Mercury MCM Series Operating manual

B
1
72526
IMPORTANT INFORMATION
MAINTENANCE
Index

1B-0 - MAINTENANCE 90-823224--2 796
Table of Contents Page
Maintenance Schedule 1B-1. . . . . . . . . . . . . . . . . . . .
Maintenance Intervals 1B-1. . . . . . . . . . . . . . . . . .
To Be Done by Dealer 1B-2. . . . . . . . . . . . . . . . . .
Tune-Up Specifications 1B-4. . . . . . . . . . . . . . . . . . .
MCM (Stern Drive) 1B-4. . . . . . . . . . . . . . . . . . . . .
MIE (Inboard) 1B-5. . . . . . . . . . . . . . . . . . . . . . . . .
Fluid Capacities 1B-6. . . . . . . . . . . . . . . . . . . . . . . . . .
All Models 1B-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 1B-7. . . . . . . . . . . . . . . .
End of First Season Checkup 1B-7. . . . . . . . . . .
Fuel Specifications 1B-8. . . . . . . . . . . . . . . . . . . . . . .
Fuel 1B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Oil 1B-9. . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Fluid 1B-10. . . . . . . . . . . . . . . . . .
Transmission Fluid 1B-10. . . . . . . . . . . . . . . . . . . .
Coolant for Closed Cooling System 1B-10. . . . .
Maintaining Crankcase Oil Level 1B-10. . . . . . . . . .
Overfilled Engine Crankcase 1B-10. . . . . . . . . . .
Checking Engine Oil Level/Filling 1B-10. . . . . . .
Changing Oil and Filter 1B-10. . . . . . . . . . . . . . . . . . .
Maintaining Power Steering Pump
Fluid Level 1B-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
With Engine Warm 1B-11. . . . . . . . . . . . . . . . . . . .
With Engine Cold 1B-11. . . . . . . . . . . . . . . . . . . . .
Filling and Bleeding Power Steering System 1B-12
Maintaining Closed Cooling Coolant Level 1B-13. .
Flushing Cooling System 1B-13. . . . . . . . . . . . . . . . .
MCM (Stern Drive) 1B-13. . . . . . . . . . . . . . . . . . . .
MIE (Inboard) 1B-15. . . . . . . . . . . . . . . . . . . . . . . .
Maintaining Transmission Fluid Level 1B-15. . . . . .
Lubrication 1B-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable 1B-16. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable 1B-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coupler/U-Joint Shaft Splines 1B-18. . .
Drive Shaft Extension Models 1B-18. . . . . . . . . .
Starter Motor 1B-19. . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 1B-19. . . . . . . .
Precautions 1B-19. . . . . . . . . . . . . . . . . . . . . . . . . .
Layup 1B-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 1B-22. . . . . . . . . . . . . . . . . .
Recommissioning 1B-34. . . . . . . . . . . . . . . . . . . . .
Index

MAINTENANCE - 1B-190-823224--2 796
Maintenance Schedule
Maintenance Intervals
Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a pre-
viously printed schedules, are generally based on an average boating application and environment. However,
individual operating habits and personal maintenance preferences can have an impact on the suggested inter-
vals.Inconsiderationofthesefactors,MerCruiserhasadjustedsomemaintenanceintervalsandcorresponding
tasks to be performed. In some cases, this may allow for more individual tasks to be performed in a single visit
to the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner and servicing
dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide
with the individual operating habits, environment, and maintenance requirements.
Always disconnect battery cables from battery BEFORE working around electrical systems components to pre-
vent injury to yourself and damage to electrical system should a wire be accidentally shorted.
SCHEDULED MAINTENANCE THAT CAN BE PERFORMED BY OWNER/OPERATOR
NOTE: Only perform maintenance which applies to your particular power package.
Task Interval
Engine Crankcase Oil - Check level
Wkl
Closed Cooling Coolant - Check level
Wkl
Power Steering Fluid - Check level
Wkl
Stern Drive Unit Oil - Check level
Wkl
Battery - Check level and inspect for damage
Weekly
Fuel Pump Sight Tube (If Equipped) - Check that no
fuel is present
W
ee
kl
y
Power Trim Pump Oil - Check level
Anodes - Inspect for erosion
Gear Housing Water Pickups - Check for marine
growth or debris
Drive Belt(s) - Inspect condition and check tension Every 100 hours of operation or 120 days.
Whichever occurs first.
Propeller Shaft - Lubricate Saltwater Use: Every 50 hours of operation or 60
days, Whichever occurs first.
Power Package - Exterior Surfaces - Spray with rust
preventative
days
,
Whichever
occurs
first
.
Freshwater Use: Every 100 hours of operation or
120 days, Whichever occurs first.
Power Package Exterior Surfaces - Clean and paint Once a year
Cooling System - Flush seawater section Saltwater Use: After every use.
Index

