MerCruiser Alpha One V6 User manual

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IDENTIFICATION RECORD
Please Record the Following Information
1. Engine Model and Horsepower
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MERCURY MARINE
A BRUNSWICK COMPANY
FOND DU LAC, WI U.S.A.
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DiSPLACEMENT ...•••...•..••••••• :I5OCIO MAXW.O.T.RPM •• n ••••••••• 4200-4600RATED HORSEPOWER •••••••••••••••• 260 PLUG GAP .......
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for fuel and 011requirements refer 10Operation & Maintenance Maroa!
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Engine Serial Number
3. Transom Assembly Serial Number
The serial numbers are the manufacturer's keys to numerous engineering details
which apply to your MerCruiser® power package. When contacting your Authorized
MerCruiser Dealer about service, always specify model and serial numbers.
4.
5.
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ABC12345Z123
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TRANSOM ASSEMBLY
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Length
Purchase Date
Boat Model
SERIAL NUMBERS
Hull Identification Number (HIN)
Boat Manufacturer
Propeller Pitch
Stern Drive Unit Serial Number and Gear Ratio
Propeller Number
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DRIVE UNIT
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MerCrulser V6/V8
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TABLE OF CONTENTS READ THIS MANUAL THOROUGHLY
Printed in U.S.A.
If you don't understand any portion, contact your dealer for a
demonstration of actual starting and operating procedures.
2
Boating Safety and Seamanship 4
Operation and Maintenance 5
Water Wisdom 5
High-Performance Boat Operation 6
Conditions Affecting Operation 6
Operation 9
Additional Information 16
20-Hour Break-In Period 16
20-Hour Check-Up 16
Specifications 17
Fuel Requirements 17
Crankcase Oil 18
Maintenance 23
Miscellaneous Maintenance 46
Out of Season Storage 47
Troubleshooting 51
The description and specifications contained herein were in effect at the time this
guide was approvedfor printing. Mercury Marine, whose policy isone of continuous
improvement, reserves the right to discontinue models at any time, or to change
specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fonddu Lac,Wisconsin, U.S.A.
dl
©1988,Brunswick Corporation
The following are registered trademarks of Brunswick Corporation: Auto-
blend, Jet-prop, Mariner, Mere, MerCathode, MerCruiser, Mercury, Mercury
Marine, Quicksilver, Ride-Guide, and Thruster.
MerCrUlser V6 V8
NOTICE
Throughout this publication, and on your
power package, WARNINGS and
CAUTIONS, accompanied by the Inter-
national HazardSymbol A,maybe used
toalertthe installer/user tospecialinstruc-
tions concerning a particular service or
operation that may be hazardous if per-
formed incorrectly or carelessly. Observe
them carefully.
These "Safety Alerts" alone cannot elim-
inate the hazards that they signal. Strict
compliance with these special instruc-
tions while performing the service, plus
"common sense" operation, are major
accident prevention measures.
AWARNING
WARNING -Hazardsor unsafe practices
which could result in severe personal
injury or death.
ACAUTION
CAUTION - Hazards or unsafe practices
which could result in minor personal
injury or product or property damage.
IMPORTANT - Indicates information or
instructions that are necessaryfor proper
operation and/or maintenance.
AWARNING
The operator (driver) is responsible for
the correct and safe operation of the
boat, the equipment aboard and the
safety of all occupants aboard. We
strongly recommend that the operator
read this Operation and Maintenance
Manual and thoroughly understand the
MerCru,ser V6/V8
operational instructions for the power
package and all related accessories
before the boat is used.
AWARNING
The following advantages and disad-
vantages of an Emergency Stop Switch
(lanyard type) should be considered
before electing to use, or not to use,
such a switch.
ADVANTAGES: The purpose of an
Emergency Stop Switch is to stop the
engine when the operator leaves the
control station, either accidentally by
falling into the boat, or by falling or
being ejected overboard. This is most
likely in certain types of boats such as
low-sided bass boats and high-per-
formance boats. It is also likely as a
result of poor operating practices such
as sitting on the back of the seat at
planing speeds, standing at planing
speeds, operating at high speeds in
shallow or obstacle-infested waters,
drinking and driving, or daring, high-
speed boat maneuvers.
DISADVANTAGES: Inadvertentactiva-
tion of the switch is also a possibility.
This could cause any or all of the follow-
ing potentially hazardous situations:
• Lossof balance and falling forward of
unstable boat passengers - a particular
concern in bow rider type boats.
• Lossof power and directional control
in heavy seas, strong current or high
winds.
• Loss of control when docking.
3•

