Mercury 496 MAG Bravo User manual

2001, Mercury MarineGasoline Engines - 496 MAG Bravo Models 90Ć863020010 1101

0
CA940
Identification Record
PLEASE RECORD THE FOLLOWING INFORMATION:
1. Engine Model and Horsepower Engine Serial Number
2. Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
3. Transmission Model (Inboard) Gear Ratio Transmission Serial Number
4. Propeller Number Pitch Diameter
5. Hull Identification Number (HIN) Purchase Date
6. Boat Manufacturer Boat Model Length
7. Exhaust Gas Emissions Certificate Number (Europe Only)
SERIAL NUMBERS
The serial numbers are the manufacturer’s keys to numerous engineering details which apply to your Mercury
MerCruiserpower package. When contacting your Authorized Mercury MerCruiser Dealer about service,
always specify model and serial numbers.
The description and specifications contained herein were in effect at the time this guide was approved for
printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue
models at any time, or to change specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
2001, Mercury Marine
The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop, Mariner, Merc,
MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide, Thruster and MMPP.

1
CB801
77625
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2
27
1, 7
5
71352
ABC12345Z123
-19 48-12345
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44
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77639
1,2
276454
50072
2
4

2
CA859
Welcome!
You have selected one of the finest marine power packages available. It incorporates numerous design features
to assure 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.
Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be
pleasant!
Consumer Affairs Department
CA741
Warranty Message
The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty
are set forth in the Warranty Sections 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.

3
CA961 THIS PAGE IS INTENTIONALLY BLANK

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TABLE OF CONTENTS
Page
Warranty Information 6
Owner Warranty Registration 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
International Owner Registration 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transferable Warranty 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercury Product Protection Plan 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read This Manual Thoroughly 12
General Information 13
Lanyard Stop Switch 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Emissions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wave And Wake Jumping 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Impact With Underwater Hazards 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating With Low Water Inlets In Shallow Water 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Impact Protection 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Boating Suggestions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Speed And High-Performance Boat Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions Affecting Operation 22
Weight Distribution (Passengers And Gear) Inside The Boat 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom Of Boat 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cavitation 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Elevation And Climate Affect Performance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Information 24
Operation And Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freezing Temperature Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Plug and Bilge Pump 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attention Required After Submersion 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailering Boat 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stolen Power Package 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Service Parts 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance Suggestions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multiple EFI Engine Battery Precautions 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnosing EFI Problems 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After Break-In Period 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End of First Season Checkup 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5
Page
Operation 30
Instrumentation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audio Warning System 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Overload Protection 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Controls 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Shifting And Stopping 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1L Engine Guardian Strategy 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation Chart 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 38
Fuel Recommendations 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seacock Size Recommendation 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Oil 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 41
Fluid Capacities 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scheduled Maintenance 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Levels 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Fluids 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Water Separating Fuel Filter 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Flame Arrestor and Related Components 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propellers 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corrosion And Corrosion Protection 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Maintenance 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 65
Power Package Lay Up 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Winter Storage 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 73
Owner Service Assistance 78

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CA455
Warranty Information
Owner Warranty Registration
UNITED STATES AND CANADA ONLY
•It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the
factory immediately upon sale of the new product.
•It identifies name and address of the original purchaser, product model and serial number(s), date of sale,
type of use and selling dealer’s code, name and address. The dealer also certifies that you are the original
purchaser and user of the product.
•Upon receipt of the Warranty Registration Card at the factory, you will be issued a plastic Owner Warranty
Registration Card which is your only valid registration identification. It must be presented to the servicing
dealer should warranty service be required. Warranty claims will not be accepted without presentation of this
card.
•A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. It
is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being
processed. Should your product need service during this period, present the temporary registration card to
the dealer. He will attach it to your warranty claim form.
•Because of your selling dealer’s continuing personal interest in your satisfaction, the product should be
returned to him for warranty service.
•If your plastic card is not received within 30 days from date of new product sale, please contact your selling
dealer.
•The product warranty is not effective until the product is registered at the factory.
•NOTICE: Registration lists must be maintained by factory and dealer on marine products sold in the United
States, should notification under the Federal Boat Safety Act be required.