1B-2 - MAINTENANCE 90-823224--2 796
Maintenance Schedule (Continued)
To Be Done by Dealer
NOTE: Only perform maintenance which applies to your particular power package.
Task Interval
Seawater Pickup Pump - Disassemble and inspect Whenever insufficient seawater flow is suspected.
(If operating temperature exceeds normal range.)
Crankcase Oil and Filter Change
Ed ffi b i
Ignition system - Clean and Inspect condition.
Ed ffi b i
Flame Arrestor and Crankcase Ventilation Hose -
Clean and Inspect.
Ed ffi b i
Positive Crankcase Ventilation (PCV) Valve (If So
Equipped) - Change
Ed ffi b i
Stern Drive unit Oil - Change
Ed ffi b i
Gimbal Ring Clamping Screws - Retorque to 40 ft.
lb. (54 N·m)
Ed ffi b i
Rear Engine Mounts - Check torque to 30-40 ft. lb.
(47-54 N·m)
Ed ffi b i
Gimbal Bearing - Lubricate
Ed ffi b i
Cooling System - Clean and Inspect
Ed ffi b i
Engine Alignment - Check
Ed ffi b i
Engine Coupling Universal Joint Shaft Splines -
Lubricate End of first boating season
and thereafter,
every100 hours of operation
Steering System - Lubricate and inspect for loose,
damage or missing parts. every100
h
ours o
f
operat
i
on
or once yearly, whichever
occurs first.
Electrical System - Check for loose or damaged
wiring.
occurs
first
.
Cooling System Hoses and Clamps - Inspect for
damage and deterioration. Check Clamps for
tightness.
Closed Cooling System Pressure Cap - Clean,
inspect and test .
Continuity Circuit - Check components for loose
connections, broken or frayed wires.
Shift and Throttle Cable and Linkage - Lubricate
and inspect for loose, damaged or missing parts
Engine Exhaust System - Inspect externally for
damage, deterioration and restrictions. Check for
tightness.
Ignition System - Check Timing and adjust as
needed.
Index

MAINTENANCE - 1B-390-823224--2 796
Maintenance Schedule (Continued)
To Be Done by Dealer
NOTE: Only perform maintenance which applies to your particular power package.
Task Interval
Steering Head and Remote Control - Inspect and
Lubricate. End of first boating season and thereafter, every
100 hours of operation or once yearly whichever
Carburetor (If So Equipped) - Inspect and adjust. 100 hours of operation or once yearly, whichever
occu
r
s
fir
s
t.
Throttle Body (Fuel Injection Models) - Inspect
occurs
first
.
Fuel Filters - Replace
OY
Quicksilver Mercathode System - Test output.
OY
Closed Cooling Coolant - Test for Alkalinity Once a Year
Heat Exchanger - Clean seawater section.
Drive Unit Bellows and Clamps - Inspect
Universal Joint Cross Bearings- Inspect End of first boating season and thereafter, every
200 hours of operation or once yearly, whichever
occurs first.
Closed Cooling Coolant - Replace Every Two Years
Index

1B-4 - MAINTENANCE 90-823224--2 796
Tune-Up Specifications
MCM (Stern Drive)
Model MCM 7.4L MCM 7.4L
PT Bravo
Three
MCM 454
Magnum MCM 454 EFI MCM 502 Magnum
MCM 502
EFI
Magnum
Propshaft Ratings
HP (KW)300 (224) 300 (224) 350 (261) 385 (287) 390 (291) 415 (309)
Number of Cylinders V-8
Displacement 454 C.I.D (7.4L) 502 C.I.D. (8.2L)
Bore/Stroke In. (mm) 4.25x4.00 (108x101.6) 4.47 x 4.00
(113.5 x 101.6)
Compression Ratio 8.0:1 8.6:1
Compression Pressure 150 PSI (1034 kPa)
Idle RPM
(in Forward Gear) 650 600 650 600
Max. RPM (at W.O.T.) 4200-4600 4600-5000
Oil Pressure
(at 2000 RPM) 30-70 PSI (207-483 kPa)
Min. Oil Pressure
(at Idle) 4 PSI (28 kPa)
Fuel Pump Pressure
(at 1800 RPM) 3-7 PSI (21-48 kPa)
Fuel Rail Pressure
(Running) (E.F.I. Only) 37 PSI
(255 kPa) 37 PSI
(255 kPa)
Electrical System 12 V Negative (–) Ground
Min. Battery
Requirements 450 cca
575 mca
90A/h
650 cca,
825 mca,
or 150A/h
550 cca,
700 mca or
120A/h
650 cca,
825 mca,
or 150A/h
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type AC MR43T/Champion RV15YC4/NGK BR6FS
Spark Plug Gap .035 in (0.9 mm)
Timing (at Idle RPM) 8 Degrees BTDC
Preliminary Idle Mixture 1 1/4 Turns 1 1/4 Turns
Thermostat 143°F
(62°C) 160°F (71°C) 143°F (62°C) 160°F (71°C)
Index

