Mercruiser 4.3 MPI

Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,
Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport-Jet,
K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo,
and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection
logo is a registered service mark of Brunswick Corporation.
STERNDRIVE MODELS
GASOLINE ENGINE INSTALLATION MANUAL
Models Covered
Alpha
Models Covered Serial Number
4.3 MPI
5.0 MPI
5.0 MPI DTS 0W310000 and Above
350 MAG MPI
350 MAG MPI DTS
Bravo
Models Covered Serial Number
4.3 MPI
5.0 MPI
5.0 MPI DTS
350 MAG MPI
350 MAG MPI DTS
MX 6.2 MPI 0W310000 and Above
MX 6.2 MPI DTS
350 MAG MPI Horizon
350 MAG MPI Horizon DTS
MX 6.2 MPI Horizon
MX 6.2 MPI Horizon DTS
Notice
NOTICE
After completing installation, these instructions should be placed with the product for the
owner's future use.
NOTICE
Predelivery preparation instructions must be performed before delivering boat to the
product owner.
Page i © 2005 Mercury Marine 90-864196050 FEBRUARY 2005

Notice to Boat Manufacturer/Installer
Throughout this publication, Warnings and Cautions (accompanied by the International
Hazard Symbol ) are used to alert the manufacturer or installer 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
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
! WARNING
WARNING ‑ indicates a potentially hazardous situation that, if not avoided, could result
in death or serious injury.
! CAUTION
CAUTION ‑ indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury or property damage. It may also be used to alert against unsafe
practices.
IMPORTANT: Indicates information or instructions that are necessary for proper

installation and/or operation.
NOTE: Refer to the appropriate Mercury MerCruiser Product Applications Manual for
application recommendations.
This installation manual has been written and published by Mercury MerCruiser to aid the
boat manufacturer (OEM) in the installation of the products described herein.
It is assumed that these personnel are familiar with marine product installation.
Furthermore, it is assumed that they are familiar with, if not trained in, the recommended
installation procedures of Mercury MerCruiser product.
We could not possibly know of or advise the marine trade of all conceivable installations
and of the possible hazards and/or results of each installation. Therefore, the OEM is
responsible for any installation that does not fulfil the requirements of this manual.
It is the responsibility of the boat manufacturer to select the appropriate engine/transom/
drive package (including the correct gear ratio and propeller) for a given boat. Mercury
MerCruiser recommends that any new or unique hull/power package combination be
thoroughly water tested prior to sale, to verify that the boat performs as desired, and that
the engine operates in the appropriate RPM range.
It is recommended that a Mercury MerCruiser Product Application Engineer (PAE) be
contacted for assistance. For assistance outside the United States, contact the local
Mercury Marine office or authorized distributor.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at time of publication. Mercury Marine reserves the
right to make changes at any time without obligation. As required, revisions to this manual
will be sent to all OEM boat companies.
Page ii
Manual Outline
1 - Important Information
Important Information
1
2 - Boat Construction
3 - Exhaust System
Boat Construction
2
3
4 - Fuel System
Exhaust System
5 - Cooling System
6 - Drive System And Engine Installation
7 - Starting And Electrical
8 - Remote Controls
Fuel System
4
9 - Predelivery Preparation And Storage
Cooling System
5
Drive System And Engine
Installation
6
Starting And Electrical
7
Remote Controls
8
Predelivery Preparation And
Storage
9
Page iii
SECTION - 1 IMPORTANT INFORMATION
SECTION 1 - IMPORTANT INFORMATION 1

Table of Contents
Torque Specifications.............................................................................................................................................. 2
Quicksilver Products................................................................................................................................................ 2
Accessories ...................................................................................................................................................... 2
Remote Controls And Instrumentation for DTS System.......................................................................................... 2
Serial Number Decal Placement............................................................................................................................. 3
Bravo Three Notice: Trim-in Limit Insert.................................................................................................................. 3
Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 3
Internal Power Steering With Internal Tie Bar Only ......................................................................................... 4
Internal Power Steering With Internal and External Tie Bar ............................................................................. 4
External Power Steering .................................................................................................................................. 4
External Power Steering With Low External Tie Bar ........................................................................................ 4
Corrosion Protection................................................................................................................................................ 4
Anti-fouling Paint..................................................................................................................................................... 4
Emission Control Information Label........................................................................................................................ 6
Owner Responsibility ........................................................................................................................................ 7
Star Label................................................................................................................................................................ 7
Hang Tag................................................................................................................................................................. 8
90-864196050 FEBRUARY 2005 Page 1 / 8

IMPORTANT INFORMATION SECTION - 1
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
NOTE: The propeller torque stated is a minimum torque value.
Description Nm lb. in. lb. ft.

Exhaust tube clamp 4 35
Exhaust pipe bolts 34 25
Exhaust block‑off plate bolts 34 25
75 55
Bravo One propeller nut
Then align tabs with grooves
81 60
Bravo Two propeller nut
Bravo Three front propeller nut 136 100
Bravo Three rear propeller nut 81 60
Rear engine mounting bolts 47 35
Steering cable coupler nut 47 35
Steering system pivot bolts 34 25
Sterndrive unit fasteners 68 50
Transom assembly fasteners 34 25
Mounting clip screw 12.2 108
Hose clamps 3.4‑6.8 30‑60
Water inlet fitting bolts 5 45
Water inlet block‑off screw 5 45
Finger tight + 1‑¾ to 2‑¼ turns with a
Fuel inlet fitting
wrench. Do not overtighten.
Gen III Cool Fuel Module captured nut 19 168
Battery stud 8‑11 71‑91
Propeller shaft anode screw 19 168
Quicksilver Products
Accessories
Quicksilver gauges, remote controls, steering systems, propellers, and other accessories are
available for this product. Mercury MerCruiser recommends the use of Quicksilver parts on all
applications. Refer to Mercury Precision Parts Accessories Guide for a complete listing.
This Guide is available from:
Attn: Parts Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939
Outside of U.S.A., order through Distribution Center or Distributor.
Remote Controls And Instrumentation for DTS System

The Digital Throttle and Shift system (DTS) requires the use of specialized helm components,
including a command module kit and electronic remote control. Refer to the Mercury Precision
Parts/Quicksilver Accessories Guide.
Page 2 / 8 90-864196050 FEBRUARY 2005

Serial Number Decal Placement

There are 3 sets of engine, transom assembly, and sterndrive serial number decal strips provided
with each power package. One should be used for each of the following:
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance and Warranty Manual identification page
Affix engine serial number decal to specification / serial number decal.
8331
a
a - Specification/serial number decal
Bravo Three Notice: Trim‑in Limit Insert

NOTE: Bravo One, Two and Three Models are equipped with a trim‑in limit insert.
It has been brought to our attention that some boats (predominantly deep‑Vee heavy boats) will
roll up on their side under certain, specific, operating conditions. The roll can be either to port or
starboard and may be experienced while moving straight ahead, or while making a turn. The roll
occurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near full
trim‑in. While the boat will not roll completely over, the roll may be sufficient to unseat the operator
or passengers, and thereby create an unsafe situation.
The roll is caused by stern‑lift created from excessive sterndrive unit trim‑in. Under these extreme
stern‑lift / bow‑down conditions, instability can be created, which may cause the boat to roll. Weight
distribution to the stern can reduce stern‑lift and, in some circumstances, help to control the
condition. Weight distribution in the bow, port or starboard, may worsen the condition.
The trim‑in limit insert reduces stern‑lift by preventing the sterndrive unit from reaching the last
few degrees of full trim under. While this device should reduce the rolling tendency, it may not
eliminate the tendency entirely. The need for this trim‑in limit insert, and its effectiveness, can only
be determined through boat testing and is ultimately the responsibility of the boat manufacturer.
! WARNING
It is recommended that only qualified personnel adjust the trim‑in limit inserts. The boat must be
water tested after adjusting the trim‑in limit inserts to ensure that the modified trim‑in range does
not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is
trimmed in at higher speeds. Increased trim‑in range may cause handling problems on some
boats, which could result in personal injury.
Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives you must select one of several possible steering systems.
! CAUTION
Failure to observe the recommended Tie Bar Arrangements could result in serious damage to
the steering and/or trim system components. This damage could adversely affect control of the
boat. Observe the recommended Tie Bar Arrangements as presented in this section.
90-864196050 FEBRUARY 2005 Page 3 / 8

Internal Power Steering With Internal Tie Bar Only

At the lower end of the performance spectrum, boats not capable of speeds in excess of 97 km/
h. (60 MPH), the basic internal tie bar is recommended. It connects the slave sterndrive to the
sterndrive that is directly connected to the factory power steering output. This internal tie bar is
available in a variety of lengths from the sterndrive manufacturer.
Internal Power Steering With Internal and External Tie Bar
As a boat moves into the moderate performance range of 97‑113 km/h. (60‑70 MPH) or for a
reduction in steering backlash, an external tie bar should be added. External tie bars are usually
designed to attach at the aft power trim cylinder bosses. This location is an excellent choice
because of its proximity to the propeller. HOWEVER, because of the potential overstress that can
occur if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part
Number 90362A3) should be installed to limit this potential tilt differential to about 20 degrees.
IMPORTANT: Mercury Marine does not recommend the use of an external tie bar ONLY with no
internal tie bar when using the internal power steering system. This can cause excessive loads
on the steering components on the sterndrive connected to the internal power steering system.
These increased loads can damage the steering components, resulting in increased play in the
steering of the boat.
External Power Steering
When boat speeds move past 113 km/h (70 MPH) or if additional steering backlash reduction is
desired, external power steering is recommended. This normally will include an external tie bar
mounted at the same general location as the power steering cylinders, which are generally
attached at the top of the sterndrive's drive shaft housing. With this steering system, no internal
tie bar should be used. These steering cylinders can be attached either inboard (between) or
outboard of the sterndrives.
External Power Steering With Low External Tie Bar
For the fastest boats, over 129 km/h (80 MPH) , or for the ultimate in steering backlash reduction,
use external power steering, BUT (where mechanically possible) with the external tie bar mounted
at the trim cylinder boss location (as previously described in "Internal Power Steering with Internal
and External Tie Bar" statements). Again, this system does not use an internal tie bar.
Corrosion Protection
Mercury MerCruiser power packages are equipped with anodes to help protect them from galvanic
corrosion under moderate conditions. However, for severe conditions or if using a stainless steel
propeller, it is recommended that a Quicksilver Anti‑Corrosion Anode Kit and/or a MerCathode
System with 2 additional transom mounted anode assemblies be installed (some models have a
MerCathode System as standard equipment). A MerCathode Monitor also is available to allow the
operator to check the operation of the MerCathode System with the push of a button. (Refer to
Mercury Precision Parts Accessories Guide for part numbers.)
Boats that are connected to AC shore power require additional protection to prevent destructive
low voltage galvanic currents from passing through the shore power ground wire. A Quicksilver
Galvanic Isolator can be installed to block the passage of these currents while still providing a path
to ground for dangerous fault (shock) currents. (Refer to Mercury Precision Parts Accessories
Guide for part number.)
IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and
anodes may be unable to handle the increased galvanic corrosion potential.
Anti‑fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint
will not be covered by the limited warranty.
Painting Boat Hull or Boat Transom: Anti‑fouling paint may be applied to boat hull and boat
transom but you must observe the following precautions:
Page 4 / 8 90-864196050 FEBRUARY 2005

IMPORTANT: Do not paint anodes or pressure wash anodes or MerCathode System reference
electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.
IMPORTANT: If anti‑fouling protection is required for boat hull or boat transom, copper base paint,
if not prohibited by law, can be used. If using copper based anti‑fouling paint, observe the following:
• Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks,
or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) UNPAINTED
area on transom of the boat around these items.
8107
a - Painted boat transom b - Minimum 40 mm (1‑1/2 in.) unpainted

area around transom assembly
NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine paint or
an anti‑fouling paint that DOES NOT contain copper or any other material that could conduct
electrical current. Do not paint drain holes, anodes, MerCathode system or items specified by boat
manufacturer.
! CAUTION
Improper boat cleaning procedures can cause product damage. Washing the MerCathode
assembly, especially with a brush or high pressure washer, will damage the MerCathode
assembly making it unable to inhibit galvanic corrosion. When cleaning the boat, do not use a
brush or a high pressure washer to wash the MerCathode assembly found on the bottom of the
transom assembly.
90-864196050 FEBRUARY 2005 Page 5 / 8

Do not wash the sterndrive unit with a power washer as this can damage the coating on the
reference wire of the MerCathode assembly, if equipped, and increase corrosion.
b
6211
a - MerCathode reference electrode c - Do not pressure wash

b - Do not paint
Emission Control Information Label

A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine
at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement,
the label lists the engine serial number, family, FEL (emission level), date of manufacture (month,
year), and the engine displacement. Please note that the low emissions certification will not affect
the fit, function, or performance of the engines. Boatbuilders and dealers may not remove the label
or the part it is affixed to before sale. If modifications are necessary, contact Mercury MerCruiser
about the availability of replacement decals before proceeding.
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
SERIAL# OMXXXXXXXX
D.O.M. JAN. 2003
FAMILY XXXXX_XXXXXX
DISP X.XL
FEL. XX.X g/kW-hr
11018
Emission Control Label ‑ Non CE Marked

"SERIAL#" ‑ Engine Serial Number
"FAMILY" ‑ Engine Family
"FEL." ‑ Family Emission Limit
"D.O.M." ‑ Date of Manufacture
Page 6 / 8 90-864196050 FEBRUARY 2005

"DISP" ‑ Piston Displacement
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
SERIAL# OMXXXXXX
D.O.M. Dec 2004
FAMILY XXXXX XXXXXX
FEL. XX.X g/kW-hr DISP. X.XL 0575
10652
Emission Control Label ‑ CE Marked

"SERIAL#" ‑ Engine Serial Number
"FAMILY" ‑ Engine Family
"FEL." ‑ Family Emission Limit
"D.O.M." ‑ Date of Manufacture
"DISP" ‑ Piston Displacement
CE ‑ When this mark is present in the lower right corner of the Emission Control Information Label,
on the engine, the Declaration of Conformance applies. Refer to the front page of this Manual for
further information.
Owner Responsibility
The owner/operator is required to have routine engine maintenance performed to maintain
emission levels within prescribed certification standards.
The owner/operator is not to modify the engine in any manner that would alter the horsepower or
allow emissions levels to exceed their predetermined factory specifications.
Star Label
Beginning January 1, 2003, one Three‑Star label will be included with each factory‑certified
Mercury MerCruiser engine.
All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission
rating. The Three‑Star label identifies that these engines meet the California Air Resources Board's
Sterndrive and Inboard marine engine 2003 exhaust emission standards. Engines meeting these
standards have 65% lower emissions than One‑Star ‑ Low Emissions engines.
The Three‑Star label will be affixed on the left side of the hull as shown.
XX 1234 XX
a b
mc79531
a - Recommended location b - Secondary location
90-864196050 FEBRUARY 2005 Page 7 / 8

One Star ‑ Low emission

The one‑star label identifies personal watercraft, outboard,
sterndrive and inboard engines that meet the Air
Resources Board's Personal Watercraft and Outboard
marine engine 2001 exhaust emission standards. Engines
meeting these standards have 75% lower emissions than
conventional carbureted two‑stroke engines. These
mc79569-1 engines are equivalent to the U.S. EPA's 2006 standards
for marine engines.
Two Stars ‑ Very Low emission
FO
IDA
The two‑star label identifies personal watercraft, outboard,
sterndrive and inboard engines that meet the Air
marine engine 2004 exhaust emission standards. Engines
meeting these standards have 20% lower emissions than
One Star ‑ Low‑Emission engines.
mc79570-1
Three Stars ‑ Ultra Low emission
The three‑star label identifies engines that meet the Air

A
SS
D
marine engine 2008 exhaust emission standards or the
Sterndrive and Inboard marine engine 2003 exhaust
emission standards. Engines meeting these standards
have 65% lower emissions than One Star ‑ Low Emission
mc79571-1 engines.
Four Stars ‑ Super Ultra Low emission
T
The Four Star label identifies engines that meet the Air
RN
Resources Board's Sterndrive and Inboard marine engine
F
2009 exhaust emission standards. Personal Watercraft

and Outboard marine engines may also comply with these
standards. Engines meeting these standards have 90%
lower emissions than One Star ‑ Low Emission engines.
mc79572-1
Hang Tag
The Dealer must mark the appropriate box on one hang tag to match the Star label affixed to the
boat. The dealer is responsible for displaying the hang tag in a visible location on the boat on
display in California. Failure to properly display the hang tag could result in a citation and possible
fine to the dealer from the California Air Resources Board.
If in California, the dealer must place the hang tag in a visible location in the boat prior to displaying
the boat.
Page 8 / 8 90-864196050 FEBRUARY 2005

SECTION - 2 BOAT CONSTRUCTION
SECTION 2 - BOAT CONSTRUCTION

Table of Contents
Boat Construction.................................................................................................................................................... 2
Transom Thickness and Surface Plane............................................................................................................2
2
Transom Cutout.................................................................................................................................................2
Checking Transom Thickness...........................................................................................................................2
Engine Bed........................................................................................................................................................2
90-864196050 FEBRUARY 2005 Page 1 / 2

BOAT CONSTRUCTION SECTION - 2
Boat Construction
Transom Thickness and Surface Plane
IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the
sterndrive unit mounts.
Transom Specifications
Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical center line
Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.)
Transom surfaces in area where transom assembly will be mounted (includes vertical as well
Flatness as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.) Outer Surface ‑ Flat within
2 mm (1/16 in.)
Angle 10 ‑16 degrees
a e
d d
b
c 7508
a - Transom thickness d - Transom plate coverage ‑ 203 mm

b - Inner surface (8 in.) from center
c - Outer surface e - Transom angle
Transom Cutout
Refer to Section 6 ‑ Drive System And Engine Mounting.
Checking Transom Thickness
Refer to Section 6 ‑ Drive System And Engine Mounting.
Engine Bed
IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum
of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.
This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer
(structure) to obtain the 6 mm (1/4 in.) dimension.
Description Specification
Difference between starboard and
57.2 cm (22‑1/2 in.)
port engine mount
Mount adjustment up and down
6 mm (1/4 in.)
(minimum)
NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure that
the front and rear mount locations in the vessel are parallel and in the same plane. This may be
checked by tying a string from the left front mount location to the right rear mount location and
another from right front to left rear. The strings should touch where they cross.
Page 2 / 2 90-864196050 FEBRUARY 2005

SECTION - 3 EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Exhaust System Caution......................................................................................................................................... 2
Preferred Exhaust System....................................................................................................................................... 2
Through The Transom And Through The hull Exhaust System Design.................................................................. 2
3
Measuring Exhaust Elbow Height........................................................................................................................... 3
Methods For Measuring Exhaust Elbow Height...................................................................................................... 6
Straight Edge Method ...................................................................................................................................... 6
Clear Hose Method for Measuring Exhaust Elbow Height...................................................................................... 7
Collector And Water Lift Muffler Equipped ....................................................................................................... 8
Exhaust Resonator Guidelines................................................................................................................................ 9
90-864196050 FEBRUARY 2005 Page 1 / 11

EXHAUST SYSTEM SECTION - 3
Exhaust System Caution

! CAUTION
It is the responsibility of the boat manufacturer or installing dealer to properly locate the engine
and install the exhaust system. Improper installation may allow water to enter the exhaust
manifolds and combustion chambers and severely damage the engine. Damage caused by
water in the engine will not be covered by Mercury MerCruiser Warranty, unless this damage is
the result of defective parts.
Preferred Exhaust System

Most Mercury MerCruiser sterndrive engines were developed and tested for Y‑pipe or through the
propeller exhaust systems. Using the Y‑pipe system limits the potential for water intrusion due to
the exhaust system design.
Through The Transom And Through The hull Exhaust System Design
These engines are equipped with a wet exhaust system in which exhaust is mixed with water in
the exhaust elbows. This cools the exhaust and allows the use of heat resistant rubber hose on
the outlet side of the system. These specifications must be observed by the OEM and muffler
manufacturer when designing and installing the exhaust system:
• Through the prop exhaust utilizing the y‑pipe is the desired system on all models covered in
this manual.
• Heat resistant exhaust hose that complies with specifications SAE J2006 or UL 1129 should
be used (ABYC standard).
• Exhaust hoses should be no smaller than the minimum sizes. Larger hoses should be used
on applications with long hose runs.
Minimum Exhaust Hose Size

Single Outlet System
Model Dual Outlet System Single Hose
Dual Hose Portion
Portion
All Models 102 mm (4 in.) 102 mm (4 in.) 102 mm (4 in.)
• Sharp bends in exhaust hoses should be avoided.

• Exhaust hoses can be installed at up to a 5° angle relative to the exhaust elbow outlets. Refer
to Exhaust Hose Connections.
• Exhaust elbows must be the prescribed distance above the water line. Install risers if needed.
See Measuring Exhaust Elbow Height.
• The exhaust hose attached to exhaust elbow must have a minimum of 10° downward slope.
On longer hose applications, slope can be reduced to 3° in the portion of exhaust system that
is more than 457 mm (18 in.) away from elbow.
NOTE: Mercury MerCruiser's recommendations is more stringent than ABYC recommendation of
a minimum drop in the exhaust system of 1/2 in. per foot with an overall drop of not less than 102
mm (4 in.) between the exhaust elbow outlets and the boat outlets.
Slope Conversion
Degrees Drop vs. Run Distance from Elbow
3 5/8 in. / ft 52 mm / m < 18 in.
6 1‑1/4 in. / ft 105 mm / m < 18 in.
7 1‑7/16 in. / ft 122 mm / m < 18 in.
10 2‑1/8 in. / ft 176 mm / m < 18 in.
Page 2 / 11 90-864196050 FEBRUARY 2005

Slope Conversion
Degrees Drop vs. Run Distance from Elbow
12 2‑1/2 in. / ft 212.5 mm / m < 18 in.
14 2‑15/16 in. / ft 249 mm / m < 18 in.
19 4‑1/8 in. / ft 344 mm / m < 18 in.
• The drop in the exhaust hose must be continuously sloping downward so that a low spot does
not exist at any point.
• Through the hull exhaust fittings (flanges, outlets) must be equipped with internal shutters and
external flappers to prevent the reverse flow of water into the engine. Refer to Exhaust Through
The Hull Fittings.
• Exhaust outlets must be above the water line with boat at rest in the water and a full load
aboard, as well as while underway. This is necessary to minimize engine back pressure.
• Every exhaust hose connection should be secured with at least 2 hose clamps. The clamps
should be stainless steel and at least 13 mm (1/2 in.) wide. Clamps which rely solely on spring
tension should not be used. (ABYC Standard).
• The exhaust system must be adequately supported for proper orientation and to prevent
overstressing the exhaust manifolds and elbows. The support requirements will vary with
exhaust system design and the amount of G‑forces to be encountered.
• The through transom exhaust system must meet the exhaust back pressure specification.
• Straight through transom exhaust or silent choice exhaust must have an exhaust hose of at
least 305 mm (12 in.), have an adequately muffled tip, and meet all aforementioned
specifications.
• The system must have the capability to be serviced, reassembled, and replaced while
maintaining all of the specifications. The boat builder must provide documentation, such as
manuals, drawings, or orientation marks on production assemblies.
• If a waterlift/collector system is used, the waterline is defined as the waterline inside the
collector. All measurements must be taken from that waterline to measure exhaust elbow
heigh.
• in‑line mufflers, collectors, and hoses must self drain after engine shut‑down. See muffler/
collector section.
Measuring Exhaust Elbow Height

The height of the exhaust elbows and the slope of the exhaust hoses must be within the dimensions
specified to prevent water intrusion problems. Exhaust elbow risers must be installed, if needed,
to obtain the proper height and/or slope. Measurement must be taken with the boat in the water.
It is important that the boat be loaded as outlined following to simulate the maximum loading
conditions likely to be encountered in normal operation.
IMPORTANT: Load distribution recommendations are the responsibility of the boat manufacturer.
Any load distribution conditions that will affect the exhaust system height and slope compliance
must be clearly communicated to the operator in the owner's manual. For example, the number
of people that can be located on the swim platform simultaneously should be included in the
manual, if this could pose a problem.
1. Fill fuel, water, waste water and heater tanks to maximum capacity. People or weights can be
used to simulate these loads if desired. Refer to conversions:
• 1 U.S. gallon of water = 8.3 lb
• 1 liter of water = 1 kg
• 1 U.S. gallon of gasoline = 6 lb
• 1 liter of gasoline = 0.72 kg
2. Add maximum allowable cargo weight to boat in areas where it will be stowed, including
refrigerator and lockers. Do not forget the PWC, if applicable.
90-864196050 FEBRUARY 2005 Page 3 / 11

3. Add average passenger weight in all locations where each passenger will sit during normal
operation.
4. Allow for a minimum of 2 people on the swim platform for docked conditions. Seat people
starting at the rear of the boat.
NOTE: ABYC specifies an average passenger weight of 64 kg (141 lb) for boat loading
calculations. This should be used as a minimum. An average passenger weight of 86 kg (190 lb)
is desirable.
5. Measure exhaust elbow height as outlined under Methods For Measuring Exhaust Elbow
Height.
6. Measure exhaust system slope as specified following.
7. Leave fluid and cargo weights where they are, but remove passenger weights from boat.
Beginning at the bow, reload passenger weight (the equivalent of one person at a time) while
retaking readings. Use all of the available seating areas in the bow first. Continue adding
passenger weight (and taking readings), moving from the bow to the stern until the maximum
people weight has been added back on board.
8. Repeat Step 7, but this time start at stern of boat and work toward bow.
9. Measurements under all loading conditions should be within these specifications:
NOTE: Exhaust elbow height is measured to the waterline in the water lift muffler (instead of the
water line) on applications so equipped. Refer to the appropriate Mercury MerCruiser Product
Applications Manual for more information.
Minimum Exhaust Elbow Height

Model Specification
V6 and V8 Alpha/Bravo 330 mm (13 in.)
NOTE: Through transom exhaust applications must have an exhaust hose length of 305 mm
(12 in.).
c
a
9173
Using a universal protractor (inclinometer) to measure slope

a - Protractor c - Minimum 305 mm (12 in.).
b - Exhaust hose or tube
Minimum Exhaust Hose Slope

Specification
Model Within 457 mm. (18 in.) of
Remainder of system (if applicable)
engine
All models 10 degrees 3 degrees
10. Install risers if height is insufficient. Modify exhaust system and/or install risers, if slope is
insufficient. Refer to the Mercury Precision Parts / Quicksilver Accessory Guide for part
numbers.
Page 4 / 11 90-864196050 FEBRUARY 2005

Model Riser Options

V6 Sterndrive 43 mm (1.7 in.) 76 mm (3 in.) 152 mm (6 in.)
Model Riser Options

V8 Sterndrive 43 mm (1.7 in.) 76 mm (3 in.) 119 mm (4.7 in.) 152 mm (6 in.)
NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.

11. If measurements are less than specified, exhaust elbow risers must be installed to achieve
proper dimension.
12
11
9 6
10
7
8
5
6
3 4
1
7932
Typical riser installation

1- Exhaust manifold bolt (4) 7 - Restrictor gasket, with turbulator
2- Exhaust manifold 8 - Block off gasket, with turbulator
3- Full flow gasket, with turbulator (closed cooled models)
4- Full flow gasket 9 - Exhaust elbow
5- Riser 10 - Hose fitting
6- Pipe plug 11 - Washers (4)
12 - Exhaust elbow bolt (4)
NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.

12. Applications With Through The Propeller Exhaust: Recheck exhaust elbow height.
13. Applications With Through The Hull Or Through The Transom Exhaust:
a. Move load weight to bow to simulate greatest bow‑down attitude the boat will encounter
in normal operation.
b. Recheck exhaust system slope.
14. Move load weight and cargo weight to stern of boat to stimulate greatest stern‑down attitude
the boat will encounter such as when loading.
90-864196050 FEBRUARY 2005 Page 5 / 11

IMPORTANT: Be sure to consider swim platform loading and personal watercraft.

15. Recheck exhaust system measurements.
Minimum Exhaust Elbow Height From Top of Elbow to Waterline

Model Measurement
V6 and V8 Sterndrive 330 mm (13 in.)
9141
a - Highest point on exhaust elbow c - Waterline

b - Measurement
NOTE: Additional requirements for through the hull or transom exhaust system applications:
Continuous Downward Slope From Horizontal

Engine
Model Installation Minimum Maximum
Angle
48 mm (1‑7/8 in.) 105 mm (4‑1/8 in.) per
Sterndrive 0 degrees 9 degrees 19 degrees
per 305 mm (12 in.) 305 mm (12 in.)
Methods For Measuring Exhaust Elbow Height

IMPORTANT: Refer to Measuring Exhaust Elbow Height for instructions on proper loading of boat
and complete measurement instructions.
Straight Edge Method
1. Place a straight edge across boat.
2. With the straight edge above the engine as shown, measure the distance between the straight
edge and the top of the exhaust elbow.
3. Ensure that the boat is level from side‑to‑side, using a level or inclinometer. Then, measure
the distance between the straight edge and the outside waterline.
Page 6 / 11 90-864196050 FEBRUARY 2005

4. The difference between these two measurements is the exhaust elbow height above the
waterline. Refer to Measuring Procedures and compare measurement to specifications.
c
b
d
e
a
7957
a - Waterline d - Measurement between straight edge

b - Top of exhaust elbow and top of exhaust elbow
c - Straight edge e - Measurement between straight edge
and waterline
Clear Hose Method for Measuring Exhaust Elbow Height

1. Obtain a 8‑10 mm (5/16 ‑ 3/8 in.) diameter hose approximately 4.5 m (15 ft) long. Put a metal
fitting or a weight on one end of the hose to keep that end of the hose below the waterline.
2. Put the weighted end of the hose over the port or starboard side of the boat, keeping it in line
with the engine's exhaust elbow.
3. Route the remainder of the hose toward the engine's exhaust manifold and elbow. Ensure that
this open end section of the hose is as vertical as possible from the boat's bilge to the top of
the exhaust elbow.
4. Coil excess hose in bilge of boat, keeping it below the water line.
5. Lower open end of hose and siphon water until it starts to come out of the hose. Put a finger
over the hose and lift open end until it is at the top of the exhaust elbow.
6. Slowly take finger off end of hose to let the water level stabilize. The water will seek the level
of the water outside the boat. Keep hose close to exhaust elbow and as vertical as possible.
7. Make sure that the boat is level (side‑to‑side) using a level or inclinometer.
90-864196050 FEBRUARY 2005 Page 7 / 11

8. The measurement between water in hose and top of exhaust elbow is the exhaust elbow
height.
c
a e
8340
9142
a - Waterline d - Weight
b - Top of exhaust elbow e - Measurement ‑ waterline to top of
c - Clear plastic hose exhaust elbow
Collector And Water Lift Muffler Equipped

IMPORTANT: Engine must have been operated previously to fill muffler with water.
1. Attach a clear hose to the muffler drain plug or drain valve.
2. If the clear hose is attached to a drain valve, open the drain valve.
3. Start the engine to fill the muffler and clear hose.
4. Route the remainder of the clear hose toward the engine's exhaust manifold and elbow.
Ensure that this open end section of the clear hose is as vertical as possible from the boat's
bilge to the top of the exhaust elbow.
5. Coil excess clear hose in bilge of boat, keeping it below the waterline.
6. Lower open end of clear hose and siphon water until it starts to come out of the clear hose.
Put a finger over the clear hose and lift the open end until it is level with the top of the exhaust
elbow.
7. Slowly take finger off the end of the clear hose to let the water level stabilize. The water will
seek the level of the water inside the water lift muffler. Keep the clear hose close to exhaust
elbow and as vertical as possible.
8. Make sure that the boat is level (side‑to‑side) using a level or inclinometer.
Page 8 / 11 90-864196050 FEBRUARY 2005

9. The measurement between the water in the clear hose and the top of the exhaust elbow is
the exhaust elbow height above the water line.
b c
e f
h
a
i
g 7555
Typical
a - Water line f - Minimum exhaust elbow height with
b - 457 mm. (18 in.) minimum between maximum load
exhaust elbow and collector g - Drain plug or drain valve
c - 10 degree downward slope minimum h - External flappers
d - 3 degree downward slope minimum i - Clear hose
e - Collector
a
7556
c
Typical S‑pipe Used With Water Lift Muffler
a - Water line c - Drain plug or drain valve
b - Minimum exhaust elbow height with
maximum load
Exhaust Resonator Guidelines

! CAUTION
Avoid severe engine damage. Water ingestion may occur in some instances without the use of
specially designed exhaust resonators. Install exhaust resonators in the exhaust system when
specified.
IMPORTANT: MerCruiser strongly recommends exhaust resonators on all models with through
the transom exhaust.
90-864196050 FEBRUARY 2005 Page 9 / 11

On sterndrive engines using through the transom or through the hull exhaust systems, special
care must be exercised in system design and construction to prevent an adverse tuning effect on
engine exhaust output.
• The exhaust resonator is positioned with the inside flat surface at the preferred distance of
432 mm (17 in.) from the front edge of the exhaust hose but no closer than 51 mm (2 in.) to
the exhaust outlet on sterndrives. The 432 mm (17 in.) dimension can be reduced, if
necessary, to a MINIMUM of 330 mm (13 in.). This dimension must be the same on both
exhaust outlets.
c c
a b a b a
a
e e
d e d
g
g
f f 8232
b c
c
a b a e
e f
d
g 8231
a - Exhaust resonator e - Clamp ‑ positioned around center of

b - Exhaust hose resonator
c - Dimension to inside flat surface of f - Exhaust muffler
resonator approximately 432 mm g - Collector
(17 in.)
d - No less than 51 mm (2 in.) between
collector and resonator
Exhaust system tuning can be affected by various factors that are beyond the control of Mercury
MerCruiser. Following are several factors that can affect exhaust system tuning:
• Type and configuration of exhaust outlet.
Page 10 / 11 90-864196050 FEBRUARY 2005

• Length of exhaust hose.

