Mercury 3.0L Carbureted Alpha User manual

3.0L Carbureted Alpha Models 

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
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.
2004, Mercury Marine
The following are registered trademarks of Brunswick Corporation: AutoBlend, Jet-Prop,
Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, RideGuide,
Thruster and Mercury Precision Parts.
79684
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0002.1
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!
Mercury MerCruiser
0003
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 cov-
erage, how to best obtain warranty coverage, important disclaimers and limitations of
damages and other related information. Please review this important information.
0217 Mercury Marine products are designed and manufactured to comply with our own high quality
standards and applicable industry standards and regulations, as well as certain emissions
regulations. At Mercury Marine every engine is operated and tested before it is boxed for
shipment to ensure that the product is ready for use. In addition, certain Mercury Marine
products are tested in a controlled and monitored environment, for up to 10 hours of engine
run time, in order to verify and make a record of compliance with applicable standards and
regulations. All Mercury Marine product, sold as new, receives the applicable limited warranty
coverage, whether the engine participated in one of the test programs described above or not.

0004
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 Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all
related accessories before the boat is used.
0197.0 WARNING
California Proposition 65 Warning
The engine exhaust from this product contains chemicals known to the state of
California to cause cancer, birth defects or other reproductive harm.

90-860168040 JANUARY 2004 Page i
WARRANTY
Warranty Information 2. . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration 2. . . . . . . . . . . .
United States And Canada Only 2. . . . . .
International Owner Registration 3. . . . . . . . .
Outside The United States
And Canada 3. . . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .
Mercury MerCruiser One Year Limited
Warranty
(Gasoline Fueled Products Only) 4. . . . . . . .
What Is Covered 4. . . . . . . . . . . . . . . . . . . .
Duration Of Coverage 4. . . . . . . . . . . . . . .
Conditions That Must Be Met In Order
To Obtain Warranty Coverage 4. . . . . . . .
What Mercury Will Do 4. . . . . . . . . . . . . . .
How To Obtain Warranty Coverage 5. . . .
What Is Not Covered 5. . . . . . . . . . . . . . . .
Disclaimers And Limitations 5. . . . . . . . . .
California Emissions Limited Warranty 6. . . .
What Is Covered 6. . . . . . . . . . . . . . . . . . . .
Duration Of Coverage 6. . . . . . . . . . . . . . .
How To Obtain Warranty Coverage 6. . . .
What Mercury Will Do 7. . . . . . . . . . . . . . .
What Is Not Covered 7. . . . . . . . . . . . . . . .
Components Of The Emissions
Control System 8. . . . . . . . . . . . . . . . . . . . .
Disclaimers And Limitations 8. . . . . . . . . .
California Emission Control
Warranty Statement 9. . . . . . . . . . . . . . . . . . .
Your Warranty Rights
And Obligations 9. . . . . . . . . . . . . . . . . . . .
Manufacturer’s Warranty Coverage 9. . . .
Owner’s Warranty Responsibilities 9. . . .
3 Year Limited Warranty
Against Corrosion (Worldwide) 10. . . . . . . . .
What Is Covered 10. . . . . . . . . . . . . . . . . . .
Duration Of Coverage 10. . . . . . . . . . . . . .
Conditions That Must Be Met In Order
To Obtain Warranty Coverage 10. . . . . . .
What Mercury Will Do 10. . . . . . . . . . . . . .
How To Obtain Warranty Coverage 11. . . .
What Is Not Covered 11. . . . . . . . . . . . . . . .
Transferable Warranty 12. . . . . . . . . . . . . . . . . .
Direct Sale By Owner 12. . . . . . . . . . . . . . . . .
Mercury Product Protection Plan 12. . . . . . . .
United States And Canada Only 12. . . . . . . .
California Emission Certification Label 13. .
Star Label 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
One Star - Low Emission 13. . . . . . . . . . . .
Two Stars - Very Low Emission 13. . . . . .
Three Stars - Ultra Low Emission 13. . . .
Four Stars - Super Ultra
Low Emission 13. . . . . . . . . . . . . . . . . . . . .
GETTING TO KNOW YOUR POWER PACKAGE
Features And Controls 16. . . . . . . . . . . . . . . . .
Lanyard Stop Switch 16. . . . . . . . . . . . . . . . . .
Instrumentation 18. . . . . . . . . . . . . . . . . . . . . . .
Remote Controls 19. . . . . . . . . . . . . . . . . . . . .
Panel Mounted 19. . . . . . . . . . . . . . . . . . . .
Console Mounted 20. . . . . . . . . . . . . . . . . .
Power Trim 21. . . . . . . . . . . . . . . . . . . . . . . . . .
Single Engine Trim/Trailer 22. . . . . . . . . . .
Dual Engine Trim/Trailer 22. . . . . . . . . . . .
Electrical System Overload Protection 23. . .
Audio Warning System 25. . . . . . . . . . . . . . . .
Emissions Information 26. . . . . . . . . . . . . . . . .
Emission Control Information Label 26. . . . .
Owner Responsibility 26. . . . . . . . . . . . . . . . . .
Star Label 27. . . . . . . . . . . . . . . . . . . . . . . . . . .

