Rear engine mounting bolts
Rear engine mount Inner transom plate mount Bolt Washer
e - Spacer f - Fiber washer g - Stainless steel washer (optional spacer kit)

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

! CAUTION
Avoid 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 inside diameter of the exhaust hose to avoid causing hot spots, which could eventually burn through the exhaust hose. Connect the exhaust hoses and tubes to the exhaust elbows so that they do not restrict the flow of discharge water from the exhaust elbows. Exhaust hoses must be properly installed on exhaust elbow outlets. Discharge water from the exhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots that could burn through the hose.
7628
7629
Correct
Incorrect
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SECTION - 6
a c d e
Exhaust connection a - Maximum misalignment +/- 5 degrees b - Exhaust outlet centerline (14 degrees vs. crankshaft centerline) c - Exhaust hose centerline
b
9290
d - Angle vs. horizontal e - Horizontal (level surface)
IMPORTANT: Exhaust hoses/tubes should be secured at each connection with at least 2 hose clamps. All exhaust connections, including those at the exhaust elbow, should be secured with 2 hose clamps. ABYC standards also specify the use of stainless steel clamps with a minimum 13 mm (1/2 in.) band width. Do not use spring tension clamps. 1. Torque all exhaust hose and/or exhaust tube clamps.
a
7631
a - Hose clamps
Description Exhaust tube clamps Hose clamps Nm 4 3.4-6.8 lb. in. 35 30-60 lb. ft.
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SECTION - 6
Engine Alignment Sterndrive Models

1. If applicable, open perforated area in bell housing dust cover.
8378
a - Dust cover
! CAUTION
Do not use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Alignment Tool may cause improper alignment and damage to gimbal bearing and/or engine coupler.
! CAUTION
To 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 bearing or 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 the engine coupler splines.
Alignment Tool Assembly 91-805475A 1
3. If the alignmet tool does not fit, remove it and carefully raise or lower the front end of the engine as necessary. 4. If applicable, attach the engine hoist to the engine aligment hook to raise or lower the front end of engine. NOTE: Models not equipped with engine alingment hooks; require adjusting the front engine mounts 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 gimbal bearing to the coupler.
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SECTION - 6
6. If necessary, firmly strike the sides of the Alignment Tool at 90 degree increments to help align the gimbal bearing.
d a b
e
a - Alignment Tool b - Gimbal bearing c - Engine coupler d - Hammer e - 90 degree increments
7784
7. Repeat step 4. until the Alignment Tool installs easily (SLIDES FREELY WITH MINIMAL EFFORT) all the way into and out of engine coupler splines. Do not check by turning the alignment tool. IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum of 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 required to 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.
b a
8503
a - Alignment Tool (use only recommended Alignment Tool)
b - End to be inserted through gimbal housing assembly
11. When alignment is correct, tighten locknut securely. Recheck alignment.
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SECTION - 6
12. Bend tab down on adjusting nut.
a b c d
8504
a - Nut and lockwasher b - Adjustment nut
c - Direction (counterclockwise) to raise front of engine d - Tab washer
13. Remove Alignment Tool. If not installing drive, fold bell housing dust cover flap back into place and tape shut for boat shipment. Dust cover flap will have to be removed before operating engine. 14. Remove the engine alignment hook from the engine.
Electrical Connections
! CAUTION
Avoid damage to the electrical system components caused by improper work or diagnostic practices. 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 and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts.
Tube Ref No.
25
Description Liquid Neoprene
Where Used All electrical connections
Part No. 92-25711-3
Instrumentation Connections-MPI Engines

We recommend the use of Quicksilver Instrumentation and Wiring Harnesses. On dual station applications, oil pressure and water temperature senders (on engine) must be changed. Refer to Mercury Precision Parts Accessories Guide for selection. The 4 basic gauges that must be used with the engine are: Tachometer Oil pressure Water temperature
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SECTION - 6
Voltmeter IMPORTANT: Maximum accessory load on the engine harness is 15 amps. If additional accessory load 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
Typical a - Engine harness plug 4. Connect 14-pin harness to engine. Turn locking ring until firm snap is felt.
23136
SMARTCRAFT PRODUCT
A Mercury SmartCraft System instrument package can be purchased for this product. A few of the functions the instrument package will display are engine rpm, coolant temperature, water pressure, battery voltage, fuel consumption, and engine operating hours. The Smartcraft instrument package 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 functions monitored and basic operation of the SmartCraft Instrument package. Refer to the instructions included with the instruments for installation instructions.
Audio Warning System Connections

! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Engine or fuel tank compartments may have gasoline or gasoline vapors present that could be ignited by components that are not external ignition proof. The audio warning alarm is not external ignition-proof. Do not mount the audio warning alarm in the engine or fuel tank compartments.
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SECTION - 6
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 the OFF 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
a
APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION:
b
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)
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 function continuously for proper corrosion protection.
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SECTION - 6
2. Connect the Mercathode Red/Purple wire directly to the battery positive lead.
d a b c
8507
a - ORANGE lead - from anode on transom assembly (part of quick connect) b - RED/PURPLE wire - to positive (+) battery terminal
Tube Ref No.
25
c - BLACK wire - from engine harness d - BROWN wire - from electrode on transom assembly(part of quick connect)
Where Used MerCathode connections
Part No. 92-25711-3

ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information) ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also 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 using the 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 battery switch) 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 to the source and the circuit protection device. This will require the use of an Accessory cable kit. Accessory Part Numbers
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SECTION - 6
Battery Cables Connection

IMPORTANT: 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 Connections

1. Connect power trim pump BLACK (-) battery cable to negative (-) battery terminal and pump RED (+) battery cable to positive (+) battery terminal.
b
6842
a - Positive battery lead

Tube Ref No.
25
b - Negative battery lead

Where Used Battery Terminals Part No. 92-25711-3
Transom Connections
Gear Lube Monitor Connection
IMPORTANT: Avoid using excessive hose when routing it to gear lube monitor. Hose should be routed directly to oil reservoir in as straight a line as possible to avoid low spots (traps) in the system.
! CAUTION
Ensure that hose is not kinked when connecting in the following step. If hose is kinked, gear lube monitor 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.
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SECTION - 6
3. Fasten the quick connect.
7800
a - Gear lube monitor hose assembly from transom b - Gear lube monitor hose assembly from gear lube monitor
c - Quick connect fitting
Power-Assisted Steering Hoses

IMPORTANT: 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 a a b
a - Hydraulic lines
b
16225
b - Power-assisted steering control valve
NOTE: Steering Fluid can be added at this time if desired.
Seawater Inlet Fitting Connection

! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. An improperly connected seawater inlet hose could result in excess water in the bilge. Ensure that the seawater inlet 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.
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SECTION - 6
a.
Position the retainer clip in the closed position.
a b
8512
Seawater inlet hose assembly a - Retainer clip closed c - Hose decal b - Quick connect fitting Position the seawater inlet hose assembly with the center of the retainer clip and the hose decal toward the engine. IMPORTANT: Tabs and slots are sized to only mate at the correct orientation. Mate the small tab with the small slot. c. Align the slots of the quick connect fitting to the tabs of the water inlet fitting. b.
g h
b c
e f
8513
abcd-
Quick connect fitting Small slot Large slot Seawater inlet fitting
efgh-
Small tab Large tab Center of retainer clip (toward engine) Centerline of water inlet fitting (toward engine)
Ensure that the center line of the water inlet fitting and the center of the retainer clip are positioned toward the engine. 2. Push the seawater inlet hose assembly onto the water inlet fitting until connected.
d.
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SECTION - 6
NOTE: The retainer clip snaps into place and resumes the closed position when properly connected.
b
8514
Shown with engine removed for visual clarity a - Centerline of water inlet fitting c - Hose decal b - Retainer clip in closed position
! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. An improperly connected seawater inlet hose could result in excess water in the bilge. Ensure that the seawater inlet hose is connected properly by performing the specified pull test. 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 of 111 N (25 lbf). If the seawater inlet hose does not become separated from the seawater inlet fitting when force is applied, the seawater inlet hose is connected and sealed properly.
a b
8515
Shown with engine removed for visual clarity a - Seawater inlet hose c - Seawater inlet fitting b - Quick connect fitting If the seawater inlet hose does become separated from the seawater inlet fitting, reinstall as 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. b.
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SECTION - 6
NOTE: The seawater inlet hose connects to the engine and the transom.
b e a c d
8516
Seawater inlet hose assembly a - Seawater inlet hose d - Seawater inlet fitting b - To engine e - Hose clamps c - Quick connect fitting 5. Models Using The Seawater Extension Hose Assembly: NOTE: The seawater inlet hose connects to the engine and the transom, the seawater extension hose assembly connects to the transom and the seawater inlet hose. a. When connecting the seawater extension hose assembly to the seawater inlet hose assembly, position the center of the retainer clip away from the engine.
e a c
8517
Shown with engine removed for visual clarity a - Retainer clip position (away from d - Quick connect fitting (to seawater inlet engine) fitting) b - Seawater extension hose e - Seawater inlet fitting (to transom) c - Seawater inlet hose (to engine seawater pump)
! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. An improperly connected seawater inlet hose could result in excess water in the bilge. Ensure that the seawater inlet hose is connected properly by performing the specified pull test. b. Perform a pull test and ensure that the requirements for checking the integrity of the connection are met.
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SECTION - 6
NOTE: The seawater extension hose assembly connects to the transom and the seawater inlet hose.
g g g d b a
a - Seawater inlet hose b - Quick connect fitting to extension hose c - Quick connect male fitting d - Extension hose
g e c
8518
e - Quick connect fitting to seawater inlet fitting f - Seawater inlet fitting g - Hose clamp
Alpha Shift Cable Installation

Alpha Sterndrive Shift Cable Installation
IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control. 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.
A B
Arrow indicates direction of motion IMPORTANT: When installing shift cables, ensure that 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.
6614
SHIFT CABLE TRAVEL

We recommend the use of a Quicksilver remote control and cable. Refer to Mercury Precision Parts 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).
Description Shift cable travel1 Specification 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 installing the remote control shift cable and using the shift assist assembly (provided) to place the proper load on the shift cable.
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SECTION - 6
1. Place a mark on the tube against the edge of the cable end guide.
d e
a b c
7809
a
a - Shift assist assembly b - Remote control shift cable - in FORWARD gear position c - Edge of cable end guide d - Remote control shift cable - in REVERSE gear position e - Measurement taken from mark to edge of cable end guide
SEPARATE SHIFT AND THROTTLE CONTROLS

IMPORTANT: If boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS, the shift assist assembly that is shipped with the engine should not be used. The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly. The Spacer Kit (23-11284A1) will have to be ordered to connect remote control shift cable when shift assist assembly is not used.
c b a d
7810
a - Clevis pin b - Washer
c - Spacer d - Cotter pin
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SECTION - 6
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 (LH or RH) drive unit, as explained following: RIGHT-HAND ROTATION - Control cable will have to be installed in remote control so that cable end will move in direction "A" when shift handle is placed in the FORWARD position. LEFT-HAND ROTATION - Control cable will have to be installed in remote control so that cable end will move in direction "B" when shift handle is placed in the FORWARD position.
A B
INSTALLATION
1. Remove shift assist assembly. 2. Remove shift cable attaching hardware.
6614
b
7812
a - Shift assist 3. Install intermediate cable.
b - Shift plate
7813
4. Secure the brass barrel retainer with the cotter pin.
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SECTION - 6
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 the following 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."
7815
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.
! CAUTION
Do not attempt to install or remove control cable barrel from stud without first removing end guide anchor pin from shift lever and removing cable. Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur. 9. 10. 11. 12. Place remote control and and sterndrive unit in FORWARD gear. Install the remote control shift cable. Place remote control handle in NEUTRAL. Install the shift assist assembly. Ensure that it fits over the clevis pin and barrel stud with no resistance.
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SECTION - 6
13. Install the fastening hardware. If shift assist assembly attaching points will not align, verify controller is in NEUTRAL. Remove the shift cable and reposition the adjustment barrel as required to allow the shift assembly to be installed with no effort.
d a
e b
With shift assist assembly a - Remote control shift cable b - Shift assist assembly c - Clevis pin (and cotter pin not shown)
7818
d - Large ID washer e - Small ID washer and cotter pin
d a c e
f g
i h b
7841
abcde-
Without shift assist assembly Remote control shift cable Clevis pin Cotter pin (existing) (not shown) Spring (existing) (not shown) Washer (existing)
fghi-
Washer Spacer Washer (existing) Cotter pin (existing)
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SECTION - 6
Bravo Shift Cable Installation and Adjustment

Bravo Models Shift Cable Installation
NOTE: Bravo Models Only: Using shift cable adjustment tool (91-12427), shift cables can be adjusted 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 the remote 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 in FORWARD gear position.
A
21621
IMPORTANT: When installing shift cables, ensure that 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.
Bravo Models Shift Cable Adjustment

1. Remove the adjustment tool.
21611
a - Adjustment tool
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SECTION - 6
2. Loosen the adjustable stud and move it to dimension, as shown. Retighten stud.
b
21612
a - Adjustable stud
b - 76 mm (3 in.) (center of pivot bolt to center of stud)
3. Install sterndrive shift cable. 4. Install cotter pin. 5. Insert cotter pin from top and spread ends fully.
21616
a - Sterndrive shift cable b - Long cotter pin
c - Short cotter pin
6. Place adjustment tool over sterndrive shift cable, as shown. Hold tool in place using a piece of tape over the barrel retainer.
21615
a - Adjustment tool
b - Sterndrive shift cable
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SECTION - 6
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 the following 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."
7815
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.
! CAUTION
Do not attempt to install or remove control cable barrel from stud without first removing end guide anchor pin from shift lever and removing cable. Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur. 10. Remove control cable end guide from shift lever by removing clevis pin.
a b
21613
a - Control cable end guide b - Clevis pin c - Backlash center
d - Control cable barrel e - 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.
90-864196060 MAY 2006
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SECTION - 6
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 until slot 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.
21614
a - RH rotation Bravo One, Two, Three FORWARD, LH rotation Bravo One and Two REVERSE slot
b - LH rotation Bravo One and Two FORWARD, 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.
Tube Ref No.
80
Description SAE Engine Oil 30W
Where Used Shift cable pivot points
Part No. Obtain Locally
Shift Cable Installation For DTS System

IMPORTANT: 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: 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 flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power-assisted steering valve and loop over to the shift actuator on the engine. NOTE: Following this routing will prevent the engine coupler from damaging the cable.
8995
Page 68 / 113
90-864196060 MAY 2006
SECTION - 6
NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be 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.
Tube Ref No.
34
Where Used Shift cable stud
Part No. 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.
b e a f d c
8996
a - Shift actuator b - Shift cable c - Locknut 5. Insert cotter pin from top and spread ends.
d - Shift cable stud e - Shift cable barrel f - Washers
8997
a - Cotter pin
Throttle Cable Installation and Adjustment

1. 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.
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SECTION - 6
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.
g d c b
abcde-
i j
9378
Cable end guide Throttle lever screw Locknut and flat washer (small) Throttle lever Idle speed adjustment screw
fghij-
Idle cam Throttle bracket Cable barrel Flat washer and locknut (large) Throttle cable anchor stud
Alpha Sterndrive Installation

Alpha Notice: Increased Trim-in Range Capability
The Alpha trim cylinders provide the capability for an increased trim-in range. A spacer can be removed from the trim cylinders to increase the trim-in range by approximately 1-1/2 degrees. This will improve the acceleration on some boats by forcing the bow down more quickly. If the spacers are to be removed, the boat must be water tested to ensure that the increased trim-in range does not cause any undesired boat handling characteristics (bow-steer, chine-walk, etc.) if the sterndrive is trimmed in while the boat is operated at higher speeds. The boat should be tested under all conceivable load conditions and maneuvers to ensure that the additional trim-in does not pose a problem. The final decision and responsibility for use of the additional trim-in range is left up to the boat manufacturer.
! WARNING
It is recommended that only qualified personnel adjust the trim-in limit inserts. The boat must be water tested after adjusting the trim-in limit inserts to ensure that the modified trim-in range does not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is trimmed in at higher speeds. Increased trim-in range may cause handling problems on some boats, which could result in personal injury.
Alpha Trim Cylinder Spacer Removal

