Mercury MerCruiser MCM 4.3L BRAVO User manual

1
B
MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-1
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Tools 1B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 1B-2. . . . .
Maintenance Schedules 1B-3. . . . . . . . . . . . . .
Maintenance Intervals 1B-3. . . . . . . . . . . . .
Gas Sterndrive 1B-3. . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance * 1B-3. . . . . . . . . . . .
Scheduled Maintenance * 1B-4. . . . . . . . . .
Engine and Tune-Up Specifications 1B-5. . . .
MCM (Sterndrive) 1B-5. . . . . . . . . . . . . . . . .
Fluid Capacities 1B-6. . . . . . . . . . . . . . . . . . . . .
Sterndrive Engines 1B-6. . . . . . . . . . . . . . .
Sterndrives 1B-6. . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 1B-7. . . . . . . . . . . . .
After Break-in Period 1B-7. . . . . . . . . . . . . . . .
End of First Season Checkup 1B-7. . . . . . . . .
Specifications 1B-8. . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 1B-8. . . . . . . . . . .
Test For Alcohol Content In Gasoline 1B-10
Power Steering Fluid 1B-10. . . . . . . . . . . . . . . .
Coolant for Closed Cooling System 1B-10. . . .
Crankcase Oil 1B-11. . . . . . . . . . . . . . . . . . . . . .
Overfilled Crankcase Oil 1B-11. . . . . . . . . . .
Checking Engine Oil Level / Filling 1B-12. .
Changing Oil and Filter 1B-12. . . . . . . . . . . . . . .
Changing Water Separating Fuel Filter 1B-13.
Power Steering System 1B-15. . . . . . . . . . . . . .
Checking Fluid Level 1B-15. . . . . . . . . . . . . .
Engine Cold 1B-15. . . . . . . . . . . . . . . . . . . . .
Filling and Bleeding 1B-16. . . . . . . . . . . . . . .
Closed Cooling System 1B-17. . . . . . . . . . . . . .
Checking Coolant Level 1B-17. . . . . . . . . . .
Flushing System 1B-18. . . . . . . . . . . . . . . . . .
Lubrication 1B-20. . . . . . . . . . . . . . . . . . . . . . . . .
Throttle Cable 1B-20. . . . . . . . . . . . . . . . . . . .
Shift Cable 1B-20. . . . . . . . . . . . . . . . . . . . . . .
Engine Coupler /
U-Joint Shaft Splines 1B-21. . . . . . . . . . . . .
Sterndrive Drive
Shaft Extension Models 1B-22. . . . . . . . . . .
Cleaning Flame Arrestor 1B-22. . . . . . . . . . . . .
Top Mounted Flame Arrestor 1B-23. . . . . . .
Serpentine Drive Belt 1B-23. . . . . . . . . . . . . . . .
Component Location 1B-23. . . . . . . . . . . . . .
Serpentine Belt Routing 1B-24. . . . . . . . . . . . . .
S/N 0L619083 and Below 1B-24. . . . . . . . . .
S/N 0L619084 and Above 1B-25. . . . . . . . .
Inspection 1B-26. . . . . . . . . . . . . . . . . . . . . . .
Replacing and/or Adjusting Tension 1B-26.
Ignition Timing 1B-27. . . . . . . . . . . . . . . . . . . . . .
Thunderbolt V Models 1B-27. . . . . . . . . . . . .
EFI 1B-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage 1B-29. . . .
Precautions 1B-29. . . . . . . . . . . . . . . . . . . . . .
Power Package Layup 1B-31. . . . . . . . . . . .
Draining Instructions 1B-33. . . . . . . . . . . . . .
Draining Sterndrive 1B-38. . . . . . . . . . . . . . .
Recommissioning 1B-39. . . . . . . . . . . . . . . . .