• Amount of back‑pressure in exhaust system. Refer to the appropriate Mercury MerCruiser
Product Applications Manual.
Exhaust Resonator Kit use on Sterndrive Models:
CAN Be Used With: CANNOT Be Used With:

Transom mounted muffler tips Silent Choice Exhaust System
Waterlift mufflers or other mufflers that are mounted
Below swim platform exhaust
outboard of exhaust elbows
Mufflers that mount between exhaust elbow and
Open exhaust
exhaust tip
90-864196050 FEBRUARY 2005 Page 11 / 11

SECTION - 4 FUEL SYSTEM
SECTION 4 - FUEL SYSTEM

Table of Contents
Fuel Delivery System .............................................................................................................................................. 2
90-864196050 FEBRUARY 2005 Page 1 / 3

FUEL SYSTEM SECTION - 4
Fuel Delivery System

The fuel delivery system must be designed to deliver the fuel to the engine with minimal restriction
and at the lowest temperature. Gasoline is extremely sensitive to vaporizing if placed under a
vacuum (low pressure) and exposed to moderate or high temperatures. This is particularly true if
winter blend fuels with a high RVP (Reid Vapor Pressure) are encountered in warmer temperature
areas. Excessive restriction in the fuel delivery system may cause a condition known as vapor
locking. This typically occurs after the engine has been operated at high RPM and then shut off
and allowed to sit for 15 minutes to 2 hours. During this time the engine heat soaks, causing the
temperature of the fuel system to increase. Upon restart, the combination of heat and vacuum in
the fuel system causes the fuel to vaporize. The fuel system cannot handle this vapor and
therefore, fuel starvation results when the boater attempts to resume operation. Depending upon
the degree of vapor locking, this can range from a hesitation or bog when accelerating to a
complete stalling of the engine. To minimize the potential for this problem, the guidelines should
be observed to limit fuel delivery restriction to 6.9 kPa (2 in. Hg) or less and fuel inlet temperature
to 44 C (110 F) or less.
The fuel delivery system is an integral part of the boat. Mercury MerCruiser makes no attempt in
this manual to cover all aspects of design and integration of the fuel delivery system, due to a
broad range of possible configurations and the numerous regulations and standards that cover
this area. The applicable standards and regulations for the markets where your product will be
sold should be observed, along with any information from the fuel system component
manufacturers. The following general guidelines are provided:
! WARNING
Avoid serious injury or death and property damage due to improper boat design and
construction. Always adhere to all applicable Marine Regulations (United States Coast Guard
[USCG], European Union ‑ Recreational Craft Directive [EU‑RCD], and so on) and the standards
they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers
[SAE], International Standards Organization [ISO], and so on) when designing and constructing
the boat and the boat components, such as the engine compartment, fuel delivery system and
exhaust system.
The main concern of a boat's fuel system is safety; this must be achieved through a technically
sound installation and constant inspection.
The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.
The fuel tank is an integrated component of the boat. Refer to the special information on service
and maintenance, which you have received from the tank manufacturer.
Only a few points related to function and safety are listed here [Refer to boating standards (NMMA,
ABYC, etc.) and Coast Guard regulations for complete guidelines]:
• All connections should be on the upper side of the tank.
• The drain plug at the lowest point on the tank serves to permit the removal of water and
sediment.
• The tank breather pipe must have an inner diameter of at least 13 mm (1/2 in.) and must be
fitted with a swan neck to prevent water from entering the tank.
It is recommended that the exact route and length of the fuel lines be established at the first
installation of the engine to prevent problems later in connecting them to the engine.
All fuel lines must be well secured. The holes where the lines run through the bulkheads should
be carefully rounded off or protected with rubber grommets. This prevents damage to the lines
from abrasion.
The following, but not limited to the following, additional fuel connection related points, applying
to all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA,
ABYC, etc.) and Coast Guard regulations for complete guidelines]:
1. Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up
impurities.
Page 2 / 3 90-864196050 FEBRUARY 2005

SECTION - 4 FUEL SYSTEM
2. The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg)
through out engine operating range.
IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today's
fuels. It can also cause poor engine performance because of fuel starvation.
3. Fuel lines used must be Coast Guard approved (USCG Type A1).
Minimum Fuel Line Diameter 10 mm (3/8 in.) minimum
4. On Multi‑Engine Gasoline Installations: It is best to use a fuel pickup and supply line for each
engine. If a single pickup and line is used, line must be 13 mm (1/2 in.) ID or larger.
5. On installations that require long lines or numerous fittings: The fuel lines and fittings ID must
be greater than 10 mm (3/8 in.).
6. Fuel lines should be installed free of stress and firmly secured to prevent vibration and/or
chafing.
7. Sharp bends in fuel lines must be avoided.
8. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to
absorb deflection when engine is running.
90-864196050 FEBRUARY 2005 Page 3 / 3

SECTION - 5 COOLING SYSTEM
SECTION 5 - COOLING SYSTEM

Table of Contents
Seawater Connections - General Information......................................................................................................... 2
Specifications....................................................................................................................................................2
Seawater Pickup...............................................................................................................................................2
Seawater Pickup Requirements........................................................................................................................2
Seawater Pickup - General Information ..................................................................................................... 3
Seacock - General Information .................................................................................................................. 4
Sea Strainer - General Information ............................................................................................................ 4
Y-Fitting................................................................................................................................................................... 5
Hot Water Heater Hose Connections - MPI Models ............................................................................................... 6
Supply Hose Connection .................................................................................................................................. 7
Return Hose Connection .................................................................................................................................. 8
Water Flow Diagrams.............................................................................................................................................. 9
V-6 and V-8.......................................................................................................................................................9
V-8 Closed Cooled Bravo Models with Risers ........................................................................................... 9
5
V6 Closed Cooled Alpha Models with Risers .......................................................................................... 10
V8 Closed Cooled Bravo Models ............................................................................................................. 11
V6 Closed Cooled Sterndrive Models ...................................................................................................... 12
V6 Seawater Cooled Bravo MPD Models ................................................................................................ 13
V8 Seawater Cooled Bravo MPD Models ................................................................................................ 14
V8 Seawater Cooled Bravo Models Except MPD Models ....................................................................... 15
V6 Seawater Cooled Bravo Models Except MPD Models ....................................................................... 16
V6 And V8 Seawater Cooled Alpha MPD Models ................................................................................... 17
V6 And V8 Seawater Cooled Alpha Models Except MPD Models ........................................................... 18
90-864196050 FEBRUARY 2005 Page 1 / 18

COOLING SYSTEM SECTION - 5
Seawater Connections ‑ General Information

Specifications
Minimum flow (closed cooled models only) 114 liters per minute (30 gallons per minute) at 4000 rpm
Minimum pressure (closed cooled models
138 kPa (20 psi) at 4000 rpm
only)
Water pickup 32 mm (1‑1/4 in.) ID wire reinforced
Water inlet hose
Seacock 32 mm (1‑1/4 in.) connections
Seawater strainer
Seawater Pickup
This section covers through the hull and through the transom water inlets only. For information on
sterndrive water inlet connections, refer to the appropriate section after engine installation.
Seawater Pickup Requirements
IMPORTANT: Seawater hose used must be wire reinforced to avoid collapsing hose when suction
is created by seawater pump impeller.
c
f
b
e b b
d
a
7924
Typical installation shown with a through the hull water pick up

a - Quicksilver seawater pickup and e - Seawater hose to engine
seacock f - Seawater pump hose connector (if
b - Hose clamp equipped)
c - Seawater hose to seawater strainer g - Below seawater pump level
d - Quicksilver seawater strainer
IMPORTANT: Do not install the water pickup directly in line with the propeller, as the pickup may
create turbulence and allow air to flow into the propeller slipstream. This will cause propeller
ventilation and will adversely affect boat performance.
IMPORTANT: Make gradual bends in the seawater hoses to avoid kinks. Hoses must not come
in contact with steering system components, engine coupler, or drive shaft.
• The seawater pickup must be large enough to permit sufficient water flow to engine seawater
pickup pump for adequate engine cooling.
Page 2 / 18 90-864196050 FEBRUARY 2005

• The seawater pickup also must supply a positive head while underway.
• The seawater pickup should be located as close to the seawater pump inlet as possible and
in an area where an uninterrupted, solid stream of water will flow past when the boat is
underway.
• Refer to appropriate Mercury MerCruiser Product Applications Manual.
SEAWATER PICKUP - GENERAL INFORMATION
A transom seawater pick up or a through the hull seawater pickup can be used.
IMPORTANT: Seawater pickup must have an integral seacock.
IMPORTANT: Follow seawater pickup manufacturer's installation instructions.
7542
Typical through hull seawater pickup with seacock
8619
Typical transom seawater pickup installed on boat transom

• Pickup location should be selected to minimize water inlet hose length, while providing an
optimum location for water pickup.
• Location should be in an area that will provide a solid, air‑free flow of water under all operating
conditions.
• Avoid areas with a disturbed water flow, such as those behind, or in close proximity to, the
propeller.
• Locations that are too far forward or outboard should also be avoided as these are prone to
aeration problems at high boat trim angles and in turns.
• Check for aeration as outlined under Water Supply Test.
• Provisions should be made to minimize galvanic corrosion, given the hull material being used
and the composition of the surrounding components. Some industry standards and regulations
also require that the pickup be connected into the boat's bonding system to minimize stray
current corrosion. Refer to applicable standards and regulations for more details.
90-864196050 FEBRUARY 2005 Page 3 / 18


SEACOCK - GENERAL INFORMATION
The ABYC and other industry standards / regulations require the use of a seacock on certain types
of applications to stop the entry of water in the event of a leak in the cooling system.
IMPORTANT: Follow seacock manufacturer's installation instructions.
7532
Typical seacock shown with a through the hull water pick up

• Refer to applicable standards / regulations for specific requirements. The seacock also allows
the water to be shut off when servicing the engine.
• Seacock must provide minimum restriction to water flow (refer to Specifications).
• A ball or gate valve is recommended.
• The ball valve is most common and is typically equipped with a lever type handle that operates
in a 90 degree arc. This design gives a clear indication of whether the valve is open or shut.
• Industry standards / requirements typically require that the seacock be rigidly attached to the
hull at the water pickup.
• Seacock location should be readily accessible for quick, easy operation.
SEA STRAINER - GENERAL INFORMATION
A sea strainer is recommended if the boat is to be operated in an area with a high debris content.
Page 4 / 18 90-864196050 FEBRUARY 2005

IMPORTANT: Follow sea strainer manufacturer's installation instructions.
7533
Typical sea strainer

• Sea strainer must be sized to minimize restriction (Refer to Specifications) and to provide a
reasonable service interval.
• Locate strainer in an area that will be easily accessible for servicing.
• If boat is not equipped with a seacock, strainer should be located above the waterline to
prevent water entry into boat when servicing.
• Strainer must have provision to allow draining in freezing temperature periods.
Y‑Fitting
NOTE: All closed cooled models require a through the hull or through the transom pickup in
addition to the sterndrive water inlets in order to meet the minimum flow specifications.
When additional water inlets are used, a Y‑fitting is installed to the engine seawater pump.
c
b
8485
d
a - Engine seawater pump c - Y‑ fitting port to Bravo drive
b - Hose from seawater pump inlet port d - Y‑fitting port to additional water inlet
to Y‑fitting
90-864196050 FEBRUARY 2005 Page 5 / 18

Hot Water Heater Hose Connections ‑ MPI Models

IMPORTANT: When connecting a cabin heater or hot water heater:
• Supply hose (from engine to heater) and return hose (from heater to engine) Must Not Exceed
16 mm (5/8 in.) inside diameter (ID).
• Make heater connections only at locations shown.
• Refer to manufacturers' instructions for complete installation information and procedures.
• Do not reposition engine temperature switch.
! CAUTION
Avoid a performance loss and/or possible engine damage. Engine coolant must flow
continuously from the engine intake manifold to the engine water circulating pump. Never close
off or block the engine coolant flow to or from a hot water heater using coolant supplied by the
engine intake manifold and returned to the engine water circulating pump.
! CAUTION
Avoid engine overheating which could result in engine damage. On models equipped with
Closed Cooling, an air pocket may form in the closed cooling system if some coolant is lost from
the system and the cabin heater or hot water is mounted higher than the fill cap on the heat
exchanger. Heater must be mounted lower than the fill cap of the heat exchanger on models so
equipped.
Page 6 / 18 90-864196050 FEBRUARY 2005

Supply Hose Connection

NOTE: Some models may be equiped with additional fittings.
a 9255
Seawater cooled models with air or manual drain

a - Supply hose connection locations
9256
Closed cooled models

a
9257
Seawater cooled models with multi‑point drain

90-864196050 FEBRUARY 2005 Page 7 / 18

Return Hose Connection
9258
a - Return hose connection for hot water b - Water circulating pump housing
heater
Page 8 / 18 90-864196050 FEBRUARY 2005

Water Flow Diagrams

V‑6 and V‑8
V-8 CLOSED COOLED BRAVO MODELS WITH RISERS
h
b
a
j
c i
d
k
e
g
n
f
c
o
m 8182
a- Seawater inlet i - Exhaust elbow

b- Power steering cooler j - Seawater pump
c- Gen III cool fuel module k - Heat exchanger
d- Exhaust and seawater outlet l - To power steering pump
e- Exhaust manifold m - From seawater pump
f- Distribution housing n - Seawater
g- Water circulating pump o - Ethylene glycol mix
h- Thermostat housing p - Check valve
90-864196050 FEBRUARY 2005 Page 9 / 18

V6 CLOSED COOLED ALPHA MODELS WITH RISERS
i
b
a
k
j
e
l c
h
9393
m
g n
a- Seawater inlet h - Water circulating pump
b- Power steering cooler i - Thermostat housing
c- Check valve j - Exhaust elbow
d- Fuel cooler k - Seawater pump
e- Exhaust and seawater outlet l - Heat exchanger
f- Exhaust manifold m - Seawater
g- Distribution housing n - Ethylene glycol mix
Page 10 / 18 90-864196050 FEBRUARY 2005

V8 CLOSED COOLED BRAVO MODELS

i
a
h
b
c
j
k
d
e
g
c
n
f
o
m 9385
a- Y‑fitting i - Exhaust elbow

b- Power steering cooler j - Seawater pump
c- Gen III cool fuel module k - Heat exchanger
d- Exhaust and seawater outlet l - To power steering cooler
e- Exhaust manifold m - From seawater pump
f- Distribution housing n - Seawater
g- Water circulating pump o - Ethylene glycol mix
h- Thermostat housing p - Check valve
90-864196050 FEBRUARY 2005 Page 11 / 18

V6 CLOSED COOLED STERNDRIVE MODELS

a
j i
b
l
c e
f
h
m
g 9386
n
a- Y‑fitting h - Water circulating pump
b- Power steering cooler i - Thermostat housing
c- Check valve j - Exhaust elbow
d- Fuel cooler k - Seawater pump
e- Exhaust and seawater outlet l - Heat exchanger
f- Exhaust manifold m - Seawater
g- Distribution housing n - Ethylene glycol mix
Page 12 / 18 90-864196050 FEBRUARY 2005

V6 SEAWATER COOLED BRAVO MPD MODELS
j
b
a
i
e
c
h g
f
9388
a- Seawater inlet f- Check valve

b- Power steering cooler g- Water circulating pump
c- Fuel cooler h- Thermostat housing
d- Exhaust and seawater outlet i- Exhaust elbow
e- Exhaust manifold j- Seawater pump
90-864196050 FEBRUARY 2005 Page 13 / 18

V8 SEAWATER COOLED BRAVO MPD MODELS

j
a
d
k
e
i c
h g
f
d
l
9387
a- Seawater inlet g- Water circulating pump

b- Power steering cooler h- Thermostat housing
c- Gen III Cool Fuel Module i- Exhaust elbow
d- Exhaust and seawater outlet j- Seawater pump
e- Exhaust manifold k- To power steering cooler
f- Check valve l- From seawater pump
Page 14 / 18 90-864196050 FEBRUARY 2005

V8 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS

i
h d
j
g
c e
k
l f
m 9389
a- Seawater inlet h - Thermostat housing

b- Power steering cooler i - Exhaust elbow
c- Gen III cool fuel module j - Seawater pump
d- Exhaust and seawater outlet k - Drain from starboard exhaust manifold
e- Exhaust manifold l - To power steering cooler
f- Distribution housing m - From seawater pump
g- Water circulating pump n - Check valve
90-864196050 FEBRUARY 2005 Page 15 / 18

V6 SEAWATER COOLED BRAVO MODELS EXCEPT MPD MODELS
c e
i
h d
f
9390
g
a- Seawater inlet g- Distribution housing

b- Power steering cooler h- Water circulating pump
c- Check valve i- Thermostat housing
d- Fuel cooler j- Exhaust elbow
e- Exhaust and seawater outlet k- Seawater pump
f- Exhaust manifold
Page 16 / 18 90-864196050 FEBRUARY 2005

V6 AND V8 SEAWATER COOLED ALPHA MPD MODELS

j a
c e
h
f
9391
a- Seawater inlet (from transom) f- Exhaust manifold

b- Power steering cooler g- Check valve
c- Drain plug h- Water circulating pump
d- Fuel cooler i- Thermostat housing
e- Exhaust and seawater outlet j- Exhaust elbow
90-864196050 FEBRUARY 2005 Page 17 / 18

V6 AND V8 SEAWATER COOLED ALPHA MODELS EXCEPT MPD MODELS
a
j
i c
e
h d
f
9392
a- Seawater inlet (from transom) f- Exhaust manifold

b- Power steering cooler g- Distribution housing
c- Check valve h- Water circulating pump
d- Fuel cooler i- Thermostat housing
e- Exhaust and seawater outlet j- Exhaust elbow
Page 18 / 18 90-864196050 FEBRUARY 2005

SECTION - 6 DRIVE SYSTEM AND ENGINE INSTALLATION
SECTION 6 - DRIVE SYSTEM AND ENGINE

INSTALLATION
Table of Contents
Transom Cutout....................................................................................................................................................... 4
Finding The Crankshaft Vertical Center Line....................................................................................................4
Single Engine ............................................................................................................................................. 4
Dual Engine ............................................................................................................................................... 4
Finding Crankshaft Horizontal Center Line (X-dimension)................................................................................5
90 Degree Tool Method ............................................................................................................................. 5
Tape Measure Method ............................................................................................................................... 6
Cutting Out The Transom..................................................................................................................................6
Checking The Transom Thickness....................................................................................................................8
Preliminary Connections.......................................................................................................................................... 9
Drive Shaft Extension Models...........................................................................................................................9
Engine Mounts..................................................................................................................................................9
Air Pump............................................................................................................................................................9
Power Trim Pump.............................................................................................................................................. 9
Power Trim Pump Connections and Filling.....................................................................................................10
Transom Connections........................................................................................................................................... 11
6
Installing Gimbal Housing Assembly...............................................................................................................11
Installing Inner Bravo Transom Plate .............................................................................................................12
Sensor Steering Assembly..............................................................................................................................12
Connecting Speedometer Pickup....................................................................................................................13
Models With Alpha Sterndrive and Alternative Water Pickups.............................................................................. 14
Alpha Models .................................................................................................................................................. 15
Models With Bravo Sterndrive and Alternative Water pickups.............................................................................. 17
Alternative Water Pickups .............................................................................................................................. 17
Bravo Models ................................................................................................................................................. 17
Bravo Models Exhaust Preparation....................................................................................................................... 20
Gear Lube Monitor Connection At Gimbal Housing.............................................................................................. 21
Alternative Mounting Of Gear Lube Monitor On Transom..................................................................................... 22
Installing Steering System..................................................................................................................................... 22
Engine Installation................................................................................................................................................. 27
Transom Preparation.......................................................................................................................................27
Shift Cable Routing.........................................................................................................................................29
Engine Preparation..........................................................................................................................................30
Gen III Cool Fuel Module Inlet Fitting..............................................................................................................31
Fuel Inlet Fitting...............................................................................................................................................32
Exhaust System Hose / Tube Connections.....................................................................................................35
Engine Alignment Sterndrive Models..............................................................................................................37
Electrical Connections........................................................................................................................................... 39
Instrumentation Connections...........................................................................................................................39
SmartCraft Product .................................................................................................................................. 40
Continuity Wire Connection.............................................................................................................................40
Trim Position Sender Connections..................................................................................................................41
Audio Warning System Connections...............................................................................................................41
MerCathode Connections (If Equipped)..........................................................................................................42
Battery Cables Connection..............................................................................................................................43
Power Trim Pump Connections....................................................................................................................... 43
Fluid Connections.................................................................................................................................................. 44
Gear Lube Monitor Connection.......................................................................................................................44
Power Steering Hoses.....................................................................................................................................44
Gen III Cool Fuel Module Water Hose Connection.........................................................................................45
90-864196050 FEBRUARY 2005 Page 1 / 88

DRIVE SYSTEM AND ENGINE INSTALLATION SECTION - 6
Alpha Seawater Cooled Models Using Sterndrive Water Pickups..................................................................46

Bravo Seawater Cooled Models Using Sterndrive Water Pickups..................................................................46
Closed Cooled Bravo Models Using Sterndrive and Alternative Water Pickups.............................................49
Seawater Pump Pickup Connection................................................................................................................50
Coolant Recovery System...............................................................................................................................50
Fuel Connection To Fuel Supply.....................................................................................................................51
Fuel Line Connection To Gen III Cool Fuel Module........................................................................................52
Fuel Line Connection ............................................................................................................................... 52
Shift Cable Installation........................................................................................................................................... 52
Alpha Sterndrive Shift Cable Installation.........................................................................................................52
Shift Cable Travel .................................................................................................................................... 52
Separate Shift and Throttle Controls ....................................................................................................... 53
Installation ................................................................................................................................................ 54
Bravo Models Shift Cable Installation.............................................................................................................. 57
Bravo Models Shift Cable Adjustment.............................................................................................................58
Throttle Cable Installation And Adjustment........................................................................................................... 61
Shift Cable Installation For DTS System............................................................................................................... 62
DTS System Installation........................................................................................................................................ 64
Sterndrive Unit....................................................................................................................................................... 64
Alpha Notice: Increased Trim-in Range Capability.......................................................................................... 64
Alpha Trim Cylinder Spacer Removal.............................................................................................................64
Alpha Trim Cylinder Disassembly...................................................................................................................66
Alpha Trim Cylinder Reassembly....................................................................................................................67
Alpha Trim Cylinder Installation....................................................................................................................... 68
Alpha Sterndrive Installation............................................................................................................................70
Trim Cylinder Installation ......................................................................................................................... 75
Speedometer Connection - Alpha Models.......................................................................................................75
Bravo Sterndrive Installation...........................................................................................................................76
Trim Cylinder installation ......................................................................................................................... 82
Speedometer Connections - Bravo Models..................................................................................................... 82
Installing the Pitot Sensor................................................................................................................................83
Paddle Wheel Speed Sensor Installation (If Equipped)..................................................................................84
Parts Provided ......................................................................................................................................... 84
Selecting Location ................................................................................................................................... 85
Transom Angle Requirements ................................................................................................................. 85
Installing Bracket ..................................................................................................................................... 85
Routing the Cable .................................................................................................................................... 86
Drilling Hole Through Transom (optional) ......................................................................................... 86
Without Drilling Hole Through Transom (optional) ............................................................................ 86
Installing and Removing the Paddle Wheel ............................................................................................. 87
Wiring Connections .................................................................................................................................. 87
Template - Paddle Wheel Speed Sensor ................................................................................................ 87
Page 2 / 88 90-864196050 FEBRUARY 2005

Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
Liquid soap Exhaust tubes Obtain Locally
7 Loctite 271 Threadlocker Trim cylinder bolt threads 92-809819
9 Loctite 567 PST Pipe Sealant Fuel inlet fitting 92-809822

Battery terminals
All electrical connections
25 Liquid Neoprene 92-25711-3
MerCathode connections
Battery Terminals
Power steering bushings
Upper and lower pivot bolts
34 Special Lubricant 101 Clevis pin 92-802865A1
Steering cable end
Trim cylinder end cap
80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
Gear lube monitor
87 High Performance Gear Lubricant 92-802854A1
Gear Lube Monitor
Coupler splines
Ujoint O-rings
91 Engine Coupler Spline Grease 92-802869A1
Drive shaft splines
U-joint O-rings
Trim cylinder hardware
Trim cylinder
95 2-4-C Marine Lubricant with Teflon Bell housing studs 92-802859A1
Bell Housing Studs
O-ring seals
Special Tools
Tapered Insert Tool 91‑43579
Removes and installs the tapered insert retainer into the water
inlet hose.
9197
Alignment Tool Assembly 91‑805475A 1
Aligns the engine and the sterndrive unit during installation.

9183
Trim Cylinder End Cap Tool 91‑821709T
Allows easy removal of the trim cylinder end caps. Required

if tilt limit spacers are to be installed or if the trim in limit spacer
is to be removed (to allow additional trim in range).
9191
90-864196050 FEBRUARY 2005 Page 3 / 88

Shift Slide Stabilizer 91‑865232
Holds the shift slide in the proper position as the sterndrive is

installed onto the bell housing studs.
9184
Transom Cutout
Finding The Crankshaft Vertical Center Line
SINGLE ENGINE
1. Locate and mark the vertical center line on the transom, if known. This is also the crankshaft
vertical center line.
2. If unknown, a compass can be used to locate the vertical center line:
a. Mark identical locations on each side of the boat 304 mm (12 in.) from the bottom of the
hull.
b. Position the fixed end of a compass at the marks and draw arcs on the transom.
c. Draw the crankshaft vertical center line through the intersection points of the 2 arcs.
b e
a
c b e
d
7687
Single engine installation

a - 304 mm (12 in.) d - Arc intersection points
b - Identical side marks e - Crankshaft vertical center line
c - Compass arc
DUAL ENGINE
1. Locate and mark the vertical center line on the transom. Refer to Single Engine procedure.
2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical center
lines on either side of the vertical center line.
Minimum Distance Between Crankshaft Vertical Center lines (Dual Side‑By‑Side)

Model Measurement
V6 and V8 Sterndrive 838 mm (33 in.)
IMPORTANT: Crankshaft vertical center lines must be an equal distance from boat vertical center
line.
Page 4 / 88 90-864196050 FEBRUARY 2005

3. Draw the 2 crankshaft vertical center lines through the intersection of the marks.
b
c c
b
a 7688
Dual installation
a - Vertical center line c - Crankshaft vertical center lines
b - 1/2 minimum distance between
crankshaft center line marks
Finding Crankshaft Horizontal Center Line (X‑dimension)

X‑dimension can be measured by the 90 Degree Tool Method or by the Tape Measure Method.
90 DEGREE TOOL METHOD
1. Construct the 90 degree tool.
90
a
b 7689
a - 34.5 cm (13‑9/16 in.) b - 1.2 m (4 ft)
IMPORTANT: The 34.5 cm (13‑9/16 in.) dimension should only be raised or lowered after proper
testing.
• ‑To lower drive unit ‑ Subtract from dimension "a".
• To raise drive unit ‑ Add to dimension "a".
2. Place the 90 degree tool along the boat bottom at the vertical center line.
3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical center
line. This is the crankshaft horizontal center line or X‑dimension.
90-864196050 FEBRUARY 2005 Page 5 / 88

4. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.
c
b b
a 7690 a 7691
Single engine Dual engine

a - 90 degree tool along boat bottom at c - Crankshaft horizontal center line
vertical center line
b - Contact point
TAPE MEASURE METHOD

1. Determine the X‑dimension from the following chart.
IMPORTANT: This dimension should only be raised or lowered after proper testing.
Transom Angle (degrees) X‑dimension

16 36.4 cm (14‑5/16 in.)
15 36.2 cm (14‑1/4 in.)
14 36.0 cm (14‑3/16 in.)
13 35.9 cm (14‑1/8 in.)
12 35.7 cm (14‑1/16 in.)
11 35.6 cm (14 in.)
10 35.4 cm (13‑15/16 in.)
2. On the vertical crankshaft center line, measure up from the bottom of the transom to the
X‑dimension selected previously. This is the crankshaft horizontal center line at the
X‑dimension.
3. Draw a line perpendicular to the vertical center line at the crankshaft horizontal center line.
a
a
c c
b
b
7692 7693
Single engine Dual engine

a - Vertical center line c - Crankshaft horizontal center line
b - X‑dimension that corresponds to
transom angle
Cutting Out The Transom

IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is
suitable for most boats. Best mounting location for a particular boat, however, can be determined
only by testing.
Page 6 / 88 90-864196050 FEBRUARY 2005

1. Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from X‑Dimension.

2. Heavy duty applications: Subtract 25 mm (1 in.) from X‑Dimension.
3. Above 40 km/h (25 mph): Use X‑Dimension shown.
4. Above 80 km/h (50 mph): The X‑Dimension can be increased to improve performance in some
applications. However, pulling power for skiing will decrease. During testing, X‑Dimension
should be increased 13 mm (1/2 in.) at a time until desired performance is achieved but in no
case should it ever be increased by more than:
Maximum Increase In X‑Dimension

Bravo One and Three 76 mm (3 in.)
Bravo Two 25 mm (1 in.)
Extreme care should be taken when raising drive unit to ensure that water supply does not become
aerated. Use clear water inlet hose to monitor incoming water and monitor engine temperature
gauge to ensure engine does not overheat.
In applications where cooling water to the engine is supplied by a through the hull or through the
transom fitting, the sterndrive height will not cause cooling water aeration.
IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed height
will not be covered by Mercury MerCruiser warranty.
1. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased separately).
90-79135--5
7893
7694
Transom cutout template Transom drilling fixture kit

2. Follow instructions indicated on template or provided with drilling fixture.
3. Ensure that centerline on either the template or transom drilling fixture align with lines
previously marked on transom.
4. Drill two 6 mm (1/4 in.) pilot holes at a 60 degree angle for hole saw guides.
90-864196050 FEBRUARY 2005 Page 7 / 88

5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole saw
cutout is made incorrectly, drive unit steering lever may contact transom causing limited
steering travel.
a
b
7695
a - 51 mm (2 in.) hole saw holes b - 60 degrees versus transom angle

(steering lever cutout)
6. Cut the transom on the cut line at a 90 degree angle. If the transom cutout is made incorrectly
the gimbal housing or exhaust system may improperly contact the boat transom causing
transom mounting problems.
7. Seal the inside edge of the transom cutout opening with a suitable sealant to prevent water
absorption and deterioration of the transom.
b
a
d c
7696
a - Cut line c - Exhaust pipe area

b - 90 degrees to transom d - Mounting holes perpendicular to
transom (8)
Checking The Transom Thickness

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the
sterndrive unit mounts.
1. Ensure that transom thickness and surface conform to specifications.
Page 8 / 88 90-864196050 FEBRUARY 2005

Transom Specifications
Thickness Between 51 ‑ 57 mm (2 ‑ 2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical center line
Parallelism Inner and outer surfaces must be parallel within 3 mm (1/8 in.)
Transom surfaces in area where transom assembly will be mounted (includes vertical as well
Flatness as horizontal dimensions) :Inner Surface ‑ Flat within 3 mm (1/8 in.) Outer Surface ‑ Flat within
2 mm (1/16 in.)
Angle 10 ‑16 degrees
7697
a - Measuring thickness c - Suitable mandrel to check for uniform

b - Measuring flatness transom thickness
Preliminary Connections
Drive Shaft Extension Models
If your power package is equipped with a drive shaft extension, refer to the Drive Shaft Extension
Installation Instructions (90‑866039) included with your engine package.
You will also need to order extensions for the gear lube monitor and MerCathode quick connects.
Refer to your parts catalog for current part numbers.
Engine Mounts
NOTE: On offshore boats or boats which will be used in rough water areas, Mercury MerCruiser
recommends the use of a solid plate engine mount.
Air Pump
NOTE: Some models have air pump mounted on the engine and other models have the air pump
in a parts bag.
1. Select an easily accessible mounting location for the air pump.
2. Mount the air pump.
8992
Power Trim Pump

1. Select an appropriate mounting location (floor or transom) for the trim pump that:
• Is within length limits of BLACK and GRAY hydraulic hoses coming from gimbal housing
assembly.
90-864196050 FEBRUARY 2005 Page 9 / 88

• Is close to the battery so that trim pump battery leads can be connected.
• Allows easy access to trim pump oil fill and vent locations.
• Is in an area where pump will not be exposed to water.
• Prevents the power steering booster cylinder from coming in contact with the trim pump
when the steering wheel is turned in either direction (right or left).
NOTE: Template 90‑863152 provides mounting hole location for floor or transom mounting.
2. Mount the pump in the desired location.
Power Trim Pump Connections and Filling
IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking out
of system.
1. Connect hydraulic hoses to trim pump. Ensure that the quick connect fitting completely seat
when connecting the hoses.
a
c
g
b d 7698
e
a- Positive battery lead e- GRAY hydraulic hose (DOWN hose)
b- Negative battery lead f- Fill/vent cap
c- Harness connector g- Dual mount trim pump bracket
d- BLACK hydraulic hose (UP hose) h- Trim limit switch connected and
secured
2. Connect power trim pump control harness to trim pump.
7699
a - Control harness b - Trim pump connector
Page 10 / 88 90-864196050 FEBRUARY 2005

3. Connect trim limit switch wires and secure with wire retainer and tie strap.
b 7700
a - Trim limit switch wires b - Wire retainer and cable tie
NOTE: Fill cap assembly with Mercury M logo on top: New design of fill cap does not require
removal. The cap plug and fill cap are assembled and should not be separated.
a b
7701
a - Fill cap assembly (top and b - Fill cap on trim pump reservoir
underneath side views)
Transom Connections
Installing Gimbal Housing Assembly
1. Carefully remove transom assembly from shipping carton.
2. Remove and read all tags attached to transom assembly.
7713
a - Shipping hardware b - Trim cylinder suppport
3. Remove the shipping hardware.

4. Remove the dust cover if boat will be shipped with drive installed.
5. Do not remove the Shift Slide Installation Tool.
6. Retain the serial number envelope.
90-864196050 FEBRUARY 2005 Page 11 / 88

Installing Inner Bravo Transom Plate

1. Insert wires, hoses, and shift cable through appropriate openings in inner transom plate.
2. Position gimbal housing on transom and hold in place.
IMPORTANT: Tighten the transom assembly fasteners using an X‑pattern torque sequence,
starting from the middle fasteners. Tighten in small increments and go around the pattern several
times until the proper torque is achieved.
3. Secure transom assembly with fasteners. Torque the fasteners.