1. Disconnect "UP" trim hose from "UP" port on trim cylinder.
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90-864196060 MAY 2006
SECTION - 6
2. Disconnect "DOWN" trim hose from hydraulic connector on gimbal housing. Plug holes with 22-38609 plug.
d b a
a - "UP" hose b - "UP" port on trim cylinder
7843
c - "DOWN" hose d - Hydraulic connector
3. Remove front power trim cylinder mounting hardware.
b d
a - Front anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
4827
d - E-ring (port and starboard) (2) e - Plastic caps (port and starboard) (2)
4. Remove rear power trim cylinder mounting hardware.
e b
7844
a - Rear anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
90-864196060 MAY 2006
Page 71 / 113
SECTION - 6
Alpha Trim Cylinder Disassembly

! WARNING
It 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 that the increased trim range does not cause the boat to exhibit an undesirable boat handling characteristic if the drive is trimmed in at higher speeds. The increased trim-in range may cause handling problems on some boats which could result in personal injury.
! CAUTION
Ensure work area is clean before disassembling power trim cylinders. Cylinder parts can be damaged by dirt entering into power trim system.
! CAUTION
Trim cylinders can be damaged by improper clamping. Clamping the center section of the trim cylinder 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.
7845
a - Piston rod assembly

Trim Cylinder End Cap Tool
b - Cylinder
91-821709T
Page 72 / 113
90-864196060 MAY 2006
SECTION - 6
3. Remove bolt, washer, and spacer. Be careful not to lose check balls. Discard spacer.
h d e f g c
7846
a
abcd-
Trim cylinder shock piston bolt Spacer Washer Springs (3)
efgh-
Spring pins (3) Check balls (3) Shock piston assembly O-ring
Alpha Trim Cylinder Reassembly

! CAUTION
Ensure that work area and all components are clean before reassembling trim cylinders. Power trim components can become damaged if dirt gets into system. 1. Apply sealant to threads of shock piston bolt.
Tube Ref No.
7
Description Loctite 271 Threadlocker
Where Used Trim cylinder bolt threads
Part No. 92-809819
2. Install washer and bolt and torque.

Description Trim cylinder shock piston bolt Nm 23 lb. in. lb. ft. 17
! CAUTION
Trim cylinders can be damaged by improper clamping. Clamping on the trim cylinder center section during service procedures can cause damage that could result in a loss of some trim-in or trim-out. Clamp the trim cylinder only on the front mounting flange.
! CAUTION
Prevent trim cylinder damage caused by corrosion. Always apply Special Lubricant 101 to the end cap threads before assembly. 3. Apply lubricant to end cap threads and install piston rod assembly into cylinder.
90-864196060 MAY 2006
Page 73 / 113
SECTION - 6
4. Torque end cap using the spanner wrench.
a b
c
a - End cap b - Piston rod assembly
Tube Ref No.
34
7847
c - Cylinder
Where Used Trim cylinder end cap Nm 61
Part No. 92-802865A1 lb. in. lb. ft. 45
Description Trim cylinder end cap
5. Position trim cylinder rear connecting ends.
7848
a - Port trim cylinder b - Starboard trim cylinder
c - Connecting ends (offset as shown)
Alpha Trim Cylinder Installation

1. 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.
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SECTION - 6
4. Attach E-rings and plastic caps to end of anchor pin.
b d
a - Front anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
Tube Ref No.
95
4827
Description 2-4-C Marine Lubricant with Teflon
Where Used Trim cylinder hardware
Part No. 92-802859A1
5. 6. 7. 8.
Install trim cylinders rear mounting hardware. Coat area in trim cylinder between bushings with lubricant. Replace anchor pin and install bushings and washers. Attach E-rings and plastic caps to end of anchor pin.
e b
7844
a - Rear anchor pin b - Bushing (port and starboard) (4) c - Flat washer (port and starboard) (2)
Tube Ref No.
95
Where Used Trim cylinder
Part No. 92-802859A1
9. Reconnect trim hoses after air bleeding power trim cylinders and hoses following procedures outlined in Mercury MerCruiser Service Manual 14.
90-864196060 MAY 2006
Page 75 / 113
SECTION - 6
1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)
7713
Typical a - Dust cover 2. Remove gear lube monitor cap. Fill with lubricant. b - Trim cylinder support
5497
a - - Gear lube monitor cap

Tube Ref No.
87
b - "OPERATING RANGE" line

Where Used Gear lube monitor Part No. 92-802854A1
Description High Performance Gear Lubricant
3. Push dribble valve stem in until gear lube appears.
7851
a - Dribble valve stem
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SECTION - 6
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.
Tube Ref No.
87
Where Used Gear lube monitor
Part No. 92-802854A1
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap. IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing drive 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 c b
7852
a - Rubber gasket b - Water passage O-ring

Tube Ref No.
95
c - Studs (6)
Where Used Bell housing studs
Part No. 92-802859A1
9. Grease sterndrive U-joint O-rings, and drive shaft splines. A grease packet for this procedure is provided with the sterndrive packaging.
a a b
7853
a - U-joint O-rings
b - Drive shaft splines
90-864196060 MAY 2006
Page 77 / 113
DRIVE SYSTEM AND ENGINE INSTALLATION Tube Ref No.

91
SECTION - 6 Description Where Used Ujoint O-rings Where Used Drive shaft splines Part No. 92-802869A1 Part No. 92-802869A1
Engine Coupler Spline Grease Description Engine Coupler Spline Grease
Tube Ref No.

91
10. Ensure U-joint bellows are clean and free of debris.
7854
a - U-joint bellows 11. Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft. Do this by placing remote control shift lever in: FORWARD gear position for RH drive or REVERSE gear position for LH drive unit.
c a
d b
7855
a - Shift shaft b - Shift shaft coupler
c - Shift slide d - Slot
IMPORTANT: Shift slide assembly is free to rotate on core wire. Ensure that shift slide remains in upright 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.
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SECTION - 6
14. Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide.
b c c
a - Shift shaft lever b - Roller
Shift Slide Stabilizer
7859
c - Shift Shaft Slide Stabilizer Tool d - Gasket

91-865232
15. Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE while simultaneously turning propeller shaft COUNTERCLOCKWISE.
7856
a - Drive unit shift shaft IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dual engine installations. The LH rotation drive unit can be identified by the decal on the back side of the 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 to scratch acceleration plate or trim cylinders. b. Guide U-joint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into drive shaft housing. Ensure that shift slide remains upright and engaged with bell housing shift shaft lever. c. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align U-joint shaft splines with engine coupler splines while sliding sterndrive into bell housing.
90-864196060 MAY 2006
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SECTION - 6
IMPORTANT: If drive unit will not slide into bell housing, ensure that the shift shaft and couplers are positioned properly. Do not force drive unit into position.
b
7857
a - Gasket d. e. f.
b - Shift slide
Remove Shift Slide Stabilizer Tool and discard. Slide sterndrive all the way into bell housing. Secure sterndrive to bell housings using fasteners as shown. Torque the fasteners.
a b
7858
a - Locknut and flat washers
b - Locknut and continuity circuit washer (no flat washer at this location)
Description Sterndrive unit fasteners
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.
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90-864196060 MAY 2006
SECTION - 6
2. Install the plastic caps by snapping in place.NOTE: Upon installation of hardware apply lubricant to all components except plastic caps.
a b c d e
b
a - Aft anchor pin b - Bushings c - Flat washers
Tube Ref No.
95
a
d - E-ring clips e - Plastic caps
7849
Where Used Trim cylinder hardware
Part No. 92-802859A1
3. Position the sterndrive unit serial number decal.
Speedometer Connection - Alpha Models

1. 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.
4803
a - Male end of speedometer tube fitting
b - Female end of speedometer tube fitting
90-864196060 MAY 2006
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SECTION - 6
Ensure that the speedometer tube is secured and out of the way of moving parts.
b a
8029
a - Male end of speedometer tube fitting
b - Female end of speedometer tube fitting
Bravo Installation
Engine Alignment Check
The engine alignment tool must slide in and out of the engine coupler and the gimbal bearing with little or no friction.
! CAUTION
Damage to engine and sterndrive can result from improper engine alignment. Align your engine as specified in the Mercury MerCruiser Installation Manual for your engine package.
! CAUTION
Do not use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Alignment Tool may cause improper alignment and damage to gimbal bearing and/or engine coupler. 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.
a
21671
a - Alignment tool
Alignment Tool Assembly 91-805475A 1
Page 82 / 113
90-864196060 MAY 2006
SECTION - 6
b.
Hit the sides of the alignment tool with a synthane hammer at 90 degree increments to help align the gimbal bearing to the coupler as shown in the following steps:
a
4889
a - Alignment tool b - Gimbal bearing c.
c - Engine coupler d - 90 degree increments
Hit the alignment tool upward and downward.
b a
b
21672
a - Synthane hammer d.
b - Alignment tool
Hit the alignment tool on the port side and on the starboard side.
b
21673
a - Synthane hammer e. f.
b - Alignment tool
Pull the tool out and insert it through the gimbal bearing and into the engine coupler splines. If the alignment tool does not fit, or is very tight, remove the tool.
90-864196060 MAY 2006
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SECTION - 6
NOTE: Apply grease to the alignment tool before checking alignment. When the tool is removed the tool is wiped clean on the tight side. This can help determine where the engine adjustment is needed. Adjust the engine mounts as necessary: Refer to the appropriate Mercury MerCruiser 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 gimbal bearing with little or no friction.
c a
a - Alignment tool b - Gimbal housing
4781
c - Gimbal bearing
Bravo Sterndrive Installation

1. If applicable, remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts and flat washers.)
b
8993
Typical a - Dust cover b - Trim cylinder support
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SECTION - 6
2. Remove gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE".
5497
Gear lube monitor a - Gear lube monitor cap

Tube Ref No.
87
b - "OPERATING RANGE" line

Where Used Gear Lube Monitor Part No. 92-802854A1
3. To purge air from the system, push in on the dribble valve stem until the new gear lube appears.
21440
a - Dribble Valve 4. Release the dribble valve.
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SECTION - 6
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.
c b a
19947
Gear lube monitor a - Gear lube level at the "ADD" mark b - Gear lube level at the "OPERATING RANGE"
Tube Ref No.
87
c - Cap
Where Used Gear Lube Monitor
Part No. 92-802854A1
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do not overtighten the cap.
19962
a - Gear lube monitor cap 7. Coat the O-rings on the sterndrive U-joint with lubricant
a
a - O-rings
a
21441
Page 86 / 113
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SECTION - 6
8. Coat the splines on the sterndrive U-joint with lubricant.
a
a - Splines
Tube Ref No.
91 91
21442
Description Engine Coupler Spline Grease Engine Coupler Spline Grease
Where Used U-joint O-rings Driveshaft splines
Part No. 92-802869A1 92-802869A1
9. Ensure that the U-joint bellows are clean and free of debris.
21456
Bell housing of the transom assembly a - U-joint bellows edge b - U-joint bellows 10. Lubricate the bell housing studs.
a a
21457
a - Bell Housing Studs (6)

Tube Ref No.
95
b - Tube of lubricant
Where Used Bell housing studs Part No. 92-802859A1
90-864196060 MAY 2006
Page 87 / 113
SECTION - 6
11. Lubricate the shift linkage O-ring.
a
21678
a - Shift linkage O-ring

Tube Ref No.
95
Description 2-4-C with Teflon
Where Used O-ring
Part No. 92-802859A1
12. Lubricate the water passage seal.
a
21679
a - Water passage seal

Tube Ref No.
95
Where Used Water passage seals
Part No. 92-802859A1
Page 88 / 113
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SECTION - 6
13. Pull out the shift linkage as far as it moves. Jaws will open.
b
a
c c
5311
21471
a - Shift linkage assembly b - Jaws open
c - Underside of lower lip
IMPORTANT: As the sterndrive is inserted into the entry of the bell housing, the shift cable must be 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 back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps "A", "B" and "C."
5312
IMPORTANT: If bell housing shift cable does not line up to properly enter jaws of shift linkage assembly, 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:
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Page 89 / 113
SECTION - 6
a.
Remove the nuts from the trim cylinders.
d e
21521
a - Socket b - Wrench c - Anchor pin b.
d - Ground wires e - Trim cylinders
Position the sterndrive so that the universal joint shaft aligns with the bell housing bore.
c
a - Universal joint b - Bell housing c.
21518
c - Shift linkage d - Shift cable
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.
c
21519
a - Shift cable b - Shift linkage jaws open
c - Shift linkage jaws engage the shift cable
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SECTION - 6
d.
If necessary, rotate the propeller shaft COUNTERCLOCKWISE slightly (using a propeller) to align U-joint shaft splines with splines in engine coupling, then slide sterndrive all the way into bell housing.
b a c
21520
a - Bell housing studs b - Dribble valve
c - Shift cable
16. Secure sterndrive to bell housing with 5 flat washers and 6 locknuts. Start from the center and torque the nuts.
a b
21680
a - Locknut (6) flat washers (5) b - Ground plate (washer not used here)
Description Sterndrive fasteners
c - Torque wrench
Nm 68
lb. in.
lb. ft. 50
TRIM CYLINDER INSTALLATION

1. Install the mounting hardware of the trim cylinder forward as shown 2. Lubricate anchor pin threads to prevent threads from galling.
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Page 91 / 113
SECTION - 6
3. Hand thread locknuts onto the pin. Do not tighten at this time.
d e
14326
Front abcdAnchor pin Retainer clip groove Flat washer (large I.D.) Retainer clip
efgh-
Bushing Flat washer (small I.D.) Locknut Plastic cap

Part No. 92-802859A1
Tube Ref No.