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-2 90-861328--1 NOVEMBER 1999
Tools
Description Part Number
Timing Light 91-99379
Quicksilver Scan Tool 91-823686A2
Lubricants / Sealants / Adhesives
Description Part Number
Quicksilver Liquid Neoprene 92-25711--3
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Loctite Pipe Sealant With Teflon Obtain Locally
Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-3
Maintenance Schedules
Maintenance Intervals
Maintenance intervals and the tasks to be performed, as shown in this current schedule, or
as found in a previously printed schedules, are generally based on an average boating
application and environment. However, individual operating habits and personal mainte-
nance preferences can have an impact on the suggested intervals. In consideration of these
factors, Mercury MerCruiser has adjusted some maintenance intervals and corresponding
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.
CAUTION
Always disconnect battery cables from battery BEFORE working around electrical
systems components to prevent injury to yourself and damage to electrical system
should a wire be accidentally shorted.
Gas Sterndrive
Routine Maintenance * Each
Day
Start
Each
Day
End Weekly Every
Two
Months
Check crankcase oil (interval can be extended based on experi-
ence). 
If operating in salt, brackish or polluted waters, flush cooling sys-
tem after each use. 
Check drive unit oil level, trim pump oil level and power steering
pump fluid level. 
Check water pickups for debris or marine growth. Check water
strainer and clean. Check coolant level. 
Inspect drive unit anodes and replace if 50 percent eroded. 
Inspect fuel pump sight tube and have pump replaced if fuel is
present. 
Check battery connections and fluid level. 
Lubricate propeller shaft and the retorque nut (if operating in only
freshwater, this maintenance may be extended to every four
months).

Operating in Saltwater Only: treat engine surface with corrosion
guard. 
Clean air filter every 50 hours of operation. 
* Only perform maintenance which applies to your particular power package
 Standard Models
 Horizon Models

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-4 90-861328--1 NOVEMBER 1999
Gas Sterndrive(Continued)
Scheduled Maintenance *
Annu-
ally
Every
100
hours or
Annually
Every
200
hours
or 3
years
Every
300
hours
or 3
years
Every
2
years
Every
5
years
Touch-up paint power package and spray with corrosion
guard. 
Change crankcase oil and filter. 
Change drive unit oil and retorque connection of gimbal
ring to steering shaft. 
Replace fuel filter(s). 
Check steering system and remote control for loose,
missing or damaged parts. Lubricate cables and link-
ages. 
Inspect U-joints, splines and bellows. Check clamps.
Check engine alignment. Lubricate U-joints splines.  
Lubricate gimbal bearing and engine coupler.  
Check continuity circuit for loose or damaged connec-
tions. Test MerCathodeunit output on Bravo Models.  
Retorque engine mounts.  
Check spark plugs, wires, distributor cap and ignition
timing. Check and adjust idle speed.  
Clean flame arrestor and crankcase ventilation hoses.
Replace PCV valve.  
Check electrical system for loose, damaged or corroded
fasteners.  
Inspect condition and tension of belts.  
Check cooling system and exhaust system hose clamps
for tightness. Inspect both systems for damage or leaks.  
Disassemble and inspect seawater pump and replace
worn components.  
Clean seawater section of closed cooling system.
Clean, inspect and test pressure cap.  
Replace coolant. 
* Only perform maintenance which applies to your particular power package
 Standard Models
 Horizon Models
Whichever Occurs First
 Interval will be reduced if not using extended life coolant.
 Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-5
Engine and Tune-Up Specifications
MCM (Sterndrive)
Model MCM 4.3L
ALPHA /
BRAVO
MCM 4.3LH
ALPHA /
BRAVO
MCM 4.3L
EFI
ALPHA /
BRAVO
Propshaft Horsepower
(SAV1 Rating) 190 205 (190)22101(188)2
Propshaft Kilowatts (SAV1 Rating) 142 153 (142)21571(146)2
Number of Cylinders V-6
Displacement 262 cid (4.3 l)
Bore / Stroke - in. (mm) 4.0 x 3.48 (101.6 x 88.4)
Compression Ratio 9.4:1 9.4:1
Compression Pressure Minimum 100 psi (690 kPa)7
Idle rpm In Neutral3650 rpm5600 rpm5
Maximum rpm (at WOT)34400-4800 rpm
Oil Pressure (at 2000 rpm) Minimum 30 psi (207 kPa)
Minimum Oil Pressure (at Idle) Minimum 4 psi (28 kPa)
Fuel Pressure (1800 rpm) 3-7 psi (21-48 kPa) 30 psi ( kPa)
Electrical System 12 V Negative (–) Ground
Alternator Rating 55 or 65 amp 8
Minimum Battery Requirements 375 cca / 475 mca / 90 Ah
Firing Order 1-6-5-4-3-2
Spark Plug Type AC - MR43LTS
Champion - RS12YC
NGK - BPR6EFS
Spark Plug Gap .045 in. (1.1 mm)
Timing (at idle rpm)410°BTDC 8°BTDC
Preliminary Idle Mixture 1 1/4 Turns DNA
Thermostat 160°F (71°C)
1Power Rated in Accordance with NMMA (National Marine Manufacturers’ Association) rating procedures.
2Power Rated in Accordance with SAV1 rating procedures. This rating procedure is used to certify that the
engine complies with “Stage 1” Bodensee and Swiss Regulations. Horsepower differences shown result from
differences in test rpm, allowable test tolerances, and/or installation of special kit components.
3Measured using an accurate service tachometer with engine at normal operating temperature.
4Timing must be set using a special procedure as outlined in the appropriate section of this manual. Timing can-
not be properly set using the conventional method.
5A special procedure must be followed to adjust idle rpm. Consult your Authorized Mercury MerCruiser Dealer
before attempting this procedure.
6Idle speed on EFI models is not adjustable.
7Minimum recorded compression in any one cylinder should not be less than 70 percent of the highest recorded
cylinder.
8Serial Number Break for 65 Amp alternator: OL619083 and above.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-6 90-861328--1 NOVEMBER 1999
Fluid Capacities
NOTICE
Unit Of Measurement: U.S. Quarts (Liters)
All capacities are approximate fluid measures.
Sterndrive Engines
Model All Models
Crankcase Oil (With Filter) 14-1/2 (4.3)
Seawater Cooling System 215 (14.1)
Closed Cooling System 20 (19)
1Always use dipstick to determine exact quantity of oil or fluid required.
2Seawater Cooling System capacity information is for winterization use only.
Sterndrives
NOTICE
Unit Of Measurement: U.S. Fluid Ounces (Milliliters)
All capacities are approximate fluid measures.
Model ALPHA ONE
Drive Unit Oil Capacity (With Gear Lube Monitor) 64 (1892)
Model BRAVO ONE BRAVO TWO BRAVO THREE
Drive Unit Oil Capacity
(With Gear Lube Monitor) 88 (2603) 104 (3076) 96 (2839)

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-7
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 per-
formance. During this break-in period, the following rules must be observed:
•Do not operate below 1500 rpm for extended periods of time for first 10 hours. Shift into
gear as soon as possible after starting and advance throttle above 1500 rpm if condi-
tions 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 opera-
tion 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 Mercury MerCruiser power package, the following recommen-
dations should be considered:
•Use a propeller that allows the engine to operate at or near the top of the maximum rpm
range (refer to “Specifications”section) when at full throttle with a normal boat load.
•Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged op-
eration at maximum (full throttle) rpm.
End of First Season Checkup
At the end of the first season of operation, an Authorized Mercury 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), you should
contact your dealer at the end of the first 100 hours of operation, or once yearly, whichever
occurs first.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-8 90-861328--1 NOVEMBER 1999
CA261
Specifications
Fuel Recommendations
IMPORTANT: Use of improper gasoline can damage your engine seriously. Engine
damage resulting from use of improper gasoline is considered misuse of engine, and
damage caused thereby will not be covered under the limited warranty.
