Mercury 540 Bravo User manual

Thank You
for your purchase of one of the finest marine power packages available. It
incorporates numerous design features to ensure operating ease and
durability.
With proper care and maintenance, you will thoroughly enjoy using this
product for many boating seasons. To ensure maximum performance and
carefree use, we ask that you thoroughly read this manual.
The Operation, Maintenance and Warranty Manual contains specific
instructions for using and maintaining your product. We suggest that this
manual remain with the product for ready reference whenever you are on
the water.
Again, thank you for purchasing one of our Mercury Marine products. We
sincerely hope your boating will be pleasant!
Warranty Message
! WARNING
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,
Maintenance and Warranty Manual and thoroughly understand the
operational instructions for the power package and all related
accessories before the boat is used.
The product you have purchased comes with a limited warranty from
Mercury Marine; the terms of the warranty are set forth in the Warranty
Information section of this manual. The warranty statement contains a
description of what is covered, what is not covered, the duration of
coverage, how to best obtain warranty coverage, important disclaimers
and limitations of damages, and other related information. Please review
this important information.
Safety Alerts and Notices
Throughout this publication, dangers, warnings, cautions, and notices,
accompanied by the international HAZARD symbol !, are used to alert
the operator and technician to special instructions concerning a particular
service or operation that may be hazardous if performed incorrectly or
carelessly. Observe these safety alerts carefully.
These safety alerts alone cannot eliminate the hazards they signal. Strict
compliance to these special instructions when performing the service, and
common sense operation are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
eng i
© 2014 Mercury Marine 540 Bravo Sterndrive Models 90-8M0086929 414

! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major
component failure.
IMPORTANT: Identifies information essential to the successful completion of
the task.
NOTE: Indicates information that helps in the understanding of a particular step
or action.
! WARNING
The engine exhaust from this product contains chemicals known to the state
of California to cause cancer, birth defects or other reproductive harm.
Copyright and Trademark Information
© MERCURY MARINE. All rights reserved. Reproduction in whole or in
part without permission is prohibited.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo,
K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves
Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury
Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft,
Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're
Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a
trademark of Brunswick Corporation. Mercury Product Protection is a registered
service mark of Brunswick Corporation.
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Warranty Information
Warranty Registration United States and Canada.............................................. 1
Transfer of Warranty........................................................................................... 1
Mercury Racing Division One Year Limited Warranty United States and Canada
............................................................................................................................ 2
Products Sold to Government Agencies............................................................. 4
Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products
............................................................................................................................ 5
California Emission Control Warranty Statement............................................... 6
California Emission Control Warranty Rights and Obligations............................ 9
E.P.A. Emission Controls..................................................................................10
General Information
Before Operating Your Boat............................................................................. 12
Boat Horsepower Capacity............................................................................... 12
High‑Speed and High‑Performance Boat Operation........................................ 13
Paddle Wheel and Water Temperature Sensors.............................................. 13
Lanyard Stop Switch......................................................................................... 13
Trailering the Boat............................................................................................ 14
Protecting People in the Water......................................................................... 14
Exhaust Emissions........................................................................................... 15
Wave and Wake Jumping................................................................................. 17
Impact With Underwater Hazards..................................................................... 18
Operating in Shallow Water.............................................................................. 19
Safe Boating Suggestions................................................................................ 20
Stolen Power Package..................................................................................... 22
Specifications
Engine Identification......................................................................................... 23
Fuel Requirements........................................................................................... 23
Low Permeation Fuel Hose Requirement ........................................................ 25
Crankcase Oil................................................................................................... 25
Capacities......................................................................................................... 26
General Engine Specifications..........................................................................27
Engine Operating Limitations............................................................................28
Engine Break‑in................................................................................................ 28
After Break‑In Period........................................................................................ 29
eng iii