95
Where Used Anchor pin threads
IMPORTANT: On Bravo One, Two, and Three Models the trim-in limit insert must be properly positioned before installing the trim cylinder anchor pin in the following steps. NOTE: Ensure that the trim-in limit insert is reinstalled in the same position as before removal of the sterndrive. If you are not sure of the original position, contact the boat manufacturer for their recommendation. Refer to Special Information at the front of this section before reinstalling the trim-in limit insert.
14571
a - Trim-in limit insert Bravo One and Two (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.
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SECTION - 6
IMPORTANT: The position of the trim-in limit insert on the Bravo Three sterndrive should only be changed after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a particular boat application.
d e
c
a - Aft anchor pin b - Larger flat washers (2) c - Bushings (4)
Tube Ref No.
95
f
9295
d - Small ID flat washers (2) e - Locknuts (2) f - Plastic caps (2)

Where Used Trim cylinder hardware Part No. 92-802859A1
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 b a c
21677
a - Socket and tool b - Wrench tool
c - Plastic cap (4)
Speedometer Connections - Bravo Models

1. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately atop the transom end of the anti-ventilation plate.
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SECTION - 6
2. Insert speedometer tube fitting into opening on topside of anti-ventilation plate, in position shown.
b
5319
a - Tube fitting
b - Opening
3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
5320
a - Fitting installed (handle pointing forward)
Bravo Sterndrive Shift Check (Engine Running)

! WARNING
Contact with moving sterndrive components and the propeller can cause personal injury or death. To avoid possible injury , remove the propeller and ensure that no people or animals are in 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.
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SECTION - 6
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.
a b
4805
Typical single handle remote control shown a - Drive trim switch b - Drive trailer button 3. Connect a garden water hose between flushing attachment and water source.
Dual Water Pick-up Flush Gearcase Seal Kit Flushing Device Flushing Kit 91-881150K 1 91-44357Q 2 91-849996T 1
4. Partially open water source until water continuously leaks out around the flushing device.
! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that 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 using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation. 5. Place remote control handle in NEUTRAL, idle speed position and start engine.
! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range.
! CAUTION
Sterndrive not shifting properly can cause engine and sterndrive damage. Contact your authorized Mercury MerCruiser dealer for proper adjustment. NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of 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 each gear. FORWARD-detent-NEUTRAL-detent-REVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment. 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.
90-864196060 MAY 2006
Page 95 / 113
SECTION - 6
9. 10. 11. 12.
Check that the sterndrive propeller shaft is not turning. Shift the remote control handle to REVERSE, idle speed position. Check that the sterndrive propeller shaft is turning in the REVERSE direction. 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 Problems

NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear. 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 when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, 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 bend 2. 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 on too-short cables result in kinks and too-long cables require unnecessary bends or loops. Both conditions place extra stress on the cables. IMPORTANT: Shift cable/throttle cable lubrication points use 2-4-C with Teflon.
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SECTION - 6
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 - Remote control end b - Engine end
Tube Ref No.
95
7874
c - Adjusting barrel d - Lubricating point

Where Used Shift cable end Part No. 92-802859A1
NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GEN II 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 Description Mounting surface maximum thickness Minimum cable bend radius at any point Specification 25 mm (1 in.) 305 mm (12 in.)
4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 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 is shifted 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 the shift plate. 9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1.5 m (5 ft) of the shift plate. 10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud. NOTE: Lubricate attaching points with engine oil.
Description SAE 30W Engine Oil Where Used Shift cable pivot points Part Number Obtain Locally
11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows:
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SECTION - 6
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 flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power steering valve and loop over to the shift plate 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 and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the pre-delivery inspection 12. 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

! WARNING
When adjusting trim limit switch, use extreme care that the engine is not started and keep clear of the area near the propeller. Use care to prevent placing hands in an area where injury could occur because of drive unit movement.
! CAUTION
Trim limit switch MUST BE adjusted exactly as outlined. If switch is adjusted incorrectly, drive unit could move out beyond the gimbal ring support flanges and cause damage to sterndrive unit. IMPORTANT: All Bravo models must have the trim-in-limit insert positioned properly before performing the trim position sender adjustment.
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90-864196060 MAY 2006
SECTION - 6
1. Ensure that the trim-in-limit insert is positioned as shown for the appropriate Bravo model.
8548
8557
Bravo One and Two (positioned forward) a - Trim-in-limit insert
Bravo Three (positioned aft)
2. Bravo sterndrive, adjust trim limit switch as follows: a. Loosen screws and turn trim limit switch clockwise to end of slots.
16524
Trim limit switch a - Screws b. c. Ensure drive unit is in the full DOWN/IN position. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON.
90-864196060 MAY 2006
Page 99 / 113
SECTION - 6
d.
Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.
21675
Trim limit switch a - Rotate Counterclockwise To Adjust
a
8558
Bravo trim cylinder extended a - Trim Limit Dimension 21-3/4 in. (552 mm) e. Retighten screws when adjustment is correct.
Trim Position Sender Adjustment - Analog Gauges

1. Loosen both trim position sender retaining screws.
21676
a - Retaining screws
b - Trim position sender
! CAUTION
Do not start engine in the following step or damage to sterndrive unit and engine could result from lack of cooling water. 2. Turn ignition key to RUN position. 3. Trim sterndrive unit to the full DOWN/IN position.
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90-864196060 MAY 2006
SECTION - 6
4. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown.
a
7883
a - Trim gauge needle 5. Tighten retaining screws and turn ignition key to the OFF position.
21674
Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method
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.
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Page 101 / 113
SECTION - 6
3. 4. 5. 6.
Turn ignition key switch to the RUN position. Set the scan tool to display TRIM POS counts and note the value displayed. TRIM POS counts must be between 20 and 24 counts. 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
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.
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SECTION - 6
Bravo Sterndrive Propeller Installation

! WARNING
Ensure that remote control is in NEUTRAL position and ignition key is removed from switch prior to installing propeller.
! WARNING
Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when tightening propeller nut.
a b c
4826
a - Wood block b - Propeller
c - Propeller nut under socket
BRAVO ONE MODELS

IMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the direction of rotation of the propeller shaft. 1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.
Tube Ref No.
34 95 94
Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon Anti-Corrosion Grease
Where Used Propeller shaft splines Propeller shaft splines Propeller shaft splines
Part No. 92-802865A1 92-802859A1 92-802867A1
NOTE: Anti-corrosion grease is for salt water applications only. 2. Install the propeller with the attaching hardware as shown.
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Page 103 / 113
SECTION - 6
3. Torque the propeller nut.
d e a b c g
abcd5301
Typical Bravo One models Propeller shaft splines e - Drive sleeve adapter Forward thrust hub f - Tab washer Flo-Torque II drive hub g - Propeller nut Propeller
a b
c
d e f g
19816
abcd-
Bravo One XR models Propeller shaft Propeller hub insert with snubbers Propeller Thick washer
e - Washer f - Washer g - 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 torque values. Refer to the literature supplied with the prop to verify the proper prop nut torque.
Description Bravo One propeller nut Nm 75 lb. in. lb. ft. 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.
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90-864196060 MAY 2006
SECTION - 6
5. Bend the 3 tabs down into the grooves.
c d e
4750
a - Prop b - Tab washer c - Drive sleeve adapter
d - Tab bent down e - Propeller nut
BRAVO TWO MODELS

Tube Ref No.
34 95 94
Part No. 92-802865A1 92-802859A1 92-802867A1
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.
c d f a b e
Bravo Two a - Propeller shaft splines b - Forward thrust hub c - Propeller
8566
d - Spline washer e - Tab washer f - Propeller nut
NOTE: The propeller torque stated is a minimum torque value.
90-864196060 MAY 2006
Page 105 / 113
DRIVE SYSTEM AND ENGINE INSTALLATION Description Bravo Two propeller nut Nm 81 lb. in.
SECTION - 6 lb. ft. 60
Then align tabs with groves
4. 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.
c d e
4750
BRAVO THREE
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.
Tube Ref No.
34 95 95
Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon 2-4-C Marine Lubricant with Teflon
Part No. 92-802865A1 92-802859A1 92-802859A1
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.
Propeller Nut Tool Description Bravo Three front propeller nut 91-805457T 1 Nm 136 lb. in. lb. ft. 100
5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 6. Align splines and install aft propeller. 7. Install propeller nut and torque. NOTE: The propeller torque stated is a minimum torque value.
Description Bravo Three rear propeller nut Nm 81 lb. in. lb. ft. 60
Page 106 / 113
90-864196060 MAY 2006
SECTION - 6
8. Install propeller shaft anode and screw and torque.
e f b a j
5304
i g h
Bravo Three abcdeDescription Propeller shaft anode screw
Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller
fghij-
Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode

! WARNING
! WARNING
a b c
4826
a - Wood block b - Propeller
c - Propeller nut under socket
BRAVO ONE MODELS

IMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the direction of rotation of the propeller shaft.
90-864196060 MAY 2006
Page 107 / 113
SECTION - 6
Tube Ref No.
34 95 94
Part No. 92-802865A1 92-802859A1 92-802867A1
d e a b c g
abcd5301
Typical Bravo One models Propeller shaft splines e - Drive sleeve adapter Forward thrust hub f - Tab washer Flo-Torque II drive hub g - Propeller nut Propeller
a b
c
d e f g
19816
abcd-
Bravo One XR models Propeller shaft Propeller hub insert with snubbers Propeller Thick washer
e - Washer f - Washer g - Propeller nut

Description Bravo One propeller nut Nm 75 lb. in. lb. ft. 55
Page 108 / 113
90-864196060 MAY 2006
SECTION - 6
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.
c d e
4750
BRAVO TWO MODELS

Tube Ref No.
34 95 94
Part No. 92-802865A1 92-802859A1 92-802867A1
c d f a b e
8566
90-864196060 MAY 2006
Page 109 / 113
DRIVE SYSTEM AND ENGINE INSTALLATION Description Bravo Two propeller nut Nm 81 lb. in.
SECTION - 6 lb. ft. 60
Then align tabs with groves
4. 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.
c d e
4750
BRAVO THREE
Tube Ref No.
34 95 95
Description Special Lubricant 101 2-4-C Marine Lubricant with Teflon 2-4-C Marine Lubricant with Teflon
Part No. 92-802865A1 92-802859A1 92-802859A1
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.
Propeller Nut Tool Description Bravo Three front propeller nut 91-805457T 1 Nm 136 lb. in. lb. ft. 100
5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 6. Align splines and install aft propeller. 7. Install propeller nut and torque. NOTE: The propeller torque stated is a minimum torque value.
Description Bravo Three rear propeller nut Nm 81 lb. in. lb. ft. 60
Page 110 / 113
90-864196060 MAY 2006
SECTION - 6
8. Install propeller shaft anode and screw and torque.
e f b a j
5304
i g h
Bravo Three abcdeDescription Propeller shaft anode screw
Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller
fghij-
DTS System Installation

Refer to DTS System Installation section 7 - Electrical System
Shift Cable Installation For DTS System

IMPORTANT: 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: 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 flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power steering valve and loop over to the shift actuator on the engine.
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SECTION - 6
NOTE: Following this routing will prevent the engine coupler from damaging the cable.
8995
NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be 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.
b e a f d c
8996
a - Shift actuator b - Shift cable c - Locknut
d - Shift cable stud e - Shift cable barrel f - Washers
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SECTION - 6
4. Insert cotter pin from top and spread ends.
8997
a - Cotter pin
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SECTION - 6
NOTES:
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SECTION - 7
STARTING AND ELECTRICAL
SECTION 7 - STARTING AND ELECTRICAL

Table of Contents
General Information................................................................................................................................................. 3 Information and ChecklistInstallation Using 14-Pin Connection....................................................................3 Power Trim Electrical Connection.....................................................................................................................3 Batteries.................................................................................................................................................................. 4 Battery Specifications........................................................................................................................................4 Battery Cables...................................................................................................................................................4 Multiple MPI Engine Battery Information...........................................................................................................5 Electrical System Precautions...........................................................................................................................5 DTS System Installation.......................................................................................................................................... 6 SC5000 Data Cable ......................................................................................................................................... 6 Data Cable Routing - New Installations ........................................................................................................... 6 Wiring Diagrams...................................................................................................................................................... 7 Wire Color Code Abbreviations.........................................................................................................................7 14 Pin Engine Harness - Boat Harness - Single Engine - Single Station..........................................................7 14 Pin Engine - Analog Gauge Harness...........................................................................................................9 Non-DTS Single Station Instrumentation Installation - Typical........................................................................ 10 Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly).................11 Power Trim System.........................................................................................................................................13 MerCathode System ....................................................................................................................................... 14 ECM 555 MPI System Engine Wiring Diagrams.............................................................................................15 CAN, Fuel Level, Paddle Wheel and Temperature Circuit ...................................................................... 15 Typical DTS Control System...........................................................................................................................16 Panel mount ERC and Smartcraft instrumentation .................................................................................. 16 14 Pin Engine Harness Connector..................................................................................................................16 4.3L MPI Engine Wiring Diagram with 14 Pin.................................................................................................18 5.0L and 5.7L MCM Alpha Engine Wiring Diagrams with 14 Pin....................................................................20 5.0L and 5.7L MCM Bravo Engine Wiring Diagrams with 14 Pin....................................................................22 DTS Installation..................................................................................................................................................... 23 Special Tools - DTS Installation......................................................................................................................23 Installation Guidelines for DTS System Components.....................................................................................23 Data Harness ........................................................................................................................................... 23 Connectors .............................................................................................................................................. 24 Weather Caps.................................................................................................................................................24 Battery Harness Information and Installation........................................................................................................ 24 DTS Battery Specifications.............................................................................................................................. 24 Data Harness Pulling Procedure........................................................................................................................... 25 Connecting 14 Pin Data Harness - Single Engine................................................................................................. 26 Single Helm .................................................................................................................................................... 26 Dual Helm ....................................................................................................................................................... 26 Connecting 14 Pin Data Harness - Dual Engine................................................................................................... 27 Single Helm .................................................................................................................................................... 27 Dual Helm ....................................................................................................................................................... 27 Installing DTS Command Module and Harness - Single Engine........................................................................... 28 Harness Installation ........................................................................................................................................ 28 Module Installation ......................................................................................................................................... 29 Installing DTS Command Module and Harness - Dual Engine............................................................................. 30 Harness Installation ........................................................................................................................................ 30 Module Installation ......................................................................................................................................... 32 Junction Box (If Equipped).................................................................................................................................... 33 Analog Gauge Interface (AGI)............................................................................................................................... 34 Analog Gauge Interface (AGI) Installation....................................................................................................... 34 Typical AGI Application with System View .............................................................................................. 35
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SECTION - 7
Configuring Analog/Digital Tachometer Signal through PCM.........................................................................35 PCM Configuration with DDT ................................................................................................................... 36 PCM Configuration with CDS .................................................................................................................. 36 Typical 14 Pin DTS Wiring Diagrams.................................................................................................................... 37 DTS Panel Control Wiring...............................................................................................................................37 DTS Single Console Control Wiring................................................................................................................38 DTS Single Console Control Wiring with Dual Helm.......................................................................................39 DTS Dual Console Control Wiring...................................................................................................................40 DTS Dual Console Control Wiring with Dual Helm.......................................................................................... 41 DTS Zero Effort Control Wiring - Single Engine..............................................................................................42 DTS Zero Effort Control Wiring - Dual Engine ................................................................................................ 43
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SECTION - 7
Special Tools
Data Cable Puller 91-888462A1 Attaches to end of DTS data harness to aid in pulling harness through boat. Prevents damage to DTS data harness.
4618
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 larger accessory loads. SmartCraft data is not supported across the adapters so a separate CAN line will be needed on a boat using SmartCraft instrumentation and an adapter harness.
Information and ChecklistInstallation Using 14-Pin Connection

Refer to Mercury Precision Parts and Accessories Guide or OEM Rigging and Accessories Guide for part number information 1. 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 harness 3. 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 applications b. A remote control can have a lanyard stop switch and will connect directly to the boat harness or a separate stop switch can be installed and connected to the boat harness c. 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. An accessory kit is available to provide accessory power up to 40 amps.