WATER WISDOM
OPERATION AND MAINTENANCE
As we cannot possibly know of and
advise the boating public of all conceiv-
able boat! power package types and / or
poor operating practices, the final deci-
sion of whether or not to use an
Emergency Stop Switch rests with you,
the owner/driver.
We strongly recommend that other occu-
pants be instructed on proper starting
and operating procedures so they will
be prepared should they be required to
operate the power package and boat in
an emergency.
AWARNING
It is difficult for persons standing or
floating in the water to move clear if
they see a powerboat heading toward
them, even at slow speed. Shift the unit
to neutral and shut off engine when
your boat is near people in the water.
Serious injury is likely if a person in the
water is struck by a moving boat, gear
housing, propeller, or accessory rigidly
attached to your boat or motor.
AWARNING
The use of accessories not manufactured
or sold by Mercury Marine is not recom-
mended for use with your MerCruiser
unit. If your MerCruiser unit is equipped
with an accessory not manufactured by
Mercury Marine, be sure to read the
Operation and Maintenance Manual for
that accessory before operation. If you
haven't been supplied with such a man-
ual. contact your dealer or the manu-
facturer of the accessory to secure the
applicable manual. .
It is the operator's responsibility to per-
form all safety checks; to ensure that all
lubrication and maintenance instructions
are complied with for safe operation; and
to return the unit to an Authorized
MerCruiser Dealerfor a periodic checkup.
Normal maintenance service and replace-
ment parts are the responsibility of the
owner / operator and as such, are not
considered defects in workmanship or
material within the terms of the warranty.
Individual operating habits and usage
contribute to the need for maintenance
service.
Proper maintenance and care of your
power package will ensure optimum per-
formance, and will keep your overall oper-
ating expenses at a minimum. See your
Authorized MerCruiser Dealer for service
aids.
BOATING SAFETY AND SEAMANSHIP
• Do not overload! Know your boat's
operating and loading limitations.
• Check safety equipment on board.
addition, here are suggestions of safety
equipment to carry when boating:
• Approved life jackets for each person
on board.
Boating safety and seamanship Courses
are periodically offered by the following
national, state and provincial organiza-
tions:
• Coast Guard Auxiliary.
• Power Squadrons.
• Red Cross.
• State or provincial agencies, charged
with water safety enforcement.
In the United States:
To help locate the course nearest you,
contact Boat/U.S. Foundation's toll-free
4
national boating safety education hotline
at 1-800-336-BOA T.
You should also review the NMMA
Sources of Waterway Information booklet.
It lists regional Sources of safety, cruising
and local navigation and is available at no
charge by writing to:
Sources of Waterway Information
National Marine Manufacturers
Association
410 N. Michigan Avenue
Chicago, Il 60611 U.S.A.
We strongly recommend that all power-
boat operators attend one of these
Courses.
MerCrUiser V6/V8
• Know your boating area and avoid
hazardous locations.
• Know signs of weather change and
avoid foul weather and rough-sea
boating.
• Tell someone where you are going and
when you expect to return.
• Know boating's "Rules of the Road"
(signals and navigation).
• Be on the alert! Watch "the other
guy", the water and your wake.
• Do not drink alcoholic beverages and
drive a boat. Some state laws apply to
boats as well as motor vehicles.
In order to safely enjoy the waterways,
there are a few precautions that should
be observed. Check with authorities in
regard to local and other governmental
boating regulations and restrictions. In
MerCruiser V6/V8
• Approved throwable personal flotation
device.
• Approved fire extinguisher(s); paddle or
oar.
• Signal devices: flashlight, rockets or
flares, flag and whistle or horn.
• Spare propeller.
• Tools for necessary minor repairs; first
aid kit and book.
• Anchor and extra anchor line; water-
proof storage containers.
• Manual bilge pump and extra drain
plugs; compass and map or chart of area.
• Spare operating equipment; batteries,
bulbs, fuses, etc.
• Transistor radio; drinking water.
5-

HIGH-PERFORMANCE
BOAT OPERATION CONDITIONS AFFECTING
OPERATION
(Continued)
CONDITIONS AFFECTING
OPERATION
If this product is to be used on a high-
speed, high-performance boat applica-
tion, we urge you to request an initial
orientation and familiarization demon-
stration ride with your dealer and, to
WEIGHT DISTRIBUTION
Positioning of weight (passengers and
gear) inside the boat has the following
effects:
A. Shifting weight to rear (stern).
• Generally increases speed and engine
RPM.
• At extremes. can cause boat to por-
poise.
• Causes bowtobounce in choppy water.
• Increases danger of following wave
splashing into boat when coming off
plane.
B. Shifting weight to front (bow).
• Improves ease of planing.
• Improves rough water ride.
• At extremes, can cause boat to veer
back and forth (bow steer).
BOTTOM OF BOAT
To maintain maximum speed, the fol-
lowing conditions of the boat bottom
should be observed.
obtain a copy of "Hi-Performance Boat
Operation" booklet, Part No. 90-86168.
This booklet is available for a nominal fee
from your Authorized MerCruiser Dealer
or Mercury Marine.
A. Clean, free of barnacles and marine
growth.
B. Free of distortion; nearly flat where it
contacts the water.
C. Straight and smooth, fore and aft.
Marine vegetation may accumulate when
boat is docked. This growth must be
removed before operation; it may clog
water inlets and cause engine to overheat.
CAVITATION
Cavitation occurs when water flow cannot
follow the contour of a fast-moving
underwater object. such as a gear housing
or propeller. Cavitation permits the pro-
peller to speed up, but the boat speed to
reduce. Cavitation can seriously erode
the surface of the gear housing or
propeller. Common causes of cavitation
are:
A. Weeds or other debris snagged on
propeller or gear housing.
B. Bent propeller blade or damaged gear
housing skeg.
C. Raised burrs or sharp edges on pro-
peller or gear housing.
VENTILATION
Ventilation is caused by surface air or
exhaust gases which are introduced
around the propeller resulting in propeller
speedUp and a reduction in boat speed.
Excessive ventilation is annoying and
usually caused by:
A. Drive unit trimmed out too far.
B. A missing propeller diffuser ring.
C. A damaged propeller or gear housing,
which allows exhaust gases to escape
between propeller and gear housing.
D. Drive unit installed too high on
transom.
PROPELLER SELECTION
Select a propeller that will allow the
power package to operate at or near the
top of the recommended full throttle RPM
range with a normal load. Maximum
engine speed (RPM) for propeller selec-
tion exists when boat speed is maximum
and trim is minimum for the speed. (High
RPM. caused by an excessive trim angle,
should not be used in determining correct
propeller.) Normally. there is a 300 to 500
RPM change between propeller pitches.
Full throttle RPM range is listed in SPECI-
FICATIONS.
If full throttle operation is below the
recommended range shown in SPECIFI-
CATIONS. the propeller must be changed
to prevent loss of performance and pos-
sible engine damage.
After initial propeller installation, the fol-
lowing common problems may require
that the propeller be changed to a lower
pitch:
• Warmer weather and greater humidity
cause an RPM loss.
• Operating in a higher elevation causes
an RPM loss.
• Operating with a damaged propeller or
dirty boat bottom or gear housing causes
an RPM loss.
• Operating with an increased load (ad-
ditional passengers, pulling skiers, etc.).
For better acceleration, such as is needed
for water skiing, use next lower pitch
propeller; however, do not operate at full
throttle when using ski propeller but not
pulling skiers.
Propellers are available for specific boat-
ing requirements. Consult your Author-
ized MerCruiser Dealer for recommenda-
tions.
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\ 6 Me,Ccu',e,V6/V8 MecCcu',e,V61V8 7
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OPERATION
8
10
9
MerCruiser V6/V8
INSTRUMENTATION
The following is a brief explanation of
instrumentation typically found on some
boats. The owner/operator should be
familiar with all instruments and their func-
tions on the boat.
1Speedometer - ind.icates boat speed.
2Tachometer - indicates engine RPM.
3Oil Pressure Gauge - indicates engine
oil pressure.
4Battery Meter - indicates battery volt-
age.
SWater Temperature Gauge - indicates
engine operating temperature.
6Fuel Gauge - indicates fuel tank volume.
7Power Trim Gauge - indicates drive
unit angle (trim up/out and down/in).
8Hour Meter - records engine running
time.
MerCruiser V6/V8
9Bilge Blower Switch - must be operated
for five minutes to ventilate bilge.
10 Ignition Switch - allows operator to
start and stop engine.
MODELS WITH
AUDIO WARNING SYSTEM
Warning buzzer will sound if: (1) cooling
system water temperature rises too high or,
(2) engine oil pressure gets too low. If
buzzer sounds, stop engine immediately. If
cause for warning buzzer sounding cannot
be found, consult your MerCruiser Dealer.
IMPORTANT: Warning buzzer also will
sound ifignition key isturned to RUN posi-
tion and engine isnot started within 7 to 14
seconds. This allows operator tofrequently
test the operation of the audio warning sys-
tem. It is recommended that warning sys-
tem be tested at least once every 5 hours of
operation.
9
el - - - - - - - -