Operation
Instrumentation................................................................................................. 30
Warning System............................................................................................... 30
Electrical System Overload Protection............................................................. 31
Remote Controls (Console Mounted Zero Effort)............................................. 36
Starting, Shifting, and Stopping........................................................................ 37
Operation Chart................................................................................................ 38
Freezing Temperature Operation..................................................................... 39
Drain Plug and Bilge Pump...............................................................................39
Launching And Boat Operation Care................................................................ 39
Conditions Affecting Operation
Weight Distribution............................................................................................40
Bottom Of Boat................................................................................................. 40
Cavitation.......................................................................................................... 40
Ventilation......................................................................................................... 40
Propeller Selection............................................................................................41
Conditions That Lower Engine Performance.................................................... 41
iv eng

Maintenance
Service Responsibilities.................................................................................... 43
Replacement Service Parts.............................................................................. 43
Do‑It‑Yourself Maintenance Suggestions......................................................... 44
Servicing High‑Horsepower Engines................................................................ 45
Engine Maintenance Charts............................................................................. 45
Bravo Drive Maintenance Charts...................................................................... 47
Checking Fluid Levels.......................................................................................50
Closed Cooling System.................................................................................... 54
Changing Fluids................................................................................................ 57
Lubrication........................................................................................................ 63
Propellers..........................................................................................................66
Flushing the Power Package............................................................................ 69
Cleaning Seawater (Raw Water) Section of Oil Cooler.................................... 73
Changing Positive Crankcase Ventilation Valve............................................... 74
Cleaning the Flame Arrestor............................................................................. 74
Serpentine Drive Belt........................................................................................ 76
Water‑Separating Fuel Filter.............................................................................79
Corrosion and Corrosion Protection................................................................. 81
Battery.............................................................................................................. 87
Bottom of Boat.................................................................................................. 87
Inspection and Maintenance............................................................................. 88
Attention Required After Submersion............................................................... 88
Cold Weather or Extended Storage
Draining the Seawater System......................................................................... 89
Drain System Identification............................................................................... 89
Air‑Actuated Single‑Point Drain System........................................................... 91
Manual Drain System....................................................................................... 96
Draining Water from the Cool Fuel Module...................................................... 98
Battery Storage................................................................................................. 99
Recommissioning the Power Package............................................................. 99
eng v

Troubleshooting
Engine Will Not Crank.....................................................................................101
Engine Cranks But Will Not Start.................................................................... 101
Engine Hard to Start, Runs Rough, Misses, and/or Backfires........................ 102
Low Engine Coolant (Closed Cooling) Temperature...................................... 102
Poor Performance...........................................................................................103
Insufficient Engine Temperature..................................................................... 103
High Engine Temperature...............................................................................103
Low Engine Oil Pressure................................................................................ 104
Battery Will Not Come Up On Charge............................................................ 104
Power Trim Does Not Operate (Motor Doesn't Run)...................................... 104
Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)
........................................................................................................................ 105
Electrical Analog Trim Gauge Malfunction...................................................... 105
Remote Control Operates Hard, Binds, Has Excessive Free‑Play or Makes
Unusual Sounds............................................................................................. 105
Steering Wheel Turns Hard or Jerky.............................................................. 106
Seawater Pressure Is Below Specification..................................................... 106
Seawater Pressure Is Above Specification..................................................... 106
Owner Service Assistance
Local Repair Service.......................................................................................107
Service Away from Home............................................................................... 107
Parts and Accessories Inquiries..................................................................... 107
Service Assistance......................................................................................... 107
Mercury Marine Service Offices...................................................................... 107
Ordering Literature
United States and Canada..............................................................................109
Outside The United States and Canada......................................................... 109
Maintenance Log
Maintenance Log............................................................................................ 110
vi eng