NOTE: ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information) ABYC further recommends: if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also 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.
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SECTION - 7
1. Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps (CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power trim pump and should be connected directly to the battery. 2. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any boat with a battery switch: The red current conductor (for the trim pump) must be: a. Connected to the switched side of the battery switch and either: i. provided with circuit protection within 7 inches of the power source or ii. 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 the source and the circuit protection device. This will require the use of an accessory kit.
Batteries
Battery Specifications
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: It is recommended (required in some states) that the battery be installed in an enclosed 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 V6 and V8 MPI models V8 DTS models Minimum required cranking battery size 750 cca, 950 mca, 180 Ah 800 cca, 1000 mca, 180 Ah
Battery Cables
Select proper size positive (+) and negative (-) battery cables. Using the following chart, battery should 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. Use electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and a subsequent failure.
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SECTION - 7 Cable Length Less than or equal to 1.1m (3.5 ft.) 1.1 - 1.8m (3.5 - 6 ft.) 1.8 - 2.3m (6 - 7.5 ft.) 2.3 - 2.9m (7.5 - 9.5 ft.) 2.9 - 3.7m (9.5 - 12 ft.) 3.7 - 4.6m (12 - 15 ft.) 4.6 - 5.8m (15 - 19 ft.)
STARTING AND ELECTRICAL Cable Gauge 25 mm2 (4) 35 mm2 (2) 50mm2 (1) 50mm2 (0) 70mm2 (00) 95mm2 (000) 120mm2 (0000)
Both positive (+) and negative (-) cables
Multiple MPI Engine Battery Information

Batteries: Boats with multi-engine MPI power packages require each engine be connected to its own battery. This ensures that the engine's Electronic Control Module (ECM) has a stable voltage source. Battery switches: Battery switches should always be positioned so each engine is operating off its own battery. Do not operate engines with switches in BOTH or ALL position. In an emergency, another engine's battery can be used to start an engine with a dead battery. Battery isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose. 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., Model 32023A could also be used. Generators: The generator's battery should be considered another engine's battery.
Electrical System Precautions

The following precautions apply to all engines:
! CAUTION
Avoid damage to the electrical system, and components. Refer to the following precautions when working 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 powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose. NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.
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SECTION - 7
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 engines alternator could be charging either bank of batteries through the Model 32023A battery isolator. Any other manufacturers battery isolator that is the same type as the Sure Power Inc., Model 32023A could also be used. Generators: The generators battery should be considered another engines battery.
DTS System Installation

! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control.
SC5000 Data Cable

! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not pull on cable connectors when pulling cable into boat. Observe correct pulling procedure. Pulling on connectors can loosen terminals resulting in open or poor electrical connections. Open or poor electrical connections may result in loss of throttle and shift control. IMPORTANT: Do not route cable near engine ignition components (coils, spark plug leads, and spark plugs). An electrical field generated from these components could cause a problem with data transmission. IMPORTANT: Do not route cables near sharp edges, hot surfaces or moving parts. Fasten cables away 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 Installations

1. 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.
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SECTION - 7
Wiring Diagrams
Wire Color Code Abbreviations
Wire Color Abbreviations BLK BRN GRN PNK RED WHT LT or LIT Black Brown Green Pink Red White Light BLU GRY ORN or ORG PPL or PUR TAN YEL DK or DRK Blue Gray Orange Purple Tan Yellow Dark
14 Pin Engine Harness - Boat Harness - Single Engine - Single Station

NOTE: Dual engines are treated as 2 singles in the same boat and are not connected together.
2 7 1 11 10 4 3 8 5 9
1234514 pin Duetsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 - Lanyard (outboard) or E Stop connection
12340
7 - Warning horn 8 - Accessory load (10 AMP) 9 - Gauge connector/can connector for SmartCraft 10 - Can 1 with resistor cap 11 - Can 3 with weather cap
NOTE: The lanyard stop switch (PPL and PPL/WHT wires) breaks power to the ECM to stop engine. The switch is normally closed until activated. Therefore the PPL and PPL/WHT wires must be connected together if Lanyard Stop Switch is not used, or if the E Stop Switch is used.
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SECTION - 7
NOTE: E Stop Switch (BLK and BLK/YEL wires) connects ground to ECM to stop engine. The switch is normally open, the circuit closes when switch is activated. Wires must be separate unless connected through E Stop Switch.
A B A B
WHT DKBLU
ORG GRN
11
A B
A B
10
RED BLK ORG GRN PPL GRY YEL DKBLU WHT PPL_WHT BLK RED
A B C D E F G H J K A B C
8 7 5 6
BLK
PPL
1
BRN
1 1
PPL_WHT
A B C D E F G H J K L M N P
GRN YEL_RED GRY BRN YEL GRN_WHT BLU_WHT DKBLU WHT ORG BLK_YEL PPL BLK RED
BLK
PPL
BLK_YEL
BLK
PPL
5
1
1
YEL_RED
YEL_RED
4
1
RED
RED BLU_WHT GRN_WHT RED BLK PPL_WHT PPL BLK_YEL YEL_RED
3 2
12339
A B C A B C D E F
12345-
14 pin Duetsch connector Key switch connector Trim switch (outboard only) Neutral switch Lanyard switch (sterndrive) or key switch + connection 6 - lanyard (outboard) or E Stop connection
78910 11 -
Warning horn Accessory load (10 AMP) Gauge connector Can 1 with resistor cap Can 3 with weather cap
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SECTION - 7
14 Pin Engine - Analog Gauge Harness

8 9 10 2 3 4 5 1 7
12312
12345-
Connector to boat harness Trim Tach Key on (+) Temp
678910 -
Oil Ground (-) Can (+) or spare Can (-) or spare 12V (+)
BRN_WHT
2 3 4 5 6 7
GRY
PPL
A B C D E F G H J K
DK_BLU WHT BRN_WHT GRY PPL TAN LTBLU BLK RED
TAN
LTBLU
BLK
WHT
8 9 10
12318
DK_BLU
RED
12345-
Connector to boat harness Trim Tach Key on (+) Temp
678910 -
Oil Ground (-) Can (+) or spare Can (-) or spare 12V (+)
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 and Accessory Guide or MerCruiser Rigging Guide
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SECTION - 7
Non-DTS Single Station Instrumentation Installation - Typical

12345678910 11 12 13 14 15 16 17 18 Ignition (key) switch Not used on MerCruiser products Neutral start switch Lanyard stop Audio warning alarm 10 pin 150 GT Female Can 3 line (not used) 120 ohm resister Oil pressure (Can 3+) Water temperature(Can 3-) Trim position Horn Can 1+ Can 1Spare Spare Tachometer/Link Crank 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 E-stop Wake Ground 12 volts 3-pin metri pack (Female) 3-pin metri pack (Male) Ground 12 volt continuous 12 volt switched 6 pin connector (Male) Relay 6 pin connector (Female) Accessory +12 volts Ground Run E-Stop Crank
NOTE: Refer to gauge manufacturer's instructions for specific connections.
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SECTION - 7
Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly)
a b
c
a - Connection to control box b - Connection to trim pump
12323
c - Connections to trim limit switch
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SECTION - 7
b
A
C1
B
DK BLU-WHT
RED
GRN-WHT RED
3 1
C2
4 2
PPL-WHT DK BLU-WHT
a
1
T2 T1
c
a - Connection to control box b - Connection to trim pump
1
12322
c - Connections to trim limit switch
Page 12 / 43
GRN-WHT
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SECTION - 7
Power Trim System
BLU/WHT
BLK GRN/WHT
RED
BLK
a
RED/PPL
c
BLU/WHT
BLK
RED
e
YEL/RED YEL/RED RED/PPL GRN/WHT PPL/WHT GRN/WHT
BLU/WHT
d g f
BLU/WHT
BLK
BLK
7866
abcd-
20 amp fuse Ground bolt (floor mount) UP solenoid 110 amp fuse
e - DOWN solenoid f - Y-harness (optional) g - Neutral switch to instrument wiring harness h - Trim limit switch
ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for additional information)
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BLK
SECTION - 7
ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump may not be connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery switch. Wire length requirements and location of circuit protection are also specified.
MerCathode System
a b
c
8526
a - Controller b - 20 amp fuse
c - Electrode d - BLACK wire - with engine harness
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SECTION - 7
ECM 555 MPI System Engine Wiring Diagrams

CAN, FUEL LEVEL, PADDLE WHEEL AND TEMPERATURE CIRCUIT
b
SPLICE 100
BLK/PNK
BLK/PNK
LT BLU/BLK B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
GRY
DK GRN/YEL
LT BLU
BLK/PNK
A K
B J
C H
D G
E F
GRY/BLK
SPLICE 104 WHT

BLK
LT BLU/ORN D
GRY
PPL
SPLICE 102
PPL
7993
a - ECM 555 b - Fuel level connector c - ECM 555
d - Paddle wheel/seawater temp connector e - To 10-pin connector key switch f - CAN connector
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SECTION - 7
Typical DTS Control System

PANEL MOUNT ERC AND SMARTCRAFT INSTRUMENTATION
NOTE: Refer to the Command Module Installation Kit.
BLK-YEL
BLK-YEL BLK
BLK
WHITE BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED
8010
Shown with panel mount ERC, Smartcraft instrumentation, foot throttle, accessory relay, and start/stop button.
14 Pin Engine Harness Connector

Mechanical 14-Pin Connector Pin-Out Pin A B C D E F G H J K L M N P PINK BLACK PURPLE DK GREEN/YELLOW DK BLUE WHITE LT BLUE Open Open ORANGE/WHITE BROWN/DK BLUE GRAY/WHITE YELLOW/BLACK TAN Wire Color + 12 Volt Ground (-) Wake E-Stop Analog oil pressure CAN 1+ CAN 1Spare Spare Analog trim position Audio warning horn Tachometer/Link gauge Crank Analog coolant temperature Function
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BLUE
SECTION - 7
NOTES:
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SECTION - 7
4.3L MPI Engine Wiring Diagram with 14 Pin
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12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 -
Idle Air Control Valve Digital Coolant Injector 5 Injector 3 Injector 1 Lube Connector A Connector B Main power relay Fuel pump relay Fuses Resistor Fuel pump 50A circuit breaker Analog coolant 14 pin Analog oil pressure Starter relay Slave output Chassis ground Alternator ground Alternator excitation TMAP
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 -
Throttle positioning sensor Neutral safety Crank POS sensor Shift switch Alternator output Starter fuse 50A circuit breaker ('90A') Mercathode anode Mercathode electrode Transom harness Digital oil pressure Paddle / fuel level Sea pump Ignition coil Coil driver Injector 6 Injector 4 Injector 2 Tachometer lead Mercathode ground Lube ground Knock even sensor Diagnostic
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SECTION - 7
5.0L and 5.7L MCM Alpha Engine Wiring Diagrams with 14 Pin
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12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 -
Idle Air Control Valve Digital Coolant Injector 1 Injector 8 Knock sensor odd Connector A Connector B Lube Main power relay Injector 4 Injector 7 Fuel pump relay Fuses Resistor Fuel pump 50A circuit breaker Analog coolant 14 pin Analog oil pressure Slave output Starter relay Cam sensor TMAP Alternator excitation Throttle positioning sensor
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 -
Neutral safety Crank POS sensor Chassis ground Alternator ground Shift switch Alternator output Starter fuse 50A circuit breaker ('90A') Mercathode anode Mercathode electrode Transom harness Digital oil pressure Paddle / fuel level Sea pump Ignition coil Coil driver Injector 2 Injector 5 Injector 3 Injector 6 Tachometer lead Mercathode ground Lube ground Knock even sensor Diagnostic
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SECTION - 7
5.0L and 5.7L MCM Bravo Engine Wiring Diagrams with 14 Pin
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SECTION - 7
12345678910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 -
Idle Air Control Valve Digital Coolant Injector 1 Injector 8 Knock sensor odd Connector A Connector B Lube Main power relay Injector 4 Injector 7 Fuel pump relay Fuses Resistor Fuel pump 50A circuit breaker Analog coolant 14 pin Analog oil pressure Starter relay Slave output Chassis ground Alternator ground Alternator excitation TMAP
26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 -
Cam sensor Throttle positioning sensor Neutral safety Crank POS sensor Shift switch Alternator output 50A circuit breaker ('90A') Starter fuse Mercathode anode Mercathode electrode Transom harness Digital oil pressure Paddle / fuel level Sea pump Ignition coil Coil driver Injector 2 Injector 5 Injector 3 Injector 6 Tachometer lead Mercathode ground Lube ground Knock even sensor Diagnostic
DTS Installation
Special Tools - DTS Installation
Data Cable Puller 91-888462A1
Installation Guidelines for DTS System Components

! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe into any wire insulation of the DTS system. Splicing or probing will damage the wire insulation allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle and shift control.
DATA HARNESS
! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not pull on cable connectors when pulling cable into boat. Observe correct pulling procedure. Pulling on connectors can loosen terminals resulting in open or poor electrical connections. Open or poor electrical connections may result in loss of throttle and shift control.
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SECTION - 7
CONNECTORS
IMPORTANT: Connectors should never have to be forced into the receptacle. Ensure that connectors are free of any lubricant or dielectric grease before installation. When the connector is properly aligned, it will only take a small amount of pressure to insert it into the receptacle. Rotate the locking collar to secure the electrical connection. NOTE: Connect only one data harness of the required length between the engine and helm. If a data harness is too short, do not connect multiple harnesses together to make up the required length. For installations requiring a data harness length longer than 12.2 m (40 ft.), contact Mercury Marine for more information.
Weather Caps
Weather caps are to be used whenever there are any unused connectors on a harness. Verify all connections are tight to prevent moisture or corrosion occurring inside the connections. Typical weather caps are as follows:
4958
a
a - 10 pin cap b - 5 pin cap
d
c - 3 pin cap d - 2 pin cap
NOTE: A complete listing of weather caps with part numbers is not available at the time of the publication.
Battery Harness Information and Installation

DTS 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 Guard regulations must be adhered to when installing the battery. Ensure that battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations. IMPORTANT: It is recommended (required in some states) that the battery be installed in an enclosed case. Refer to regulations for your area.
Minimum SAE Starting Battery Requirements - BCI GRP 24 MCA CCA Ah 1000 800 180 (International Rating)
NOTE: Due to the wide variety of battery manufacturers throughout the world, ratings and physical battery sizes will vary. Check with the manufacturer for a starting battery with a MCA, CCA, or Ah specification 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. If your boat application requires additional battery loads for boat accessories or marine electronics, it is recommended that an auxiliary battery or batteries be installed.
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SECTION - 7
! CAUTION
Hex 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.
Description Hex nuts Nm 13.5 lb. in. 120 lb. ft.
IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine installation manual for size requirements. Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not supplied.
NOTICE - DTS & Optimax Engines
DO NOT USE DEEP CYCLE BATTERIES!
DTS (Digital Throttle and Shift) applications and Optimax engines must use a marine starting battery with 1000 MCA, 800 CCA, or 180 Ah. rating. 13.5Nm (120 lbs. in.)
IMPORTANT: Battery cable size and length is critical. Refer to engine installation manual for size requirements.
37-895387 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.
DO NOT USE WING NUTS.
3486
Data Harness Pulling Procedure

IMPORTANT: 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 these components could cause interference with data transmission. IMPORTANT: Do not route data harness near sharp edges, hot surfaces or moving parts. Fasten cables 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 be 7.6 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 data harness connector end following installation.
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SECTION - 7
NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.
Connecting 14 Pin Data Harness - Single Engine

Single Helm
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).
b a
3619
a - 14 pin data harness
b - Clamp or cable tie
Dual Helm
b
c d
e
a - 14 pin data harness b - Helm 2 (upper helm) - auxilary c - Helm 1 (lower helm) - primary
3682
d - Dual helm adapter (Y harness) e - Clamp or cable tie
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SECTION - 7
Connecting 14 Pin Data Harness - Dual Engine

Single Helm
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).
b
a - 14 pin data harness
3977
Dual Helm
a
c b c
e
a - Helm 2 (upper helm) b - Helm 1 (lower helm) c - 14 pin data harness
3978
d - Dual helm adapter (Y harness) e - Clamp or cable tie
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SECTION - 7
Installing DTS Command Module and Harness - Single Engine

Harness Installation
Locate a routing path for the harness connections so they reach their installation points. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could cut the harness. 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.
b
3622
Single Helm Application a - DTS command module harness
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SECTION - 7
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.
Terminator CAN 1
Terminator CAN 2
f d h g b c
d
3677
abcd-
Dual Helm Application Helm 2 (upper helm) Helm 1 (lower helm) DTS command module harness Clamp or cable tie
efgh-
CAN 1 connector CAN 2 connector Weather caps 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.
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SECTION - 7
Mounting the Command Module with the supplied rubber grommets/bushings to minimize vibration.
3939
a - DTS Command Module
Installing DTS Command Module and Harness - Dual Engine