OPERATION
(Continued)
10
1
5
MerCruiser V6/V8
REMOTE CONTROLS
Your boat may be equipped with one of
many Quicksilver® remote controls avail-
able. All controls feature an integral safety
switch that allows starting engine in
NEUTRAL only. Also, all controls may not
have all features shown. If boat is equip-
ped with a remote control other than
shown, consult your dealer for a descrip-
tion andl or demonstration of the control.
1Neutral Lock Bar - must be squeezed
before control handle can be moved from
NEUTRAL
2Control Handle - controls both shift
and throttle. First 45° of movement is for
shifting.
3THROTTLE ONLY Button - allows
engine throttle advancement without
shifting gears to assist engine starting.
4FRICTION Screw - adjusts control
handle friction so motor speed can be set
and driver does not have to hold handle.
MerCruiser V6/V8
Turn screw clockwise to increase friction.
Do not thread screw all the way out.
5DETENT Screw - controls the effort
needed to move control handle out of
NEUTRAL. To increase tension, turn screw
clockwise; the decrease, turn screw coun-
terclockwise. Do not thread screw all the
way out.
6Shift Lever - shifts unit into gear with
full lever movement. Move lever forward
to shift to FORWARD gear. Move lever
backward to shift to REVERSE gear. Lever
in full vertical position shifts to NEUTRAL.
ACAUTION
Never shift unit into or out of gear
unless throttle lever is at idle RPM.
7Throttle Lever - allows engine RPM to
be increased or decreased.
IMPORTANT: Boatsequipped with dual
power packages may have both shift
levers on one control and both throttle
levers on the other control.
11

28 If equipped with Trailer Only button,
press until drive unit reaches desired
position.
2A If equipped with three-button con-
trol panel, simultaneously press center
and UP buttons until drive unit reaches
desired height.
2Trailer Position - Press button until
drive unit reaches desired height.
Power Trim Operation
IMPORTANT: If TRAILER button(sl are
held depressed after drive unit reaches
end of upward travel, an internal circuit
breaker will open and pump will stop.
Should this happen, release button(sl
and allow motor to cool for about one
minute. Circuit breaker will reset and
Power Trim operation may be resumed.
4Trim Up/Out - Press UP on Trim switch
until drive unit reaches desired trim
position.
4A Ifequipped with three-button control
panel, press center UP/OUT button until
drive unit reaches desired trim position.
48 If equipped with Trim switch in top of
control handle, mo\(e switch forward (UP)
until drive unit reac'hes desired trim
position.
38 If equipped with Trim switch in top of
control handle, move switch back (DOWN)
until drive unit reaches desired position.
3Lower Drive Unit - Press DOWN on
Trim switch until drive unit reaches
desired position.
3A If equipped with three-button con-
trol panel, press IN button until drive unit
reaches desired position.
• In most cases, reduce boat speed.
OPERATION
(Continued)
POWER TRIM
• Cause boat to accelerate and plane off
slower.
• In excess, cause porpoising and/or
propeller ventilation.
1In most cases, best overall per-
formance is obtained with drive unit
adjusted so boat will run at a 3° to 5°
angle to water.
• Lift bow of boat.
The Power Trim ™system alIows operator
to raise and lower drive unit for trailering,
beaching, launching and shallow water
operation. Power Trim also allows oper-
ator to adjust drive unit angle, while
underway, to provide ideal boat angle for
varying load and water conditions.
Trimming Drive Unit Up/Out Will:
• Generally increase top speed.
• Increase clearance over submerged
objects.
• Generally improve ride in choppy
Water.
• Cause overheating if trimmed up/out
beyond gimbal ring support flanges.
ACAUTION
Never trim drive unit up/out using
TRAILER switch while boat is underway.
Use extreme caution when operating with
drive unit raised. Severe damage to drive
unit may result if unit is raised beyond the
gimbal ring support flanges at engine
speeds above 1200 RPM.
Trimming Drive Unit Down/In Will:
• Help boat accelerate and plane off
quicker.
3A
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12 MerCruiser V6/V8 MerCruiser V6/V8 13
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OPERATION
(Continued) OPERATION
(Continued)
STARTING, SHIFTING AND STOP-
PING
AWARNING
Before starting engine, operate bilge
blower for at least five minutes to
remove any explosive fumes from
engine compartment. If boat is not
equipped with a bilge blower. open
. engine hatch and leave open while
starting engine.
IMPORTANT: Observe the following:
• Do not start engine without water
being supplied to seawater pickup pump
(to prevent pump or engine damage).
• Do not operate starter motor contin-
uously for more than 30 seconds.
• When engine starts, quickly reduce
throttle setting to avoid exceeding 1500
RPM.
• Never shift drive unit unless engine is
at idle RPM.
A. Check all items listed in OPERATION
CHART.
B. Perform any other necessary checks,
as indicated by your dealer, or specified in
your boat owner's manual.
C. Place drive unit in full down/in posi-
tion.
D. Place control handle in NEUTRAL
E. Position throttle setting as follows:
COLD ENGINE - Move control/throttle
lever to full throttle, then return to about
1/4 throttle. In extreme cold it may be
necessary to pump lever more than once.
WARM ENGINE - Move control/throttle
lever to 1/4 throttle position.
FLOODED ENGINE - Move control/throttle
lever to full throttle. Be prepared to
decrease engine speed to 1000-1500
RPM as Soon as engine starts.
F. Turn ignition key to START. Release
key when engine starts and allow switch
to return to RUN position. Move controll
throttle lever back to decrease engine
RPM to 1000-1500 RPM if necessary.
G. Check oil pressure gauge immediately
after engine starts. If oil pressure is n01
within specified range (see SPECIFICA-
TIONS), stop engine immediately and
determine cause.
H. If engine is cold, run engine for 1or 2
minutes at fast idle (1000-1500 RPM).
I. After engine has warmed up, check
water temperature gauge to ensure that
engine temperature is not abnormally
high. If it is, stop engine immediately and
determine cause.
J. Be sure charging system is functioning
correctly.
K. Observe power package for fuel, oil,
water and exhaust leaks.
L. To shift drive unit, return controll
throttle lever to NEUTRAL. Move controll
shift lever with a firm, quick motion
forward to shift to FORWARD gear, or
backward to shift to REVERSE. After
shifting drive unit, advance throttle to
desired setting.
M. Move control/shift lever to NEUTRAL
and allow engine to drop to IDLE speed. If
engine has been run at high speed for a
long period of time, allow engine to cool
by running at IDLE speed for 3 to 5
minutes.
N. Turn ignition key to OFF.
OPERATION CHART
BEFORE AFTER
WHILE
AFTER
STARTING STARTING
UNDERWAY
STOPPING
Open engine
Observe all gauges
Observe all gaugesTurn ignition
hatch. to check condition
to monitor engine
key OFF.
of engine. If not condition. normal, stop engine .
Turn battery
Check for fuel, oil, Turn battery
switch ON. if water. fluid and switch OFF. if
so equipped. exhaust leaks. etc. so equipped.
Operate bilge
Check shift and Close fuel valve.
blowers, if so throttle control
equipped. operation.
Open fuel shut-
Check steering Close seacock, if
off valve. operation so equipped.
Open seacock, if
Flush cooling
so equipped. system if in salt-
water area.
Place drive unit in full downlin
position.
Perform all other
checks specified by
your dealer and/ or
boat builder.
14
[1111111 .. Me,C,""., V6IVB _Me'C,"',e, V6IVB
15