MAINTENANCE - 1B-590-823224--2 796
MIE (Inboard)
Model MIE 7.4L MIE 454 EFI MIE 8.2L
Propshaft Ratings
HP (KW) 310 (231) 395 (231) 400 (298)
Number of Cylinders V-8
Displacement 454 C.I.D (7.4L) 502 C.I.D. (8.2L)
Bore/Stroke 4.25x4.00 In. (108x101.6 mm) 4.47x4.00 (113.5x101.6)
Compression Ratio 8.0:1 8.6:1
Compression Pressure 150 PSI (1034 kPa) 150 PSI (1034 kPa)
Idle RPM
(in Forward Gear) 650 600 600
Max. RPM (at W.O.T.) 4000-4400 4600-5000 4400-4800
Oil Pressure
(at 2000 RPM) 30-70 PSI (207-483 kPa)
Min. Oil Pressure
(at Idle) 4 PSI (28 kPa)
Fuel Pump Pressure
(at 1800 RPM) 3-7 PSI (21-48 kPa) 3-7 PSI (21-48 kPa)
Fuel Rail Pressure
(Running) (E.F.I. Only) 37 PSI (255 kPa)
Electrical System 12 V Negative (–) Ground
Min. Battery
Requirements 450 cca, 575 mca or 90A/h 650 cca, 825 mca, or 150A/h 550 cca, 700 mca or 120A/h
Firing Order 1-8-4-3-6-5-7-2
Spark Plug Type AC MR43T/Champion RV15YC4/NGK BR6FS
Spark Plug Gap .035 in (0.9 mm)
Timing (at Idle RPM) 8 Degrees BTDC
Preliminary Idle Mixture 1-1/4 Turns 1-1/4 Turns
Thermostat 143°F
(62°C) 160°F (71°C) 143°F (62°C)
72008
LH ROTATION
FRONT
Firing Order
1-8-4-3-6-5-7-2
Index

1B-6 - MAINTENANCE 90-823224--2 796
Fluid Capacities
NOTICE
All capacities are approximate fluid measures.
All capacities are U.S. Quarts (Litres).
MODEL MCM AND MIE
454 CID / 7.4L MCM AND MIE 7.4L MPI MCM AND MIE 502 CID / 8.2L
Crankcase Oil1(With Filter) 7 (6.6) 7 (6.6)
Seawater Cooling System220 (19)
Closed Cooling System 28 (26.5) 118 (17) 218 (17) 228 (26.5) 2
1Closed cooling system with manifolds included in coolant side of system.
2Closed cooling system without manifolds included in coolant side of system.
IMPORTANT: It may be necessary to adjust oil levels depending on installation angle and cooling sys-
tems (heat exchanger and fluid lines).
MAKE AND MODEL CAPACITY QUARTS (LITRES) FLUID TYPE
Hurth 630A 3-1/4 (3)
D III A i T i i
630V 4.25 (4.0)
Dexron III Automatic Transmission
800A2 5-3/4 (5.5)
D
exron
III
A
utomat
i
c
T
ransm
i
ss
i
on
Fluid
800AM 4-2/5 (4.2)
Fluid
Velvet Drive 1:1 2 (1.9)
NOTE: Always use dipstick to determine exact quantity of fluid required
NOTE: Seawater cooling system capacity information is for winterization use only
Index

MAINTENANCE - 1B-790-823224--2 796
All Models
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 maximum engine performance. During this
break-in period, the following rules must be
observed:
•Do not operate below 1500 RPM for extended
periodsof timefor first10 hours.Shift intogear as
soon as possible after starting and advance
throttle above 1500 RPM if conditions permit
safe operation.
•Do not operate at one speed consistently 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 temperature.
After Break-in Period
To help extend the life of your MerCruiser power
package, the following recommendations should be
considered;
•Use a propeller that allows the engine to operate
at or near the top of the maximum RPM range
(See “Specifications” section) when at full throttle
with a normal boat load.
•Operation at 3/4 throttle setting or lower is recom-
mended. Refrain from prolonged operation at
maximum (full throttle) RPM.
End of First Season Checkup
At the end of the first season of operation, an
Authorized MerCruiser Dealer should be contacted
to discuss and/or perform various scheduled
maintenance items. If you are in an area where the
product is operated continuously (year-round
operation),youshouldcontact your dealerattheend
of the first 100 hours of operation, or once yearly,
whichever occurs first.
Index