Harness Installation
Locate a routing path for the harness connections so they reach their installation points. 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.
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SECTION - 7
Make sure all connections are tight and seal all unused connectors with weather caps.
c a
Terminator CAN 2
Terminator CAN 1
b
Terminator CAN 2
Terminator CAN 1
d
Single Helm Application a - CAN link harness b - CAN 2 Terminator resistors - do not remove c - CAN 1 connectors
e
3689
d - Clamp or cable tie e - DTS command module harness
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SECTION - 7
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.
b c
e a d
1
4079
Dual helm application a - Weather caps b - CAN link harness c - Helm 2
d - DTS Command Module harness e - Termination resistors - do not remove from helm 2 f - 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.
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SECTION - 7
Ensure the wiring harness connected to the command module will reach all the connection points.
4080
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
e
ob01481
a - Clamp b - Weather cap (859318T 2) c - Junction box
d - 25.4 cm (10 in.) e - DTS command module harness
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SECTION - 7
Analog Gauge Interface (AGI)

Analog Gauge Interface (AGI) Installation
NOTE: This Analog Gauge Interface (AGI) can only be used with the 14 pin Digital Throttle and Shift (DTS) system to drive analog and/or SmartCraft System Link gauges. For analog gauges, use ring terminals on AGI harness to connect to analog sender inputs on gauge backs, and tape back any unused terminals. For SmartCraft System Link gauges, use 3 pin System Link connection on 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 prevent moisture from collecting at base of wires and wicking into module. Route and secure all wires and harnesses 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 manufacturers specifications.
Analog Gauge Type Tachometer Oil Pressure/Oil Level Water Temperature Trim Positions Fuel Level AGI Harness Wire Color Gray Blue Tan Brown/White Pink/Black
GRY PNK/BLK BRN/WHT TAN BLU
f
a - AGI module b - 14 pin connection c - AGI harness
3688
d - Analog gauge terminal connections e - System Link 3 pin connection f - 10 pin CAN data connection
3. Route and connect wire from key switched 12 volt positive power source to analog gauges. Secure connections per gauge manufacturers specifications. 4. Route and connect ground wire from analog gauges to a common ground. Secure connections per gauge manufacturers specifications. 5. Connect any SmartCraft System Link gauges to 3 pin System Link connection. The AGI system can support 10 System Link gauges per helm, 2 helms maximum. 6. Plug 14 pin AGI harness connection into AGI module. 7. Connect 10 pin CAN data harness connection on command module harness to AGI harness. a. If SmartCraft System View is not being used, plug 10 pin CAN data connection on AGI harness directly into 10 pin CAN data connection on command module harness. b. If SmartCraft System View is being used, a junction box and harness adaptor will be required. Plug 10 pin CAN data connection on command module harness, 10 pin CAN data connection on System View harness, and one end of harness adaptor into junction box. Plug 10 pin CAN data connection on AGI harness into other end of harness adaptor. Insulate any unused connection ports on junction box with weather caps.
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SECTION - 7
TYPICAL AGI APPLICATION WITH SYSTEM VIEW

OFF O
a
N
d e
b f h
GRY PNK/BLK BRN/WHT TAN BLU
g
a - System View display b - 10 pin CAN data connection on System View harness c - SmartCraft Junction Box d - Weather Cap
3957
e - Harness Adaptor f - 10 pin CAN data connection on AGI harness g - AGI module h - 10 pin CAN data connection on Command Module harness
Configuring Analog/Digital Tachometer Signal through PCM

IMPORTANT: The engine Propulsion Control Module (PCM) tachometer configuration factory default has been set to an analog. This will allow the operation of one analog tachometer. Depending on the desired use of analog/digital gauges, the PCM set-up may have to be configured from analog to a digital. Following are optional uses of analog and digital gauges and the setting for the tachometer configuration in the PCM necessary to run them.
Gauge Configuration Analog Tachometer Only System Link Gauges used with System View, System Monitor, or System Tach System Link Gauges used in conjunction with System Link Adaptor Harness and Command Module Harness without the use of System View, System Monitor or System Tach Analog Digital X X
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STARTING AND ELECTRICAL Gauge Configuration AGI used with or without System View, System Monitor or System Tachometer, to run analog and System Link Gauges
SECTION - 7 Analog Digital X
The Digital Diagnostic Tool (DDT) or Computer Diagnostic System (CDS) can be used to select analog or digital PCM tachometer configuration.
PCM CONFIGURATION WITH DDT

IMPORTANT: 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 CDS

1. 2. 3. 4. 5. 6. Attach CDS to engine. Refer to on-line help if needed. From Logon screen, navigate to Engine Select screen. From Engine Select screen fill in engine type information and select Tool Box. From Tool Box screen, select Active Diagnostics. From Active Diagnostics screen, scroll down and select Tach Link Config. To change PCM configuration from default of analog to digital, select Enable and then select Run. 7. To change PCM configuration from digital to analog, select Disable and then select Run.
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SECTION - 7
Typical 14 Pin DTS Wiring Diagrams

DTS Panel Control Wiring
c a f
BLK/YEL
OFF O
d
N
BLK/YEL BLK
BLK
i
BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED
WHITE BLUE
l r q o m p n
5104
abcdefghi-
Remote control Remote control connections Key switch Start/stop switch (optional) SmartCraft System View (optional) SmartCraft Link Gauge (optional) Display harness Horn Horn
j - GPS connection k - Cable adaptor (male to female) l - Weather caps m - Junction box (optional) n - DTS Command Module harness o - Terminator resistors p - DTS Command Module q - Accessory power relay (optional) r - Foot throttle (optional)
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SECTION - 7
DTS Single Console Control Wiring

d c
BLK/YEL
OFF O
N
f g
b
BLK/YEL BLK
BLK
h i
j
BLK/ORG PUR/YEL GRN/YEL GRN/ORG GRN/RED
WHITE BLUE
m s r o p
5103
abcdefghij-
Remote control Remote control connections Lanyard stop switch Key switch Start/stop switch (optional) SmartCraft System View (optional) SmartCraft Link Gauge (optional) Display harness Horn Horn
k - GPS connection l - Cable adaptor m - Weather caps n - Junction box (optional) o - Terminator resistor p - DTS Command Module harness q - DTS Command Module r - Accessory power relay (optional) s - Foot throttle (optional)
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SECTION - 7
DTS Single Console Control Wiring with Dual Helm

d f g h b e c
n m o d p q a t l k j
g h
n m s u r
3588
abcdefghijk-
Helm 1 Helm 2 Clamps (use as required) Remote control Key switch connector not used seal with weather cap Start/stop switch (2 required at helm ) Lanyard stop switch System View (optional) Horn Foot throttle connector Accessory power relay connector (optional, not used at second helm)
l - Terminator resistors (helm 2 only) m - DTS Command Module n - DTS Command Module harness o - Data harness p - Start/stop switch (optional at helm 1) q - Key switch r - Accessory power relay s - Terminator resistors not used seal connectors with weather caps t - Dual helm adaptor harness u - Data harness to engine
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SECTION - 7
DTS Dual Console Control Wiring

NOTE: Optional foot throttle is not compatible in multiple engine applications.
b a c
h h g
+
l f g g f
h h j n
abcdefDTS Control Key Switch Lanyard Stop Switch System View (optional) Air Temp Sensor Command module ghijkn
12112
Horn Clamp To starboard engine To port engine Connector, Start/Stop Switch (optional) l - Accessory Power Relay (optional)
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SECTION - 7
DTS Dual Console Control Wiring with Dual Helm

NOTE: Optional foot throttle is not compatible in multiple engine applications.
c d f
e d
n h d i o p c f j k d l q m d k j p g i o d
a n
r o
t m i v
abcdefghijkHelm 1 (primary) Helm 2 (auxiliary) Remote control Connector not used seal with weather cap Start/stop switch (required at helm #2) Lanyard stop switch System View (optional) Clamps (use as required) DTS Command Module Junction box connection (optional) Terminator resistor (required at helm #2)
r t d u j i s
l - CAN link harness m - Horn n - DTS Command Module harness o - Data harness p - Key switch q - Start/stop switch (optional at helm 1) r - Dual helm adaptor harness s - Data harness to starboard engine t - Accessory power relay u - Remove terminator resistor and seal with weather cap v - Data harness to port engine
3310
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SECTION - 7
DTS Zero Effort Control Wiring - Single Engine

a
GRN/WHT BLU/WHT RED
OFF O
N
b c
BLK/YEL
GRN/WHT
BLU/WHT
BLK/YEL BLK
RED
BLK
e k
WHITE BLUE
f l
h j
i
7731
abcdef-
Start/stop switch (optional) System View (optional) SmartCraft Link gauge GPS Connection Display harness Cable adaptor
ghijkl-
Weather caps Junction box DTS Command Module Accessory power relay (optional) DTS Command Module harness Adaptor
Page 42 / 43
90-864196060 MAY 2006
SECTION - 7
DTS Zero Effort Control Wiring - Dual Engine

i
GRN/WHT BLU/WHT RED
f a
GRN/WHT
BLU/WHT
RED
j
+
b d c e
b c
h g
abcdefSystem View (optional) Horn Junction box connection (optional) Accessory power relay (optional) DTS Command Module To starboard engine ghijk-
g
7725
Terminator resistor CAN link harness To port engine DTS Command Module harness Connector - Start/stop switch (optional)
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WHT BLU
SECTION - 7
NOTES:
Page 44 / 43
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SECTION - 8
REMOTE CONTROLS
SECTION 8 - REMOTE CONTROLS

Table of Contents
Remote Control Installation..................................................................................................................................... 4 Locating and Drilling Mounting Area.................................................................................................................4 Installing DTS Panel Mount Control..................................................................................................................4 Installing DTS Single Handle Console Control..................................................................................................6 Installing DTS Dual Handle Console Control....................................................................................................9 Installing DTS Zero Effort Control...................................................................................................................12 Steering System Information................................................................................................................................. 14 High Speed Or Twin Engine Applications Steering Recommendation ...........................................................14 Steering Helm and Cable................................................................................................................................15 Steering Cable Specifications.........................................................................................................................16 Hydraulic (Helm) Steering...............................................................................................................................16 Sterndrive Shift Cable Information........................................................................................................................ 17 Propeller Rotation............................................................................................................................................17 Checking Alpha Shift Cable Installation and Adjustment................................................................................17 Bravo Sterndrive Shift Check (Engine Running).............................................................................................21 Troubleshooting Shift Problems......................................................................................................................22 DTS Remote Control - Sterndrive...................................................................................................................25 DTS Calibration..................................................................................................................................................... 25 Special Tools - DTS Calibration......................................................................................................................25 Methods of Calibration....................................................................................................................................26 System View Display Connection.................................................................................................................... 26 DTS System Reset..........................................................................................................................................26 Calibration Setup.............................................................................................................................................27 Special Instructions for Dual Helm Vessels ............................................................................................. 27 Calibration ................................................................................................................................................ 27 Console Mount and Panel Mount Controls .............................................................................................. 29 Console Mount and Panel Mount Controls with Foot Throttle ................................................................. 29 Zero Effort Controls ................................................................................................................................. 29 Zero Effort Controls with Foot Throttle ..................................................................................................... 30 Setting Trailer and Trim Limit................................................................................................................................ 30 Setting Trailer Limit with DDT.......................................................................................................................... 30 Setting Trailer Limit with CDS.........................................................................................................................31 Setting Trim Limit with DDT............................................................................................................................. 31 Setting Trim Limit with CDS............................................................................................................................32 Troubleshooting Procedure................................................................................................................................... 32 Troubleshooting Information............................................................................................................................32 Default Sensor Values ............................................................................................................................. 32 Fault Conditions ....................................................................................................................................... 32 Sticky/Non-Sticky Faults .......................................................................................................................... 33 Engine Guardian ...................................................................................................................................... 33 Warning Horn Signals .............................................................................................................................. 33 Special Tools - DTS Troubleshooting.............................................................................................................. 33
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Page 1 / 34
REMOTE CONTROLS
SECTION - 8

Tube Ref No.
95
Where Used Shift cable end
Part No. 92-802859A1
Special Tools
Dual Water Pick-up Flush Gearcase Seal Kit 91-881150K 1
Blocks off the front water inlet holes on the dual water inlet gearcases.
9194
Flushing Device
91-44357Q 2
9192
Flushing Kit
91-849996T 1

9195
Male to Male 10 Pin Adapter
84-892452A01 Allows connection between CAN 1 communications cable and Computer Diagnostic System in applications where a junction box is not used. 84-892663
4621
Can 1 Diagnostic Cable
Connects into a junction box or male to male adapter cable for Command Module configuration. Not for use with DDT.
4680
Adapter Harness
84-822560A13 Data link harness between engine and Computer Diagnostic System (CDS) or Digital Diagnostic Terminal (DDT).
5826
Page 2 / 34
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SECTION - 8 Computer Diagnostic System (CDS)
REMOTE CONTROLS Order through SPX Monitors all electrical systems for proper function, diagnostics. and calibration purposes. For additional information, pricing, or to order the Computer Diagnostic System contact: SPX Corporation 28635 Mound Rd. Warren, MI 48092 or call: USA - 1-800-345-2233 Canada - 800-345-2233 Europe - 49 6182 959 149 Australia - (03) 9544-6222 SPX P/N MM-46225
4520
Breakout Box
Connects to Propulsion Control Module (PCM) to test engine circuits and components without probing wires. May be used with Computer Diagnostic System (CDS).
5974
Terminal Test Probe Kit
SPX P/N MM-46523
Test probes adapt test meter leads to harness connections without damaging harness terminals. May be used with Computer Diagnostic System (CDS).
7915
12 Volt Shunt Connector
889675A01
Connects to data harness allowing operation of the DTS system with the Digital Diagnostic Terminal.
8036
Adapter Harness
84-822560A5 Data link harness between engine and Digital Diagnostic Terminal (DDT).
4009
2 to 4 Pin Harness Adapter
84-822560A12
Adapts the 2 pin Digital Diagnostic Terminal harness to the 4 pin connector on the engine.
4679
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Page 3 / 34
REMOTE CONTROLS DMT 2004 Digital Multimeter 91-892647A01
SECTION - 8
H z TEMP mA V Hz mV
OFF
A
IG IP
TEMP
Measures RPM, ohms, amperes, AC and DC voltages; records maximums and minimums simultaneously, and accurately reads in high RFI environments.
Hz
mA
COM
4516
Remote Control Installation

Locating and Drilling Mounting Area
1. Locate area of boat where the remote control is to be mounted. Allow sufficient clearance for handle 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.
3600
a - Template
Installing DTS Panel Mount Control

1. Ensure opening is free of sharp edges. 2. Route wiring for the remote control into opening.
ob00040
3. Connect trim harness and lever harness.
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SECTION - 8
REMOTE CONTROLS
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 handle movement.
a
5086
a - Trim harness 5. Place the remote control into the opening.
b - Lever harness
3250
6. Fasten the remote control with three #12 x 1.25 in. long screws.
a a
3251
a - Mounting screw (3) 7. Control Handle Tension Adjustment This screw can be adjusted to increase or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "" to decrease tension.
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REMOTE CONTROLS
SECTION - 8
8. Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "" to decrease tension.
3252
a - Control handle tension adjustment screw b - Detent tension adjustment screw 9. Install front and back bezel covers with attaching screws.
b c
3254
a - Front cover b - Back cover
c - Screw - (2) M4 x 12
Installing DTS Single Handle Console Control