ADDITIONAL INFORMATION ADDITIONAL INFORMATION
(Continued)
SPECIFICATIONS
Use extreme caution when operating in
• Cooling System - Inspect all hoses f shallow water or where underwater ob-
damage and deterioration; check all ho~ jects are known to be pre~~nt. Use
clamps for adequate tightness. extreme care to prevent stnklng sub-
merged objects while operating in RE-
VERSE. No impact protection is provided
in REVERSE.
17
• Before recovery. contact an Authorized
MerCruiser Dealer.
• After recovery, immediate service by
an Authorized MerCruiser Dealer is
required to prevent serious damage to
power package.
ATTENTION REQUIRED AFTER SUB-
MERSION
Boat can be trailered with drive unit in up
or down position. Adequate road clearance
is required between road and gear housing
skeg when trailering with drive unit in
down position.
TRAllERING BOAT
If adequate road clearance is a problem.
place drive unit in full trailer position and
support with an optional trailer kit which
is available from your Authorized Mer-
Cruiser Dealer.
• Starting and operating difficulties.
• Fuel permeation through flexible fuel
lines.
• Wear and damage of internal engine
parts.
The adverse effects of alcohol are more
severe with methyl alcohol (methanol)
and are worse with increasing alcohol
content.
Some of these adverse effects are due to
the tendency of gasolines containing
alcohol to absorb moisture from the air,
resulting in a phase of water and alcohol
separating from the gasoline in the fuel
tank.
MerCruiser V6/V8
If drive unit should strike a submerged
object, stop engine as soon as possible
and inspect drive unit for damage. If
damage is present or suspected, boat
should be taken to an Authorized Mer-
Cruiser Dealer for thorough inspection
and necessary repair. Operating a
damaged drive unit could cause additional
damage to other parts of drive unit, or
could affect control of boat. If continued
running is necessary, do so at greatly
reduced speeds.
IMPORTANT: Impact protection system
cannot be designed to ensure total pro-
tection from impact damage under all
conditions.
FUEL REQUIREMENTS
IMPORTANT: Use of improper gasoline
can cause severe engine damage. Engine
damage resulting from use of improper
gasoline is considered misuse of engine,
and damage caused thereby will not be
covered under the limited warranty.
The use of any good grade leaded regular,
unleaded regular or premium gasolines
with a minimum posted octane rating of
86 (research octane number 90), are satis-
factory for use in your engine. (High-
performance models are exceptions.) How-
ever, gasolines containing alcohol, either
methyl alcohol (methanol) or ethyl alcohol
(ethanol) may cause increased:
• Corrosion of metal parts.
• Deterioration of elastomer and plastic
parts.
• Check all fluid levels.
• Check carburetor adjustment.
• Inspect ignition system and timing.
• Check for loose, missing or damagel
parts.
• Check shift and throttle cable adjust
ments - lubricate and inspect for loose
damaged or missing parts.
• Steering System - Lubricate and in
spect for loose, damaged or missing parts
• Inspect all drive belts.
• Check engine alignment.
• Complete Engine Exhaust System .
Inspect for damage and deterioration;
check all hose clamps for adequate
tightness.
FREEZING TEMPERATURE OPERA-
TION
IMPORTANT: If boat is operated during
periods of freezing temperature. pre.
cautions must be taken to prevent
freezing damage to power package.
Refer to OUT OF SEASON STORAGE
for draining instructions.
DRIVE UNIT IMPACT PROTECTION
The Power Trim hydraulic system is
designed to provide impact protection for
drive unit. If a submerged object is struck
while boat is moving forward, the hy-
draulic system will cushion kickup of
drive unit as it clears the object, reducing
damage to unit. After drive unit has
cleared object, the hydraulic system
allows drive unit to return to original
operating position, preventing loss of
steering control and engine overspeed.
MerCruiser V6/V8
20-HOUR BREAK-IN PERIOD
IMPORTANT: The first 20 hours of
operation is the engine break-in period.
Correct break-in is essential to obtain
minimum oil consumption and maxi-
mum engine performance. During this
break-in period. the following rules
must be observed:
• Do not operate below 1500 RPM for
extended periods of time for first 10
hours. Shift into gear as soon as possible
after starting and advance throttle above
1500 RPM if conditions permit safe
operation.
• Do not operate at one speed con-
sistently for extended periods.
• Do not exceed 3/4 throttle during first
10 hours. During next 10 hours. occasional
operation at full throttle is permissible (5
minutes at a time maximum).
• Avoid full throttle acceleration from
IDLE speed.
• Do not operate at full throttle until
engine reaches normal operating temper-
ature.
• Frequently check crankcase oil level.
Add oil if needed. It is normal for oil
consumption to be high during break-in
period.
• After 20-hour break-in period, drain
crankcase oil and replace oil filter (see
MAINTENANCE). Fill crankcase with cor-
rect oil (see SPECIFICATIONS).
20-HOUR CHECKUP
After first 20 hours of operation, an
Authorized MerCruiser Dealer should be
contacted for the fOllowing maintenance.
The boat owner is responsible for any
charges.
• Change crankcase oil and filter.
16