Page ii 90-860168040 JANUARY 2004
ON THE WATER
Safe Boating Suggestions 30. . . . . . . . . . . . . .
Be Alert To
Carbon Monoxide Poisoning 32. . . . . . . . . . .
Good Ventilation 33. . . . . . . . . . . . . . . . . . .
Poor Ventilation 33. . . . . . . . . . . . . . . . . . . .
Basic Boat Operation 34. . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 34. . . .
Operation Chart 35. . . . . . . . . . . . . . . . . . . .
Starting And Stopping The Engine 36. . . . . .
Starting Engine After Stopped
While In Gear 37. . . . . . . . . . . . . . . . . . . . . . . .
Trailering The Boat 37. . . . . . . . . . . . . . . . . . .
Freezing Temperature Operation 37. . . . . . .
Drain Plug and Bilge Pump 37. . . . . . . . . . . .
Protecting People In The Water 38. . . . . . . . .
While You Are Cruising 38. . . . . . . . . . . . . . . .
While Boat Is Stationary 38. . . . . . . . . . . . . . .
Passenger Safety Message -
Pontoon And Deck Boats 39. . . . . . . . . . . . . .
Wave And Wake Jumping 40. . . . . . . . . . . . . . .
Impact With Underwater Hazards 41. . . . . . . .
Drive Unit Impact Protection 42. . . . . . . . . . .
Conditions Affecting Operation 42. . . . . . . . .
Weight Distribution
(Passengers And Gear)
Inside The Boat 42. . . . . . . . . . . . . . . . . . . . . .
Bottom Of Boat 42. . . . . . . . . . . . . . . . . . . . . . .
Cavitation 43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 43. . . . . . . . . . . . . . . . . . . . . . . . . . .
Elevation And Climate 43. . . . . . . . . . . . . . . . .
Propeller Selection 44. . . . . . . . . . . . . . . . . . . .
Getting Started 45. . . . . . . . . . . . . . . . . . . . . . . . .
20-Hour Break-In Period 45. . . . . . . . . . . . . . .
After Break-In Period 45. . . . . . . . . . . . . . . . . .
End of First Season Checkup 45. . . . . . . . . .