1. 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.
Page 6 / 34
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SECTION - 8
REMOTE CONTROLS
IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle movement.
b c a
5098
a - Trim harness b - Lever harness 5. Place the remote control into the opening.
c - Trackpad harness
3296
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REMOTE CONTROLS
SECTION - 8
6. Fasten the remote control with four M6 x 40 long screws.
b c
a - Mounting screw (4) M6 x 40 b - Washer
3297
c - Nut - nylon insert
! CAUTION
Do not turn control handle tension adjustment screw clockwise more than 11 turns from the initial point of hex head contact with bracket. Damage to the module may occur.
! CAUTION
Do 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 or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "" to decrease tension. 8. Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "" to decrease tension.
b
5102
a - Detent tension adjustment
b - Control handle tension adjustment
Page 8 / 34
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SECTION - 8
REMOTE CONTROLS
9. Install the side cover with attaching screws.
b a
3298
a - Attaching screws (4) M4 x 20
b - Side cover (2)
Installing DTS Dual Handle Console Control

1. 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.
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REMOTE CONTROLS
SECTION - 8
IMPORTANT: Allow slack in the trim button harness going to the control handle. This harness will flex and move during control handle movement.
b c d
a
a - Bayonet ends b - Trim button harness c - Blue paint dot 4. Place the remote control into the opening.
3305
d - Yellow paint dot e - Starboard engine f - Port engine
3306
Page 10 / 34
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SECTION - 8
REMOTE CONTROLS
5. Fasten the remote control with four M6 x 40 screws.
b c
a - Mounting Screw (4) M6 x 40 b - Washer
3307
c - Nut - nylon insert
! CAUTION
Do not turn control handle tension adjustment screw clockwise more than 11 turns from the initial point of hex head contact with bracket. Damage to the module may occur.
! CAUTION
Do 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 or decrease the overall effort to move the control handle. This will help prevent the handle from unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "" to decrease tension. 7. Detent Tension Adjustment Screw This screw can be adjusted to increase or decrease the effort to move control handle into or out of detent position. Turn screw towards "+" to increase tension or towards "" to decrease tension.
b
5102
a - Detent tension adjustment
b - Control handle tension adjustment
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REMOTE CONTROLS
SECTION - 8
8. Install the side cover with attaching screws.
a b
3308
a - Side cover (2)
b - Attaching screws (4) M4 x 20
Installing DTS Zero Effort Control

1. Ensure opening is free of sharp edges. 2. Route wiring for the remote control into opening. 3. Connect trim, lever and adaptor harnesses.
G RN/W HT G RN/WHT B LU/W HT B LU/W HT
b
R ED
LEVER 1
f
5181
a - Throttle adaptor harness b - Remote control c - Trim harness
R ED
d - Trackpad - not used e - Lever 1 harness (blue) f - Trim adaptor harness
Page 12 / 34
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SECTION - 8
REMOTE CONTROLS
4. Ensure the control is positioned so the forward-neutral-reverse (F-N-R) decal is in the correct orientation.
b c d
5184
b c d a
5182
Forward Cant Models a - Reverse b - Neutral
Aft Cant Models c - Forward d - F-N-R decal location
5. Ensure the control is position so the forward-neutral-reverse ("F-N-R") decal is in the correct orientation.
a b
c b
c - Shift lever d - "F-N-R" label
a
4749
a - Throttle lever b - Trim switch
! CAUTION
To avoid possible corrosion damage, always install nylon washer between each screw and the control quadrant plate. Improper installation may result in chipped paint, triggering corrosion.
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REMOTE CONTROLS
SECTION - 8
6. Secure control to the console using the 8 X 1-1/4 in. self tapping screws and nylon washers.
a b c d
5192
a - 8 X 1-1/4 in. self tapping screw (4) b - Nylon washer (4)
c - Control quadrant assembly d - Console
Steering System Information

High Speed Or Twin Engine Applications Steering Recommendation
Mercury MerCruiser power packages come standard with Mercury MerCruiser's internal power steering. This durable system provides precise effortless steering control and is recommended for most sport boat applications. On certain applications, however, Mercury MerCruiser recommends the use of an external power steering system where the power steering cylinders connect directly to the sterndrive unit on the outside of the boat. This arrangement gives additional support for even tighter, 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 power steering should be used, as this varies from boat design to boat design. Mercury MerCruiser recommends using external power steering on boats which operate in excess of 70 mph. There are 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 power steering is required rests with the boat manufacturer and must be made after a thorough test and evaluation of each specific boat. If there is any question whether or not external power steering is necessary, 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 hydraulic actuated. External power steering and hydraulic helm systems can be obtained from the following after market suppliers: Latham Marine, Inc. 280 S.W. 32nd Court Ft. Lauderdale, FL 33315 Phone: (305) 462-3055 Fax: (305) 462-3081, Mayfair Marine Machine 12890 N. W. 30th Avenue Opalocka, FL 33054 Phone: (305) 681-1815,
Page 14 / 34
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SECTION - 8
REMOTE CONTROLS
Steering Helm and Cable

Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. The steering cable coupler nut must also have a means of locking it to the guide tube, as specified in ABYC requirements.
! WARNING
Failure to use a steering cable locking device could cause loss of steering, causing possible damage to the boat or injury. NOTE: All current production Quicksilver RideGuide steering cables have a self-locking coupler nut and do not require an external locking device. (Other cable manufacturers also make cables with self-locking coupler nuts.)
7255
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 external locking device such as a locking sleeve must be used.
! CAUTION
If steering cable with improper dimensions is installed, severe damage to transom assembly and/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.
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Steering Cable Specifications

IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.
a b e f
c d g
C L
k l
j i
7254
abcdef-
Coupler nut - 7/8 - 14 UNF - 28 thread 29.8 cm (11-3/4 in.) minimum Interface point 12.7 mm (1/2 in.) maximum 10.7 mm (27/64 in.) minimum flat 3.1 mm (7/64 in.) minimum radius
g - 15.9 mm (5/8 in.) maximum diameter end 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.) maximum k - 15.9 mm (5/8 in.) diameter tube l - Cable travel: mid-travel position 42.9 cm (16-7/8 in.) total travel to be20.3 cm (8 in.) minimum to 22.8 cm (9 in.) maximum travel each side of mid-travel position 1.02 cm (4 in.) minimum to 114 mm (4-1/2 in.) maximum
Hydraulic (Helm) Steering

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

Propeller 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 Adjustment

IMPORTANT: 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 of the 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
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2. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).
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 rotating propeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).
7870
5. Right-hand (RH) rotation drive unit - Verify remote control travel for REVERSE gear.
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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 rotating propeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).
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
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8. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).
7817
IMPORTANT: It may be necessary to make additional adjustments if using extra long remote control shift cable, if there are a lot of bends in the cable, or if the remote control has inadequate output 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. Clutch should engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with REVERSE gear. Retighten stud. Shift remote control several times and stop in REVERSE to recheck shift cutout switch position. Pin must be centered. b. Left-hand (LH) propeller rotation drive unit - Shift remote control into FORWARD gear, WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutch should engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear. Retighten stud. Shift remote control several times and stop in FORWARD to recheck shift cutout switch position. Pin must be centered. 10. If drive unit is installed and the package is equipped with a two lever remote control with separate shift and throttle levers: a. Right-hand (RH) propeller rotation drive unit - While turning propeller shaft CLOCKWISE, move remote control shift handle into full REVERSE position. Clutch should engage before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with REVERSE gear. Retighten stud. Shift remote control several times and stop in REVERSE to recheck shift cutout switch position. Pin must be centered.
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b.
Left-hand (LH) propeller rotation drive unit - While turning propeller shaft CLOCKWISE, move remote control shift handle into full FORWARD position. Clutch should engage before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear. Retighten stud. Shift remote control several times and stop in FORWARD to recheck shift cutout switch position. Pin must be centered.
a b
7871
a - Adjustable stud
b - Shift interrupt switch plunger
Bravo Sterndrive Shift Check (Engine Running)

! WARNING
Contact with moving sterndrive components and the propeller can cause personal injury or death. To avoid possible injury , remove the propeller and ensure that no people or animals are in 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.
a b
4805
Typical single handle remote control shown a - Drive trim switch b - Drive trailer button 3. Connect a garden water hose between flushing attachment and water source.
Dual Water Pick-up Flush Gearcase Seal Kit 91-881150K 1
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REMOTE CONTROLS Flushing Device Flushing Kit 91-44357Q 2 91-849996T 1
SECTION - 8
4. Partially open water source until water continuously leaks out around the flushing device.
! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that 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 using a through the hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation. 5. Place remote control handle in NEUTRAL, idle speed position and start engine.
! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range.
! CAUTION
Sterndrive not shifting properly can cause engine and sterndrive damage. Contact your authorized Mercury MerCruiser dealer for proper adjustment. NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out of 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 each gear. FORWARD-detent-NEUTRAL-detent-REVERSE IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle is engaged. Consult your authorized Mercury MerCruiser dealer/representative for proper adjustment. 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 Problems

NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into FORWARD gear. 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 when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, the cables will be interfered with; this will cause very hard shifting.
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NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.
7873
Proper cable bend
7872
Improper cable bend 2. 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 on too-short cables result in kinks and too-long cables require unnecessary bends or loops. Both conditions 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 - Remote control end b - Engine end
7874
c - Adjusting barrel d - Lubricating point
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REMOTE CONTROLS Tube Ref No.

95
SECTION - 8 Description 2-4-C Marine Lubricant with Teflon Where Used Shift cable end Part No. 92-802859A1
NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GEN II 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 Description Mounting surface maximum thickness Minimum cable bend radius at any point Specification 25 mm (1 in.) 305 mm (12 in.)
4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 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 is shifted 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 the shift plate. 9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within 1.5 m (5 ft) of the shift plate. 10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud. NOTE: Lubricate attaching points with engine oil.
Description SAE 30W Engine Oil Where Used Shift cable pivot points Part Number Obtain Locally
11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows: NOTE: Cable route is the same for through transom and through prop exhaust. 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 flywheel housing. b. The cable should then be routed under the starboard rear engine mount and turn toward the transom. c. The cable should then go up behind the power steering valve and loop over to the shift plate on the engine, where it is connected to the anchor points on the shift plate.
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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 and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the pre-delivery inspection 12. 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 - Sterndrive

IMPORTANT: Boat must be equipped with Mercury electronic remote control. Start in gear protection is provided by this control system and prevents the engine from starting when the control is actuated in FORWARD or REVERSE.
T R I M
SL CL R O SC ET L E
F R
RN U
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 to the Mercury Precision Parts/Quicksilver Accessories Guide. The Digital Throttle and Shift system (DTS) works with specialized helm component, command module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver Accessories Guide.
DTS Calibration
Special Tools - DTS Calibration
Male to Male 10 Pin Adapter Can 1 Diagnostic Cable 84-892452A01 84-892663
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REMOTE CONTROLS Adapter Harness Computer Diagnostic System (CDS) 84-822560A13 Order through SPX
SECTION - 8
Methods of Calibration
NOTE: DTS system calibration must be performed following complete system installation. It must also be completed after an accessory or replacement part is added to the system that requires new configuration codes. A DTS system reset must be performed prior to calibration, or if an error is 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 harness shown in the following diagrams. Follow the System View calibration setup instructions for the DTS. If the DTS system was previously calibrated, perform a DTS system reset to restore the factory default settings.
System View Display Connection

If the boat is not equipped with a System View display, temporarily connect a System View display to the DTS command module harness as shown. After calibration, remove System View and harness, seal harness connections with weather caps.
a c
b c
O N
OFF
OFF
RUN
OFF
BLK/WHT BLK/YEL
BLK BLK/YEL
BLK/YEL BLK
BLK/YEL BLK/WHT
d e
WHT BLU
WHT BLU
d f h i
5003
abcde-
Single engine connection Dual engine connection System View System View harness Cable adapter (male to male)
fghi-
14 pin data harness from engine DTS Command Module harness Weather caps Junction box
DTS System Reset

The DTS system reset will restore the engine setup and remote control menus to factory default settings. DTS reset must be completed prior to system calibration, after an error is made during the 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 to the DTS command module harness.
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1. Use the trackpad on the System View and highlight the "SETTINGS" directory on the home screen. 2. Press and hold in the bottom arrow on the trackpad for 10 seconds. Continue holding after 10 seconds 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 FACTORY DEFAULTS" selection on the reset screen. Press "SELECT" button to accept. The reset screen will ask the question "ARE YOU SURE YOU WANT TO RESTORE VESSEL CONFIGURATION TO FACTORY DEFAULTS". Highlight "YES" and press "SELECT" button to accept. 5. DTS system reset is complete. The engine setup and remote control menus have been restored back to the factory defaults.
Calibration Setup
SPECIAL INSTRUCTIONS FOR DUAL HELM VESSELS
Perform the calibration setup at each helm using the System View. After setup is complete at one helm, repeat setup on the second helm. If only one System View is installed in the vessel, the System View must be temporarily connected to the second helm. An extra System View can temporarily be connected at the second 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 have to be performed each time it is moved to a different helm. Refer to DTS System Reset procedure. Calibration can be started at either helm. However, if one System View is being used, it is best to 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.
CALIBRATION
NOTE: The following calibration procedure is for using method 2, using a System View display screen. If method 1, using a Mercury Marine Computer Diagnostic System is used, follow the on-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 been completed on the another helm. Select "YES" on dual helm vessels if calibration has already been completed on the other helm. NOTE: If "YES" is selected, module initialization was completed at the other station. Calibration will 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 down arrows to change the number of engines or helms. Use the left or right arrow to change from the 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 NEUTRAL IDLE". Press "SELECT" to continue. NOTE: On dual helm vessels, helm identified as 1 is the helm with the ignition key switch. Helm identified as 2 is the helm with the start/stop switch. On dual engine installations, engine identified as 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.
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6. The next screen should read, "ASSIGN STATION IDENTIFICATION FOR THIS SYSTEM VIEW". Assign "1" for System View connected at helm 1. When applicable, assign "2" for System View connected at helm 2. Press "SELECT" button to continue. 7. The next screen should read, "SELECT THE ENGINE CONFIGURATION THE SYSTEM VIEW IS CONNECTED TO". Press "SELECT" button to continue.
a b
a c b
a c d 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?" (single engines only). Press "SELECT" button to continue.
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IMPORTANT: All Verado engines shift as a standard rotation, right hand. All OptiMax and MerCruiser 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 THIS VESSEL?" Press "SELECT" button to continue. 12. The next screen should read, "PLEASE SELECT FROM THE FOLLOWING CONTROL TYPES": 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 order for 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 View display, 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 order for the command module to learn all the lever positions.
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1. Move shift lever to reverse position and move throttle lever to WOT. Press "SELECT" when levers are in position. 2. Keep shift lever in reverse and move throttle lever to idle. Press "SELECT" when levers are in position. 3. Move shift lever to neutral and keep throttle lever at idle. Press "SELECT" when levers are in position. 4. Move shift lever to forward and keep throttle lever at idle. Press "SELECT" when levers are in position. 5. Move shift lever to forward and move throttle lever to WOT. Press "SELECT" when levers are in position. 6. Move shift lever to neutral and move throttle lever 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.
ZERO EFFORT CONTROLS WITH FOOT THROTTLE

Move the control lever and foot throttle to the selected positions as instructed on the System View display, 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 Limit

Setting Trailer Limit with DDT
! CAUTION
The trailer limit must be set before setting the trim limit. Failure to set the trailer limit prior to setting the trim limit, will create a programming error in the engine PCM. The PCM must be reprogrammed to correct the error. Contact Mercury Marine Technical Service Department for instruction 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.
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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

! CAUTION
The trailer limit must be set before setting the trim limit. Failure to set the trailer limit prior to setting the trim limit, will create a programming error in the engine PCM. The PCM must be reprogrammed to correct the error. Contact Mercury Marine Technical Service Department for instruction 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. 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 position sensor. 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