Transom assembly hardware 34 25
IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing
wire when steering lever moves.
a
b
d
a
5 7
3 2
e
1 4
8 6
8585
a - Locknuts and flat washers (8) d - Transom plate continuity wires

b - Bolt e - Torque sequence
c - Steering lever continuity wires
Sensor Steering Assembly

1. Remove nuts from upper 2 transom studs.
2. Remove cotter pin and clevis pin from steering lever.
Page 12 / 88 90-864196050 FEBRUARY 2005

3. Install new clevis pin and secure with existing cotter pin.
a
h
a
d
f
e
b g 8403
a- Transom stud holes e- Cotter pin

b- Pitot tube connection f- Clevis pin
c- Plug g- Tie strap
d- Guide h- Alignment mark
4. Slide guide onto the groove in the clevis pin.

5. Bolt the steering assembly to the transom.
6. Remove the brass plug from the transom.
7. Install pitot barbed fitting.
8. Attach pitot tube to barbed fitting and secure with a tie strap.
9. Plug sensor into transom harness.
Connecting Speedometer Pickup
! CAUTION
Excess water in bilge can damage engine or cause boat to sink. Do not remove plug from
speedometer pickup tube fitting unless connection is to be utilized.
1. Remove the protective cap from the male quick connect.
90-864196050 FEBRUARY 2005 Page 13 / 88

2. Connect a 4 mm (5/32 in.) speedometer hose (not provided) from speedometer to barb fitting.
Secure hose with tie strap.
a
b
c c e
d
7703
Typical
a - Male quick connect d - Hose
b - Female quick connect e - Tie strap
c - Barbed fitting
! CAUTION
Avoid water leaking into boat. Speedometer hose is filled with water, especially during boat
operation. Hose contact with moving or rotating engine parts could cause damage to the hose
resulting in water leaking into boat. Do not let speedometer hose contact steering system
components, engine coupler or drive shaft.
3. Secure the hose to the transom with the hose clip and screw that are provided in the parts
bag. Ensure that the hose does not contact the steering system components or the engine
coupler and drive shaft.
Models With Alpha Sterndrive and Alternative Water Pickups

A water inlet block‑off kit must be used if the sterndrive unit water pickup will not be used to supply
water to the engine. When installing the block‑off plate, it is necessary to cut the water hose that
is located between the bell housing and the gimbal housing. This allows water to continue to
circulate through the sterndrive unit for cooling.
! CAUTION
Avoid overheating the sterndrive. The seawater inlet holes must be allowed to flow water without
being obstructed or damage to the sterndrive will result. Do not dead‑end the seawater hose
from bell housing. Cut hose as recommended in procedures.
Page 14 / 88 90-864196050 FEBRUARY 2005

Alpha Models
1. Cut water tube off close to cover. Remove and discard the screws and cover.
b
c
a
b
9260
a - Water Tube Cover c - Water Tube

b - Screws
2. Remove rubber grommet from cavity around tube.
a
b
9283
a - Water Tube (Cut Off In Previous b - Rubber Grommet

Step)
3. Remove and discard bell housing sta‑strap and clip that retains wires and speedometer hose.
f
d
c
a
b
e 9281
a - Sta‑Strap d - Bell Housing Assembly

b - Clip e - Speedometer Hose
c - Bell Housing Hose f - Trim Limit Switch Wire Harness
90-864196050 FEBRUARY 2005 Page 15 / 88

4. Cut the bell housing hose close to the bell housing as shown.
9285
a - Bell Housing Hose b - Cut Line
5. Pull on hose to withdraw water tube through gimbal housing opening. Remove hose with
remaining piece of water tube from gimbal housing.
b
a
9286
a - Bell Housing Hose b - Water Tube (Cut Off Previously)
6. Sta‑strap (obtain locally) speedometer hose and trim limit switch wire harness together onto
piece of hose remaining on bell housing.
7. Install the block‑off plate with new gasket. Secure with screws and lockwashers. Torque the
screws.
a
d
c
7262
a - Block‑off plate c - Screw
b - Gasket d - Lockwasher
Page 16 / 88 90-864196050 FEBRUARY 2005


Water inlet block off screw 5 45
8. Install a through the hull or through the transom seawater pickup, seawater strainer, and
seacock.
9. Connect the seawater inlet hose between seawater pump and seawater strainer.
10. Secure all hoses with hose clamps.
Models With Bravo Sterndrive and Alternative Water pickups

Alternative Water Pickups
A water inlet block‑off kit must be used if the sterndrive unit water pickup will not be used to supply
water to the engine. When installing the block‑off plate, it is necessary to cut the water hose that
is located between the bell housing and the gimbal housing. This allows water to continue to
circulate through the sterndrive unit for cooling.
! CAUTION
Avoid overheating the sterndrive. The seawater inlet holes must be allowed to flow water without
being obstructed or damage to the sterndrive will result. Do not dead‑end the seawater hose
from bell housing. Cut hose as recommended in procedures.
Bravo Models
1. Remove the existing water fitting and gasket. Discard the screws and washers.
8486
Bravo shown
a - Water inlet fitting b - Screws and lockwashers
90-864196050 FEBRUARY 2005 Page 17 / 88

2. Remove the tapered insert in the gimbal housing using the Tapered Insert Tool. Discard the
insert.
c
a
a
b
8487
a - Tapered insert c - Gimbal housing cross‑sectional view

b - Tapered Insert Tool
Tapered Insert Tool 91‑43579

3. Install the block‑off plate with new gasket. Secure with screws and lockwashers. Torque the
screws.
a
d
c
8488
a - Block‑off plate c - Screw

b - Gasket d - Lockwasher

Water inlet block off screw 5 45
Page 18 / 88 90-864196050 FEBRUARY 2005

4. Move the trim limit switch wires and speedometer hose aside. Reach between the gimbal
housing and the bell housing and detach the water hose from the gimbal housing where the
tapered insert was removed in Step 2.
a
d
e
c
b
8489
a - Trim limit switch wires d - Water hose

b - Speedometer hose e - Tapered insert
c - Gimbal housing
! WARNING
Avoid water leakage into the boat. If the U‑joint bellows is damaged, water will enter the boat.
Be careful not to damage the U‑joint bellows when removing the section of the water hose
attached between the gimbal housing and the bell housing.
NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them when
cutting the water hose. The existing tie strap and clip can be reused if they are moved and
repositioned after the hose is cut.
5. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where
it is fitted into the bell housing in the area shown. Do not damage the U‑joint bellows.
6. Discard loose hose piece.
7. Secure the trim limit switch wires and speedometer hose to the remaining section of water
hose using existing tie strap and clip.
c e
b
d a
8490
a - Tie strap d - Speedometer hose

b - Clip e - Trim limit wire harness
c - Water inlet hose f - Cutting area
8. Install a through the hull or through the transom seawater pickup, seawater strainer, and
seacock.
9. Connect the seawater inlet hose between seawater pump and seawater strainer.
10. Secure all hoses with hose clamps.
90-864196050 FEBRUARY 2005 Page 19 / 88

Bravo Models Exhaust Preparation

IMPORTANT: When installing through the transom exhaust, it is recommended that the exhaust
bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at
the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller
performance on some boats.
1. If required, remove and discard clamps and bellows from gimbal housing.
IMPORTANT: When installing through the propeller exhaust:
• With Bravo One and Bravo Two Sterndrives, an exhaust tube MAY BE INSTALLED for a slight
increase in performance.
• With most Bravo Three Sterndrive Models, an exhaust tube MAY BE INSTALLED for a slight
increase in performance.
• With a Silent Choice Exhaust System, the exhaust bellows must be removed and an exhaust
tube MUST BE INSTALLED.
• With any application, installation of an exhaust tube will increase exhaust noise.
2. If required, install exhaust tube on gimbal housing as follows:
a. Remove and discard clamps and exhaust bellows.
! CAUTION
Exhaust tube clamp may corrode if grounding clip is not installed.
b. Install grounding clip on tube.
NOTE: Bellows adhesive is not used when installing an exhaust tube.
c. Position tube so that "SIDE" markings on tube are facing toward the right and left sides.
d. Install and torque the clamp.
c
b
a 8406
a - Exhaust tube d - Exhaust tube

b - Clamp e - Grounding clip
c - "SIDE" marking

Exhaust tube clamp 4 35
Page 20 / 88 90-864196050 FEBRUARY 2005

Gear Lube Monitor Connection At Gimbal Housing

! CAUTION
Avoid sterndrive unit damage. The quick release button on the gear lube monitor 90 degree hose
fitting may not lock on the gimbal housing fitting if touching or depressed by the water inlet fitting,
or block‑off plate if equipped. Failure to lock the 90 degree hose fitting on the gimbal housing
fitting could result in a loose 90 degree hose fitting causing a loss of gear lube and damage to
the sterndrive unit. Ensure the 90 degree hose fitting is locked on the gimbal housing fitting.
NOTE: The gear lube monitor hose is now in the parts bag on the engine.
1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal
housing.
d
a c
b
7704
a - Hose c - Gimbal housing fitting

b - Quick release 90 degree fitting d - Quick connect fitting
NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting,
or block‑off plate if equipped. Release button must not contact water fitting or block‑off plate, if
equipped.
2. Position quick release button on hose fitting away from water inlet fitting. Release button must
not contact water fitting.
e b
6635
Bravo transom
a - Water inlet fitting d - J‑clip
b - Bolts and star washers e - Quick release button
c - Gear lube monitor hose
90-864196050 FEBRUARY 2005 Page 21 / 88


Water inlet fitting bolts 5 45
NOTE: The hose must not come into contact with the steering system components or the engine
coupler and drive shaft.
Alternative Mounting Of Gear Lube Monitor On Transom

IMPORTANT: The mounting location specified must be above the steering lever on the transom
assembly. Hose must be positioned to avoid moving parts (steering system, engine coupler).
1. Install the gear lube monitor bracket in the specified location and secure with lag screws and
flat washers.
2. Install the gear lube monitor in the bracket. Secure the monitor with the retaining strap.
a
c
b 7706
a - Bracket c - Gear lube monitor and cap

b - Lag screw and flat washer d - Retaining strap
Installing Steering System

NOTE: For dual installations, power steering unit can be mounted on port or starboard transom
assembly. Measure exact distance between power package center lines. Select a tie bar from
Mercury Precision Parts / Quicksilver Accessory Guide. Refer to tie bar installation instructions
before proceeding.
1. Inspect the bushings for debris. Lubricate the power steering bushings.
7709
a - Bushings

34 Special Lubricant 101 Power steering bushings 92-802865A1
2. Remove the protective shipping caps.
Page 22 / 88 90-864196050 FEBRUARY 2005

3. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.
b b
a
c
b
7710
a - Bushing c - Upper and lower pivot bolt

b - Protective shipping caps

34 Special Lubricant 101 Upper and lower pivot bolts 92-802865A1
4. Position the steering assembly so that the pivot bolts will enter the bushings in the power
steering control valve.
5. Install the upper and lower pivot bolts along with tab washers. Ensure that the tab washer
tangs straddle the ridge on the inner transom plate.
7761
Upper Pivot Bolt And Tab Washer Shown (Lower Similar)

a - Tab washer tang b - Ridge
6. Turn the pivot bolts all the way in, by hand, to ensure proper steering assembly alignment.
7. Ensure that the steering assembly pivots freely.
8. Torque the pivot bolts. Bend the tab washer tabs against the corresponding flats on the bolt
heads.
90-864196050 FEBRUARY 2005 Page 23 / 88

NOTE: It may be necessary to tighten the pivot bolts further to align the flats on bolt head with the
tabs on the washer.
b a
8495
a - Pivot bolt b - Bent tab

Upper and lower pivot bolt 34 25
! CAUTION
MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid from the
control valve ports. Wear eye protection.
9. While wearing eye protection, to avoid expelled fluid, move the control valve cable guide tube
in the directions shown, so that it will be less difficult to pull it out or push it in during connection.
a a
b
b
8496
a - Port b - Control valve cable guide tube
10. Connect the clevis to the steering lever. Lubricate the clevis pin. Be sure to spread both ends
of the cotter pin.
Page 24 / 88 90-864196050 FEBRUARY 2005

NOTE: Insert the clevis pin from the top to ensure that the cotter pin hole is as shown in the
diagram.
a b
7822
a - Clevis c - Clevis pin

b - Steering lever d - Cotter pin

34 Special Lubricant 101 Clevis pin 92-802865A1
IMPORTANT: Quicksilver RideGuidet steering cable has a self‑locking coupler nut and does not
require an external locking sleeve or locking plate.
7255
a - Self‑locking coupler nut
90-864196050 FEBRUARY 2005 Page 25 / 88

! CAUTION
Proper steering system function requires that the steering cable and outer casing must be free
to move back and forth. Items fastened to the steering cable and outer casing prevent free
movement. Do not fasten any items to the steering cable and outer casing.
7827
a - Steering cable and outer casing
11. Connect the steering cable as follows:

a. Coat the steering cable end with a liberal amount of lubricant.

34 Special Lubricant 101 Steering cable end 92-802865A1
b. Install the steering cable and secure with hardware as shown.

IMPORTANT: Cable guide tube flat surfaces must be positioned vertically or slight feedback in
the steering system could be encountered.
c. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical
position. Torque the coupler nut. Ensure that the flat surfaces are still aligned vertically
after torque is applied to the coupler nut.
d
g
e f
c
a b
d
7830
a- Steering cable e- Steering cable end

b- Grease fitting f- Clevis
c- Cable coupler nut g- Clevis pin
d- Cable guide tube h- Cotter pin
Page 26 / 88 90-864196050 FEBRUARY 2005

Engine Installation
Transom Preparation
IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks
and scratches and O‑ring must be properly seated in groove or water and exhaust may leak into
boat.
1. Ensure the exhaust pipe and gimbal housing mating surfaces are clean and free of nicks and
scratches.
2. Ensure the O‑ring is properly seated in the groove.
6638
a - Gimbal housing mating surface b - O‑ring
3. Loosen hose clamps and remove exhaust pipe and bellows from engine.
4. Remove the shipping plug from the engine coupler.
a 7767
a - Shipping plug
5. Through The Propeller Exhaust Models: Install exhaust pipe assembly using 4 bolts and
lockwashers. Torque bolts.
b
a
8499
a - Exhaust pipe b - Bolts and lockwashers (4)
90-864196050 FEBRUARY 2005 Page 27 / 88


Exhaust pipe bolts 34 25
6. Through The Transom Exhaust Models: Install block‑off plate using 4 bolts and lockwashers.
Torque bolts.
b
a
8404
a - Block‑off plate b - Bolts and lockwashers (4)

Exhaust block‑off plate bolts 34 25
NOTE: Through the transom exhaust fittings can be installed at this time.
! CAUTION
Avoid product damage caused by improper engine alignment. Improper engine alignment can
be caused by mismatched flywheel housing mounts and inner transom plate mounting hardware.
Ensure that the flywheel housing mounts and the inner transom plate mounting hardware, port
and starboard, are the correct parts and match before installing the engine.
7. These models have new design mounts ‑ knurled bottom surface: Use the fiber washer only.
Do not use the double‑wound lockwasher.
a
7960
Typical flywheel housing, all similar

a - Late style mount ‑ knurled surface b - Fiber washer
Page 28 / 88 90-864196050 FEBRUARY 2005

8. Position rear engine mount attaching hardware on inner transom plate mounts as shown.
7839
a - Fiber Washer (2) b - Locknut (2)
Shift Cable Routing

1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:
a. The cable should come through the transom, above the exhaust pipe and make a turn
toward the starboard side of the boat between the exhaust pipe and the engine flywheel
housing.
b. The cable should then be routed under the starboard rear engine mount and turn toward
the transom.
c. The cable should then go up behind the power steering valve and loop over to the shift
actuator on the engine.
NOTE: Following this routing will prevent the engine coupler from damaging the cable.
8995
Refer to Section 8 ‑ Remote Control.
90-864196050 FEBRUARY 2005 Page 29 / 88

Engine Preparation
1. To gain access to the starboard engine mount; loosen the captured nut from the hose retainer
bracket and remove the bracket and water hose from the Gen III Cool Fuel Module.
c a
b
8208
a - Captured nut c - Water hose

b - Retainer bracket
2. Remove and read all tags attached to engine.

3. Remove all hardware that secures engine to shipping container.
4. Connect battery cables to engine. Observe the following:
a. Ensure that the grounding stud and starter solenoid terminal are free of paint or any other
material that could cause a poor electrical connection.
b. Install battery positive (+) wire directly to the large starter solenoid stud.
c. After battery cables are connected, apply a thin coat of sealant to the terminals.

Battery stud 8‑11 71‑97

25 Liquid Neoprene Battery terminals 92-25711-3
d. Slide rubber boot over positive (+) terminal after making connection.
5. Drape battery cables over top of engine to prevent interference during installation.
Page 30 / 88 90-864196050 FEBRUARY 2005

IMPORTANT: There is a fuse located at the starter solenoid. Do not remove this fuse.
c
a
8501
a - Positive (+) battery cable location c - 90 amp fuse ‑ Do not remove

b - Starter solenoid
6. If not already done, remove shipping plug from coupler and lubricate splines.
a 7767
Typical
a - Shipping plug

91 Engine Coupler Spline Grease Coupler splines 92-802869A1
Gen III Cool Fuel Module Inlet Fitting

! WARNING
Overtightening the fuel inlet fitting can lead to fuel leaks, avoid severe personal injury or death
from a gasoline fire or explosion. Do not use a power tool (i.e. impact wrench) to tighten the fuel
inlet fitting.
1. Install an adaptor or a fitting to the brass inlet fitting of Gen III Cool Fuel Module. To prevent
cracking the casting or causing fuel leaks, turn fuel inlet adaptor or fitting in by hand until
finger‑tight. Tighten the fitting an additional 1‑3/4 to 2‑1/4 turns with wrench. DO NOT
OVERTIGHTEN.
90-864196050 FEBRUARY 2005 Page 31 / 88

IMPORTANT: Hold brass fuel inlet fitting with a suitable wrench while tightening the fuel inlet
adaptor fittings.
b
9360
a - Fuel inlet fitting b - Gen III Cool Fuel Module

Description Procedure
Finger‑tight + 1‑3/4 to 2‑1/4 turns with a
Fuel inlet adaptor or fitting
wrench. Do not overtighten.
Fuel Inlet Fitting

IMPORTANT: The following information is provided to ensure proper installation of brass fittings
or plugs installed into fuel pump system.
• Use Loctite 565 Pipe Sealant with Teflon on threads of fuel inlet fittings or plugs. DO NOT
USE TEFLON TAPE.
! WARNING
Avoid serious injury or death and property damage due to improper boat design and
construction. Always adhere to all applicable Marine Regulations (United States Coast Guard
[USCG], European Union ‑ Recreational Craft Directive [EU‑RCD], and so on) and the standards
they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers
[SAE], International Standards Organization [ISO], and so on) when designing and constructing
the boat and the boat components, such as the engine compartment, fuel delivery system and
exhaust system.
! WARNING
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into fuel pump or
fuel filter base can crack casting and/or cause a fuel leak.
1. Remove plastic plug from fuel inlet hole.

2. Apply sealant to threads of fuel inlet fitting. DO NOT USE TEFLON TAPE.
! WARNING
Overtightening the fuel inlet fitting can lead to fuel leaks, avoid severe personal injury or death
from a gasoline fire or explosion. Do not use a power tool (i.e. impact wrench) to tighten the fuel
inlet fitting.
Page 32 / 88 90-864196050 FEBRUARY 2005

3. Install fuel inlet fitting in fuel pump or filter base. To prevent cracking the casting or causing
fuel leaks, turn fuel inlet fitting in by hand until finger‑tight. Tighten the fitting an additional 1‑3/4
to 2‑1/4 turns with wrench. DO NOT OVERTIGHTEN.
IMPORTANT: Hold brass fittings with a suitable wrench while tightening fuel inlet fittings.

Description Procedure
Fuel inlet fitting Finger‑tight + 1‑3/4 to 2‑1/4 turns with a wrench. Do not overtighten.
! CAUTION
Engine compartment size may require the removal of additional components.
NOTE: An installation jig (91‑806794A02) can be used to align and adjust engine mounts. Refer
to instructions with fixture for proper use.
1. Remove the engine cover, if equipped.
9289
Closed cool model shown, seawater cooled similar

a - Engine cover knob b - Engine cover
2. Attach a suitable sling to the front and rear lifting eyes on engine and adjust so that engine is
level when suspended.
c
a 9287
a - Rear lifting eye c - Center lifting eye

b - Front lifting eye
90-864196050 FEBRUARY 2005 Page 33 / 88

3. Lift engine into position (in boat) using an overhead hoist.

4. Align rear engine mounts with inner transom plate mounts while simultaneously aligning
exhaust tube with exhaust pipe bellows.

Liquid soap Exhaust tubes Obtain Locally
5. To help with installation, apply lubricant into the exhaust tubes.

IMPORTANT: The quick drain oil fitting clearance must be greater than 13 mm (1/2 in.) from the
engine compartment and boat bottom.
6. If equipped with quick drain oil: Ensure that the quick drain oil fitting has a clearance of more
than 13 mm (1/2 in.) from the engine compartment and boat bottom.
7. If clearance is 13 mm (1/2 in.) or less:Remove the quick drain oil fitting and install the oil drain
plug from parts bag directly into the engine oil pan.
8. If clearance is greater than 13 mm (1/2 in.):
a b f c 7771
a - Bilge drain plug d - Flange

b - Tether e - Toward interior of boat
c - Quick oil drain hose plug f - Clip
a. Push end of oil drain hose out of boat hull through flange.
b. Pull oil drain hose out until it is 304 cm (12 in.) from the flange.
c. Move alignment clip on the oil drain hose and squeeze to position it on the hose just
inside of the boat hull against the flange.
d. Connect bilge drain plug to oil drain hose plug using clip.
b a
c
d
7618
a - Oil drain hose c - Clip

b - Alignment clip d - Bilge drain plug
e. Push oil drain hose through flange into boat hull.

f. Install bilge drain plug in hull.
Page 34 / 88 90-864196050 FEBRUARY 2005

9. Install both rear engine mounting bolts and hardware and torque. Do not relieve hoist tension.
c
c
e
d
e
a g a
f b
7961
f
b 7772
a- Rear engine mount e - Spacer

b- Inner transom plate mount f - Fiber washer
c- Bolt g - Stainless steel washer (optional
d- Washer spacer kit)

Rear engine mounting bolts 47 35
10. Loosen both adjusting nuts on front engine mounts to allow for adjustment during alignment.
11. Attach the front mounts to the stringers.
12. Remove the engine hoist.
Exhaust System Hose / Tube Connections
! CAUTION
Avoid exhaust hose failure which could cause exhaust or discharge water to enter the boat.
Discharge water from the exhaust elbow must flow without restriction around the entire inside
diameter of the exhaust hose to avoid causing hot spots which could eventually result in a
burned‑through exhaust hose. Connect the exhaust hoses and tubes to the exhaust elbows so
that they do not restrict the flow of discharge water from the exhaust elbows.
90-864196050 FEBRUARY 2005 Page 35 / 88

Exhaust hoses must be properly installed on exhaust elbow outlets. Discharge water from the
exhaust elbow must flow around the entire inside diameter of hose to avoid causing hot spots that
could burn through the hose.
7628 7629
Correct Incorrect
c
d
b
e
9290
Exhaust connection
a - Maximum misalignment +/‑ 5 d - Angle vs. horizontal
degrees e - Horizontal (level surface)
b - Exhaust outlet centerline (14
degrees vs. crankshaft centerline)
c - Exhaust hose centerline
IMPORTANT: Exhaust hoses/tubes should be secured at each connection with at least 2 hose
clamps.
All exhaust connections, including those at the exhaust elbow, should be secured with 2 hose
clamps. ABYC standards also specify the use of stainless steel clamps with a minimum 13 mm
(1/2 in.) band width. Do not use spring tension clamps.
1. Torque all exhaust hose and/or exhaust tube clamps.
a
7631
a - Hose clamps

Exhaust tube clamps 4 35
Hose clamps 3.4‑6.8 30‑60
Page 36 / 88 90-864196050 FEBRUARY 2005

Engine Alignment Sterndrive Models

1. If applicable, open perforated area in bell housing dust cover.
8378
a - Dust cover
! CAUTION
Do not use an alignment tool from another manufacturer. Alignment tools other than Quicksilver
Alignment Tool may cause improper alignment and damage to gimbal bearing and/or engine
coupler.
! CAUTION
To avoid damage to gimbal bearing, engine coupler, or alignment tool:
Do not attempt to force Quicksilver alignment tool.
Do not raise or lower engine with alignment tool inserted (or partially inserted) in gimbal bearing
or engine coupler.
Do not raise engine mount bracket above top of engine mount stud.
2. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the
engine coupler splines.
Alignment Tool Assembly 91‑805475A 1

3. If the alignmet tool does not fit, remove it and carefully raise or lower the front end of the engine
as necessary.
4. If applicable, attach the engine hoist to the engine aligment hook to raise or lower the front
end of engine.
NOTE: Models not equipped with engine alingment hooks; require adjusting the front engine
mounts equally to raise and lower the front end of the engine.
5. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the
engine coupler splines.
NOTE: It may be necessary to hit the Alignment Tool with a synthane hammer to set the gimbal
bearing to the coupler.
90-864196050 FEBRUARY 2005 Page 37 / 88

6. If necessary, firmly strike the sides of the Alignment Tool at 90 degree increments to help align
the gimbal bearing.
d
c
a b
7784
e
a - Alignment Tool d - Hammer
b - Gimbal bearing e - 90 degree increments
c - Engine coupler
7. Repeat step 4. until the Alignment Tool installs easily (SLIDES FREELY WITH MINIMAL
EFFORT) all the way into and out of engine coupler splines. Do not check by turning the
alignment tool.
IMPORTANT: The finished boat stringer must position the front engine mount so that a minimum
of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted to contact the stringer.
This allows for future engine alignment or adjustments. Make proper alterations to the boat stringer
(structure) to obtain the 6 mm (1/4 in.) dimension.
IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required
to align engine.
8. Adjust front engine mounts until they rest on boat stringers.
9. Relieve hoist tension entirely and fasten both front mounts to boat stringer using 9 mm
(3/8 in.) lag bolts.
10. Recheck alignment with Alignment Tool. Tool must enter coupling splines freely. If not,
readjust front mounts.
b
a
8503
a - Alignment Tool (use only b - End to be inserted through gimbal

recommended Alignment Tool) housing assembly
11. When alignment is correct, tighten locknut securely. Recheck alignment.
Page 38 / 88 90-864196050 FEBRUARY 2005

12. Bend tab down on adjusting nut.
a
b d
c
8504
a - Nut and lockwasher c - Direction (counterclockwise) to raise

b - Adjustment nut front of engine
d - Tab washer
13. Remove Alignment Tool. If not installing drive, fold bell housing dust cover flap back into place
and tape shut for boat shipment. Dust cover flap will have to be removed before operating
engine.
14. Remove the engine alignment hook from the engine.
Electrical Connections
! CAUTION
Avoid damage to the electrical system components caused by improper work or diagnostic
practices. Observe the following precautions when working on or around an electrical harness,
or when adding electrical accessories:
• Do not tap electrical accessories into the engine electrical harness.
• Do not puncture (probe) wires for testing.
• Do not reverse battery leads.
• Do not splice wires into the electrical harness.
• Do not attempt diagnostics without proper, approved service tools.
IMPORTANT: When routing all wire harnesses and hoses, ensure that they are routed and
secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts.

25 Liquid Neoprene All electrical connections 92-25711-3
Instrumentation Connections
We recommend the use of Quicksilver Instrumentation and Wiring Harnesses. On dual station
applications, oil pressure and water temperature senders (on engine) must be changed. Refer to
Mercury Precision Parts Accessories Guide for selection.
The 4 basic gauges that must be used with the engine are:
• Tachometer
• Oil pressure
• Water temperature
• Voltmeter
90-864196050 FEBRUARY 2005 Page 39 / 88

IMPORTANT: Connect fused accessory panel (40‑amp current draw maximum) must be
connected as shown in the wiring diagrams.
1. Route instrumentation wiring harness back to engine, ensuring that harness does not rub or
get pinched. If an extension harness is required, be sure to secure connection properly.
2. Fasten harnesses to boat at least every 46 cm (18 in.) using appropriate fasteners.
3. Place hose clamp over instrumentation wiring harness.
4. Connect the instrumentation wiring harness to engine harness plug at location shown.
9291
Typical
a - Engine harness plug
5. Tighten hose clamp to secure wiring harness to engine harness plug.

SMARTCRAFT PRODUCT
A Mercury SmartCraft System instrument package can be purchased for this product. A few of the
functions the instrument package will display are engine rpm, coolant temperature, water pressure,
battery voltage, fuel consumption and engine operating hours.The SmartCraft Instrument package
will also aid in Engine Guardian diagnostics.
The SmartCraft Instrument package will display critical engine alarm data and potential problems.
Refer to the Mercury SmartCraft Operator's Supplement (90‑10229023) for the warning functions
monitored and basic operation of the SmartCraft Instrument package. Refer to the instructions
included with the instruments for installation instructions.
Continuity Wire Connection
1. Connect continuity circuit wire from engine to transom assembly.
Page 40 / 88 90-864196050 FEBRUARY 2005

IMPORTANT: Do not attach any accessory ground (‑) wires to transom plate ground point.
Accessory ground wires can only be attached to ground stud on engine.
a 7794
a - Continuity wire
Trim Position Sender Connections

1. Connect trim position sender wires (from transom assembly) to engine harness. Use the ORG/
GRY wire for analog gauges and the ORG/WHT wire for digital gauges.
ORG/GRY
ORG/WHT
a BLK
BLK
BLK b
9292
a - Engine harness bullet connector b - Transom assembly bullet connector
Audio Warning System Connections

! WARNING
Avoid serious injury or death from a gasoline fire or explosion. Engine or fuel tank compartments
may have gasoline or gasoline vapors present that could be ignited by components that are not
external ignition proof. The audio warning alarm is not external ignition‑proof. Do not mount the
audio warning alarm in the engine or fuel tank compartments.
1. Select a location for audio warning alarm that meets all of the following:
• Alarm can be easily heard, yet is out of sight
• Alarm can be easily accessed for installation and maintenance
• Alarm will remain dry
• Alarm is within length limits of the 46 cm (18 in.) purple alarm wire that connects to the
"I" terminal or 12 volt source on switched side of ignition switch.
NOTE: The terminal to which wire is attached must have no voltage when ignition switch is in the
OFF position.
90-864196050 FEBRUARY 2005 Page 41 / 88

2. Place alarm in desired location and secure to wire bundle with tie strap provided.
3. Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge or
ignition switch. Tighten connection securely.
4. Connect TAN/BLUE wire from alarm to TAN/ BLUE wire from instrument harness.
5. Place the small (transparent) decals on the bottom of the water temperature and the oil
pressure gauges.
6. Place the large decal on the instrument panel or other appropriate location easily viewed by
the operator.
ALARM INDICATES LOW

OIL OR OVERHEATING
a
APPLY THE PROPER DECAL TO THE DASHBOARD
OR OTHER APPROPRIATE LOCATION:
b
AUDIO WARNING HORN WILL SOUND WHEN:
1. ENGINE OIL PRESSURE IS TOO LOW
2. ENGINE TEMP. IS TOO HIGH, OR
3. DRIVE OIL LEVEL IS TOO LOW
TO TEST AUDIO WARNING HORN:

TURN KEY TO "ON" POSITION (ENGINE OFF)
7799
a - Small decal (transparent) b - Larger decal
7. Test audio warning system during Predelivery Preparation section.

MerCathode Connections (If Equipped)
The MerCathode controller assembly is located on the back of the front lifting eye.
1. Connect wires to MerCathode controller assembly and MerCathode quick connect. Apply a
thin coat of sealant to all connections.
Page 42 / 88 90-864196050 FEBRUARY 2005

IMPORTANT: Opposite end of RED/PURPLE wire must be connected directly to battery positive
(+) terminal. Do not connect it to a switched positive (+) circuit. MerCathode system must function
continuously for proper corrosion protection.
d
a
c
b
8507
a - ORANGE lead ‑ from anode on c - BLACK wire ‑ from engine harness

transom assembly (part of quick d - BROWN wire ‑ from electrode on
connect) transom assembly(part of quick
b - RED/PURPLE wire ‑ to positive (+) connect)
battery terminal

25 Liquid Neoprene MerCathode connections 92-25711-3
Battery Cables Connection

IMPORTANT: Engine electrical system is negative (‑) ground.
1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal.
2. Connect engine negative (‑) battery cable (usually BLACK) to negative (‑) battery terminal.
Power Trim Pump Connections
1. Connect power trim pump BLACK (‑) battery cable to negative (‑) battery terminal and pump
RED (+) battery cable to positive (+) battery terminal.
b
6842
a - Positive battery lead b - Negative battery lead
90-864196050 FEBRUARY 2005 Page 43 / 88


25 Liquid Neoprene Battery Terminals 92-25711-3
Fluid Connections
Gear Lube Monitor Connection
IMPORTANT: Avoid using excessive hose when routing it to gear lube monitor. Hose should be
routed directly to oil reservoir in as straight a line as possible to avoid low spots (traps) in the
system.
! CAUTION
Ensure that hose is not kinked when connecting in the following step. If hose is kinked, gear lube
monitor will not function properly and damage to sterndrive unit could occur.
1. Locate the gear lube monitor quick connect at the rear of the engine.
2. Locate the gear lube monitor quick connect at transom.
IMPORTANT: Hose must not come in contact with steering system components, engine coupler,
U‑joint shaft, or drive shaft.
3. Fasten the quick connect.
c a
b
7800
a - Gear lube monitor hose assembly c - Quick connect fitting

from transom
b - Gear lube monitor hose assembly
from gear lube monitor
Power Steering Hoses

IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks.
1. Disconnect the quick connect fittings on the power steering hoses.
2. Connect the power steering hoses to the control valve. Ensure that the quick connects snap
into place.
3. Route hoses as appropriate to avoid contact with the steering system components.
Page 44 / 88 90-864196050 FEBRUARY 2005

4. Use extra hose clips to secure hose to transom.
6686
Models with one hose routed behind power steering control valve
a - Pressure hose b - Return hose
NOTE: Power
Steering Fluid can be
added at this time if
desired.
Gen III Cool Fuel Module Water Hose Connection

1. Install water hose and hose retainer braket to the Gen III Cool Fuel Module. Secure with
captured nut.
2. Torque the capured nut.
c a
b
8208
a - Captured nut c - Water hose

b - Retainer bracket

Gen III Cool Fuel Module. 19 168
90-864196050 FEBRUARY 2005 Page 45 / 88

Alpha Seawater Cooled Models Using Sterndrive Water Pickups

1. Connect water inlet hose to water inlet fitting on transom.
b
a
7802
a - Water inlet tube c - Seawater inlet hose

b - Hose clamp
2. Secure with hose clamp.

