8.2 Installation Manual_8M0032375

Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K-planes, Mariner,
MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts,
Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft,
Sport-Jet, Verado, VesselView, Zero Effort, Zeus, and #1 On the Water are registered trademarks of
Mercury MerCruiser
Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick
Corporation.
STERNDRIVE 8.2 MAG MODELS

INSTALLATION MANUAL
Models Covered
Bravo
Models Covered Serial Number
8.2 MAG
8.2 MAG H.O.
Not available at time of printing
SeaCore 8.2 MAG
SeaCore 8.2 MAG H.O.
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.
Notice to Boat Manufacturer/Installer

Throughout this publication, dangers, warnings, cautions, and notices, (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.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
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.
NOTE: Refer to the appropriate Mercury MerCruiser Product Applications Manual for application recommendations.
Page i © 2013 Mercury Marine 90-8M0032375 AUGUST 2013

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 Integration Engineer (PIE) 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.
Copyright and Trademark Information

Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser,
Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing,
MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, and #1
On the Water are registered trademarks of Brunswick Corporation. Mercury Product Protection is a registered service mark of
Brunswick Corporation.
Page ii
1
Manual Outline
Important Information
1 - Important Information
2 - Boat Construction
3 - Exhaust System
Boat Construction
2
3
4 - Fuel System
Exhaust System
5 - Cooling System
4
6 - Drive System and Engine Mounting
7 - Starting and Electrical Fuel System
8 - Remote Controls
9 - Predelivery Preparation and Storage
Cooling System
5
Drive System and Engine Mounting
6
Starting and Electrical
7
Remote Controls
8
Predelivery Preparation and
Storage 9
Page iii
Page iv
SECTION - 1 IMPORTANT INFORMATION
SECTION 1 - IMPORTANT INFORMATION 1

Table of Contents
Quicksilver Products................................................................................................................................................ 2
Accessories ...................................................................................................................................................... 2
Remote Controls and Instrumentation for the DTS System.................................................................................... 2
Identification............................................................................................................................................................ 2
Information Decal ............................................................................................................................................. 2
Quick Response (QR) Code.............................................................................................................................. 3
Serial Number Decal Strips............................................................................................................................... 3
Engine Serial Number ...................................................................................................................................... 3
Bravo Sterndrive Serial Number and Identification........................................................................................... 4
Bravo Transom Serial Number.......................................................................................................................... 5
Bravo Three Notice: Trim‑In Limit Insert (Non‑DTS)............................................................................................... 5
SmartCraft/DTS Models ................................................................................................................................... 6
Multiple Sterndrive Steering Tie Bar Arrangements................................................................................................ 6
Internal Power‑Assisted Steering with Internal Tie Bar Only ........................................................................... 6
Internal Power‑Assisted Steering with Internal and External Tie Bar ............................................................... 6
External Power Steering .................................................................................................................................. 6
External Power Steering With Low External Tie Bar ........................................................................................ 6
SeaCore Components and Castings....................................................................................................................... 6
Stainless Steel Fasteners........................................................................................................................................ 7
Corrosion Protection................................................................................................................................................ 7
Anti‑Fouling Paint.................................................................................................................................................... 7
Emission Control Information Label........................................................................................................................ 9
Owner Responsibility ........................................................................................................................................ 9
90-8M0032375 AUGUST 2013 Page 1 / 10

IMPORTANT INFORMATION SECTION - 1
Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
95 2-4-C with PTFE Threads of stainless steel fasteners 92-802859A 1
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
Mercury Marine
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 the 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.
Identification
Information Decal
The information decal is located on the coolant reservoir.
a
b a- Quick response (QR) code
b- Service point information
c- Engine serial number
d- Transom serial number
e- Sterndrive serial number
f- Specifications
d
e
f
50314
Page 2 / 10 90-8M0032375 AUGUST 2013

Quick Response (QR) Code

Scan the QR code link with a smartphone to access additional product information.
50444
Smartphone link
IMPORTANT: Refer to the owner's manual included with each engine for detailed product information.
Serial Number Decal Strips

There are three sets of engine, transom assembly, and sterndrive serial number decal strips provided with each
power package. Affix one of each to the following:
• Information decal
• Warranty registration card
• Operation, Maintenance, and Warranty Manual identification page
Engine Serial Number

The engine serial number stamp is located on the starboard side of the engine block next to the flywheel housing
cover.
a b c a - Flywheel housing cover

b - Engine serial number stamp
c - Engine block
43554
90-8M0032375 AUGUST 2013 Page 3 / 10

Bravo Sterndrive Serial Number and Identification

The Bravo sterndrive serial number, gear ratio, model number, and bar code are embedded in the ground plate
on the port side of the sterndrive.
33533
Bravo sterndrive information on ground plate
The serial number is also stamped on the driveshaft housing behind the back cover. This is used as a permanent
reference for authorized MerCruiser dealers.
44426
Bravo sterndrive serial number stamping
Page 4 / 10 90-8M0032375 AUGUST 2013

Bravo Transom Serial Number

The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.
Transom Serial No. xxxxxxxxx
53651
Bravo transom assembly decal
The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized
MerCruiser dealers.
44425
Serial number location on gimbal housing
Bravo Three Notice: Trim‑In Limit Insert (Non‑DTS)

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.
90-8M0032375 AUGUST 2013 Page 5 / 10

! WARNING
On some boats, increased trim‑in range can cause handling problems at high speeds, resulting in personal
injury or death. We recommend that only qualified personnel adjust the trim‑in limit inserts and test the boat for
handling problems.
SmartCraft/DTS Models
The trim limit for DTS models is a function of the PCM. Refer to the DTS System Calibration Section for proper
set‑up procedures.
Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives you must select one of several possible steering systems.
NOTICE
Incorrect tie bar installation can damage the drive and steering system. Do not let the tie bar contact other
components during severe turning conditions. Always calculate sufficient turning clearances, observe
recommended tie bar arrangements, and check for proper installation before operating the boat.
Internal Power‑Assisted 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‑assisted steering output. This internal tie bar is available in a variety of lengths from the
sterndrive manufacturer.
Internal Power‑Assisted 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‑assisted 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.
SeaCore Components and Castings

Mercury MerCruiser SeaCore power packages are equipped with additional stainless steel components and
particular aluminum castings with special coatings. Do not replace SeaCore components with non‑SeaCore. Use
only the specified Mercury MerCruiser SeaCore components and castings on these power packages.
Page 6 / 10 90-8M0032375 AUGUST 2013

Stainless Steel Fasteners

SeaCore models are equipped with additional stainless steel fasteners to maximize corrosion resistance in
saltwater environments.
Stainless steel fasteners are subject to galling when installed without lubrication. Galling can result in fastener
destruction, improper clamp loads, or both. Galled fasteners may appear to torque properly, but still have
incorrect clamp loads.
Apply lubricant 2‑4‑C with PTFE or an equivalent, on the threads of stainless steel fasteners during installation to
avoid galling. Lubricate at least the first 8 mm (1/4 in.) of the threads before installation.

95 2-4-C with PTFE Threads of stainless steel fasteners 92-802859A 1
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 two 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 the 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:
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.
90-8M0032375 AUGUST 2013 Page 7 / 10

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.
a - Painted boat transom

b - Minimum 40 mm (1‑1/2 in.) unpainted area around
transom assembly
8107
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.
NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any
cleaning equipment such as brushes or high‑pressure washers to clean the MerCathode assembly.
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.
c a a - MerCathode reference electrode

b - Do not paint
c - Do not pressure wash
b
6211
Page 8 / 10 90-8M0032375 AUGUST 2013

Emission Control Information Label

A tamper‑resistant emission control information (ECI) label is affixed to the engine in a visible location at the time
of manufacture by Mercury MerCruiser. Please note that the low emissions certification will not affect the fit,
function, or performance of the engine. 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. In addition to the required emissions statement, the label lists the engine serial
number, family, applicable emission standard, date of manufacture (month, year), and engine displacement.
ECIEXEMP
EMISSION CONTROL INFORMATION
a- Applicable standard
NOT FOR SALE IN US
THIS ENGINE IS SOLELY FOR EXPORT AND IS THEREFORE EXEMPT
b- Engine serial number
UNDER 40 CFR 1068.230 FROM U.S. EMISSION STANDARDS AND a c- Engine family name
RELATED REQUIREMENTS. REFER TO THE OWNERS MANUAL
FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS. d- Hydrocarbons plus oxides of nitrogen family
SERIAL #: XXXXXXXX b DOM: MMM YYYY e emission limit
FAMILY: XXXXXXXXXXXX c DISP: X.XL POWER : XXX kW f e - Date of manufacture
HC+NOx FEL : XX.X g/kWh d CO FEL : XXX g/kWh g 0575
f - Engine displacement, engine power
44881
g - Carbon monoxide family emission limit
IMPORTANT: A CE mark in the lower right corner of the Emission Control Information label indicates that an EU
Declaration of Conformance applies. Refer to the front page of this manual for further information.
IMPORTANT: Engines designated as exempt from either Federal EPA or California emission control regulations
are not covered by a separate emission control component warranty. The product's Mercury MerCruiser
manufacturer's warranty is not affected by the engine's designation under Federal EPA or California emission
control regulations.
ECI Label Standard of Compliance

ECIEXEMP
EMISSION CONTROL INFORMATION

NOT FOR SALE IN US
THIS ENGINE IS SOLELY FOR EXPORT AND IS THEREFORE EXEMPT
UNDER 40 CFR 1068.230 FROM U.S. EMISSION STANDARDS AND Indicates a marine engine for export and is exempt under 40
RELATED REQUIREMENTS. REFER TO THE OWNERS MANUAL CFR 1068.255 from United States EPA exhaust emission
FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
regulations for 2010.
SERIAL #: XXXXXXXX DOM: MMM YYYY This marine engine is not for sale in U.S.
FAMILY: XXXXXXXXXXXX DISP: X.XL POWER : XXX kW
HC+NOx FEL : XX.X g/kWh CO FEL : XXX g/kWh 0575
44880
Owner Responsibility
The operator must have routine engine maintenance performed to maintain emission levels within prescribed
certification standards.
The operator may not modify the engine in any manner that alters the horsepower or allows emissions levels to
exceed factory specifications.
90-8M0032375 AUGUST 2013 Page 9 / 10

NOTES:
Page 10 / 10 90-8M0032375 AUGUST 2013

SECTION - 2 BOAT CONSTRUCTION
SECTION 2 - BOAT CONSTRUCTION

Table of Contents
Boat Construction.................................................................................................................................................... 2 2
Transom Thickness and Surface Plane............................................................................................................ 2
Transom Cutout.................................................................................................................................................2
Checking Transom Thickness........................................................................................................................... 2
Engine Bed........................................................................................................................................................ 2
Boat Type Recommendation ............................................................................................................................ 2
90-8M0032375 AUGUST 2013 Page 1 / 4

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 centerline
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 as horizontal
Flatness
dimensions): Inner surface ‑ Flat within 3 mm (1/8 in.); Outer surface ‑ Flat within 2 mm (1/16 in.)
Angle 10–16°
a e
d d
b
c 7508
a- Transom thickness
b- Inner surface
c- Outer surface
d- Transom plate coverage ‑ 203 mm (8 in.) from center
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
Description Measurement
Difference between starboard and port engine mount 57.2 cm (22‑1/2 in.)
Mount adjustment up and down (minimum) 6 mm (1/4 in.)
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.
Boat Type Recommendation

We recommend 8.2 models for use in most sport boat applications with the exception of the following:
Page 2 / 4 90-8M0032375 AUGUST 2013

SECTION - 2 BOAT CONSTRUCTION
• Bravo applications that require that the sterndrive be mounted more than 76 mm (3 in.) above the standard
X‑dimension (i.e., catamarans, certain stepped bottom boats). For those applications, we recommend our
Performance Product models with a Super Speedmaster sterndrive which are designed specifically for
surfaced propeller operation.
• Applications that require other than standard Quicksilver propellers to get the boat up on plane or to keep the
propeller from ventilating when up on plane.
• Boats that require the engine be run above 3200 RPM to keep them on plane.
• Racing applications or other highly abusive applications where the boat and the sterndrive will come out of
the water frequently. These, again, are applications where we recommend our Performance Product models
with Super Speedmaster sterndrive.
90-8M0032375 AUGUST 2013 Page 3 / 4

BOAT CONSTRUCTION SECTION - 2
NOTES:
Page 4 / 4 90-8M0032375 AUGUST 2013

SECTION - 3 EXHAUST SYSTEM
SECTION 3 - EXHAUST SYSTEM

Table of Contents
Exhaust System....................................................................................................................................................... 2
Important Information........................................................................................................................................ 2
Exhaust System Connections........................................................................................................................... 2
3
Exhaust Emissions Sampling............................................................................................................................ 2
Carbon Monoxide Exposure.............................................................................................................................. 3
Be Alert To Carbon Monoxide Poisoning ................................................................................................... 3
Stay Clear of Exhaust Areas ...................................................................................................................... 3
Good Ventilation ....................................................................................................................................... 3
Poor Ventilation ........................................................................................................................................ 4
Preferred Exhaust System................................................................................................................................ 4
Exhaust Emissions ........................................................................................................................................... 4
Magnum Bravo Model Exhaust Recommendation............................................................................................ 4
Measuring Exhaust Elbow Height........................................................................................................................... 5
General Information...........................................................................................................................................5
Exhaust Angle Measurement ..................................................................................................................... 6
Boat Requirements............................................................................................................................................6
Loading Requirements...................................................................................................................................... 6
Loading the Boat (Boats with a Capacity Plate)................................................................................................ 7
Example ..................................................................................................................................................... 8
Loading the Boat (Boats without a Capacity Plate)........................................................................................... 9
Example ................................................................................................................................................... 10
Clear Hose Measurement Method.................................................................................................................. 12
Clear Hose Measurement Method from Muffler Drain..................................................................................... 12
90-8M0032375 AUGUST 2013 Page 1 / 14

EXHAUST SYSTEM SECTION - 3
Exhaust System
Important Information
NOTICE
Improperly designing, installing, or modifying the engine’s exhaust system can introduce seawater or water
from condensation into the combustion chambers, damaging the engine. The installing dealer or boatbuilder is
responsible for proper installation of the exhaust system as explained in the installation instructions for the
product. Engine damage resulting from water ingestion is not covered by the product warranty, unless the
damage is the result of a defective part supplied by the engine manufacturer.
The exhaust system must be installed in accordance with the information contained in this section to prevent
water intrusion problems. Special care is required on the transom or hull exhaust applications, as these
custom‑designed exhaust systems can create a tuning effect that can cause water to be forced back into the
engine. Refer to the product's application manual and perform the tasks under Checking for Water Intrusion to
ensure that water intrusion is not occurring. It is the boat manufacturer's responsibility for ensuring that water
intrusion does not exist with their unique exhaust system.
Engines with through propeller exhaust have been carefully designed and tested to avoid water intrusion
problems and no additional testing is required. These applications require that only that exhaust elbow height be
checked as outlined under Measuring Exhaust Elbow Height.
! WARNING
Installing the exhaust system incorrectly can lead to serious injury or death. When installing or designing
exhaust systems, follow all federal, state, and local boating and safety standards for the market in which the
boat will be sold.
Exhaust system design and installation can affect:

• Noise level.
• Performance.
• Water Intrusion.
• Carbon monoxide levels.
• Component longevity.
Exhaust System Connections

IMPORTANT: The exhaust system supplied by Mercury MerCruiser is compliant with the ABYC Standard P‑1. If
components are used in any portion of the exhaust system that modify the design of the supplied system, it is the
boatbuilder's responsibility to ensure that the new system complies with the ABYC Standards. Exhaust system
connections to components other than those supplied by Mercury MerCruiser must use two stainless steel
clamps with a minimum width of 13 mm (1/2 in.) at each joint.
Exhaust Emissions Sampling

Exhaust gas emission regulations require field access to uncontaminated and undiluted engine exhaust. Mercury
MerCruiser models covered by these regulations are equipped with (or have available) exhaust system
components that allow access to the exhaust gas stream suitable for analysis.
Page 2 / 14 90-8M0032375 AUGUST 2013

IMPORTANT: To comply with exhaust gas emission regulations, design considerations determined by the boat
builder and specific engine installations must allow for field access to the exhaust gas sampling ports.
45320
Access area for exhaust gas sampling—8.2 MAG and 8.2 MAG H.O.
Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning
Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines,
including the engines that propel boats, and the generators that power boat accessories. By itself, CO is
odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.
Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and
intoxication, include headache, dizziness, drowsiness, and nausea.
! WARNING
Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness,
brain damage, or death. Avoid exposure to carbon monoxide.
Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.
Stay Clear of Exhaust Areas
41127
Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases.
When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or
boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat
(platform dragging, teak/body surfing). This dangerous practice not only places a person in an area of high
engine exhaust concentration, but also subjects them to the possibility of injury from the boat propeller.
Good Ventilation
Ventilate the passenger area, open side curtains or forward hatches to remove fumes.
90-8M0032375 AUGUST 2013 Page 3 / 14

Example of desired air flow through the boat:
43367
Poor Ventilation
Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with
insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your
boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary
boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while the boat is stationary:
a a - Operating the engine when the

b boat is moored in a confined
space
b - Mooring close to another boat
that has its engine operating
21626
2. Examples of poor ventilation while the boat is moving:
a a - Operating the boat with

b
the trim angle of the bow
too high
b - Operating the boat with
43368 no forward hatches
open (station wagon
effect)
Preferred Exhaust System

Most Mercury MerCruiser sterndrive engines were developed and tested for the Y‑pipe or through the propeller
exhaust systems. The only exceptions to this are the 8.2 models. However, by using the Y‑pipe system, you limit
the potential for water intrusion due to the exhaust system design.
Exhaust Emissions
IMPORTANT: Mercury MerCruiser declares that our sterndrive or inboard engines without integral exhaust, when
installed in a recreational craft, in accordance with the manufacturers supplied instructions, will meet the exhaust
emissions requirements of the directive mentioned in the appropriate Mercury MerCruiser Operation,
Maintenance & Warranty Manual. The engine must not be put into service until the recreational craft in which it is
to be installed has been declared in conformity, if so required, with the relevant provision of the Directive.
Magnum Bravo Model Exhaust Recommendation

IMPORTANT: To get maximum performance from Magnum Bravo models, through‑the‑transom exhaust is
required. It is recommended that the exhaust bellows on the transom assembly be removed and replaced. 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.
NOTE: If noise regulations do not allow the use of through‑the‑transom exhaust, an exhaust pipe kit and the
specified intermediate exhaust elbow risers must be installed for through‑the‑propeller exhaust. This also
requires an exhaust tube that is used in place of the exhaust bellows.
Page 4 / 14 90-8M0032375 AUGUST 2013

IMPORTANT: To comply with the EU (European Union) Noise Emission Standard under Mercury's EU Noise
Certification, the 8.2 sterndrive engines must install and use the exhaust pipe kit with a specified intermediate
exhaust elbow riser kit. Installation and use of any other exhaust components will require individual certification
of installation with governing authority.
24338
Exhaust pipe kit and intermediate exhaust elbow riser kit
Measuring Exhaust Elbow Height

General Information
Install exhaust elbows within the specified height dimensions to prevent water intrusion. Install exhaust elbow
risers as needed to obtain the proper exhaust elbow height and exhaust angle. Risers cannot exceed 203.2 mm
(8 in.). Take all measurements with the boat in the water and loaded to simulate the maximum loading conditions
for normal operation.
IMPORTANT: If installing a waterlift muffler, measure the elbow height to the waterline inside the waterlift muffler,
not the waterline outside of the boat. Refer to Clear Hose Measurement Method from Muffler Drain.
IMPORTANT: The boat manufacturer is responsible for load distribution recommendations. Boatbuilders must
communicate any load distribution conditions that affect the exhaust system such as maximum occupancy of the
swim platform to the operator in the owner's manual.
Measurements for all loading conditions must meet the following specifications:
Model Minimum Exhaust Elbow Height

8.2 381 mm (15 in.)
Minimum Exhaust Hose Slope

Minimum Exhaust Hose Slope
Model Remainder of System
within 45.7 cm (18 in.) of engine
(if applicable)
8.2 10° 3°
If the exhaust elbow height or exhaust angle is insufficient, modify the exhaust system or install the appropriate
exhaust riser. Refer to the appropriate Mercury Precision Parts and Accessory Guide for part numbers.
The maximum exhaust riser height is specified in the table below.
Maximum Exhaust Riser Height

Model Low Medium High
8.2 51 mm (2 in.) 152 mm (6 in.) 203 mm (8 in.)
90-8M0032375 AUGUST 2013 Page 5 / 14

Exhaust Angle Measurement

Measure the exhaust angle of each section of the exhaust system using an inclinometer as shown in the diagram
below. Begin the measurement at the exhaust elbow outlet continuing along each section to the exhaust exit
point of the boat. Perform all exhaust angle measurements with the boat at rest in the water. Perform the first set
of measurements without a load in the boat. Perform the second set of measurements with the boat fully loaded.
See Loading Requirements.
c a - Inclinometer
b - Exhaust hose or tube
c - Minimum 305 mm (12 in.)
a
b
8235
Boat Requirements
IMPORTANT: Consider the following requirements before performing the exhaust elbow waterline height
measurement. No prototype hulls or light layup hulls should be considered. Any measurement performed on
nonproduction boats, prototype hulls, or light layup hulls could be inaccurate and could result in product damage.
• All boats that display a CE certification capacity plate must use the maximum capacity as stated on the
CE certification capacity plate to perform the exhaust elbow waterline measurement.
• All boats that only display the US Coast Guard (USCG) capacity plate must use the maximum capacity as
stated on the USCG capacity plate to perform the exhaust elbow waterline measurement.
• For boats that do not have a capacity plate, the maximum capacity load is the number of persons that can sit
on designated seating plus cargo excluding cabin space.
• Measurements used for official Mercury MerCruiser audit at the OEM boatbuilder must be performed on
current production boats. No prototype hulls or light layup hulls will be considered for official audit purposes.
• Measurements used for official Mercury MerCruiser audit at the OEM boatbuilder must use the CE
certification maximum load for any boat model that will be sold outside of the United States.
Loading Requirements
1. Fill the fuel tanks, fresh water tanks or holding tanks, ballast tanks, and heater tanks to simulate fully loaded
condition.
2. Weights can be used to simulate these load conditions if desired. Place weights in the corresponding area for
which the load is being replaced. Refer to the following 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
3. For the purpose of MerCruiser waterline height measurements:
• One person is equivalent to 74.84 kg (165 lb)
• Cargo per person is equivalent to 11.34 kg (25 lb)
4. Add weight for any additional boat options: extra battery, battery charger, tower, arch, generator, ballast
tanks, ballast sacks, television, carpet, anchor, stereo/entertainment equipment, washer/dryer, safe, etc.
5. If a swim platform is an option, the swim platform must be installed for the waterline height measurement.
Use the following guide to determine the correct swim platform load:
Page 6 / 14 90-8M0032375 AUGUST 2013

a. Boats less than 8.84 m (29 ft) long, not including boats that are 8.84 m (29 ft) long, must add the
maximum rated swim platform weight capacity to the swim platform.
b. Boats less than 8.84 m (29 ft) long, not including boats that are 8.84 m (29 ft) long, that do not have a
maximum rated swim platform weight capacity, must add 181.45 kg (400 lb) to the swim platform.
c. Boats 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, must add the maximum rated swim
platform weight capacity to the swim platform.
d. Boats 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, that do not have a maximum rated swim
platform weight capacity, must add 226.80 kg (500 lb) to the swim platform.
Loading the Boat (Boats with a Capacity Plate)