Quicksilver 4-Cycle Marine Engine Oil
SPECIFICATIONS
(Continued)
150 psi
(1035 kPa)
4200-
4600 RPM
180 psi
(1241 kPa)
4400-
4800 RPM
350
MAGNUM
270
201
350 C.I.D.
(5.7L)
V8
4.00 In.
(101.6mm)
3.48 In.
(88.39 mm)
9.3:1
150 psi (1035 kPa)
4200-4600 RPM
650-700 RPM
3-7 psi (21-48 kPa)
30-55 psi
(207-379 kPa)
650-700 RPM
3-7 psi (21·48 kPa)
30-55 psi (207-379 kPa)
4 psi (28 kPa)
143°F (62°C)
260
194
5.7
4.3 4.3LX5.0LX
175
205230
131
153170
262 C.I.D.
262 C.I.D.305 C.I.D.
(4.3L) (4.3L)
(5L)
V6
V6V8
180 psi
(1241 kPa)
4400-
4800 RPM
4.00 In. 3.74 In.
(101.6 mm) (94.99 mm)
3.48 In. (88.39 mm)
9.3:1
ENGINE
MODEl
MODEl
SPECIFICATIONS
(Continued)
Horsepower'
Kilowatts'
Maximum RPM @W.O.T.
Compression Ratio
Compression Pressure
1At Flywheel
Thermostat
Displacement
Stroke
Idle RPM in Forward Gear
Fuel Pump Pressure
Oil Pressure @2000 RPM
Min. Oil Pressure @Idle
Engine Type
Bore
Horsepower'
Kilowatts'
Stroke
Compression Ratio
Compression Pressure
Maximum RPM @W.O.T.
Idle RPM in Forward Gear
Fuel Pump Pressure
Oil Pressure @2000 RPM
Engine Type
Bore
Displacement
sumed before they can absorb enoug
moisture to cause trouble, but boat
often sit idle long enough for phas
separation to take place. In additior
internal corrosion may take place duriol
storage if alcohol has washed protectiv:
oil films from internal components.
CRANKCASE Oil
To help obtain optimum engine per
formance andtoprovidemaximum protec
tion, we strongly recommend the use a
Quicksilver 4-Cycle Marine Engine Oil. I
not available, a good grade, straigh
weight, detergent automotive oil of Cor
rect viscosity, with anAPIclassification 0
SF, may be used.
The chart below isaguide to crankcase oil
selection. Oil filter should always be
changed with oil.
In those areas where recommended
straight weight oil is not available, a
multi-viscosity 20W-40 (SF) or, as a
second but less preferable choice, 20W.
50 (SF)may be used.
IMPORTANT: Theuse of non-detergent
oils, multi-viscosity oils (other than
20W-40 or 20W-50). low quality oils or
oils which contain solid additives speci-
fically are not recommended.
AWARNING
FIRE AND EXPLOSION HAZARD: Fuel
leakage from any part of fuel system
can beafire and explosion hazard which
can cause serious bodily injury or death.
Careful periodic inspection of entire
fuel system is mandatory, particularly
after storage. All fuel components in-
cluding fuel tanks, whether plastic,
metal or fiberglass, fuel lines, primer
bulbs, fittings, fuel filters and carbur-
etors should be inspected for leakage,
softening, hardening, swelling or cor-
rosion. Any sign of leakage or deterior-
ation requires replacement before
further engine operation.
Because of possible adverse effects of
alcohol ingasoline,it isrecommendedthat
only alcohol-free gasoline be used where
possible. If only fuel containing alcohol is
available, or if the presence of alcohol is
unknown, increased inspection frequency
for leaksand abnormalities is required.
IMPORTANT: When operating a Mer-
Cruiser engine on gasoline containing
alcohol. storage of gasoline in the fuel
tank for long periods should beavoided.
long periods of storage, common to
boats, create unique problems. In cars,
alcohol-blend fuels normally are con-
18
32<>F 50'OF
DOe 100e
AMBIENT TEMPERATURE
MerCrUiser V6/V8
Min. Oil Pressure @Idle
Thermostat
1At Flywheel
MerCruiser V6/V8
4 psi (28 kPa)
143° F (620 C)