1B-8 - MAINTENANCE 90-823224--2 796
Fuel Specifications
Fuel
!CAUTION
Useofimproper gasoline can damage the engine
seriously. Engine damage that results from use
ofimpropergasolineisconsideredmisuse of the
engineandisnotcoveredunder MerCruiserWar-
ranty.
USA and Canada
Fuelhaving a posted pump Octane Rating of87 (R+
M) / 2 minimum. Premium gasoline [92 (R + M) / 2] is
also acceptable . DO NOT use leaded gasolines.
Outside USA and Canada
FuelhavingapostedpumpOctaneRatingof92RON
minimum. Premium gasoline (98 RON) is also ac-
ceptable. If unleaded is not available, use a major
brand of leaded gasoline.
Gasolines containing alcohol, either methyl alcohol
(methanol) or ethyl alcohol (ethanol) may cause in-
creased:
•Corrosion of metal parts.
•Deterioration of elastomer and plastic parts.
•Fuel permeation through flexible fuel lines.
•Wear and damage of internal engine parts.
•Starting and operating difficulties.
Someoftheseadverseeffectsareduetothetenden-
cyofgasolinescontainingalcoholtoabsorbmoisture
fromthe air, resultingin a phaseof waterand alcohol
separating from the gasoline in the fuel tank.
The adverse effects of alcohol are more severe with
methyl alcohol (methanol) and are worse with in-
creasing alcohol content.
!WARNING
Fire and Explosion Hazard: Fuel leakage from
any part of the fuel system can be a fire and ex-
plosion hazard which can cause serious bodily
injuryordeath. Careful periodicinspectionofthe
entirefuelsystem ismandatory,particularlyafter
storage. All fuel system components including
fuel tanks (whether plastic, metal or fiberglass),
fuel lines, primer bulbs, fittings, fuel filters and
carburetors should be inspected for leakage,
softening, hardening, swelling or corrosion. Any
sign of leakage or deteriorationrequires replace-
ment before further engine operation.
Becauseofpossible adverseeffectsofalcohol in
gasoline, it is recommended that only alco-
hol-free gasoline be used where possible. If only
fuelcontainingalcoholisavailable,or if the pres-
ence of alcohol is unknown, increased inspec-
tion frequency for leaks and abnormalities is re-
quired.
!WARNING
Avoid gasoline fire or explosion.Improper instal-
lation of brass fittings or plugs into fuel pump or
fuel filter base can crack casting and/or cause a
fuel leak.
IMPORTANT: When operating a MerCruiser en-
gine on gasoline containing alcohol, storage of
gasoline in the fuel tank for long periods should
be avoided. Long periods of storage, common to
boats, create unique problems. In cars, alco-
hol-blend fuels normally are consumed before
they can absorb enough moisture to cause
trouble, but boats often sit idle long enough for
phase separation to take place. In addition, inter-
nal corrosion may take place during storage if al-
cohol has washed protective oil films from inter-
nal components.
GASOLINE / ALCOHOL BLENDS
Manynewmotorvehicleownermanualsarewarning
aboutthepotential damagefromusing gasoline con-
taining alcohol, especially METHANOL. They cite
possiblefuelsystemdamageandperformanceprob-
lems. These are just two of the hazards that may be
caused by alcohol. These same problems as well as
the additional safety risk of fire and explosion from
fuel system leaks apply to marine inboard engines.
METHANOL is more severe in its bad effect than is
ETHANOL. Alcohol is also more severe in older en-
gines since newer engines have materials which are
more resistant to alcohol.
EFFECTS OF GASOLINE / ALCOHOL BLENDS
ON MARINE ENGINES
Corrosion of metals may result from use of alco-
hol-gasoline blends. Portable or permanently in-
stalled fuel tanks of metal or fiberglass, fuel filters,
fuel lines and float bowls may be affected by alcohol
blended fuels. Many fiberglass fuel tanks are slowly
dissolvedbyalcohol,leadingimmediatelytofilterand
carburetor plugging and eventually to tank failure.
Fuels containing alcohol will absorb moisture from
the air. At first, this moisture will remain in solution,
Index