For boats with a capacity plate, use the maximum load for persons and gear as listed on the capacity plate to
determine the number of persons to place onto the boat for exhaust elbow waterline height measurements.
IMPORTANT: Use 20 in. for an average passenger seat width when measuring bench seating. Round up or
down at 0.5 to obtain a whole person. See the examples listed below.
• 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons.
• 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.
1. Take the maximum capacity weight as listed on the capacity plate (XXXX lbs, persons, gear) and subtract
the swim platform load, if applicable.
2. Next divide the weight by 74.84 kg (165 lb) per person. This gives the whole number and remainder of
74.84 kg (165 lb) persons to load onto the boat.
3. Put the remainder of a person in the next available seat. See the boat loading diagram.
24860
24861
CE capacity plate USCG capacity plate

IMPORTANT: If there is not enough seating for the number of people, treat the leftover weight as cargo.
Load cargo weight onto the boat before loading passenger weight.
4. If applicable, load cargo (leftover persons weight) onto the boat. Distribute cargo as described below.
IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage
application from the Optional Cargo Distribution table that best applies to your boat configuration.
Preferred Cargo Distribution

Aft storage Center storage Bow storage
25% 50% 25%
Optional Cargo Distribution

25% 75% None
None 75% 25%
50% None 50%
None 100% None
100% None None
None None 100%
90-8M0032375 AUGUST 2013 Page 7 / 14

5. Perform the first measurement with the swim platform loaded and the person taking the waterline
measurement on the boat.
6. Load the swim platform if equipped.
7. Measure the exhaust elbow waterline height.
IMPORTANT: View all boat seating as rows that are parallel to the transom of the boat.
8. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight
is loaded onto the boat. Repeat until a person weight is loaded into each seat in that row.
9. Continue the process moving forward toward the bow of the boat to the next row of seats until a person
weight is loaded into each seat.
NOTE: The total weight loaded onto the boat must not exceed the maximum capacity displayed on the capacity
plate.
NOTE: The following example is provided as a reference.
Example
NOTE: This example uses a boat that is less than 8.84 m (29 ft) long, not including a boat that is 8.84 m (29 ft)
long that does not have a maximum rated swim platform weight capacity, and must add 181.45 kg (400 lb) to the
swim platform.
NOTE: Use 0.50 lb as the break point to round up or down to obtain a whole pound.
1. Maximum load (persons and gear) from capacity plate – swim platform load = remaining weight to be placed
in the boat.
• 1100 lb – 400 lb = 700 lb
2. Remaining weight to be placed in the boat ÷ MerCruiser person weight = number of persons to load onto the
boat.
• 700 lb ÷ 165 lb = 4.24 persons
3. Total number of persons – number of whole persons = remaining persons.
• 4.24 persons – 4 persons = 0.24 remaining persons
4. Remainder persons ÷ MerCruiser person weight = remainder MerCruiser person weight.
• 0.24 × 165 lb = 40 lb
5. Using the totals in this example, load four 165‑lb persons and one 40‑lb person onto boat seating with 400 lb
on the swim platform.
• 400 lb + 165 lb = 565 lb
• 565 lb + 165 lb = 730 lb
• 730 lb + 165 lb = 895 lb
• 895 lb + 165 lb = 1060 lb
Page 8 / 14 90-8M0032375 AUGUST 2013

• 1060 lb + 40 lb = 1100 lb
d e
b
a
c
f
24862
Boat loading diagram

a - Swim platform load
b - MerCruiser person weight (one)
c - MerCruiser person weight (two)
d - MerCruiser person weight (three)
e - MerCruiser person weight (four)
f - Remainder MerCruiser person weight (five)
Loading the Boat (Boats without a Capacity Plate)

For boats that do not display a capacity plate, the number of persons to be loaded onto the boat for measuring
purposes is the number of persons that can sit on designated seating excluding cabin space. An additional
weight of 25 lb per person is to be added to the boat before loading passenger weight onto the boat.
IMPORTANT: Use 20 in. for an average passenger seat width when measuring bench seating. Round up or
down at 0.5 to obtain a whole person. See the examples below.
• 48 in. (bench seat length) ÷ 20 in. (seat width) = 2.4 persons. 2.4 persons rounded down = 2 persons.
• 55 in. (bench seat length) ÷ 20 in. (seat width) = 2.75 persons. 2.75 persons rounded up = 3 persons.
1. Total number of persons that can sit on designated seating excluding cabin space × MerCruiser person
weight = maximum passenger load for measurement.
• Number of persons × 165 lb (MerCruiser person weight) = XXXX lb maximum passenger load.
2. Maximum passenger load from the calculation above – swim platform load if applicable.
3. Divide the weight by 165 lb per person. This gives the number of 165‑lb persons to load onto the boat.
Round up to next whole number. See Example 3.
IMPORTANT: To account for cargo, add a weight of 25 lb per person to the boat before loading passenger
weight onto the boat.
4. Calculate the cargo by multiplying 25 lb by the number of persons that can sit on designated seating
excluding cabin space. See Example.
5. Load the cargo onto the boat. Distribute cargo as described below.
IMPORTANT: If the boat configuration does not allow for aft, center, and bow storage, choose the storage
application from the Optional Cargo Distribution table that best applies to your boat configuration.
Preferred Cargo Distribution

25% 50% 25%
90-8M0032375 AUGUST 2013 Page 9 / 14

Optional Cargo Distribution

25% 75% None
None 75% 25%
50% None 50%
None 100% None
100% None None
None None 100%
6. Perform the first measurement with the swim platform loaded and the person measuring the waterline on the
boat.
7. Load the swim platform if equipped.
8. Measure the exhaust elbow waterline height.
9. Load a person weight into a seat, and measure the exhaust elbow waterline height after each person weight
is loaded onto the boat. Repeat until a person weight is loaded into each seat in that row.
10. Continue the process moving forward toward the bow of the boat to the next row of seats until a person
weight is loaded into each seat.
Example
NOTE: The following example is provided as a reference.
This example uses a boat that is 8.84 m (29 ft) long and greater than 8.84 m (29 ft) long, that does not have a
maximum rated swim platform weight capacity, and must add 226.80 kg (500 lb) to the swim platform.
IMPORTANT: The Designated Seating Diagram following illustrates the number of passengers that can sit on
designated seating excluding cabin space.
6 9
2
4 7
1
5 8
3
24863
Designated seating diagram
This example uses nine persons as the maximum passenger load.

NOTE: Use 0.50 lb as the break point to round up or down to obtain a whole pound.
1. To determine the maximum cargo load multiply the maximum passenger load by the maximum cargo weight
per passenger.
• 9 passengers × 25 lb = 225 lb
2. To determine the preferred cargo distribution for aft, center, and bow storage:
a. To determine the maximum aft storage cargo weight, multiply the maximum cargo weight by 25%.
3. To determine the maximum center storage cargo weight, multiply the maximum cargo weight by 50%.
a. 225 lb × 50% = 112.50 lb
b. 112.50 lb rounded up = 113 lb
4. To determine the maximum bow storage cargo weight, multiply the maximum cargo weight by 25%.
• 225 lb × 25% = 56.25 lb
• 56.25 lb rounded down = 56 lb
Page 10 / 14 90-8M0032375 AUGUST 2013

5. To determine the maximum number of passengers to load onto the boat, multiply 9 passengers by 165 lb
(MerCruiser person weight) to get a 1485 lb (total passenger load).
• 9 passengers × 165 lb = 1485 lb
6. Subtract the swim platform load from the total passenger load to get the remaining weight to be placed in the
boat.
• 1485 lb – 500 lb = 985 lb
7. Divide the remaining weight to be placed onto the boat by the MerCruiser person weight to get the maximum
number of passengers to load onto the boat.
• 985 lb ÷ 165 lb = 5.9 passengers
• 5.90 passengers rounded up = 6 passengers
8. Using the totals in this example load 56 lb cargo in the aft storage, 113 lb cargo in the center storage, and 56
lb cargo in the bow storage onto the boat before adding passenger weight. Then, load six 165 lb passengers,
onto the boat with 500 lb on the swim platform.
• 500 lb + 225 lb = 725 lb
• 725 lb + 165 lb = 890 lb
• 890 lb + 165 lb = 1055 lb
• 1055 lb + 165 lb = 1220 lb
• 1220 lb + 165 lb = 1385 lb
• 1385 lb + 165 lb = 1550 lb
• 1550 lb + 165 lb = 1715 lb
g
c i
a e j
b h
f
d
24864
Cargo, swim platform, and passenger weight loading diagram

a - Swim platform load
b - MerCruiser person weight (one)
c - MerCruiser person weight (two)
d - MerCruiser person weight (three)
e - MerCruiser person weight (four)
f - MerCruiser person weight (five)
g - MerCruiser person weight (six)
h - Aft storage
i - Center storage
j - Bow storage
90-8M0032375 AUGUST 2013 Page 11 / 14

Clear Hose Measurement Method

1. Obtain an 8–10 mm (5/16–3/8 in.) inner diameter (ID) clear hose approximately 4.5 m (15 ft) long. Install a
metal fitting or a weight on one end of the hose to keep that end of the hose below the waterline. The fitting
or weight must not restrict water from filling the clear hose.
b a - Clear hose
b - Fitting
b c c - Unrestricted opening
24865
IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline
height measurement on the side that sits lower in the water.
2. Put the weighted end of the clear hose over the side of the boat (port or starboard) that is sitting lower in the
water.
3. Submerge the clear hose until completely filled with water.
4. Place a finger over the open end of the clear hose before removing it from the water.
5. Coil the excess clear hose into the bottom of the boat bilge. Keep the coil of clear hose below the waterline.
6. Keeping the clear hose in line with the engine's exhaust elbow, lift the end of the clear hose up to the highest
point of the exhaust manifold collector and elbow.
7. Slowly take the finger off of the end of the clear hose to let the water level stabilize. The water will seek the
level of the water outside of the boat. Keep the clear hose close to the exhaust elbow and as vertical as
possible.
b a - Waterline
b - Top of exhaust elbow
c - Waterline to top of exhaust elbow
measurement
d
a d - Clear hose
c
d e - Weight
e
33026
Clear Hose Measurement Method from Muffler Drain

IMPORTANT: Measure the exhaust elbow height to the waterline inside of the waterlift muffler (instead of the
waterline outside of the boat) on applications so equipped.
IMPORTANT: The engine must have been operated previously to fill the muffler with water.
IMPORTANT: On engines equipped with more than one exhaust elbow, perform the exhaust elbow waterline
height measurement on the side that sits lower in the water.
1. Attach a clear hose to the muffler drain point or seacock drain point.
2. Start the engine to fill the muffler and hose.
3. If attached to the seacock drain, open the seacock.
4. 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.
5. Coil excess hose in the bilge of the boat, keeping it below the waterline.
Page 12 / 14 90-8M0032375 AUGUST 2013

6. Lower the open end of the 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.
7. Slowly take the finger off of the end of the hose to let the water level stabilize. The water will seek the level of
the water outside the boat. Keep the hose close to the exhaust elbow and as vertical as possible.
8. The measurement between the water in the hose and the top of the exhaust elbow is the exhaust elbow
height. The maximum riser height is 20.3 cm (8 in.) on 8.2 models.
Typical vertical waterlift

muffler
a - Minimum exhaust
elbow height with
a maximum load
b - Clear hose for
measuring waterline
b
44882
IMPORTANT: Horizontal waterlift mufflers are permitted for use only if the bottom of the muffler is below the
crankshaft centerline.
Typical horizontal waterlift muffler

a - Minimum exhaust elbow height
with maximum load
b - Clear hose for measuring
waterline
a
b 44883
90-8M0032375 AUGUST 2013 Page 13 / 14

NOTES:
Page 14 / 14 90-8M0032375 AUGUST 2013

SECTION - 4 FUEL SYSTEM
SECTION 4 - FUEL SYSTEM

Table of Contents
Fuel Delivery System .............................................................................................................................................. 2
Controlling Evaporative Emissions.................................................................................................................... 2
EPA and California Regulations—Low‑Permeation Fuel Hose......................................................................... 2
Fuel Delivery System Specifications................................................................................................................. 2
Vapor Locking ............................................................................................................................................ 2
Fuel Lines and Fittings ............................................................................................................................... 2
Fuel Tank ................................................................................................................................................... 3
4
Water‑Separating Fuel Filters........................................................................................................................... 4
90-8M0032375 AUGUST 2013 Page 1 / 4

FUEL SYSTEM SECTION - 4
Fuel Delivery System

Controlling Evaporative Emissions
Specific installation steps are required to control evaporative emissions. The installer and/or the vessel
manufacturer must meet the requirements of EPA regulation 1045.112 and federal regulation 40 CFR part 1060.
EPA and California Regulations—Low‑Permeation Fuel Hose

California Regulations for New Spark‑Ignition Inboard and Sterndrive Pleasure Craft
(3) Requirements of engine manufacturers and boat manufacturers under Option 2 and using Low Permeation
Fuel Line Hose:
(A) Each manufacturer that chooses Option 2 must provide written instructions, as part of the installation
materials provided to purchasers of the engine, to use Low Permeation fuel Line Hose for the primary Fuel line
connecting the fuel tank to the engine of any boat that is manufactured for sale, sold, or offered for sale in
California, or that is introduced, delivered or imported into California for introduction into commerce.
(B) Each boat manufactured must install Low Permeation Fuel Line Hose for the primary Fuel line connecting the
fuel tank to the engine of any boat that is manufactured for sale, sold, or offered for sale in California that uses an
engine from a manufacturer that chooses Option 2.
Low Permeation Fuel Line Hose is USCG Type A1‑15, defined as not exceeding 15 g/m²/24 h with CE10 fuel at
23° C as specified in SAE J 1527—Marine Fuel Hoses.
Fuel Delivery System Specifications

! WARNING
Improper boat design and construction may result in serious injury or death. Adhere to all applicable marine
regulations (United States Coast Guard [USCG], European Union–Recreational Craft Directive [EU‑RCD], etc.)
and the standards they reference (American Boat and Yacht Council [ABYC], Society of Automotive Engineers
[SAE], International Standards Organization [ISO], etc.) when designing and constructing the boat and other
components, such as the engine compartment, fuel delivery system, or exhaust system.
The fuel delivery system must deliver the fuel to the engine with minimal restriction and at the lowest possible
temperature. Gasoline will vaporize quickly if placed under a vacuum (low pressure) at moderate or high
temperatures.
Vapor Locking
IMPORTANT: Vacuum readings higher than specified can cause vapor locking and poor engine performance.
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, engine heat causes the temperature of the fuel system to increase. Upon restart, the
combination of heat and vacuum in the fuel system vaporizes the fuel.
The symptoms of a fuel vapor lock include hesitation or bog when accelerating and engine stall. To minimize
vapor locking the fuel delivery system should meet these specifications:
Description Specification
Fuel delivery vacuum 6.9 kPa (2 in. Hg) (1 psi) or less
Fuel inlet temperature 44° C (110° F) or less
Keep the slope of the fuel line as consistent as possible avoiding elevated sections that can trap vapor and
contribute to vapor locking problems.
Fuel Lines and Fittings
IMPORTANT: If the engine is equipped with a boost pump, an in‑line filter must be installed between the fuel
tank and the boost pump. This filter is provided with the engine package.
IMPORTANT: Use the minimum fuel line and fitting sizes. Larger sizes may be required on applications with
longer fuel line runs or numerous fittings.
Page 2 / 4 90-8M0032375 AUGUST 2013

SECTION - 4 FUEL SYSTEM
Minimum fuel line diameter on single‑engine gasoline installations 10 mm (3/8 in.) ID or larger
Minimum fuel line diameter on multi‑engine gasoline installations
10 mm (3/8 in.) ID or larger
with a pickup and line for each engine
Minimum fuel line diameter on multi‑engine gasoline installations
13 mm (½ in.) ID or larger
with single pickup and line
US boating standards and regulations specify the sole use of USCG Type A1‑15 fuel lines in the engine
compartment or in any location in the boat where a break in the line could result in a discharge of 150 cc (5 oz) of
fuel in 2½ minutes. Refer to EPA and California Regulations—Low‑Permeation Fuel Hose.
To meet 2007 California Air Resources Board and EPA regulations, any boat manufactured for sale, sold or
offered for sale in California, or that is introduced, delivered or imported into California for introduction into
commerce must use low Permeation Fuel Hose from the primary connection of the fuel tank to engine.
Use low permeation fuel hose, which cannot exceed 15 g/m²/24 h with CE10 fuel at 23° C as specified in SAE J
1527—Marine Fuel Hoses. For more information refer to EPA and California Regulations—Low‑Permeation
Fuel Hose.
In addition to increasing restriction, long fuel line lengths and numerous fittings can increase fuel temperature by
absorbing heat from the engine compartment. Refer to the Fuel System Pressure and Temperature Test in the
appropriate engine service manual or applications manual to determine the fuel pressure and temperature. If the
temperature is excessive, reduce the fuel line length, the number of fittings, or insulate the components.
Observe the following fuel line guidelines:
• Route the fuel lines as low as possible in the engine compartment to keep them in the coolest region. The
temperature in the engine compartment increases significantly with increased height.
• Keep the slope of the fuel line as consistent as possible to avoid high spots that can trap vapor and
contribute to vapor locking problems.
• Round off holes or use grommets where the lines run through the bulkheads to prevent fuel line damage
from vibration and chafing.
• Install the fuel line free of stress and firmly secured to prevent vibration and chafing. Do not allow clamps to
pinch or kink the line.
• Avoid sharp bends in the fuel line.
• Use a flexible fuel line to connect the fuel supply line to the fuel inlet fitting on the engine to absorb deflection
between the engine and the hull structure when the engine is running.
Fuel Tank
This manual cannot cover all aspects of the fuel delivery system because of the broad range of possible
configurations and the numerous regulations and standards. Observe the applicable standards and regulations
for the markets where your product will be sold, along with any information from the fuel system component
manufacturers.
Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines. Only a
few points related to function and safety are listed here:
The main concern of a boat's fuel system is safety, which depends on a technically sound installation and
constant inspection. The fuel system 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.
• All connections should be on the upper side of the tank.
• Establish the exact route and length of the fuel lines at the first installation of the engine to prevent problems
later.
• 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 (½ in.) and must be fitted with a swan
neck to prevent water from entering the tank.
• Fuel pickup should be at least 25 mm (1 in.) from the bottom of fuel tank to prevent picking up impurities.
90-8M0032375 AUGUST 2013 Page 3 / 4

FUEL SYSTEM SECTION - 4
• The maximum measured vacuum at the engine's fuel inlet must not exceed 6.9 kPa (2 in. Hg) (1 psi)
throughout engine operating range. Use a digital vacuum gauge to measure the vacuum at the engine's fuel
inlet.
• Use Coast Guard approved (USCG Type A1) fuel lines. Refer to EPA and California Regulations—
Low‑Permeation Fuel Hose.
• Secure all fuel lines.
Water‑Separating Fuel Filters

The use of a water‑separating fuel filter is recommended. Refer to the Applications Manual for specifications.
Place the filter as close to the fuel pump as possible and still allow reasonable service access.
While a water‑separating fuel filter provides additional protection, more than one fuel filter in the line is not
recommended. The installation of additional filters may cause:
• Fuel vapor locking
• Difficult warm‑starting
• Piston detonation due to lean fuel mixture
• Poor drivability
Page 4 / 4 90-8M0032375 AUGUST 2013

SECTION - 5 COOLING SYSTEM
SECTION 5 - COOLING SYSTEM

Table of Contents
General Information................................................................................................................................................. 2
Seawater Supply System........................................................................................................................................ 2
Seawater Supply Hose Specifications............................................................................................................... 2
Seawater Inlet Hose.......................................................................................................................................... 2
Sterndrive Seawater Supply.............................................................................................................................. 3
Installing the Y‑Fitting........................................................................................................................................ 4
Through‑the‑Hull Seawater Pickup System...................................................................................................... 4
Seawater Pickup............................................................................................................................................... 5
Seacock.............................................................................................................................................................6
Sea Strainer...................................................................................................................................................... 7
Installing the Hot Water Heater............................................................................................................................... 7
Hose Connections ............................................................................................................................................ 8
Water Flow Diagram—8.2 MAG and 8.2 MAG H.O. Models................................................................................. 10 5
90-8M0032375 AUGUST 2013 Page 1 / 10

COOLING SYSTEM SECTION - 5
Lubricant, Sealant, Adhesives

Hose fitting threads and plastic plug threads
9 Loctite 567 PST Pipe Sealant 92-809822
Connector threads
116 RTV 587 Ultra Blue Silicone Sealer Sealing surfaces and screw shaft 92-809825
122 Extended Life Antifreeze/Coolant Closed cooling system 92-877770K1
General Information
The 8.2 engine is fitted with a closed cooling system designed to keep the engine operating temperature at
approximately 79 °C (175 °F) for optimum performance, fuel economy, and durability. The Mercury MerCruiser
closed cooling systems are sometimes called fresh water‑cooling and use a combination of fresh water
(antifreeze and water) and seawater for cooling. Refer to the cooling system flow diagram at the end of this
section.
To monitor the cooling system, a temperature sensor is incorporated into the audio warning system, which alerts
the operator of an abnormal condition if the temperature exceeds approximately 93 °C (200 °F).
NOTE: This engine is not equipped with an analog temperature sender. When using analog gauges an AGI box
is required.
The cooling system must receive a sufficient amount of seawater under all operating conditions to operate
properly.
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer
damage. Provide a sufficient supply of water to the water inlets during operation.
Seawater Supply System

Seawater Supply Hose Specifications
Description Hose and Connection Vacuum
Seawater inlet hose
Seawater pickup 32 mm (1‑1/4 in.) I.D.
Able to support 34 kPa (10 in. Hg) (5 psi) of
low restriction routing and
Seacock (ABYC requirement) vacuum without collapsing hose
connections
Sea strainer (optional)
Seawater Inlet Hose

• A reinforced hose capable of supporting 34 kPa (10 in. Hg) (5 psi) vacuum must be used to prevent the
seawater inlet hose from collapsing from pump suction.
• The hose should be oil and seawater resistant.
• Use the shortest hose length possible with the least number of bends to minimize restriction.
• All connections must be secured with hose clamps.
Page 2 / 10 90-8M0032375 AUGUST 2013

• Fasten the hose as appropriate to maintain proper routing and to prevent chafing or contact with other
moving parts.
a b a - Seawater inlet hose

b - Hose clamp connection to
pump inlet
c - Seawater outlet hose
d - Hose clamp connection to
pump outlet
c
d 43341
Sterndrive Seawater Supply