SPECIFICATIONS
(Continued) SPECIFICATIONS
(Continued)
TUNE-UP CAPACITIES
12-volt Negative (-) Ground
55 Amps
Minimum IMinimum IMinimum
400 Amps - 400 Amps - 305 Amps _
Cold Cranking Cold Cranking Cold Cranking
Amperage Amperage Amperage
Drive Unit Oil
Capacity
Seawater Cooling
System2
Closed Cooling System I20 U.S. Qts. (19.3 L)
'Always use dipstick to determine exact quantity of oil required.
2Seawater Cooling System capacity information is for winterization use only.
5.0LX
Approx.
5.5 U.S.
Quarts
(5.2L)
4.3LX
Approx.
4.5 U.S.
Quarts
(4.28L)
15 U.S. Qts. (14.1 L)
Approximately 32 fl. oz. (946ml)
4.3
Approx.
4.5 U.S.
Quarts
(4.28L)
Crankcase Oil Capacity
w/New Filter'
MODEL
350
MAGNUM
5.0LX
AC-MR44T
or Champion
RV8C
B
4.3LX
AC-MR43T
or Champion
RV8C
5.7
4.3
AC-MR43T
or Champion
RV8C
A
MODEL
Spark Plug Gap
Timing @Idle RPM
MODEL
Firing Order
Spark Plug Type
Electrical System
Alternator Rating
Recommended
Battery
Rating
Closed Cooling I20 U.S. Qts. (19.3 L)
System
'Always use dipstick to determine exact quantity of oil required.
2Seawater Cooling System capacity information is for winterization use only.
Approximately 32 fl. oz. (946ml)
350
MAGNUM
Approx. 5.5 U.S.
Quarts (5.2L)
15 U.S. Qts. (14.1 L)
5.7MODEL
Crankcase Oil
Capacity w/New
Filter'
Drive Unit Oil
Capacity
Seawater Cooling
System2
AC-MR43T or Champion RV8C
.035 In. (.9 mm)
80 BTDC
B
Firing Order
1-8-4-3-6-5-7-2
B
L.H. ROTATION
FRONT
12-Volt Negative (-) Ground
55 Amps
Minimum 350 Amps -
Cold Cranking Amperage
Firing Order
1-6-5-4-3-2
Spark Plug Type
Spark Plug Gap
Timing @Idle RPM
Firing Order
Electrical System
Alternator Rating
Recommended
Battery Rating
A
L.H. ROTATION
FRONT
20 MerCrulser V6/V8 l'vlerCruiser V6/V8 21

MAINTENANCE
9
2 3
11
8
GASOLINE
5
10
5
~ WARNING
.Iways disconnect battery cables from
attery before working around electrical
ystem components to prevent injury to
ourself or damage to electrical system.
MPORTANT: Referto MAINTENANCE
:HART for complete listing of all
cheduled maintenance to beperformed.
;ome listings can bedone by owner / op-
,rator. while others should beperformed
IY an Authorized MerCruiser Dealer.
~eforeattempting maintenance or repair
Jrocedures not covered in this manual.
t is recommended that a MerCruiser
:;erviceManual(s) bepurchased andread
:horoughly.
MAINTENANCE AIDS
1Power Steering System - Quicksilver
Power Trim and Steering Fluid, or Dexron
II Automatic transmission fluid (ATF).
2All Pivot Points - SAE 30W motor oil.
3Fogging (Winterizing) Engine - Quick-
silver Storage Seal or SAE 20W motor oil.
4Exposed Portion of Steering Cable and
Propeller Shaft - Quicksilver Special
Lubricant 101.
5Stern Drive Unit - Quicksilver Gear
Lube.
6All Grease Fittings, Universal Joints,
Engine Coupler and Splined Universal
Joint Shaft - Quicksilver 2-4-C Marine
Lubricant.
7All Exterior Surfaces - Quicksilver
Primer and Spray Paint and Quicksilver
Corrosion Guard.
8Power Trim System - Quicksilver Power
Trim and Steering Fluid, or SAE lOW-3D
motor oil.
9Crankcase Oil - Quicksilver 4-Cycle
Marine Engine Oil. (Refer to SPECIFICA-
TIONS for alternatives and oil recommen-
dations for varying ambient temperatures.)
10 Closed Cooling System Coolant -
50/50 mixture of ethylene glycol anti-
freeze (must meet GM specification
1825 M) and tap water. Areas where tem-
peratures generally do not go below 32° F
(0° C). rust inhibitor and tap water is
acceptable.
11 Gasoline Stabilizer - Quicksilver
Mari ne Fuel System Treatment and Stabi-
lizer.
12 Grease Fittings on Drive Shaft Ex-
tension Models -Quicksilver 2-4-C Marine
Lubricant.
22 MerCruiser V6/V8 MerCruiser V6/V8 23

MAINTENANCE
I(Continued)
MAINTENANCE CHART
Only perform maintenance which applies to your particular power package.
c-
INTERVAL
TASK
• = To Be Performed by Owner
Every 50
Every 100
At Least
• =
To Be Performed by an Authorized MerCruiser Dealer Hours or
Hours or
Once a
F=
Freshwater Areas Only
Weekly
60 Days120 Days
Year
S=
Saltwater Areas Only Location and Service
Fuel Pump Sight Tube - •
Check for fuel
TASK INTERVAL
Cooling System Hoses
Every 50 Every 100
At Least
and Clamps - Inspect for •
Hours or Hours orOnce a
damage and deterioration. S.
F.
Location and Service Weekly
60 Days
120 Days
Year
Check clamps for tightness
Engine Crankcase Oil _ •Engine Exhaust System-
Check level Inspect for damage, deter-
ioration and restrictions. S•
F.
•
Closed Cooling Coolant _ •Check clamps for tightness
Check level
Ignition System - Check Drive Belts (All) -
•
timing; adjust if needed •
Inspect condition and •
check tension
Crankcase Oil and Oil •
•
Ignition System - Clean •
•
Filter - Change
and inspect condition
Power Steering Fluid _ •Flame Arrestor and
Check level
Crankcase Ventilation Hose -
•
•
Stern Drive Unit Oil _ •Clean and inspect
Check level
Continuity Circuit - Check
Steering System - Lubricate components for loose
and inspect for loose, connections, broken or
S.
F.
•
damaged or missing parts S.
F••frayed wires
Battery - Check level and •Shift and Throttle Cable and
inspect for damage Linkage - Lubricate and
Electrical System (Entire) _ inspect for loose, damaged
S.
F.
•
Check for loose or or missing parts
damaged wiring S.
F••
Power Trim Pump Oil - •
ICheck level
25
24
MerCruiser V6/V8
MerCruiser V6/V8
II J•
... --- -
i[ ~MAINTENANCE