FUEL RATINGS
Mercury MerCruiser engines will operate satisfactorily when using a major brand of
unleaded gasoline as follows:
USA and Canada - having a posted pump Octane Rating of 87 (R+M)/2 minimum. Premium
gasoline [92 (R+M)/2 Octane] is also acceptable. DO NOT use leaded gasoline.
Outside USA and Canada - having a posted pump Octane Rating of 90 RON minimum.
Premium gasoline (98 RON) is also acceptable. If unleaded gasoline is not available, use
a major brand of leaded gasoline.
CA291
USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY)
This type of gasoline is required in certain areas of the USA. The two types of “oxygenates”
used in these fuels are Alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the “oxygen-
ate”that is used in the gasoline in your area, refer to “Gasolines Containing Alcohol.”
These “Reformulated Gasolines”are acceptable for use in your Mercury MerCruiser
engine.
VAPOR LOCKING
Fuels containing alcohol and winter grade fuels will aggravate vapor lock problems. A vapor
lock condition can be identified by the following problems:
•Engine starts and, upon advancing throttle, shuts off and will not restart.
•If engine does restart, it shuts off when advancing throttle.
•Engine is difficult to restart after operating the boat and then leaving the engine off for 1 to
3 hours.
Other factors may combine to increase vapor locking. These factors include but are not lim-
ited to:
•air temperature
•fuel tank location
•fuel supply system
•engine coolant temperature
•temperature and vacuum of fuel to engine
•engine compartment air temperature and ventilation
Other conditions should be ruled out before treating the problem as vapor locking.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-9
CA618
GASOLINES CONTAINING ALCOHOL
If the gasoline in your area contains either “methanol”(methyl alcohol) or “ethanol”(ethyl
alcohol), you should be aware of certain adverse effects that can occur. These adverse
effects are more severe with “methanol.”Increasing the percentage of alcohol in the fuel can
also worsen these adverse effects.
Some of these adverse effects are caused because the alcohol in the gasoline can absorb
moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the
fuel tank.
The fuel system components on your Mercury MerCruiser engine will withstand up to 10%
alcohol content in the gasoline. We do not know what percentage your boat’s fuel system
will withstand. Contact your boat manufacturer for specific recommendations on the boats
fuel system components (fuel tanks, fuel lines and fittings). Be aware that gasolines
containing alcohol may cause increased:
•Corrosion of metal parts.
•Deterioration of rubber or plastic parts.
•Fuel permeation through rubber fuel lines.
•Starting and operating difficulties.
WARNING
FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of fuel system can be
a fire and explosion hazard which can cause serious bodily injury or death. Careful
periodic inspection of entire fuel system is mandatory, particularly after storage. All
fuel components including fuel tanks, whether plastic metal or fiberglass, fuel
lines, fittings, fuel filters and carburetors/fuel injection components should be in-
spected for leakage, softening, hardening, swelling or corrosion. Any sign of leak-
age or deterioration requires replacement before further engine operation.
Because of possible adverse effects of alcohol in gasoline, it is recommended that only alco-
hol-free gasoline be used where possible. If only fuel containing alcohol is available, or if
the presence of alcohol is unknown, increased inspection frequency for leaks and abnorma-
lities is required.
IMPORTANT: When operating a Mercury MerCruiser engine 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 alcohol-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, internal corrosion may take place during storage if alcohol has washed pro-
tective oil films from internal components.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-10 90-861328--1 NOVEMBER 1999
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 or a mark at about 1/3 full. A pencil mark on a piece of adhesive
tape may be used.
PROCEDURE
1. Fill the container with water to the mark.
2. Add fuel almost to fill the container, leaving some air space, then cap the container. The
proportions 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 upright 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 the dividing line between water and fuel becomes cloudy, use the
middle of the cloudy band.