MAINTENANCE - 1B-990-823224--2 796
but once the water content of the fuel has built up to
about one-half of one percent, it will separate out
(phase separation), bringing the alcohol with it. This
alcohol-watermixturesettlestothebottomofthefuel
tank and if this mixture gets into the engine, the en-
gine can be seriously damaged internally, as it may
washtheprotectivefilmofoilofftheboreofanycylin-
derthatit enters. Beforetheenginecan be restarted,
it is necessary to remove the separated alcohol and
water layer, flush out the fuel system with clean fuel
and remove and dry the spark plugs.
BOAT / MOTOR STORAGE
When operating a MerCruiser engine on gasoline
containing alcohol, storage of gasoline in the fuel
tank for long periods of time should be avoided.
Long periods of storage, common to boats, create
unique problems. In cars, gasoline/alcohol blend
fuelsnormallyare consumedbeforethey can absorb
enough moisture to cause trouble,but boats oftensit
idle long enough for phase separation to take place.
In addition, internal corrosion may take place during
storageifalcoholhaswashedprotectiveoilfilmsfrom
internal components.
WINTER STORAGE
If boat is to be placed in winter storage, carburetors
must be run dry at idle RPM. Permanent fuel tanks
should be drained completely and Quicksilver Gaso-
line Stabilizer and Conditioner added to any fuel re-
maining in the tank. Portable fuel tanks should be
emptied completely.
WARRANTY
Performance problems and fuel system or other
damage resulting from the use of gasoline-alcohol
blendedfuelsarenottheresponsibilityofMerCruiser
and will not be covered under our warranty.
CONTINUING EVALUATIONS
The effects of gasoline with ETHANOL and METHA-
NOL are still being evaluated by the United States
CoastGuard,theNationalMarineManufacturersAs-
sociation(NMMA),Mercury Marineandotherengine
and boat manufacturers.
We have recommended pump posting of alcohol
content of gasoline. Further we recommend using
gasoline known not to contain any METHANOL or
ETHANOL when possible.
TEST FOR ALCOHOL CONTENT IN GASOLINE
The following is an acceptable and widely used field
procedure for the detection of alcohol in gasoline.
Use any small transparent bottle or tube that can be
capped and is, or can be, provided with graduations
oramarkatabout1/3full.Apencilmarkonapieceof
adhesive tape may be used.
Procedure
1. Fill the container with water to the mark.
2. Addfuel almostto fillthe container, leavingsome
air space, then cap the container. The propor-
tions of fuel to water are not critical, but there
should be 2 to 3 times as much fuel as water.
3. Shake container vigorously and allow it to sit up-
right for 3 to 5 minutes. If the volume of water
appears to have increased, alcohol is present. If
you are not sure, there is no need for concern. If
thedividinglinebetweenwaterandfuelbecomes
cloudy, use the middle of the cloudy band.
Crankcase Oil
To help obtain optimum engine performance and to
provide maximum protection, we strongly recom-
mend the use of Quicksilver 4-Cycle Marine Engine
Oil.Ifnotavailable,agoodgrade,straightweight,de-
tergentautomotiveoilofcorrectviscosity,withanAPI
classification of SF or SG, may be used.
The following chart is a guide to crankcase oil selec-
tion. 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
SG) or, as a second but less preferable choice,
20W-50 (SF or SG) may be used.
IMPORTANT: The use of non-detergent oils, mul-
ti-viscosity oils (other than 20W-40 or 20W-50),
low quality oils or oils which contain solid addi-
tives specifically are not recommended.
72010
Index