Warranty Registration United States and Canada
Outside United States and Canada–Check with your local distributor.
1. You may change your registered address at any time, including at time of
warranty claim, by calling Mercury Marine or sending a letter or fax with
your name, old address, new address, and engine serial number to
Mercury Marine’s warranty registration department. Your dealer can also
process this change of information.
Mercury Marine
Attn.: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
NOTE: Registration lists must be maintained by Mercury Marine and any
dealer on marine products sold in the United States, should a safety recall
notification under the Federal Safety Act be required.
2. At the time of sale, the dealer should complete the warranty registration
and immediately submit it to Mercury Marine via MercNET, E‑mail, or
mail. Upon receipt of this warranty registration, Mercury Marine will record
the registration.
IMPORTANT: Your warranty coverage begins at the time of sale, but warranty
claims cannot be processed until the product is registered with Mercury
Marine.
Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the
remainder of the unused portion of the limited warranty. This will not apply to
products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill
of sale or purchase agreement, new owner’s name, address and engine serial
number to Mercury Marine’s Warranty Registration Department. In the United
States and Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
Upon processing the transfer of warranty, Mercury Marine will send registration
verification to the new owner of the product by mail.
There is no charge for this service.
WARRANTY INFORMATION
eng 1

For products purchased outside the United States and Canada, contact the
distributor in your country, or the Marine Power Service Center closest to you.
Mercury Racing Division One Year Limited Warranty United
States and Canada
WHAT IS COVERED: Mercury Marine warrants its new products and
refurbished products sold under the term of Pacemaker, to be free of defects in
material and workmanship during the period described below.
DURATION OF WARRANTY COVERAGE FOR RECREATIONAL USE: The
limited warranty provides coverage for one (1) year from either the date the
product is first sold to a recreational‑use retail purchaser, or the date on which
the product is first put into service, whichever occurs first. The repair or
replacement of parts or the performance of service under this warranty does
not extend the life of this warranty beyond its original expiration date.
TRANSFER OF COVERAGE: The limited warranty is transferable to a
subsequent purchaser, but only for the remainder of the unused portion of the
limited warranty. This will not apply to products used for commercial
applications.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY
COVERAGE: Warranty coverage is available only to retail customers that
purchase from a Dealer authorized by Mercury Marine to distribute the product
in the country in which the sale occurred, and then only after the Mercury
Marine specified predelivery inspection process is completed and documented.
Warranty coverage becomes available upon proper registration of the product
by the authorized dealer. Inaccurate warranty registration information regarding
recreational use, or subsequent change of use from recreational to commercial
may void the warranty at the sole discretion of Mercury Marine. Routine
maintenance outlined in the Operation and Maintenance Manual must be timely
performed in order to maintain warranty coverage. Mercury Marine reserves the
right to make warranty coverage contingent upon proof of proper maintenance.
WHAT MERCURY WILL DO: Mercury Marine's sole and exclusive obligation
under this warranty is limited to, at our option, repairing a defective part,
replacing such part or parts with new or Mercury Marine certified
remanufactured parts, or refunding the purchase price of the Mercury Marine
product. Mercury Marine reserves the right to improve or modify products from
time to time without assuming an obligation to modify products previously
manufactured.
WARRANTY INFORMATION
2 eng

HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide
Mercury Marine with a reasonable opportunity to repair and reasonable access
to the product for warranty service. Warranty claims shall be made by
delivering the product for inspection to a Mercury Marine dealer authorized to
service the product. If the purchaser cannot deliver the product to such a
dealer, written notice must be given to Mercury Marine. Mercury Marine will
then arrange for the inspection and any covered repair. The purchaser, in that
case, shall pay for all related transportation charges and travel time. If the
service provided is not covered by this warranty, the purchaser shall pay for all
related labor and material and any other expenses associated with that service.
The purchaser shall not, unless requested by Mercury Marine, ship the product
or parts of the product directly to Mercury Marine. Proof of registered ownership
must be presented to the dealer at the time warranty service is requested in
order to obtain coverage.
WHAT IS NOT COVERED: This limited warranty does not cover routine
maintenance items, tune ups, adjustments, normal wear and tear, and faded
paint.
This limited warranty also does not cover damage caused by any of the
following:
• Abuse
• Abnormal use
• Use of a propeller or gear ratio that does not allow the engine to run in its
recommended RPM range. Refer to the Operation and Maintenance
Manual.
• Operation of the product in a manner inconsistent with the recommended
operation and duty cycle. Refer to the Operation and Maintenance
Manual.
• Neglect
• Accident
• Submersion
• Improper installation (proper installation specifications and techniques are
set forth in the installation instructions for the product)
• Improper service
• Use of an accessory or part that was not manufactured or sold by Mercury
Marine and that damages the Mercury product
• Operation with fuels, oils, or lubricants that are not suitable for use with
the product. Refer to the Operation and Maintenance Manual.
• Alteration or removal of parts
• Water entering the engine through the fuel intake, air intake, or exhaust
system
• Insufficient cooling water caused by blockage of the cooling system by a
foreign body, running the engine out of water, mounting the engine too
high on the transom, or running the boat with the engine/drive trimmed out
too far
WARRANTY INFORMATION
eng 3