The 8.2 Bravo engine packages do not require additional seawater pickups if:
• The sterndrive gearcase has dual water pickups.
• The boat is capable of 64 km/h (40 mph) fully loaded and operated within the specified operating range.
The 8.2 Bravo Two sterndrive packages must have a through‑the‑hull or through‑the‑transom seawater pickup in
addition to the sterndrive side water pickups. Install the Y‑fitting at the engine's seawater pump inlet. See
Installing the Y‑Fitting.
Seawater Pickups Required for 8.2 Engine Models with Bravo Sterndrive
Boat speed with the maximum Through‑the‑hull or
SeaCore Bravo has side SeaCore Bravo has dual
load operating within the through‑the‑transom
water pickup water pickup
specified range seawater pickup
64 km/h (40 mph) or greater Not required
30180
Required,
Less than 64 km/h (40 mph)
see Installing the Y‑Fitting
30181 30180
Required,
64 km/h (40 mph) or greater
see Installing the Y‑Fitting
30181
90-8M0032375 AUGUST 2013 Page 3 / 10

Installing the Y‑Fitting

All 8.2 engine models with Bravo Two sterndrive require a through‑the‑hull or through‑the‑transom seawater
pickup and a Y‑fitting at the engine seawater pump inlet port. The Y‑fitting directs the seawater from the
sterndrive and through‑the‑hull or through‑the‑transom seawater pickup to the engine's seawater pump to meet
the minimum flow specifications.
a
a - Y‑fitting port to water inlet from sterndrive
b - Y‑fitting port to water inlet from through‑the‑hull or
through‑the‑transom seawater pickup
c - Hose 101.6 mm (4 in.) from seawater pump inlet to Y‑fitting
d - Engine seawater pump
d
b c 43629
NOTE: The 8.2 engine models are not factory equipped with a Y‑fitting. Refer to Mercury Parts Catalog, Closed
Cooling Systems (Bravo) to order one Y‑fitting 864727, three hose clamps 815504222, and seawater supply
bulk hose that meets MerCruiser specifications.
1. Cut a 101.6 mm (4 in.) length piece of the supply hose and install it to the seawater pump inlet and the
Y‑fitting.
2. Install a seawater supply hose to the Y‑fitting and the sterndrive's water inlet at the transom. Cut off any
excess hose as needed.
3. Install a seawater supply hose to the Y‑fitting and the through‑the‑hull or through‑the‑transom seawater
pickup. Cut off any excess hose as needed.
4. Properly secure all hoses to all fittings to prevent water leaking into the boat.
Through‑the‑Hull Seawater Pickup System

IMPORTANT: The seawater hose used must be able to support 34 kPa (10 in. Hg) (5 psi) vacuum to avoid
collapsing the hose when suction is created by the seawater pump impeller.
g
Typical through-the-hull
seawater pickup installation
a - Quicksilver seawater
pickup and seacock
b - Hose clamps
c c - Seawater hose to
seawater strainer
f d - Quicksilver seawater
strainer
b e - Seawater hose to engine
e b b f - Seawater pump hose
d connector (if equipped)
g - Below seawater pump
level
a
43179
IMPORTANT: Do not install the seawater 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.
Page 4 / 10 90-8M0032375 AUGUST 2013

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 seawater flow to engine seawater pickup
pump for adequate engine cooling.
• 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 seawater will flow past when the boat is underway.
• The seawater hose connections below the water line use two hose clamps.
Seawater Pickup
Either a through‑transom or through‑hull seawater pickup can be used. Select a pickup location to minimize the
seawater inlet hose length while providing an optimum location for the seawater pickup. The location should be in
an area that will provide a solid, air‑free flow of seawater under all operating conditions. Avoid areas with a
disturbed seawater 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 Seawater Supply Test.
IMPORTANT: Do not install the seawater pickup directly in line with the propeller, as pickup may create
turbulence and allow air to flow into the propeller slip‑stream. This will cause propeller ventilation and will
adversely affect boat performance.
Openings in seawater pickup should be approximately 3 mm (1/8 in.) maximum to prevent larger debris from
entering and clogging the cooling system.
IMPORTANT: Use a seawater strainer if the seawater pickup openings exceed 3 mm (1/8 in.).
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.
IMPORTANT: External seawater pickup must have an integral seacock.
7532
Typical seacock and boat bottom clamshell pickup
90-8M0032375 AUGUST 2013 Page 5 / 10

Typical transom pickup

b a - Hose fitting
d
e b - Nut (4)
a c f c - Gasket
d - O‑ring (4)
g e - Washer (4)
f - Screw (4)
g - Plastic plug
h - Pickup
h
i - Screen
j - Screw (2)
i
j 7558

Loctite 567 PST Pipe
9 Hose fitting threads and plastic plug threads 92-809822
Sealant
RTV 587 Ultra Blue
116 Sealing surfaces and screw shaft 92-809825
Silicone Sealer
Seacock
The ABYC and other industry standards and regulations require the use of a seacock on certain types of
applications to stop the entry of seawater in the event of a leak in the cooling system. Refer to applicable
standards and regulations for specific requirements. The seacock also allows the seawater to be shut off when
servicing the engine.
The seacock must provide minimum restriction to seawater flow (see Specifications). A ball valve 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
and requirements typically require that the seacock be rigidly attached to the hull at the seawater pickup.
Seacock location should be readily accessible for quick, easy operation.
7532
Typical seacock
Page 6 / 10 90-8M0032375 AUGUST 2013

Sea Strainer
A sea strainer is recommended if the boat is to be operated in an area with a high debris content. The strainer
must be sized to minimize restriction (See Specifications) and to provide a reasonable service interval. Locate
the strainer in an area that will be easily accessible for servicing. If the boat is not equipped with a seacock, the
strainer should be located above the seawater‑line to prevent seawater entry into boat when servicing. The
strainer must have provision to allow draining in freezing temperature periods.
7533
Typical Sea Strainer
Installing the Hot Water Heater

IMPORTANT: Hot water heater supply and return hoses must not exceed specification.
Hot Water Heater Hose Specification

Supply hose
16 mm (5/8 in.) ID
Return hose
When connecting a cabin heater or hot water heater:

• Use specified hot water heater supply and return hoses.
• Make the engine connections for the hot water heater only at the locations described in Hose Connections.
• Refer to the heater manufacturer's instructions for complete installation information and procedures.
• Do not reposition the engine temperature sensor; it must remain where installed by the factory.
• Inspect the complete system for leaks after the heater is connected to the cooling system.
• Monitor the engine coolant temperature after the heater is connected.
90-8M0032375 AUGUST 2013 Page 7 / 10

Hose Connections
a a - Heater supply (pipe plug)

b - Heater return (pipe plug)
b 50452
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not
to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local
restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
1. Place a 4 Liter (1 US gal) fluid catch container under the pipe plugs.
2. Remove the pipe plug from the heater supply and return locations on the engine. Properly dispose of the
coolant.
3. Apply sealant to the threads of each hose connector and install. Tighten 1–2 turns beyond hand‑tight.

9 Connector threads 92-809822
Sealant
4. Install the supply and return heater hose to the appropriate connector and secure with a hose clamp.
IMPORTANT: The coolant section of the closed cooling system must be filled with a 50/50 mixture of
Extended Life Antifreeze/Coolant and distilled water.
5. Add clean coolant to the full level in the coolant reservoir. Secure the coolant pressure cap.

Extended Life Antifreeze/
122 Closed cooling system 92-877770K1
Coolant
NOTICE
NOTICE
Blocking the coolant flow at the heater can cause reduced engine performance or overheating. Check for
continuous coolant flow from the engine to the water circulating pump.
6. Supply cooling water to the engine.
7. If applicable, supply cooling water to the sterndrive.
8. Start the engine and check for leaks and adequate coolant flow.
9. Allow the engine to reach normal operating temperature. Ensure that engine temperature remains normal
and that no leaks are present.
Page 8 / 10 90-8M0032375 AUGUST 2013

! CAUTION
A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from
burns. Allow the engine to cool down before removing the coolant pressure cap.
10. Stop the engine. If necessary, add new coolant to the full level in the coolant reservoir.
90-8M0032375 AUGUST 2013 Page 9 / 10

Water Flow Diagram—8.2 MAG and 8.2 MAG H.O. Models

NOTE: Certain components in the following diagram may look different than on your particular power package,
but the water and coolant flow paths remain similar on all engines.
16 2
7
3
8
9
10
1 7
4
9
6
5 8
13
14 11
15
50858
12
1- Seawater pump and starboard water drain valve

2- Fuel supply module
3- Steering fluid cooler
4- Oil cooler
5- Port seawater drain valve
6- Heat exchanger
7- Exhaust manifold
8- Exhaust water drain hose (only functions during seawater drain)
9- Check valve
10 - Coolant reservoir
11 - Crossover
12 - Water circulating pump
13 - Thermostat
14 - Glycol coolant flow
15 - Seawater flow
16 - Exhaust outlet
Page 10 / 10 90-8M0032375 AUGUST 2013

SECTION - 6 DRIVE SYSTEM AND ENGINE MOUNTING
SECTION 6 - DRIVE SYSTEM AND ENGINE

MOUNTING
Table of Contents
Transom Cutout....................................................................................................................................................... 4
Finding the Crankshaft Vertical Centerline........................................................................................................ 4
Single Engine ............................................................................................................................................. 4
Dual Engine ............................................................................................................................................... 4
Finding Crankshaft Horizontal Centerline (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
Driveshaft Extension Models............................................................................................................................. 9
Engine Mounts.................................................................................................................................................. 9
All Bravo Models............................................................................................................................................... 9
Mounting Water Drain Air Pump to Boat ........................................................................................................ 10
Transom Connections........................................................................................................................................... 10
Installing Gimbal Housing Assembly............................................................................................................... 10
6
Installing Inner Transom Plate ........................................................................................................................ 11
Connecting Speedometer Pickup.................................................................................................................... 12
Exhaust Preparation........................................................................................................................................ 13
Seawater Inlet Fitting and Gear Lube Monitor Fitting............................................................................................ 14
Seawater Inlet Fitting Installation (Bravo)........................................................................................................ 14
Gear Lube Monitor Connection at Gimbal Housing......................................................................................... 15
Exhaust at Transom.............................................................................................................................................. 15
Transom Exhaust Connections....................................................................................................................... 15
Power Trim Installation.......................................................................................................................................... 16
Power Trim Pump............................................................................................................................................ 16
Power Trim Pump Connections and Filling..................................................................................................... 17
Steering System Installation.................................................................................................................................. 18
Hydraulic (Helm) Steering............................................................................................................................... 18
Steering Helm and Cable................................................................................................................................ 18
Steering Cable Specifications......................................................................................................................... 19
Installing Steering System............................................................................................................................... 19
Sensor Steering Assembly.................................................................................................................................... 23
Installing the Pitot Sensor...................................................................................................................................... 24
Preliminary Transom Harness Connections.......................................................................................................... 25
Transom Harness............................................................................................................................................ 25
Transom Harness—DTS................................................................................................................................. 25
Engine Installation................................................................................................................................................. 26
Transom Preparation.......................................................................................................................................26
Shift Cable Routing......................................................................................................................................... 27
Engine Preparation..........................................................................................................................................27
Installing the Engine........................................................................................................................................ 30
Exhaust System Hose and Tube Connection.................................................................................................. 31
Engine Alignment............................................................................................................................................ 32
Electrical Connections........................................................................................................................................... 35
Boat Harness and Instrumentation Connections............................................................................................. 35
SmartCraft Product .................................................................................................................................. 36
Engine Harness Connections.......................................................................................................................... 36
90-8M0032375 AUGUST 2013 Page 1 / 66

DRIVE SYSTEM AND ENGINE MOUNTING SECTION - 6
Continuity Wire Connection ..................................................................................................................... 37

Audio Warning System Connections............................................................................................................... 37
MerCathode Connections................................................................................................................................38
Power Trim Electrical Connection................................................................................................................... 39
Power Trim Pump Connections....................................................................................................................... 40
Battery Cables Connection..............................................................................................................................40
Fluid Connections.................................................................................................................................................. 40
Gear Lube Monitor Connection....................................................................................................................... 40
Power‑Assisted Steering Hoses...................................................................................................................... 40
Bravo Seawater Cooled Models Using Sterndrive Water Pickups.................................................................. 41
Seawater Pump Pickup Connection................................................................................................................ 44
Fuel Line Connection to Gen III Cool Fuel Module......................................................................................... 44
Fuel Line Connection ............................................................................................................................... 44
Bravo Model Shift Cable Installation..................................................................................................................... 45
Bravo Models Shift Cable Installation.............................................................................................................. 45
Bravo Models Shift Cable Adjustment............................................................................................................. 46
Shift Cable Installation for the DTS System.......................................................................................................... 48
DTS System Installation........................................................................................................................................ 49
Throttle Cable Installation and Adjustment............................................................................................................ 49
Bravo Sterndrive Installation................................................................................................................................. 50
Trim Cylinder Installation................................................................................................................................. 57
Speedometer Connections ‑ Bravo Models..................................................................................................... 59
Trim Limit and Trim Position Settings.............................................................................................................. 60
Bravo Sterndrive Shift Check (Engine Running)............................................................................................. 60
Troubleshooting Shift Problems...................................................................................................................... 61
Paddle Wheel Speed Sensor Installation (If Equipped)........................................................................................ 63
Parts Provided ................................................................................................................................................ 63
Selecting Location .......................................................................................................................................... 64
Transom Angle Requirements ....................................................................................................................... 64
Installing Bracket ............................................................................................................................................ 64
Routing the Cable .......................................................................................................................................... 65
Drilling Hole Through Transom (optional) ................................................................................................ 65
Without Drilling Hole Through Transom (optional) ................................................................................... 65
Installing and Removing the Paddle Wheel ................................................................................................... 65
Wiring Connections ........................................................................................................................................ 65
Template ‑ Paddle Wheel Speed Sensor ....................................................................................................... 66
Page 2 / 66 90-8M0032375 AUGUST 2013

Lubricants, Sealants, Adhesives

Coupler splines
Extreme Grease U-joint O-rings 8M0071842
Driveshaft splines
Wiring connections
25 Liquid Neoprene 92- 25711 3
All electrical connections
27 Bellows Adhesive Exhaust bellows mounting surface 92-86166Q1
80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
87 High Performance Gear Lubricant Gear lube monitor 92-858064K01

Gimbal housing studs
Power steering bushings
Upper and lower pivot bolts
Clevis pin
Steering cable end
Threads of rear engine mounting bolts
95 2-4-C with PTFE 92-802859A 1
Shift cable stud
Threads of bell housing studs
O-ring
Water passage seals
Trim cylinder hardware
Shift cable end
Special Tools
Alignment Tool Assembly 91‑805475A 1
Aligns the engine and the sterndrive unit during installation.

9183
Dual Water Pick‑up Flush Gearcase Seal

91‑881150K 1
Kit
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
90-8M0032375 AUGUST 2013 Page 3 / 66

Flushing Kit 91‑849996T 1
Use for flushing gearcases with low water inlets.
9195
Transom Cutout
Finding the Crankshaft Vertical Centerline
Single Engine
1. Locate and mark the vertical centerline on the transom, if known. This is also the crankshaft vertical
centerline.
2. If unknown, a compass can be used to locate the vertical centerline:
a. Mark identical locations on each side of the boat 29.4 cm (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 centerline through the intersection points of the two arcs.
b e
a
c b e
d
7687
Single engine installation

a - 29.4 cm (12 in.)
b - Identical side marks
c - Compass arc
d - Arc intersection points
e - Crankshaft vertical centerline
Dual Engine
1. Locate and mark the vertical centerline on the transom. Refer to Single Engine procedure.
2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical centerlines on either
side of the vertical centerline.
Minimum Distance Between Crankshaft Vertical Centerlines (Dual Side‑By‑Side)

Model Measurement
8.2 95.25 cm (37‑½ in.)
IMPORTANT: Crankshaft vertical centerlines must be an equal distance from boat vertical centerline.
Page 4 / 66 90-8M0032375 AUGUST 2013

3. Draw the two crankshaft vertical centerlines through the intersection of the marks.
b
c c
b
a 7688
Dual installation
a - Vertical centerline
b - 1/2 minimum distance between crankshaft centerline marks
c - Crankshaft vertical centerlines
Finding Crankshaft Horizontal Centerline (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.
a - 34.5 cm (13‑9/16 in.)

90 b - 1.2 m (4 ft)
a
b 7689
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 centerline.
3. Locate the point at which top of the 90 degree tool contacts the transom on the vertical centerline. This is the
crankshaft horizontal centerline or X‑dimension.
90-8M0032375 AUGUST 2013 Page 5 / 66

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

a - 90 degree tool along boat bottom at vertical centerline
b - Contact point
c - Crankshaft horizontal centerline
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 centerline, measure up from the bottom of the transom to the X‑dimension
selected previously. This is the crankshaft horizontal centerline at the X‑dimension.
3. Draw a line perpendicular to the vertical centerline at the crankshaft horizontal centerline.
a
a
c c
b
b
7693
7692
Single engine Dual engine

a - Vertical centerline
b - X‑dimension that corresponds to transom angle
c - Crankshaft horizontal centerline
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 / 66 90-8M0032375 AUGUST 2013

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).
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.
90-8M0032375 AUGUST 2013 Page 7 / 66

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 - 51 mm (2 in.) hole saw holes (steering lever cutout)

a b b - 60 degrees versus transom angle
7695
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.
a- Cut line
b- 90 degrees to transom
c- Exhaust pipe area
d- Mounting holes perpendicular to transom (8)
b
a
d c
7696
Checking the Transom Thickness

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit
mounts.
Ensure that transom thickness and surface conform to specifications.
Page 8 / 66 90-8M0032375 AUGUST 2013

Transom Specifications
Thickness Between 51–57 mm (2–2‑1/4 in.) for 203 mm (8 in.) to either side of the vertical centerline
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 as horizontal
Flatness
dimensions): Inner surface ‑ Flat within 3 mm (1/8 in.); Outer surface ‑ Flat within 2 mm (1/16 in.)
Angle 10–16°
7697
a - Measuring thickness
b - Measuring flatness
c - Suitable mandrel to check for uniform transom thickness
Preliminary Connections
Driveshaft Extension Models
If your power package is equipped with a driveshaft extension, refer to the Driveshaft 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.
All Bravo Models

IMPORTANT: The trim‑in limit insert must be properly positioned before installing the trim cylinder anchor pin.
NOTE: When removing the sterndrive, note the position of the insert for reference when reinstalling the
sterndrive.
90-8M0032375 AUGUST 2013 Page 9 / 66

Ensure that the trim‑in limit insert is positioned correctly for the appropriate Bravo model.
Bravo One and Two (positioned forward)

a - Trim‑in limit insert
a
8548
Bravo Three (positioned aft)

a - Trim‑in limit insert
a
8557
IMPORTANT: The position of the trim‑in limit insert on the Bravo Three sterndrive should only be changed after
the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original position for a
particular boat application.
Mounting Water Drain Air Pump to Boat

NOTE: The air pump is used to activate the water drain system and should be mounted on the boat transom in a
easily accessible area.
1. Select an accessible mounting location for the air pump that is away from moving parts.
2. Mount the air pump with the bracket and fasteners provided in the parts bag on the engine.
c
b a - Pump
b - Bracket
c - Screw holes
b
a
43158
Transom Connections
Installing Gimbal Housing Assembly
1. Carefully remove transom assembly from shipping carton.
Page 10 / 66 90-8M0032375 AUGUST 2013

2. Remove and read all tags attached to transom assembly.
a - Shipping hardware
b - Trim cylinder suppport
a
7713
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.
Installing Inner Transom Plate

1. Insert wires, hoses, and shift cable through the appropriate openings in the inner transom plate.
2. Position the gimbal housing on the transom and hold in place.
3. Apply lubricant to the first 8 mm (1/4 in.) of the threads of the gimbal housing studs.

95 2-4-C with PTFE Gimbal housing studs 92-802859A 1
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.
4. Secure transom assembly with fasteners. Tighten the fasteners to the specified torque.
Description Nm lb‑in. lb‑ft

Transom assembly hardware 34 – 25
NOTE: The trim limit is adjusted using the PCM on SmartCraft transom models.
IMPORTANT: The steering lever continuity circuit wire is positioned to avoid stressing the wire when the
steering lever moves.
90-8M0032375 AUGUST 2013 Page 11 / 66

IMPORTANT: Transom harness ground must be attached as shown.
c
a
5 7
a
a
3 2
b
1 4
e 8 6
23138
a- Locknuts and flat washers (8)

b- Hydraulic hoses and MerCathode wire
c- Steering lever continuity wire
d- Transom plate continuity wire
e- Torque sequence
f- Analog and digital trim sender wires
g- Ground from transom harness
Connecting Speedometer Pickup

NOTICE
Removing the plug from the speedometer pickup fitting can introduce water into the bilge. Do not remove the
the plug unless you intend to make a connection to a speedometer pickup.
1. Remove the protective cap from the male quick connect.
Page 12 / 66 90-8M0032375 AUGUST 2013

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
b - Female quick connect
c - Barbed fitting
d - Hose
e - Tie strap
! CAUTION
A ruptured speedometer hose can introduce water into the bilge, causing boat damage or possible sinking.
Position or install the speedometer hose away from moving parts or pinch points, such as steering system
components, engine coupler, or driveshaft, which could damage the hose.
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.
Exhaust Preparation
IMPORTANT: When installing through the transom exhaust, remove the exhaust bellows on the transom
assembly and install the exhaust tube. 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 the 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 switchable exhaust system, the exhaust tube must be installed.
• With any application, installation of an exhaust tube will increase exhaust noise.
2. If required, install the exhaust tube on the gimbal housing as follows:
a. Remove and discard the clamps and exhaust bellows.
IMPORTANT: Failure to install the grounding clip can damage the exhaust tube due to corrosion.
Always install the grounding clip.
b. Install the grounding clip on the exhaust tube.
c. Apply adhesive to the exhaust tube mounting surface.
90-8M0032375 AUGUST 2013 Page 13 / 66


27 Bellows Adhesive Exhaust bellows mounting surface 92-86166Q1
d. Allow bellows adhesive to dry until no longer tacky (approximately 10 minutes).

e. Position tube so that "SIDE" markings on tube are facing toward the right and left sides.
f. Install and torque the clamp.
e a- Exhaust tube
b- Clamp
c- "SIDE" marking
d- Exhaust tube
d e- Grounding clip
c
b
a 8406
Description Nm lb–in. lb–ft

Exhaust tube clamp 3 26 –
Seawater Inlet Fitting and Gear Lube Monitor Fitting

Seawater Inlet Fitting Installation (Bravo)
Install a new gasket, seawater inlet fitting, and screws. Torque screws.
a Seawater inlet fitting

a shown with gear lube
hose J-clip
b a - Seawater inlet fitting
b - Screw (2)
c - Gasket
d - Star washers
d
21634
Description Nm lb. in. lb. ft.