1B-10 - MAINTENANCE 90-823224--2 796
Power Steering Fluid
Use Quicksilver Power Trim and Steering Fluid, or
automatic transmission Fluid (ATF), Dexron, Dexron
II, Dexron IIl.
Transmission Fluid
Velvet Drive - 10 wt. tractor hydraulic fluid meeting
the C-3/TO-2 specification (preferably Mobil 424,
Chevron, or Citgo).
Hurth - Automatic transmission fluid (ATF) Dexron II
or Dexron IIl.
Coolant for Closed Cooling System
!CAUTION
Alcohol or Methanol base antifreeze or plain wa-
ter, are not recommended for use in fresh water
section of cooling system at any time.
We recommend that the coolant section of closed
cooling system be filled with Quicksilver Pre-Mixed
Engine Coolant. In areas where the possibility of
freezingdoesnotexist,itispermissibletouseasolu-
tion of rust inhibitor and water (mixed to manufactur-
er’s recommendations).
MerCruiser V-8 engines can use any type of perma-
nent antifreeze or any brand antifreeze solution that
meets GM specification 1825M.
Maintaining Crankcase Oil
Level
Overfilled Engine Crankcase
Overfilled crankcases (oil level being too high ) can
cause a fluctuation or drop in oil pressure and rocker
arm “clatter” on MerCruiser engines. The over-full
condition results in the engine crankshaft splashing
and agitating the oil, causing it to foam (become aer-
ated). The aerated oil causes the hydraulic valve lift-
ers to “bleed down.” This, in turn, results in rocker
arm “clatter” and loss of engine performance, due to
the valves not opening properly.
Care must be taken when checking engine oil level.
Oil level must be maintained between the ADD mark
and the FULL mark on the dipstick. To ensure that
you are not getting a “false reading,” make sure the
followingstepsaredonebeforecheckingtheoillevel.
•Boat “at rest” in the water, or
•If boat is on a trailer, raise or lower bow until the
boat is setting at the approximate angle that it
would be if setting “at rest” in the water.
•Allow sufficient time for oil to drain into the crank-
case if engine has just been run or oil has just
been added.
Checking Engine Oil Level/Filling
IMPORTANT: ENGINE CRANKCASE OIL MUST
BE CHECKED AT INTERVALS SPECIFIED IN
“MAINTENANCE SCHEDULE” CHART. It is nor-
mal for an engine to use a certain amount of oil
in the process of lubrication and cooling of the
engine. The amount ofoil consumption is greatly
dependent upon engine speed, with consump-
tion being highest at wide-open-throttle and de-
creasing substantially as engine speed is re-
duced.
1. Stop engine and allow boat to come to a rest.
2. Allowoiltodrainbackintooilpan-approximately
5 minutes.
3. Remove dipstick. Wipe clean and reinstall. Push
dipstick all the way into dipstick tube.
4. Remove dipstick and note the oil level.
5. Oil level must be between the FULL and ADD
marks.
6. If oil level is below ADD mark, proceed to Steps
7 and 8.
7. Removeoilfillercapfromvalverockerarmcover.
8. Addrequiredamountofoiltobringlevelupto,but
not over, the FULL mark on dipstick.
Changing Oil and Filter
1. Startengineand rununtilitreaches normal oper-
ating temperatures.
IMPORTANT: Change oil when engine is warm
from operation, as it flows more freely, carrying
away more impurities.
2. Stop engine.
3. Remove drain plug from oil pan or from oil drain
hose.
Index

MAINTENANCE - 1B-1190-823224--2 796
NOTE:Ifdrainplugisnotaccessiblebecauseofboat
construction, oil may be removed through dipstick
tube, using a Quicksilver Crankcase Oil Pump. (See
Quicksilver Accessory Guide.)
4. After oil has drained completely, reinstall drain
plug (if removed) and tighten securely.
5. Remove and discard oil filter and its sealing ring.
6. Coatsealingringonnewfilterwithengineoil,and
install.Tightenfiltersecurely(followingfilterman-
ufacturer’s instructions). Do not over-tighten.
7. Fill crankcase with oil.
8. Start engine and check for leaks.
Maintaining Power Steering
Pump Fluid Level
With Engine Warm
1. Stop engine and position drive unit so that it is
straight back.
2. Remove fill cap/dipstick from power steering
pump and note fluid level.
72517
ba
a - Fill Cap / Dipstick
b - Power Steering Pump
3. Level should be between the FULL HOT mark
and ADD mark on dipstick.
72518
a
a - Proper Fluid Level with Engine Warm
4. If level is below ADD mark, but fluid is still visible
inpumpreservoir,addrequiredamountofQuick-
silverPowerTrimandSteeringFluidorautomatic
transmission fluid (ATF), Dexron, or Dexron II,
throughfill cap opening,tobring levelupto FULL
HOT mark on dipstick. DO NOT OVERFILL.
5. Iffluidisnotvisibleinreservoir,aleakexistsinthe
power steering system. Find cause and correct.
With Engine Cold
1. With engine stopped, position drive unit so that it
is straight back.
2. Remove fill cap/dipstick from power steering
pump and note fluid level.
3. Level should be between FULL COLD mark and
bottom of dipstick.
72519
a
a - Proper Fluid Level with Engine Cold
Index