Expenses related to haul‑out, launch, towing, storage, telephone, rental,
inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss
of income, tournament fees, club fees, prize money or any other type of
incidental or consequential damages are not covered by this warranty.
Expenses associated with the removal and/or replacement of boat partitions or
material caused by boat design for access to the product are not covered by
this warranty.
WHAT WILL VOID THE WARRANTY: The commercial use of the product,
defined as any work or employment related use of the product, or any income
generating use of the product, even if such use is only occasional, will void the
warranty. Use of the product for racing or other competitive activity, at any
point, even by a prior owner of the product, voids the warranty.
No individual or entity, including Mercury Marine authorized dealers, has been
given authority by Mercury Marine to make any affirmation, representation or
warranty regarding the product, other than those contained in this limited
warranty, and if made, shall not be enforceable against Mercury Marine.
TERMINATION OF COVERAGE: Warranty coverage is terminated for used
product obtained in any of the following ways:
• Repossession from a retail customer
• Purchase at an auction
• Purchase from a salvage yard
• Purchase from an insurance company that obtained the product as a
result of an insurance claim
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED
WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE
EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES
ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME
STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,
LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,
THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO
COUNTRY.
Products Sold to Government Agencies
Contact the Mercury Racing Sales Department for a copy of the Government
Agencies Warranty Packet Kit, which explains the conditions required for
government agencies to receive warranty when purchasing Mercury Racing
Outboard or Sterndrive product.
WARRANTY INFORMATION
4 eng

Mercury Racing Sales Department
N7840 County Road UU
Fond du Lac, WI 54937-9385
920-921-5330
Fax [phone]
Warranty Coverage and Exclusions for Mercury Racing
Sterndrive Products
The purpose of this section is to help eliminate some of the more common
misunderstandings regarding warranty coverage. The following information
explains some of the types of services that are not covered by warranty. The
provisions set forth following have been incorporated by reference into the
Mercury Racing Division Three‑Year Limited Warranty Against Corrosion
Failure, the Mercury Racing Division 90‑Day, Six‑Month and One‑Year Limited
Warranties.
Keep in mind that warranty covers repairs that are needed within the warranty
period because of defects in material and workmanship. Installation errors,
accidents, normal wear, and a variety of other causes that affect the product
are not covered.
Warranty is limited to defects in material or workmanship, but only to retail
customers that purchase from a dealer authorized by Mercury Marine to
distribute the product in the country in which the sale occurred, and then only
after the Mercury Marine specified predelivery inspection process is completed
and documented.
Should you have any questions concerning warranty coverage, contact your
authorized dealer. They will be pleased to answer any questions that you may
have.
GENERAL EXCLUSIONS FROM WARRANTY
1. Minor adjustments and tune‑ups, including checking, cleaning or adjusting
spark plugs, ignition components, carburetor or EFI settings, filters, belts,
controls, and checking lubrication made in connection with normal
services.
2. Damage caused by lack of maintenance.
3. Haul‑out, launch, towing charges, and all related transportation charges
and/or travel time, etc.
4. Additional service work requested by customer other than that necessary
to satisfy the warranty obligation.
5. Labor performed by other than an authorized dealer may be covered only
under following circumstances: When performed on an emergency basis
providing there are no authorized dealers in the area who can perform the
work required or have no facilities to haul out, etc., and prior factory
approval has been given to have the work performed at this facility.
6. Use of other than Mercury Precision or Quicksilver parts when making
warranty repairs.
WARRANTY INFORMATION
eng 5