Seawater inlet fitting screws 5 45
Page 14 / 66 90-8M0032375 AUGUST 2013

Gear Lube Monitor Connection at Gimbal Housing

1. Connect the quick release 90 degree fitting of the gear lube monitor hose to the gimbal housing.
d a
Model with block-off plate
a - Hose
a b - Quick release 90 degree fitting
c c - Seawater inlet fitting
d - J‑clip
b
21623
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.
Model with Quick connect

b seawater inlet fitting
a - Gear lube monitor hose
b - Seawater inlet fitting
c - Quick release button
c 21624
NOTE: The hose must not come into contact with the steering system components or the engine coupler and
drive shaft.
Exhaust at Transom
Transom Exhaust Connections
IMPORTANT: The exhaust pipe or block‑off plate and the gimbal housing mating surface must be clean and free
of nicks and scratches. The O‑ring must be properly seated in groove or water may leak into the boat.
NOTE: Exhaust block‑off plate kit must be ordered separately.
90-8M0032375 AUGUST 2013 Page 15 / 66

Qty. Description Part Number

1 Exhaust block‑off plate kit 861776A2
a - Seal
21630
1. For through‑the‑transom exhaust installations, install a block‑off plate using four bolts and lockwashers.
Tighten the bolts to the specified torque.
b a - Block‑off plate
b - Bolts
c c - Lockwashers
a
21625

Exhaust block‑off plate bolts 34 – 25
2. For through‑the‑propeller exhaust installations, install the exhaust pipe. Tighten the bolts to the specified
torque.
a - Engine exhaust pipe
a
16231

Exhaust pipe to gimbal housing bolts 34 – 25
Power Trim Installation

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.
• 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.
Page 16 / 66 90-8M0032375 AUGUST 2013

• 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
a- Positive battery lead
c b- Negative battery lead
c- Harness connector
g d- BLACK hydraulic
hose (UP hose)
e- GRAY hydraulic
hose (DOWN hose)
f- Fill/vent cap
h g- Dual mount trim
pump bracket
f h- Trim limit switch
connected and
secured
b d 7698
e
2. Connect power trim pump control harness to trim pump.
a a - Control harness
b - Trim pump connector
b
7699
a a - Fill cap assembly (top and

underneath side views)
b b - Fill cap on trim pump reservoir
7701
90-8M0032375 AUGUST 2013 Page 17 / 66

Steering System Installation

Hydraulic (Helm) Steering
If your power package is equipped with compact hydraulic steering, refer to the Compact Hydraulic (Helm)
Steering installation instructions.
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 can cause serious injury or death due to loss of boat control. Use
a locking device, such as a self‑locking coupler or external locking device when installing steering controls.
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 nut.)
a a - Quicksilver RideGuide steering cable self‑locking coupler nut

(identified by groove)
7255
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.
! WARNING
Failure to use the correct cables or other steering system components can cause serious injury or death due to
loss of boat control. Use only approved or required components when installing steering systems.
1. Steering cable must be the correct length, particularly when installed in larger boats.
2. Avoid sharp bends, kinks, or loops in cable.
3. Fully extended steering cable end dimension must be as specified.
Page 18 / 66 90-8M0032375 AUGUST 2013

Steering Cable Specifications

IMPORTANT: Power‑assisted 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

b- 298 mm (11‑3/4 in.) minimum
c- Interface point
d- 12.7 mm (1/2 in.) maximum
e- 10.7 mm (27/64 in.) minimum flat
f- 3.1 mm (7/64 in.) minimum radius
g- 15.9 mm (5/8 in.) maximum diameter end fitting
h- 9.5 mm (3/8 in.)
i- 9.8 mm (3/8 in.) diameter through hole (chamfered each side)
j- 34.9 mm (1‑3/8 in.) maximum
k- 15.9 mm (5/8 in.) diameter tube
l- Cable travel: mid‑travel position ‑ 429 mm (16‑7/8 in.) total travel to be 203 mm (8 in.) minimum to 228 mm
(9 in.) maximum travel each side of mid‑travel position ‑ 102 mm (4 in.) minimum to 114 mm (4‑1/2 in.)
maximum
Installing Steering System

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

95 2-4-C with PTFE Power steering bushings 92-802859A 1
90-8M0032375 AUGUST 2013 Page 19 / 66

3. Remove the upper and lower pivot bolts and ensure that the threads are well lubricated.
a
a - Upper pivot bolt
b - Lower pivot bolt
b
21631

95 2-4-C with PTFE Upper and lower pivot bolts 92-802859A 1
4. Position the steering assembly so that the pivot bolts will enter the bushings in the power‑assisted 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.
a Upper pivot bolt and tab washer

b shown (lower similar)
a - Tab washer tang
b - Ridge
b
a 21632
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. Tighten the pivot bolts to the specified torque. Bend the tab washer tabs against the corresponding flats on
the bolt heads.
Page 20 / 66 90-8M0032375 AUGUST 2013

NOTE: It may be necessary to tighten the pivot bolts further to align the flats on the bolt head with the tabs
on the washer.
b b
a
21691
a - Pivot bolt
b - Bent tab

Upper and lower pivot bolt 34 – 25
! CAUTION
Contents under pressure. Moving the control valve cable guide tube with the hoses disconnected expels fluid
from the ports. Wear eye protection while servicing the system.
9. While wearing eye protection to avoid expelled fluid, move the control valve cable guide tube as 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.

a. Lubricate the clevis pin.

95 2-4-C with PTFE Clevis pin 92-802859A 1
90-8M0032375 AUGUST 2013 Page 21 / 66

b. Insert the clevis pin.
b a - Clevis
a b - Clevis pin
20396
c. Insert the cotter pin.

d. Spread both ends of the cotter pin.
c
a - Cotter pin
b - Clevis pin
c - Steering lever
b
a a 20399
IMPORTANT: Quicksilver RideGuide steering cable has a self‑locking coupler nut and does not require an
external locking sleeve or locking plate.
a a - Self‑locking coupler nut
7255
NOTICE
Fastening any items to the steering cables or outer casings prevents normal operation. The steering cable and
outer casing must be free to move back and forth. Do not fasten any items to the steering cable and outer
casing.
a - Steering cable and outer casing
7827
11. Connect the steering cable as follows:
Page 22 / 66 90-8M0032375 AUGUST 2013

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

95 2-4-C with PTFE Steering cable end 92-802859A 1
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. Tighten
the coupler nut to the specified torque. Ensure that the flat surfaces are still aligned vertically after
torque is applied to the coupler nut.

Steering cable coupler nut 47 – 35
d
g
e f
c
a b
d
7830
a- Steering cable
b- Grease fitting
c- Cable coupler nut
d- Cable guide tube
e- Steering cable end
f- Clevis
g- Clevis pin
h- Cotter pin
Sensor Steering Assembly

1. Remove nuts from upper 2 transom studs.
2. Remove cotter pin and clevis pin from steering lever.
90-8M0032375 AUGUST 2013 Page 23 / 66

3. Install new clevis pin and secure with existing cotter pin.
c a- Transom stud holes

b- Pitot tube connection
a c- Plug
h d- Guide
a e- Cotter pin
d
f- Clevis pin
f
g- Tie strap
e h- Alignment mark
b g 8403
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.
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.
a - Male quick‑connect fitting

b - Yellow plug
b
a
mc79613-1
IMPORTANT: Ensure that the fittings snap into place.

2. Connect the quick‑connect pitot hose to the fitting on the transom.
a a - Female quick‑connect fitting

b - Male quick‑connect fitting
mc79614-1
Page 24 / 66 90-8M0032375 AUGUST 2013

3. Connect the pitot hose quick‑connect fitting on the transom.
b a - Pitot sensor
a
b - Quick‑connect fitting on transom
12119
Preliminary Transom Harness Connections

Transom Harness
The transom harness connects to the engine harness and the following transom connections; engine to transom
ground, analog trim, and the MerCathode. Wires are color coded and connections are tagged for easy
installation.
IMPORTANT: Secure ground ring terminal (black wire) to screw on port side of transom plate.
1. Ensure that the transom harness ground ring is secured with the continuity circuit wire on transom plate.
2. If equipped, connect the transom harness MerCathode connector to the MerCathode connector from
transom.
3. Analog trim: Connect transom harness analog connector to the analog connector from transom.
4. Make all transom wiring connections and secure with clamps. Transom harness connector should be placed
in a safe location and will be connected to the engine after the engine is installed.
Transom Harness—DTS
DTS engines are shipped with an adapter to connect the transom harness to the power trim pump. See Section
7 ‑ Boat Harness Installation Guidelines.
IMPORTANT: Secure ground ring terminal (black wire) to the transom bonding strap screw on the port side of
transom plate.
1. Ensure that the transom harness ground ring is secured with the continuity circuit wire on transom plate.
2. Make all transom wiring connections and secure with clamps.
90-8M0032375 AUGUST 2013 Page 25 / 66

3. Position the transom harness in a safe place out of the way for the engine installation. The transom harness
connects to the engine harness after the engine is installed.
b c Transom harness—DTS
a - 16‑pin connector to engine harness
d
b - Power trim connects to power trim harness (color
coded)
e
c - SmartCraft steering sensor
f d - SmartCraft pitot sensor
j e - Analog trim gauge
g f - MerCathode
g - Transom ground (to the transom bonding strap
a screw)
h h - Digital trim gauge
i 25154 i - DTS power trim harness connects to transom
harness
j - DTS power trim harness connects to trim pump
Engine Installation
Transom Preparation
NOTICE
Mismatched flywheel housing mounts and inner transom plate mounting hardware will result in improper engine
alignment and possible engine damage. 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.
1. When installing mounts with knurled bottoms, use only the fiber washer. Do not install double‑wound
lockwashers to knurled mounts.
a
7960
Typical flywheel housing, all similar

a - Late‑style mount: knurled surface
b - Fiber washer
Page 26 / 66 90-8M0032375 AUGUST 2013

2. Position rear engine mount attaching hardware on the inner transom plate mounts as shown.
a - Fiber washer (2)

b - Locknut (2)
7839
Shift Cable Routing

Route the intermediate shift cable from the transom assembly to the shift actuator as follows:
IMPORTANT: Do not move the shift cable stud on the shift arm.
IMPORTANT: The shift cable barrel is preset and cannot be adjusted.
• 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.
• The cable should then be routed under the starboard rear engine mount and turn toward the transom.
• The cable should then go in back of the steering cylinder assembly and loop over to the shift actuator on the
engine.
NOTE: Following this routing will prevent the engine coupler from damaging the cable.
8995
Shift cable routing
Refer to Section 8 ‑ Remote Control.
Engine Preparation
1. Install the battery positive (+) cable directly to the positive (+) stud on the engine as follows.
90-8M0032375 AUGUST 2013 Page 27 / 66

a. Slide the rubber boot down the cable.
43051
b. Remove the lockwasher and nut holding the starter positive (+) cable to the positive (+) stud on the
engine.
a b a- Nut
c
b- Lockwasher
c- Nut
d- Positive (+) starter cable
e- Rubber boot
d
43052
c. Slide the battery cable through the rubber boot and place on the positive (+) stud over the starter battery
cable.
b a - Positive (+) battery cable

a
b - Positive (+) starter cable
c - Rubber boot
c
43495
d. Install the lockwasher and nut to secure both cables.
Page 28 / 66 90-8M0032375 AUGUST 2013

e. Tighten the nut to the specified torque.
a b c a- Positive (+) stud

b- Nut
c- Lockwasher
d- Positive (+) battery cable
e- Positive (+) starter cable
f- Nut
d e f 43496

Positive battery cable on the engine stud nut 10 89 –
f. Apply a thin coat of sealant over the stud and the connection.

25 Liquid Neoprene Wiring connections 92- 25711 3
g. Slide the rubber boot over the cable connection.
43486
h. Drape the battery cable over the top of the engine to prevent interference during installation.
IMPORTANT: There is a fuse located at the starter solenoid. Do not remove this fuse.
a b a - Starter solenoid
b - 90–amp fuse ‑ do not remove
c - Engine oil pan
43054
90-8M0032375 AUGUST 2013 Page 29 / 66

2. If not already done, remove the shipping plug from the engine coupler and lubricate the splines.
a b c a - Shipping plug
b - Engine coupler
c - Flywheel housing
43498

Extreme Grease Coupler splines 8M0071842
3. Remove all hardware that secures the engine to the shipping container.
4. Remove and read all tags attached to the engine.
Installing the Engine

IMPORTANT: Do not allow the engine to rest on the oil pan.
NOTE: Do not use silicone on the exhaust tubes.
1. Attach a suitable sling and spreader bar (to prevent plenum and throttle plate damage) to the lifting eyes on
the engine and adjust so that the engine is level when suspended.
NOTE: ECT model shown, non‑ECT model similar.
a - Front lifting eye

b - Rear lifting eye
50453
2. Lift the engine into position (in boat) using an overhead hoist.
3. Align the rear engine mounts with the inner transom plate mounts while simultaneously aligning the exhaust
tube with the exhaust pipe bellows.
4. To help with installation, apply lubricant into the exhaust tubes.
Page 30 / 66 90-8M0032375 AUGUST 2013

Description Where Used Part Number

Liquid Soap Exhaust tubes Obtain locally
5. Apply lubricant to the first 6 mm (1/4 in.) of the threads of the rear engine mounting bolts.

95 2-4-C with PTFE Threads of rear engine mounting bolts 92-802859A 1
6. Install both rear engine mounting bolts and hardware. Relieve the hoist tension from the engine lifting eyes.
Tighten the mounting bolts to the specified torque.
c
c
e
d
e
a g a
f b
7961 f 7772
b
a- Rear engine mount
b- Inner transom plate mount
c- Bolt
d- Washer
e- Spacer
f- Fiber washer
g- Stainless steel washer (optional spacer kit)

Rear engine mounting bolts 47 – 35
7. Loosen both adjusting nuts on the front engine mounts to allow for adjustment during alignment.
8. Attach the front mounts to the stringers.
9. Remove the engine hoist.
Exhaust System Hose and Tube Connection

NOTICE
Hot spots in exhaust hoses can damage hoses and cause leaks. Ensure that discharge water from the exhaust
elbow flows without restriction through all hoses and fittings.
IMPORTANT: The exhaust system supplied by Mercury MerCruiser is compliant with the ABYC Standard P‑1. If
components are used in any portion of the exhaust system that modify the design of the supplied system, it is the
boat builder's responsibility to ensure that the new system complies with the ABYC Standards. Exhaust system
connections to components other than those supplied by Mercury MerCruiser must use two stainless steel
clamps with a minimum width of 13 mm (1/2 in.) at each joint.
90-8M0032375 AUGUST 2013 Page 31 / 66

Install hoses on exhaust elbow outlets so discharge water from the exhaust elbow flows around the entire inside
diameter of the hose.
8420 8288
Correct alignment Incorrect connection
To avoid hot spots that can burn exhaust hoses, install the exhaust hoses at the angle shown below.
a
c
b
44886
a - Exhaust outlet centerline

b - Parallel with crankshaft centerline
c - Exhaust angle 14° ± 5°
Secure all exhaust hoses or tubes with at least two hose clamps. Tighten to specification.
Engine Alignment
1. Gently lift the top back edge of the silencer and pull forward to remove.
a - Silencer
b - Flame arrester
50395
Page 32 / 66 90-8M0032375 AUGUST 2013

2. Place a suitable polymer strap under the plenum behind the throttle body for assistance during engine
alignment.
a a - Suitable polymer strap

b b - Plenum
c - Throttle body
50445
3. If applicable, open the perforated area in the bell housing dust cover.
a - Dust cover
8378
NOTICE
Improper use of the alignment tool may result in personal injury or damage to the gimbal bearing or engine
coupler. Do not operate the engine with the alignment tool installed. Do not attempt to force the alignment tool,
raise or lower the engine with the tool inserted in the gimbal bearing or engine coupler, or raise the engine
mount bracket above the top of the engine mount stud.
IMPORTANT: Alignment tools from other manufacturers may cause improper alignment and damage to the
gimbal bearing or engine coupler. Use only the Quicksilver alignment tool.
4. 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
5. If the tool does not fit, remove it and carefully raise or lower the front end of the engine as necessary, and
attempt to insert the alignment tool.
NOTE: It may be necessary to hit the alignment tool with a synthane hammer to set the gimbal bearing to the
coupler.
90-8M0032375 AUGUST 2013 Page 33 / 66

6. If necessary, firmly strike the sides of the alignment tool at 90° increments to help align the gimbal bearing.
d
c
a b
7784
e
a- Alignment tool
b- Gimbal bearing
c- Engine coupler
d- Hammer
e- 90° increments
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 the
align the engine.
8. Adjust the front engine mounts until they rest on the boat stringers.
9. Relieve the hoist tension entirely and fasten both the front mounts to the boat stringer using 9 mm (3/8 in.)
lag bolts.
10. Recheck the alignment with the alignment tool. The tool must enter the coupling splines freely. If not, readjust
the front mounts.
a - Alignment tool (use only recommended alignment tool)

b - End to be inserted through gimbal housing assembly
b
a
8503
11. When the alignment is correct, tighten locknut securely. Recheck the alignment.
Page 34 / 66 90-8M0032375 AUGUST 2013

12. Bend the tab down on the adjusting nut.
a- Nut and lockwasher

b- Tab washer
c- Direction (counterclockwise) to raise front of engine
d- Adjustment nut
a
b d
c
8504
13. Remove the alignment tool. If not installing the sterndrive, fold the bell housing dust cover flap back into
place and tape it shut for the boat shipment.The dust cover flap will have to be removed before operating the
engine.
14. Remove the strap from the plenum if used for the engine center alignment.
15. Install the silencer.
Electrical Connections
IMPORTANT: Refer to the following precautions when working on or around the electrical harness, or when
adding other electrical accessories, to avoid damage to the electrical system.
• Do not tap accessories into the engine harness.
• Do not puncture wires for testing (probing).
• Do not reverse the battery leads.
• Do not splice wires into the harness.
• Do not attempt diagnostics without the 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
Boat Harness and Instrumentation Connections

We recommend the use of Mercury/Quicksilver Instrumentation and Wiring Harnesses.
The four basic gauges that must be used with the engine are:
• Tachometer
• Oil pressure
• Water temperature
• Voltmeter
IMPORTANT: Maximum accessory load on the engine harness is 15 amps. If additional accessory load is
needed, an accessory kit is available.
1. If an extension harness is required, connect the boat harness to the extension harness and connect the
extension harness to the engine harness. Ensure that the harness does not rub or get pinched.
90-8M0032375 AUGUST 2013 Page 35 / 66

2. Fasten harnesses to the boat at least every 46 cm (18 in.) using appropriate fasteners.
Typical
a - Engine harness plug
23135
3. Connect the 14‑pin harness to the engine. Turn the locking ring until a firm snap is felt.
23136
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 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.
Engine Harness Connections

IMPORTANT: The 14‑pin wiring harness can supply a maximum 15 amps of accessory power. An accessory
relay and harness kit is available for higher accessory needs.
1. Route the instrumentation harness to engine. Do not allow the harness to rub or get pinched. If an extension
harness is required, secure the connection properly.
2. Fasten the harnesses to the boat at least every 45.7 cm (18 in.), using appropriate fasteners.
Page 36 / 66 90-8M0032375 AUGUST 2013

3. Connect the following:
a b c d e
a- Paddle wheel and tank level connector
b- Depth transducer connector
c- 14‑pin harness connector
d- Power harness connector
e- Transom harness connector
43057
Continuity Wire Connection

IMPORTANT: Models equipped with 14‑pin engine harness have the transom continuity circut incorporated into
the transom harness.
Audio Warning System Connections

! WARNING
Installing non‑potted electrical components in explosive environments can result in serious injury or death from
fire or explosion. Install all non‑potted electrical components such as warning alarms away from environments
where fuel or fuel vapor is present such as engine or fuel tank compartments.
1. Select a location for the 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 the wire is attached must have no voltage when ignition switch is in the "OFF"
position.
2. Place the alarm in desired location and secure it to wire bundle with the tie strap provided.
3. Connect the tan/blue wire from the alarm to the tan/blue wire from the instrument harness.
4. Connect the purple wire from the alarm to any purple wire terminal on the instrument gauge or ignition
switch. Tighten the connection securely.
a - Alarm
b - Tan/blue wire
b c - Purple wire
a
45019
90-8M0032375 AUGUST 2013 Page 37 / 66

5. Place the small transparent alarm decals on the bottom of the water temperature and the oil pressure
gauges.
45021
Small transparent alarm decals
6. Choose the proper large decal for the engine package installed and place it on the instrument panel or other
appropriate location easily viewed by the operator.
a a - Models equipped with a drive reservoir having low

oil level switch
b - Models equipped with a transmission
c - All other models
b
45020
7. Test the audio warning system as detailed.

a. Turn the ignition switch to the "ON" position without cranking the engine.
b. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
MerCathode Connections
The engine harness supports the MerCathode system. The engine harness has a MerCathode connector that
connects to a MerCathode connector on the transom harness.
1. Locate the MerCathode controller assembly on the engine rear starboard.
a - MerCathode
b - Red/purple wire
a
50540
Page 38 / 66 90-8M0032375 AUGUST 2013

2. Connect the MerCathode red/purple wire directly to the positive (+) terminal of the battery or to a point that
will not shut off if a battery switch is used. This insures the proper operation of the MerCathode unit.
a
a - MerCathode
b - Red/purple wire
c - 5‑amp fuse
50534
IMPORTANT: The red/purple wire must be connected directly to the battery positive (+) terminal. Do not
connect it to a switched positive (+) circuit. MerCathode system must function continuously for proper
corrosion protection.
Power Trim Electrical Connection

ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the positive
conductor of any battery or battery bank with CCA rating greater than 800 amps (see ABYC for additional
information).
ABYC further recommends, if a boat is equipped with a battery switch, the power trim pump may not be
connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery
switch. Wire length requirements and location of circuit protection are also specified.
MerCruiser has developed three methods to facilitate compliance with ABYC recommendations. These come in
the form of one standard production and two accessory kits.
• Installations with batteries (or battery banks) rated at less than or equal to 800 cold cranking amps (CCA)
and without battery switches: The trim pump may be installed using the wires supplied with the power trim
pump and should be connected directly to the battery.
• Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any
boat with a battery switch: The red current conductor (for the trim pump) must be connected to the switched
side of the battery switch and either:
• provided with circuit protection within 7 inches of the point of connection with the power source or
• provided with circuit protection within 40 inches of the point of connection with the power source and
sheathed the entire length of wire from the point of connection at the source to the circuit protection
device. This will require the use of an Accessory cable kit.
Accessory Part Numbers

Part Number Description Color Length Type
889282A02 Cable assembly – trim pump Red 183 cm (72 in.) Fused and sheathed
889282A01 Cable assembly – trim pump Red 102 cm (40 in.) Sheathed
90-8M0032375 AUGUST 2013 Page 39 / 66

Power Trim Pump Connections

Connect power trim pump black (–) battery cable to negative (–) battery terminal and pump's red (+) battery cable
to positive (+) battery terminal or to the switched side of the battery switch.
a - Positive battery lead

a
b - Negative battery
lead
b
6842
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.
3. Install the power harness. Refer to Section 7—Power Harness.
4. Secure the battery cables and the power harness leads to the battery with hex nuts. Tighten the hex nuts to
the specified torque.