Power Steering Fluid
Use Quicksilver Power Trim and Steering Fluid or automatic transmission Fluid (ATF)
Dexron III.
Coolant for Closed Cooling System
CAUTION
Alcohol or Methanol base antifreeze or plain water, 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 Extended
Life Ethylene Glycol 5/100 Antifreeze/Coolant mixed 50/50 with purified water. In areas
where the possibility of freezing does not exist, it is permissible to use a solution of rust inhi-
bitor and water (mixed to manufacturer’s recommendations).
If any non-compatible coolant is added to this coolant, coolant must be changed every 2
years or 400 hours, whichever occurs first. All coolants other than Extended Life 5/100
Ethylene Glycol Antifreeze/Coolant must be changed every 2 years or 400 hours, whichever
occurs first.
Mercury MerCruiser V-8 engines can use any type of permanent antifreeze or any brand
antifreeze solution that meets GM specification 1825M.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-11
CA693
Crankcase Oil
To help obtain optimum engine performance and to provide maximum protection, we
strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil. This oil is
a special blend of 25-weight and 40-weight oils for marine engines. If not available, a good
grade, straight weight, detergent automotive oil of correct viscosity, with an API
classification of SH,CF/CF-2, may be used.
In those areas where Quicksilver 4-Cycle 25W-40 Marine Engine Oil or a recommended
straight weight oil are not available, a multiviscosity 20W-40 (SH, CF/CF-2) or, as a second
but less preferable choice, 20W-50, with API service ratings of SH, CF/CF-2 may be used.
IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Quicksil-
ver 25W-40 or a good quality 20W-40 or 20W-50), synthetic oils, low quality oils or oils
that contain solid additives are specifically not recommended.
The chart below is a guide to crankcase oil selection. The oil filter should always be changed
with oil.
70534
Quicksilver 4-Cycle Marine Engine Oil
SAE 20W
SAE 30W
SAE 40W
32°F
0°C
50°F
10°C
AIR TEMPERATURE
Overfilled Crankcase Oil
Overfilled crankcases (oil level being too high ) can cause a fluctuation or drop in oil pressure
and rocker arm “clatter”on Mercury MerCruiser engines. The over-full condition results in
the engine crankshaft splashing and agitating the oil, causing it to foam (become aerated).
The aerated oil causes the hydraulic valve lifters 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 following steps are done before checking the oil level.
•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 crankcase if engine has just been run or oil
has just been added.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-12 90-861328--1 NOVEMBER 1999
Checking Engine Oil Level / Filling
IMPORTANT: ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS
SPECIFIED IN “MAINTENANCE SCHEDULE” CHART. It is normal for an engine to use
a certain amount of oil in the process of lubrication and cooling of the engine. The
amount of oil consumption is greatly dependent upon engine speed, with
consumption being highest at wide-open-throttle and decreasing substantially as
engine speed is reduced.
1. Stop engine and allow boat to come to a rest.
2. Allow oil to drain back into oil pan - approximately 5 minutes.
3. Remove dipstick.
4. Wipe clean and reinstall. Push dipstick all the way into dipstick tube.
5. Remove dipstick and note the oil level.
6. Oil level must be between the FULL or OP RANGE and ADD marks.
7. If oil level is below ADD mark, proceed to Steps 8. and 9.
8. Remove oil filler cap from valve rocker arm cover.
9. Add required amount of oil to bring level up to, but not over, the FULL mark on dipstick.
Changing Oil and Filter
1. Start engine and run until it reaches normal operating 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.
IMPORTANT: If engine is factory equipped with Quick Drain Oil Hose, pull tether
through bilge drain before removing drain plug from oil drain hose.
NOTE: If drain plug is not accessible because of boat 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. Coat sealing ring on new filter with engine oil and install. Tighten filter securely (following
filter manufacturer’s instructions). Do not overtighten.