TASK INTERVAL INTERVAL
TASK
Every 50 Every 100At leastl Every 50
Every 100
At least
Hours or Hours orOnce aHours or
Hours orOnce a
location and Service
Weekly
60 Days120 Days
Year Weekly
60 Days120 Days
Year
location and Service
Stern Drive Unit Oil _ •
Change •
•
Heat Exchanger - Clean
Propeller Shaft _ seawater sectionLubricate s.
F•
•
Cooling System - Flush S.AFTER USE EACH DAY
Transom Gimbal Housing seawater section
Assembly Swivel Shaft and Power Package Exterior
F·
•
Pin, Hinge Pins and Gimbal
Surfaces - Spray with rust
S·
Bearing Lubricate S.F••
preventive
Engine Coupling, Stern Closed Cooling Coolant - • EVERY 2 YEARS
Drive Unit Universal Joint
Replace
Shaft Splines and Cross •
Zinc Alloy Trim Tab,
Bearings - Lubricate •
Anodic Heads, Anodic
Drive Shaft Extension Plate and Quicksilver
Models Only - Lubricate S.
F.•
Anti-Corrosion Anode Kit
Engine Alignment - Check •
•
(Optional) - Inspect for •
erosion
Fuel Filters - Replace •
Gear Housing WaterPower Package Exterior Pickups* - Check for
•
Surfaces - Clean and paint •
marine growth or debris •
Steering Head and Remote Carburetor - Adjust
. f . e cooling is in the thru-hull
Control - Inspect and
I *Closed Cooled Models - a second water pickup or engm
lubricate •
Ifitting.
Quicksilver MerCathode® System - Test output •
,
Closed Cooling Coolant _
Test for alkalinity •
MAINTENANCE
(Continued)
MAINTENANCE CHART
(Continued)
III
I '
, I
I
26 MerCruiser V6/V8 MerCruiser V6/V8
I1111II1I1111 __ ---
MAINTENANCE
(Continued)
MAINTENANCE CHART
(Continued)
27

MAINTENANCE
(Continued)
29
A 20 amp in-line fuse is in wire connected
to positive (+) terminal on controller. If fuse
is blown, system will not operate.
MODELS WITH
MERCATHODE SYSTEM
4Quicksilver Three-Button Power Trim
Control Panel is further protected by a 20
amp in-line fuse.
2A 20 amp fuse may be located in
ignition switch "I" terminal lead to protect
electrical system. Check for blown fuse if
key is turned to START and nothing
happens (and circuit breaker is not
tripped).
3The Power Trim System is protected
from overload by 110 amp fuse and a 20
amp in-line fuse on Power Trim pump.
Reset circuit breaker. If breaker remains
open, electrical overload has not been
eliminated. Further checks mustbe made
on electrical system.
In an emergency, when engine must be
operated and cause for high current draw
cannot be located and corrected, turn OFF
or disconnect all accessories connected
to engine and instrumentation wiring.
OVERLOAD PROTECTION
ELECTRICAL SYSTEM
If an electrical overload occurs, a fuse will
blow or the circuit breaker will trip open.
The cause must be found and corrected
before replacing fuse or resetting circuit
breaker.
MerCruiser V6/V8
1A circuit breaker provides protection
for engine wiring harness and instrumen-
tation power lead. Reset by pushing RESET
button IN.
MerCruiser VS/V8
1.
28
II
!III
I
1111"",
I"
1'1
III,
I
1111111
"I
I1III

MAINTENANCE
(Continued)
!~II"
III
II
lilli,"
1
8
7
30
2
6
""
~'::
@)i 0f-I~-*
~I
MerCruiser V6/V8
CHECKING FLUID LEVELS
Crankcase Oil
Stop engine. Allow approximately five
minutes for oil to drain into oil pan. Boat
must be at rest in water.
1Remove dipstick. Wipe clean and re-
install fully into dipstick tube.
2Remove dipstick and observe oil level.
Oil level must be between FULL and ADD.
If oil level is below ADD:
3Remove oil filler cap. Add specified oil
(refer to page 18) to bring level up to, but
not over, FULL mark on dipstick.
IMPORTANT: Do not overfill crank-
case oil.
Drive Unit Oil
4Remove OIL VENT screw and sealing
washer from drive shaft housing. Oil
should come up to OIL VENT hole. If oil
level is low, fill drive unit through OIL
VENT hole until correct level is reached.
Reinstall sealing washer and OIL VENT
screw. Tighten securely.
IMPORTANT: If more than 2 fl. oz. (Sgml)
of Quicksilver Gear Lube is required to fill
drive unit, a seal may be leaking. Contact
your Authorized MerCruiser Dealer for ser-
vice. Damage to unit may occur due to lack
of lubrication.
Power Trim Pump
Place drive unit in full down/in position.
MerCruiser V6/V8
•••
5Remove fill cap from reservoir, check
that "caplug" is removed from filler neck,
and observe oil level. Level must be up to,
but not over bottom of filler neck. Add
Quicksilver Power Trim and Steering Fluid
or SAE 10W-30 motor oil, if required, to
bring level to bottom offiller neck. Replace
cap. (SA) The fill cap is vented, frequently
check that vent hole is open and unre-
stricted.
Power Steering Pump
Stop engine and position drive unit straight
back.
6Remove FILLCAP/DIPSTICK and
observe level. Add specified fluid if re-
quired. Reinstall FILLCAP/DIPSTICK.
IMPORTANT: If fluid is not visible in
pump, contact your Authorized Mer-
Cruiser Dealer.
Engine Coolant - Closed Cooled Models
Only
AWARNING
Do not remove coolant cap when engine
is hot. Coolant may discharge violently.
7Check coolant level in coolant recovery
bottle. Add specified coolant as required.
8Periodically remove cap from coolant
reservoir to ensure that coolant recovery
system is functioning properly. Coolant
level must be at top of reservoir filler
neck. If coolant is low, inspect gasket in
cap for damage and replace if necessary.
To have cap tested, contact your
Authorized MerCruiser Dealer. Inspect
coolant recovery system for leaks.
31