Hex nut 13.5 120 –
5. Spray battery terminals with a battery connection sealant to help prevent corrosion.
Fluid Connections
Gear Lube Monitor Connection
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 driveshaft.
3. Fasten the quick connect.
a b c e
d a- Gear lube monitor hose assembly from transom
b- O‑ring
c- Quick connect release
d- Gear lube monitor hose assembly from gear lube
monitor
43559
e - Connection secured
Power‑Assisted Steering Hoses

IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leaks.
1. Disconnect the quick connect fittings on the power‑assisted steering hoses.
Page 40 / 66 90-8M0032375 AUGUST 2013

2. Connect the power‑assisted 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.
4. Use extra hose clips to secure hose to transom.
a
a
b b
16225
a - Hydraulic lines
b - Power‑assisted steering control valve
NOTE: Steering fluid can be added at this time if desired.
Bravo Seawater Cooled Models Using Sterndrive Water Pickups

IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is connected
properly.
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.
c
Seawater inlet hose assembly
a - Retainer clip closed
b - Quick connect fitting
a c - Hose decal
8512
b
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 with the correct orientation. Mate the small tab with
the small slot.
90-8M0032375 AUGUST 2013 Page 41 / 66

c. Align the slots of the quick connect fitting to the tabs of the water inlet fitting.
g
a- Quick connect fitting
h b- Small slot
c- Large slot
d- Seawater inlet fitting
b e e- Small tab
a f- Large tab
d g- Center of retainer clip
c f (toward engine)
h - Centerline of water
8513 inlet fitting (toward
engine)
d. Ensure that the centerline 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.
a - Centerline of water inlet fitting

c a b - Retainer clip in closed position
c - Hose decal
8514
IMPORTANT: Perform a pull test at the seawater inlet connection to ensure the seawater inlet hose is
connected properly.
3. Perform a pull test on the water hose quick connection.
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.
a - Seawater inlet hose

b - Quick connect fitting
c - Seawater inlet fitting
a c
b
8515
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.
Page 42 / 66 90-8M0032375 AUGUST 2013

NOTE: The seawater inlet hose connects to the engine and the transom.
Seawater inlet hose assembly

e b a - Seawater inlet hose
d b - To engine
e c c - Quick connect fitting
d - Seawater inlet fitting
a 8516
e - Hose clamps
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.
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 engine)

b- Seawater extension hose
c- Seawater inlet hose (to engine seawater pump)
d- Quick connect fitting (to seawater inlet fitting)
e- Seawater inlet fitting (to transom)
b. Perform a pull test to ensure that the requirements for checking the integrity of the connection are met.
90-8M0032375 AUGUST 2013 Page 43 / 66

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

b- Quick connect fitting to extension hose
c- Quick connect male fitting
d- Extension hose
e- Quick connect fitting to seawater inlet fitting
f- Seawater inlet fitting
g- Hose clamp
Seawater Pump Pickup Connection

Ensure that the seawater inlet hose is connected to the upper hose fitting of the seawater pump.
a - Seawater inlet hose

b - Seawater (out) hose to cooler
c - Seawater pump
c
43074
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 the shipping plug from the fuel fitting.
2. Connect the flexible fuel line to the fuel fitting.
Page 44 / 66 90-8M0032375 AUGUST 2013

IMPORTANT: Hold fuel inlet fitting stationary with a suitable wrench while tightening the fuel line.
a b a - Gen III Cool Fuel module

b - Fuel fitting
43055
Bravo Model Shift Cable Installation

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.
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.
90-8M0032375 AUGUST 2013 Page 45 / 66

Bravo Models Shift Cable Adjustment

1. Remove the adjustment tool.
Typical Bravo shift bracket shown without switch

a - Adjustment tool
8588
a
2. Loosen the adjustable stud and move it to dimension, as shown. Retighten the stud.
a Typical Bravo shift bracket shown without switch

a - Adjustable stud
b - 76 mm (3 in.) (center of pivot bolt to center of
stud)
b
8587
3. Install the sterndrive unit shift cable.

4. Install the cotter pin.
5. Insert the cotter pin from the top and spread ends fully.
b Typical Bravo shift bracket shown without switch

a - Washers (2)
b - Long cotter pin
c - Short cotter pin
a c 8523
Page 46 / 66 90-8M0032375 AUGUST 2013

6. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place using a piece of tape over
the barrel retainer.
Typical Bravo shift bracket shown without switch

a - Adjustment tool
b - Sterndrive unit shift cable
8522
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.
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" halfway 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 centerline of stud. Ensure that backlash
center mark is aligned with edge of control cable end guide.
10. Remove control cable end guide from shift lever by removing clevis pin.
b
a Typical Bravo shift bracket shown without switch
c a - Control cable end guide
d
b - Clevis pin
c - Backlash center
d - Control cable barrel
e e - Stud
8593
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.
90-8M0032375 AUGUST 2013 Page 47 / 66

18. Shift the remote control into reverse and repeat the adjustment process.
a - RH rotation: Bravo One, Two, and Three forward; LH rotation: Bravo

One and Two reverse slot
b - LH rotation: Bravo One and Two forward; RH rotation: Bravo One,
Two, and Three reverse slot
a
8525
b
19. Remove adjustment tool.
20. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to 180°.
21. Lubricate shift cable pivot points.

80 SAE Engine Oil 30W Shift cable pivot points Obtain Locally
Shift Cable Installation for the 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:
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
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 predelivery inspection.
2. Apply lubricant to the threads of the shift cable stud.

95 2-4-C with PTFE Shift cable stud 92-802859A 1
3. Install the intermediate shift cable to the shift actuator on the engine.
Page 48 / 66 90-8M0032375 AUGUST 2013

4. Tighten locknut until it makes contact and then loosen 1/2 turn.
b
a- Shift actuator
b- Shift cable
c- Locknut
e c
d- Shift cable stud
e- Shift cable barrel
a
f- Washers
8996
5. Insert the cotter pin from the top and spread the ends.
a - Cotter pin
a
8997
DTS System Installation

Refer to Section 7 ‑ DTS System Installation.
Throttle Cable Installation and Adjustment

1. Place the remote control handles in the neutral idle position.
IMPORTANT: Ensure that the cable is routed to avoid sharp bends and/or contact with moving parts. Do not
fasten any items to the throttle cable. The outer cable must be free to move when the cable is actuated.
90-8M0032375 AUGUST 2013 Page 49 / 66

2. Install the cable end guide on the throttle lever, then push the cable barrel end lightly toward the throttle lever
end. (This will place a slight preload on the shift cable to avoid slack in the cable when moving the remote
control lever.) Adjust the barrel on the throttle cable to align with the hole in anchor plate. Ensure that the
hole in barrel positions the cable as shown.
a- Cable end guide

b- Hex spacer
c- Flat washer
d- Locknut
e- Sleeve
f- Barrel
a
b
c e
f
d
43159
3. Secure the throttle cable with the hardware as shown and tighten securely. Loosen locknut "a" 1/2 turn.
4. Place the remote control throttle level in the wide‑open throttle position and ensure the throttle plates are
completely open.
5. Return the remote control throttle lever to the idle position and ensure the throttle lever is completely closed.
Bravo Sterndrive Installation

1. If applicable, remove the trim cylinder support and dust cover from the bell housing studs. Retain elastic stop
nuts and flat washers.
Typical
a - Dust cover
b - Trim cylinder support
a
8993
Page 50 / 66 90-8M0032375 AUGUST 2013

2. Remove the gear lube monitor cap. Fill the gear lube monitor to the "COLD FILL" level.
a - Gear lube monitor

b - "COLD FILL" level
b
COLD FILL
50333

High Performance Gear
87 Gear lube monitor 92-858064K01
Lubricant
3. To purge air from the system, push in on the dribble valve stem until the new gear lube appears.
a - Dribble valve
21440
4. Release the dribble valve.
90-8M0032375 AUGUST 2013 Page 51 / 66

5. If the gear lube in the gear lube monitor is below the "COLD FILL" level, fill the gear lube monitor to the
"COLD FILL" level with the specified fluid. Do not overfill.
a - "COLD FILL" level
a
COLD FILL
50471

Lubricant
6. Coat the O‑rings on the sterndrive U‑joint with lubricant.
a a
21441
a - O‑rings
7. Coat the splines on the sterndrive U‑joint with lubricant.
a - Splines
a
21442

Extreme Grease U-joint O-rings 8M0071842
Extreme Grease Driveshaft splines 8M0071842
Page 52 / 66 90-8M0032375 AUGUST 2013

8. Ensure that the U‑joint bellows are clean and free of debris.
Bell housing of the transom assembly

a - U‑joint bellows edge
b - U‑joint bellows
a b
21456
9. Apply lubricant to the first 6 mm (1/4 in.) of the threads of the bell housing studs.
b a - Bell housing studs (6)

b - Tube of lubricant
a
a
21457

95 2-4-C with PTFE Threads of bell housing studs 92-802859A 1
10. Lubricate the shift linkage O‑ring.
a - Shift linkage O‑ring
a
21678

95 2-4-C with PTFE O-ring 92-802859A 1
90-8M0032375 AUGUST 2013 Page 53 / 66

11. Lubricate the water passage seal.
a - Water passage seal
a
21679

95 2-4-C with PTFE Water passage seals 92-802859A 1
12. Pull out the shift linkage as far as it moves. The jaws will open.
b
a
c
c
21471
5311
a - Shift linkage assembly
b - Jaws open
c - Underside of lower lip
IMPORTANT: As the sterndrive is inserted into the entry of the bell housing, the shift cable must be closely
checked to ensure that it enters the jaws of the shift linkage assembly of the sterndrive.
13. Place the remote control in neutral position.
Page 54 / 66 90-8M0032375 AUGUST 2013

NOTE: As the 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
IMPORTANT: If the bell housing shift cable does not line up to properly enter the jaws of the shift linkage
assembly, use your hand to guide the cable into place while installing the sterndrive.
14. Place the driveshaft housing in position on the bell housing and install the sterndrive, as follows:
a. Remove the nuts from the trim cylinders.
a- Socket
c b- Wrench
a b c- Anchor pin
d- Ground wires
e- Trim cylinders
d
e
21521
b. Position the sterndrive so that the universal joint shaft aligns with the bell housing bore.
a- Universal joint
a b b- Bell housing
c- Shift linkage
d- Shift cable
c d 21518
90-8M0032375 AUGUST 2013 Page 55 / 66

c. Guide the U‑joint shaft through the bearing in the gimbal housing and into the engine coupler. Ensure
that the shift linkage jaws engage the bell housing shift cable assembly.
a - Shift cable
b - Shift linkage jaws
open
c - Shift linkage jaws
engage the shift
a b c cable
21519
d. If necessary, rotate the propeller shaft counterclockwise slightly (using a propeller) to align the U‑joint
shaft splines with the splines in the engine coupling, then slide the sterndrive all the way into the bell
housing.
a - Bell housing studs

b - Dribble valve
c - Shift cable
b
a c
21520
15. Secure the sterndrive to the bell housing with four flat washers and six locknuts. Do not use flat washers on
the ground plate.
Ground plate with serial number and gear ratio

a - Washers not used here
25908
Page 56 / 66 90-8M0032375 AUGUST 2013

16. Start from the center and tighten the nuts to the specified torque.
a - Locknuts (6), flat washers (4)

b - Torque wrench
a
b
25909

Sterndrive fasteners 68 – 50
Trim Cylinder Installation

1. Install the mounting hardware of the trim cylinder forward as shown.
2. Lubricate the anchor pin threads to prevent the threads from galling.
3. Hand thread the locknuts onto the pin. Do not tighten at this time.
NOTE: Upon installation of hardware apply lubricant to all stainless steel components.
a b c
d e Front
e f a - Anchor pin
g h
b - Retainer clip groove
c - Flat washer (large I.D.)
d - Retainer clip
e - Bushing
14326 f - Flat washer (small I.D.)
g - Locknut
h - Plastic cap

95 2-4-C with PTFE Trim cylinder hardware 92-802859A 1
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.
90-8M0032375 AUGUST 2013 Page 57 / 66

NOTE: Ensure that the trim‑in limit insert is reinstalled in the same position as before removal of the
sterndrive. If you are not sure of the original position, contact the boat manufacturer for their
recommendation. Refer to All Bravo Models in this section and Bravo Three Notice: Trim‑In Limit Insert
(Non‑DTS) at the front of this manual before reinstalling the trim‑in limit insert.
a b
14571
a - Trim‑in limit insert Bravo One and Two (positioned forward)

b - Trim‑in limit insert Bravo Three (positioned aft)
IMPORTANT: The position of the trim‑in limit insert on the Bravo Three sterndrive should only be changed
after the boat has been properly tested. Contact the boat manufacturer if you are not sure of the original
position for a particular boat application.
4. Install the mounting hardware of the trim cylinder aft as shown.
5. Lubricate the anchor pin threads to prevent the threads from galling.
6. Hand thread the locknuts onto the anchor pin.
NOTE: Upon installation of hardware apply lubricant to all stainless steel components.
c b c
a
d e
c f
9295
a- Aft anchor pin

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

95 2-4-C with PTFE Trim cylinder hardware 92-802859A 1
7. Tighten the locknuts until the washer and locknut contact the shoulder on the anchor pin.
Page 58 / 66 90-8M0032375 AUGUST 2013

8. Install plastic caps and tighten hand‑tight only.
b b a
c
21677
a - Socket and tool

b - Wrench tool
c - Plastic cap (4)
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.
2. Insert speedometer tube fitting into opening on topside of anti‑ventilation plate, in position shown.
a - Tube fitting
b - Opening
a
5319
3. With fitting fully seated, turn handle to left to a tightly seated position, as shown.
a - Fitting installed (handle pointing forward)
5320
90-8M0032375 AUGUST 2013 Page 59 / 66

Trim Limit and Trim Position Settings

To adjust the trim limit switch and the trim position sender see Section 9—Predelivery Preparation for the
appropriate procedure.
Bravo Sterndrive Shift Check (Engine Running)

! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller
installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop
switch to prevent the engine from starting. Place a block of wood between the propeller blade and the
anti‑ventilation plate.
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 Typical single handle remote control shown

a - Drive trim switch
b b - Drive trailer button
4805
3. Connect a garden water hose between flushing attachment and water source.
91‑881150K 1
Kit
Flushing Device 91‑44357Q 2
Flushing Kit 91‑849996T 1
4. Partially open water source until water continuously leaks out around the flushing device.
NOTICE
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.
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.
Page 60 / 66 90-8M0032375 AUGUST 2013

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.
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 PTFE.
90-8M0032375 AUGUST 2013 Page 61 / 66

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.
b
a- Remote control end
b- Engine end
c- Adjusting barrel
c d- Lubricating point
7874
d

95 2-4-C with PTFE Shift cable end 92-802859A 1
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.
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.
Page 62 / 66 90-8M0032375 AUGUST 2013

c. The cable should then go up behind the power steering valve and loop over to the shift plate on the
engine, where it is connected to the anchor points on the shift plate.
• Following this routing will prevent the engine coupler from damaging the cable.
8995
Through prop exhaust shown
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 predelivery 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.
Paddle Wheel Speed Sensor Installation (If Equipped)

Parts Provided
e
d
a i
b
c
i
h
ABCD
f 29269
j
g
a- Spare pin yoke

b- Wire retainer
c- Connector
d- Bracket
e- Paddle wheel
f- Flat washer (2)
g- #10 ‑ 19 mm (3/4 in.) screw (4)
h- Cable cap
i- #6 ‑ 12 mm (1/2 in.) screw (4)
j- Clamp (2)
90-8M0032375 AUGUST 2013 Page 63 / 66

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 a - 13° transom angle

b - 20° transom angle
29272
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.
a a - Shim
29276
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 1.5 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.
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.
e a- Template
a b- 50 mm (2 in.)
c- #10 screw
b d- Flat washer (2)
e- Caulking
c d 29282
Page 64 / 66 90-8M0032375 AUGUST 2013

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- Splash well drain hole

a
b- Cable cap
c- Cable clamp
b d- Paddle wheel assembly
e- Distance between first cable clamp and top of
paddle wheel ‑ 25.4 mm (1.0 in.)
c
e
d
29285
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.
a
a - Tabs
b - Pins
b 29288
Wiring Connections
IMPORTANT: Before making wire connections, make sure wires are routed through the transom.
90-8M0032375 AUGUST 2013 Page 65 / 66

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 BA
WHT
DC BA
YEL
BLU
BL K
29289
b b
a
a - Connector
b - Wire retainer
Template ‑ Paddle Wheel Speed Sensor
a a - Drill holes here

b - Align dotted line with the transom bottom edge and
fold under
29291
Page 66 / 66 90-8M0032375 AUGUST 2013

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

Table of Contents
General Information ................................................................................................................................................ 3
Weather Caps................................................................................................................................................... 3
Boat Harness and Accessories Information...................................................................................................... 3
Power Trim Electrical Connection..................................................................................................................... 4
Power Supply.......................................................................................................................................................... 4
Battery Specifications........................................................................................................................................ 4
Battery Cables................................................................................................................................................... 4
Multiple MPI Engine Battery Information........................................................................................................... 5
Power Harness.................................................................................................................................................. 5
Engine Harness and Accessory Power Supply................................................................................................. 6
Installation Guidlines for Mechanical and DTS........................................................................................................ 6
Junction Box (If Equipped)................................................................................................................................ 6
Data Harness Pulling Procedure....................................................................................................................... 6
Analog Gauge Interface (AGI) Installation......................................................................................................... 7
Configuring Analog/Digital Tachometer Signal through PCM........................................................................... 8
Boat Harness Guidelines...................................................................................................................................8
Boat Harness 14‑pin Connector to Engine ................................................................................................ 8
Neutral Switch ............................................................................................................................................ 8
Lanyard Stop Switch .................................................................................................................................. 9
Optional E‑Stop ......................................................................................................................................... 9
Warning Horn ............................................................................................................................................. 9
Accessory Relay Connection ..................................................................................................................... 9
7
Additional Relay Kit .................................................................................................................................... 9
Gauge Connection ................................................................................................................................... 10
CAN P(CAN 1) Connections .................................................................................................................... 11
CAN V (CAN 3) Connection ..................................................................................................................... 11
Fuel Tank Connector ............................................................................................................................... 12
Transom Ground Connection .................................................................................................................. 12
Harness and Connections for Mechanical............................................................................................................. 12
Key, Trim, and Transom.................................................................................................................................. 12
Trim Switch .............................................................................................................................................. 14
Transom Harness .................................................................................................................................... 14
Wiring Diagrams for Mechanical............................................................................................................................ 15
Boat Wiring—8.2 Mag Mechanical.................................................................................................................. 15
Single Station ........................................................................................................................................... 15
Dual Station ............................................................................................................................................. 16
Transom Harness............................................................................................................................................ 16
Boat Harness...................................................................................................................................................17
Drawing .................................................................................................................................................... 17
Diagram ................................................................................................................................................... 18
Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness Assembly)................. 19
Power Trim System—8.2 Mag (Except DTS Models)..................................................................................... 21
Wire Color Code Abbreviations....................................................................................................................... 22
8.2 Mechanical 14 Pin Engine Harness Connector......................................................................................... 22
Harness and Connections for DTS........................................................................................................................ 22
Configuring the PCM Using the CDS G3........................................................................................................ 22
Configuring the PCM ............................................................................................................................... 22
Configuring the DTS Command Module .................................................................................................. 23
Installation Guidelines for DTS System Components..................................................................................... 23
Data Harness ........................................................................................................................................... 23
90-8M0032375 AUGUST 2013 Page 1 / 36

STARTING AND ELECTRICAL SECTION - 7
Connectors .............................................................................................................................................. 23
DTS Battery Specifications.............................................................................................................................. 23
Key, Lanyard, and Transom............................................................................................................................ 24
Key Switch Connector ............................................................................................................................. 24
Start/Stop Switch Installation ................................................................................................................... 25
Wiring Schematics ................................................................................................................................... 26
Lanyard Stop Switch Installation .............................................................................................................. 26
Single Engine Lanyard Connections ........................................................................................................ 28
Transom Harness—DTS ......................................................................................................................... 28
Wiring Diagrams for DTS....................................................................................................................................... 29
DTS Single Console Mount Control Wiring: Single Helm................................................................................ 29
DTS Single Engine Single Helm with Slim Binnacle Control........................................................................... 30
DTS Single Engine Dual Helm with Slim Binnacle Control............................................................................. 32
Transom Harness—DTS................................................................................................................................. 34
Wire Color Code Abbreviations....................................................................................................................... 35
8.2 DTS 14 Pin Engine Harness Connector.................................................................................................... 35
Page 2 / 36 90-8M0032375 AUGUST 2013

Special Tools
Data Cable Puller 888462A 1
Attaches to end of DTS data harness to aid in pulling harness through boat.
4618 Prevents damage to DTS data harness.
CDS G3 Diagnostic Interface Tool with

8M0046124
Harness
Provides diagnostic support for the Computer Diagnostic System.
41993
General 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:
a- 10 pin cap
b- 5 pin cap
c- 3 pin cap
4958 d- 2 pin cap
c d
a b
Boat Harness and Accessories Information

Refer to the Mercury Precision Parts and Accessories Guide or the OEM Rigging and Accessories Guide for part
number information.
1. Ensure that the 14‑pin boat harness is the correct length to properly route from the boat dash to the locking
14‑pin electrical connector on the engine.
2. If SmartCraft instruments and analog instruments are desired on the same boat, an analog gauge interface
(AGI) adapter to power the analog gauges.
3. A key switch assembly plugs into the 14‑pin boat harness (both 3‑position and 4‑position available).
4. Select a remote control assembly:
a. The remote control must be compatible with MerCruiser applications.
b. A remote control can have a lanyard stop switch and will connect directly to the boat harness or a
separate stop switch can be installed and connected to the boat harness.
c. A power trim switch can be part of the remote control or a separate dash mounted power trim switch can
be installed.
5. A separate harness is required to connect the control or dash mounted power trim switch to the power trim
pump. (Do not use the connector in the 14‑pin boat harness labeled power trim. This connection is for
outboard only.)
6. Up to 15 amps of accessory power can be supplied through the 14‑pin wiring harness. An accessory kit is
available to provide accessory power up to 40 amps.
90-8M0032375 AUGUST 2013 Page 3 / 36

Power Trim Electrical Connection

NOTE: ABYC (American Boat and Yacht Council) installation recommends installing a battery switch in the
positive conductor of any battery or battery bank with CCA rating greater than 800 amperes. (See ABYC for
additional information)
ABYC further recommends: if a boat is equipped with a battery switch, the power trim pump may not be
connected to the continuously energized circuit (battery). It must be connected to the switched side of the battery
switch. Wire length requirements and location of circuit protection are also specified.
MerCruiser has developed three methods to facilitate compliance with ABYC recommendations. These come in
the form of one standard production and two accessory kits.
1. Installations with the batteries (or battery banks) rated at less than or equal to 800 Cold Cranking Amps
(CCA) and without battery switches: The trim pump may be installed using the wires supplied with the power
trim pump and should be connected directly to the battery.
2. Installations with batteries (or battery banks) rated at more than 800 CCAs (requiring a battery switch) or any
boat with a battery switch: The red current conductor (for the trim pump) must be:
a. Connected to the switched side of the battery switch and either:
i. provided with circuit protection within 7 inches of the power source or
ii. Provided with circuit protection within 40 inches of the point of connection with the power source,
sheathed the entire length of wire from the point of connection to the source and the circuit
protection device.
This will require the use of an accessory kit.
Part Number Description Color Length Type

8M2000587 Cable Assembly – Trim Pump Red 72 inches Fused
8M2000588 Cable Assembly – Trim Pump Red 40 inches Sheathed
Power Supply
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.
IMPORTANT: Engine electrical system is negative (‑) ground.
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.
IMPORTANT: Battery cables should always be tightened with a wrench
• Battery capacity rating of at least:
Model Minimum required cranking battery size

V6 and V8 MPI models 750 cca, 950 mca, 180 Ah
V8 DTS models 800 cca, 1000 mca, 180 Ah
Battery Cables
IMPORTANT: The OEM or designer of the vessel is responsible for selecting the proper battery cable size to
replace the minimum cable gauge listed in the following table, if they use the cables for additional electrical loads
and cranking the engine.
Using the following chart, select the proper size positive (+) and negative (–) battery cables.
• Add the positive and negative cable lengths together.
• Divide by two to obtain the average cable length.
Page 4 / 36 90-8M0032375 AUGUST 2013

Minimum Cable Gauge

Cable Length
(engine cranking only)
Less than or equal to 2.7 m (9 ft.) 13.3 mm2 (6)
2.7–4.6 m (9–15 ft.) 21.2 mm2 (4)
4.6–7.6 m (15–25 ft.) 33.6 mm2 (2)
7.6–9.5 m (25–31 ft.) 42.4 mm2 (1)
9.5–11.9 m (31–39 ft.) 53.5 mm2 (0)
11.9–15.2 m (39–50 ft.) 67.4 mm2 (00)
15.2–19.2 m (50–63 ft.) 85.0 mm2 (000)
19.2–24.4m 63–80 ft.) 107.0 mm2 (0000)
Table applies to positive (+) and negative (–) cables
NOTE: Locate the battery as close to the engine as possible.