90-860168040 JANUARY 2004 Page iii
SPECIFICATIONS
Specifications 47. . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 48. . . . . . . . . . . . . . .
Fuel Ratings 48. . . . . . . . . . . . . . . . . . . . . . .
Using Reformulated
(Oxygenated) Gasolines (USA Only) 48.
Gasolines Containing Alcohol 49. . . . . . . .
Engine Oil 50. . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Specifications 51. . . . . . . . . . . . . . . . .
Fluid Specifications 52. . . . . . . . . . . . . . . . . . .
3.0 Liter (181 cid) 52. . . . . . . . . . . . . . . . . .
Sterndrive Fluid Specifications 52. . . . . . . . .
MAINTENANCE
Owner/Operator Responsibilities 54. . . . . . . .
Dealer Responsibilities 54. . . . . . . . . . . . . . . . .
Maintenance 55. . . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself
Maintenance Suggestions 56. . . . . . . . . . . . .
Inspection 57. . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive Maintenance Chart 57. . . . . . . . . .
Routine Maintenance 57. . . . . . . . . . . . . . . . .
Scheduled Maintenance 58. . . . . . . . . . . . . . .
Maintenance Record 60. . . . . . . . . . . . . . . . . .
Engine Oil 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking 61. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Oil and Filter 63. . . . . . . . . . . . . . . .
Quick Drain Oil 63. . . . . . . . . . . . . . . . . . . .
Engine Oil Pump 63. . . . . . . . . . . . . . . . . . .
All Models 64. . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Fluid, If Equipped 65.
Checking 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing 65. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Oil 66. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking 66. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing 67. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim Pump Fluid 69. . . . . . . . . . . . . . . . .
Checking 69. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing 69. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Sight Tube Inspection 70. . . . . . .
3.0L Models 70. . . . . . . . . . . . . . . . . . . . . . . . .
Flame Arrestor
and Related Components 71. . . . . . . . . . . . . .
Cleaning 71. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positive Crankcase
Ventilation Valve (PCV) 72. . . . . . . . . . . . . . . .
Changing 72. . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 73. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System 73. . . . . . . . . . . . . . .
Manual Steering System 74. . . . . . . . . . . . . . .
Throttle Cable 75. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable - Typical 75. . . . . . . . . . . . . . . . . . .
Engine Coupler 76. . . . . . . . . . . . . . . . . . . . . . .
Propellers 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alpha 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 77. . . . . . . . . . . . . . . . . . . . . . . . . .
Repair 77. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 78. . . . . . . . . . . . . . . . . . . . . . . .
Drive Belts 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking 79. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing - Front Mount Models 80. . . . . . . .
Power Steering Pump
Drive Belt, If Equipped 80. . . . . . . . . . . . .
Alternator Belt 80. . . . . . . . . . . . . . . . . . . . .
Replacing - Side Mount Models 81. . . . . . . . .
Power Steering Pump
Drive Belt, If Equipped 81. . . . . . . . . . . . .
Alternator Belt 81. . . . . . . . . . . . . . . . . . . . .
Corrosion Protection 82. . . . . . . . . . . . . . . . . . .
Painting Your Power Package 85. . . . . . . . . .
Emissions (Europe Only) 86. . . . . . . . . . . . . . .
Sealed Carburetor Mixture Screws 86. . . . . .
Emissions Testing 86. . . . . . . . . . . . . . . . . . . .
Installing Test Probes 87. . . . . . . . . . . . . . . . .