Bravo Seawater Cooled Models Using Sterndrive Water Pickups
! CAUTION
Excess water in the bilge can damage the engine or cause the boat to sink. An improperly
connected seawater inlet hose could result in excess water in the bilge. Ensure that the seawater
inlet hose is connected properly by performing the specified pull test.
NOTE: The retainer clip must be in the closed position prior to installation.
1. Install the seawater inlet hose assembly to the water inlet fitting.
a. Position the retainer clip in the closed position.
8512
b
Seawater inlet hose assembly
a - Retainer clip closed c - Hose decal
b - Quick connect fitting
b. Position the seawater inlet hose assembly with the center of the retainer clip and the
hose decal toward the engine.
IMPORTANT: Tabs and slots are sized to only mate at the correct orientation. Mate the small tab
with the small slot.
Page 46 / 88 90-864196050 FEBRUARY 2005

c. Align the slots of the quick connect fitting to the tabs of the water inlet fitting.
g
h
b e
a
d
c f
8513
a- Quick connect fitting e- Small tab

b- Small slot f- Large tab
c- Large slot g- Center of retainer clip (toward engine)
d- Seawater inlet fitting h- Centerline of water inlet fitting (toward
engine)
d. Ensure that the center line of the water inlet fitting and the center of the retainer clip are
positioned toward the engine.
2. Push the seawater inlet hose assembly onto the water inlet fitting until connected.
NOTE: The retainer clip snaps into place and resumes the closed position when properly
connected.
c a
8514
a - Centerline of water inlet fitting c - Hose decal

b - Retainer clip in closed position
! CAUTION
IMPORTANT: A pull test must be performed at the seawater inlet connection.

3. Perform a pull test on the water hose quick connection.
90-864196050 FEBRUARY 2005 Page 47 / 88

a. Pull on the seawater inlet hose near the connection point with an approximate force of
111 N (25 lbf). If the seawater inlet hose does not become separated from the seawater
inlet fitting when force is applied, the seawater inlet hose is connected and sealed
properly.
c
a
b
8515
a - Seawater inlet hose c - Seawater inlet fitting

b - Quick connect fitting
b.
If the seawater inlet hose does become separated from the seawater inlet fitting, reinstall
as specified.
c. When all steps have been completed, check for any leaks at this connection.
4. Connect the seawater inlet hose to the engine seawater pump.
NOTE: The seawater inlet hose connects to the engine and the transom.
e b
d
e c
a 8516
Seawater inlet hose assembly

a - Seawater inlet hose d - Seawater inlet fitting
b - To engine e - Hose clamps
c - Quick connect fitting
5. Models Using The Seawater Extension Hose Assembly:

NOTE: The seawater inlet hose connects to the engine and the transom, the seawater extension
hose assembly connects to the transom and the seawater inlet hose.
Page 48 / 88 90-864196050 FEBRUARY 2005

a. When connecting the seawater extension hose assembly to the seawater inlet hose
assembly, position the center of the retainer clip away from the engine.
a
c
8517
a - Retainer clip position (away from d - Quick connect fitting (to seawater inlet
engine) fitting)
b - Seawater extension hose e - Seawater inlet fitting (to transom)
c - Seawater inlet hose (to engine
seawater pump)
! CAUTION
b. Perform a pull test and ensure that the requirements for checking the integrity of the
connection are met.
NOTE: The seawater extension hose assembly connects to the transom and the seawater inlet
hose.
g
g
g
e f
g
d
b c
8518
a
a - Seawater inlet hose e - Quick connect fitting to seawater inlet
b - Quick connect fitting to extension fitting
hose f - Seawater inlet fitting
c - Quick connect male fitting g - Hose clamp
d - Extension hose
Closed Cooled Bravo Models Using Sterndrive and Alternative Water Pickups
1. Install the alternative water pickup hose to Y‑fitting.
2. Install the sterndrive water pickup hose to Y‑fitting.
90-864196050 FEBRUARY 2005 Page 49 / 88

3. Secure hoses to Y‑fitting with hose clamps.
c
b
8485
d
Typical Y‑fitting and seawater pump
a - Engine seawater pump c - Y‑ fitting port to Bravo sterndrive water
b - Hose connecting the Y‑fitting to the pickup
seawater pump inlet port d - Y‑fitting port to alternative water pickup
Seawater Pump Pickup Connection

1. Remove shipping cap and connect the seawater inlet hose to the upper hose fitting of the
seawater pump.
9321
Seawater Pump Connections

a - Seawater inlet hose fitting b - Seawater (out) hose to cooler
Coolant Recovery System

NOTE: This section applies to Closed Cooled models only.
! CAUTION
Avoid engine overheating and subsequent damage to the engine. The coolant recovery system
will operate properly only when the connections are completely sealed. Ensure that the plastic
tubing connections are completely sealed.
Page 50 / 88 90-864196050 FEBRUARY 2005

1. Connect plastic tubing to bayonet fitting on heat exchanger. Secure with tubing clamp
provided.
a 8210
a - Plastic tubing b - Tubing clamp
2. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution.
3. Reinstall cap.
4. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of
the following:
• Within limits of clear plastic tubing.
• Level with or above the heat exchanger fill neck.
• Accessible for observing coolant level and filling.
5. Mount coolant recovery bottle and mounting bracket in desired location using two 19 mm
(3/4 in.) long screws and flat washers.
6. Route plastic tubing to recovery bottle. Ensure that tubing is positioned away from any moving
parts. Cut plastic tubing as required and connect to bottom connection on recovery bottle and
secure with tubing clamp provided.
7. Fasten plastic tubing to boat, as necessary, with 2 hose clips and 13 mm (1/2 in.) long screws
(provided).
b
b
c d
7804
a - Recovery bottle and mounting c - Plastic tubing

bracket d - Tubing clamp
b - Screws and flat washers
Fuel Connection To Fuel Supply

A flexible fuel line must be used to connect fuel line to engine to absorb deflection when engine
is running.
90-864196050 FEBRUARY 2005 Page 51 / 88

1. Connect the flexible fuel line from the boat fuel supply to the engine inlet fuel fitting.
IMPORTANT: Hold the fuel inlet fitting stationary with a suitable wrench while tightening the fuel
lines.
Fuel Line Connection To Gen III Cool Fuel Module
FUEL LINE CONNECTION
A flexible fuel line must be used to connect fuel line to engine to absorb deflection when engine
is running.
1. Remove shipping plug.
2. Connect the flexible fuel line to the Gen III Cool Fuel Module fitting.
IMPORTANT: Hold fuel inlet fitting stationary with a suitable wrench while tightening the fuel line.
b
9360
a - Fuel fitting b - Gen III Cool Fuel Module
Shift Cable Installation

Alpha Sterndrive Shift Cable Installation
IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the
remote control.
• If shift cable end guide moves in direction "A" when control lever is placed in FORWARD,
remote control is set up for RIGHT‑HAND (RH) propeller rotation.
• If shift cable end guide moves in direction "B" when control lever is placed in FORWARD,
remote control is set up for LEFT‑HAND (LH) propeller rotation.
B 6614
Arrow indicates direction of motion

IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid
sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.
SHIFT CABLE TRAVEL
We recommend the use of a Quicksilver remote control and cable. Refer to Mercury Precision
Parts Accessories Guide for selection. However, if a control other than Quicksilver is to be used,
control must provide specified shift cable travel (at the shift plate end).
Page 52 / 88 90-864196050 FEBRUARY 2005

Shift cable travel1 73 mm (2‑7/8 in.)‑80 mm (3‑1/8 in.)2
1 At the shift plate end

2 With a 6.8‑9 kg (15‑20 lb) load applied to the cable end guide
NOTE: On engines with Alpha drives, the measurement indicated above can be taken by installing
the remote control shift cable and using the shift assist assembly (provided) to place the proper
load on the shift cable.
1. Place a mark on the tube against the edge of the cable end guide.
d
e
a
b c
7809
a
a - Shift assist assembly d - Remote control shift cable ‑ in
b - Remote control shift cable ‑ in REVERSE gear position
FORWARD gear position e - Measurement taken from mark to edge
c - Edge of cable end guide of cable end guide
SEPARATE SHIFT AND THROTTLE CONTROLS

IMPORTANT: If boat is being equipped with a REMOTE CONTROL THAT HAS SEPARATE
SHIFT AND THROTTLE LEVERS, the shift assist assembly that is shipped with the engine should
not be used. The use of the shift assist assembly with this type of remote control can cause the
shift lever to move out of gear unexpectedly.
90-864196050 FEBRUARY 2005 Page 53 / 88

The Spacer Kit (23‑11284A1) will have to be ordered to connect remote control shift cable when
shift assist assembly is not used.
d 7810
a - Clevis pin c - Spacer

b - Washer d - Cotter pin
NOTE: Do not discard shift assist assembly until after it is used below.
IMPORTANT: Shift cable must be connected at the remote control for the appropriate rotation (LH
or RH) drive unit, as explained following:
RIGHT‑HAND ROTATION ‑ Control cable will have to be installed in remote control so that cable
end will move in direction "A" when shift handle is placed in the FORWARD position.
LEFT‑HAND ROTATION ‑ Control cable will have to be installed in remote control so that cable
end will move in direction "B" when shift handle is placed in the FORWARD position.
B 6614
INSTALLATION
1. Remove shift assist assembly.
Page 54 / 88 90-864196050 FEBRUARY 2005

2. Remove shift cable attaching hardware.
b
7812
a - Shift assist b - Shift plate
3. Install intermediate cable.
7813
4. Secure the brass barrel retainer with the cotter pin.

5. Secure the cable end guide with washers (one on each end of the end guide) and cotter pin.
6. Locate center of remote control and control cable play (backlash).
IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making the
following adjustment.
a. a. Shift remote control to NEUTRAL.
b. Push in on control cable end with enough pressure to remove play and mark position "a"
on tube.
c. Pull out on control cable end with enough pressure to remove play and mark position "b"
on tube.
90-864196050 FEBRUARY 2005 Page 55 / 88

d. Measure distance between marks "a" and "b" and mark position "c" half‑way between
marks "a" and "b."
a 7815
b
7. Temporarily install control cable end guide into shift lever and insert anchor pin.
8. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure
that backlash center mark is aligned with edge of control cable end guide.
! CAUTION
Do not attempt to install or remove control cable barrel from stud without first removing end guide
anchor pin from shift lever and removing cable. Attempting to bend control cable to install or
remove barrel will place undue stress on cable end guide and shift lever and damage to both
could occur.
9. Place remote control and and sterndrive unit in FORWARD gear.
10. Install the remote control shift cable.
11. Place remote control handle in NEUTRAL.
12. Install the shift assist assembly. Ensure that it fits over the clevis pin and barrel stud with no
resistance.
Page 56 / 88 90-864196050 FEBRUARY 2005

13. Install the fastening hardware. If shift assist assembly attaching points will not align, verify
controller is in NEUTRAL. Remove the shift cable and reposition the adjustment barrel as
required to allow the shift assembly to be installed with no effort.
a
c
e
b 7818
With shift assist assembly

a - Remote control shift cable d - Large ID washer
b - Shift assist assembly e - Small ID washer and cotter pin
c - Clevis pin (and cotter pin not shown)
d f
e g
a
i
h
b 7841
Without shift assist assembly

a- Remote control shift cable f- Washer
b- Clevis pin g- Spacer
c- Cotter pin (existing) (not shown) h- Washer (existing)
d- Spring (existing) (not shown) i- Cotter pin (existing)
e- Washer (existing)
Bravo Models Shift Cable Installation

NOTE: Bravo Models Only: Using Adjustment Tool (91‑12427), shift cables can be adjusted
without or with the sterndrive installed, using the following procedure.
90-864196050 FEBRUARY 2005 Page 57 / 88

IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the
remote control.
• Bravo One/Two ‑ If shift cable end guide moves in direction A when control lever is placed in
FORWARD, remote control is set up for RIGHT‑HAND (RH) propeller rotation.
• Bravo One/Two ‑ If shift cable end guide moves in direction B when control lever is placed in
FORWARD, remote control is set up for LEFT‑HAND (LH) propeller rotation.
B 6614
Arrow indicates direction of motion

• Bravo Three ‑ Front propeller on sterndrive unit is always LH Rotation and rear propeller is
always RH Rotation. Shift cable end guide must move in direction A, when control lever is
placed in FORWARD gear position.
A
8519
IMPORTANT: When installing shift cables, ensure that cables are routed in such a way as to avoid
sharp bends and/or contact with moving parts. Do not fasten any items to shift cables.
Bravo Models Shift Cable Adjustment
1. Remove the adjustment tool.
8588
a
Typical Bravo shift bracket shown without switch
a - Adjustment tool
Page 58 / 88 90-864196050 FEBRUARY 2005

2. Loosen the adjustable stud and move it to dimension, as shown. Retighten stud.
b
8587

a - Adjustable stud b - 76 mm (3 in.) (center of pivot bolt to
center of stud)
3. Install sterndrive unit shift cable.

4. Install cotter pin.
5. Insert cotter pin from top and spread ends fully.
a c 8523

a - Washers (2) c - Short cotter pin
b - Long cotter pin
6. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place using a
piece of tape over the barrel retainer.
8522

a - Adjustment tool b - Sterndrive unit shift cable
7. Locate center of remote control and control cable play (backlash).

IMPORTANT: Keep center mark "c" aligned with control cable end guide edge when making the
following adjustment.
a. Shift remote control to NEUTRAL.
90-864196050 FEBRUARY 2005 Page 59 / 88

b. Push in on control cable end with enough pressure to remove play and mark position "a"
on tube.
c. Pull out on control cable end with enough pressure to remove play and mark position "b"
on tube.
d. Measure distance between marks "a" and "b" and mark position "c" half‑way between
marks "a" and "b."
a 7815
b
8. Temporarily install control cable end guide into shift lever and insert anchor pin.
9. Adjust control cable barrel so that hole in barrel centers with vertical center line of stud. Ensure
that backlash center mark is aligned with edge of control cable end guide.
! CAUTION
Do not attempt to install or remove control cable barrel from stud without first removing end guide
anchor pin from shift lever and removing cable. Attempting to bend control cable to install or
remove barrel will place undue stress on cable end guide and shift lever and damage to both
could occur.
10. Remove control cable end guide from shift lever by removing clevis pin.
b
a c
d
8593

a - Control cable end guide d - Control cable barrel
b - Clevis pin e - Stud
c - Backlash center
11. Install the control cable.

12. Install the washer and cotter pin to secure the barrel.
13. Install the clevis pin.
14. Install the cotter pin into the clevis pin from the top and spread the ends.
15. Remove the adjustment tool.
16. Shift remote control lever into FORWARD position. Place end of adjustment tool in barrel
retainer. If slot does not fit over stud, loosen shift lever stud and slide stud up or down until
slot in tool fits over stud. When adjustment is correct, retighten stud.
17. Lift the adjustment tool so that the slot is above the stud.
Page 60 / 88 90-864196050 FEBRUARY 2005

18. Shift the remote control into REVERSE and repeat the adjustment process.
a
8525
b
a - RH rotation Bravo One, Two, Three b - LH rotation Bravo One and Two
FORWARD, LH rotation Bravo One FORWARD, RH rotation Bravo One,
and Two REVERSE slot Two and Three REVERSE slot
19. Remove adjustment tool.

20. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180
degrees.
21. Lubricate shift cable pivot points.

80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
Throttle Cable Installation And Adjustment

1. Place remote control handles in NEUTRAL / IDLE position.
IMPORTANT: Ensure that cable is routed to avoid sharp bends and/or contact with moving parts.
Do not fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.
2. Adjust cable so that it can be placed on both studs simultaneously.
3. Place cable over studs. Do not adjust cable after installation.
4. Secure throttle cable with hardware as shown and tighten securely. Loosen locknut 1/2 turn.
b a
8217
Typical
a - Flat washer and locknut c - End guide
b - Cable barrel
90-864196050 FEBRUARY 2005 Page 61 / 88

5. Place remote control throttle lever in the wide open throttle (WOT) position. Ensure that throttle
plates are completely open.
9293
a - Throttle plate
6. Return remote control throttle lever to IDLE position and ensure that throttle lever is completely
closed.
9294
a - Throttle plate
Shift Cable Installation For DTS System

IMPORTANT: Do not move the shift cable stud on the shift arm.
IMPORTANT: The shift cable barrel is preset and CANNOT be adjusted.
1. Route the intermediate shift cable from the transom assembly to the shift actuator as follows:
housing.
the transom.
actuator on the engine.
Page 62 / 88 90-864196050 FEBRUARY 2005

NOTE: Following this routing will prevent the engine coupler from damaging the cable.
8995
NOTE: A final check of the adjustments should be made with the boat in the water and engine
running. If this cannot be done or is not done at your manufacturing facility, arrangement should
be made with the dealer to do this as part of the pre‑delivery inspection.
2. Install the intermediate shift cable to the shift actuator on the engine.
3. Tighten locknut until it contacts and then loosen 1/2 turn.
e c
8996
a - Shift actuator d - Shift cable stud

b - Shift cable e - Shift cable barrel
c - Locknut f - Washers
90-864196050 FEBRUARY 2005 Page 63 / 88

4. Insert cotter pin from top and spread ends.
8997
a - Cotter pin
DTS System Installation

Refer to DTS System Installation section 7 ‑ Electrical System
Sterndrive Unit
Alpha Notice: Increased Trim‑in Range Capability
The Alpha trim cylinders provide the capability for an increased trim‑in range. A spacer can be
removed from the trim cylinders to increase the trim‑in range by approximately 1‑1/2 degrees. This
will improve the acceleration on some boats by forcing the bow down more quickly. If the spacers
are to be removed, the boat must be water tested to ensure that the increased trim‑in range does
not cause any undesired boat handling characteristics (bow‑steer, chine‑walk, etc.) if the
sterndrive is trimmed in while the boat is operated at higher speeds. The boat should be tested
under all conceivable load conditions and maneuvers to ensure that the additional trim‑in does not
pose a problem. The final decision and responsibility for use of the additional trim‑in range is left
up to the boat manufacturer.
! WARNING
It is recommended that only qualified personnel adjust the trim‑in limit inserts. The boat must be
water tested after adjusting the trim‑in limit inserts to ensure that the modified trim‑in range does
not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is
trimmed in at higher speeds. Increased trim‑in range may cause handling problems on some
boats, which could result in personal injury.
Alpha Trim Cylinder Spacer Removal

1. Disconnect "UP" trim hose from "UP" port on trim cylinder.
Page 64 / 88 90-864196050 FEBRUARY 2005

2. Disconnect "DOWN" trim hose from hydraulic connector on gimbal housing. Plug holes with
22‑38609 plug.
d c
b
a 7843
a - "UP" hose c - "DOWN" hose

b - "UP" port on trim cylinder d - Hydraulic connector
3. Remove front power trim cylinder mounting hardware.
a
c
e
b
d 4827
a - Front anchor pin d - E‑ring (port and starboard) (2)

b - Bushing (port and starboard) (4) e - Plastic caps (port and starboard) (2)
c - Flat washer (port and starboard) (2)
4. Remove rear power trim cylinder mounting hardware.
b a
d
a c e
b 7844
a - Rear anchor pin d - E‑ring (port and starboard) (2)

90-864196050 FEBRUARY 2005 Page 65 / 88

Alpha Trim Cylinder Disassembly

! WARNING
It is recommended that only qualified personnel perform the adjustment to the trim cylinders.
The boat must be water tested after removing the spacers from the trim cylinders to ensure that
the increased trim range does not cause the boat to exhibit an undesirable boat handling
characteristic if the drive is trimmed in at higher speeds. The increased trim‑in range may cause
handling problems on some boats which could result in personal injury.
! CAUTION
Ensure work area is clean before disassembling power trim cylinders. Cylinder parts can be
damaged by dirt entering into power trim system.
! CAUTION
Trim cylinders can be damaged by improper clamping. Clamping the center section of the trim
cylinder during service procedures can cause damage that could result in a loss of trim control.
Clamp the trim cylinder only on the front mounting flange.
1. Remove plug previously installed, if applicable.

2. Remove end cap with spanner wrench and remove piston rod assembly from cylinder.
7845
a - Piston rod assembly b - Cylinder
Trim Cylinder End Cap Tool 91‑821709T
Page 66 / 88 90-864196050 FEBRUARY 2005

3. Remove bolt, washer, and spacer. Be careful not to lose check balls. Discard spacer.
h
f
e
d
g
c
b
a 7846
a- Trim cylinder shock piston bolt e- Spring pins (3)

b- Spacer f- Check balls (3)
c- Washer g- Shock piston assembly
d- Springs (3) h- O‑ring
Alpha Trim Cylinder Reassembly

! CAUTION
Ensure that work area and all components are clean before reassembling trim cylinders. Power
trim components can become damaged if dirt gets into system.
1. Apply sealant to threads of shock piston bolt.

7 Loctite 271 Threadlocker Trim cylinder bolt threads 92-809819
2. Install washer and bolt and torque.

Trim cylinder shock piston bolt 23 17
! CAUTION
Trim cylinders can be damaged by improper clamping. Clamping on the trim cylinder center
section during service procedures can cause damage that could result in a loss of some trim‑in
or trim‑out. Clamp the trim cylinder only on the front mounting flange.
! CAUTION
Prevent trim cylinder damage caused by corrosion. Always apply Special Lubricant 101 to the
end cap threads before assembly.
3. Apply lubricant to end cap threads and install piston rod assembly into cylinder.
90-864196050 FEBRUARY 2005 Page 67 / 88

4. Torque end cap using the spanner wrench.
c
7847
a - End cap c - Cylinder

b - Piston rod assembly

34 Special Lubricant 101 Trim cylinder end cap 92-802865A1

Trim cylinder end cap 61 45
5. Position trim cylinder rear connecting ends.
a b
7848
a - Port trim cylinder c - Connecting ends (offset as shown)

b - Starboard trim cylinder
Alpha Trim Cylinder Installation

1. Install trim cylinders forward mounting hardware.
2. Coat area in trim cylinder between bushings with lubricant.
3. Replace anchor pin and install bushings and washers.
Page 68 / 88 90-864196050 FEBRUARY 2005

4. Attach E‑rings and plastic caps to end of anchor pin.
a
c
e
b
d 4827
a - Front anchor pin d - E‑ring (port and starboard) (2)


2-4-C Marine Lubricant with
95 Trim cylinder hardware 92-802859A1
Teflon
5. Install trim cylinders rear mounting hardware.
6. Coat area in trim cylinder between bushings with lubricant.
7. Replace anchor pin and install bushings and washers.
8. Attach E‑rings and plastic caps to end of anchor pin.
b a
d
a c e
b 7844
a - Rear anchor pin d - E‑ring (port and starboard) (2)


95 Trim cylinder 92-802859A1
Teflon
9. Reconnect trim hoses after air bleeding power trim cylinders and hoses following procedures
outlined in Mercury MerCruiser Service Manual 14.
90-864196050 FEBRUARY 2005 Page 69 / 88

Alpha Sterndrive Installation

1. Remove trim cylinder support and dust cover from bell housing studs. (Retain elastic stop nuts
and flat washers.)
7713
Typical
a - Dust cover b - Trim cylinder support
2. Remove gear lube monitor cap. Fill with lubricant.
a b
5497
a - ‑ Gear lube monitor cap b - "OPERATING RANGE" line

High Performance Gear
87 Gear lube monitor 92-802854A1
Lubricant
Page 70 / 88 90-864196050 FEBRUARY 2005

3. Push dribble valve stem in until gear lube appears.
7851
a - Dribble valve stem
4. Once gear lube appears, release dribble valve stem.

5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING
RANGE" (full) line with specified fluid. Do not overfill.

87 Gear lube monitor 92-802854A1
Lubricant
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do
not overtighten the cap.
IMPORTANT: Rubber gasket must be properly positioned in bell housing bore before installing
drive unit or water may leak into boat.
7. Ensure that rubber gasket and water passage O‑ring are properly positioned in bell housing.
8. Coat bell housing studs with lubricant.
a
c c
7852
a - Rubber gasket c - Studs (6)

b - Water passage O‑ring

95 Bell housing studs 92-802859A1
Teflon
90-864196050 FEBRUARY 2005 Page 71 / 88

9. Grease sterndrive U‑joint O‑rings, and drive shaft splines. A grease packet for this procedure
is provided with the sterndrive packaging.
7853
a - U‑joint O‑rings b - Drive shaft splines

91 Engine Coupler Spline Grease Ujoint O-rings 92-802869A1

91 Engine Coupler Spline Grease Drive shaft splines 92-802869A1
10. Ensure U‑joint bellows are clean and free of debris.
7854
a - U‑joint bellows
Page 72 / 88 90-864196050 FEBRUARY 2005

11. Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and
aft. Do this by placing remote control shift lever in: FORWARD gear position for RH drive or
REVERSE gear position for LH drive unit.
c
a
b
7855
a - Shift shaft c - Shift slide

b - Shift shaft coupler d - Slot
IMPORTANT: Shift slide assembly is free to rotate on core wire. Ensure that shift slide remains in
upright position and is properly engaged with shift shaft lever roller while installing drive unit.
12. Engage shift shaft roller into shift shaft lever.
13. Place gasket on bell housing.
14. Shift Shaft Slide Stabilizer Tool is installed on the stud directly below shift slide.
a d
b
c
c 7859
a - Shift shaft lever c - Shift Shaft Slide Stabilizer Tool

b - Roller d - Gasket
Shift Slide Stabilizer 91‑865232
90-864196050 FEBRUARY 2005 Page 73 / 88

15. Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE
while simultaneously turning propeller shaft COUNTERCLOCKWISE.
7856
a - Drive unit shift shaft
IMPORTANT: Install RH or LH drive unit on the appropriate transom assembly when making dual
engine installations. The LH rotation drive unit can be identified by the decal on the back side of
the upper drive shaft housing, which states: "Alpha One ‑ Counter Rotation"
16. Install sterndrive unit as follows:
a. Position trim cylinder straight back (over top of acceleration plate). Be careful not to
scratch acceleration plate or trim cylinders.
b. Guide U‑joint shaft through gimbal bearing and into engine coupler while simultaneously
guiding shift slide into drive shaft housing. Ensure that shift slide remains upright and
engaged with bell housing shift shaft lever.
c. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly to help align U‑joint
shaft splines with engine coupler splines while sliding sterndrive into bell housing.
IMPORTANT: If drive unit will not slide into bell housing, ensure that the shift shaft and couplers
are positioned properly. Do not force drive unit into position.
b
7857
a - Gasket b - Shift slide
d. Remove Shift Slide Stabilizer Tool and discard.

e. Slide sterndrive all the way into bell housing.
Page 74 / 88 90-864196050 FEBRUARY 2005

f. Secure sterndrive to bell housings using fasteners as shown. Torque the fasteners.
7858
a - Locknut and flat washers b - Locknut and continuity circuit washer

(no flat washer at this location)

17. Return remote control shift lever to the NEUTRAL position.
TRIM CYLINDER INSTALLATION
1. Install trim cylinders on aft end of sterndrive unit with hardware as shown.
2. Install the plastic caps by snapping in place.NOTE: Upon installation of hardware apply
lubricant to all components except plastic caps.
b c d e
a 7849
b
a - Aft anchor pin d - E‑ring clips
b - Bushings e - Plastic caps
c - Flat washers

Teflon
3. Position the sterndrive unit serial number decal.
Speedometer Connection ‑ Alpha Models
1. Raise drive to gain access to area between gimbal housing and sterndrive, immediately above
the transom end of the anti‑ventilation plate.
2. Align plastic slots on male and female portions and insert.
90-864196050 FEBRUARY 2005 Page 75 / 88

3. Push down to secure.
4803
a - Male end of speedometer tube fitting b - Female end of speedometer tube

fitting
Ensure that the speedometer tube is secured and out of the way of moving parts.
8029
a - Male end of speedometer tube fitting b - Female end of speedometer tube

fitting
Bravo Sterndrive Installation

1. If applicable, remove trim cylinder support and dust cover from bell housing studs. (Retain
elastic stop nuts and flat washers.)
8993
Typical
a - Dust cover b - Trim cylinder support
Page 76 / 88 90-864196050 FEBRUARY 2005

2. Remove gear lube monitor cap. Fill the gear lube monitor to the "OPERATING RANGE".
a b
5497
a - Gear lube monitor cap b - "OPERATING RANGE" line

87 Gear Lube Monitor 92-802854A1
Lubricant
3. To purge air from the system, push in on the dribble valve stem until the new gear lube appears.
5502
a - Dribble Valve
4. Release the dribble valve.

5. If the gear lube monitor is below the (full) line: Fill the gear lube monitor to the "OPERATING
RANGE" (full) line with specified fluid. Do not overfill.