1B-12 - MAINTENANCE 90-823224--2 796
4. If level is below bottom of dipstick, but fluid is still
visiblein pumpreservoir, addrequired amountof
Quicksilver Power Trim and Steering Fluid or au-
tomatic transmission fluid (ATF), Dexron Dexron
II, or Dexron III, through fill cap opening, to bring
level up to FULL COLD mark on dipstick. DO
NOT OVERFILL.
If fluid is not visible in reservoir, a leak exists in the
power steering system. Find cause and correct.
Filling and Bleeding Power
Steering System
IMPORTANT: Power steering system must be
filled exactly as explained in the following to be
sure that all air is bled from the system. All air
mustberemoved,or fluid in pumpmayfoamdur-
ing operation and be discharged from pump res-
ervoir. Foamy fluid also may cause power steer-
ing system to become spongy, which may result
in poor boat control.
1. With engine stopped, position drive unit so that it
is straight back. Remove fill cap/dipstick from
power steering pump. Add Quicksilver Power
Trim and Steering Fluid or automatic transmis-
sion fluid (ATF), Dexron, Dexron II or Dexron III,
asrequired,tobringleveluptoFULLCOLDmark
on dipstick.
IMPORTANT: Use only Quicksilver Power Trim
and Steering Fluid or automatic transmission
fluid(ATF),Dexron,DexronIIorDexronIIl inpow-
er steering system.
2. Turnsteeringwheel backandforthto end oftrav-
el in each direction several times, then recheck
fluid level and add fluid, if necessary.
3. Install vented fill cap.
!CAUTION
DO NOT operate engine without water being
supplied to seawater pickup pump, or pump im-
peller may be damaged and subsequent over-
heating damage to engine may result.
4. Start engine and run at fast idle (1000-1500
RPM) until engine reaches normal operating
temperature. During this time, turn steering
wheel back and forth to end of travel in each di-
rection several times.
5. Position drive unit so that it is straight back and
stop engine. Remove fill cap from pump. Allow
any foam in pump reservoir to disperse, then
check fluid level and add fluid, as required, to
bringlevel upto FULLHOT markon dipstick.DO
NOT OVERFILL.Reinstall fill cap securely.
IMPORTANT: Drive unit must be positioned
straight back and power steering fluid must be
hot to accurately check fluid level.
6. Iffluidisstillfoamy(inStep5),repeatSteps4and
5until fluiddoes notfoam andlevel remainscon-
stant.
Index

MAINTENANCE - 1B-1390-823224--2 796
Maintaining Closed Cooling
Coolant Level
!WARNING
Allowengine tocooldownbeforeremovingpres-
sure cap. Sudden loss of pressure could cause
hot coolant to boil and discharge violently. After
engine has cooled, turn cap 1/4 turn to allow any
pressure to escape slowly, then push down and
turn cap all the way off.
1. Coolant level in heat exchanger should be full (to
bottom of filler neck).
IMPORTANT: When reinstalling pressure cap, be
sure to tighten it until it contacts stop on filler
neck.
2. Coolant level should be between the ADD and
FULL marks on coolant recovery reservoir with
the engine at normal operating temperature.
72520
a
a - Coolant Recovery Reservoir
Flushing Cooling System
Ifengineisoperatedinsalty,polluted,ormineral-lad-
en water, flush cooling system (preferably after each
use) to reduce corrosion and prevent the accumula-
tionof deposits in the system. Thoroughly flushcool-
ing system prior to storage.
MCM (Stern Drive)
BOAT OUT OF WATER
1. Install flushing attachment over water pickup
holes in gear housing as shown.
2. Attach a garden hose between the flushing at-
tachment and a water tap.
72693
a
b
a - Flushing Attachment
b - Hose
!WARNING
When flushing, be certain the area around pro-
peller is clear, and no one is standing nearby. To
avoid possible injury, remove propeller.
!CAUTION
Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump
may collapse flushing hose, causing engine to
overheat.
Index

1B-14 - MAINTENANCE 90-823224--2 796
!CAUTION
Watch temperature gauge on dash to ensure that
engine does not overheat.
3. Partiallyopenwatertap(approximately1/2maxi-
mum capacity). DO NOT use full water pressure.
4. Place remote control in neutral, idle speed posi-
tion, and start engine.
5. Operate engine at idle speed in neutral for 10
minutes, or until discharge water is clear, then
stop engine.
6. Shut off water tap. Remove garden hose and
flushing attachment.
BOAT IN WATER
1. Raise drive unit to full UP position.
2. Install flushing attachment over water pickup
holes in gear housing as shown.
3. Attach a garden hose between the flushing at-
tachment and a water tap.
72693
a
b
a - Flushing Attachment
b - Hose
4. Lower drive unit to full IN position.
!CAUTION
Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump
may collapse flushing hose, causing engine to
overheat.
!CAUTION
Watch temperature gauge on dash to ensure that
engine does not overheat.
5. Partiallyopenwatertap(approximately1/2maxi-
mum capacity). DO NOT use full water pressure.
6. Place remote control in neutral, idle speed posi-
tion, and start engine.
7. Operate engine at idle speed in neutral for 10
minutes, then stop engine.
8. Shut off water tap.
9. Raise drive unit to full UP position.
10. Remove garden hose and flushing attachment.
Index