7. Engine noise does not necessarily indicate a serious engine problem. If
diagnosis indicates a serious internal engine condition, which could result
in a failure, condition responsible for noise should be corrected under the
warranty.
8. Lower unit and/or propeller damage caused by striking a submerged
object is considered a marine hazard.
9. Water in the starter motor.
10. Starter motors and/or armatures, or field coil assemblies, which are
burned, or where lead is thrown out of commutator because of excess
cranking.
11. Valve or valve seat grinding required because of wear.
California Emission Control Warranty Statement
INTRODUCTION
The California Air Resources Board has promulgated air emissions regulations
for inboard and sterndrive engines. The regulations apply to all inboard and
sterndrive engines that were manufactured for the 2014 and 2015 model year.
Mercury Racing, in compliance with those regulations, provides this limited
warranty for the emission control systems (see the components of the emission
control system listed following), and further warrants that the inboard or
sterndrive engine was designed, built, and equipped to conform with all
applicable regulations adopted by the California Air Resources Board pursuant
to its authority in Chapters 1 and 2, Part 5, Division 26 of the Health and Safety
Code. For information regarding the limited warranty for the nonemissions
related components of the inboard or sterndrive engine, please see the limited
warranty statement for your engine.
WHAT IS COVERED
Mercury Racing warrants the components of the emissions control systems
(see the components of the emission control system listed following) of its new,
2009 model year and later California‑certified high performance sterndrive
engines, registered to a California resident, to be free from defects in material
or workmanship that cause the failure of a warranted part to be identical in all
material respects to that part as described in the application of Mercury Racing
for certification from the California Air Resources Board, for the period of time,
and under the conditions identified below. The cost to diagnose a warranty
failure is covered if the warranty claim is approved. Damage to other engine
components caused by the failure of a warranted part will also be repaired
under warranty.
WARRANTY INFORMATION
6 eng

DURATION OF COVERAGE
This limited warranty provides coverage for the components of the emissions
control systems. Specific emission control related parts on new high
performance sterndrive engines greater than 500 horsepower are warranted for
a period of three years or 480 hours (as determined by the engine’s
ECM‑integrated hour meter), whichever first occurs, for electronic
emission‑related components including, but not limited to, sensors (e.g.,
oxygen sensors, mass air flow sensors, crankshaft position sensors, etc.),
solenoids (e.g., fuel injectors, idle control valves, pressure regulators, etc.),
ignition components, powertrain control modules, and for the following:
catalysts, carburetors, fuel pumps, evaporative components (including
low‑permeation hoses), exhaust gas recirculation, and other direct emissions
devices. For new high performance sterndrive engines mechanical
emission‑related components, including but not limited to, the engine block,
crankshaft, camshaft, connecting rods, valves, manifolds, rotating parts,
pistons, and turbo/superchargers are warranted for a period of 1 year or 150
hours (as determined by the engine’s ECM‑integrated hour meter), whichever
first occurs for engines greater than 500 horsepower and less than or equal to
650 horsepower and for a period of 1 year or 50 hours (as determined by the
engine’s ECM‑integrated hour meter), whichever first occurs for engines
greater than 650 horsepower. Emission related normal maintenance items such
as spark plugs and filters that are on the warranted parts list are warranted up
to their first required replacement interval only. Refer to Emission Control
System Components and Maintenance Schedule. The repair or replacement
of parts, or the performance of service under this warranty, does not extend the
life of this warranty beyond its original expiration date. Unexpired warranty
coverage can be transferred to a subsequent purchaser. Refer to Transfer of
Warranty.
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury Racing with a reasonable opportunity to
repair and reasonable access to the product for warranty service. Warranty
claims shall be made by delivering the product for inspection to a Mercury
dealer authorized to service the product. If purchaser cannot deliver the product
to such a dealer, please notify Mercury Racing and Mercury Racing will then
arrange for the inspection and any covered repair. The purchaser, in that case,
shall pay for all related transportation charges and/or travel time. If the service
provided is not covered by this warranty, the purchaser shall pay for all related
labor and material, and any other expenses associated with that service. The
purchaser shall not, unless requested by Mercury Racing, ship the product or
parts of the product directly to Mercury Racing.
WARRANTY INFORMATION
eng 7