Lubricant
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap. Do
not overtighten the cap.
90-864196050 FEBRUARY 2005 Page 77 / 88

7. Coat sterndrive U‑joint O‑rings and drive shaft splines with grease.
8591
a - U‑joint O‑rings (3) b - Drive shaft splines

91 Engine Coupler Spline Grease U-joint O-rings 92-802869A1
91 Engine Coupler Spline Grease Drive shaft splines 92-802869A1
IMPORTANT: The edge of the U‑joint bellows acts as a seal between the bell housing and the
drive shaft housing. Ensure that the surface is not damaged.
8. Ensure that the U‑joint bellows are clean and free of debris.
8590
a - U‑joint bellows b - Bell housing
Page 78 / 88 90-864196050 FEBRUARY 2005

9. Lubricate the bell housing studs.
a
a
5307
a - Bell Housing Studs (6)

95 Bell Housing Studs 92-802859A1
Teflon
10. Lubricate the O‑ring seals.
a
5310
a - O‑ring seals

95 O-ring seals 92-802859A1
Teflon
90-864196050 FEBRUARY 2005 Page 79 / 88

11. Pull out shift linkage as far as it moves. Jaws will open.
c
c
5311
a - Shift linkage assembly c - Underside of lower lip

b - Jaws open
IMPORTANT: As sterndrive is inserted into sterndrive unit, entry of the bell housing shift cable
must be closely checked to ensure that cable enters the jaws of shift linkage assembly in the
sterndrive.
12. Place remote control in NEUTRAL position.
NOTE: As bell housing shift cable enters the shift linkage assembly, it pushes the assembly back
into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps "A", "B" and
"C."
C 5312
Page 80 / 88 90-864196050 FEBRUARY 2005

IMPORTANT: If bell housing shift cable does not line up to properly enter jaws of shift linkage
assembly, use your hand to guide the cable into place while installing the sterndrive.
a
b
5313
a - Shift linkage assembly b - Shift cable
13. Place drive shaft housing in position on bell housing and install sterndrive unit, as follows:
a. Remove the nuts from the trim cylinders.
b. Position trim cylinders so they point straight backwards.
c. Position sterndrive so that universal joint shaft aligns with bell housing bore.
d. Guide U‑joint shaft through bearing in gimbal housing and into engine coupler. Ensure
that shift linkage jaws engage the bell housing shift cable assembly.
e. If necessary, rotate propeller shaft COUNTERCLOCKWISE slightly (using a propeller)
to align U‑joint shaft splines with splines in engine coupling, then slide sterndrive unit all
the way into bell housing.
14. Secure sterndrive unit to bell housing with 5 flat continuity washers and 6 locknuts. Start from
the center and torque the nuts.
b
a a
5314
a - Locknut (6) flat continuity washers (5) b - Ground plate (continuity washer not
used here)

IMPORTANT: On Bravo One, Two and Three Models, the Trim‑In Limit Insert must be properly
positioned before installing the trim cylinder anchor pin in the following steps.
90-864196050 FEBRUARY 2005 Page 81 / 88

15. Ensure that the Trim‑In Limit Insert is positioned as shown for the appropriate Bravo model.
a a
8548 8557
Bravo One and Two (positioned forward) Bravo Three (positioned aft)
a - Trim‑in limit insert
TRIM CYLINDER INSTALLATION

1. Install trim cylinders on aft end of sterndrive unit with hardware as shown.
2. Tighten the locknuts until the washer and locknut contact the shoulder on the anchor pin.
3. Install plastic caps and tighten hand‑tight only.
NOTE: Upon installation of hardware apply lubricant to all components except plastic caps.
c b c
a
d e
c f
9295
a - Aft anchor pin d - Small ID flat washers (2)

b - Larger flat washers (2) e - Locknuts (2)
c - Bushings (4) f - Plastic caps (2)

Teflon
4. Position the sterndrive unit serial number decal.
Speedometer Connections ‑ Bravo Models
1. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately
atop the transom end of the anti‑ventilation plate.
Page 82 / 88 90-864196050 FEBRUARY 2005

2. Insert speedometer tube fitting into opening on topside of anti‑ventilation plate, in position
shown.
5319
a - Tube fitting b - Opening
3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
5320
a - Fitting installed (handle pointing forward)
Installing the Pitot Sensor

IMPORTANT: The pitot hose must not come into contact with the steering system components or
the engine coupler.
1. Remove the yellow cap from the quick‑connect fitting at the transom.
b
a
mc79613-1
a - Male quick‑connect fitting b - Yellow plug
IMPORTANT: Ensure that the fittings snap into place.
90-864196050 FEBRUARY 2005 Page 83 / 88

2. Connect the quick‑connect pitot hose to the fitting on the transom.
mc79614-1
a - Female quick‑connect fitting b - Male quick‑connect fitting
3. Connect the pitot hose quick‑connect fitting on the transom.
b a
12119
a - Pitot sensor b - Quick‑connect fitting on transom
Paddle Wheel Speed Sensor Installation (If Equipped)

PARTS PROVIDED
d i
a e
b c i
h
ABCD
f g j ob01505
a- Spare pin yoke f- Flat washer (2)

b- Wire retainer g- #10 ‑ 19 mm (3/4 in.) screw (4)
c- Connector h- Cable cap
d- Bracket i- #6 ‑ 12 mm (1/2 in.) screw (4)
e- Paddle wheel j- Clamp (2)
Page 84 / 88 90-864196050 FEBRUARY 2005

SELECTING LOCATION
Single engine installation ‑ Mount paddle wheel on the transom where the propeller blade is
rotating downward. Usually the right (starboard) side to minimize cavitation. If feasible, mount at
least 50 mm (2 in.) beyond the swing radius of the propeller.
Dual engine installation ‑ Mount the paddle wheel between the engines as close to the center line
(keel) of the boat as possible. On slower, heavier displacement boats, however, positioning it
farther from the keel is acceptable.
NOTE: Do not mount the paddle wheel directly behind any stakes, ribs, intakes or outlets for live
wells or any protrusion that may cause turbulence or cavitation.
TRANSOM ANGLE REQUIREMENTS
Standard 13° to 20° transoms ‑ No special adjustment required.
a b
ob01507
a - 13° transom angle b - 20° transom angle
Stepped or undercut transom with 3 angles ‑ A small shim of tapered plastic, metal or wood must
be fabricated and installed as shown. Mount the paddle wheel on the step for best performance.
ob01508
a - Shim
INSTALLING BRACKET
1. Cut out the template. At the location selected, tape the template to the transom. Make sure
the black dotted line on the template is aligned with the transom bottom edge, as shown.
NOTE: The mounting template provided is located on the last page of this instruction sheet.
2. Using a #28 or 9/64 in. bit, drill two 22 mm (7/8 in.) deep holes where indicated on the template.
To prevent drilling too deeply, wrap masking tape around the drill bit 22 mm (7/8 in.) from the
point end of drill bit.
NOTE: In fiberglass hulls, first chamfer the gelcoat using a 6 mm (1/4 in.) drill; drilling about
15 mm (1/16 in.) deep to prevent surface cracks.
3. To prevent water seepage into the transom, apply a marine sealer (such as RTV) to the two
#10 screws provided. Using the washer provided, attach and tighten the bracket to the hull
making sure the bracket is flush with the underside of the hull.
90-864196050 FEBRUARY 2005 Page 85 / 88

4. Fill any gap between the housing and the transom with a caulking material, as shown. Using
a putty knife, smooth the surface to ensure proper water flow.
c d ob01509
a - Template d - Flat washer (2)

b - 50 mm (2 in.) e - Caulking
c - #10 screw
ROUTING THE CABLE

DRILLING HOLE THROUGH TRANSOM (OPTIONAL)
1. Select a transom location for the hole above the water line that does not interfere with other
cables and controls.
2. Drill a 15 mm (5/8 in.) diameter hole.
3. Route the cable through the drilled hole. Seal the transom hole with silicone (RTV) or a
comparable marine sealer after the cable has been routed through.
NOTE: The hole for the first clamp should be 25 mm (1 in.) above the paddle wheel. The hole for
the second clamp should be positioned halfway between the first clamp and the cap covering the
transom hole drilled for the cable.
4. Using a 2.8 mm (7/64 in.) bit, drill holes for the clamps and cap approximately 13 mm
(1/2 in.) deep.
5. Apply silicone sealer (RTV) or a comparable marine sealer to the screw threads, install the
cable clamps and feed the cable through cable cap.
WITHOUT DRILLING HOLE THROUGH TRANSOM (OPTIONAL)
Route the cable over the transom or through a drain hole that is above the water line.
a
b
c
d
ob01510
a- Splash well drain hole

b- Cable cap
c- Cable clamp
d- Paddle wheel assembly
e- Distance between first cable clamp and top of paddle wheel ‑ 25.4 mm (1.0 in.)
Page 86 / 88 90-864196050 FEBRUARY 2005

INSTALLING AND REMOVING THE PADDLE WHEEL

Installation ‑ Slide the pins into the slots in the bracket and snap the tabs into place.
Removal ‑ squeeze open (unlock) the tabs and pull on the paddle wheel.
b ob01511
a - Tabs b - Pins
WIRING CONNECTIONS
IMPORTANT: Before making wire connections, make sure wires are routed through the transom.
NOTE: Wires can only be pushed into the connector one way. Align the wire terminal with the tabs
inside the connector. Have the wiring routed through the transom. Push each wire terminal into
its respective location in the connector. Push wire in until they snap into place. Secure wires into
connector with the wire retainer.
DC B A
WHT
DC BA
YEL
BLU
BLK
a b ob01512
b
a - Connector b - Wire retainer
TEMPLATE - PADDLE WHEEL SPEED SENSOR
ob01513
a - Drill holes here

b - Align dotted line with the transom bottom edge and fold under
90-864196050 FEBRUARY 2005 Page 87 / 88

Page 88 / 88 90-864196050 FEBRUARY 2005

SECTION - 7 STARTING AND ELECTRICAL
SECTION 7 - STARTING AND ELECTRICAL

Table of Contents
Battery Specifications.............................................................................................................................................. 3
Battery Cables .................................................................................................................................................. 3
Multiple MPI Engine Battery Information................................................................................................................. 3
DTS System Installation.......................................................................................................................................... 4
SC5000 Data Cable ......................................................................................................................................... 4
Data Cable Routing - New Installations ........................................................................................................... 4
Wiring Diagrams...................................................................................................................................................... 5
Instrumentation..................................................................................................................................................5
Single Station Installations - Typical .......................................................................................................... 5
Power Trim System...........................................................................................................................................6
MerCathode System ......................................................................................................................................... 7
ECM 555 MPI System Engine Wiring Diagrams...............................................................................................8
Typical Starting System ............................................................................................................................. 8
Typical Starting System (continued) .......................................................................................................... 8
Wake, Horn and Tachometer Circuits ...................................................................................................... 10
CAN, Fuel Level, Paddle Wheel and Temperature Circuit ...................................................................... 11
Transom Harness .................................................................................................................................... 12
Typical DTS Control System...........................................................................................................................13
Panel mount ERC and Smartcraft instrumentation .................................................................................. 13
14 Pin Engine Harness Connector..................................................................................................................13
DTS Installation..................................................................................................................................................... 14
Special Tools - DTS Installation......................................................................................................................14
7
Installation Guidelines for DTS System Components.....................................................................................14
Data Harness ........................................................................................................................................... 14
Connectors .............................................................................................................................................. 14
Weather Caps.................................................................................................................................................14
Battery Harness Information and Installation........................................................................................................ 15
DTS Battery Specifications.............................................................................................................................. 15
Data Harness Pulling Procedure........................................................................................................................... 16
Connecting 14 Pin Data Harness - Single Engine................................................................................................. 16
Single Helm .................................................................................................................................................... 16
Dual Helm ....................................................................................................................................................... 17
Connecting 14 Pin Data Harness - Dual Engine................................................................................................... 17
Single Helm .................................................................................................................................................... 17
Dual Helm ....................................................................................................................................................... 18
Installing DTS Command Module and Harness - Single Engine........................................................................... 18
Harness Installation ........................................................................................................................................ 18
Module Installation ......................................................................................................................................... 20
Installing DTS Command Module and Harness - Dual Engine............................................................................. 21
Harness Installation ........................................................................................................................................ 21
Module Installation ......................................................................................................................................... 23
Junction Box (If Equipped).................................................................................................................................... 24
Analog Gauge Interface (AGI)............................................................................................................................... 25
Analog Gauge Interface (AGI) Installation....................................................................................................... 25
Typical AGI Application with System View .............................................................................................. 26
Configuring Analog/Digital Tachometer Signal through PCM.........................................................................26
PCM Configuration with DDT ................................................................................................................... 27
PCM Configuration with CDS .................................................................................................................. 27
Typical 14 Pin DTS Wiring Diagrams.................................................................................................................... 28
DTS Panel Control Wiring...............................................................................................................................28
DTS Single Console Control Wiring................................................................................................................29
DTS Single Console Control Wiring with Dual Helm.......................................................................................30
90-864196050 FEBRUARY 2005 Page 1 / 41

STARTING AND ELECTRICAL SECTION - 7
DTS Dual Console Control Wiring...................................................................................................................31

DTS Dual Console Control Wiring with Dual Helm.......................................................................................... 32
DTS Zero Effort Control Wiring - Single Engine..............................................................................................33
DTS Zero Effort Control Wiring - Dual Engine ................................................................................................ 34
Typical 10 Pin DTS Wiring Diagrams.................................................................................................................... 35
Switched 12V Accessory Connection.............................................................................................................. 35
Single Engine With Panel Control...................................................................................................................36
Single Engine with Console Control................................................................................................................37
Single Engine with Zero Effort Control............................................................................................................38
Twin Engine with Console Control..................................................................................................................39
Twin Engine with Zero Effort Control............................................................................................................... 40
System Wiring Installation Checklist...............................................................................................................40
Data Cable ............................................................................................................................................... 40
Junction Box (if equipped) ....................................................................................................................... 41
Non-Mercury Marine Supplied Ignition Key Switch .................................................................................. 41
Electronic Remote Control ....................................................................................................................... 41
DTS Command Module Harness ............................................................................................................. 41
Battery ..................................................................................................................................................... 41
Lanyard Stop Switch ................................................................................................................................ 41
Page 2 / 41 90-864196050 FEBRUARY 2005

Special Tools
Data Cable Puller 91‑888462A1
Attaches to end of DTS data harness to aid in pulling harness

4618 through boat. Prevents damage to DTS data harness.
Battery Specifications
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard
regulations must be adhered to when installing the battery. Ensure that battery cable installation
meets the pull test requirements and that positive battery terminal is properly insulated in
accordance with regulations.
IMPORTANT: It is recommended (required in some states) that the battery be installed in an
enclosed case. Refer to regulations for your area.
• Select a battery that meets all of the following specifications:
• 12‑volt marine type.
• Tapered post connectors or side terminal connectors.
IMPORTANT: Do not use a battery with wing nut connectors.
• Battery capacity rating of at least:
Model Minimum required cranking battery size

V6 and V8 MPI models 750 cca, 950 mca, 180 Ah
Battery Cables
Select proper size positive (+) and negative (‑) battery cables. Using the following chart, battery
should be located as close to engine as possible.
• Add the positive (+) and negative (‑) battery cable lengths together.
• Divide by 2 to obtain the average cable length.
IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use
electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and
a subsequent failure.
Cable Length Cable Gauge

Less than or equal to 1.1m (3.5 ft.) 25 mm2 (4)
1.1 ‑ 1.8m (3.5 ‑ 6 ft.) 35 mm2 (2)
1.8 ‑ 2.3m (6 ‑ 7.5 ft.) 50mm2 (1)
2.3 ‑ 2.9m (7.5 ‑ 9.5 ft.) 50mm2 (0)
2.9 ‑ 3.7m (9.5 ‑ 12 ft.) 70mm2 (00)
3.7 ‑ 4.6m (12 ‑ 15 ft.) 95mm2 (000)
4.6 ‑ 5.8m (15 ‑ 19 ft.) 120mm2 (0000)
Both positive (+) and negative (‑) cables
Multiple MPI Engine Battery Information

Batteries: Boats with multi‑engine MPI power packages require each engine be connected to its
own battery. This ensures that the engine's Electronic Control Module (ECM) has a stable voltage
source.
90-864196050 FEBRUARY 2005 Page 3 / 41

Battery switches: Battery switches should always be positioned so each engine is operating off its
own battery. Do not operate engines with switches in BOTH or ALL position. In an emergency,
another engine's battery can be used to start an engine with a dead battery.
Battery isolators: Isolators can be used to charge an auxiliary battery used for powering
accessories in the boat. They should not be used to charge the battery of another engine in the
boat unless the type of isolator is specifically designed for this purpose.
NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.
1. The boat may have 2 engines connected to a single Model 32023A battery isolator.
2. The Model 32023A battery isolator is connected to 2 banks of batteries.
3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.
4. The second battery in each bank is connected in parallel to the cranking battery.
5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2 charging
sources, 120 amps (maximum alternator output).
6. When the engines are operating, either engine's alternator could be charging either bank of
batteries through the Model 32023A battery isolator.
Any other manufacturer's battery isolator that is the same type as the Sure Power Inc., Model
32023A could also be used.
Generators: The generator's battery should be considered another engine's battery.
DTS System Installation

! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe
into any wire insulation of the DTS system. Splicing or probing will damage the wire insulation
allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle
and shift control.
SC5000 Data Cable

! WARNING
To avoid the possibility of serious injury or death from loss on boat control, do not pull on cable
connectors when pulling cable into boat. Observe correct pulling procedure. Pulling on
connectors can loosen terminals resulting in open or poor electrical connections. Open or poor
electrical connections may result in loss of throttle and shift control.
IMPORTANT: Do not route cable near engine ignition components (coils, spark plug leads, and
spark plugs). An electrical field generated from these components could cause a problem with
data transmission.
IMPORTANT: Do not route cables near sharp edges, hot surfaces or moving parts. Fasten cables
away from any sharp edge, fastener or object that could wear into the cable.
IMPORTANT: Avoid sharp bends in the cable. Minimum bend radius MUST be 3 inches.
Data Cable Routing ‑ New Installations
1. Inspect the routing path to ensure surfaces are free of any sharp edges or burrs.
2. Route the cable.
7943
3. Fasten the cable to the boat with tie straps or clips.
Page 4 / 41 90-864196050 FEBRUARY 2005

Wiring Diagrams
Instrumentation
SINGLE STATION INSTALLATIONS - TYPICAL
1
8 2
7 3
10
6 5 4
TAN/BLU
PPL
b
BLK
BLK
c BLK
LT
GND d e
SW UNSW
GND GND GND
YEL/RED
12V LT LT LT
BRN/WHT
RED/PPL
LT BLU
GRY
12V 12V
TAN
PPL
12V
2 SEND SEND SEND
1 3
SIG 4
PPL
PPL
PPL
f
PPL
PPL
B
h L GND
S
I T
g
SEND
12V
PPL
i
YEL/RED
PPL PPL
YEL/RED
7865
a- Audio warning alarm f- Ignition switch

b- Tachometer g- Trim indicator (Sterndrive only)
c- Oil pressure h- Read/observe note 1 and 2.
d- Water temperature i- Read/observe note 3.
e- Battery meter j- To engine wiring harness
NOTE: 1 Connect wires together with screw and hex nut; apply Liquid Neoprene to connection
and slide rubber sleeve over connection.
Refer to gauge manufacturer's instructions for specific connections.
NOTE: 2 2 Power for a fused accessory panel may be taken from this connection. Load must not
exceed 40 amps. Panel ground wire must be connected to instrument terminal that has an 8‑gauge
black (ground) harness wire connected to it.
90-864196050 FEBRUARY 2005 Page 5 / 41

NOTE: 33 Lanyard stop switch lead and neutral safety switch leads must be soldered and covered
with shrink tube for a water proof connection. If an alternate method of connection is made, verify
connection is secure and sealed for a water proof connection.
Power Trim System
BLK
RED
BLK
BLU/WHT
GRN/WHT
b
a
RED/PPL
c
BLK
BLU/WHT
RED
BLK
e
RED/PPL GRN/WHT
YEL/RED
YEL/RED
GRN/WHT
PPL/WHT
BLU/WHT
d
g
f
BLU/WHT
h
BLK
BLK
7866
a- 20 amp fuse e - DOWN solenoid

b- Ground bolt (floor mount) f - Y‑harness (optional)
c- UP solenoid g - Neutral switch to instrument wiring
d- 110 amp fuse harness
h - Trim limit switch
Page 6 / 41 90-864196050 FEBRUARY 2005

MerCathode System
a
c
8526
a - Controller c - Electrode
b - 20 amp fuse d - BLACK wire ‑ with engine harness
90-864196050 FEBRUARY 2005 Page 7 / 41

ECM 555 MPI System Engine Wiring Diagrams

TYPICAL STARTING SYSTEM
a RED/PUR
YEL/RED
B c
S
I f
YEL/RED
YEL/RED
RED/PUR
YEL/RED
RED/PUR
RE
D
d
YEL/RED
YEL/
RED
g e
BLK
i
BLK
RED
h
8213
a- Ignition switch f- Wire junction

b- 20 amp fuse g- Neutral safety switch
c- Starter slave solenoid h- 90 amp fuse
d- Circuit breaker i- Engine ground (‑)
e- Starter motor
TYPICAL STARTING SYSTEM (CONTINUED)

This is a general description of the positive current flow from the battery through the starting system
until the starter motor cranks.
Page 8 / 41 90-864196050 FEBRUARY 2005

NOTE: Ensure that all connections are tight and have the required resistance.
• Battery to the solenoid switch on the starter (RED battery cable).
• Solenoid switch to the circuit breaker (RED).
• Circuit breaker to the wire junction (RED/PPL).
• Wire junction to the wiring harness plug Terminal 6 (RED/PPL).
• Wiring harness plug to the 20 amp fuse (RED/PPL).
• 20 amp fuse to the ignition switch Terminal B (RED/PPL). At this point the ignition switch is
turned to the START position.
• Ignition switch Terminal B to Terminal S.
• Ignition switch Terminal C to the neutral start switch (YEL/RED). NEUTRAL START SWITCH
MUST BE AT NEUTRAL POSITION.
• Neutral start switch to the wiring harness plug Terminal 7 (YEL/RED).
• Wiring harness plug to the starter solenoid (small terminal) (YEL/RED). Also, ensure that the
small terminal (BLK) wire is grounded.
• Starter solenoid is now CLOSED, completing circuit between the large terminal (RED/PPL)
and the other large terminal (YEL/RED), causing the starter motor to crank.
90-864196050 FEBRUARY 2005 Page 9 / 41

WAKE, HORN AND TACHOMETER CIRCUITS

b
BLK
GRY/WHT
DK BLU c
1
2 8
10
TAN 3 7 YEL/RED
9
4 6
a d
5
ORN/LT BLU
m RED/PPL e
k
PPL
l f
A B C D E
BRN/DK BLU
K J H G F
j
GRY/WHT
PPL PPL
SPLICE 102
SPLICE 113 g
A h B
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16
17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24
i
7994
GRY/WHT PPL
a- Analog coolant sender h - ECM 555
b- To splice 104 ‑ ground i - Tachometer signal
c- Analog oil pressure sender j - Tachometer connector
d- To slave solenoid k - To analog trim sender
e- To Splice 103 ‑ b+ from 50 amp circuit l - Warning horn circuit
breaker m - 10‑pin harness connector
f - CAN connector
g - To alternator excite
Page 10 / 41 90-864196050 FEBRUARY 2005

CAN, FUEL LEVEL, PADDLE WHEEL AND TEMPERATURE CIRCUIT
b A B C
SPLICE 100
BLK/PNK
BLK/PNK
LT BLU/BLK
A B
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
a 9 10 11 12 13 14 15 16 9 10 11 12 13 14 15 16 c
17 18 19 20 21 22 23 24 17 18 19 20 21 22 23 24
GRY
DK GRN/YEL
LT BLU/ORN
SPLICE 104
GRY/BLK
BLK/PNK
WHT
LT BLU
GRY
BLK
A B C D E
f A B C D d
K J H G F
PPL
7993
SPLICE 102 PPL e
a - ECM 555 d - Paddle wheel/seawater temp
b - Fuel level connector connector
c - ECM 555 e - To 10‑pin connector key switch
f - CAN connector
90-864196050 FEBRUARY 2005 Page 11 / 41

TRANSOM HARNESS
a K J H G F
A B C D E
b
SPLICE 100 g
BLK/PNK
11 12 13 14 15 16
20 21 22 23 24
PNK/DK BLU
8
c
7
6
Splice 101
GRY
5
WHT/LT BLU
ORG/WHT
4
B
d i
17 18 19
3
h
10
2
ORG/LT BLU
9
1
e f
1
11 12 13 14 15 16
2
20 21 22 23 24
8
8
10
7
7
6
3
9
5
A
4 6
4
5
17 18 19
3
10
2
9
1
9307
a- Transom harness connector f - 10‑pin connector

b- ECM g - Steering position
c- 5 volt ground h - Dual trim gauge connection (for use
d- 5 volt power with Smartcraf Instrumentation
e- Analog trim gauge connection systems)
i - Pitot pressure
Page 12 / 41 90-864196050 FEBRUARY 2005

Typical DTS Control System

PANEL MOUNT ERC AND SMARTCRAFT INSTRUMENTATION
NOTE: Refer to the Command Module Installation Kit.
BLK-YEL
BLK
BLK-YEL
BLK
WHITE
BLUE
BLK/ORG
PUR/YEL
GRN/YEL
GRN/ORG
GRN/RED
8010
Shown with panel mount ERC, Smartcraft instrumentation, foot throttle, accessory relay, and start/stop button.
14 Pin Engine Harness Connector

Mechanical 14‑Pin Connector Pin‑Out
Pin Wire Color Function
A PINK + 12 Volt
B BLACK Ground (‑)
C PURPLE Wake
D DK GREEN/YELLOW E‑Stop
E DK BLUE Analog oil pressure
F WHITE CAN 1+
G LT BLUE CAN 1‑
H Open Spare
J Open Spare
K ORANGE/WHITE Analog trim position
L BROWN/DK BLUE Audio warning horn
M GRAY/WHITE Tachometer/Link gauge
N YELLOW/BLACK Crank
P TAN Analog coolant temperature
90-864196050 FEBRUARY 2005 Page 13 / 41

DTS Installation
Special Tools ‑ DTS Installation
Installation Guidelines for DTS System Components

! WARNING
To avoid the possibility of serious injury or death from loss of boat control, do not splice or probe
into any wire insulation of the DTS system. Splicing or probing will damage the wire insulation
allowing water to enter the wiring. Water intrusion may lead to wiring failure and loss of throttle
and shift control.
DATA HARNESS
! WARNING
To avoid the possibility of serious injury or death from loss on boat control, do not pull on cable
connectors when pulling cable into boat. Observe correct pulling procedure. Pulling on
connectors can loosen terminals resulting in open or poor electrical connections. Open or poor
electrical connections may result in loss of throttle and shift control.
CONNECTORS
IMPORTANT: Connectors should never have to be forced into the receptacle. Ensure that
connectors are free of any lubricant or dielectric grease before installation. When the connector
is properly aligned, it will only take a small amount of pressure to insert it into the receptacle. Rotate
the locking collar to secure the electrical connection.
NOTE: Connect only one data harness of the required length between the engine and helm. If a
data harness is too short, do not connect multiple harnesses together to make up the required
length. For installations requiring a data harness length longer than 12.2 m (40 ft.), contact Mercury
Marine for more information.
Weather Caps
Weather caps are to be used whenever there are any unused connectors on a harness. Verify all
connections are tight to prevent moisture or corrosion occurring inside the connections.
Typical weather caps are as follows:
4958
c d
a b
a - 10 pin cap c - 3 pin cap
b - 5 pin cap d - 2 pin cap
NOTE: A complete listing of weather caps with part numbers is not available at the time of the
publication.
Page 14 / 41 90-864196050 FEBRUARY 2005

Battery Harness Information and Installation

DTS Battery Specifications
IMPORTANT: Do not use deep cycle batteries for the main engine starting battery.
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and Coast Guard
regulations must be adhered to when installing the battery. Ensure that battery cable installation
meets the pull test requirements and that positive battery terminal is properly insulated in
accordance with regulations.
IMPORTANT: It is recommended (required in some states) that the battery be installed in an
enclosed case. Refer to regulations for your area.
Minimum SAE Starting Battery Requirements ‑ BCI GRP 24

MCA 1000
CCA 800
Ah 180 (International Rating)
NOTE: Due to the wide variety of battery manufactures throughout the world, ratings and physical
battery sizes will vary. Check with the manufacturer for a starting battery with a MCA, CCA, or Ah
specification that will be equal to or greater than the SAE Standard J537 specified above.
IMPORTANT: For DTS products, each engine must be equipped with its own starting battery. If
your boat application requires additional battery loads for boat accessories or marine electronics,
it is recommended that an auxiliary battery or batteries be installed.
! CAUTION
Hex nuts must be used to secure battery leads to battery posts to avoid loss of electrical power.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts.
Torque nuts to specifications.

Hex nuts 13.5 120
IMPORTANT: Battery cable size and length is critical. Refer to Battery Cable Size tables or engine
installation manual for size requirements.
Decal needs to be placed on or near battery box for future service reference. One 5/16 in. and
one 3/8 in. hex nut are supplied per battery for wing nut replacement. Metric hex nuts are not
supplied.
NOTICE - DTS & Optimax Engines

DO NOT USE DEEP CYCLE BATTERIES!
DTS (Digital Throttle and Shift) applications and
Optimax engines must use a marine starting
battery with 1000 MCA, 800 CCA, or 180 Ah.
rating. 13.5Nm (120 lbs. in.)
DO NOT
USE WING
IMPORTANT: NUTS.
Battery cable size and length is critical. Refer to
engine installation manual for size requirements.
37-895387
Place decal on or near battery box for future service

reference. 5/16" and 3/8" hex nuts supplied for
wing nut replacement. Metric hex nuts not supplied.
3486
90-864196050 FEBRUARY 2005 Page 15 / 41

Data Harness Pulling Procedure

IMPORTANT: Do not route data harness near engine ignition components (coils, spark plug leads,
and spark plugs), high power VHF coax or radios. An electrical field generated from these
components could cause interference with data transmission.
IMPORTANT: Do not route data harness near sharp edges, hot surfaces or moving parts. Fasten
cables away from any sharp edges, fasteners or objects that could wear into the harness.
IMPORTANT: Avoid sharp bends in the data harness. Minimum bend radius should be 7.6 cm
(3 in.) for the final wiring installation.
1. Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could
cut the harness.
2. Install cable pulling tool to data harness.
3. Secure pulling tool with 2 cable ties.
IMPORTANT: The cables ties must be tight to prevent any slipping during installation.
3836
IMPORTANT: Carefully inspect data harness pins to ensure all pins are securely fastened to data
harness connector end following installation.
NOTE: Data harness should be secured with mounting clips or cable ties along the routing path.
Connecting 14 Pin Data Harness ‑ Single Engine

Single Helm
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).
b
a
3619
a - 14 pin data harness b - Clamp or cable tie
Page 16 / 41 90-864196050 FEBRUARY 2005

Dual Helm
e 3682
a - 14 pin data harness d - Dual helm adapter (Y harness)

b - Helm 2 (upper helm) ‑ auxilary e - Clamp or cable tie
c - Helm 1 (lower helm) ‑ primary
Connecting 14 Pin Data Harness ‑ Dual Engine

Single Helm
IMPORTANT: Avoid sharp bends in the harness. Minimum bend radius should be 7.6 cm (3 in.).
b
3977
a - 14 pin data harness b - Clamp or cable tie
90-864196050 FEBRUARY 2005 Page 17 / 41

Dual Helm
e 3978
a - Helm 2 (upper helm) d - Dual helm adapter (Y harness)

b - Helm 1 (lower helm) e - Clamp or cable tie
c - 14 pin data harness
Installing DTS Command Module and Harness ‑ Single Engine

Harness Installation
• Locate a routing path for the harness connections so they reach their installation points.
• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could
cut the harness.
• Fasten and support the harness with clamps or cable ties along the routing path.
Page 18 / 41 90-864196050 FEBRUARY 2005

• Make sure all connections are tight and seal all unused connectors with weather caps.
3622
Single Helm Application

a - DTS command module harness b - Clamp or cable tie
90-864196050 FEBRUARY 2005 Page 19 / 41

NOTE: For dual helm application ‑ Remove CAN 1 and CAN 2 terminator resistors from helm 1
(helm closest to the engine), and seal connectors with weather caps.
a
c
Terminator Terminator
CAN 1 CAN 2
e f
d
g
c
b
3677
Dual Helm Application

a- Helm 2 (upper helm) e- CAN 1 connector
b- Helm 1 (lower helm) f- CAN 2 connector
c- DTS command module harness g- Weather caps
d- Clamp or cable tie h- Terminator resistors, blue (CAN1 &
CAN2)
Module Installation
• Although the Command Module connection is watertight, it is recommended that it be mounted
in an area that stays relatively dry.
• Mount in an area where the wiring connection will not get stepped on or disturbed.
• Mount in an area that is accessible for troubleshooting and servicing the system.
• Ensure the wiring harness connected to the command module will reach all the connection
points.
Page 20 / 41 90-864196050 FEBRUARY 2005

• Mounting the Command Module with the supplied rubber grommets/bushings to minimize
vibration.
3939
a - DTS Command Module
Installing DTS Command Module and Harness ‑ Dual Engine

Harness Installation
• Locate a routing path for the harness connections so they reach their installation points.
• Inspect the routing path to make sure surfaces are free of any sharp edges or burrs that could
cut the harness.
• Fasten and support the harness with clamps or cable ties along the routing path.
90-864196050 FEBRUARY 2005 Page 21 / 41

• Make sure all connections are tight and seal all unused connectors with weather caps.
Terminator
CAN 1
a
Terminator
CAN 2
b
Terminator
CAN 2
Terminator
CAN 1
c
e
d 3689
Single Helm Application

a - CAN link harness d - Clamp or cable tie
b - CAN 2 Terminator resistors ‑ do not e - DTS command module harness
remove
c - CAN 1 connectors
Page 22 / 41 90-864196050 FEBRUARY 2005

NOTE: For dual helm application ‑ Remove CAN 1 and CAN 2 terminator resistors from helm 1
(helm closest to the engine), and seal connectors with weather caps.
b
c
e
d
a 2
d
1
4079
Dual helm application

a - Weather caps d - DTS Command Module harness
b - CAN link harness e - Termination resistors ‑ do not remove
c - Helm 2 from helm 2
f - Helm 1
Module Installation
• Although the Command Module connection is watertight, it is recommended that it be mounted
in an area that stays relatively dry.
90-864196050 FEBRUARY 2005 Page 23 / 41

• Ensure the wiring harness connected to the command module will reach all the connection
points.
4080
a - DTS Command Module
Junction Box (If Equipped)

• Although the junction box connections are watertight, it is recommended that the junction box
be mounted in an area that stays relatively dry.
• Ensure the DTS command module harness will reach all the connection points.
• Fasten all junction box connections within 25.4 cm (10 in.) of the junction box.
• Seal all unused connections with weather caps.
b c
a
d
e
ob01481
a - Clamp d - 25.4 cm (10 in.)

b - Weather cap (859318T 2) e - DTS Command Module harness
c - Junction box
Page 24 / 41 90-864196050 FEBRUARY 2005

Analog Gauge Interface (AGI)

Analog Gauge Interface (AGI) Installation
NOTE: This Analog Gauge Interface (AGI) can only be used with the 14 pin Digital Throttle and
Shift (DTS) system to drive analog and/or SmartCraft System Link gauges. For analog gauges,
use ring terminals on AGI harness to connect to analog sender inputs on gauge backs, and tape
back any unused terminals. For SmartCraft System Link gauges, use 3 pin System Link connection
on AGI harness. The AGI system can support 10 System Link gauges per helm, 2 helms maximum.
IMPORTANT: Mount AGI module with wires coming out of potting facing downward to prevent
moisture from collecting at base of wires and wicking into module. Route and secure all wires and
harnesses away from hot or moving parts.
1. With screws and washers supplied in kit, mount the AGI module securely under dash or helm
in close proximity to gauges being used.
2. Refer to the following table for AGI harness wire color/analog gauge sender input connections.
Tape back any unused terminals. Secure connections per gauge manufacturers
specifications.
Analog Gauge Type AGI Harness Wire Color

Tachometer Gray
Oil Pressure/Oil Level Blue
Water Temperature Tan
Trim Positions Brown/White
Fuel Level Pink/Black
a b c GRY
PNK/BLK
BRN/WHT
TAN
d
BLU
f
e 3688
a - AGI module d - Analog gauge terminal connections

b - 14 pin connection e - System Link 3 pin connection
c - AGI harness f - 10 pin CAN data connection
3. Route and connect wire from key switched 12 volt positive power source to analog gauges.
Secure connections per gauge manufacturers specifications.
4. Route and connect ground wire from analog gauges to a common ground. Secure connections
per gauge manufacturers specifications.
5. Connect any SmartCraft System Link gauges to 3 pin System Link connection. The AGI
system can support 10 System Link gauges per helm, 2 helms maximum.
6. Plug 14 pin AGI harness connection into AGI module.
7. Connect 10 pin CAN data harness connection on command module harness to AGI harness.
a. If SmartCraft System View is not being used, plug 10 pin CAN data connection on AGI
harness directly into 10 pin CAN data connection on command module harness.
b. If SmartCraft System View is being used, a junction box and harness adaptor will be
required. Plug 10 pin CAN data connection on command module harness, 10 pin CAN
data connection on System View harness, and one end of harness adaptor into junction
box. Plug 10 pin CAN data connection on AGI harness into other end of harness adaptor.
Insulate any unused connection ports on junction box with weather caps.
90-864196050 FEBRUARY 2005 Page 25 / 41

TYPICAL AGI APPLICATION WITH SYSTEM VIEW
OFF O
a
N
c
d
e
b
h
GRY
PNK/BLK
BRN/WHT
TAN
BLU
g
3957
a - System View display e - Harness Adaptor

b - 10 pin CAN data connection on f - 10 pin CAN data connection on AGI
System View harness harness
c - SmartCraft Junction Box g - AGI module
d - Weather Cap h - 10 pin CAN data connection on
Command Module harness
Configuring Analog/Digital Tachometer Signal through PCM

IMPORTANT: The engine Propulsion Control Module (PCM) tachometer configuration factory
default has been set to an analog. This will allow the operation of one analog tachometer.
Depending on the desired use of analog/digital gauges, the PCM set‑up may have to be configured
from analog to a digital.
Following are optional uses of analog and digital gauges and the setting for the tachometer
configuration in the PCM necessary to run them.
Gauge Configuration Analog Digital

Analog Tachometer Only X
System Link Gauges used with System View, System Monitor, or System Tach ‑ ‑
System Link Gauges used in conjunction with System Link Adaptor Harness and Command
X
Module Harness without the use of System View, System Monitor or System Tach
Page 26 / 41 90-864196050 FEBRUARY 2005