IMPORTANT: Terminal ends must be soldered to the 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 subsequent failure.
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.
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.
Power Harness
IMPORTANT: You must install the appropriate power harness for your application. All engines (including the
mechanical models) using the PCM09 must connect the harness clean power.
1. Connect the power harness to the battery. Ensure the lead with the fuse is installed onto the positive battery
terminal.
2. Install the lead without the fuse onto the negative battery terminal.
3. Secure the battery cables and the power harness leads to the battery with hex nuts. Tighten the hex nuts to
the specified torque.

Hex nut 13.5 120 –
90-8M0032375 AUGUST 2013 Page 5 / 36

4. Secure the power harness to the battery cable with a cable tie.
3711
5. Spray the battery terminals with a battery connection sealant to help retard corrosion.
Engine Harness and Accessory Power Supply

If the engine harness is used to supply power for boat accessories (lights, blower, pumps, stereo, or any other
electrical device using the engine wiring harness for power), the maximum accessory power available on the
14‑pin wiring harness is 15 amps. Relay kits are available to provide additional accessory power at the helm.
This maximum is fuse‑protected and must be observed. If the fuse opens, the engine will stop and will not restart
until the fuse is corrected.
Installation Guidlines for Mechanical and DTS

Junction Box (If Equipped)
• Although the junction box connections are watertight, it is recommended the junction box 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 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.
a- Clamp
c b- Weather cap (859318T 2)
b c- Junction box
d- 25.4 cm (10 in.)
a e- DTS command module harness
d
29220
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 ensure 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 two cable ties.
Page 6 / 36 90-8M0032375 AUGUST 2013

IMPORTANT: The cable ties must be tight to prevent any slipping during installation.
3836
Data Cable Puller 888462A 1
IMPORTANT: Carefully inspect data harness pins to ensure that 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.
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
b- 14 pin connection
c- AGI harness
d- Analog gauge terminal connections
e- System Link 3 pin connection
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.
90-8M0032375 AUGUST 2013 Page 7 / 36

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.
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 allows the operation of one analog tachometer. Depending on the desired use of analog or
digital gauges, the PCM setup 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 VesselView, System Monitor, or System Tach X X
System Link gauges used in conjunction with System Link adapter harness and command module
X
harness without the use of VesselView, System Monitor, or System Tach
AGI used with or without VesselView, System Monitor, or System Tachometer, to run analog and System
X
Link gauges
The computer diagnostic system (CDS G3) can communicate with the DTS command module and will configure
the PCM for using an AGI and other special SmartCraft gauge configurations.
If you need assistance. contact the Mercury Technical Service Department.
Customer Contact
Dealers Contact MerCruiser Dealer Technical Service (1‑920‑929‑5884)
Contact your local product application engineer (PAE) for assistance. If they cannot be
Boatbuilders
reached, contact MerCruiser Dealer Technical Service (1‑920‑929‑5884)

8M0046124
Harness
Boat Harness Guidelines

Boat Harness 14-pin Connector to Engine
Select the boat harness by length.
Boat Harness
Length of the Boat Boat Harness and Key Switch Boat Harness
Harness Three Position (off/run/start) (key switch is not included)
61 cm (02 ft.) 84‑896537 K02 84‑896537 A02
4.6 m (15 ft.) 84‑896537 K15 84‑896537 A15
6.0 m (20 ft.) 84‑896537 K20 A84‑896537 20
7.3 m (24 ft.) 84‑896537 K24 84‑896537 A24
8.8 m (29 ft.) 84‑896537 K29 84‑896537 A29
12.2 m (40 ft.) 84‑896537 K40 84‑896537 A40
NOTE: Extension harnesses are also available if longer length is needed.

Neutral Switch
The neutral switch connects to the remote control.
Page 8 / 36 90-8M0032375 AUGUST 2013

On dual‑helm installations, the lower and the upper station controls need a neutral safety switch.
Lanyard Stop Switch
Purple and purple/white wires are connected together through a normally closed stop switch.
When the lanyard is pulled and the switch is tripped, the circuit is opened and the power to the engine, ECM, or
ignition system is interrupted and the engine is shut off.
If a lanyard stop switch is not used, or an E stop switch is used, these two wires must be plugged together for the
engine to run.
Optional E-Stop
The E‑stop lanyard switch connection is used on Mercury outboards and can be used on MerCruiser MPI
engines.
The black and black/yellow wires are connected together through a lanyard switch that is normally open. When
the lanyard is pulled and the switch is tripped, the circuit will close and ground the ECM to shut the engine off.
When this connection is not used, the wires should be kept separate and capped.
Warning Horn
The audio warning horn and connections are included with the Mercury harness assemblies. (Another horn is
also supplied with the engine for those using custom wiring systems.)
Accessory Relay Connection
Accessory relay kit connection. The 14‑pin wiring system is able to provide up to 15 amps of accessory
power to the helm through the purple wire (key controlled) or the red wire (constant on) circuit. This
harness is fuse protected on the engine with a 15‑amp fuse on the engine. If the fuse is blown, the engine will not
start or continue to run.
An accessory relay kit connected to this location can provide up to 40 amps of accessory power. The key switch
will power‑up the relay in the "accessory" position and "run" position.
25048
Relay With Power Harness
Additional Relay Kit

An additional 40‑amp relay kit can be installed and connected to a junction box at the dash gauge connection
location. This location will power up with the key in the "run" position only.
90-8M0032375 AUGUST 2013 Page 9 / 36

The use of both relay kits will result in a maximum of 80 amps of key switch controlled power at the
helm. This multiplies out on dual engine and dual helm applications as long as the power wires to the helm are
adequate to carry the total current demand.
25144
Accessory relay harness
Gauge Connection
The gauge connection of the boat harness connects to the analog gauge harness.
If SmartCraft instrumentation is used, connect to a SmartCraft junction box.
If a combination of SmartCraft and analog is used, an AGI (analog gauge interface) kit is used to provide analog
instrumentation. The AGI harness connects to the junction box along with the SmartCraft connection.
IMPORTANT: The AGI requires setting the tachometer signal to digital with CDS or DDT.
AGI (Analog Gauge Interface)
Length of the Harness Analog Gauge Harness (14 pin)

1.5 m (5 ft.) 84‑892990T01
3.0 m (10 ft.) 84‑892990T10
4.6 m (15 ft.) 84‑892990T15
Page 10 / 36 90-8M0032375 AUGUST 2013

A system link adapter can be used to connect SmartCraft link gauges without a System Gauge (requires
resetting tach signal to digital with CDS or DDT) fuel tank and trim gauge setting will be defaulted. There is no
provision with link gauge to calibrate these gauges.
25147
System Link SC 100 adapter
CAN P(CAN 1) Connections

CAN 1 (CAN P) connection with a terminator resistor in place:
• If a this is a dual engine and the SmartCraft instrumentation is used, the terminator resistor is removed and a
jumper harness connects the CAN P (CAN 1) lines together so that the engines will share SmartCraft data.
• The resistors on the engines are the required terminator resistors for the SmartCraft‑equipped dual engine
applications.
• If the boat is dual engine and dual helm, the terminator resistor at the lower helm is removed from the
connector. The jumper harness is installed at the upper station.
25149
Two pin link harness—CAN
CAN V (CAN 3) Connection

CAN V (CAN 3) connection is not currently used by MerCruiser. Leave protective cap in place.
90-8M0032375 AUGUST 2013 Page 11 / 36

Fuel Tank Connector

The fuel tank, auxiliary tank, and paddle wheel harness must be ordered separately. The harness connects to the
paddle wheel and tank level connector on the engine harness.
43703
Paddle wheel and tank level connector
Qty Description Part Number

1 Fuel tank, auxiliary tank, and paddle wheel harness 84‑859743T03
Transom Ground Connection

The ground wire for the transom is incorporated into the transom harness included with the engine.
Connect the ground wire in the transom harness under the bonding strap screw on the transom. Do not connect
any other ground wires here.
Use the ground studs on the flywheel housing for other grounding needs.
NOTE: In some cases, a ground wire to connect to the flywheel housing may be attached to the bonding screw
on the transom. This ground wire is not needed with the transom harness, but can be connected to the flywheel
housing or removed. In any case the grounding wire in the transom harness must be connected to the bonding
strap screw.
a b Ground wire from the transom harness to the transom bonding

strap screw
a - Bonding strap screw
b - Ground wire from transom harness
25173
Harness and Connections for Mechanical

Key, Trim, and Transom
1. A mounting bezel is not available for the three position key switch.
Page 12 / 36 90-8M0032375 AUGUST 2013

NOTE: 899203A01 Decal and washer kit is available for the three position key switch if needed.
25046
Typical three position key switch (off/run/start)
2. The four position key switch is available with mounting hardware.
25044
25045
Typical four position key switch (off/accessory/run/start)
NOTE: When installing the key switch verify that the drain hole in the barrel of the switch is positioned
downward for proper drainage.
3. For dual helm installation, a key switch is used at the upper and lower station. The key switches must
operate independently.
IMPORTANT: For dual helm installation, both key switches used must be modified to operate independently.
IMPORTANT: Cutting the black / yellow stripe wire disconnects the E stop circuit incorporated in the key
switch.
4. To modify the key switches, cut the black / yellow stripe wire at each key switch and cover both open wire
ends with heat shrink tubing.
Typical key switch

a - Black/yellow stripe wire
a a
25136 25136
IMPORTANT: The key switch at the station being used should be the only key switch in the "run" position. If
both station key switches are in the "run" position the engine cannot be turned off with the key switch and the
lanyard stop switches will not function.
5. If a momentary stop switch is added, the "stop" switch will override the key switch and the engine will shut off
when the stop switch is activated.
6. If a stop button is desired on a dual helm installation. the black wire and black/yellow stripe wire can be
clipped at the key switch and connected to a normally open momentary button switch. Any marine
momentary push button, rocker style or toggle switch could be utilized to create the "stop" switch. Label the
switch on the dash after installation.
7. To Install a momentary "stop" switch:
a. Cut the black wire at the key switch and cover the cut wire at the key switch with heat shrink tubing.
b. Install an eye terminal on the black wire from the connector side. Cover cut wire ends with heat shrink
tubing.
c. Install an eye terminal on the black/yellow stripe wire from the connector side. Cover cut wire ends with
heat shrink tubing.
90-8M0032375 AUGUST 2013 Page 13 / 36

d. Connect the black wire and the black/yellow stripe wire eye terminals to a momentary switch.
Trim Switch
The trim switch connection is only used on Mercury outboards.
MerCruiser models require a separate trim harness from the trim control to the power the trim pump connection.
A "Y" harness is available with adapters to connect the dual helm power trim harnesses together to connect to
the power trim pump. DTS models do not need the separate trim harness.
Use the power trim adapter harness for the single helm harness connection the remote control to the power trim
pump.
25166
Power trim adapter harness
If installing dual helm, use a power trim extension harness from the upper and lower helm to a "Y" harness.
25168
Power trim extension harness
An adapter connects the "Y" harness to the power trim pump, (The original hog nose "Y" harness).
25171 25172
Power trim Y-harness Power trim adapter harness
Transom Harness
This Transom harness is designed so that connections can be made after the transom is installed in the boat but
before the engine is installed. Connections made before the engine is installed are:
Page 14 / 36 90-8M0032375 AUGUST 2013

• MerCathode connection
• Trim connections
• Ground connection
• SmartCraft sensor connections
Secure the wiring and position the engine connector out of the way until the engine is installed.
After the engine is in place, make the single connection between the transom and the engine.
b Transom harness
b - Trim limit connection
c d - SmartCraft pitot sensor
g e - Analog trim gauge (only with AGI box)
a d
f - Digital trim gauge
e g - MerCathode
h
h - Transom ground (to the transom bonding strap screw)
f 25153
Wiring Diagrams for Mechanical

Boat Wiring—8.2 Mag Mechanical
NOTE: Twin engines are treated as two single engines in the same boat. No twin engine disconnect is required.
Single Station
25043
90-8M0032375 AUGUST 2013 Page 15 / 36

Dual Station
25041
Transom Harness
b Transom harness—8.2
b - Trim limit connection
c d - SmartCraft pitot sensor
g e - Analog trim gauge (only with AGI box)
a d
f - Digital Trim gauge
e g - MerCathode
h
h - Transom ground (to the transom bonding strap screw)
f 25153
Page 16 / 36 90-8M0032375 AUGUST 2013

Boat Harness
Drawing
2
1 - 14‑pin Deutsch connector
11 2 - Key switch connector
7 10 4 3 - Trim switch (outboard
only)
4 - Neutral switch
3 5 - Lanyard switch
1
8 (sterndrive) or key switch +
6 connection
6 - Lanyard (outboard) or
5
E‑stop connection
9
12340 7 - Warning horn
8 - Accessory relay
connection (15‑amp)
9 - Gauge connector/CAN
connector for SmartCraft
10 - CAN P with resistor cap
11 - CAN 3 (CAN V) with
weather cap
90-8M0032375 AUGUST 2013 Page 17 / 36

Diagram
A B A B
11 A B A B
10
ORG
GRN
DKBLU
WHT
RED
A B C D E F G H J K
BLK
ORG
GRN
PPL 9
GRY
YEL
WHT
DKBLU
PPL_WHT
A B C
BLK
RED
8
PPL
1
7
BRN
5
1
PPL_WHT
1
PPL
BLK
GRN BLK_YEL
1
A B C D E F G H J K L M N P
YEL_RED
GRY 6
BRN BLK BLK
1
YEL
GRN_WHT
1 BLU_WHT
DKBLU
PPL
WHT
YEL_RED
1
ORG
BLK_YEL
PPL 4
BLK YEL_RED
1
RED
RED
3
A B C
BLU_WHT
RED GRN_WHT
RED
A B C D E F
BLK
PPL_WHT
PPL 2
BLK_YEL
YEL_RED
12339
1- 14‑pin Deutsch connector

2- Key switch connector
3- Trim switch (outboard only)
4- Neutral switch
5- Lanyard switch (sterndrive) or key switch + connection
6- Lanyard (outboard) or E‑stop connection
7- Warning horn
8- Accessory relay connection (15‑amp)
9- Gauge connector
10 - CAN P with resistor cap
11 - CAN 3 (CAN V) with weather cap
NOTE: Dual engines are treated as two singles in the same boat and are not connected together.
NOTE: The lanyard stop switch (PPL and PPL/WHT wires) breaks power to the ECM or ignition to stop the
engine. The switch is normally closed until activated. Therefore the PPL and PPL/WHT wires must be connected
together if lanyard stop switch is not used, or if the E‑stop switch is used.
NOTE: E‑stop switch (BLK and BLK/YEL wires) connects ground to ECM to stop engine. The switch is normally
open; the circuit closes when switch is activated. Wires must be separate unless connected through E‑stop
switch.
Up to 15 amps total accessory power can be provided; on purple wire (switched) and the red wire (continuous
power).
Page 18 / 36 90-8M0032375 AUGUST 2013

An accessory relay kit can be used for loads up to 40‑amps. Refer to the MerCruiser Parts and Accessory
Guide or MerCruiser Rigging Guide
Helm Trim Control Switch to Power Trim Pump Harness Assembly (Control Harness
Assembly)
a b
a - Connection to control
box
b - Connection to trim
pump
c - Connections to trim
limit switch
c 12323
90-8M0032375 AUGUST 2013 Page 19 / 36

a - Connection to control
b box
C1
B
C
b - Connection to trim
pump
c - Connections to trim limit
DK BLU-WHT
RED
GRN-WHT
switch
GRN-WHT 3 4 PPL-WHT
RED 1 2 DK BLU-WHT
C2
1
T2
T1
c 12322
Page 20 / 36 90-8M0032375 AUGUST 2013

Power Trim System—8.2 Mag (Except DTS Models)
BLK
RED
BLK
BLU/WHT
GRN/WHT
a b
RED/PPL
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 23807
a- 20‑amp fuse
b- Ground bolt (floor mount)
c- UP solenoid
d- DOWN solenoid
e- 110‑amp fuse
f- Y‑harness (optional)
g- Neutral switch to instrument wiring harness
h- Trim limit from PCM through transom harness
90-8M0032375 AUGUST 2013 Page 21 / 36

Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY or GRA Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark
8.2 Mechanical 14 Pin Engine Harness Connector

8.2 Mechanical 14‑Pin Connector Pin‑Out Engine Side
Pin Wire Color Function
A PNK/PPL Power (+)
B BLK Ground (‑)
C PPL Wake
D GRN/YEL E‑stop
E – N/A
F WHT CAN 1+ (CAN P)
G LT BLU CAN 1‑ (CAN P)
H – N/A
J – N/A
K – N/A
L BRN/BLU Horn
M GRY/WHT Tachometer/link gauge
N YEL/BLK Crank sensor
P – N/A
Harness and Connections for DTS

Configuring the PCM Using the CDS G3
The computer diagnostic system (CDS G3) can communicate with the DTS command module and with the
PCM09 controller. Refer to the following information when configuring the vessel or the engine using the CDS G3
tool.
Configuring the PCM
The computer diagnostic system (CDS G3) will configure the following, which require communication through the
propulsion control module (PCM09):
• Trailer and trim limit
• Engine location
• TachLink Config‑Enable, which configures the PCM for using an AGI and other special SmartCraft gauge
configurations
• AutoSync‑Enable/Disable
If you need assistance, contact the Mercury Technical Service Department:
Page 22 / 36 90-8M0032375 AUGUST 2013

Customer Contact
Dealers Contact MerCruiser Dealer Technical Service (1‑920‑929‑5884)
Contact your local product application engineer (PAE) for assistance. If they cannot be
Boatbuilders
reached, contact MerCruiser Dealer Technical Service (1‑920‑929‑5884)

8M0046124
Harness
Configuring the DTS Command Module

The CDS can configure the DTS command module. Refer to the appropriate procedures to configure the
following:
• Vessel configuration
• Handle adaptation
• CAN‑based trackpad locations
IMPORTANT: If directed to use the MotoViewer service tool to configure the PCM, do not use MotoViewer and
the CDS software at the same time.
Installation Guidelines for DTS System Components

! WARNING
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. 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.
Data Harness
! WARNING
Prevent serious injury or death from a loss of boat control. Pulling on or flexing connectors can loosen
terminals and cause open or intermittent electrical connections, which will interrupt control of throttle and
shifting. Do not pull on cable connectors when pulling cables through the boat. Do not allow cables to flex at
connection points. Fasten all electrical harnesses within 25 cm (10 in.) of any connection.
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.
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
90-8M0032375 AUGUST 2013 Page 23 / 36

Minimum SAE Starting Battery Requirements ‑ BCI GRP 24

Ah 180 (International Rating)
NOTE: Due to the wide variety of battery manufacturers 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 previously.
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.
! WARNING
Failure to properly secure the battery leads can result in a loss of power to the Digital Throttle and Shift (DTS)
system, leading to serious injury or death due to loss of boat control. Secure the battery leads to the battery
posts with hex nuts to avoid loose connections.
When connecting engine battery, hex nuts must be used to secure battery leads to battery posts. Torque nuts to
specifications.
Description Nm lb. in. lb. ft.

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.
Spray terminals with a battery connection sealant to help retard corrosion.
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
NUTS
IMPORTANT:
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
Key, Lanyard, and Transom

Key Switch Connector
1. A mounting bezel is not available for the three position key switch.
NOTE: 899203A01 Decal and washer kit is available for the three position key switch if needed.
25046
Typical three position key switch (off/run/start)
Page 24 / 36 90-8M0032375 AUGUST 2013

2. The four position key switch is available with mounting hardware.
25044
25045
Typical four position key switch (off/accessory/run/start)
NOTE: When installing the ignition verify that the drain hole in the barrel of the switch is positioned
downward for proper drainage.
Start/Stop Switch Installation
! CAUTION
Avoid injury or product damage. Obstructions, such as braces and wiring, may be unseen when looking at the
front of the dashboard. Before drilling or cutting any holes in the dashboard, check the area behind the
dashboard for obstructions. Do not drill or cut when obstructions are present.
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal
injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the
battery cables from the battery before maintaining, servicing, installing, or removing engine or drive
components.
1. Disconnect both battery cables.

2. Select an appropriate dashboard location for the start/stop switch.
3. Drill a 54 mm (2‑1/8 in.) mounting hole using a hole saw.
4. Place the start/stop switch into the dashboard.
NOTE: For thick dashboards, reverse the retainer nut for additional thread engagement.
5. Secure the switch in place with the retainer nut.
a - Retainer nut
b - Dashboard
c
c - Start/stop switch
a
b 17971
6. Connect the switch to the command module harness.
90-8M0032375 AUGUST 2013 Page 25 / 36

Wiring Schematics
NOTE: In dual helm applications, a start/stop switch is optional at helm 1. The ignition key switch connector will
be capped at helm 2, making a start/stop switch required.
RUN
OFF
d
b
a
a c b
18960
12307
Panel Mount Control Applications Console Mount/Slim Binnacle Control Applications

(Helm 1 shown)
a- Start/stop switch connector
b- Ignition key switch
c- Ignition key switch connector (weather cap at helm 2)
d- Lanyard stop switch connectors
Lanyard Stop Switch Installation
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal
injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the
battery cables from the battery before maintaining, servicing, installing, or removing engine or drive
components.
1. Disconnect the battery cables from the battery.