7. Fill crankcase with oil. See “Specifications”for type of oil and quantity.
8. Check dipstick to ensure oil level is up to, but not over, FULL or OP RANGE mark on
dipstick.
9. Start engine and check for leaks.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-13
Changing Water Separating Fuel Filter
WARNING
Be careful when changing water separating fuel filter. Gasoline is extremely
flammable and highly explosive under certain conditions. Be sure ignition key is
OFF. Do not smoke or allow spark or open flame in area when changing fuel filter.
Wipe up any spilled fuel immediately.
WARNING
Make sure no fuel leaks exist before closing engine hatch.
CAUTION
The electric fuel pump and factory installed water separating fuel filter have been
carefully designed to function properly together. Do not install additional fuel filters
and/or water separating fuel filters between fuel tank and engine.
The installation of additional filters may cause:
•Fuel Vapor Locking
•Difficult Warm-Starting
•Piston Detonation Due to Lean Fuel Mixture
•Poor Driveability
1. Unsnap latch and slidetop and bottom cover pieces, if equipped, from around the water
separating fuel filter and bracket.
75034
a
a-Fuel Filter Cover
NOTE: Top and bottom cover pieces are formed with a groove on each side that slides
around the brackets outer edges.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-14 90-861328--1 NOVEMBER 1999
2. Remove water separating fuel filter and sealing ring from mounting bracket and discard.
70573
b
a
a-Fuel Filter
b-Sealing Ring
3. Coat sealing ring on new filter with motor oil.
4. Thread filter onto bracket and tighten securely by hand. Do not use a filter wrench.
5. Start and run engine.
6. Check filter connection for gasoline leaks. If leaks exist, recheck filter installation.
7. Install cover pieces around fuel filter. Be certain top part of cover latches to lower part.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-15
Power Steering System
Checking Fluid Level
ENGINE WARM
1. Stop engine. Position drive unit so that it is straight back.
2. Remove fill cap / dipstick from power steering pump and note fluid level.
74908
ab
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 in pump reservoir, add required amount
of Quicksilver Power Trim and Steering Fluid or automatic transmission fluid (ATF) Dex-
ron III through fill cap opening, to bring level up to FULL HOT mark on dipstick. DO NOT
OVERFILL.
5. If fluid is not visible in reservoir, a leak exists in the power steering system. Find cause
and correct.
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
4. If level is below bottom of dipstick, but fluid is still visible in pump reservoir, add required
amount of Quicksilver Power Trim and Steering Fluid or automatic Dexron III transmis-
sion fluid (ATF), through fill cap opening, to bring level up to FULL COLD mark on dip-
stick. DO NOT OVERFILL.
If fluid is not visible in reservoir, a leak exists in the power steering system. Find cause and
correct.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-16 90-861328--1 NOVEMBER 1999
Filling and Bleeding
IMPORTANT: Power steering system must be filled exactly as explained in the follow-
ing to be sure that all air is bled from the system. All air must be removed, or fluid in
pump may foam during operation and be discharged from pump reservoir. Foamy
fluid also may cause power steering system to become spongy, which may result in
poor boat control.
1. With engine stopped, position drive unit so that it is straight back.
2. Remove fill cap / dipstick from power steering pump.
3. Add Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission
fluid (ATF), as required, to bring level up to FULL COLD mark on dipstick.
IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III auto-
matic transmission fluid (ATF), in power steering system.
4. Turn steering wheel back and forth to end of travel in each direction several times.
5. Recheck fluid level and add fluid, if necessary.
6. Install vented fill cap. Tighten securely.
CAUTION
DO NOT operate engine without water being supplied to seawater pickup pump, or
pump impeller may be damaged and subsequent overheating damage to engine
may result.
7. 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
direction several times.