Gauge Configuration Analog Digital

AGI used with or without System View, System Monitor or System Tachometer, to run
X
analog and System Link Gauges
The Digital Diagnostic Tool (DDT) or Computer Diagnostic System (CDS) can be used to select
analog or digital PCM tachometer configuration.
PCM CONFIGURATION WITH DDT
IMPORTANT: The use of DDT cartridge 1.3.1 or above must be used for PCM configuration.
1. Attach DDT to engine and power up. Refer to DDT Owners Manual if needed.
2. Press 1. "MERCURY MARINE"
3. Press 1. "TO CONTINUE"
4. Press 2. "MANUAL TEST"
5. Arrow down and Press 5. "SPECIAL FUNCTION"
6. Arrow down and Press 9. "TACH LINK CONFIG"
7. "CONFIGURE TACH SOFTWARE DRIVER?" ‑ Press 1. "YES"
8. "TACH LINK CONFIG" ‑ Press 1. "FOR LINK" (Digital) ‑ Press 2. "FOR ANALOG"
9. After task completion confirmation, Press "MODE" to Exit
PCM CONFIGURATION WITH CDS
1. Attach CDS to engine. Refer to on‑line help if needed.
2. From Logon screen, navigate to Engine Select screen.
3. From Engine Select screen fill in engine type information and select Tool Box.
4. From Tool Box screen, select Active Diagnostics.
5. From Active Diagnostics screen, scroll down and select Tach Link Config.
6. To change PCM configuration from default of analog to digital, select Enable and then select
Run.
7. To change PCM configuration from digital to analog, select Disable and then select Run.
90-864196050 FEBRUARY 2005 Page 27 / 41

Typical 14 Pin DTS Wiring Diagrams

DTS Panel Control Wiring
c OFF O
d e
N
a
f
BLK/YEL
b
BLK
BLK/YEL
BLK
WHITE
BLUE
+ -
i
BLK/ORG j
PUR/YEL
GRN/YEL k
GRN/ORG
GRN/RED
r q o
m
p n
5104
a- Remote control j - GPS connection

b- Remote control connections k - Cable adaptor (male to female)
c- Key switch l - Weather caps
d- Start/stop switch (optional) m - Junction box (optional)
e- SmartCraft System View (optional) n - DTS Command Module harness
f- SmartCraft Link Gauge (optional) o - Terminator resistors
g- Display harness p - DTS Command Module
h- Horn q - Accessory power relay (optional)
i- Horn r - Foot throttle (optional)
Page 28 / 41 90-864196050 FEBRUARY 2005

DTS Single Console Control Wiring

d
c OFF O e f
N
BLK/YEL
g
BLK
b
BLK/YEL
BLK
h
WHITE
BLUE
j + -
BLK/ORG
PUR/YEL
k
GRN/YEL l
GRN/ORG
GRN/RED
s r
o
n
q p
5103
a- Remote control k - GPS connection

b- Remote control connections l - Cable adaptor
c- Lanyard stop switch m - Weather caps
d- Key switch n - Junction box (optional)
e- Start/stop switch (optional) o - Terminator resistor
f- SmartCraft System View (optional) p - DTS Command Module harness
g- SmartCraft Link Gauge (optional) q - DTS Command Module
h- Display harness r - Accessory power relay (optional)
i- Horn s - Foot throttle (optional)
j- Horn
90-864196050 FEBRUARY 2005 Page 29 / 41

DTS Single Console Control Wiring with Dual Helm

f g
d
b e
c
n
i
m k j
o l
g
d
p h
q
a
n
i
m j
s
r
u 3588
a- Helm 1 l - Terminator resistors (helm 2 only)

b- Helm 2 m - DTS Command Module
c- Clamps (use as required) n - DTS Command Module harness
d- Remote control o - Data harness
e- Key switch connector not used – seal p - Start/stop switch (optional at helm 1)
with weather cap q - Key switch
f- Start/stop switch (2 required at helm ) r - Accessory power relay
g- Lanyard stop switch s - Terminator resistors not used – seal
h- System View (optional) connectors with weather caps
i- Horn t - Dual helm adaptor harness
j- Foot throttle connector u - Data harness to engine
k- Accessory power relay connector
(optional, not used at second helm)
Page 30 / 41 90-864196050 FEBRUARY 2005

DTS Dual Console Control Wiring

NOTE: Optional foot throttle is not compatible in multiple engine applications.
b d
b
a c
k k
e
h
h
g
+ –
l l
g f
f g
h
h
h
j n n i
12112
a- DTS Control g- Horn

b- Key Switch h- Clamp
c- Lanyard Stop Switch i- To starboard engine
d- System View (optional) j- To port engine
e- Air Temp Sensor k- Connector, Start/Stop Switch
f- Command module (optional)
l - Accessory Power Relay (optional)
90-864196050 FEBRUARY 2005 Page 31 / 41

DTS Dual Console Control Wiring with Dual Helm

NOTE: Optional foot throttle is not compatible in multiple engine applications.
c e
g
d d
f
b
n
d d
i d m d
i
o j k l k j o
p q p g
c f
t r
r o
t
m
o i u
u d i
j d j 3310
v s
a- Helm 1 (primary) l - CAN link harness
b- Helm 2 (auxiliary) m - Horn
c- Remote control n - DTS Command Module harness
d- Connector not used – seal with o - Data harness
weather cap p - Key switch
e- Start/stop switch (required at helm q - Start/stop switch (optional at helm 1)
#2) r - Dual helm adaptor harness
f- Lanyard stop switch s - Data harness to starboard engine
g- System View (optional) t - Accessory power relay
h- Clamps (use as required) u - Remove terminator resistor and seal
i- DTS Command Module with weather cap
j- Junction box connection (optional) v - Data harness to port engine
k- Terminator resistor (required at helm
#2)
Page 32 / 41 90-864196050 FEBRUARY 2005

DTS Zero Effort Control Wiring ‑ Single Engine

a b
BLU/WHT
GRN/WHT
OFF O
N
RED
c
BLK/YEL
BLK
BLU/WHT
GRN/WHT
BLK/YEL
RED
BLK
e
WHITE
BLUE
k
+ -
f d
l
h g
j
i
7731
a- Start/stop switch (optional) g- Weather caps

b- System View (optional) h- Junction box
c- SmartCraft Link gauge i- DTS Command Module
d- GPS Connection j- Accessory power relay (optional)
e- Display harness k- DTS Command Module harness
f- Cable adaptor l- Adaptor
90-864196050 FEBRUARY 2005 Page 33 / 41

DTS Zero Effort Control Wiring ‑ Dual Engine
i f
BLU/WHT
GRN/WHT
RED
a
k k
GRN/WHT
BLU/WHT
RED
WHT
BLU
j
+
b
b d
d
c
e
e
g g
7725
a- System View (optional) g- Terminator resistor
b- Horn h- CAN link harness
c- Junction box connection (optional) i- To port engine
d- Accessory power relay (optional) j- DTS Command Module harness
e- DTS Command Module k- Connector ‑ Start/stop switch
f- To starboard engine (optional)
Page 34 / 41 90-864196050 FEBRUARY 2005

Typical 10 Pin DTS Wiring Diagrams

Switched 12V Accessory Connection
e d
PPL
RED
c
g
a b
+ -
h 11766
a - Accessory power relay e - Power harness with 40 Amp fuse

(84‑888429K01) (84‑889611K02)
b - DTS Command Module harness f - Complete kit (84‑889611K01)
c - Terminal block (86‑889679) g - Fuse
d - Switched 12 volt h - 12 volt battery
90-864196050 FEBRUARY 2005 Page 35 / 41

Single Engine With Panel Control

k g
i m
BLK-YEL
BLK
j
BLK-YEL
BLK
n
f
WHITE
BLUE
n +-
e b
c
h o 11767
d
a
a- DTS Command Module i - Start/stop switch (optional)

b- DTS Command Module harness j - Lanyard stop switch
c- Junction box k - Remote control
d- Termination resistor l - Remote control connector
e- Horn m - System View (optional)
f- Connector ‑ foot throttle n - "D" clamps
g- Key switch o - To engine
h- Accessory power relay (optional)
Page 36 / 41 90-864196050 FEBRUARY 2005

Single Engine with Console Control

g i
m
k
BLK-YEL
j
BLK
BLK-YEL
BLK
l
WHITE
f
BLUE
n +-
e
c
b
h
o
a d 11768

d- Termination resistor l - Remote control connections
f- Connector ‑ foot throttle n - "D" clamps
g- Key switch o - To engine
h- Accessory power relay (optional)
90-864196050 FEBRUARY 2005 Page 37 / 41

Single Engine with Zero Effort Control

g i
k
GRN/WHT
BLU/WHT
RED
OFF
ON
BLK-YEL
BLK
j
l
GRN/WHT
BLU/WHT
RED
BLK-YEL
BLK
e
WHITE
BLUE
b
+-
f
n
o
a d
h 11769

d- Termination resistor l - Remote control connections
f- Zero Effort adaptor n - "D" clamps
g- Key switch o - Not used (seal with weather cap)
h- Accessory power relay (optional) p - To engine
Page 38 / 41 90-864196050 FEBRUARY 2005

Twin Engine with Console Control

k m
q p
j
g g
BLK-WHT
BLK-WHT
BLK-YEL
BLK-YEL
l
i i
BLK-YEL
BLK-YEL
BLK
BLK
n
WHITE
BLUE
+-
b
e e
h f n
q p
d d
c
c a 11770
o
a- DTS Command Module j - Lanyard stop switch
b- DTS Command Module harness k - Remote control
c- Junction box l - Remote control connections
d- Weather cap m - System View (optional)
e- Horn n - "D" clamps
f- Connector ‑ Zero Effort controls o - CAN link harness
g- Key switch p - To starboard engine
h- Accessory power relay (optional) q - To port engine
i- Connector ‑ start/stop switch
(optional)
90-864196050 FEBRUARY 2005 Page 39 / 41

Twin Engine with Zero Effort Control

q p
j m
GRN/WHT
BLU/WHT
g
RED
g
k
BLK-WHT
BLK-WHT
BLK-YEL
BLK-YEL
l GRN/WHT i i
BLU/WHT
RED
BLK-YEL
BLK-YEL
BLK
BLK
n
WHITE
BLUE
n
+-
b
e e
n
f n
h h
q p
d d
c
c a 11771
o
a- DTS Command Module j - Lanyard stop switch
b- DTS Command Module harness k - Remote control connections
c- Junction box l - Not used (seal with weather cap)
d- Weather cap m - System View
e- Horn n - "D" clamps
f- Zero Effort adaptor o - CAN link harness
g- Key switch p - To starboard engine
h- Accessory power relay (optional) q - To port engine
i- Connector ‑ start/stop switch
(optional)
System Wiring Installation Checklist

DATA CABLE
Verify the data harness is not routed near sharp edges, hot surfaces or moving parts.
Page 40 / 41 90-864196050 FEBRUARY 2005

Verify data harness is not routed near ignition components (coils, spark plug leads, and spark
plugs), high power VHF coax or radios.
JUNCTION BOX (IF EQUIPPED)
Verify the data harness is not routed near sharp edges, hot surfaces or moving parts.
Ensure the harness connections are fastened within 25.4 cm (10 in.) of the junction box.
Verify that all unused receptacles are covered with a weather cap.
NON-MERCURY MARINE SUPPLIED IGNITION KEY SWITCH
If a non‑Mercury Marine ignition key is used, verify that it passes the ingress protection testing
per IEC IP66 specification minimum. Ignition switches must pass this specification.
ELECTRONIC REMOTE CONTROL
Ensure Electronic Remote Control (ERC) connections are completed following ERC
installation instructions prior to engine operation.
DTS COMMAND MODULE HARNESS
Verify that all connectors are properly inserted and locked in their receptacle (remote control,
key switch, command module, lanyard stop switch and junction box, if equipped).
Verify that while moving the remote control handle (full forward and full reverse) the harness
has unobstructed movement (moves freely).
Verify that the lanyard stop switch is wired into the system correctly.
Verify that the harness is fastened along the routing path.
Verify that all unused connectors have weather caps to prevent corrosion.
BATTERY
Verify that wing nuts have been replaced with hex nuts, provided.
Verify that all engine battery cables are connected to the correct terminals.
Verify that the DTS power harness leads are connected to the starting battery and secured
with locknuts.
Ensure the 5 Amp fuse for the DTS power harness is accessible.
LANYARD STOP SWITCH
Verify that the switch is installed.
Verify that the switch is connected to the DTS command module harness.
90-864196050 FEBRUARY 2005 Page 41 / 41

SECTION - 8 REMOTE CONTROLS
SECTION 8 - REMOTE CONTROLS

Table of Contents
Remote Control Installation..................................................................................................................................... 4
Locating and Drilling Mounting Area.................................................................................................................4
Installing DTS Panel Mount Control..................................................................................................................5
Installing DTS Single Handle Console Control..................................................................................................7
Installing DTS Dual Handle Console Control..................................................................................................10
Installing DTS Zero Effort Control...................................................................................................................13
Steering System Information................................................................................................................................. 15
High Speed Or Twin Engine Applications Steering Recommendation ...........................................................15
Steering Helm and Cable................................................................................................................................16
Steering Cable Specifications.........................................................................................................................17
Hydraulic (Helm) Steering...............................................................................................................................17
Sterndrive Shift Cable Information........................................................................................................................ 18
Propeller Rotation............................................................................................................................................18
Checking Alpha Shift Cable Installation and Adjustment................................................................................18
Bravo Sterndrive Shift Check (Engine Running).............................................................................................22
Troubleshooting Shift Problems......................................................................................................................23
DTS Remote Control - Sterndrive...................................................................................................................26
DTS Calibration..................................................................................................................................................... 26
Special Tools - DTS Calibration......................................................................................................................26
Methods of Calibration....................................................................................................................................27
System View Display Connection.................................................................................................................... 27
DTS System Reset..........................................................................................................................................27
Calibration Setup.............................................................................................................................................28
Special Instructions for Dual Helm Vessels ............................................................................................. 28
Calibration ................................................................................................................................................ 28
Console Mount and Panel Mount Controls .............................................................................................. 30 8
Console Mount and Panel Mount Controls with Foot Throttle ................................................................. 30
Zero Effort Controls ................................................................................................................................. 30
Zero Effort Controls with Foot Throttle ..................................................................................................... 31
Setting Trailer and Trim Limit................................................................................................................................ 31
Setting Trailer Limit with DDT.......................................................................................................................... 31
Setting Trailer Limit with CDS.........................................................................................................................32
Setting Trim Limit with DDT............................................................................................................................. 32
Setting Trim Limit with CDS............................................................................................................................33
Troubleshooting Procedure................................................................................................................................... 33
Troubleshooting Information............................................................................................................................33
Default Sensor Values ............................................................................................................................. 33
Fault Conditions ....................................................................................................................................... 33
Sticky/Non-Sticky Faults .......................................................................................................................... 34
Engine Guardian ...................................................................................................................................... 34
Warning Horn Signals .............................................................................................................................. 34
Special Tools - DTS Troubleshooting.............................................................................................................. 34
90-864196050 FEBRUARY 2005 Page 1 / 35

REMOTE CONTROLS SECTION - 8

95 2-4-C Marine Lubricant with Teflon Shift cable end 92-802859A1
Special Tools
Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1
Blocks off the front water inlet holes on the dual water inlet
gearcases.
9194
Flushing Device 91‑44357Q 2
Attaches to the water intakes; provides a fresh water

connection when flushing the cooling system or operating the
engine.
9192
Flushing Kit 91‑849996T 1
Use for flushing gearcases with low water inlets.
9195
Male to Male 10 Pin Adapter 84‑892452A01
Allows connection between CAN 1 communications cable

and Computer Diagnostic System in applications where a
4621 junction box is not used.
Can 1 Diagnostic Cable 84‑892663
Connects into a junction box or male to male adapter cable

for Command Module configuration. Not for use with DDT.
4680
Adapter Harness 84‑822560A13
Data link harness between engine and Computer Diagnostic

System (CDS) or Digital Diagnostic Terminal (DDT).
5826
Page 2 / 35 90-864196050 FEBRUARY 2005

Computer Diagnostic System (CDS) Order through SPX

Monitors all electrical systems for proper function,
diagnostics. and calibration purposes. For additional
information, pricing, or to order the Computer Diagnostic
System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA ‑ 1‑800‑345‑2233
4520
Canada ‑ 800‑345‑2233
Europe ‑ 49 6182 959 149
Australia ‑ (03) 9544‑6222
Breakout Box SPX P/N MM‑46225
Connects to Propulsion Control Module (PCM) to test engine

circuits and components without probing wires. May be used
with Computer Diagnostic System (CDS).
5974
Terminal Test Probe Kit SPX P/N MM‑46523
Test probes adapt test meter leads to harness connections

without damaging harness terminals. May be used with
Computer Diagnostic System (CDS).
7915
DDT Cartridge v1.3 91‑880118A03
Contains a diagnostic program for the PCM, allowing

technicians to access all diagnostic capabilities available
through the engine's PCM. Used with Digital Diagnostic
SYSTEMS DIAGNOSTICS
4013 Terminal.
Contains a diagnostic program for the PCM, allowing

technicians to access all diagnostic capabilities available
through the engine's PCM. Used with Digital Diagnostic
SYSTEMS DIAGNOSTICS
4013 Terminal.
Digital Diagnostic Terminal (DDT) 91‑823686A2
Displays problem codes. Also monitors various sensors,

DIGITAL
DIAGNOSTIC
circuits, and components. Performs self‑test procedures on
select engine electrical systems. Cartridges and harnesses to
TERMINAL
use on the engines are sold separately.

4011
90-864196050 FEBRUARY 2005 Page 3 / 35

12 Volt Shunt Connector Part number currently not available for this printing
Connects to data harness allowing operation of the DTS

system with the Digital Diagnostic Terminal.
8036
Data link harness between engine and Digital Diagnostic

Terminal (DDT).
4009
2 to 4 Pin Harness Adapter 84‑822560A12
Adapts the 2 pin Digital Diagnostic Terminal harness to the 4

pin connector on the engine.
4679
DMT 2004 Digital Multimeter 91‑892647A01
Measures RPM, ohms, amperes, AC and DC voltages;

records maximums and minimums simultaneously, and
H z TEMP
mA
A
V Hz
accurately reads in high RFI environments.

mV IG
OFF IP
TEMP
A mA COM V Hz
4516
DDT Diagnostic Reference Manual 90‑881204003
Technician Reference Manual
Lists procedures, specifications and sensor outputs that can

be monitored by using the Digital Diagnostic Terminal.
Digital
Diagnostic
Terminal
Software Version 1.3
SmartCraft Systems
Printed in U.S.A. 90-881204003 603
6160
Remote Control Installation

Locating and Drilling Mounting Area
1. Locate area of boat where the remote control is to be mounted. Allow sufficient clearance for
handle movement and clearance for the wiring.
2. Select the correct template for mounting application.
3. Place template over mounting area; cut and drill as instructed on template.
Page 4 / 35 90-864196050 FEBRUARY 2005

IMPORTANT: After cutting mounting area, make sure opening is free of sharp edges.
3600
a - Template
Installing DTS Panel Mount Control

1. Ensure opening is free of sharp edges.
2. Route wiring for the remote control into opening.
ob00040
3. Connect trim harness and lever harness.

4. Insert the bayonet end into bracket hole. This will prevent connector from pulling out.
90-864196050 FEBRUARY 2005 Page 5 / 35

IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle
movement.
5086
a - Trim harness b - Lever harness
5. Place the remote control into the opening.
3250
6. Fasten the remote control with three #12 x 1.25 in. long screws.
3251
a - Mounting screw (3)
7. Control Handle Tension Adjustment – Screw can be adjusted to increase or decrease the
overall effort to move the control handle. This will help prevent the handle from unwanted
motion in rough water. Turn screw towards "+" to increase tension or towards "–" to decrease
tension.
Page 6 / 35 90-864196050 FEBRUARY 2005

8. Detent Tension Adjustment Screw – This screw can be adjusted to increase or decrease the
effort to move control handle into or out of detent position. Turn screw towards "+" to increase
tension or towards "–" to decrease tension.
b a
3252
a - Control handle tension adjustment screw

b - Detent tension adjustment screw
9. Install front and back bezel covers with attaching screws.
b
a
3254
a - Front cover c - Screw ‑ (2) M4 x 12

b - Back cover
Installing DTS Single Handle Console Control

3509
3. Connect trim, lever and trackpad harnesses.

4. Insert the bayonet end of the lever harness into bracket hole. This will prevent connector from
pulling out.
90-864196050 FEBRUARY 2005 Page 7 / 35

IMPORTANT: Allow slack in the trim harness. Harness will flex and move during control handle
movement.
b
c
5098
a - Trim harness c - Trackpad harness

b - Lever harness
3296
Page 8 / 35 90-864196050 FEBRUARY 2005

6. Fasten the remote control with four M6 x 40 long screws.
b
c 3297
a - Mounting screw (4) M6 x 40 c - Nut ‑ nylon insert

b - Washer
! CAUTION
Do not turn control handle tension adjustment screw clockwise more than 11 turns from the initial
point of hex head contact with bracket. Damage to the module may occur.
! CAUTION
Do not turn detent adjusting screw clockwise more than 11 turns from full out position. Damage
to the module may occur.
7. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase or
decrease the overall effort to move the control handle. This will help prevent the handle from
unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–"
to decrease tension.
a b
5102
a - Detent tension adjustment b - Control handle tension adjustment
90-864196050 FEBRUARY 2005 Page 9 / 35

9. Install the side cover with attaching screws.
3298
a - Side cover (2) b - Attaching screws (4) M4 x 20
Installing DTS Dual Handle Console Control

1. Make sure opening is free of sharp edges.
3606
3. Insert the bayonet ends into bracket holes. This will prevent connectors from pulling out.
Page 10 / 35 90-864196050 FEBRUARY 2005

IMPORTANT: Allow slack in the trim button harness going to the control handle. This harness will
flex and move during control handle movement.
c d
e f
a
3305
a - Bayonet ends d - Yellow paint dot

b - Trim button harness e - Starboard engine
c - Blue paint dot f - Port engine
90-864196050 FEBRUARY 2005 Page 11 / 35

3306
5. Fasten the remote control with four M6 x 40 screws.
b
c
3307
a - Mounting Screw (4) M6 x 40 c - Nut ‑ nylon insert

b - Washer
! CAUTION
Do not turn control handle tension adjustment screw clockwise more than 11 turns from the initial
point of hex head contact with bracket. Damage to the module may occur.
! CAUTION
Do not turn detent adjusting screw clockwise more than 11 turns from full out position. Damage
to the module may occur.
6. Control Handle Tension Adjustment Screw – This screw can be adjusted to increase or
decrease the overall effort to move the control handle. This will help prevent the handle from
unwanted motion in rough water. Turn screw towards "+" to increase tension or towards "–"
to decrease tension.
Page 12 / 35 90-864196050 FEBRUARY 2005

a b
5102
a - Detent tension adjustment b - Control handle tension adjustment
8. Install the side cover with attaching screws.
3308
a - Side cover (2) b - Attaching screws (4) M4 x 20
Installing DTS Zero Effort Control

90-864196050 FEBRUARY 2005 Page 13 / 35

3. Connect trim, lever and adaptor harnesses.
B LU/W HT
G RN/W HT
c
R ED
d
a
e
B LU/W HT
G RN/WHT
R ED
LEVER 1
f
5181
a - Throttle adaptor harness d - Trackpad ‑ not used

b - Remote control e - Lever 1 harness (blue)
c - Trim harness f - Trim adaptor harness
4. Ensure the control is positioned so the forward‑neutral‑reverse (F‑N‑R) decal is in the correct
orientation.
a b
c
5184
a b b c
c a
d d
5182
Forward Cant Models Aft Cant Models

a - Reverse c - Forward
b - Neutral d - F‑N‑R decal location
Page 14 / 35 90-864196050 FEBRUARY 2005

5. Ensure the control is position so the forward‑neutral‑reverse ("F‑N‑R") decal is in the correct
orientation.
d
d
c
a c
a
b b
4749
a - Throttle lever c - Shift lever
b - Trim switch d - "F‑N‑R" label
! CAUTION
To avoid possible corrosion damage, always install nylon washer between each screw and the
control quadrant plate. Improper installation may result in chipped paint, triggering corrosion.
6. Secure control to the console using the 8 X 1‑1/4 in. self tapping screws and nylon washers.
b
c
d
5192
a - 8 X 1‑1/4 in. self tapping screw (4) c - Control quadrant assembly

b - Nylon washer (4) d - Console
Steering System Information

High Speed Or Twin Engine Applications Steering Recommendation
Mercury MerCruiser power packages come standard with Mercury MerCruiser's internal power
steering. This durable system provides precise effortless steering control and is recommended for
most sport boat applications. On certain applications, however, Mercury MerCruiser recommends
the use of an external power steering system where the power steering cylinders connect directly
to the sterndrive unit on the outside of the boat. This arrangement gives additional support for even
tighter, more firm steering control, and is recommended for the following applications:
• High speed single or twin engine applications and/or boats with unusual handling
characteristics.
90-864196050 FEBRUARY 2005 Page 15 / 35

NOTE: It is virtually impossible to give a specific recommendation as to when external power

steering should be used, as this varies from boat design to boat design. Mercury MerCruiser
recommends using external power steering on boats which operate in excess of 70 mph. There
are boats which operate at 60 mph that would benefit from the use of external power steering.
Because of the many variables involved, the final decision as to whether or not external power
steering is required rests with the boat manufacturer and must be made after a thorough test and
evaluation of each specific boat. If there is any question whether or not external power steering is
necessary, Mercury MerCruiser recommends that it be installed.
• Any Hi‑Performance sport boat powered by three or more engines.
• Offshore boats or other applications where the boat and sterndrive units may come out of the
water occasionally.
External power steering systems are generally either mechanical cable actuated or hydraulic
actuated.
External power steering and hydraulic helm systems can be obtained from the following after
market suppliers:
Latham Marine, Inc.
Ft. Lauderdale, FL 33315
Phone: (305) 462-3055
Fax: (305) 462-3081,
Mayfair Marine Machine
12890 N. W. 30th Avenue
Opalocka, FL 33054
Phone: (305) 681-1815,
Steering Helm and Cable
Transom assembly is shipped with the steering cable guide tube preset for cables with end
dimensions that comply with ABYC standards as outlined in the NMMA certification handbook.
The steering cable coupler nut must also have a means of locking it to the guide tube, as specified
in ABYC requirements.
! WARNING
Failure to use a steering cable locking device could cause loss of steering, which could cause
damage to the boat and/or injury.
NOTE: All current production Quicksilver RideGuide steering cables have a self‑locking coupler
nut and do not require an external locking device. (Other cable manufacturers also make cables
with self‑locking coupler nuts.)
7255
a - Quicksilver RideGuide steering cable self‑locking coupler nut (identified by groove)
IMPORTANT: If using a steering cable that does not have a self‑locking coupler nut, an external
locking device such as a locking sleeve must be used.
Page 16 / 35 90-864196050 FEBRUARY 2005

! CAUTION
If steering cable with improper dimensions is installed, severe damage to transom assembly
and/or steering system may result.
1. Steering cable must be the correct length, particularly when installed in larger boats.
2. Avoid sharp bends, kinks, or loops in cable.
3. Refer to Steering Cable Specifications for fully extended steering cable and dimensions.
Steering Cable Specifications
IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may
mean a steering cable has been installed that does not have the correct dimensions.
c
a
b d
e g
f
C
L
j
k h
l i
7254
a- Coupler nut ‑ 7/8 ‑ 14 UNF ‑ 28 thread g - 15.9 mm (5/8 in.) maximum diameter
b- 29.8 cm (11‑3/4 in.) minimum end fitting
c- Interface point h - 9.5 mm (3/8 in.)
d- 12.7 mm (1/2 in.) maximum i - 9.8 mm (3/8 in.) diameter through hole
e- 10.7 mm (27/64 in.) minimum flat (chamfered each side)
f- 3.1 mm (7/64 in.) minimum radius j - 34.9 mm (1‑3/8 in.) maximum
k - 15.9 mm (5/8 in.) diameter tube
l - Cable travel: mid‑travel position ‑
42.9 cm (16‑7/8 in.) total travel to
be20.3 cm (8 in.) minimum to 22.8 cm
(9 in.) maximum travel each side of
mid‑travel position ‑ 1.02 cm (4 in.)
minimum to 114 mm (4‑1/2 in.)
maximum
Hydraulic (Helm) Steering

If your power package is equipped with Compact Hydraulic Steering, refer to the Compact
Hydraulic (Helm) Steering Installation Instructions .
90-864196050 FEBRUARY 2005 Page 17 / 35

Sterndrive Shift Cable Information

Propeller Rotation
Propeller rotation for sterndrive can be right hand or left hand rotation as viewed from the aft end
of the propeller.
4802 4747
Right hand rotation Left hand rotation
Checking Alpha Shift Cable Installation and Adjustment

IMPORTANT: Do not use excessive force when holding pressure on the drive unit shift cable.
Gasoline Alpha Models Only: Excessive force would be indicated by movement of the V‑notch of
the actuator lever assembly.
1. Right‑hand (RH) rotation drive unit ‑ Verify remote control travel for FORWARD gear.
a. Place the remote control in FORWARD gear, past detent, into WOT position.
7807
Page 18 / 35 90-864196050 FEBRUARY 2005

2. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating
propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintain
a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all
slack from the cable).
7817
3. Left‑hand (LH) rotation drive unit ‑ Verify remote control travel for FORWARD gear.
a. a. Place the remote control in FORWARD gear, past detent, into WOT position.
7807
4. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotating
propeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a light
pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack
from the cable).
7870
5. Right‑hand (RH) rotation drive unit ‑ Verify remote control travel for REVERSE gear.
90-864196050 FEBRUARY 2005 Page 19 / 35

a. Place the remote control in REVERSE gear, past detent, into WOT position.
7869
6. Place drive unit into gear by pulling out on drive unit shift cable while simultaneously rotating
propeller shaft clockwise until shaft stops to ensure full clutch engagement. Maintain a light
pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack
from the cable).
7870
7. Left‑hand (LH) rotation drive unit ‑ Verify remote control travel for REVERSE gear.
a. Place the remote control in REVERSE gear, past detent, into WOT position.
7869
Page 20 / 35 90-864196050 FEBRUARY 2005

8. Place drive unit into gear by pushing in on drive unit shift cable while simultaneously rotating
propeller shaft counterclockwise until shaft stops to ensure full clutch engagement. Maintain
a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all
slack from the cable).
7817
IMPORTANT: It may be necessary to make additional adjustments if using extra long remote
control shift cable, if there are a lot of bends in the cable, or if the remote control has inadequate
output travel.
9. If drive unit is installed and the package is equipped with a single lever shift/throttle control:
a. Right‑hand (RH) propeller rotation drive unit ‑ Shift remote control into REVERSE gear,
WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutch should
engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable
stud on shift lever and move it up in slot until clutch engages with REVERSE gear.
Retighten stud. Shift remote control several times and stop in REVERSE to recheck shift
cutout switch position. Pin must be centered.
b. Left‑hand (LH) propeller rotation drive unit ‑ Shift remote control into FORWARD gear,
WOT position while simultaneously rotating propeller shaft CLOCKWISE. Clutch should
engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable
stud on shift lever and move it up in slot until clutch engages with FORWARD gear.
Retighten stud. Shift remote control several times and stop in FORWARD to recheck
shift cutout switch position. Pin must be centered.
10. If drive unit is installed and the package is equipped with a two lever remote control with
separate shift and throttle levers:
a. Right‑hand (RH) propeller rotation drive unit ‑ While turning propeller shaft CLOCKWISE,
move remote control shift handle into full REVERSE position. Clutch should engage
before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on
shift lever and move it up in slot until clutch engages with REVERSE gear. Retighten
stud. Shift remote control several times and stop in REVERSE to recheck shift cutout
switch position. Pin must be centered.
90-864196050 FEBRUARY 2005 Page 21 / 35

b. Left‑hand (LH) propeller rotation drive unit ‑ While turning propeller shaft CLOCKWISE,
move remote control shift handle into full FORWARD position. Clutch should engage
before shift lever comes to a stop. If clutch does not engage, loosen adjustable stud on
shift lever and move it up in slot until clutch engages with FORWARD gear. Retighten
stud. Shift remote control several times and stop in FORWARD to recheck shift cutout
switch position. Pin must be centered.
a
b
7871
a - Adjustable stud b - Shift interrupt switch plunger
Bravo Sterndrive Shift Check (Engine Running)

! WARNING
Contact with moving sterndrive components and the propeller can cause personal injury or
death. To avoid possible injury , remove the propeller and ensure that no people or animals are
in the area of the sterndrive.
This test requires sufficient water supply to your engine and sterndrive.
1. Check sterndrive for proper gear shift with boat out of water.
2. Use the sterndrive tilt switch on the remote control handle to lower the sterndrive to DOWN/
IN position. Do not allow the sterndrive skeg to contact the ground.
a
b
4805
Typical single handle remote control shown

a - Drive trim switch b - Drive trailer button
3. Connect a garden water hose between flushing attachment and water source.
Page 22 / 35 90-864196050 FEBRUARY 2005