Page iv 90-860168040 JANUARY 2004
STORAGE
Cold Weather Or Extended Storage 90. . . . . .
Preparing Your Power Package
For Storage 90. . . . . . . . . . . . . . . . . . . . . . . . .
Battery 92. . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 93. . . . . . . . . . . . . . . . . . .
3.0L Single Point Drain 94. . . . . . . . . . . . . . . .
Draining Seawater Section of
Closed Cooled (Coolant) Models 96. . . . . . .
Sterndrive 99. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing Clogged Blue Drain Hoses 100. . . .
Flushing The Power Package 102. . . . . . . . . .
Sterndrive Water Pickup 102. . . . . . . . . . . . . .
Flushing Attachments 102. . . . . . . . . . . . . .
Power Package Recommissioning 105. . . . .
TROUBLESHOOTING
Troubleshooting Charts 108. . . . . . . . . . . . . . .
Starter Motor Will Not Crank Engine,
Or Cranks Slow 108. . . . . . . . . . . . . . . . . . . . .
Engine Will Not Start,
Or Is Hard To Start 108. . . . . . . . . . . . . . . . . .
Engine Runs Rough, Misses
And/Or Backfires 109. . . . . . . . . . . . . . . . . . . .
Poor Performance 109. . . . . . . . . . . . . . . . . . .
Excessive Engine Temperature 110. . . . . . . .
Insufficient Engine Temperature 110. . . . . . .
Low Engine Oil Pressure 110. . . . . . . . . . . . .
Battery Will Not Come Up On Charge 111. . .
Remote Control Operates Hard,
Binds, Has Excessive Free-play
Or Makes Unusual Sounds 111. . . . . . . . . . . .
Steering Wheel Turns Hard Or Jerky 112. . .
Power Trim Does Not Operate
(Motor Doesn’t Operate) 112. . . . . . . . . . . . .
Power Trim Does Not Operate
(Motor Operates But Sterndrive Unit
Does Not Move) 112. . . . . . . . . . . . . . . . . . . .
CUSTOMER ASSISTANCE INFORMATION
Owner Service Assistance 114. . . . . . . . . . . . .
Local Repair Service 114. . . . . . . . . . . . . . . . .
Service Away From Home 114. . . . . . . . . . . .
Stolen Power Package 114. . . . . . . . . . . . . . .
Attention Required After Submersion 114. . .
Replacement Service Parts 115. . . . . . . . . . .
Parts And Accessories Inquiries 115. . . .
Resolving A Problem 116. . . . . . . . . . . . . . . . .
Mercury Marine Service Offices 117. . . . . . .
Customer Service Literature 118. . . . . . . . . . .
English Language 118. . . . . . . . . . . . . . . . . . .
Other Languages 118. . . . . . . . . . . . . . . . . . . .
Andre sprog 118. . . . . . . . . . . . . . . . . . . . . . . .
Andere talen 118. . . . . . . . . . . . . . . . . . . . . . . .
Muut kielet 118. . . . . . . . . . . . . . . . . . . . . . . . . .
Autres langues 119. . . . . . . . . . . . . . . . . . . . . .
Andere Sprachen 119. . . . . . . . . . . . . . . . . . . .
Altre lingue 119. . . . . . . . . . . . . . . . . . . . . . . . .
Andre språk 119. . . . . . . . . . . . . . . . . . . . . . . . .
Outros Idiomas 119. . . . . . . . . . . . . . . . . . . . . .
Otros idiomas 119. . . . . . . . . . . . . . . . . . . . . . .
Andra språk 119. . . . . . . . . . . . . . . . . . . . . . . . .
  119. . . . . . . . . . . . . . . . . . . . . .
Ordering Literature 120. . . . . . . . . . . . . . . . . . . .
United States and Canada 120. . . . . . . . . . . .
Outside The United States
and Canada 120. . . . . . . . . . . . . . . . . . . . . . . .

90-860168040 JANUARY 2004 Page v
NOTES:

Page vi 90-860168040 JANUARY 2004
NOTES:

1
WARRANTY
90-860168040 JANUARY 2004 Page 1
WARRANTY
Table of Contents
Warranty Information 2. . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration 2. . . . . . . . . . . .
United States And Canada Only 2. . . . . .
International Owner Registration 3. . . . . . . . .
Outside The United States
And Canada 3. . . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 4. . . . . . . . . . . . . . . . . . . . . . .
Mercury MerCruiser One Year Limited
Warranty
(Gasoline Fueled Products Only) 4. . . . . . . .
What Is Covered 4. . . . . . . . . . . . . . . . . . . .
Duration Of Coverage 4. . . . . . . . . . . . . . .
Conditions That Must Be Met In Order
To Obtain Warranty Coverage 4. . . . . . . .
What Mercury Will Do 4. . . . . . . . . . . . . . .
How To Obtain Warranty Coverage 5. . . .
What Is Not Covered 5. . . . . . . . . . . . . . . .
Disclaimers And Limitations 5. . . . . . . . . .
California Emissions Limited Warranty 6. . . .
What Is Covered 6. . . . . . . . . . . . . . . . . . . .
Duration Of Coverage 6. . . . . . . . . . . . . . .
How To Obtain Warranty Coverage 6. . . .
What Mercury Will Do 7. . . . . . . . . . . . . . .
What Is Not Covered 7. . . . . . . . . . . . . . . .
Components Of The Emissions
Control System 8. . . . . . . . . . . . . . . . . . . . .
Disclaimers And Limitations 8. . . . . . . . . .
California Emission Control
Warranty Statement 9. . . . . . . . . . . . . . . . . . .
Your Warranty Rights
And Obligations 9. . . . . . . . . . . . . . . . . . . .
Manufacturer’s Warranty Coverage 9. . . .
Owner’s Warranty Responsibilities 9. . . .
3 Year Limited Warranty
Against Corrosion (Worldwide) 10. . . . . . . . .
What Is Covered 10. . . . . . . . . . . . . . . . . . .
Duration Of Coverage 10. . . . . . . . . . . . . .
Conditions That Must Be Met In Order
To Obtain Warranty Coverage 10. . . . . . .
What Mercury Will Do 10. . . . . . . . . . . . . .
How To Obtain Warranty Coverage 11. . . .
What Is Not Covered 11. . . . . . . . . . . . . . . .
Transferable Warranty 12. . . . . . . . . . . . . . . . . .
Direct Sale By Owner 12. . . . . . . . . . . . . . . . .
Mercury Product Protection Plan 12. . . . . . . .
United States And Canada Only 12. . . . . . . .
California Emission Certification Label 13. .
Star Label 13. . . . . . . . . . . . . . . . . . . . . . . . . . .
One Star - Low Emission 13. . . . . . . . . . . .
Two Stars - Very Low Emission 13. . . . . .
Three Stars - Ultra Low Emission 13. . . .
Four Stars - Super Ultra
Low Emission 13. . . . . . . . . . . . . . . . . . . . .

WARRANTY
Page 2 90-860168040 JANUARY 2004
0005
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.
•You may change your address at any time, including at time of warranty claim, by
calling Mercury MerCruiser or sending a letter or fax with you name, old address,
new address, and engine serial number to Mercury MerCruiser’s warranty
registration department. Your dealer can also process this change of information.
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939
Phone: [phone]
Fax: [phone]

WARRANTY
90-860168040 JANUARY 2004 Page 3
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 bylaw. 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.

WARRANTY
Page 4 90-860168040 JANUARY 2004
0006
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 recreational use retail purchaser, or the date on which the product is first put
into service, whichever occurs first. Commercial 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 original 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 Marine 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 purchase price of the Mercury product. Mercury
reserves the right to improve or modify products from time to time without assuming an
obligation to modify products previously manufactured.

WARRANTY
90-860168040 JANUARY 2004 Page 5
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable opportunity to repair, and
reasonable access to the product for warranty service. Warranty claims shall be made by
delivering the product for inspection to a Mercury dealer authorized to service the product.
If purchaser cannot deliver the product to such a dealer, 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 service. Purchaser shall not, unless
requested by Mercury, ship the product or parts of the product directly to Mercury. 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.
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 manner 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 racing 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 partitions 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 EXCLUSIONS IDENTIFIED ABOVE. AS A
RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY
FROM STATE TO STATE AND COUNTRY TO COUNTRY.