Drive Unit and Transom Assembly
8For propeller shaft lubrication, see
PROPELLER.
Shift Cable
6Lubricate pivot points with SAE 30W
motor oil.
NOTE: Engine coupling, universal joints
and shaft splines are greased with Quick-
silver 2-4-C Marine Lubricant. Contact
your Authorized MerCruiser Dealer for
this service.
Drive Shaft Extension Models Only
9Lubricate drive shaft grease fittings, at
transom end, with 2-4-C Marine Lubricant.
Throttle Cable
5Lubricate pivot points with SAE 30W
motor oil.
7Lubricate upper and lower swivel pins,
both hinge pins, and gimbal bearing, with
2-4-C Marine Lubricant.
10 Lubricate drive shaft grease fittings,
at engine end, with 2-4-C Marine Lubri-
cant.
MAINTENANCE
(Continued)
On dual engine boats, lubricate all pivot
points, including tie bar pivot points, with
SAE 30W motor oil.
3Lubricate control valve fitting with
2-4-C Marine Lubricant.
4Lubricate steering system pivot points
with SAE 30W motor oil.
If steering cable does not have grease
fitting, inner wire of cable cannot be
greased.
2With steering cable fully extended, lub-
ricate exposed part of cable with 2-4-C
Marine Lubricant.
Steering System
AWARNING
Do not grease steering cable while
extended. Hydraulic lock could occur
and cause loss of steering control.
LUBRICATION
If Steering Cable Has Grease Fittings:
1With cable ful~y retracted into cable
housing, lubricate fitting with 2-4-C Marine
Lubricant.
3
""I
32 MerCruiser V6/V8 MerCru,ser V6/V8 33

MAINTENANCE
(Continued)
ili
I
:,[
34
'"
MerCruiser V6/V8
PROPELLER
AWARNING
Remote Contr.ol must be in NEUTRAL
and ignition key removed from switch
before removing and/or installing pro-
peller.
AWARNING
Place a block of wood between anti-
ventilation plate and propeller to protect
hands from propeller blades and to pre-
vent propeller from rotating when re-
moving propeller nut.
ACAUTION
Periodically check propeller nut fortight-
nessduring boating season. A minimum
of 551bs. ft. (75 N.m) torque is required.
Removal
1Place wood block between propeller
bladeand antiventilation plateto prevent
rotation. Straighten bent tabs on tab
washer.
2Turn propeller shaft nut counter-
clockwise to remove nut.
3Slide tab washer, spline washer, con-
tinuity washer, propeller and thrust hub
off propeller shaft.
MerCruiser V6/V8
Repair
Somedamagedpropellerscanberepaired.
See your dealer.
Installation
IMPORTANT: If reusing tab washer,
carefully inspecttabs for cracks or other
damage. Replacetab washer if condition
is questionable.
4Apply a liberal coat of one of the fol-
lowing Quicksilver lubricants to propeller
shaft:Anti-Corrosion Grease,Special Lub-
ricant 101, or 2-4-C Marine Lubricant.
5Slide thrust hub into propeller hub,
with stepped side toward propeller hub.
6Align splines and place propeller and
thrust hub on propeller shaft.
7Placecontinuity washer, splinewasher
and tab washer onto shaft.
8Install propeller nut. Tighten nut se-
curely. A minimum of 55 Ibs.ft. (75 N.m)
torque is required. Bendthree tabs on tab
washer down into grooves in spline
washer. After first use, bend the three
tabs straight, retighten propeller nut to
minimum 55 Ibs.ft. torque (75 N.m).Bend
tabs backdown intospline washer. Check
propeller at least after 20 hours of
operation. Do not operate with loose
propeller.
35
--.

Seawater section of heat exchanger
should be cleaned at least once ayear or
whenever decreased cooling efficiency is
noticed.
Closed Cooled Models
4Disconnect water inlet hose from aft
endofseawater pickuppump.Usingappro-
priate connector, connect hose between
connector and water tap. Partially open
water tap (about 1/2 maximum).
Place remote control in NEUTRAL, idle
speed position and start engine. Operate
engine at idle speed, in NEUTRAL, for
about 10minutes, oruntil dischargewater
is clear. Stop engine. Shut off water,
remove flushing connector from pump
inlet and reconnect water inlet hose.
Tighten hose clamp securely.
Cleaning Seawater Section of Heat
Exchanger - Closed Cooled Models Only
5Remove bolts securing end plates to
each endof heat exchanger. Removeend
plates, sealing washers and gaskets.
Discard sealing washers and gasketsand
clean gasket material from end plates and
heat exchanger.
Clean water passages in heat exchanger
by inserting a suitable size wire brush in-
to each passage. Use compressed air to
blow looseparticles out. Apply Quicksilver
PerfectSealto both sidesof new endplate
gaskets. Assemble new gaskets, new
sealing washers and end plates onto heat
exchanger. Install bolts and tighten
securely. Start engineand inspect cooling
system for leaks.
it.CAUTION
Do not run engine above 1500 RPM
when flushing. Suction created by sea-
water pickup pump may collapse
flushing hose, causing engine and/or
drive unit to overheat.
it.CAUTION
Watch temperature gauge on dash to
ensure that engine does not overheat.
MAINTENANCE
(Continued)
To prevent silt and/or salt buildup in
cooling system, flush with freshwater at
specified intervals.
1Install Quicksilverflushing attachment
(orequivalent) overwater intake openings
in gear housing.
2Connecthosebetweenflushing attach-
ment and water tap.
3With drive unit in normal operating
Position, partially open water tap (about
1/2 maximum). Place remote control in
NEUTRAL,idle speed position and start
engine. Operate engine at idle speed, in
NEUTRAL,for about 10 minutes, or until
diScharge water is clear. Stop engine,
shutoffwater andremoveflushing attach-
ment.
Seawater Cooled Models
If flushing cooling system with boat in
water,raisedrive unit toTRAILERposition,
install flushing attachment and lower
drive unit to full down/in position.
IFLUSHING COOLING SYSTEM
!AWARNING
I When flushing, be certain the area
" around propeller is clear, and no one is
standing nearby. To avoid possible
injury, remove propeller.
)
(
j
j~
I
f
I
-0
..c:>
3
4
'\
L0
\
--
-
.....--",.
2
1
5
36 MerCruiser V6IVa MerCruiser V6/V8 37