7
International Owner Registration
OUTSIDE THE UNITED STATES AND CANADA
•It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the
distributor or Marine Power Service Center responsible for administering the warranty registration/claim
program for your area.
•The Warranty Registration Card identifies your name and address, product model and serial number(s), date
of sale, type of use and the selling distributor’s/dealer’s code number, name and address. The
distributor/dealer also certifies that you are the original purchaser and user of the product.
•A copy of the Warranty Registration Card, designated as the “Purchaser’s Copy”, MUST be given to you
immediately after the card has been completely filled out by the selling distributor/dealer. This card represents
your factory registration identification, and should be retained by you for future use when required. Should
you ever require warranty service on this product, your dealer may ask you for the Warranty Registration Card
to verify date of purchase and to use the information on the card to prepare the warranty claim form(s).
•In some countries, the Marine Power Service Center will issue you a permanent (plastic) Warranty
Registration Card within 30 days after receiving the “Factory Copy”of the Warranty Registration Card from
your distributor/dealer. If you receive a plastic Warranty Registration Card, you may discard the “Purchaser’s
Copy”that you received from the distributor/dealer when you purchased the product. Ask your
distributor/dealer if this plastic card program applies to you.
•For further information concerning the Warranty Registration Card and its relationship to Warranty Claim
processing, refer to the “International Warranty.”Refer to “Table of Contents.”
IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law.
It is our desire to have ALL products registered at the factory should it ever be necessary to contact you.
Make sure your dealer/distributor fills out the warranty registration card immediately and sends the
factory copy to the Marine Power International Service Center for your area.

8
CC1048 Warranty Policies
Mercury MerCruiser One Year Limited Warranty (Gasoline Fueled Products
Only)
WHAT IS COVERED
Mercury Marine warrants its new products to be free of defects in material and workmanship during the period
described below.
DURATION OF COVERAGE
This Limited Warranty provides coverage for either one (1) year from the date the product is first sold to a recre-
ational use retail purchaser, or the date on which the product is first put into service, whichever occurs first. Com-
mercial users of these products receive warranty coverage of either one (1) year from the date of first retail sale,
or the accumulation of 500 hours of operation, whichever occurs first. Commercial use is defined as any work
or employment related use of the product, or any use of the product which generates income, for any part of the
warranty period, even if the product is only occasionally used for such purposes. The repair or replacement of
parts, or the performance of service under this warranty, does not extend the life of this warranty beyond its origi-
nal expiration date. Unexpired warranty coverage can be transferred from one recreational use customer to a
subsequent recreational use customer upon proper re-registration of the product. Unexpired warranty coverage
cannot be transferred either to or from a commercial use customer.
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 Ma-
rine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine
specified pre-delivery 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 (unless properly re-
registered) 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 obtain warranty coverage. Mercury
Marine reserves the right to make any warranty coverage contingent upon proof of proper maintenance.
WHAT MERCURY WILL DO
Mercury’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 re-manufactured parts, or refunding the pur-
chase 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.
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the prod-
uct 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, written notice
must be given to Mercury. We will then arrange for the inspection and any covered repair. 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, purchaser shall pay for all related labor and material, and any other expenses associated with that ser-
vice. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercu-
ry. The warranty registration card is the only valid registration identification and must be presented to the dealer
at the time warranty service is requested in order to obtain coverage.

9
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 RPM range (see the Operation and Maintenance Manual), operation of the product in a man-
ner inconsistent with the recommended operation/duty cycle section of 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 which damages
the Mercury product and was not manufactured or sold by us, jet pump impellers and liners, operation with fuels,
oils or lubricants which are not suitable for use with the product (see the Operation and Maintenance Manual),
alteration or removal of parts, water entering the engine through the fuel intake, air intake or exhaust system or
damage to the product from 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 trimmed out too far. Use of the product for racing or other competitive activity, or operating with a rac-
ing type lower unit, at any point, even by a prior owner of the product, voids the warranty.
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 parti-
tions or material caused by boat design for access to the product are not covered by this 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.
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 EXCLU-
SIONS 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.