2. Select a location for the lanyard stop switch that will allow the lanyard to be pulled free without interference
and will be within wire length limitations.
3. Mark the location for flush or surface mounting.
! CAUTION
Avoid injury or product damage. Obstructions, such as braces and wiring, may be unseen when looking at the
front of the dashboard. Before drilling or cutting any holes in the dashboard, check the area behind the
dashboard for obstructions. Do not drill or cut when obstructions are present.
4. If the dashboard is fiberglass, apply masking tape to area that is to be drilled to prevent the dashboard from
chipping or cracking.
5. If the dashboard is vinyl covered, remove the vinyl with a razor blade from the area to be drilled to prevent
the vinyl from tearing.
6. Surface Mounting: Drill pilot holes for the self‑tapping screws. The appropriate drill size for aluminum is
4 mm (5/32 in.) and for wood or fiberglass use drill size 4.5 mm (11/64 in.).
IMPORTANT: Ensure that wires are routed properly to prevent pinching the wires between the back of the
switch and the mounting surface.
Page 26 / 36 90-8M0032375 AUGUST 2013

7. Install the switch assembly using the surface mount adapter. Ensure the wires are routed properly.
c a - Wire routing
a b - Self‑tapping screw
(2)
c - Adapter
b
a
a
4932
8. Flush Mounting: Use a hole saw to cut a 54 mm (2‑1/8 in.) hole in the desired location.
9. Install the switch assembly using the mounting clamp behind the dashboard.
NOTE: To aid installation, first secure the screw to the switch using a nut.
c
a - Nut to aid installation
a
b - Mounting clamp
c - Washer and nut
b
4933
10. Route the switch wires to prevent possible chafing or flexing during boat operation.
11. Secure the wires with cable ties.
12. Connect the lanyard stop switch wires.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or
can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
13. Connect the battery cables.
14. Perform an operational test of the lanyard stop switch.
90-8M0032375 AUGUST 2013 Page 27 / 36

Single Engine Lanyard Connections
a
ON
FCN
SCROLL RUN
SELECT OFF
F R
d
e
b
f
d
g
c
18983
Panel Mount Control Applications Console Mount/Slim Binnacle Control Applications

(Helm 1 shown)
a- Panel mount control
b- Lever 1 connector
c- Handle connector
d- Lanyard stop switch connectors
e- Start/stop switch connector
f- Ignition key switch
g- Ignition key switch connector ‑ weather cap at helm 2
DTS engines are shipped with an adapter to connect the transom harness to the power trim pump.
b c Transom Harness—DTS
d
b - Power trim connects to power trim harness (color
coded)
e
f d - SmartCraft pitot sensor
j e - Analog trim gauge (only with AGI box)
g f - MerCathode
g - Transom ground (to the transom bonding strap
a screw)
h h - Digital trim gauge
i 25154 i - DTS power trim harness connects to transom
harness
j - DTS power trim harness connects to trim pump
Page 28 / 36 90-8M0032375 AUGUST 2013

Wiring Diagrams for DTS

DTS Single Console Mount Control Wiring: Single Helm
k l
n
RUN
m
OFF
i
b f h j
c e o
d p
a q
g
1 2 3
r 23357
s
a - Engine
b - 14‑pin data harness
c - CAN 1 (blue and white wires, terminator)
d - CAN 2 (brown and yellow wires, terminator)
e - CAN 3 (orange and green wires, weather cap)
f - Command module
g - Junction box
h - System View/trackpad connector
i - Switched power relay
j - Warning horn
k - Lanyard stop switch
l - Start/stop switch
m - Ignition key switch
n - Single console control
o - Lever 1 connector
p - Handle connector
q - Trackpad connector
r - Foot throttle
s - Components on DTS Helm Panel
90-8M0032375 AUGUST 2013 Page 29 / 36

DTS Single Engine Single Helm with Slim Binnacle Control
RUN
OFF
s m
l
k
j
h
r
g
3
f 2
e
1
c
b
a
53664
Page 30 / 36 90-8M0032375 AUGUST 2013

a - Engine
b - Engine CAN 2 connector (brown and yellow) ‑ blue terminator resistor
c - Engine CAN 1 connector (blue and white) ‑ yellow or red terminator resistor
d - 14‑pin data harness
e - CAN 1 connector (blue and white) ‑ blue terminator resistor
f - CAN 2 connector (brown and yellow) ‑ blue terminator resistor
g - CAN 3 connector (orange and green) ‑ weather cap
h - Command module
i - Junction box
j - Switched power relay
k - Command module harness
l - Warning horn
m - Foot throttle connector
n - Lanyard stop switch
o - Start/stop switch (optional)
p - Ignition key switch
q - Slim binnacle control
r - VesselView harness
s - VesselView screen
90-8M0032375 AUGUST 2013 Page 31 / 36

DTS Single Engine Dual Helm with Slim Binnacle Control
R
o
R
n
F
m p
r l
h
q g
f 3
2
1
c
a
b
53666
Page 32 / 36 90-8M0032375 AUGUST 2013

a - Engine
b - Engine CAN 2 connector (brown and yellow) ‑ blue terminator resistor
c - Engine CAN 1 connector (blue and white) ‑ yellow or red terminator resistor
d - 14‑pin data harness (from engine)
e - CAN 1 connector (blue and white) ‑ weather cap
f - CAN 2 connector (brown and yellow) ‑ weather cap
g - CAN 3 connector (orange and green) ‑ weather cap
h - Command module
i - Junction box
j - Switched power relay
k - Warning horn
l - Start/stop switch (optional at helm 1)
m - Ignition key switch
n - Slim binnacle control
o - Slim binnacle control
p - Helm command module harness
q - VesselView harness
r - VesselView screen
90-8M0032375 AUGUST 2013 Page 33 / 36

b
A
C
B
BLK-PNK
GRA-BLK
ORN-PNK
a C BLK-PNK
B PNK-DK BLU
R
A GRA-BLK
L
BLK-PNK A
C
GRA-BLK B
R
L WHT-LT BLU
d
A GRA-BLK ORN-WHT 1
B BLK-PNK
C WHT-LT BLU
D PNK-DK BLU e
E ORN-PNK ORN B
F ORN-WHT
G ORN BRN A
H BRN
J BLK
L R
K
L
BLK
BLK 1 f
M
N GRN
P PPL
BLK
R DK BLU
S
1
k
1
1
23810
g
j i h
a- Steering
b- Digital trim
c- Pitot
d- Analog trim
e- MerCathode
f- Analog trim
g- Ground
h- Trim down
i- Relay power
j- Trim up
k- 16‑pin connector
Page 34 / 36 90-8M0032375 AUGUST 2013

Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY or GRA Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark
8.2 DTS 14 Pin Engine Harness Connector

8.2 DTS 14‑Pin Connector Pin‑Out Engine Side
Pin Wire Color Function
A PNK/PPL + 12 Volt CLEAN
B BLK Ground (‑) CLEAN
C PPL Wake
D GRN/YEL E‑stop
E ORN/BLU CAN H (+)
F WHT CAN 1+ (CAN P)
G LT BLU CAN 1‑ (CAN P)
H RED/PPL Power
J BLK Ground
K GRN/ORN CAN X (+) 2
L GRN/RED CAN X (‑) 2
M GRY/WHT Tachometer/link gauge
N OPEN –
P BRN/ORN CAN H (‑)
90-8M0032375 AUGUST 2013 Page 35 / 36

NOTES:
Page 36 / 36 90-8M0032375 AUGUST 2013

SECTION - 8 REMOTE CONTROLS
SECTION 8 - REMOTE CONTROLS

Table of Contents
Computer Diagnostic System CDS G3.................................................................................................................... 3
High Speed or Twin Engine Applications Steering Recommendation .................................................................... 3
Propeller Rotation.................................................................................................................................................... 4
DTS Remote Control ‑ Sterndrive............................................................................................................................ 5
DTS Calibration....................................................................................................................................................... 5
Methods of Calibration...................................................................................................................................... 5
Setting Trailer and Trim Limit.................................................................................................................................. 6
Troubleshooting....................................................................................................................................................... 6
Special Tools ‑ DTS Troubleshooting................................................................................................................ 6
General Information...........................................................................................................................................6
Default Sensor Values ............................................................................................................................... 6
Fault Conditions ......................................................................................................................................... 6
Sticky/Non‑Sticky Faults ............................................................................................................................ 6
Engine Guardian ........................................................................................................................................ 6
Audio Warning System...................................................................................................................................... 7
Testing the Audio Warning System ........................................................................................................... 7
Connecting the Computer Diagnostic System (CDS G3) Service Tool............................................................. 7
Models Equipped with a SmartCraft Diagnostic Port ................................................................................ 7
Models Equipped with a SmartCraft Diagnostic Junction Box .................................................................. 8
Models Not Equipped with SmartCraft Diagnostic Port or Junction Box .................................................. 9
Computer Diagnostic System w/trim dem (CDS) G3 ..................................................................................... 11
Warning Horn Signals..................................................................................................................................... 12
Caution .................................................................................................................................................... 13
Severe ..................................................................................................................................................... 13
Testing the Audio Warning System ......................................................................................................... 13
Special Tools ‑ DTS Troubleshooting.............................................................................................................. 13
8
90-8M0032375 AUGUST 2013 Page 1 / 14

REMOTE CONTROLS SECTION - 8
Special Tools
Computer Diagnostic System (CDS G3) Order from SPX
Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer
Diagnostic System G3 contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA: 1 800 3452233
4520 Canada: 800 345 2233
Europe: + 49 6182 959 149
Australia: (03) 9544 6222
CDS G3 Diagnostic Interface Tool With

8M0046124
Harness
Provides diagnostic support for the Computer Diagnostic System.
41993
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
12 Volt Shunt Connector 889675A01
Connects to data harness allowing operation of the DTS system with the Digital
Diagnostic Terminal.
8036
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
Page 2 / 14 90-8M0032375 AUGUST 2013

DMT 2004 Digital Multimeter 91‑892647A01
H z TEMP
Measures RPM, ohms, amperes, AC and DC voltages; records maximums and
minimums simultaneously, and accurately reads in high RFI environments.
mA
A
V Hz
mV IG
OFF IP
TEMP
A mA COM V Hz
4516
CDS G3 Termination Harness 84‑8M0045065
Contains termination resistors to allow communication when G3 is connected

43351 to the engine's diagnostic connector.
Computer Diagnostic System CDS G3 Order through SPX or Mercury

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
Computer Diagnostic System CDS G3

The new tool Computer Diagnostic System (CDS G3) procedural information is not available at time of printing. If
you have the CDS hardware, order the software and cable 8M0046124 from Mercury. The complete system is
available from SPX.
8M0046124
Harness
High Speed or Twin Engine Applications Steering Recommendation

Mercury MerCruiser power packages come standard with Mercury MerCruiser's internal power assisted steering
system. 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 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.
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.
90-8M0032375 AUGUST 2013 Page 3 / 14

External power steering and hydraulic helm systems can be obtained from the following after market suppliers:
Latham Marine, Inc.
280 S.W. 32nd Court
Ft. Lauderdale, FL 33315
Phone: (800) 422-7267
Fax: (954) 462-3081,
Mayfair Marine Machine
12890 N. W. 30th Avenue
Opalocka, FL 33054
Phone: (305) 681-1815,
Propeller Rotation
Propeller rotation for a Bravo sterndrive in forward gear can be clockwise or counterclockwise, as viewed from
the aft (rear) end of the propeller.
a b
43659
a - Clockwise rotation
b - Counterclockwise rotation
Page 4 / 14 90-8M0032375 AUGUST 2013

Dual sterndrive applications are generally configured to turn the propellers outboad (in forward gear) as pictured.
a - Counterclockwise rotation
b - Clockwise rotation
b
a
43658
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
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.
• 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.
90-8M0032375 AUGUST 2013 Page 5 / 14

Setting Trailer and Trim Limit

See Computer Diagnostic System (CDS) G3 in this section.
Troubleshooting
Special Tools ‑ DTS Troubleshooting
CAN P Diagnostic Cable 84‑892663
8M0046124
Harness
General 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.
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.
In addition, some faults are programmed to ignore certain engine speeds. For example, the low block pressure
sensor and sea pump pressure sensor faults are 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 if 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 CDS 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
Engine Guardian reduces the potential for engine damage by restricting engine power when the PCM detects a
potential problem. Below are some examples of what Engine Guardian monitors:
Page 6 / 14 90-8M0032375 AUGUST 2013

• Oil pressure
• Engine overspeed
• Exhaust manifold temperature
IMPORTANT: Guardian can reduce power anywhere from 100% to idle, depending on the severity of the
problem. If forced to idle, boat speed might not respond to throttle operation.
Audio Warning System

The Mercury MerCruiser power package may be equipped with an audio warning system. The audio warning
system will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
The audio warning system will sound with a continuous horn if one of the following occurs:
• Engine oil pressure too low
• Engine temperature too hot
• Sterndrive oil level too low (if equipped with a drive reservoir having low oil level switch)
• Transmission temperature is too hot (if equipped)
NOTICE
A continuous horn indicates a critical fault. Operating the engine during a critical fault can damage
components. If the warning horn emits a continuous beep, do not operate the engine unless avoiding a
hazardous situation.
If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot
be determined, contact your authorized Mercury MerCruiser dealer.
Testing the Audio Warning System
1. Turn the ignition switch to the "ON" position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
Connecting the Computer Diagnostic System (CDS G3) Service Tool

NOTE: The computer diagnostic system (CDS G3) procedural information is available in the help menu. If you
have the CDS hardware, order the software and cable 8M0046124 from Mercury.
8M0046124
Harness
Models Equipped with a SmartCraft Diagnostic Port

1. Ensure all engine key switches and engines are off.
2. Locate the SmartCraft diagnostic port at the boat helm.
NOTE: The diagnostic port may not be mounted on the dashboard if space is limited, but may be mounted
under the dashboard, or in the cabin at an inconspicuous, but accessible location.
90-8M0032375 AUGUST 2013 Page 7 / 14

3. Remove the cover and insert the CDS G3 interface harness connection.
47772
SmartCraft diagnostic port
4. Connect the CDS G3 interface USB port connector to the USB port on the G3 service tool.
b c
a - CDS G3 interface tool
a b - CDS G3 interface USB port
connector
c - CDS G3 service tool
d - USB port on the CDS G3 service
tool
d 47771
Models Equipped with a SmartCraft Diagnostic Junction Box

2. Locate the standard junction box under the boat helm and connect the CDS G3 interface harness.
a b a - Junction box
b - CDS G3 interface harness connector
45647
Page 8 / 14 90-8M0032375 AUGUST 2013

3. Connect the CDS G3 interface USB port connector to the USB port on the CDS G3 service tool.
b c
a - CDS G3 interface tool
a b - CDS G3 interface USB port
connector
c - CDS G3 service tool
d - USB port on the CDS G3 service
tool
d 47771
Models Not Equipped with SmartCraft Diagnostic Port or Junction Box

IMPORTANT: The CDS G3 termination harness is a terminal resistor. Only use it when connecting to the engine
harness terminator connection. Do not connect the termination harness to the junction box or diagnostic port at
the helm.
47754
CDS G3 termination harness
CDS G3 Termination Harness 84‑8M0045065
90-8M0032375 AUGUST 2013 Page 9 / 14

2. Locate the yellow or red terminator resistor on the engine harness and remove it by pushing the tab in while
pulling the connections apart. Retain the yellow or red terminator resistor to reinstall after using the service
tool.
a b c
47733
Terminator resistor red or yellow

a - Terminator connection
b - Yellow or red terminator resistor
c - Tab
3. Connect the CDS G3 termination harness to the terminator connection on the engine.
a b a - CDS G3 termination harness

b - Terminator connection
47734
4. Connect the CDS G3 termination harness connector to the CDS G3 interface harness connector.
Page 10 / 14 90-8M0032375 AUGUST 2013

5. Connect the CDS G3 interface USB connector to the USB port on the CDS G3 service tool.
a b a - CDS G3 interface
harness connector
c d b - CDS G3 termination
harness connector
c - CDS G3 interface
USB connector
d - CDS G3 service tool
e - USB port on the CDS
G3 service tool
f - CDS G3 interface
tool
e 47735
Computer Diagnostic System w/trim dem (CDS) G3

Use the CDS G3 service tool for the following if applicable:
1. Configuration—Helm Configuration, CAN Pad Configuration, Drive Configuration, Compass Configuration,
Import
47774
90-8M0032375 AUGUST 2013 Page 11 / 14

2. Active Test—Set Trailer Limit, Set Trim Limit, Set Engine Location, Set Tach Link
47775
3. Trim the drive up using the ERC, or other switch, to the desired position for the trim limit. Measure from
anchor pin centers. The distance between both front and rear pins must not exceed 55.25 cm (21.75 in.) in
full trim position.
55.25 cm
(21.75 in.)
35087
IMPORTANT: The distance between both front and rear pins must not exceed 55.25 cm (21.75 in.) in full trim
position.
Warning Horn Signals

IMPORTANT: The audio warning system alerts the operator that a problem has occurred. It does not protect the
engine from damage.
The Mercury MerCruiser power package may be equipped with an audio warning system. Most faults cause the
warning horn circuit to activate. How the warning horn activates depends on the severity of the problem.
Page 12 / 14 90-8M0032375 AUGUST 2013

There are two warning horn states:

• Caution
• Severe
Caution
If a caution is detected, the audio warning system will sound for six one‑second intervals.
ON ON ON ON ON ON
1 1 1 1 1 1
a - Horn (on or off)
a 1 1 1 1 1
b - Time (in seconds)
OFF OFF OFF OFF OFF OFF
b
33402
Below are some examples of a caution fault:

• Drive oil is low (sterndrive models only)
• Sensor failure
Severe
IMPORTANT: Operators are advised to contact an authorized Mercury MerCruiser dealer if a severe fault is
activated.
If a severe fault is detected, the audio warning system sounds for six seconds, turns off for six seconds, and
sounds for six more seconds. Then the audio warning system sounds for two half‑second intervals every sixty
seconds.
ON ON ON ON ON ON
6 6 6 60 ½ ½ 60 ½ ½
a
OFF
OFF OFF
b
40388
a - Horn (on or off)

b - Time (in seconds)
Below are some examples of a severe fault:

• Transmission fluid temperature is too hot
• Engine oil pressure is too low
• Engine temperature is too hot
• Seawater pressure is too low
Testing the Audio Warning System
1. Turn the ignition switch to the "ON" position without cranking the engine.
2. Listen for the audio alarm. The alarm will sound if the system is functioning correctly.
Special Tools ‑ DTS Troubleshooting

Computer Diagnostic System CDS G3 Order through SPX or Mercury
CAN P Diagnostic Cable 84‑892663
90-8M0032375 AUGUST 2013 Page 13 / 14


8M0046124
Harness
Page 14 / 14 90-8M0032375 AUGUST 2013

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

STORAGE
Table of Contents
Predelivery Preparation........................................................................................................................................... 3
Engine Oil.......................................................................................................................................................... 4
Checking .................................................................................................................................................... 4
Filling ......................................................................................................................................................... 4
Steering Fluid.................................................................................................................................................... 5
Power Trim Pump.............................................................................................................................................. 5
Sterndrive Gear Lube Monitor........................................................................................................................... 6
Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method..................................................... 7
Trim Position Sender Adjustment ‑ SmartCraft Gauges Multimeter Method..................................................... 8
Propeller Selection............................................................................................................................................ 8
General Information ................................................................................................................................... 8
Engine Rev‑Limiter .................................................................................................................................... 9
Bravo Sterndrive Propeller Installation.............................................................................................................. 9
Bravo One Models ..................................................................................................................................... 9
Bravo Two Models ................................................................................................................................... 11
Bravo Three ............................................................................................................................................. 11
Battery Connection.......................................................................................................................................... 12
Priming the Fuel System................................................................................................................................. 12
Test Running Engine ...................................................................................................................................... 13
Boat Out of the Water .............................................................................................................................. 13
Boat in the Water ..................................................................................................................................... 13
Testing Preparation ................................................................................................................................. 14
Testing .................................................................................................................................................... 14
Boat in the Water Tests................................................................................................................................... 15
Engine Idle Speed ................................................................................................................................... 15
Wide‑Open Throttle Test ......................................................................................................................... 15
Engine Operating Range................................................................................................................................. 16
Alternate Priming Procedure for Fuel System ...................................................................................................... 16
9
Fabricating a Pressure‑Relief Collection Tool................................................................................................. 16
Priming the Fuel System................................................................................................................................. 17
Using Fuel from the Boat Tank ................................................................................................................ 17
Using Fuel from a Portable Tank ............................................................................................................. 18
Flushing the Seawater System—Sterndrive Models............................................................................................. 18
General Information—Bravo Sterndrive.......................................................................................................... 18
Sterndrive Water Pickups ........................................................................................................................ 19
Flushing Attachments .............................................................................................................................. 19
Boat Out of the Water—Bravo Sterndrive....................................................................................................... 19
Boat in the Water—Bravo Sterndrive.............................................................................................................. 20
Boat Out of the Water—Alternative Water Pickups......................................................................................... 21
Boat in the Water—Alternative Water Pickups................................................................................................ 22
Power Package Flushing Procedure............................................................................................................... 23
Models Using The Sterndrive Water Pickup ............................................................................................ 23
Cold Weather or Extended Storage...................................................................................................................... 25
Preparing Power Package for Storage............................................................................................................ 26
Engine and Fuel System Preparation ...................................................................................................... 26
Draining the Seawater System.............................................................................................................................. 27
Drain System Identification.............................................................................................................................. 27
Air‑Actuated Single‑Point Drain System .................................................................................................. 27
Manual Drain System .............................................................................................................................. 28
Air‑Actuated Single‑Point Drain System.......................................................................................................... 28
90-8M0032375 AUGUST 2013 Page 1 / 36

PREDELIVERY PREPARATION AND STORAGE SECTION - 9
Boat in the Water ..................................................................................................................................... 28

Manual Drain System...................................................................................................................................... 32
Boat in the Water ..................................................................................................................................... 32
Draining Water from the Cool Fuel Module..................................................................................................... 33
Draining the Sterndrive....................................................................................................................................34
Battery Storage...................................................................................................................................................... 35
Recommissioning the Power Package.................................................................................................................. 35
Page 2 / 36 90-8M0032375 AUGUST 2013

Lubricant, Sealant, Adhesives

Extreme Grease Propeller shaft splines 8M0071842
9 Loctite 567 PST Pipe Sealant The threads of the barbed hose fitting 92-809822
19 Perfect Seal Drain plug threads 92-34227Q02
80 SAE Engine Oil 30W Power trim pump Obtain Locally
87 High Performance Gear Lube Gear lube monitor 92-858064K01
95 2-4-C with PTFE Propeller shaft splines 92-802859A 1

Power Trim Pump
114 Power Trim and Steering Fluid 92-858074K01
Power trim pump
115 Premium Plus 2-cycle TC-W3 Outboard Oil Fuel system 92-858026K01
124 Fuel System Treatment & Stabilizer Fuel system 92-8M0047932
Special Tools
Propeller Nut Tool 91‑805457T 1
Aids in the removal and installation of the front propeller nut.
10677
Flushing Device 44357T 2
Attaches to the water intakes; provides a fresh water connection when flushing
the cooling system or operating the engine.
9192

881150K 1
Kit
Blocks off the front water inlet holes on an outboard or Bravo Dual Water
Pick‑up (DWP) gearcases. Use with side inlet flushing tool. (P/N 91044357T2)
9194
Predelivery Preparation
Once the power package installation is complete, the following final steps should be taken to prepare the power
package for delivery to the customer. It is the boat manufacturer's responsibility to perform these procedures, or
to make an arrangement with the dealer to have these procedures completed.
90-8M0032375 AUGUST 2013 Page 3 / 36

Engine Oil
NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not
to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local
restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.
Checking
1. Stop the engine. Allow approximately five 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.
a - Oil dipstick handle

b - Operating range
b
50315
3. Remove the dipstick and observe the oil level. Oil level must be in the operating range. Reinstall the dipstick
into the dipstick tube.
Filling
IMPORTANT: Do not overfill the engine with oil.
IMPORTANT: Always use the dipstick to determine the exact quantity of oil required.
1. Remove the oil fill cap.
a
a - Oil fill cap
50316
2. Add the specified engine oil to bring the level up to, but not over, the operating range mark on the dipstick.
Recheck the oil level.
Page 4 / 36 90-8M0032375 AUGUST 2013

3. Replace the fill cap.
All Models Capacity Fluid Type

Mercury 25W‑40 Synthetic Blend 4‑Stroke
Engine oil (with filter) 6.5 Liter (7 US qt)
Engine Oil
Steering Fluid
1. Using the steering wheel, position the sterndrive so that it is in the straight ahead position.
2. Remove the fill cap from the steering fluid reservoir and note the fluid level.
3. The fluid level should be in the operating range on the dipstick.
a- Reservoir
b- Hot level
b HOT c- Cold level
c COLD d- Add mark
d ADD
50868
4. If the fluid level is in the add range, add the required amount of fluid through the fill cap opening to bring the
level up to the operating range on the dipstick. Do not overfill.