WARRANTY
Page 6 90-860168040 JANUARY 2004
218.0
California Emissions Limited Warranty
The California Air Resources Board has promulgated air emissions regulations for inboard
and sterndrive engines. The regulations apply to all inboard and sterndrive engines that
were manufactured for the 2003 model year1and later. Mercury Marine, in compliance with
those regulations, provides this limited warranty for the emission control systems (see the
components of the emission control system listed following), and further warrants that the
inboard or sterndrive engine was designed, built and equipped to conform with all applicable
regulations adopted by the California Air Resources Board pursuant to its authority in
Chapters 1 and 2, Part 5, Division 26 of the Health and Safety Code. For information
regarding the limited warranty for the non-emissions related components of the inboard or
sterndrive engine, please see the limited warranty statement for your engine.
WHAT IS COVERED
Mercury Marine warrants the components of the emissions control systems (see the
components of the emission control system listed following) of its new, 2003 model year1
and later California certified inboard and sterndrive engines, registered2to a California
resident, to be free from defects in material or workmanship that cause the failure of a
warranted part to be identical in all material respects to that part as described in the
application of Mercury Marine for certification from the California Air Resources Board, for
the period of time, and under the conditions identified below. The cost to diagnose a
warranty failure is covered under the warranty (if the warranty claim is approved). Damage
to other engine components caused by the failure of a warranted part will also be repaired
under warranty.
DURATION OF COVERAGE
This limited warranty provides coverage for the components of the emissions control
systems of new 2003-2008 model year1inboard and sterndrive engines for 2 years from
either the date the product is first sold, or first put into service, whichever occurs first.
Emission related normal maintenance items such as spark plugs and filters, that are on the
warranted parts list (see following) are warranted up to their first required replacement
interval only. (See Maintenance Schedule). The repair or replacement of parts, or the
performance of service under this warranty, does not extend the life of this warranty beyond
its original expiration date. Unexpired warranty coverage can be transferred to a
subsequent purchaser. (See instructions on transfer of warranty).
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable opportunity to repair and reasonable
access to the product for warranty service. Warranty claims shall be made by delivering the
product for inspection to a Mercury dealer authorized to service the product. If purchaser
cannot deliver the product to such a dealer, please notify Mercury Marine and Mercury 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 service. Purchaser shall not, unless requested by Mercury,
ship the product or parts of the product directly to Mercury.

WARRANTY
90-860168040 JANUARY 2004 Page 7
WHAT MERCURY WILL DO
Mercury Marine’s sole and exclusive obligation under this warranty is limited to, at our
expense and at our option, repairing or replacing defective parts with new or Mercury Marine
certified re–manufactured parts, or refunding the purchase price of the Mercury product.
Mercury reserves the right to improve or modify products from time to time without assuming
an obligation to modify products previously manufactured.
WHAT IS NOT COVERED
This limited warranty does not cover routine maintenance items, tune ups, adjustments,
normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear
ratio that does not allow the engine to run in its recommended wide–open–throttle RPM
range (see Specifications), operation of the product in a manner inconsistent with the
recommended operation procedures, neglect, accident, submersion, improper installation
(proper installation specifications and techniques are set forth in the installation instructions
for the product), improper service, use of an accessory or part 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 Specifications section), alteration or removal of parts,
or water entering the engine through the fuel intake, air intake or exhaust system. Use of
the product for racing or other competitive activity, or operating with a racing 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 partitions or material caused by
boat design for access to the product are not covered by this warranty.
Non–warranty maintenance, replacement, or repair of emission control devices and
systems may be performed by any marine engine repair establishment or individual. The
use of non–Mercury parts for non–warranty maintenance or repairs will not be grounds for
disallowing other warranty work. The use of add–on (as defined at section 1900 (b)(1) and
(b)(10) of Title 13 of the California Code of Regulations) or modified parts not exempted by
the California Air Resources Board may be grounds for disallowing a warranty claim, at the
discretion of Mercury Marine. Failures of warranted parts caused by the use of a
non–exempted add–on or modified part will not be covered.
1
Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply
with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning
as calendar year. As an example, 2003 model year products refers to products manufactured during
calendar year 2003.
2
Your dealer will register your engine for warranty coverage for you. The warranty registration process is not
related in any way to the process of obtaining a license, title or registration from state boating authorities.
You should ask your dealer to update your warranty registration information to reflect a change of address
or a transfer of ownership. (This change may be made at any time.) See the Warranty Registration section
of your manual or your dealer for more information.