10
CC1049
3 Year Limited Warranty Against Corrosion (Worldwide)
WHAT IS COVERED
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M2Jet Drive, Tracker by
Mercury Marine Outboard, MerCruiser Inboard or sterndrive engine (Product) will not be rendered inoperative
as a direct result of corrosion for the period of time described below.
DURATION OF COVERAGE
This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold,
or the date on which the product is first put into service, whichever occurs first. The repair and replacement of
parts, or the performance of service under this warranty does not extend the life of this warranty beyond its origi-
nal expiration date. Unexpired warranty coverage can be transferred to subsequent (noncommercial use) pur-
chaser upon proper re-registration of the product.
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 Ma-
rine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine
specified pre-delivery inspection process is completed an documented. Warranty coverage becomes available
upon proper registration of the product by the authorized dealer. Corrosion prevention devices specified in the
Operation and Maintenance Manual must be in use on the boat, and routine maintenance outlined in the Opera-
tion and Maintenance Manual and must be timely performed (including without limitation the replacement of sac-
rificial anodes, use of specified lubricants, and touch-up nicks and scratches) in order to maintain warranty cover-
age. Mercury Marine reserves the right to make warranty coverage contingent upon proof of proper
maintenance.
WHAT MERCURY WILL DO
Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part,
replacing such part or parts with new or Mercury Marine certified re-manufactured parts, or refunding the pur-
chase 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.
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable opportunity to repair, and reasonable access to the prod-
uct 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, written notice
must be given to Mercury. We will then arrange for the inspection and any covered repair. 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, purchaser shall pay for all related labor and material, and any other expenses associated with that ser-
vice. Purchaser shall not, unless requested by Mercury, ship the product or parts of the product directly to Mercu-
ry. The warranty registration card is the only valid registration identification and must be presented to the dealer
at the time warranty service is requested in order to obtain coverage.

11
WHAT IS NOT COVERED
This limited warranty does not cover electrical system corrosion; corrosion resulting from damage, corrosion
which causes purely cosmetic damage, abuse or improper service; corrosion to accessories, instruments, steer-
ing systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold with less
than a one year limited Product warranty; replacement parts (parts purchased by the Customer); products used
in a commercial application. Commercial use is defined as any work or employment related use of the product,
or any use of the product which generates income, for any part of warranty period, even if the product is only
occasionally used for such purposes.
CA459
Transferable Warranty
The product 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.
Direct Sale By Owner
•The second owner can be registered as the new owner and retain the unused portion of the limited warranty
by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show
proof of ownership. In the United States and Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 West Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
•A new Owner Warranty Registration Card will be issued with the new owner’s name and address. Registration
records will be changed on the factory computer registration file.
•There is no charge for this service.
Outside the United States and Canada, please contact the distributor in your country, or the Marine
Power International Service Center closest to you, for the transferable warranty procedure that would
apply to you.
CA862
Mercury Product Protection Plan
United States And Canada Only
(Certain performance products, triple engine installations, and commercial applications are excluded)
The Mercury Product Protection Plan provides coverage against unexpected mechanical and electrical
breakdowns that may occur beyond the standard limited warranty.
The optional Mercury Product Protection Plan is the only Factory Plan available for your engine.
Two, three or four - year term plans can be purchased up to 12 months after the original engine registration date.
See your participating Mercury MerCruiser dealer for complete program details.

12
CA755
Read This Manual Thoroughly
IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF
ACTUAL STARTING AND OPERATING PROCEDURES.
NOTICE
Throughout this publication, and on your power package, WARNINGS and CAUTIONS, accompanied by the
International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a
particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them
carefully.
These “Safety Alerts”alone cannot eliminate the hazards that they signal. Strict compliance with these special
instructions while performing the service, plus “common sense”operation, are major accident prevention
measures.
WARNING
WARNING-Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
CAUTION-Hazards or unsafe practices which could result in minor personal injury or product or
property damage.
IMPORTANT: - Indicates information or instructions that are necessary for proper operation and/or
maintenance.
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 Op-
eration, Maintenance and Warranty Manual and thoroughly understand the operational instructions
for the power package and all related accessories before the boat is used.