MAINTENANCE - 1B-1590-823224--2 796
MIE (Inboard)
!CAUTION
If boat is in the water, seacock, if so equipped,
must remain closed until engine is to be
re-started, to prevent water from flowing back
into cooling system and/or boat. If boat is not
fittedwithaseacock,waterinlethosemustbeleft
disconnected and plugged (to prevent water
from flowing back into cooling system and/or
boat). As a precautionary measure, attach a tag
to the ignition switch or steering wheel of the
boat with the warning: Open seacock or recon-
nect water inlet hose before starting engine.
IMPORTANT: If a seacock is to be installed for
this purpose, valve used must have an internal
cross-sectional area equal to or greater than wa-
ter inlet hose to prevent restricting water flow
during normal operation. A 1-1/4 in. (32 mm), or
larger, brass ball valve or gate valve is recom-
mended.
1. If boat is in water, close seacock, if so equipped,
or disconnect and plug seawater inlet hose to
prevent seawater from entering boat.
2. Remove inlet hose from seawater pickup pump.
3. Using an adaptor, connect a garden hose from a
water tap to seawater pump inlet.
4. Partiallyopenwatertap(approximately1/3maxi-
mum). Do not use full water pressure.
5. Place the remote control lever in neutral position
and start engine.
!WARNING
When flushing, be certain the area around pro-
peller is clear, and no one is standing nearby. To
avoid possible injury, remove propeller.
!CAUTION
Do not run engine above 1500 RPM when flush-
ing. Suction created by seawater pickup pump
may collapse flushing hose, causing engine to
overheat.
!CAUTION
Watch temperature gauge on dash to ensure that
engine does not overheat.
6. Operate engine at idle speed in neutral for 10
minutes, or until discharge water is clear. Stop
engine.
7. Shut off water tap. Remove garden hose and
adaptor from pump inlet and reconnect water in-
let hose. Be sure to tighten hose clamp securely.
IMPORTANT: If boat is in the water, do not open
water inlet valve until engine is to be restarted to
prevent contaminated water from flowing back
into engine. If boat is not fitted with a valve, leave
water inlet hose disconnected and plugged.
Maintaining Transmission
Fluid Level
IMPORTANT: Be sure to push dipstick all the way
down into dipstick tube when checking fluid
level.
1. Remove dipstick to check transmission fluid lev-
el. Fluid level may be over the full mark because
fluid from the cooler and lines has drained back
into the transmission. If fluid level is low, add the
specified fluid through the dipstick hole until full
mark on dipstick is reached. DO NOT OVER-
FILL.
72527
Hurth
Index

1B-16 - MAINTENANCE 90-823224--2 796
72526
Velvet Drive
IMPORTANT: To accurately check fluid level, en-
gine MUST BE run at 1500 RPM for 2 minutes im-
mediately prior to checking level.
2. Start engine and run at 1500 RPM for 2 minutes
to fill all circuits, lines, and cooler.
3. Stop engine and quickly check level before fluid
drains back into transmission. Add fluid if neces-
sary.
4. If fluid level is extremely low, check transmission
case, cooler, and hoses for leaks.
IMPORTANT: Velvet Drive - transmission - use 10
wt. tractor hydraulic fluid meeting the C-3/TO-2
specification (preferably Mobil 423, Chevron, or
Citgo).
Hurth transmission - use Dexron II or Dexron III
automatic transmission fluid (ATF).
Lubrication
Throttle Cable
MODELS WITH 4 BARREL CARBURETOR
72014
b
a
a - Pivot Points
b - Guide Contact Surface
MODELS WITH THROTTLE BODY FUEL
INJECTION
75038
a
a
b
a - Pivot Points
b - Guide Contact Surface
Index

MAINTENANCE - 1B-1790-823224--2 796
MODELS WITH MULTI-PORT FUEL INJECTION
72791
b
a
a
a - Pivot Points
b - Guide Contact Surface
Shift Cable
72016
b
a
a
a
b
MCM Models - Typical Shift Cable
a - Pivot Points
b - Guide Contact Surface
MIE MODEL TYPICAL SHIFT CABLE AND
TRANSMISSION LINKAGE
71208
a
a
b
Hurth
a - Pivot Points
b - Guide Contact Surface
72528
a
a
b
Velvet Drive
a - Pivot Points
b - Guide Contact Surface
Index

1B-18 - MAINTENANCE 90-823224--2 796
Engine Coupler/U-Joint Shaft Splines
NOTE:Enginecouplerandshaftsplinesaregreased
with Quicksilver Engine Coupler Spline Grease,
92-816391A4; universal joints are greased with
Quicksilver 2-4-C Marine Lubricant.
NOTE: Refer to MerCruiser Stern Drive Service
Manual for stern drive unit removal and installation,
if necessary.
IMPORTANT:SternDriveUnitdoesnothavetobe
removed to grease coupler.
72529
a
b
MCM Models
a - Quicksilver Engine Coupler Spline Grease
b - Grease Fitting(s) Use Grease Fitting If Drive Is Installed
72531
a
a
a
Typical Bravo Drive
a - Quicksilver Engine Coupler Spline Grease
Drive Shaft Extension Models
72018
a
a
Transom End
a - Lubrication Points
72028
a
a
Engine End
a - Lubrication Points
Index