! CAUTION
The trailer limit must be set before setting the trim limit. Failure to set the trailer limit prior to setting the trim limit, will create a programming error in the engine PCM. The PCM must be reprogrammed to correct the error. Contact Mercury Marine Technical Service Department for instruction on reprogramming the PCM. The trim limit configures the PCM to control the maximum up trim limit. The trim limit function is only 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.
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3. 4. 5. 6. 7. 8.
The "SELECT FUNCTION" screen will appear. Press 5 - "SPECIAL FUNCTIONS". The "SELECT FUNCTION" screen will appear. Press 7 - "TRIM LIMIT". The "TRIM LIMIT" screen will appear. To set the maximum up trim limit, press 1 - "YES". Trim the engine/drive to the desired trim position. To "CONTINUE" press 1 - "YES". The maximum trim limit setting is stored in the PCM. To "CONTINUE" press 1 "YES". 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

! CAUTION
The trailer limit must be set before setting the trim limit. Failure to set the trailer limit prior to setting the trim limit, will create a programming error in the engine PCM. The PCM must be reprogrammed to correct the error. Contact Mercury Marine Technical Service Department for instruction on reprogramming the PCM. 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 is only 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 Procedure
Troubleshooting Information
NOTE: All of the following are determined by the calibration of the PCM. Upgrading the calibration can result in changes to these settings.
DEFAULT SENSOR VALUES

Default sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignition values, when the sensor in question has exceeded its preprogrammed diagnostic limits. Default sensor 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 sensor in 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 to 100 kPa (29.5 in. Hg). This can be verified by unplugging the sensor in question and watching the data stream value. Other pressure sensors will have their own default values which may be determined as described previously.
FAULT CONDITIONS
Most faults can be detected with the engine running, or key-on, engine off. However, some faults require the presence of engine RPM, and cannot be detected key-on, engine off. Examples of this type 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 would be EST (cylinders 1 through 8) open circuit.
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SECTION - 8
REMOTE CONTROLS
In addition, some faults are programmed to ignore certain engine speeds. For example, the low block pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled until enough RPM has been achieved to develop a reasonable amount of water pressure. 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 also vary with engine RPM. Faults generally set faster at higher engine speed.
STICKY/NON-STICKY FAULTS
All faults are classified as either sticky or non-sticky. Sticky means that the fault, once set, will continue to show up as active, even if the circuit or problem has corrected itself. A key switch cycle is 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 a key switch cycle. The diagnostic tools (CDS or DDT) will continue to display a sticky fault as active, even though the cause of the fault has been corrected. Cycle the key to reset all faults if there is difficulty correcting a fault.
ENGINE GUARDIAN
Almost every fault will cause the guardian program (within the PCM) to become active. The amount of guardian protection is expressed as a percentage. The higher the percentage, the more power the engine is allowed to produce. If available power (on the CDS or DDT) is showing 100%, then guardian 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 by changing injector and ignition operation. Guardian is always accompanied by another fault or faults that actually caused the guardian to become active. The more severe the fault, the more the guardian reduces available power. A small problem, such as a non-critical sensor going circuit high or circuit low, will result in available power of 90% depending on product line. A severe problem such as low oil pressure, or a DTS shift or throttle 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 more severe situation.
WARNING HORN SIGNALS

Most faults will cause the warning horn circuit to activate. How the warning horn activates depends on 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 on the dash mounted gauges.
Special Tools - DTS Troubleshooting

Computer Diagnostic System (CDS) Breakout Box Terminal Test Probe Kit 12 Volt Shunt Connector Adapter Harness 2 to 4 Pin Harness Adapter Order through SPX SPX P/N MM-46225 SPX P/N MM-46523 889675A01 84-822560A5 84-822560A12
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REMOTE CONTROLS Adapter Harness Male to Male 10 Pin Adapter DMT 2004 Digital Multimeter 84-822560A13 84-892452A01 91-892647A01
SECTION - 8
Page 34 / 34
90-864196060 MAY 2006
SECTION - 9
PREDELIVERY PREPARATION AND STORAGE
SECTION 9 - PREDELIVERY PREPARATION AND STORAGE

Table of Contents
Predelivery Preparation........................................................................................................................................... 3 Engine Oil..........................................................................................................................................................3 Checking .................................................................................................................................................... 4 Adding Engine Oil ...................................................................................................................................... 4 Power Steering Fluid.........................................................................................................................................4 Power Trim Pump.............................................................................................................................................. 5 Drive unit gear lube monitor..............................................................................................................................6 Filling Coolant Recovery Bottle ........................................................................................................................6 Alpha Trim Limit Switch Adjustment..................................................................................................................6 Analog Guages .......................................................................................................................................... 6 Bravo Trim Limit Switch Adjustment - Analog Gauges ..................................................................................... 8 Trim Position Sender Adjustment - Analog Gauges........................................................................................10 Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method...................................................11 Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method...................................................12 Propeller Selection..........................................................................................................................................12 Alpha Sterndrive Propeller Installation ...........................................................................................................13 Alpha Models ........................................................................................................................................... 13 Bravo Sterndrive Propeller Installation............................................................................................................14 Bravo One Models ................................................................................................................................... 14 Bravo Two Models ................................................................................................................................... 15 Bravo Three ............................................................................................................................................. 16 Battery Connection..........................................................................................................................................17 Priming The Fuel System................................................................................................................................17 Test Running Engine ......................................................................................................................................18 Boat Out Of the Water ............................................................................................................................. 18 Boat In the Water ..................................................................................................................................... 18 Testing Preparation ................................................................................................................................. 18 Testing .................................................................................................................................................... 19 Boat In The Water Tests.................................................................................................................................20 Engine Idle Speed ................................................................................................................................... 20 Wide Open Throttle Test .......................................................................................................................... 20 Checking Shift Operation ......................................................................................................................... 20 Cold Weather and Extended Storage.................................................................................................................... 21 Cold Weather or Extended Storage ...............................................................................................................21 Seawater Section............................................................................................................................................21 Closed Cooling Section...................................................................................................................................21 Preparing Power Package For Storage........................................................................................................... 21 Fuel System ............................................................................................................................................. 22 Battery ..................................................................................................................................................... 22 Draining Instructions.............................................................................................................................................. 23 Identification....................................................................................................................................................23 Manual Single Point Drain System .......................................................................................................... 23 Air Actuated Single Point Drain System .................................................................................................. 23 3 Point Manual Drain System .................................................................................................................. 24 Multi-Point Drain (MPD) System .............................................................................................................. 24 Boat In Water..................................................................................................................................................25 Manual Single Point Drain System .......................................................................................................... 25 Air Actuated Single Point Drain System .................................................................................................. 26 3 Point Manual Drain System .................................................................................................................. 28 Boat Out Of The Water....................................................................................................................................29
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SECTION - 9
Manual Single Point Drain System .......................................................................................................... 29 Air Actuated Single Point Drain System ................................................................................................. 30 3 Point Manual Drain System .................................................................................................................. 32 Multi-Point Drain (MPD) System .............................................................................................................. 33 Power Package Recommissioning..................................................................................................................35 Predelivery Inspection.....................................................................................................................................37
Page 2 / 37
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SECTION - 9

Tube Ref No.
34 80 87 94 95 114 115 124
Description Special Lubricant 101 SAE Engine Oil 30W High Performance Gear Lubricant Anti-Corrosion Grease 2-4-C Marine Lubricant with Teflon Power Trim and Steering Fluid Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer
Where Used Propeller shaft splines Power trim pump Gear Lube Monitor Propeller shaft splines Propeller shaft splines Power steering pump Power trim pump Fuel system Fuel system
Part No. 92-802865A1 Obtain Locally 92-802854A1 92-802867A1 92-802859A1 92-802880A1 92-802824A1 802875A1
Special Tools
Flushing Device 91-44357Q 2
9192
Flushing Kit
91-849996T 1

9195
Predelivery Preparation
Once the power package installation is complete, the following final steps should be taken to prepare power package for delivery to the customer. It is the boat manufacturer's responsibility to perform these procedures or to make arrangement with the dealer to have these procedures completed.
Engine Oil
! CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain and dispose of oil or oil waste as directed by local authorities.
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SECTION - 9
CHECKING
1. 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 OK range 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 top of the OK range.
ADDING ENGINE OIL

IMPORTANT: Do not overfill the engine with oil. 1. Remove oil fill cap.
6077
a - Oil fill cap IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK range 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 Fluid

IMPORTANT: Use only specified lubricant.
! CAUTION
Do 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.
Page 4 / 37
90-864196060 MAY 2006
SECTION - 9
NOTE: Be prepared to add fluid to pump when first starting engine.
b
9356
a - Fill cap
Tube Ref No.
114
b - Dipstick
Description Where Used Power steering pump Where used Power steering pump Part No. 92-802880A1 Part Number Obtain locally
Description Dexron III - Automatic Transmission Fluid
Power Trim Pump

1. 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 should be maintained within the "MIN" and "MAX" lines on the reservoir.
c
8539
a - Fill cap (top and underneath side views) b - Reservoir fill neck
Tube Ref No.
114
c - "MIN" and "MAX" lines
Description Power Trim and Steering Fluid
Where Used Power trim pump
Part No. 92-802880A1
90-864196060 MAY 2006
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PREDELIVERY PREPARATION AND STORAGE Tube Ref No.

80
SECTION - 9 Description Where Used Power trim pump Part No. Obtain Locally
SAE Engine Oil 30W
3. Check the power trim pump hose fittings for leaks. If fluid is visible at the fittings, check connections.
Drive unit gear lube monitor

IMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always check oil 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.
7884
Typical a - Gear lube monitor cap

Tube Ref No.
87
b - Operating Range (full) line

Where Used Gear Lube Monitor Part No. 92-802854A1
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 Bottle

NOTE: 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 Adjustment

ANALOG GUAGES
! WARNING
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90-864196060 MAY 2006
SECTION - 9
! CAUTION
Trim limit switch MUST BE adjusted exactly as outlined. If switch is adjusted incorrectly, drive unit could move out beyond the gimbal ring support flanges and cause damage to sterndrive unit. 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.
b
7879
Trim limit switch a - Screws b. c. d. b - Slots
Ensure drive unit is in the full DOWN/IN position. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.
7880
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Page 7 / 37
SECTION - 9
a
7881
Alpha trim cylinder extended a - Maximum520 mm (20-3/4 in.) e. Retighten screws when adjustment is correct.
Bravo Trim Limit Switch Adjustment - Analog Gauges

! WARNING
! CAUTION
Trim limit switch MUST BE adjusted exactly as outlined. If switch is adjusted incorrectly, drive unit could move out beyond the gimbal ring support flanges and cause damage to sterndrive unit. IMPORTANT: All Bravo models must have the trim-in-limit insert positioned properly before performing the trim position sender adjustment. 1. Ensure that the trim-in-limit insert is positioned as shown for the appropriate Bravo model.
8548
8557
Bravo One and Two (positioned forward) a - Trim-in-limit insert
Bravo Three (positioned aft)
2. Bravo sterndrive, adjust trim limit switch as follows: NOTE: Trim position sender is located on the starboard side of gimbal ring.
Page 8 / 37
90-864196060 MAY 2006
SECTION - 9
a.
Loosen screws and turn trim limit switch clockwise to end of slots.
b
7879
Trim limit switch a - Screws b. c. d. b - Slots
Ensure drive unit is in the full DOWN/IN position. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE TRAILER BUTTON. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown.
7880
a
8558
Bravo trim cylinder extended a - Trim Limit Dimension 21-3/4 in. (552 mm) e. Retighten screws when adjustment is correct.
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SECTION - 9
Trim Position Sender Adjustment - Analog Gauges

NOTE: Trim position sender is located on the starboard side of gimbal ring. 1. Loosen both trim position sender retaining screws.
b a
7882
! CAUTION
Do not start engine in the following step or damage to sterndrive unit and engine could result from 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.
a
7883
a - Trim gauge needle 5. Tighten retaining screws and turn ignition key to the OFF position.
b a
7882
Page 10 / 37
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SECTION - 9
Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method

NOTE: Trim position sender is located on the starboard side of gimbal ring.
21076
a - Trim position sender 1. 2. 3. 4. 5. 6.
Trim the sterndrive unit to the full DOWN/IN position. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool. Turn ignition key switch to the RUN position. Set the scan tool to display TRIM POS counts and note the value displayed. TRIM POS counts must be between 20 and 24 counts. 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.
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SECTION - 9
Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method

NOTE: Trim position sender is located on the starboard side of gimbal ring.
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 Selection
IMPORTANT: 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 package with the correct propeller. Specified engine WOT and operating rpm range are listed in the Mercury MerCruiser 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 of the recommended WOT operating rpm range with a normal load. If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage. After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch. Warmer weather and greater humidity cause a loss of rpm. Operating in a higher elevation causes a loss of rpm. Operating with increased load (additional passengers, pulling skiers) causes a loss of rpm.
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90-864196060 MAY 2006
SECTION - 9
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not 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 a particular application. Available propellers are listed in the Mercury Precision Parts Accessories Guide. See BOAT IN THE WATER TESTS, Maximum RPM Test at the back of this manual.
Alpha Sterndrive Propeller Installation

! WARNING
! WARNING
7885
1. To aid in future removal of the propeller, liberally coat propeller shaft splines with lubricant.
Tube Ref No.
34
Where Used Propeller shaft splines
Part No. 92-802865A1
IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed through propeller nut after torquing it.
ALPHA MODELS
1. 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.
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SECTION - 9
3. Bend the 3 tabs down into grooves.
d e a b c g
abcdDescription Alpha propeller nutAlpha propeller nut1.
5301
Propeller shaft splines Forward thrust hub Flo-torque II drive hub Propeller
e - Drive sleeve adapter f - Locking tab washer g - Propeller nut
Nm 75
lb. in.
lb. ft. 55
Then align tabs with grooves.

! WARNING
! WARNING
7885
BRAVO ONE 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.
Tube Ref No.
34
Where Used Propeller shaft splines
Part No. 92-802865A1
1. The propeller torque stated is the minimum torque value.
Page 14 / 37
90-864196060 MAY 2006
SECTION - 9 Tube Ref No.

95
PREDELIVERY PREPARATION AND STORAGE Description 2-4-C Marine Lubricant with Teflon Description Anti-Corrosion Grease Where Used Propeller shaft splines Where Used Propeller shaft splines Part No. 92-802859A1 Part No. 92-802867A1
Tube Ref No.

94
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.
d e a b c g
abcdDescription Bravo One propeller nut
5301
Bravo One Propeller shaft splines Forward thrust hub Flo-Torque II drive hub Propeller
e - Drive sleeve adapter f - Tab washer g - Propeller nut
Nm 75
lb. in.
lb. ft. 55
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.
Tube Ref No.
34
Description Special Lubricant 101 Description 2-4-C Marine Lubricant with Teflon Description Anti-Corrosion Grease
Where Used Propeller shaft splines Where Used Propeller shaft splines Where Used Propeller shaft splines
Part No. 92-802865A1 Part No. 92-802859A1 Part No. 92-802867A1
Tube Ref No.

95
Tube Ref No.

94
NOTE: Anti-corrosion grease is for salt water applications only. 2. Install propeller with attaching hardware as shown.
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SECTION - 9
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.
c d f a b e
Description Bravo Two propeller nut
8566

BRAVO THREE
Tube Ref No.
34
Description Special Lubricant 101 Description 2-4-C Marine Lubricant with Teflon Description 2-4-C Marine Lubricant with Teflon
Where Used Propeller shaft splines Where Used Propeller shaft splines Where Used Propeller shaft splines
Part No. 92-802865A1 Part No. 92-802859A1 Part No. 92-802859A1
Tube Ref No.