4. Partially open water source until water continuously leaks out around the flushing device.
! CAUTION
Overheating from insufficient cooling water will cause engine and drive system damage. Ensure
that there is sufficient water always available at water inlet holes during operation.
IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using
a through the hull water inlet need a supply of cooling water available to both the sterndrive and
to the engine during operation.
5. Place remote control handle in NEUTRAL, idle speed position and start engine.
! CAUTION
Engine overheating can cause engine damage. To avoid, observe the water temperature gauge
and ensure that the engine is operating in the normal range.
! CAUTION
Sterndrive not shifting properly can cause engine and sterndrive damage. Contact your
authorized Mercury MerCruiser dealer for proper adjustment.
NOTE: The sterndrive is shifting properly when the sterndrive shifts with minimal effort in and out
of each gear FORWARD, NEUTRAL, and REVERSE, at idle speed position.
NOTE: The operator at the remote control handle should feel a slight detent before and after each
gear. FORWARD‑detent‑NEUTRAL‑detent‑REVERSE
IMPORTANT: The sterndrive is not shifting properly if the sterndrive shifts after the engine throttle
is engaged. Consult your authorized Mercury MerCruiser dealer/representative for proper
adjustment.
6. Move the remote control handle to FORWARD, idle speed position.
7. Check that the sterndrive propeller shaft is turning in the FORWARD direction.
8. Shift the remote control handle to NEUTRAL, idle speed position.
9. Check that the sterndrive propeller shaft is not turning.
10. Shift the remote control handle to REVERSE, idle speed position.
11. Check that the sterndrive propeller shaft is turning in the REVERSE direction.
12. If the sterndrive will not shift:
a. Remove the sterndrive and check for proper shift hook ups.
b. Check that the shift cables are connected
IMPORTANT: Be sure that the shift cables are routed in such a way as to avoid sharp bends and/
or contact with moving parts. DO NOT fasten any items to shift cables.
Troubleshooting Shift Problems
NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting
or chucking/racheting is encountered when shifting into FORWARD gear.
1. When installing the control box in the side panel of the boat, ensure that the cables have
enough clearance to operate. This is necessary because the cables move up and down when
the shift handle is moved. If the control box is mounted too far back toward any fiberglass
structure, the cables will be interfered with; this will cause very hard shifting.
90-864196050 FEBRUARY 2005 Page 23 / 35

NOTE: The control box housing can be rotated in 30 degree increments to improve cable routing.
7873
Proper cable bend
7872
Improper cable bend

2. Ensure that when the shift cable from the control box is led through the side gunnel of the hull,
it does not have any extremely sharp bends in it as this will cause stiff shifting.
IMPORTANT: Remote control cables MUST BE THE CORRECT LENGTH; sharp bends on
too‑short cables result in kinks and too‑long cables require unnecessary bends or loops. Both
conditions place extra stress on the cables.
IMPORTANT: Shift cable/throttle cable lubrication points use 2‑4‑C with Teflon.
3. Before installing the shift cable into the control box, extend the stainless rod eye end of the
cable and lubricate it. Move it back and forth to allow even distribution of the lubricant.
7874
d
a - Remote control end c - Adjusting barrel
b - Engine end d - Lubricating point
Page 24 / 35 90-864196050 FEBRUARY 2005


95 Shift cable end 92-802859A1
Teflon
NOTE: Allow for clearance of cables directly behind panel mount remote control. The 4000 GEN
II Series Panel Mount Remote Control mounting surface must not exceed 25 mm (1 in.) thickness.
Cable radius at any one point must not be less than 305 mm (12 in.).
4000 GEN II Series Panel Mount Remote Control

Mounting surface maximum thickness 25 mm (1 in.)
Minimum cable bend radius at any point 305 mm (12 in.)
4. Do not strap or clamp the control cables to any other cables or rigid structure within 91.4 cm
(3 ft) of the control box.
5. Ensure that the cable is not permanently kinked.
6. Ensure that there is proper clearance for cable movement when the control box is installed in
the side panel. The cables must have room to move up and down when the control handle is
shifted into either FORWARD or REVERSE.
7. Ensure that the engine was not set down on the intermediate shift cable during installation,
as this will crush the inner cable tubing and cause improper and / or stiff shifting.
8. Do not fasten the shift cable with straps or clamps to any other cable within 1.5 m (5 ft) of the
shift plate.
9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners within
1.5 m (5 ft) of the shift plate.
10. Do not overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable
end must be free to rotate on the mounting stud.
NOTE: Lubricate attaching points with engine oil.
Description Where Used Part Number

SAE 30W Engine Oil Shift cable pivot points Obtain Locally
11. Check the intermediate shift cable routing from the transom assembly to the shift plate as
follows:
NOTE: Cable route is the same for through transom and through prop exhaust.
housing.
the transom.
plate on the engine, where it is connected to the anchor points on the shift plate.
90-864196050 FEBRUARY 2005 Page 25 / 35

Following this routing will prevent the engine coupler from damaging the cable.
8995
Through prop exhaust shown

NOTE: NOTE: A final check of the adjustments should be made with the boat in the water and
engine running. If this cannot be done or is not done at your manufacturing facility, arrangement
should be made with the dealer to do this as part of the pre‑delivery inspection
12. Shift effort tools will be available for new installations using certain Quicksilver Gen II Controls.
Refer to 90‑865523 Instruction Sheet for more information.
DTS Remote Control ‑ Sterndrive
IMPORTANT: Boat must be equipped with Mercury electronic remote control. Start in gear
protection is provided by this control system and prevents the engine from starting when the control
is actuated in FORWARD or REVERSE.
T
R
IM
S
C
RO
LL
S
E
LE
CT
F R
RUN
8994
The Digital Throttle and Shift System (DTS) required to operate this engine package provides start,
stop, throttle, shift control, start in gear protection and emergency lanyard stop function. Refer to
the Mercury Precision Parts/Quicksilver Accessories Guide.
The Digital Throttle and Shift system (DTS) works with specialized helm component, command
module kit and electronic remote control. Refer to the Mercury Precision Parts/Quicksilver
Accessories Guide.
DTS Calibration
Special Tools ‑ DTS Calibration
Can 1 Diagnostic Cable 84‑892663
Page 26 / 35 90-864196050 FEBRUARY 2005

Methods of Calibration
NOTE: DTS system calibration must be performed following complete system installation. It must
also be completed after an accessory or replacement part is added to the system that requires
new configuration codes. A DTS system reset must be performed prior to calibration, or if an error
is made during the calibration setup.
• Method 1 ‑ Mercury Marine Computer Diagnostic System (CDS) ‑ Connect the CDS to the
CAN bus circuit and follow the helm configuration setup on the computer diagnostic screen.
• Method 2 ‑ Mercury Marine SmartCraft System View display ‑ If the boat is not equipped with
a System View display, temporarily connect a System View display to the helm harness shown
in the following diagrams. Follow the System View calibration setup instructions for the DTS.
If the DTS system was previously calibrated, perform a DTS system reset to restore the factory
default settings.
System View Display Connection
If the boat is not equipped with a System View display, temporarily connect a System View display
to the DTS command module harness as shown. After calibration, remove System View and
harness, seal harness connections with weather caps.
a b
c OFF
O
N
RUN
OFF
O
N
c
OFF
BLK/WHT
BLK/WHT
BLK/YEL
BLK/YEL
BLK/YEL
BLK/YEL
BLK
BLK
WHT
d
BLU
WHT
BLU
d
e
f
h g
f
i
5003
a- Single engine connection f- 14 pin data harness from engine
b- Dual engine connection g- DTS Command Module harness
c- System View h- Weather caps
d- Display harness i- Junction box
e- Cable adaptor (male to female)
DTS System Reset

The DTS system reset will restore the engine setup and remote control menus to factory default
settings. DTS reset must be completed prior to system calibration, after an error is made during
the calibration setup, or an accessory has been added or replaced.
NOTE: If the boat does not have a System View installed, temporarily connect a System View to
the DTS command module harness.
90-864196050 FEBRUARY 2005 Page 27 / 35

1. Use the trackpad on the System View and highlight the "SETTINGS" directory on the home
screen.
2. Press and hold in the bottom arrow on the trackpad for 10 seconds. Continue holding after 10
seconds then press in the top arrow. This will bring up the warning screen.
3. The warning screen will ask the question "DO YOU WANT TO CONTINUE", Highlight "YES"
and press "SELECT" button to accept. This will bring up the reset screen.
4. Use the trackpad and highlight "RESTORE VESSEL CONFIGURATION TO FACTORY
DEFAULTS" selection on the reset screen. Press "SELECT" button to accept. The reset
screen will ask the question "ARE YOU SURE YOU WANT TO RESTORE VESSEL
CONFIGURATION TO FACTORY DEFAULTS". Highlight "YES" and press "SELECT" button
to accept.
5. DTS system reset is complete. The engine setup and remote control menus have been
restored back to the factory defaults.
Calibration Setup
SPECIAL INSTRUCTIONS FOR DUAL HELM VESSELS
• Perform the calibration setup at each helm using the System View. After setup is complete at
one helm, repeat setup on the second helm.
• If only one System View is installed in the vessel, the System View must be temporarily
connected to the second helm. An extra System View can temporarily be connected at the
second helm. This will eliminate the need to move the System View between helms.
• If one System View is used between helms for calibration setup, a DTS system reset will have
to be performed each time it is moved to a different helm. Refer to DTS System Reset
procedure.
• Calibration can be started at either helm. However, if one System View is being used, it is best
to start at helm 2 (helm with the start/stop switch) and then move to helm 1.
• Calibration setup requires remote control lever movement at both helms.
NOTE: Helm 1 is always the helm with the ignition key switch. Helm 2 has the start/stop switch.
CALIBRATION
NOTE: The following calibration procedure is for using method 2, using a System View display
screen. If method 1, using a Mercury Marine Computer Diagnostic System is used, follow the
on‑screen instructions on the diagnostic computer to calibrate the system.
1. The first screen will ask if the module initialization has been completed on another station.
Select "NO" on single helm vessels and on dual helm vessels if calibration has not yet been
completed on the another helm. Select "YES" on dual helm vessels if calibration has already
been completed on the other helm.
NOTE: If "YES" is selected, module initialization was completed at the other station. Calibration
will advance to step 7.
2. The next screen should read "HOW MANY HELMS AND ENGINES ARE THERE ON THE
VESSEL?" Select the number of helms and engines the vessel has. Use the up and down
arrows to change the number of engines or helms. Use the left or right arrow to change from
the engine to helm selection. After making selections, press "SELECT" button to continue.
3. The next screen should read, "PLEASE MOVE ALL LEVERS ON ALL HELMS TO NEUTRAL
IDLE". Press "SELECT" to continue.
NOTE: On dual helm vessels, helm identified as 1 is the helm with the ignition key switch. Helm
identified as 2 is the helm with the start/stop switch. On dual engine installations, engine identified
as 1 is the starboard engine, engine identified as 2 is the port engine.
4. The next screen should read, "PLEASE MOVE LEVER FOR HELM 1 ENGINE 1 TO
REVERSE MAXIMUM". Press "SELECT" button when completed to continue.
5. The next screen should read, "HELM MODULE INITIALIZATION IS COMPLETE". Press
"SELECT" button to continue calibration.
Page 28 / 35 90-864196050 FEBRUARY 2005

6. The next screen should read, "ASSIGN STATION IDENTIFICATION FOR THIS SYSTEM
VIEW". Assign "1" for System View connected at helm 1. When applicable, assign "2" for
System View connected at helm 2. Press "SELECT" button to continue.
7. The next screen should read, "SELECT THE ENGINE CONFIGURATION THE SYSTEM
VIEW IS CONNECTED TO". Press "SELECT" button to continue.
a
b
a
c
b
a
c
d
b
5290
a - Engine 1 starboard "STBD" c - Engine 1 starboard 2 "STBD 2"

b - Engine 2 port "PORT" d - Engine 2 port 2 "PORT 2"
8. The next screen should read, "IS THIS AN ELECTRONIC THROTTLE AND SHIFT SYSTEM".
Select "YES". Press "SELECT" button to continue.
9. The next screen should read, "DO YOU HAVE FOOT THROTTLE INSTALLED?" (single
engines only). Press "SELECT" button to continue.
90-864196050 FEBRUARY 2005 Page 29 / 35

IMPORTANT: All Verado engines shift as a standard rotation, right hand. All OptiMax and
MerCruiser engines must be selected as either standard rotation or counter rotation.
10. Depending on engine type, propeller rotation screen may be displayed. The screen should
read, select prop shaft rotation for each engine. Consult engine installation manual for details.
"STND/RH" = standard rotation/right hand, "CNTR/LH" = counter rotation/left hand. Press
"SELECT" button to continue.
11. The next screen should read, "HOW MANY HELMS AND ENGINES ARE THERE ON THIS
VESSEL?" Press "SELECT" button to continue.
12. The next screen should read, "PLEASE SELECT FROM THE FOLLOWING CONTROL
TYPES": Select the control type used: 1) "PANEL MOUNT", 2) "CONSOLE MOUNT", 3)
"ZERO EFFORT". Press "SELECT" button when completed to continue.
Calibration procedure will advance to adapting the type of control selected.
CONSOLE MOUNT AND PANEL MOUNT CONTROLS
NOTE: On dual lever console controls, move and position both levers together.
Move the control lever to the selected positions as instructed on the System View display, in order
for the command module to learn all the lever positions.
1. Move control lever to maximum reverse. Press "SELECT" when the lever is in position.
2. Move control lever to reverse detent. Press "SELECT" when lever is in position.
3. Move control lever to neutral. Press "SELECT" when lever is in position.
4. Move control lever to forward detent. Press "SELECT" when lever is in position.
5. Move control lever to maximum forward. Press "SELECT" when lever is in position.
6. Move control lever to neutral. Press "SELECT" when lever is in position.
7. You have successfully completed the adaptation process. Do you accept the results. Select
"YES" and press "SELECT" to accept.
8. Initial calibration is complete. Turn the power off to the System View. Once the unit is turned
off, turn the power back on again for the settings to take effect.
CONSOLE MOUNT AND PANEL MOUNT CONTROLS WITH FOOT THROTTLE
Move the control lever and foot throttle to the selected positions as instructed on the System View
display, in order for the command module to learn all the lever positions.
1. Move control lever to maximum reverse and push foot throttle to WOT. Press "SELECT" when
lever is in position.
2. Move control lever to reverse detent and return foot throttle to idle. Press "SELECT" when
lever is in position.
3. Move control lever to neutral and keep foot throttle at idle. Press "SELECT" when lever is in
position.
4. Move control lever to forward detent and keep foot throttle at idle. Press "SELECT" when lever
is in position.
5. Move control lever to maximum forward position and push foot throttle to WOT. Press
"SELECT" when lever is in position.
6. Move control lever to neutral and return foot throttle to idle. Press "SELECT" when lever is in
position.
7. You have successfully completed the adaptation process. Select "YES" and press "SELECT"
to accept.
ZERO EFFORT CONTROLS
NOTE: On multiple engine applications, move and position levers together.
Move the control levers to the selected positions as instructed on the System View display, in order
for the command module to learn all the lever positions.
Page 30 / 35 90-864196050 FEBRUARY 2005

1. Move shift lever to reverse position and move throttle lever to WOT. Press "SELECT" when
levers are in position.
2. Keep shift lever in reverse and move throttle lever to idle. Press "SELECT" when levers are
in position.
3. Move shift lever to neutral and keep throttle lever at idle. Press "SELECT" when levers are in
position.
4. Move shift lever to forward and keep throttle lever at idle. Press "SELECT" when levers are
in position.
5. Move shift lever to forward and move throttle lever to WOT. Press "SELECT" when levers are
in position.
6. Move shift lever to neutral and move throttle lever to idle. Press "SELECT" when levers are
in position.
to accept.
ZERO EFFORT CONTROLS WITH FOOT THROTTLE
Move the control lever and foot throttle to the selected positions as instructed on the System View
display, in order for the command module to learn all the lever positions.
1. Move shift lever to reverse position and push foot throttle to WOT. Press "SELECT" when
2. Keep shift lever in reverse position and return foot throttle to idle. Press "SELECT" when levers
are in position.
3. Moved shift lever to neutral position and keep foot throttle at idle. Press "SELECT" when levers
are in position.
4. Move shift lever to forward and keep foot throttle at idle. Press "SELECT" when levers are in
position.
5. Move shift lever to forward position and push foot throttle to WOT. Press "SELECT" when
6. Move shift lever to neutral and return foot throttle to idle. Press "SELECT" when levers are in
position.
to accept.
Setting Trailer and Trim Limit

Setting Trailer Limit with DDT
! CAUTION
The trailer limit must be set before setting the trim limit. Failure to set the trailer limit prior to
setting the trim limit, will create a programming error in the engine PCM. The PCM must be
reprogrammed to correct the error. Contact Mercury Marine Technical Service Department for
instruction on reprogramming the PCM.
The function of the trailer limit:

• Outboard ‑ To limit the maximum tilt up position, preventing damage to the cowl.
• MerCruiser ‑ To limit the maximum trailer up position, preventing damage to swim platforms
etc.
NOTE: It the DDT display is blank, the interface and/or adaptor cables are not installed properly.
90-864196050 FEBRUARY 2005 Page 31 / 35

1. Connect the DDT to the DLC/Depth transducer connector on the engine.

2. Power up the DDT by turning the ignition to the ON position. On the "SELECT FUNCTION"
screen, press 2 ‑ "MANUAL TEST".
3. The "SELECT FUNCTION" screen will appear. Press 5 ‑ "SPECIAL FUNCTIONS".
4. The "SELECT FUNCTION" screen will appear. Press 8 ‑ "TRAILER LIMIT".
5. The "TRAILER LIMIT" screen will appear. To set the maximum trailer limit, press 1 ‑ "YES".
6. Trim the engine/drive up to the desired trailer position. To "CONTINUE" press 1 "YES".
7. The maximum trailer limit setting is stored in the PCM. To "CONTINUE" press 1 "YES".
8. Turn key off for 10 seconds, then back to run, for the PCM to accept the new limit. Press
"MODE" to exit the trailer limit calibration.
NOTE: If the trailer limit update failed, press 1 "TO RETRY", or "MODE" to exit.
Setting Trailer Limit with CDS
! CAUTION
The function of the trailer limit:

• Outboard ‑ To limit the maximum tilt up position, preventing damage to the cowl.
• MerCruiser ‑ To limit the maximum trailer up position, preventing damage to swim platforms
etc.
1. Connect the CDS to the engine data link harness.
2. Turn the ignition key to the "RUN" position.
3. Select the correct engine location.
4. Open the Tool Box icon in the CDS.
5. Open the Active Diagnostics Icon.
6. Scroll down the Active Diagnostics window and highlight "Trailer Limit".
7. Run the trim system completely in (down) and hold the trim button in for 3‑4 seconds. This will
configure the PCM to recognize the maximum trim in position according to the trim position
sensor.
8. Run the test.
9. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to
store the current position in the ECU."
10. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.
Setting Trim Limit with DDT
! CAUTION
The trim limit configures the PCM to control the maximum up trim limit. The trim limit function is
only supported if the PCM has input for the three wire trim sensor.
1. Power up the DDT by turning the ignition to the ON position. On the "SELECT FUNCTION"
screen, press 2 ‑ "MANUAL TEST".
2. Connect the DDT to the DLC/Depth transducer connector on the engine.
Page 32 / 35 90-864196050 FEBRUARY 2005

3. The "SELECT FUNCTION" screen will appear. Press 5 ‑ "SPECIAL FUNCTIONS".

4. The "SELECT FUNCTION" screen will appear. Press 7 ‑ "TRIM LIMIT".
5. The "TRIM LIMIT" screen will appear. To set the maximum up trim limit, press 1 ‑ "YES".
6. Trim the engine/drive to the desired trim position. To "CONTINUE" press 1 ‑ "YES".
7. The maximum trim limit setting is stored in the PCM. To "CONTINUE" press 1 "YES".
8. Turn key off for 10 seconds, then back to run, for the PCM to accept the new limit. Press
"MODE" to exit the trailer limit calibration.
If the trim limit update failed, press 1 "TO RETRY", or "MODE" to exit.
Setting Trim Limit with CDS
! CAUTION
IMPORTANT: The engine must be running above 2000 RPM in gear to initiate the trim limit.
The trim limit configures the PCM to control the maximum up trim limit. The trim limit function is
only supported if the PCM has input for the three wire trim sensor.
1. Connect the CDS to the engine data link harness.
2. Turn the ignition key to the "RUN" position.
3. Open the Tool Box icon in the CDS.
4. Open the Active Diagnostics Icon.
5. Scroll down the Active Diagnostics window and highlight "Trim Limit".
6. Run the test.
7. The CDS screen will read "Adjust the engine/outdrive to the desired position. Select OK to
store the current position in the ECU."
8. Turn the ignition key "OFF", then to "RUN" for the PCM to accept new limit.
Troubleshooting Procedure
Troubleshooting Information
NOTE: All of the following are determined by the calibration of the PCM. Upgrading the calibration
can result in changes to these settings.
DEFAULT SENSOR VALUES
Default sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignition
values, when the sensor in question has exceeded its preprogrammed diagnostic limits. Default
sensor values typically are used when the sensor has a circuit high or circuit low fault.
Most temperature sensors default to 0 °C (32 °F). This can be verified by unplugging the sensor
in question and watching the data stream value with the CDS or the DDT.
Most pressure sensors default to a preprogrammed number also. MAP sensors usually default to
100 kPa (29.5 in. Hg). This can be verified by unplugging the sensor in question and watching the
data stream value. Other pressure sensors will have their own default values which may be
determined as described previously.
FAULT CONDITIONS
Most faults can be detected with the engine running, or key‑on, engine off. However, some faults
require the presence of engine RPM, and cannot be detected key‑on, engine off. Examples of this
type of fault are EST (cylinders 1 through 8) shorted circuit and all injector faults (fuel and direct).
Some faults are only detected in the key‑on, engine off mode. Examples of the type of fault would
be EST (cylinders 1 through 8) open circuit.
90-864196050 FEBRUARY 2005 Page 33 / 35

In addition, some faults are programmed to ignore certain engine speeds. For example, the low
block pressure sensor fault (sea pump pressure on a MerCruiser) is typically not enabled until
enough RPM has been achieved to develop a reasonable amount of water pressure. Therefore,
this fault will not be set at idle.
Faults also take a certain time to set. The time it takes to set a fault varies greatly and can also
vary with engine RPM. Faults generally set faster at higher engine speed.
STICKY/NON-STICKY FAULTS
All faults are classified as either sticky or non‑sticky. Sticky means that the fault, once set, will
continue to show up as active, even in the circuit or problem has corrected itself. A key switch
cycle is required to reset a sticky fault.
A non‑sticky fault is a fault that will change it's status from active to inactive without requiring a
key switch cycle.
The diagnostic tools (CDS or DDT) will continue to display a sticky fault as active, even though
the cause of the fault has been corrected. Cycle the key to reset all faults if there is difficulty
correcting a fault.
ENGINE GUARDIAN
Almost every fault will cause the guardian program (within the PCM) to become active. The amount
of guardian protection is expressed as a percentage. The higher the percentage, the more power
the engine is allowed to produce. If available power (on the CDS or DDT) is showing 100%, then
guardian is not currently active and the engine is capable of producing full power. On a DTS engine,
guardian closes the ETC to reduce engine power. Non‑DTS engine reduce engine power by
changing injector and ignition operation.
Guardian is always accompanied by another fault or faults that actually caused the guardian to
become active. The more severe the fault, the more the guardian reduces available power. A small
problem, such as a non‑critical sensor going circuit high or circuit low, will result in available power
of 90% depending on product line. A severe problem such as low oil pressure, or a DTS shift or
throttle actuator failing, will result in forced idle which is usually displayed as 5‑6% available power.
Several minor faults occurring at the same time will cause the PCM to treat the faults as a more
severe situation.
WARNING HORN SIGNALS
Most faults will cause the warning horn circuit to activate. How the warning horn activates depends
on how serious the problem is. There are four warning horn states:
• Caution ‑ horn signal varies with product line and calibration. Minimal guardian.
• Warning ‑ horn signal varies with product line and calibration.
• Severe ‑ horn is beeping constantly.
• Critical ‑ horn is beeping constantly and guardian will be at forced idle.
In addition, depending on the gauge package, there will be warning icons and fault messages on
the dash mounted gauges.
Special Tools ‑ DTS Troubleshooting
Breakout Box SPX P/N MM‑46225
Terminal Test Probe Kit SPX P/N MM‑46523
Digital Diagnostic Terminal (DDT) 91‑823686A2
Page 34 / 35 90-864196050 FEBRUARY 2005

12 Volt Shunt Connector Part number currently not available for this printing
2 to 4 Pin Harness Adapter 84‑822560A12
DMT 2004 Digital Multimeter 91‑892647A01
DDT Diagnostic Reference Manual 90‑881204003
90-864196050 FEBRUARY 2005 Page 35 / 35

SECTION - 9 PREDELIVERY PREPARATION AND STORAGE
SECTION 9 - PREDELIVERY PREPARATION AND

STORAGE
Table of Contents
Predelivery Preparation........................................................................................................................................... 3
Engine Oil..........................................................................................................................................................4
Checking .................................................................................................................................................... 4
Adding Engine Oil ...................................................................................................................................... 4
Power Steering Fluid.........................................................................................................................................4
Power Trim Pump.............................................................................................................................................. 5
Drive unit gear lube monitor..............................................................................................................................6
Filling Coolant Recovery Bottle ........................................................................................................................7
Alpha Trim Limit Switch Adjustment..................................................................................................................7
Analog Guages .......................................................................................................................................... 7
Bravo Trim Limit Switch Adjustment - Analog Gauges ..................................................................................... 8
Trim Position Sender Adjustment - Analog Gauges........................................................................................10
Trim Position Sender Adjustment - SmartCraft Gauges Scan Tool Method...................................................11
Trim Position Sender Adjustment - SmartCraft Gauges Multimeter Method...................................................12
Propeller Selection..........................................................................................................................................12
Alpha Sterndrive Propeller Installation ...........................................................................................................13
Alpha Models ........................................................................................................................................... 13
Bravo Sterndrive Propeller Installation............................................................................................................14
Bravo One Models ................................................................................................................................... 14
Bravo Two Models ................................................................................................................................... 15
Bravo Three ............................................................................................................................................. 16
Battery Connection..........................................................................................................................................17
Priming The Fuel System................................................................................................................................17
Test Running Engine ......................................................................................................................................18
Boat Out Of the Water ............................................................................................................................. 18
Boat In the Water ..................................................................................................................................... 18
Testing Preparation ................................................................................................................................. 18
Testing .................................................................................................................................................... 19 9
Boat In The Water Tests.................................................................................................................................20
Engine Idle Speed ................................................................................................................................... 20
Wide Open Throttle Test .......................................................................................................................... 20
Checking Shift Operation ......................................................................................................................... 20
Cold Weather and Extended Storage.................................................................................................................... 21
Cold Weather or Extended Storage ...............................................................................................................21
Seawater Section............................................................................................................................................21
Closed Cooling Section...................................................................................................................................21
Preparing Power Package For Storage........................................................................................................... 21
Fuel System ............................................................................................................................................. 22
Battery ..................................................................................................................................................... 23
Draining Instructions.............................................................................................................................................. 23
Identification....................................................................................................................................................23
Manual Single Point Drain System .......................................................................................................... 23
Air Actuated Single Point Drain System .................................................................................................. 24
3 Point Manual Drain System .................................................................................................................. 24
Multi-Point Drain (MPD) System .............................................................................................................. 25
Boat In Water..................................................................................................................................................25
Air Actuated Single Point Drain System .................................................................................................. 26
Boat Out Of The Water....................................................................................................................................30
90-864196050 FEBRUARY 2005 Page 1 / 37

PREDELIVERY PREPARATION AND STORAGE SECTION - 9

Air Actuated Single Point Drain System ................................................................................................. 31
Multi-Point Drain (MPD) System .............................................................................................................. 33
Power Package Recommissioning..................................................................................................................35
Predelivery Inspection.....................................................................................................................................37
Page 2 / 37 90-864196050 FEBRUARY 2005


34 Special Lubricant 101 Propeller shaft splines 92-802865A1
80 SAE Engine Oil 30W Power trim pump Obtain Locally
87 High Performance Gear Lubricant Gear Lube Monitor 92-802854A1
94 Anti-Corrosion Grease Propeller shaft splines 92-802867A1
95 2-4-C Marine Lubricant with Teflon Propeller shaft splines 92-802859A1

Power steering pump
114 Power Trim and Steering Fluid 92-802880A1
Power trim pump
115 Premium Plus 2-cycle TC-W3 Outboard Oil Fuel system 92-802824A1
124 Fuel System Treatment & Stabilizer Fuel system 802875A1
Special Tools
Blocks off the front water inlet holes on the dual water inlet
gearcases.
9194
Attaches to the water intakes; provides a fresh water

connection when flushing the cooling system or operating the
engine.
9192
Use for flushing gearcases with low water inlets.
9195
Predelivery Preparation
Once the power package installation is complete, the following final steps should be taken to
prepare power package for delivery to the customer. It is the boat manufacturer's responsibility to
perform these procedures or to make arrangement with the dealer to have these procedures
completed.
90-864196050 FEBRUARY 2005 Page 3 / 37

Engine Oil
! CAUTION
ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by
law. Do not spill oil or oil waste into the environment when using or servicing your boat. Contain
and dispose of oil or oil waste as defined by local authorities.
CHECKING
1. Stop the engine. Allow approximately 5 minutes for the oil to drain into the oil pan. The boat
must be at rest in the water.
2. Remove the dipstick. Wipe clean and reinstall fully into the dipstick tube. Wait 60 seconds to
allow trapped air to vent.
NOTE: Ensure that dipstick is installed with oil level indication marks facing the rear of the engine
(flywheel end).
IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK
range mark on the dipstick.
3. Remove the dipstick and observe the oil level. Oil level must be between full or OK range and
add. Fill as necessary with specified fluid.
NOTE: Adding 0.95 liters (1 quart) of engine oil will raise the level from the ADD mark to the top
of the OK range.
ADDING ENGINE OIL
IMPORTANT: Do not overfill the engine with oil.
1. Remove oil fill cap.
6077
a - Oil fill cap
IMPORTANT: Add the specified engine oil to bring the level up to, but not over, the full or OK
range mark on the dipstick.
2. Add the specified engine oil to bring the level up to, but not over, the full or OK range mark on
the dipstick.
3. Replace the fill cap.
Power Steering Fluid
IMPORTANT: Use only specified lubricant.
Page 4 / 37 90-864196050 FEBRUARY 2005

! CAUTION
Do not RUN POWER STEERING DRY or pump will be damaged.
1. Position sterndrive unit so that it is straight back.

2. Remove fill cap from power steering pump and check fluid level using dipstick. Add fluid as
required.
NOTE: Be prepared to add fluid to pump when first starting engine.
a b
9356
a - Fill cap b - Dipstick

114 Power Trim and Steering Fluid Power steering pump 92-802880A1
Description Where used Part Number

Dexron III ‑ Automatic
Power steering pump Obtain locally
Transmission Fluid
Power Trim Pump

1. Check oil level with sterndrive unit in the full DOWN/IN position.
IMPORTANT: Use only specified lubricant.
90-864196050 FEBRUARY 2005 Page 5 / 37

2. Raise and lower sterndrive unit (to the full UP/OUT position) 6 to 10 times to purge air from
system. Check oil level visually, (with drive unit in the full DOWN/IN position). Oil level should
be maintained within the "MIN" and "MAX" lines on the reservoir.
a b
c
8539
a - Fill cap (top and underneath side c - "MIN" and "MAX" lines
views)
b - Reservoir fill neck

114 Power Trim and Steering Fluid Power trim pump 92-802880A1

80 SAE Engine Oil 30W Power trim pump Obtain Locally
3. Check the power trim pump hose fittings for leaks. If fluid is visible at the fittings, check
connections.
Drive unit gear lube monitor
IMPORTANT: Oil level in gear lube monitor will rise and fall during drive operation; always check
oil level when drive is cool and engine is shut down.
1. Remove the gear lube monitor cap.
2. Fill the gear lube monitor to the Operating Range (full) line.
7884
Typical
a - Gear lube monitor cap b - Operating Range (full) line

Lubricant
Page 6 / 37 90-864196050 FEBRUARY 2005

3. Ensure that the rubber gasket is inside the gear lube monitor cap.
4. Install the gear lube monitor cap. Do not overtighten.
5. Recheck gear lube level after first use.
Filling Coolant Recovery Bottle
NOTE: This section applies to Closed Cooled models only.
1. Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution.
Reinstall cap.
2. Recheck coolant level after first WOT boat test and add coolant, if necessary.
3. Maintain coolant level in coolant recovery reservoir between ADD and FULL marks with engine
at normal operating temperature.
Alpha Trim Limit Switch Adjustment
ANALOG GUAGES
! WARNING
When adjusting trim limit switch, use extreme care that the engine is not started and keep clear
of the area near the propeller. Use care to prevent placing hands in an area where injury could
occur because of drive unit movement.
! CAUTION
Trim limit switch MUST BE adjusted exactly as outlined. If switch is adjusted incorrectly, drive
unit could move out beyond the gimbal ring support flanges and cause damage to sterndrive unit.
1. Alpha sterndrive, adjust trim limit switch as follows:

NOTE: Trim limit switch is located on the port side of gimbal ring.
a. Loosen screws and turn trim limit switch clockwise to end of slots.
a b
7879
Trim limit switch

a - Screws b - Slots
b. Ensure drive unit is in the full DOWN/IN position.

c. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE
TRAILER BUTTON.
90-864196050 FEBRUARY 2005 Page 7 / 37

d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension
shown.
7880
Trim limit switch

a - Rotate Counterclockwise To Adjust
a
7881
Alpha trim cylinder extended

a - Maximum520 mm (20‑3/4 in.)
e. Retighten screws when adjustment is correct.

Bravo Trim Limit Switch Adjustment ‑ Analog Gauges
! WARNING
When adjusting trim limit switch, use extreme care that the engine is not started and keep clear
of the area near the propeller. Use care to prevent placing hands in an area where injury could
occur because of drive unit movement.
! CAUTION
Trim limit switch MUST BE adjusted exactly as outlined. If switch is adjusted incorrectly, drive
unit could move out beyond the gimbal ring support flanges and cause damage to sterndrive unit.
IMPORTANT: All Bravo models must have the trim‑in‑limit insert positioned properly before
performing the trim position sender adjustment.
Page 8 / 37 90-864196050 FEBRUARY 2005

1. Ensure that the trim‑in‑limit insert is positioned as shown for the appropriate Bravo model.
a a
8548 8557
Bravo One and Two (positioned forward) Bravo Three (positioned aft)
a - Trim‑in‑limit insert
2. Bravo sterndrive, adjust trim limit switch as follows:

NOTE: Trim position sender is located on the starboard side of gimbal ring.
a. Loosen screws and turn trim limit switch clockwise to end of slots.
a b
7879
Trim limit switch

a - Screws b - Slots
b. Ensure drive unit is in the full DOWN/IN position.

c. Using the Trim button on the remote control, trim drive unit UP/OUT. DO NOT USE
TRAILER BUTTON.
90-864196050 FEBRUARY 2005 Page 9 / 37

d. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension
shown.
7880
Trim limit switch

a - Rotate Counterclockwise To Adjust
a
8558
Bravo trim cylinder extended

a - Trim Limit Dimension 21‑3/4 in. (552 mm)
e. Retighten screws when adjustment is correct.