WHAT MERCURY RACING WILL DO
Mercury Racing's sole and exclusive obligation under this warranty is limited to,
at our expense and at our option, repairing or replacing defective parts with
new or Mercury Marine‑certified remanufactured parts, or refunding the
purchase price of the Mercury product. Mercury reserves the right to improve or
modify products from time to time without assuming an obligation to modify
products previously manufactured.
WHAT IS NOT COVERED
This limited warranty does not cover routine maintenance items, tune ups,
adjustments, normal wear and tear, damage caused by abuse, abnormal use,
use of a propeller or gear ratio that does not allow the engine to run in its
recommended wide‑open throttle RPM range (refer to Specifications),
operation of the product in a manner inconsistent with the recommended
operation procedures, neglect, accident, submersion, improper installation
(proper installation specifications and techniques are set forth in the installation
instructions for the product), improper service, jet pump impellers and liners,
operation with fuels, oils or lubricants which are not suitable for use with the
product (refer to Specifications), alteration or removal of parts.
Expenses related to haul‑out, launch, towing, storage, telephone, rental,
inconvenience, slip fees, insurance coverage, loan payments, loss of time, loss
of income, or any other type of incidental or consequential damages are not
covered by this warranty. Also, expenses associated with the removal and/or
replacement of boat partitions or material caused by boat design for access to
the product are not covered by this warranty.
Nonwarranty maintenance, replacement, or repair of emission control devices
and systems may be performed by any marine engine repair establishment or
individual. The use of non‑Mercury Racing parts for nonwarranty maintenance
or repairs will not be grounds for disallowing other warranty work. The use of
add‑on (as defined at section 1900 (b)(1) and (b)(10) of Title 13 of the
California Code of Regulations) or modified parts not exempted by the
California Air Resources Board may be grounds for disallowing a warranty
claim, at the discretion of Mercury Racing. Failures of warranted parts caused
by the use of a nonexempted add‑on or modified part will not be covered.
DISCLAIMERS AND LIMITATIONS
Disclaimers and limitations the implied warranties of merchantability and fitness
for a particular purpose are expressly disclaimed. To the extent that they
cannot be disclaimed, the implied warranties are limited in duration to the life of
the express warranty. Incidental and consequential damages are excluded from
coverage under this warranty. Some states or countries, do not allow for the
disclaimers, limitations and exclusions identified above. As a result, they may
not apply to you. This warranty gives you specific legal rights which vary from
state to state and country to country.
If you have any questions regarding your warranty rights and responsibilities,
refer to Owner Service Assistance for contact information.
WARRANTY INFORMATION
8 eng