95
Tube Ref No.

95
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.
Description Front dual propeller nut Nm 136 lb. in. lb. ft. 100
NOTE: The propeller torque stated is a minimum torque value. 5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 6. Align splines and install aft propeller. 7. Install propeller nut and torque.
Description Rear dual propeller nut Nm 81 lb. in. lb. ft. 60
Page 16 / 37
90-864196060 MAY 2006
SECTION - 9
NOTE: The propeller torque stated is a minimum torque value. 8. Install propeller shaft anode and screw and torque.
e f b a j
5304
i g h
abcdeDescription
Bravo Three Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller
fghij-
Propeller shaft anode screw
Battery Connection
IMPORTANT: Engine electrical system is negative (-) ground. 1. Ensure that all battery terminal connections are tight.
Priming The Fuel System

IMPORTANT: Use a portable fuel tank with a primer bulb fuel line.
! WARNING
Be careful when working on fuel system. Gasoline is extremely flammable and highly explosive under certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilled fuel immediately. 1. Disconnect the fuel line from the fuel tank to the fuel inlet fitting and plug the line, if attached to 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 does not 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.
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SECTION - 9
Test Running Engine

! WARNING
Avoid Injury: If engine is to be tested with the boat out of the water, the propeller must be removed to avoid injury.
! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation.
BOAT OUT OF THE WATER

For engine operation tests with the boat out of the water: IMPORTANT: If using a flushing attachment over the water inlet holes with a water hose, do not use 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 using a through the hull water inlet, need a supply of cooling water available to both the sterndrive unit and 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 WATER

For engine operation tests with the boat in the water: IMPORTANT: If using a test tank the water level must be above the water inlet holes on the sterndrive unit or the through the hull pickup. 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
! WARNING
Do 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 Manual for operating specifications. Refer to appropriate Mercury MerCruiser Service Manual for fluid capacity information. 2. Check crankcase oil level. IMPORTANT: Oil level in monitor will rise and lower during sterndrive operation. Always check oil level 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.
Page 18 / 37
90-864196060 MAY 2006
SECTION - 9
! CAUTION
If 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 suction created could cause water hose to collapse causing water supply to be cut off.
! WARNING
If 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, water must be provided to these inlets or air flow must be blocked. If a block-off plate is used, the through the transom or through the hull fitting is the only water inlet to the engine.
Flushing Device Flushing Kit 91-44357Q 2 91-849996T 1
TESTING
1. Place sterndrive in neutral , idle speed and start engine. 2. Slowly advance throttle until engine reaches 1300 rpm (+/-100 rpm).
! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range. 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 components b. Ensure that steering lever is not contacting cutout in transom. If contact is being made, modify cutout c. 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):
90-864196060 MAY 2006
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SECTION - 9
a. b.
Turn off engine. Remove cap/dipstick from power steering pump. Check fluid level and add if necessary.
7890
a
a - Dipstick (full when hot line)
Boat In The Water Tests

ENGINE IDLE SPEED
Engine should idle at RPM as specified in appropriate Mercury MerCruiser Operation, Maintenance, and Warranty Manual with boat in the water, drive unit in FORWARD gear and engine at normal operating temperature. If idle speed is incorrect, proceed as follows: 1. Ensure that throttle cable has been adjusted properly.
WIDE OPEN THROTTLE TEST

IMPORTANT: To operate engine at full throttle before the break-in period is complete, follow this procedure. 1. Place remote control in neutral , idle speed and start engine. 2. Slowly advance throttle until engine reaches 1300 rpm (+/-100 rpm).
! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature gauge and ensure that the engine is operating in the normal range. 3. 4. 5. 6. Watch all gauges for normal readings. When engines reaches mornal operating temperature, run the boat up on plane. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM. 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 the specified range so that, under a heavy load, engine speed will not fall below specifications. If engine speed is too high, replace propeller with a higher pitch propeller. Normally a 25 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 OPERATION

With sterndrive unit installed and engine operating, ensure that drive unit shifts properly, as explained 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.
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90-864196060 MAY 2006
SECTION - 9
4. Shifting from FORWARD and REVERSE to NEUTRAL: ensure drive unit is in NEUTRAL before remote control shift lever comes to the NEUTRAL detent position. Perform this check using various shifting rates to ensure that the drive unit shifts the same whether shifting fast or slow.
Cold Weather and Extended Storage

Cold Weather or Extended Storage
! CAUTION
Sterndrive unit should be stored in full down position. Universal Joint bellows may develop a set if unit is stored in raised position and may fail when unit is returned to service.
Seawater Section
IMPORTANT: Drain seawater section of closed cooling system only. IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.
! CAUTION
Seawater section of cooling system must be completely drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exist. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing is not covered by the Mercury MerCruiser Limited Warranty. IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations.
Closed Cooling Section

! CAUTION
If engine will be exposed to freezing temperatures, ensure closed cooling section is filled with an ethylene glycol antifreeze and water solution properly mixed to protect engine to lowest temperature 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 may be used, but it will require replacement every two years.
! CAUTION
Ensure that boat is out of the water or seacock is closed and that bilge pump is operating. Excess water in the bilge can damage engine or cause boat to sink.
Preparing Power Package For Storage

1. 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 instructions on the container. 2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): Fuel tanks should be drained as low as possible and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank. Refer to Fuel Requirements for additional information.
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SECTION - 9
NOTE: If desired, a portable fuel tank can be used to perform the remainder of the power package lay up procedures. Be sure to add an appropriate amount of Gasoline Stabilizer to the portable tank. 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 to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage.
FUEL SYSTEM
! WARNING
The fuel injection system is pressurized. Avoid serious injury from an explosion. Use care when removing water separating fuel filter. Allow engine to cool down before removing the water separating fuel filter. Also, hold a clean shop towel over the water separating fuel filter when removing it, to help avoid fuel spraying on the engine.
! WARNING
Fuel vapors can be present in the engine compartment. Avoid injury or power package damage caused by fuel vapors or explosion. Always ventilate the engine compartment prior to servicing the 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) gasoline b. 1.89 liter (2 U.S. qts.) Premium Plus 2-Cycle TC-W3 Outboard Oil c. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System Treatment and Stabilizer Concentrate.
Tube Ref No.
115 124
Description Premium Plus 2-cycle TC-W3 Outboard Oil Fuel System Treatment & Stabilizer
Where Used Fuel system Fuel system
Part No. 92-802824A1 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's fuel system to become completely dry. 7. Remove and discard the water separating fuel filter. 8. Install a new filter.
BATTERY
Follow the battery manufacturer's instructions for storage.
Page 22 / 37
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SECTION - 9
Draining Instructions
! CAUTION
Excess water in bilge can damage engine or cause boat to sink. Ensure that the boat is out of the water or the seacock is closed and bilge pump is operating before beginning procedure.
! CAUTION
Do not operate engine with drain system open. Excess water in bilge can damage engine or cause 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 page to 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.
Identification
MANUAL SINGLE POINT DRAIN SYSTEM
9326
a - Blue handle
b - Blue drain plug location
AIR ACTUATED SINGLE POINT DRAIN SYSTEM
c b c d d a b
9336 9327
Closed cooled models a - Blue drain plug location b - Blue air pump
Seawater cooled models c - Air manifold d - Green indicators
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SECTION - 9
3 POINT MANUAL DRAIN SYSTEM
9328
a - Blue drain plug
MULTI-POINT DRAIN (MPD) SYSTEM
b a a
93235672
10226
M110050
9330
a - Side of cylinder block
b - Bottom of exhaust manifolds
9331
a - Drain plug
Page 24 / 37
90-864196060 MAY 2006
SECTION - 9
9332
a - Drain plug
Boat In Water
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 create new threads. 3. Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system.
a
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 from distribution housing and drain manually.
b
9334
a - Drain location - orange or red
b - Blue drain plug
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SECTION - 9
5. 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 other maintenance. 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 overtighten the handle as this will create new threads. IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations. 8. Open the seacock prior to operating the engine.

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source 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.
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.
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SECTION - 9
7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat exchanger. This must be removed within 30 seconds to properly vent the cooling system.
c b c d d a b
9336 9327
8. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System instructions.
b a
a - Port side drain location
9335
b - Starboard side drain location
9. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the green indicators 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 and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations.
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SECTION - 9
14. Before launching boat, pull up on manual release valve. Verify that green indicators are no longer extended.
a
6135
a - Green indicators 15. Open the seacock prior to operating the engine.

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 1. Close the seacock. 2. Remove the blue drain plug from the distribution housing (lower front, port side).
a
a - Blue drain plug
9348
3. Immediately remove the blue drain plug from the side of the thermostat housing. This must be removed within 30 seconds to properly vent the cooling system.
8219
a - Blue drain plug location
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SECTION - 9
4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
9349
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 other maintenance. 7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do not allow engine to start. 8. Prior to launching boat or starting the engine, close the drain system by installing the 4 blue drain plugs. IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations. 9. Open the seacock prior to operating the engine.
Boat Out Of The Water

1. Place the boat on a level surface to ensure complete draining of system.
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SECTION - 9
2. Rotate blue handle COUNTERCLOCKWISE until rotation stops (approximately 2 turns). The red on the handle shaft indicates that the drain system is open. Do not force handle as this will create new threads.
9347
a - Blue handle 3. Visually verify that water is draining. If water does not drain, remove blue drain plug from distribution housing and allow to drain manually.
b
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 recommends leaving the plugs out while transporting the boat or while performing other maintenance to ensure that all water is drained. 5. Close the drain system by rotating the blue handle CLOCKWISE until it stops or installing the blue drain plug. The handle is fully seated when no red is visible. Do not overtighten handle as this will create new threads. IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations.

NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1. Place the boat on a level surface 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).
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SECTION - 9
4. Install air pump on the fitting in the air manifold.
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.
c b c d d a b
9336 9327
90-864196060 MAY 2006
Page 31 / 37
SECTION - 9
7. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System.
b a
a - Port side drain location
9335
b - Starboard side drain location
8. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the green indicators 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 and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations. 12. Before launching boat, pull up on the manual release valve. Verify that the green indicators are no longer extended.
a
6135
a - Green indicators

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain system or if the single point drain system fails. 1. Place the boat on a level surface to ensure complete draining of system.
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90-864196060 MAY 2006
SECTION - 9
2. Remove 3 blue drain plugs: 1 from the distribution housing (lower front, port side) and 2 from the seawater pickup pump (front, starboard side).
9348 9349
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 to ensure that all water is drained. 5. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do not allow engine to start. IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations. 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.
b a a
93235672
10226
M110050
9330
a - Side of cylinder block
b - Bottom of exhaust manifolds
90-864196060 MAY 2006
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SECTION - 9
c.
Water circulating pump hose.
9350
a - Water circulating pump drain plug d. Fuel cooler to thermostat housing hose.
9352
a - Drain plug e. Check valve.
9332
a - Drain plug
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SECTION - 9
3. On models with seawater pickup pump, remove the 2 blue drain plugs. If your seawater pickup pump does not have blue drain plugs or you are unable to access them, loosen clamps and remove both hoses.
a
9353
9354
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.
d a f c
9355
Sterndrive unit water drain holes a - Speedometer pitot tube db - Trim tab cavity vent hole ec - Trim tab cavity drain passage f-
Gear housing water drain hole (1 each - port and starboard) Gear housing cavity vent hole Gear housing cavity drain hole
5. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do not allow engine to start. 6. After cooling system has been drained completely, install drain plugs, reconnect hoses and tighten all hose clamps securely. IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Follow the propylene glycol manufacturer's recommendations.
Power Package Recommissioning

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.
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SECTION - 9
! CAUTION
Avoid 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 reconnect cables (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.
! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure that there is sufficient water always available at water inlet holes during operation. 5. Start the engine and closely observe instrumentation to ensure that all systems are functioning correctly. 6. Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks. 7. Inspect the steering system, shift and throttle control for proper operation.
Page 36 / 37
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SECTION - 9
Predelivery Inspection
Not Applicable Check / Adjust CHECK BEFORE RUNNING Drain plug in and petcocks closed Seawater inlet valve open Engine mounts tight Engine alignment Drive unit fasteners torqued Power trim cylinders fasteners tight Battery fully charged and secured All electrical connections tight Exhaust system hose clamps tight All fuel connections tight Correct rotation propeller (installed and torqued) Throttle, shift and steering system fasteners tightened properly Throttle plates open and close completely Crankcase oil level Power trim oil level Sterndrive unit oil level Power steering fluid level Closed cooling level Transmission fluid level Alternator belt tension Seawater pickup pump belt tension Power steering pump belt tension Audio warning system operation Not Applicable Check / Adjust ON THE WATER TEST Engine alignment (Inboards only) Starter neutral safety switch operation Water pump operation Instruments(s) operation Fuel leaks Oil leaks Water leaks Exhaust leaks Ignition timing Idle________ rpm, within specifications Forward - Neutral - Reverse gear operation Steering operation throughout range Acceleration from idle rpm WOT________ rpm within specifications (in FORWARD gear) Power trim operation Trim tab adjustmentBoat handling AFTER ON WATER TEST Propeller nut torque Fuel, oil, coolant, water and fluid leaks Oil and fluid levels Apply Quicksilver Corrosion Guard to engine package C.A.R.B. Hang Tag and Owners Manual in boat1. C.A.R.B. Decal properly affixed to boat hull1.
1. If registered to a CA resident.
90-864196060 MAY 2006
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SECTION - 9
NOTES:
Page 38 / 37
90-864196060 MAY 2006

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DENTRO-FUERABORDA MODELOS MOTOR GASOLINA MANUAL

2006 Mercury Marine

90-864196060 APRIL 2006

Drive System And Engine Installation

Starting And Electrical

Predelivery Preparation And Storage

SECCION 1 INFORMACIN IMPORTANTE

90-864196060 MAY 2006

Mandos a distancia y de instrumentacin para DTS Sistema

90-864196060 MAY 2006

Serial Number Decal Placement

Bravo Three Notice: Trim-in Limit Insert

Multiple Sterndrive Steering Tie Bar Arrangements

90-864196060 MAY 2006

Internal Power Steering With Internal Tie Bar Only

Internal Power Steering With Internal and External Tie Bar

External Power Steering

External Power Steering With Low External Tie Bar

90-864196060 MAY 2006

a - Painted boat transom

b - Minimum 40 mm (1-1/2 in.) unpainted area around transom assembly

90-864196060 MAY 2006

a - MerCathode reference electrode b - Do not paint

c - Do not pressure wash

Emission Control Information Label

EMISSION CONTROL INFORMATION

90-864196060 MAY 2006

"DISP" - Piston Displacement

EMISSION CONTROL INFORMATION

FAMILY XXXXX XXXXXX FEL. XX.X g/kW-hr

Dec 2004 X.XL

90-864196060 MAY 2006

IMPORTANT INFORMATION One Star - Low emission

90-864196060 MAY 2006

SECTION 2 - BOAT CONSTRUCTION

90-864196060 MAY 2006

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

Checking Transom Thickness

90-864196060 MAY 2006

SECTION 3 - EXHAUST SYSTEM

90-864196060 MAY 2006

Exhaust System Caution

Measuring Exhaust Elbow Height

90-864196060 MAY 2006

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

90-864196060 MAY 2006

90-864196060 MAY 2006

Measurement 330 mm (13 in.)

a - Highest point on exhaust elbow b - Measurement

Methods for Measuring Exhaust Elbow Height

Clear Hose Method for Measuring Exhaust Elbow Height

90-864196060 MAY 2006

a - Waterline b - Top of exhaust elbow c - Clear plastic hose

d - Weight e - Measurement - waterline to top of exhaust elbow

COLLECTOR AND WATER LIFT MUFFLER EQUIPPED

90-864196060 MAY 2006

90-864196060 MAY 2006

EXHAUST SYSTEM Minimum Exhaust Hose Size

90-864196060 MAY 2006

Exhaust Resonator Guidelines

90-864196060 MAY 2006

e - Clamp - positioned around center of resonator f - Exhaust muffler g - Collector

90-864196060 MAY 2006