8. Position drive unit so that it is straight back and stop engine.
9. Remove fill cap from pump.
10. Allow any foam in pump reservoir to disperse.
11. Check fluid level and add fluid, as required, to bring level up to FULL HOT mark on dip-
stick. DO NOT OVERFILL.
12. Reinstall fill cap. Tighten securely.
IMPORTANT: Drive unit must be positioned straight back and power steering fluid
must be hot to accurately check fluid level.
13. If fluid is still foamy (in Step 5.), repeat Steps 7. through 12. until fluid does not foam and
level remains constant.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-17
Closed Cooling System
Checking Coolant Level
CAUTION
Allow engine to cool down before removing pressure 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 on
filler neck.
2. Coolant level should be between the ADD and FULL marks on coolant recovery reser-
voir with the engine at normal operating temperature.
72520
a
a-Coolant Recovery Reservoir

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-18 90-861328--1 NOVEMBER 1999
Flushing System
If engine is operated in salty, polluted or mineral-laden water, flush seawater cooling system
(preferably after each use) to reduce corrosion and prevent the accumulation of deposits
in the system. Thoroughly flush the seawater cooling system prior to storage.
NOTE: For additional protection against freezing and rust to the exhaust manifolds and
other components, a 50-50 mixture of antifreeze and water can be run through the engine
during Power Package Layup.
1. Install flushing attachment and water hose over the water pickup holes in gear housing.
72693
a
b
a-Flushing Attachment
b-Hose
WARNING
When flushing, be certain the area around propeller is clear, and no one is standing
nearby. To avoid possible injury, remove propeller.
CAUTION
Do not run engine above 1500 rpm when flushing. Suction created by seawater pick-
up pump may collapse flushing hose, causing engine to overheat.
CAUTION
Watch temperature gauge on dash to ensure that engine does not overheat.
2. Open water tap enough to cool the engine, about ½of its maximum capacity. Adjust as
required so that the engine does not overheat.
3. With drive in neutral gear, start engine and advance the throttle until the engine reaches
1300 rpm.
IMPORTANT: DO NOT run the engine at idle rpm. Watch engine temperature gauge
on dash. Do not run the engine above 1500 rpm or engine overheating may occur.
4. Run engine for 10 minutes or until the discharge water is clear.
5. Slowly return the throttle to the idle position and turn engine off.
IMPORTANT: DO NOT rapidly advance or return throttle as this can cause water in-
gestion.

MAINTENANCESERVICE MANUAL NUMBER 25
90-861328--1 NOVEMBER 1999 Page 1B-19
BOAT IN WATER
1. Raise drive unit to full UP / OUT position.
2. Install flushing attachment over water pickup holes in gear housing as shown.
3. Attach a water hose between the flushing attachment and a water tap.
72693
a
b
a-Flushing Attachment
b-Hose
4. Lower drive unit to full DOWN / IN position.
CAUTION
Do not run engine above 1500 rpm when flushing. Suction created by seawater pick-
up pump may collapse flushing hose, causing engine to overheat.
CAUTION
Watch temperature gauge on dash to ensure that engine does not overheat.
5. Partially open water tap (approximately 1/2 maximum capacity). DO NOT use full water
pressure.
6. Place remote control in neutral, idle speed position, 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 / OUT position.
10. Remove water hose and flushing attachment.

MAINTENANCE SERVICE MANUAL NUMBER 25
Page 1B-20 90-861328--1 NOVEMBER 1999
Lubrication
Throttle Cable
1. Lubricate pivot points and guide contact surfaces with SAE 30W motor oil.
74941
b
a
a
a
a
b
71359
2 Barrel Carbureted Models EFI Models
a-Pivot Points
b-Guide Contact Surface
Shift Cable
MCM (STERNDRIVE) MODELS
1. Lubricate pivot points and guide contact surfaces with SAE 30W motor oil.
72016
b
ba
a
a
Typical Shift Cable
a-Pivot Points
b-Guide Contact Surface