WARRANTY
Page 8 90-860168040 JANUARY 2004
COMPONENTS OF THE EMISSIONS CONTROL SYSTEM
1. Fuel Metering System
a. Carburetor and internal parts (and/or pressure regulator or fuel injection system)
b. Intake valve(s)
2. Air Induction System
a. Intake manifold
3. Ignition System
a. Spark plugs
b. Electronic ignition system
c. Ignition coil and/or control module
d. Ignition wires
4. Positive Crankcase Ventilation (PCV) System
a. PCV Valve
b. Oil filler cap
5. Exhaust System
a. Exhaust manifold
b. Exhaust elbow
c. Intermediate exhaust elbow
d. Lower exhaust pipe
e. Tailpipe
f. Exhaust valve
6. Miscellaneous Items Used in Above Systems
a. Hoses, clamps, fittings, tubing, sealing gaskets or devices, and mounting hardware.
b. Pulleys, belts, and idlers.
c. Vacuum, temperature, check and time sensitive valves and switches
d. Electronic controls.
DISCLAIMERS AND LIMITATIONS
DISCLAIMERS AND LIMITATIONS
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT
THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN
DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND
CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS
WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE
DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A
RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY
FROM STATE TO STATE AND COUNTRY TO COUNTRY.
If you have any questions regarding your warranty rights and responsibilities, refer to Owner
Service Assistance for contact information.

WARRANTY
90-860168040 JANUARY 2004 Page 9
California Emission Control Warranty Statement
YOUR WARRANTY RIGHTS AND OBLIGATIONS
The California Air Resources Board is pleased to explain the emission control system
warranty on your 2003 model year1and later inboard or sterndrive engine. In California, new
inboard and sterndrive engines must be designed, built and equipped to meet the State’s
stringent anti-smog standards. Mercury Marine must warrant the emission control system
on your inboard or sterndrive engine for the periods of time listed below provided there has
been no abuse, neglect or improper maintenance of your inboard or sterndrive engine.
Your emission control system may include parts such as the carburetor or fuel injection
system, the ignition system, and catalytic converter. Also included may be hoses, belts,
connectors and other emission-related assemblies.
Where a warrantable condition exists, Mercury Marine will repair your inboard or sterndrive
engine at no cost to you; including diagnosis, parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
For 2003-2008 spark-ignition inboard and sterndrive marine engines: Select emission
control parts from model year12003-2008 inboard and sterndrive engines are warranted
for 2 years. If any emission-related part on your engine is defective under warranty, the part
will be repaired or replaced by Mercury Marine.
OWNER’S WARRANTY RESPONSIBILITIES
As the inboard or sterndrive engine owner, you are responsible for the performance of the
required maintenance listed in your owner’s manual. Mercury Marine recommends that you
retain all receipts covering maintenance on your inboard or sterndrive engine, but Mercury
Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the
performance of all scheduled maintenance.
As the inboard or sterndrive engine owner, you should however be aware that Mercury
Marine may deny you warranty coverage if your inboard or sterndrive engine or a part has
failed due to abuse, neglect, improper maintenance or unapproved modifications.
You are responsible for presenting your inboard or sterndrive engine to a Mercury Marine
dealer authorized to service the product as soon as a problem exists. The warranty repairs
will be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding your warranty rights and responsibilities, refer to Owner
Service Assistance for contact information.
1
Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply
with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning
as calendar year. As an example, 2003 model year products refers to products manufactured during
calendar year 2003.

WARRANTY
Page 10 90-860168040 JANUARY 2004
0007
3 Year Limited Warranty Against Corrosion (Worldwide)
WHAT IS COVERED
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M2
Jet 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 original expiration date.
Unexpired warranty coverage can be transferred to subsequent (noncommercial use)
purchaser 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 Marine 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. Corrosion prevention devices specified
in the Operation and Maintenance Manual must be in use on the boat, and routine
maintenance outlined in the Operation and Maintenance Manual must be timely performed
(including without limitation the replacement of sacrificial anodes, use of specified
lubricants, and touch-up of nicks and scratches) in order to maintain warranty coverage.
Mercury Marine reserves the right to make warranty coverage contingent upon proof of
proper maintenance.
WHAT MERCURY WILL DO
Mercury’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 purchase price of the Mercury product. Mercury
reserves the right to improve or modify products from time to time without assuming an
obligation to modify products previously manufactured.