California Emission Control Warranty Rights and Obligations
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board is pleased to explain the emission control
system warranty on your 2013‑2014 model year sterndrive engine. In
California, new sterndrive engines must be designed, built and equipped to
meet the State's stringent antismog standards. Mercury Racing must warrant
the emission control system on your sterndrive engine for the periods of time
listed below, provided there has been no abuse, neglect, or improper
maintenance of your sterndrive engine.
Your emission control system may include parts such as the carburetor or fuel
injection system, the ignition system, and catalytic converter. Also included may
be hoses, belts, connectors, and other emission‑related assemblies. Where a
warrantable condition exists, Mercury Marine will repair your sterndrive engine
at no cost to you, including diagnosis, parts and labor.
MANUFACTURER'S WARRANTY COVERAGE
Select electronic emission‑related control parts from model year 2009 and later
sterndrive engines are warranted for three years or 480 hours, whichever first
occurs. Select mechanical emission‑related components are warranted for one
year or 150 hours of operation, whichever first occurs for engines greater than
500 horsepower and less than or equal to 650 horsepower and for 1 year or 50
hours, whichever first occurs for engines greater than 650 horsepower.
However, warranty coverage based on the hourly period is only permitted for
engines that are equipped with hour meters as defined in s 2441(a)(13) or their
equivalent. If any emission‑related part on your engine is defective under
warranty, the part will be repaired or replaced by Mercury Racing.
OWNER'S WARRANTY RESPONSIBILITIES
As the sterndrive engine owner, you are responsible for the performance of the
required maintenance listed in your owner's manual. Mercury Racing
recommends that you retain all receipts covering maintenance on your
sterndrive engine, but Mercury Racing cannot deny warranty solely for the lack
of receipts or your failure to ensure the performance of all scheduled
maintenance.
As the sterndrive engine owner, you should however be aware that Mercury
Racing may deny you warranty coverage if your sterndrive engine or a part has
failed due to abuse, neglect, improper maintenance, or unapproved
modifications.
You are responsible for presenting your sterndrive engine to a Mercury Marine
distribution center as soon as a problem exists. The warranty repairs will be
completed in a reasonable amount of time, not to exceed 30 days. If you have
any questions regarding your warranty rights and responsibilities, you should
contact Mercury Racing at 1‑920‑924‑2088.
WARRANTY INFORMATION
eng 9

E.P.A. Emission Controls
INTRODUCTION
Consistent with the obligations created by 40 CFR Part 1045, Subpart B,
Mercury Marine provides an emission warranty of three years or 480 hours of
engine use, whichever occurs first, to the retail purchaser for electrical
components of the emission control system, and one year or 150 hours of
engine use, whichever occurs first, to the retail purchaser for mechanical
components of the emission control system. The engine is designed, built, and
equipped to conform at the time of sale with applicable regulations under
section 213 of the Clean Air Act, and the engine is free from defects in
materials and workmanship that cause the engine to fail to conform with
applicable regulations.
EMISSION CONTROL SYSTEM COMPONENTS
The emission‑related warranty covers all components whose failure would
increase an engine's emission of any regulated component including the
following list of components:
1. Fuel metering system
a. Carburetor and internal parts (or fuel pressure regulator or fuel
injection system)
b. Air/fuel ratio feedback and control system
c. Cold start enrichment system
d. Intake valves
2. Air induction system
a. Controlled hot air intake system
b. Intake manifold
c. Air filter
d. Turbocharger systems
e. Heat riser valve and assembly
3. Ignition system
a. Spark plugs
b. Magneto or electronic ignition system
c. Spark control system
d. Ignition coil or control module
e. Ignition wires
4. Lubrication system
a. Oil pump and internal parts
b. Oil injectors
c. Oil meter
5. Positive crankcase ventilation (PCV) system
WARRANTY INFORMATION
10 eng

a. PCV valve
b. Oil filler cap
6. Exhaust system
a. Exhaust manifold
b. Exhaust elbow
c. Intermediate exhaust elbow
d. Lower exhaust pipe
e. Tailpipe
7. Catalysts or thermal reactor system
a. Catalytic converter
b. Thermal reactor
c. Exhaust manifold
d. Exhaust valves
8. Evaporative system
a. Carbon canister
b. Fuel tanks
c. Purge valve
9. Miscellaneous items used in above systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and
mounting hardware
b. Pulleys, belts, and idlers
c. Vacuum, temperature, check and time sensitive valves and switches
d. Electronic controls
NOTE: The EPA emission‑related warranty does not cover components whose
failure would not increase an engine's emissions on any regulated pollutant.
WARRANTY INFORMATION
eng 11