13
CC942 General Information
CB839
Lanyard Stop Switch
74608
21
The purpose of a lanyard stop switch (1) 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. Some remote
control units are equipped with a lanyard stop switch. A lanyard stop switch can be installed on the dashboard
or side adjacent to the operator’s position.
The lanyard is a cord usually between 4 and 5 ft (1.22 and 1.52 m) in length when stretched out with an element
on one end made to be inserted into the switch and a snap (2) on the other end for attaching to the operator.
The lanyard is coiled to make its at-rest condition as short as possible so as to minimize the likelihood of lanyard
entanglement with nearby objects. It is made as long as it is in its stretched condition to minimize the likelihood
of accidental activation should the operator choose to move around in an area close to the normal operator’s
position. If it is desired to have a shorter lanyard, wrap the lanyard around the operator’s wrist or leg, or tie a knot
in the lanyard.
IMPORTANT: The purpose of a lanyard stop switch is to stop the engine when the operator moves far
enough away from the operator’s position to activate the switch. This would occur if the operator
accidentally falls overboard or moves within the boat a sufficient distance from the operator’s position.
Accidental ejections and falls overboard are more likely to occur in certain types of boats such as low
sided sport boats or bass boats, and high-performance boats. Accidental ejections and falls overboard
are also likely to occur as a result of poor operating practices such as sitting on the back of the seat or
gunwale at planing speeds, standing at planing speeds, sitting on elevated fishing boat decks, operating
at planing speeds in shallow or obstacle-infested waters, releasing your grip on a steering wheel that
is pulling in one direction, drinking alcohol or consuming drugs, or daring, high-speed boat maneuvers.
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.
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).
WARNING
Should the operator fall out of the boat, the possibility of serious injury or death from being run over
by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both
ends of the stop switch lanyard to the stop switch and 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:
1Occupants 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.
2Loss of power and directional control in heavy seas, strong current or high winds.
3Loss of control when docking. 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.

14
CA766
Exhaust Emissions
CA641
Courtesy of ABYC
1
CA767
Be Alert To Carbon Monoxide Poisoning
Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards,
sterndrives and inboard engines that propel boats, as well as the generators that power various boat
accessories. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication,
include headache, dizziness, drowsiness, and nausea.
WARNING
Avoid the combination of a running engine and poor ventilation. Prolonged exposure to carbon mon-
oxide in sufficient concentration can lead to unconsciousness, brain damage or death.
GOOD VENTILATION
Ventilate passenger area, open side curtains, or forward hatches to remove fumes.
1Example of desired air flow through the boat.

15
CA643
POOR VENTILATION
3A
3B Courtesy of ABYC
2A
2B
Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with
insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your
boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an unclosed area of a
stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon
monoxide.
2Examples of poor ventilation while boat is stationary:
ARunning the engine when the boat is moored in a confined space.
BMooring close to another boat that has its engine running.
3Examples of poor ventilation while boat is moving:
ARunning the boat with the trim angle of the bow too high.
BRunning the boat with no forward hatches open (station wagon effect).

16
CD543
Wave And Wake Jumping
Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is
done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly
when the boat re-enters the water.
The primary concern is the boat changing direction while in the midst of the jump. In such case the landing may
cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants
to be thrown out of their seats or out of the boat.
There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow
of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface
and “submarine”for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants
flying forward. The boat may also steer sharply to one side.
WARNING
Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a
wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake
or wave jump occurs, get low and hang on to any boat hand hold.

17
CD604
Impact With Underwater Hazards
Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where
the waters are suspected of having underwater obstacles that could be struck by the sterndrive or the boat bot-
tom.The most important thing you can do to help reduce injury or impact damage from striking a floating
or underwater object is control the boat speed. Under these conditions, boat speed should be kept to
a minimum planing speed of 15 to 25 mph (24 to 40 km/h).
Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could
result in the following:
•The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occu-
pants to be thrown out of their seats or out of the boat.
•A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.
•Impact damage to the sterndrive and/or boat.
Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situa-
tions is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters
known to have underwater obstacles.
After striking a submerged object, stop engine as soon as possible and inspect the sterndrive unit for any broken
or loose parts. If damage is present or suspected, the power package should be taken to an authorized dealer
for a thorough inspection and necessary repair.
The boat should also be checked for any hull fractures, transom fractures, water leaks.
Operating a damaged sterndrive could cause additional damage to other parts of the power package, or could
affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.
WARNING
Avoid serious injury or death from loss of boat control. Continued boating with major impact damage
can result in sudden component failure with or without subsequent impacts. Have the power package
thoroughly inspected and any necessary repairs made.

18
CA802
Operating With Low Water Inlets In Shallow Water
75827
76363
A
CAUTION
Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be
sucked into the water inlets restricting or shutting off the water supply to the engine.
Extreme care should be exercised when operating a boat equipped with low water inlets (A) while maneuvering
in shallow water. Also, avoid beaching the boat with the engine(s) running.
CA866
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 hydraulic system will cushion the 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.
Use extreme caution when operating in shallow water or where underwater objects are known to be present.
Use extreme care to prevent striking submerged object while operating in REVERSE. No impact protection is
provided in REVERSE.
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 Mercury MerCruiser 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 protection from impact
damage under all conditions.