Trim Position Sender Adjustment ‑ Analog Gauges
1. Loosen both trim position sender retaining screws.
b
a
7882
a - Retaining screws b - Trim position sender
! CAUTION
Do not start engine in the following step or damage to sterndrive unit and engine could result
from lack of cooling water.
2. Turn ignition key to RUN position.
3. Trim sterndrive unit to the full DOWN/IN position.
Page 10 / 37 90-864196050 FEBRUARY 2005

4. Rotate trim position sender as required to show full DOWN/IN position on dashboard
instrument as shown.
a
7883
a - Trim gauge needle
5. Tighten retaining screws and turn ignition key to the OFF position.
b
a
7882
Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method

b
a
7882
1. Trim the sterndrive unit to the full DOWN/IN position.

2. Remove the weather cap from the Diagnostic Link connector and connect the DDT Scan Tool.
3. Turn ignition key switch to the RUN position.
4. Set the scan tool to display TRIM POS counts and note the value displayed.
5. TRIM POS counts must be between 20 and 24 counts.
6. If TRIM POS counts are within specified range, proceed to step 6. Otherwise:
a. Loosen both trim position sender retaining screws.
90-864196050 FEBRUARY 2005 Page 11 / 37

b. Rotate the trim position sender until TRIM POS counts are within the specified range,
preferably near the middle of the range.
c. Tighten the trim position sender retaining screws.
d. Verify TRIM POS counts are still within the specified range. Repeat steps "a" through
"c" if necessary.
7. Turn the ignition key switch to the OFF position, disconnect the scan tool from the Diagnostic
Link connector, and install the weather cap in the Diagnostic Link connector.
Trim Position Sender Adjustment ‑ SmartCraft Gauges Multimeter Method
b
a
7882
1. Trim the sterndrive unit to the full DOWN/IN position.

2. Disconnect trim position sender wires from engine wiring harness connections.
3. Connect Multimeter leads to trim position sender wires and set Multimeter to display resistance
(Ohms).
4. Note resistance reading. Resistance must be between 16 and 20 Ohms.
5. If resistance reading is within specified range, proceed to step 6. Otherwise:
a. Loosen both trim position sender retaining screws.
b. Rotate the trim position sender until resistance reading is within the specified range,
preferably near the middle of the range.
c. Tighten the trim position sender retaining screws.
d. Verify resistance reading is still within the specified range. Repeat steps "a" through "c"
if necessary.
6. Disconnect the trim position sender wires from the multimeter leads and reconnect trim
position sender wires to engine wiring harness connections.
7. Refer to Mercury SmartCraft Operator's Manual for final Trim Calibration procedure.
Propeller Selection
IMPORTANT: Installed propeller must allow engine to run at its specified maximum WOT rpm.
Use an accurate service tachometer to verify engine operating rpm.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package
with the correct propeller. Specified engine WOT and operating rpm range are listed in the Mercury
MerCruiser Operation, Maintenance and Warranty Manual attached to the engine.
Select a propeller that will allow the engine power package to operate at or near the top end of
the recommended WOT operating rpm range with a normal load.
If full throttle operation is below the recommended range, the propeller must be changed to prevent
loss of performance and possible engine damage. On the other hand, operating an engine above
the recommended operating rpm range will cause higher than normal wear and/or damage.
After initial propeller selection, the following common problems may require that the propeller be
changed to a lower pitch.
• Warmer weather and greater humidity cause a loss of rpm.
Page 12 / 37 90-864196050 FEBRUARY 2005

• Operating in a higher elevation causes a loss of rpm.

• Operating with increased load (additional passengers, pulling skiers) causes a loss of rpm.
For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do
not operate at full throttle when using the lower pitch propeller but not pulling skiers.
Because of the many variables of boat design, only testing will determine the best propeller for a
particular application. Available propellers are listed in the Mercury Precision Parts Accessories
Guide.
See BOAT IN THE WATER TESTS, Maximum RPM Test at the back of this manual.
Alpha Sterndrive Propeller Installation
! WARNING
Ensure that remote control is in NEUTRAL position and ignition key is removed from switch prior
to installing propeller.
! WARNING
Place a block of wood between the anti‑ventilation plate and propeller to protect hands from
propeller blades and to prevent propeller from turning when tightening propeller nut.
7885
1. To aid in future removal of the propeller, liberally coat propeller shaft splines with lubricant.

IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed through
propeller nut after torquing it.
ALPHA MODELS
1. Install propeller with attaching hardware as shown.
2. Torque the nut, then continue to tighten until 3 tabs on the tab washer align with grooves on
spline washer.
90-864196050 FEBRUARY 2005 Page 13 / 37

3. Bend the 3 tabs down into grooves.
e
f
a
b
c
g 5301
a- Propeller shaft splines e - Drive sleeve adapter

b- Forward thrust hub f - Locking tab washer
c- Flo‑torque II drive hub g - Propeller nut
d- Propeller

75 55
Alpha propeller nutAlpha propeller nut1.
Then align tabs with grooves.
Bravo Sterndrive Propeller Installation

! WARNING
Ensure that remote control is in NEUTRAL position and ignition key is removed from switch prior
to installing propeller.
! WARNING
Place a block of wood between the anti‑ventilation plate and propeller to protect hands from
propeller blades and to prevent propeller from turning when tightening propeller nut.
7885
BRAVO ONE MODELS

IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.

1. The propeller torque stated is the minimum torque value.
Page 14 / 37 90-864196050 FEBRUARY 2005


95 Propeller shaft splines 92-802859A1
Teflon

NOTE: Anti‑corrosion grease is for salt water applications only.

3. Torque the propeller nut, then continue to tighten until 3 tabs on the tab washer align with
grooves on spline washer. Bend the 3 tabs down into grooves.
e
f
a
b
c
g 5301
Bravo One
a- Propeller shaft splines e - Drive sleeve adapter
b- Forward thrust hub f - Tab washer
c- Flo‑Torque II drive hub g - Propeller nut
d- Propeller

75 55
Bravo One propeller nut

BRAVO TWO MODELS
IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft.


Teflon


90-864196050 FEBRUARY 2005 Page 15 / 37

3. Torque the propeller nut, then continue to tighten until 3 tabs on the tab washer align with
grooves on spline washer. Bend the 3 tabs down into grooves.
c
d
f
a
b
8566
e
Bravo Two
a - Propeller shaft splines d - Spline washer
b - Forward thrust hub e - Tab washer
c - Propeller f - Propeller nut

81 60
Bravo Two propeller nut

BRAVO THREE


Teflon

Teflon

2. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.
3. Align splines and place front propeller on propeller shaft.
4. Install front propeller locknut and torque.

Front dual propeller nut 136 100

5. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub
6. Align splines and install aft propeller.
7. Install propeller nut and torque.

Rear dual propeller nut 81 60
Page 16 / 37 90-864196050 FEBRUARY 2005


8. Install propeller shaft anode and screw and torque.
e
f
b
d
c
a
i
j
g h
5304
Bravo Three
a- Rear propeller nut f- Front propeller thrust hub
b- Rear propeller g- Propeller shaft anode screw
c- Rear propeller thrust hub h- Flat washer
d- Front propeller nut i- Star washer
e- Front propeller j- Propeller shaft anode

Propeller shaft anode screw 19 168
Battery Connection
1. Ensure that all battery terminal connections are tight.
Priming The Fuel System
IMPORTANT: Use a portable fuel tank with a primer bulb fuel line.
! WARNING
Be careful when working on fuel system. Gasoline is extremely flammable and highly explosive
under certain conditions. Do not smoke or allow spark or open flame in area. Wipe up any spilled
fuel immediately.
1. Disconnect the fuel line from the fuel tank to the fuel inlet fitting and plug the line, if attached
to the engine.
2. Attach portable fuel tank to the fitting and secure tightly.
3. Squeeze the primer bulb until the bulb becomes firm.
4. Turn the ignition switch to the "RUN" position for 3 seconds and then turn OFF.
NOTE: Do not turn the key switch to the "START" position during the priming.
5. Repeat Step 3. and Step 4. three more times.
IMPORTANT: Before disconnecting the fuel line primer bulb, ensure that the bulb is soft and does
not still have fuel in it to prevent spilling fuel.
6. Disconnect the primer bulb fuel line from the fuel inlet fitting.
7. Remove the plug from the fuel tank fuel line.
8. Attach the fuel line from the fuel tank to the fuel inlet and tighten securely.
90-864196050 FEBRUARY 2005 Page 17 / 37

Test Running Engine

! WARNING
Avoid Injury: If engine is to be tested with the boat out of the water, the propeller must be removed
to avoid injury.
! CAUTION
BOAT OUT OF THE WATER

For engine operation tests with the boat out of the water:
IMPORTANT: If using a flushing attachment over the water inlet holes with a water hose, do not
use full water source pressure.
1. Install a flushing attachment over the sterndrive water inlet holes.
2. Connect a hose between the flushing attachment and a water source.
3. Open the water source about 1/2 maximum. Do not use full water pressure.
IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using
a through the hull water inlet, need a supply of cooling water available to both the sterndrive unit
and to the engine during operation.
4. On Engines With Through The Hull Water Inlet, supply sufficient cooling water to the engine.
5. Proceed to Testing Preparation.
BOAT IN THE WATER
For engine operation tests with the boat in the water:
IMPORTANT: If using a test tank the water level must be above the water inlet holes on the
sterndrive unit or the through the hull pickup.
1. Ensure that the water level is above the water inlet holes on the sterndrive or the through the
hull pickup.
2. Proceed to Testing Preparation.
TESTING PREPARATION
! WARNING
Do not leave the helm unattended when performing tests with the boat in the water.
1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight.
NOTE: Refer to appropriate Mercury MerCruiser Operation, Maintenance and Warranty Manual
for operating specifications. Refer to appropriate Mercury MerCruiser Service Manual for fluid
capacity information.
2. Check crankcase oil level.
IMPORTANT: Oil level in monitor will rise and lower during sterndrive operation. Always check oil
level when sterndrive is cool and engine is shut down.
3. Check sterndrive unit oil level in the monitor.
4. Check drive belt tension.
5. Test Audio Warning system in accordance with instructions on instrumentation panel decal.
6. Supply water to the engine either by putting boat in the water or by using the correct flush
device.
IMPORTANT: If using a test tank, ensure water level is above water intake holes.
Page 18 / 37 90-864196050 FEBRUARY 2005

! CAUTION
If using flush test device, install over water intake holes and connect a water hose as shown.
Do not use full water tap pressure. Also, do not operate engine above 1500 rpm, as suction
created could cause water hose to collapse causing water supply to be cut off.
! WARNING
If engine is to be tested with boat out of water, the propeller must be removed to avoid injury.
a b c
8781
a - Dual water pickup c - Side pickup

b - Low water pickup
IMPORTANT: Engines may also use a through the hull or through the transom inlet. If so, water
must be provided to these inlets or air flow must be blocked. If a block‑off plate is used, the through
the transom or through the hull fitting is the only water inlet to the engine.
TESTING
1. Place sterndrive in neutral , idle speed and start engine.
2. Slowly advance throttle until engine reaches 1300 rpm (+/‑100 rpm).
! CAUTION
3. Watch all gauges for normal readings.
4. Turn steering wheel RIGHT/STARBOARD, then LEFT/PORT, and ensure drive unit turns the
correct way.
5. Inspect engine compartment for water, oil, fuel, and exhaust leaks.
6. Turn steering wheel PORT until it stops and continue to apply pressure. If pump lugs (engine
rpm drops and/or power steering pump tone changes):
a. Check for an obstruction between gimbal ring and gimbal housing and all moving steering
components
b. Ensure that steering lever is not contacting cutout in transom. If contact is being made,
modify cutout
c. Check steering cable end dimension with cable FULLY EXTENDED.
90-864196050 FEBRUARY 2005 Page 19 / 37

7. Turn steering wheel STARBOARD until it stops and continue to apply pressure. If pump lugs
(engine rpm drops and/or power steering pump tone changes):
a. Turn off engine.
b. Remove cap/dipstick from power steering pump. Check fluid level and add if necessary.
7890
a - Dipstick (full when hot line)
Boat In The Water Tests

ENGINE IDLE SPEED
Engine should idle at RPM as specified in appropriate Mercury MerCruiser Operation,
Maintenance, and Warranty Manual with boat in the water, drive unit in FORWARD gear and
engine at normal operating temperature. If idle speed is incorrect, proceed as follows:
1. Ensure that throttle cable has been adjusted properly.
WIDE OPEN THROTTLE TEST
IMPORTANT: To operate engine at full throttle before the break‑in period is complete, follow this
procedure.
1. Place remote control in neutral , idle speed and start engine.
2. Slowly advance throttle until engine reaches 1300 rpm (+/‑100 rpm).
! CAUTION
3. Watch all gauges for normal readings.
4. When engines reaches mornal operating temperature, run the boat up on plane.
5. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM.
6. To test if the correct propeller has been installed, operate boat (with normal load on board) at
WOT and check RPM with an accurate tachometer. Engine RPM should be near top of the
specified range so that, under a heavy load, engine speed will not fall below specifications. If
engine speed is too high, replace propeller with a higher pitch propeller. Normally a 25 mm
(1 in.) propeller pitch change causes an RPM change of 150 RPM.
7. Return to idle speed.
8. Shut off engine.
9. Check coolant level and add coolant if necessary.
CHECKING SHIFT OPERATION
With sterndrive unit installed and engine operating, ensure that drive unit shifts properly, as
explained following:
1. Shift into FORWARD and REVERSE gear, ensuring that clutch engages before engine begins
to accelerate.
2. Accelerate engine while in FORWARD and REVERSE gear to ensure that engine does not
stop.
Page 20 / 37 90-864196050 FEBRUARY 2005

3. If the proper results are not achieved in the previous steps, shift cables must be readjusted.
4. Shifting from FORWARD and REVERSE to NEUTRAL: ensure drive unit is in NEUTRAL
before remote control shift lever comes to the NEUTRAL detent position. Perform this check
using various shifting rates to ensure that the drive unit shifts the same whether shifting fast
or slow.
Cold Weather and Extended Storage

Cold Weather or Extended Storage
! CAUTION
Sterndrive unit should be stored in full down position. Universal Joint bellows may develop a set
if unit is stored in raised position and may fail when unit is returned to service.
Seawater Section
IMPORTANT: Drain seawater section of closed cooling system only.
IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.
! CAUTION
Seawater section of cooling system must be completely drained for winter storage, or
immediately after cold weather use, if the possibility of freezing temperatures exist. Failure to
comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage
caused by freezing is not covered by the Mercury MerCruiser Limited Warranty.
IMPORTANT: Mercury MerCruiser recommends that propylene glycol antifreeze (a nontoxic and
environmentally safe) antifreeze be used in the seawater section of the cooling system for cold
weather or extended storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor
and is recommended for use in marine engines. Follow the propylene glycol manufacturer's
recommendations.
Closed Cooling Section
! CAUTION
If engine will be exposed to freezing temperatures, ensure closed cooling section is filled with
an ethylene glycol antifreeze and water solution properly mixed to protect engine to lowest
temperature to which it will be exposed.
IMPORTANT: Closed cooling section must be kept filled year‑round with recommended coolant.
IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine.
NOTE: If recommended coolant is unavailable, any type of ethylene glycol based antifreeze may
be used, but it will require replacement every two years.
! CAUTION
Ensure that boat is out of the water or seacock is closed and that bilge pump is operating. Excess
water in the bilge can damage engine or cause boat to sink.
Preparing Power Package For Storage

1. Fill the fuel tanks with fresh gasoline (that does not contain alcohol) and a sufficient amount
of Quicksilver Gasoline Stabilizer for Marine Engines to treat the gasoline. Follow instructions
on the container.
90-864196050 FEBRUARY 2005 Page 21 / 37

2. If the boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without
alcohol is not available): Fuel tanks should be drained as low as possible and Quicksilver
Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank. Refer to Fuel
Requirements for additional information.
NOTE: If desired, a portable fuel tank can be used to perform the remainder of the power package
lay up procedures. Be sure to add an appropriate amount of Gasoline Stabilizer to the portable
tank.
3. Flush the cooling system.
4. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel
with Quicksilver Gasoline Stabilizer to circulate through the fuel system. Shut off engine.
5. Change the oil and oil filter.
6. Store boat with drive unit in full down/in position.
7. For additional assurance against freezing and rust, after draining fill the cooling system with
a mixture of propylene glycol and tap water mixed to manufacturer's recommendation to
protect engine to the lowest temperature to which it will be exposed during cold weather or
extended storage.
FUEL SYSTEM
! WARNING
The fuel injection system is pressurized. Avoid serious injury from an explosion. Use care when
removing water separating fuel filter. Allow engine to cool down before removing the water
separating fuel filter. Also, hold a clean shop towel over the water separating fuel filter when
removing it, to help avoid fuel spraying on the engine.
! WARNING
Fuel vapors can be present in the engine compartment. Avoid injury or power package damage
caused by fuel vapors or explosion. Always ventilate the engine compartment prior to servicing
the power package.
1. In a 23 liter (6 U.S. gal.) remote fuel tank mix:

a. 19 liter (5 U.S. gal) regular unleaded 87 octane (90 RON) gasoline
b. 1.89 liter (2 U.S. qts.) Premium Plus 2‑Cycle TC‑W3 Outboard Oil
c. 150 ml (5 ounces) Fuel System Treatment and Stabilizer or 30 ml (1 ounce) Fuel System
Treatment and Stabilizer Concentrate.

Premium Plus 2-cycle TC-W3
115 Fuel system 92-802824A1
Outboard Oil
Fuel System Treatment &
124 Fuel system 802875A1
Stabilizer
2. Allow the engine to cool down.
IMPORTANT: Immediately wipe up any fuel spills or sprays.
3. Close the fuel shut off valve, if equipped. Disconnect and plug the fuel inlet fitting if not
equipped with a fuel shut off valve.
4. Connect the remote fuel tank (with the fogging mixture) to the fuel inlet fitting.
IMPORTANT: Supply cooling water to the engine.
5. Start and operate the engine at 1300 rpm for 5 minutes.
6. After specified operating time is complete, slowly return throttle to idle rpm and shut engine off.
IMPORTANT: Ensure that some fogging mixture remains in the engine. Do not allow the engine's
fuel system to become completely dry.
Page 22 / 37 90-864196050 FEBRUARY 2005

7. Remove and discard the water separating fuel filter.

8. Install a new filter.
BATTERY
Follow the battery manufacturer's instructions for storage.
Draining Instructions
! CAUTION
Excess water in bilge can damage engine or cause boat to sink. Ensure that the boat is out of
the water or the seacock is closed and bilge pump is operating before beginning procedure.
! CAUTION
Do not operate engine with drain system open. Excess water in bilge can damage engine or
cause boat to sink.
IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.
Your power package is equipped with a drain system. Refer to Identification on the following page
to determine which instructions apply to your power package.
The power package should be drained before flushing or prior to extended or cold weather storage.
IMPORTANT: The engine must not be operating at any point during this procedure.
Identification
MANUAL SINGLE POINT DRAIN SYSTEM
b
a
9326
a - Blue handle b - Blue drain plug location
90-864196050 FEBRUARY 2005 Page 23 / 37

AIR ACTUATED SINGLE POINT DRAIN SYSTEM
c a
b
a d b
9336
9327
Closed cooled models Seawater cooled models

a - Blue drain plug location c - Air manifold
b - Blue air pump d - Green indicators
3 POINT MANUAL DRAIN SYSTEM
a
a
9328
a - Blue drain plug
Page 24 / 37 90-864196050 FEBRUARY 2005

MULTI-POINT DRAIN (MPD) SYSTEM
b
b
a
93235672
10226 M110050
a
9330
a - Side of cylinder block b - Bottom of exhaust manifolds
a a
9331
a - Drain plug
9332
a - Drain plug
Boat In Water
1. Close the seacock.
2. Rotate blue handle COUNTERCLOCKWISE until it stops (approximately 2 turns). The red on
the handle shaft indicates that the drain system is open. Do not force handle as this will create
new threads.
90-864196050 FEBRUARY 2005 Page 25 / 37

3. Immediately remove the blue drain plug from the side of the thermostat housing. This must
be removed within 30 seconds to properly vent the cooling system.
9333
a - Blue handle b - Blue drain plug location
4. Visually verify that water is draining. If water does not drain, remove blue drain plug from
distribution housing and drain manually.
b
a
9334
a - Drain location ‑ orange or red b - Blue drain plug
5. Allow the system to drain for a minimum of 5 minutes. Mercury MerCruiser recommends
leaving the drain system open while transporting the boat or while performing other
maintenance.
6. Reinstall the blue drain plug in the thermostat housing.
7. Close the drain system by rotating the blue handle CLOCKWISE until it stops and install the
blue drain plug, if removed. The handle is fully seated when no red is visible. Do not overtighten
the handle as this will create new threads.
IMPORTANT: Mercury MerCruiser recommends that propylene glycol (a nontoxic and
recommendations.
8. Open the seacock prior to operating the engine.
NOTE: This procedure is written for the air pump that is attached to the engine. However, any air
source can be used.
2. Remove the blue air pump from the engine or remote mounting location.
3. Ensure that lever on top of pump is flush with the handle (horizontal).
Page 26 / 37 90-864196050 FEBRUARY 2005

4. Install air pump on the fitting in the air manifold.
8223
a - Green indicators
5. Pull lever on air pump up (vertical) to lock pump on the fitting.

6. Pump air into the system until both green indicators extend and water drains from both sides
of the engine. The port side will begin draining before the starboard side.
7. Immediately remove the blue drain plug from the side of the thermostat housing or the heat
exchanger. This must be removed within 30 seconds to properly vent the cooling system.
c a
b
a d b
9336
9327

90-864196050 FEBRUARY 2005 Page 27 / 37

8. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System
instructions.
9335
a
a - Port side drain location b - Starboard side drain location
9. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the green
indicators extended.
10. Crank engine over slightly with starter motor to purge any water trapped in seawater pump.
Do not allow engine to start.
11. Reinstall the blue drain plug in the thermostat housing.
12. Remove the air pump from the air manifold and return it to the mounting bracket.
13. Mercury MerCruiser recommends leaving the drain system open while transporting the boat
or while performing other maintenance. This helps ensure that all water is drained.
recommendations.
14. Before launching boat, pull up on manual release valve. Verify that green indicators are no
longer extended.
a
6135

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain
system or if the single point drain system fails.
Page 28 / 37 90-864196050 FEBRUARY 2005

2. Remove the blue drain plug from the distribution housing (lower front, port side).
a 9348
a - Blue drain plug
3. Immediately remove the blue drain plug from the side of the thermostat housing. This must
be removed within 30 seconds to properly vent the cooling system.
8219
a - Blue drain plug location
4. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side).
9349
a - Blue drain plug location
5. Verify that water is draining from each opening.

leaving the drain system open while transporting the boat or while performing other
maintenance.
7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup
pump. Do not allow engine to start.
90-864196050 FEBRUARY 2005 Page 29 / 37

8. Prior to launching boat or starting the engine, close the drain system by installing the 4 blue
drain plugs.
recommendations.
Boat Out Of The Water
1. Place the boat on a level surface to ensure complete draining of system.
2. Rotate blue handle COUNTERCLOCKWISE until rotation stops (approximately 2 turns). The
red on the handle shaft indicates that the drain system is open. Do not force handle as this
will create new threads.
9347
a - Blue handle
3. Visually verify that water is draining. If water does not drain, remove blue drain plug from
distribution housing and allow to drain manually.
b
a
9334
a - Drain location ‑ orange or red b - Blue drain plug
leaving the plugs out while transporting the boat or while performing other maintenance to
ensure that all water is drained.
5. Close the drain system by rotating the blue handle CLOCKWISE until it stops or installing the
blue drain plug. The handle is fully seated when no red is visible. Do not overtighten handle
as this will create new threads.
Page 30 / 37 90-864196050 FEBRUARY 2005


recommendations.
NOTE: This procedure is written for the air pump that is attached to the engine. However, any air
source can be used.
2. Remove the blue air pump from the engine or remote mounting location.
3. Ensure that lever on top of pump is flush with the handle (horizontal).
4. Install air pump on the fitting in the air manifold.
8223
5. Pull lever on air pump up (vertical) to lock pump on the fitting.

6. Pump air into the system until both green indicators extend and water drains from both sides
of the engine. The port side will begin draining before the starboard side.
c a
b
a d b
9336
9327

90-864196050 FEBRUARY 2005 Page 31 / 37

7. Verify that water is draining from each opening. If not, use the 3 Point Manual Drain System.
9335
a
a - Port side drain location b - Starboard side drain location
8. Allow the system to drain for a minimum of 5 minutes. Add air as necessary to keep the green
indicators extended.
9. Crank engine over slightly with starter motor to purge any water trapped in seawater pump.
Do not allow engine to start.
10. Remove the air pump from the air manifold and return it to the mounting bracket.
11. Mercury MerCruiser recommends leaving the plugs out while transporting the boat or while
performing other maintenance to ensure that all water is drained.
recommendations.
12. Before launching boat, pull up on the manual release valve. Verify that the green indicators
are no longer extended.
a
6135

NOTE: Use this procedure if your engine is not equipped with an air actuated single point drain
system or if the single point drain system fails.
Page 32 / 37 90-864196050 FEBRUARY 2005

2. Remove 3 blue drain plugs: 1 from the distribution housing (lower front, port side) and 2 from
the seawater pickup pump (front, starboard side).
a 9348
9349
a - Blue drain plug
3. Verify that water is draining from each opening.

leaving the plugs out while transporting the boat or while performing other maintenance to
ensure that all water is drained.
recommendations.
6. Prior to launching boat or starting the engine, close the drain system by re‑installing the 3 blue
drain plugs.
MULTI-POINT DRAIN (MPD) SYSTEM
2. Remove blue drain plugs from the following locations. It may be necessary to clean out drain
holes using a stiff piece of wire. Do so until the entire system is drained.
a. Port and starboard side of cylinder block.
b. Bottom of exhaust manifolds.
b
b
a
93235672
10226 M110050
a
9330
a - Side of cylinder block b - Bottom of exhaust manifolds
90-864196050 FEBRUARY 2005 Page 33 / 37

c. Water circulating pump hose.
9350
a - Water circulating pump drain plug
d. Fuel cooler to thermostat housing hose.
9352
a - Drain plug
e. Check valve.
9332
a - Drain plug
Page 34 / 37 90-864196050 FEBRUARY 2005

3. On models with seawater pickup pump, remove the 2 blue drain plugs. If your seawater pickup
pump does not have blue drain plugs or you are unable to access them, loosen clamps and
remove both hoses.
b
a
9353
9354
a - Hose clamps b - Blue drain plugs
4. Using a piece of wire, check water drain holes in sterndrive unit to ensure that they are open.
e
b
d
a
f
c
9355
Sterndrive unit water drain holes

a - Speedometer pitot tube d- Gear housing water drain hole (1
b - Trim tab cavity vent hole each ‑ port and starboard)
c - Trim tab cavity drain passage e- Gear housing cavity vent hole
f- Gear housing cavity drain hole
6. After cooling system has been drained completely, install drain plugs, reconnect hoses and
tighten all hose clamps securely.
recommendations.
Power Package Recommissioning
1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.
90-864196050 FEBRUARY 2005 Page 35 / 37

! CAUTION
Avoid electrical system damage. When installing the battery, be sure to connect the negative (‑)
battery cable to the negative (‑) battery terminal and the positive (+) battery cable to the positive
(+) battery terminal.
2. Install a fully‑charged battery. Clean the battery cable clamps and terminals and reconnect
cables (see CAUTION listed above). Tighten each cable clamp securely when connecting.
3. Coat the terminal connections with a battery terminal anti‑corrosion agent.
4. Perform all the checks in the BEFORE STARTING column of the Operations Chart.
! CAUTION
5. Start the engine and closely observe instrumentation to ensure that all systems are functioning
correctly.
6. Carefully inspect the engine for fuel, oil, fluid, water and exhaust leaks.
7. Inspect the steering system, shift and throttle control for proper operation.
Page 36 / 37 90-864196050 FEBRUARY 2005

Predelivery Inspection
Check / Check /
Not Applicable CHECK BEFORE RUNNING Not Applicable ON THE WATER TEST
Adjust Adjust
⃞ ⃞ Drain plug in and petcocks closed ⃞ ⃞ Engine alignment (Inboards only)
Starter neutral safety switch
⃞ ⃞ Seawater inlet valve open ⃞ ⃞
operation
⃞ ⃞ Engine mounts tight ⃞ ⃞ Water pump operation
⃞ ⃞ Engine alignment ⃞ ⃞ Instruments(s) operation
⃞ ⃞ Drive unit fasteners torqued ⃞ ⃞ Fuel leaks
⃞ ⃞ Power trim cylinders fasteners tight ⃞ ⃞ Oil leaks
⃞ ⃞ Battery fully charged and secured ⃞ ⃞ Water leaks
⃞ ⃞ All electrical connections tight ⃞ ⃞ Exhaust leaks
⃞ ⃞ Exhaust system hose clamps tight ⃞ ⃞ Ignition timing
Idle________ rpm, within
⃞ ⃞ All fuel connections tight ⃞ ⃞
specifications
Correct rotation propeller (installed Forward ‑ Neutral ‑ Reverse gear
⃞ ⃞ ⃞ ⃞
and torqued) operation
Throttle, shift and steering system Steering operation throughout
⃞ ⃞ ⃞ ⃞
fasteners tightened properly range
Throttle plates open and close
⃞ ⃞ ⃞ ⃞ Acceleration from idle rpm
completely
WOT________ rpm within
⃞ ⃞ Crankcase oil level ⃞ ⃞ specifications (in FORWARD
gear)
⃞ ⃞ Power trim oil level ⃞ ⃞ Power trim operation
Trim tab adjustmentBoat
⃞ ⃞ Sterndrive unit oil level ⃞ ⃞
handling
⃞ ⃞ Power steering fluid level AFTER ON WATER TEST
⃞ ⃞ Closed cooling level ⃞ ⃞ Propeller nut torque
Fuel, oil, coolant, water and fluid
⃞ ⃞ Transmission fluid level ⃞ ⃞
leaks
⃞ ⃞ Alternator belt tension ⃞ ⃞ Oil and fluid levels
Apply Quicksilver Corrosion
⃞ ⃞ Seawater pickup pump belt tension ⃞ ⃞
Guard to engine package
C.A.R.B. Hang Tag and Owners
⃞ ⃞ Power steering pump belt tension ⃞ ⃞
Manual in boat1.
C.A.R.B. Decal properly affixed
⃞ ⃞ Audio warning system operation ⃞ ⃞
to boat hull1.
1. If registered to a CA resident.
90-864196050 FEBRUARY 2005 Page 37 / 37

Mercruiser 4.3 MPI

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Mercruiser 4.3 MPI

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Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts,

Page i © 2005 Mercury Marine 90-864196050 FEBRUARY 2005

IMPORTANT: Indicates information or instructions that are necessary for proper

SECTION 1 - IMPORTANT INFORMATION 1

90-864196050 FEBRUARY 2005 Page 1 / 8

Description Nm lb. in. lb. ft.

Remote Controls And Instrumentation for DTS System

Page 2 / 8 90-864196050 FEBRUARY 2005

Serial Number Decal Placement

Bravo Three Notice: Trim‑in Limit Insert

Multiple Sterndrive Steering Tie Bar Arrangements

90-864196050 FEBRUARY 2005 Page 3 / 8

Internal Power Steering With Internal Tie Bar Only

Page 4 / 8 90-864196050 FEBRUARY 2005

a - Painted boat transom b - Minimum 40 mm (1‑1/2 in.) unpainted

90-864196050 FEBRUARY 2005 Page 5 / 8

a - MerCathode reference electrode c - Do not pressure wash

Emission Control Information Label

Emission Control Label ‑ Non CE Marked

Page 6 / 8 90-864196050 FEBRUARY 2005

"DISP" ‑ Piston Displacement

Emission Control Label ‑ CE Marked

a - Recommended location b - Secondary location

90-864196050 FEBRUARY 2005 Page 7 / 8

One Star ‑ Low emission

Three Stars ‑ Ultra Low emission

The three‑star label identifies engines that meet the Air

Four Stars ‑ Super Ultra Low emission

2009 exhaust emission standards. Personal Watercraft

Page 8 / 8 90-864196050 FEBRUARY 2005

SECTION 2 - BOAT CONSTRUCTION

90-864196050 FEBRUARY 2005 Page 1 / 2

a - Transom thickness d - Transom plate coverage ‑ 203 mm

Page 2 / 2 90-864196050 FEBRUARY 2005

SECTION 3 - EXHAUST SYSTEM

90-864196050 FEBRUARY 2005 Page 1 / 11

Exhaust System Caution

Preferred Exhaust System

Minimum Exhaust Hose Size

• Sharp bends in exhaust hoses should be avoided.

Page 2 / 11 90-864196050 FEBRUARY 2005

Measuring Exhaust Elbow Height

90-864196050 FEBRUARY 2005 Page 3 / 11

Minimum Exhaust Elbow Height

Using a universal protractor (inclinometer) to measure slope

Minimum Exhaust Hose Slope

Page 4 / 11 90-864196050 FEBRUARY 2005

Model Riser Options

Model Riser Options

NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.

Typical riser installation

NOTE: Up to a maximum of 152 mm (6 in.) of riser height can be added.

90-864196050 FEBRUARY 2005 Page 5 / 11

IMPORTANT: Be sure to consider swim platform loading and personal watercraft.

Minimum Exhaust Elbow Height From Top of Elbow to Waterline

a - Highest point on exhaust elbow c - Waterline

Continuous Downward Slope From Horizontal

Methods For Measuring Exhaust Elbow Height

Page 6 / 11 90-864196050 FEBRUARY 2005

a - Waterline d - Measurement between straight edge

Clear Hose Method for Measuring Exhaust Elbow Height

90-864196050 FEBRUARY 2005 Page 7 / 11

Collector And Water Lift Muffler Equipped

Page 8 / 11 90-864196050 FEBRUARY 2005