Before Operating Your Boat
Read this manual carefully. Safety and operating information that is practiced
along with using good common sense can help prevent personal injury and
product damage. If you have any questions, contact your dealer.
This manual as well as safety labels posted on the engine package use safety
alerts to draw your attention to special safety instructions that must be followed.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
IMPORTANT: Indicates information or instructions that are necessary for
proper operation and/or maintenance.
NOTE: Indicates information that helps in the understanding of a step or action.
Boat Horsepower Capacity
! WARNING
Exceeding the boat's maximum horsepower rating can cause serious injury
or death. Overpowering the boat can affect boat control and flotation
characteristics or break the transom. Do not install an engine that exceeds
the boat's maximum power rating.
Do not overpower or overload your boat. Most boats will carry a required
capacity plate indicating the maximum acceptable power and load as
determined by the manufacturer following certain federal guidelines. If in doubt,
contact your dealer or the boat manufacturer.
U.S. COAST GUARD CAP ACITY
MAXIMUM HORSEPOWER XXX
MAXIMUM PERSON
CAPACITY (POUNDS) XXX
MAXIMUM WEIGHT
CAPACITY XXX
26777
GENERAL INFORMATION
12 eng

High‑Speed and High‑Performance Boat Operation
If your power package is to be used on a high‑speed or high‑performance boat
with which you are unfamiliar, we recommend that you never operate it at its
high‑speed capability without first requesting an initial orientation and
familiarization demonstration ride with your dealer or an operator experienced
with your boat/power package combination. For additional information, obtain a
copy of our High‑Performance Boat Operation booklet from your dealer,
distributor, or Mercury Marine.
Paddle Wheel and Water Temperature Sensors
Paddle wheels cannot be utilized on vessels that are capable of speeds in
excess of 50 mph. Water temperature sensors cannot be connected to Race
sterndrive engines that are equipped with a propulsion control module (PCM).
The water temperatue sensor connection is utilized by the PCM for monitoring
engine oil temperature.
Lanyard Stop Switch
The purpose of a lanyard stop switch is to turn off the engine when the operator
moves far enough away from the operator's position (as in accidental ejection
from the operator's position) to activate the switch. A lanyard stop switch can
be installed as an accessory ‑ generally on the dashboard or side adjacent to
the operator's position.
While activation of the lanyard stop switch will stop the engine immediately, a
boat will continue to coast for some distance depending upon the velocity and
degree of any turn at shut down. However, the boat will not complete a full
circle. While the boat is coasting, it can cause injury to anyone in the boat's
path as seriously as the boat would when under power.
a - Lanyard cord
b - Lanyard stop switch
We strongly recommend that other occupants be instructed on proper starting
and operating procedures should they be required to operate the engine in an
emergency (e.g. if the operator is accidentally ejected).
21629
ab
GENERAL INFORMATION
eng 13

! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the
possibility of serious injury or death from being struck by the boat. Always
properly connect the operator to the stop switch using a lanyard.
! WARNING
Avoid serious injury or death from deceleration forces resulting from
accidental or unintended stop switch activation. The boat operator should
never leave the operator's station without first disconnecting the stop switch
lanyard from the operator.
Accidental or unintended activation of the switch during normal operation is
also a possibility. This could cause any, or all, of the following potentially
hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward
motion ‑ a particular concern for passengers in the front of the boat who
could be ejected over the bow and possibly struck by the gear case or
propeller.
• Loss of power and directional control in heavy seas, strong current or high
winds.
• Loss of control when docking.
Trailering the Boat
The boat can be trailered with the drive unit in up or down position. Adequate
road clearance is required between road and gear housing skeg when trailering
with the drive unit in down position.
If adequate road clearance is a problem, place drive unit in full up position.
Protecting People in the Water
WHILE YOU ARE CRUISING
It is very difficult for a person in the water to take quick action to avoid a boat
heading in their direction, even at slow speeds.
21604
Always slow down and exercise extreme caution any time you are boating in an
area where there might be people in the water.
GENERAL INFORMATION
14 eng