Power Trim and Steering
114 Power Trim Pump 92-858074K01
Fluid
5. If fluid is not in the reservoir, a leak exists in the power‑assisted steering system. Find the cause and correct.
Power Trim Pump

1. Check oil level with sterndrive unit in the full DOWN/IN position.
IMPORTANT: Use only specified lubricant.
90-8M0032375 AUGUST 2013 Page 5 / 36

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 a - Fill cap (top and

b
underneath side views)
b - Reservoir fill neck
c - "MIN" and "MAX" lines
c
8539

Power Trim and Steering
114 Power trim pump 92-858074K01
Fluid
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.
Sterndrive Gear Lube Monitor

New installations may require as much as 470 mL (16 fl oz) of gear lube added to the monitor bottle during the
break‑in period (20 hours of running time). It is important to monitor and maintain the gear lube level during the
break‑in period.
NOTE: The gear lube level will fluctuate during operation. The gear lube level should be checked with the engine
cold, before starting.
Page 6 / 36 90-8M0032375 AUGUST 2013

1. Check the gear lube monitor before start up to determine the gear lube level. Keep the gear lube at the
"COLD FILL" level.
a - Gear lube monitor

b - "COLD FILL" level
b
COLD FILL
50333
2. If the gear lube is below the "COLD FILL" level, fill the gear lube monitor with the specified gear lube so that
the gear lube is at the "COLD FILL" level. Do not overfill.

Lube
Trim Position Sender Adjustment ‑ SmartCraft Gauges Scan Tool Method
a - Trim position sender

b - Retaining screws
a
21076
1. Trim the sterndrive unit to the full DOWN/IN position.
90-8M0032375 AUGUST 2013 Page 7 / 36

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.
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
a - Trim position sender

b - Retaining screws
a
21076
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
General Information
IMPORTANT: Installed propeller must allow engine to operate at its specified maximum WOT RPM. Use an
accurate service tachometer to verify engine operating RPM.
Page 8 / 36 90-8M0032375 AUGUST 2013

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the
correct propeller. Refer to Propellers http://www.mercurymarine.com/propellers/prop‑selector. Specified engine
WOT and operating RPM range are listed in the Mercury MerCruiser Operation, Maintenance and Warranty
Manual attached to the engine.
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 an RPM loss
• Operating in a higher elevation causes an RPM loss
• Operating with increased load (additional passengers, pulling skiers, etc.)
For better acceleration, such as is needed for waterskiing, use the next lower pitch propeller. However, 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 Part/Quicksilver Accessories Guide.
Refer to Boat In The Water Tests, at the back of this manual.
Engine Rev-Limiter
IMPORTANT: The engines listed in the following chart are equipped with a RPM rev‑limiter that is set to an upper
(or limited) RPM amount. This limit is slightly above the normal operating range of the engine and is designed to
help prevent damage from excessive engine RPM. When the engine reaches the rev‑limit RPM, the horn will
sound. Once the RPM drops into the recommended operating RPM range, normal engine operation resumes.
Engine Rev‑Limiter
Model Engine Recommended Operating RPM Range Rev‑Limit RPM Setting
8.2 MAG 4600–5000 5150
8.2 MAG H.O. 4600–5000 5150
Bravo Sterndrive Propeller Installation

! WARNING
a - Wood block
b - Propeller
c - Propeller nut under socket
Bravo One Models

IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the
propeller shaft.
1. Coat the propeller shaft spline with one of the following Quicksilver lubricants.
90-8M0032375 AUGUST 2013 Page 9 / 36


2. Install the propeller with the attaching hardware as shown.

3. Tighten the propeller nut to the specified torque.
Typical Bravo One models

d a - Propeller shaft splines
b - Forward thrust hub
c - Flo‑Torque II drive hub
d - Propeller
e f e - Drive sleeve adapter
a
g f - Tab washer
b g - Propeller nut
c
5301
a Bravo One XR models

b a - Propeller shaft
b - Propeller hub insert with snubbers
c c - Propeller
d - Thick washer
d e
e - Washer
f g
f - Washer
g - Propeller nut
19816
NOTE: The propeller torque stated is a minimum torque value.

Bravo One propeller nut 75 – 55
NOTE: Bravo One XR models do not use the tab washer.

4. Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab
washer align with the grooves on the spline washer.
5. Bend the three tabs down into the grooves.
b c a- Propeller
b- Tab washer
a d
c- Drive sleeve adapter
e d- Tab bent down
e- Propeller nut
4750
Page 10 / 36 90-8M0032375 AUGUST 2013

Bravo Two Models

IMPORTANT: Use the correct rotation propeller. The propeller rotation must match the direction of rotation of the
propeller shaft.

2. Install the propeller with the attaching hardware as shown.

3. Tighten the propeller nut to the specified torque.
c Bravo Two
a - Propeller shaft splines
d
b - Forward thrust hub
f c - Propeller
a d - Spline washer
b e - Tab washer
f - Propeller nut
8566
e
NOTE: The propeller torque stated is a minimum torque value.
Bravo Two propeller nut 81 – 60
4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the
spline washer.
5. Bend the three tabs down into the grooves.
b c a- Propeller
b- Tab washer
a d
c- Drive sleeve adapter
e d- Tab bent down
e- Propeller nut
4750
Bravo Three

2. Slide the forward thrust hub onto the propeller shaft, with the tapered side toward the propeller hub.
3. Align the splines and place the front propeller on the propeller shaft.
4. Install the front propeller locknut and tighten using the propeller nut tool.
Propeller Nut Tool 91‑805457T 1
90-8M0032375 AUGUST 2013 Page 11 / 36


Bravo Three front propeller nut 136 – 100
5. Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub.
6. Align the splines and install the aft propeller.
7. Install the propeller nut and tighten to the specified torque.

Bravo Three rear propeller nut 81 – 60
8. Install the propeller shaft anode and the screw and tighten to the specified torque.
e Bravo Three
a - Rear propeller nut
f
b - Rear propeller
b c - Rear propeller thrust hub
d
c d - Front propeller nut
e - Front propeller
a f - Front propeller thrust hub
i g - Propeller shaft anode screw
j
g h h - Flat washer
i - Star washer
5304
j - Propeller shaft anode

Propeller shaft anode screw 19 168 –
Battery Connection
IMPORTANT: Engine electrical system is negative (–) ground.
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
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the
engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep
the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before
attempting to start the engine, and 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.
Page 12 / 36 90-8M0032375 AUGUST 2013

Test Running Engine

! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death.
Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury.
NOTICE
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. Also install the gearcase seal kit if the
sterndrive is equipped with dual water pickup.
a b a - Sterndrive with side

water pickup
c b - Sterndrive with
dual water pickup
d d c - Flushing device
d - Hose attachment
e - Dual water pickup
flush gearcase seal
e kit
43664

881150K 1
Kit
2. Connect a hose between the flushing attachment and a water source.
3. Open the water source about ½ 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 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 pickup on the sterndrive or the
through‑the‑hull pickup.
1. Ensure that the water level is above the water pickup on the sterndrive or the through‑the‑hull pickup.
2. Proceed to Testing Preparation.
90-8M0032375 AUGUST 2013 Page 13 / 36

Testing Preparation
! WARNING
Leaving the helm unattended while performing tests with the boat in the water may result in loss of boat control
causing serious injury or death. Ensure someone is at the helm at all times, unless the boat is secured to a
dock.
1. Ensure that the cooling system drain plugs, petcocks, and hoses are installed and tight.
NOTE: Refer to the appropriate Mercury MerCruiser Operation, Maintenance, and Warranty Manual for
operating specifications. Refer to the appropriate Mercury MerCruiser Service Manual for fluid capacity
information.
2. Check the engine crankcase oil level.
IMPORTANT: The gear lube level will fluctuate during operation. Check the gear lube level at the monitor
when sterndrive is cool and engine is shut down.
3. Check the gear lube monitor for the sterndrive gear lube level.
4. Check the engine drive belt tension.
5. Test the audio warning system in accordance with the instructions on the instrumentation panel decal.
6. Supply water to the engine either by putting the boat in the water or by using the correct flush device.
IMPORTANT: If using a test tank, ensure the water level is above the sterndrive water pickup.
IMPORTANT: If using a flush test device, do not use full water tap pressure. During operation, do not operate the
engine above 1500 RPM to ensure the engine seawater pump suction does not collapse the hose to the water
source causing the engine water supply to stop.
! WARNING
Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death.
Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury.
a - Dual water pickup

b - Side pickup
a b
43657
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 the sterndrive in neutral, idle speed, and start the engine.
2. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
3. Watch all gauges for normal readings.
4. Turn the steering wheel right/starboard, then left/port, and ensure the sterndrive turns the correct way.
5. Inspect the engine compartment for water, oil, fuel, and exhaust leaks.
6. Turn the steering wheel port until it stops and continue to apply pressure. If the pump lugs (engine RPM
drops or the power steering pump tone changes):
Page 14 / 36 90-8M0032375 AUGUST 2013

a. Check for an obstruction between the gimbal ring and the gimbal housing and all moving steering
components.
b. Ensure that the steering lever is not contacting the cutout in the transom. If contact is being made,
modify the cutout.
c. Check the steering cable end dimension with the cable fully extended.
7. Turn the steering wheel starboard until it stops and continue to apply pressure. If the pump lugs (engine RPM
drops or the power steering pump tone changes):
a. Turn off the engine.
b. Remove the fill cap from the steering reservoir. Check the fluid level and add fluid if necessary.
a- Reservoir
b- Hot level
b HOT c- Cold level
c COLD d- Add mark
d ADD
50868
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.
2. If idle is still not correct, it may be necessary to perform EFI System Diagnostic Tests on the idle circuit.
Refer to the appropriate Mercury MerCruiser Service Manual for procedures.
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 the engine.
2. Slowly advance the throttle until the engine reaches 1300 RPM (± 100 RPM).
3. Watch all gauges for normal readings.
4. When the engine reaches normal operating temperature, run the boat up on plane.
5. Advance engine RPM (in 200 RPM increments) until engine reaches its maximum rated RPM.
90-8M0032375 AUGUST 2013 Page 15 / 36

6. To test if the correct propeller has been installed, operate boat (with normal load onboard) at WOT and check
RPM with an accurate tachometer. Engine RPM should be near the top of the specified range so that, under
a heavy load, engine speed will not fall below specifications. If the 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.
Maximum rated RPM 8.2 MAG/H.O.

RPM range at WOT 4600–5000
7. Return to idle speed.
8. Shut off engine.
9. Check coolant level and add coolant if necessary.
Engine Operating Range

IMPORTANT: The engines listed in the following chart are equipped with a RPM rev‑limiter that is set to an upper
(or limited) RPM amount. This limit is slightly above the normal operating range of the engine and is designed to
help prevent damage from excessive engine rpm. When the engine reaches the rev‑limit RPM the horn will
sound. When the RPM drop into the recommended operating RPM range, normal engine operation resumes.
NOTE: Refer to the Propeller Selection if RPM adjustments are needed.
Engine Rev‑Limiter
Models Engine Recommended Operating RPM Range RPM Rev‑Limit
8.2 MAG/ H.O. 4600–5000 5150
Alternate Priming Procedure for Fuel System

Fabricating a Pressure‑Relief Collection Tool
In order to take advantage of the alternative Priming Procedure a new pressure relief collection tool will need to
be fabricated.
A 1.5 m (5 ft.) length of hose will work for most applications. A longer or shorter length of hose may be used to
meet your specific needs. Example: To ensure the hose is visible from the helm of a cruiser would require a
much longer hose than would be required for a runabout. The smaller diameter hose works best when using a
long hose to reduce the amount of time and fuel needed to become visible in the hose.
IMPORTANT: All components must be fuel rated and must be inspected regularly to ensure the tool is in safe
working condition.
Supplies needed:
• One‑gallon fuel can (collection tank) with separate vent.
• Clear hose (The hose can be from 3 mm to 9 mm (1/8 in. to 3/8 in.) diameter. The smaller diameter hose
works best when using a long hose to reduce the amount of time and fuel needed to become visible in the
hose.
• Appropriate sized barbed hose fitting.
Page 16 / 36 90-8M0032375 AUGUST 2013

• Fuel pressure adapter (90‑803135) from Mercury or other equivalent adapter.
b Pressure Relief Collection Tool

c a - One‑gallon fuel can (collection tank)
b - Separate fuel can vent
a c - Clear hose
d - Fuel pressure adapter (90‑803135)
26854
In the following example a hole was drilled through the cap. The cap was tapped according to the size of the
barbed hose fitting being used. Sealant was applied to the threads of the barbed hose fitting and the fitting was
threaded into the cap. The clear hose was connected to the barbed hose fitting and the fuel pressure adapter
attached to the other end of the clear hose.
a- One‑gallon fuel can (collection tank)

a b- Barbed hose fitting
c- Cap
c
d- Clear hose
b
e- Fuel pressure adapter
e
26855

9 The threads of the barbed hose fitting 92-809822
Sealant
Priming the Fuel System

! WARNING
Using Fuel from the Boat Tank

The fuel system is connected to the fuel tank on the boat and fuel is in the tank. This method does not require the
use of a portable fuel tank.
90-8M0032375 AUGUST 2013 Page 17 / 36

Using Fuel from a Portable Tank

A portable fuel tank is connected to the engine and no fuel is in the boat fuel tank. After test running the engine
connect the fuel line from the boat fuel tank to the fuel system. Follow the precautions in the appropriate Mercury
MerCruiser Installation Manual for disconnecting the portable fuel tank and reconnecting the fuel line from the
boat fuel tank to the boat fuel system.
The following procedure is the alternative method for priming the fuel system.
1. Remove the cap from the fuel pressure test port.
a - Fuel pressure test port
50478
2. Connect the pressure relief tool to the fuel pressure test port and open the vent on the pressure relief
collection tank.
3. Place the collection tank in a convenient location to ensure the clear hose is viewable from the helm.
4. Turn the ignition key to the "ON" position. Do not turn the ignition key to the start position.
5. When the fuel pump stops running, turn the key off.
6. Again, turn the key back to the "ON" position. Do not turn the ignition key to the start position.
7. Repeat this cycle until fuel is visible in the clear hose. Fuel does not have to reach the collection tank. Once
fuel is visible in the clear line, the air has been evacuated and the system is primed.
8. Remove the pressure relief tool from the fuel pressure test port and install the cap.
9. Wipe up any fuel that may have spilled.
10. Ventilate the engine compartment.
11. After priming the fuel system, continue the engine preparation. Refer to the appropriate Mercury MerCruiser
Installation Manual. All other procedures in the installation manual remain the same.
Flushing the Seawater System—Sterndrive Models

General Information—Bravo Sterndrive
Bravo sterndrives could be equipped with a combination of any of three different types of water pickups:
through‑hull, through‑transom, and through‑sterndrive. The flushing procedures for these systems are separated
into two categories: sterndrive water pickups and alternative water pickups.
Page 18 / 36 90-8M0032375 AUGUST 2013

Sterndrive Water Pickups

There are two types of water pickups on Bravo sterndrives: dual water and side pickups. Dual water pickups
require the flushing attachment (44357T 2) and the flush seal kit (881150K 1) and side pickups require the
flushing attachment (44357T 2).
a - Sterndrive with dual water pickup

b - Sterndrive with side water pickup
a b
43657
Flushing Attachments
The Bravo flushing attachments are ordered separately.
a b a - Sterndrive with side

water pickup
c b - Sterndrive with
dual water pickup
d d c - Flushing device
d - Hose attachment
e - Dual water pickup
flush gearcase seal
e kit
43664

881150K 1
Kit
Boat Out of the Water—Bravo Sterndrive

IMPORTANT: Flushing the power package is most effective when performed with the boat and sterndrive out of
the water.
IMPORTANT: Flushing is needed if the engine package has been operated in saltwater, brackish water,
mineral‑laden water, or polluted water. For best results, flushing is recommended after each outing and before
cold weather and extended storage.
1. Lower the sterndrive to full down/in position.
! WARNING
2. Remove the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual.
90-8M0032375 AUGUST 2013 Page 19 / 36

3. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
4. Connect the water supply hose to the water source.
NOTICE
Flushing the engine when it is not operating will result in water collecting in the exhaust system, damaging the
engine. Do not supply flush water for more than 15 seconds without the engine operating.
5. With the sterndrive in the normal operating position, completely open the water source to provide maximum
water supply.
6. Place the remote control in the neutral idle speed position.
7. Immediately start the engine.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply
hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without
sufficient cooling water supply.
8. Press the throttle only button and slowly advance the throttle until the engine reaches 1300 RPM (± 100
RPM).
9. Observe the water temperature gauge to ensure that the engine is operating in the normal range.
10. Operate the engine with the sterndrive in neutral for a minimum of 10 minutes.
11. For power packages operated in saltwater, brackish water, mineral‑laden water, or polluted water,
continue to operate the engine until the discharge water is clear.
12. Slowly return the throttle to idle speed position.
13. Stop the engine.
14. Immediately shut off the supply water and remove the flushing attachment.
15. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual.
Boat in the Water—Bravo Sterndrive

the water.
mineral‑laden water, or polluted water. For best results, flushing is recommended after each outing and before
1. Raise the sterndrive to the trailer position.
2. Install the appropriate flushing attachment over the water inlet holes in the gear housing.
3. Lower the sterndrive to the full down/in position.
4. Connect the water supply hose to the water source.
NOTICE
water supply.
RPM).
11. For engine packages operated in saltwater, brackish water, mineral‑laden water, or polluted water,
Page 20 / 36 90-8M0032375 AUGUST 2013

12. Slowly return the throttle to the idle speed position.

14. Immediately shut off the supply water. Do not remove the flushing attachment from the sterndrive at this time.
NOTICE
Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the
seacock before disconnecting the seawater inlet hose. Plug the seawater inlet hose immediately after
disconnecting it.
15. Close the seacock, if equipped, then disconnect the seawater inlet hose to prevent water from siphoning into
the engine or boat.
16. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump, and immediately
plug the hose to prevent water from siphoning into the engine or boat.
17. Raise the sterndrive to the trailer position.
18. Remove the flushing attachment from the sterndrive.
19. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose
to be reconnected before operating the engine.
Boat Out of the Water—Alternative Water Pickups

the water.
IMPORTANT: Flushing is needed If the engine package has been operated in saltwater, brackish water,
mineral‑laden water, or polluted water. For best results flushing is recommended after each outing and before
! WARNING
2. Remove the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual.
3. Close the seacock, if equipped.
4. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump.
5. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater
pump.
NOTICE
water supply.
NOTICE
RPM).
90-8M0032375 AUGUST 2013 Page 21 / 36

16. Install the water inlet hose to the seawater inlet of the seawater pump. Tighten the hose clamp securely.
17. Install the propeller. Refer to the appropriate Mercury MerCruiser sterndrive service manual.
Boat in the Water—Alternative Water Pickups

the water.
mineral‑laden water, or polluted water. For best results flushing is recommended after each outing and before
NOTICE
Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the
seacock before disconnecting the seawater inlet hose. Plug the seawater inlet hose immediately after
disconnecting it.
2. Close the seacock, if equipped, then disconnect the seawater inlet hose to prevent water from siphoning into
the engine or boat.
3. If not equipped with a seacock, disconnect the seawater inlet hose from the seawater pump and immediately
plug the hose to prevent water from siphoning into the engine or boat.
4. Using a suitable adapter, connect the flushing hose from the water source to the water inlet of the seawater
pump.
NOTICE
water supply.
NOTICE
RPM).
Page 22 / 36 90-8M0032375 AUGUST 2013

15. Tag the ignition switch with an appropriate tag requiring the seacock to be opened or the seawater inlet hose
to be reconnected before operating the engine.
Power Package Flushing Procedure

NOTE: Flushing is needed only for salt, brackish, mineral laden or polluted water applications. Flushing is
recommended after each outing for best results.
IMPORTANT: Flushing the SeaCore power package with the boat and sterndrive in the water is less effective.
Flushing the SeaCore power package is most effective when performed with the boat and sterndrive out of the
water, such as on a boat lift or trailer.
Models Using The Sterndrive Water Pickup
IMPORTANT: The system is designed to flush the Bravo sterndrive and the engine with one water source. Do
not block or remove the inlet water hose from the sterndrive to the engine.
NOTE: Engines with the sterndrive water inlet blocked off at the gimbal housing: Refer to Alternative Water
Pickups.
! WARNING
IMPORTANT: Do not allow the engine to pull air or seawater from alternative water pickup sources during the
flushing procedure. If equipped, ensure that all alternative water inlet hoses are plugged at both ends.
1. Remove the boat from the water.
2. Close the seacock, if equipped.
For visual clarity, the secock shown is not installed

c a - Hose fitting to engine
b - Seacock
c - Handle (closed position)
a b d d - To water source pickup attachment
18510
3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose
from the alternative water pickup and plug both ends, excluding the Bravo sterndrive.
4. Ensure that the inlet water hose from the sterndrive to the engine is connected.
5. Remove the quick‑connect fitting from the parts bag supplied with the engine.
6. Attach the quick‑connect fitting to a water hose.
a a - Quick connect fitting (water hose end)

b
b - Water hose
18487
90-8M0032375 AUGUST 2013 Page 23 / 36

7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine.
a - Water hose
a b - Quick‑connect fitting (water hose end)
c - Flush socket
18489
8. Open the water source of the water hose to a full flow.

9. Allow the water to flush the sterndrive for 30 seconds.
10. Place the remote control in neutral idle speed position and start engine.
NOTICE
11. Operate the engine at idle speed in neutral gear. Do not exceed 1200 RPM.
12. Monitor the engine temperature while operating the engine.
13. Flush the engine for 5 to 10 minutes or until discharge water is clear.
14. Shut off the engine.
15. Allow the water to flush the sterndrive for 10 seconds.
16. Turn off the water source.
17. Disconnect the quick‑connect fitting and water hose from the flush socket on the engine by pressing the
release button on the flush socket.
a - Quick‑connect fitting (water hose end)

a b - Flush socket release button
18488
Page 24 / 36 90-8M0032375 AUGUST 2013

18. Remove the quick‑connect fitting from the water hose.
a a - Quick‑connect fitting (water hose end)

b
b - Water hose
18487
19. Retain the quick‑connect fitting with the water hose end for repeated use by storing it separately in a storage
compartment on the boat for easy access.
IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow
the seawater pump to suck air during engine operation causing an overheating problem. Damages due to
engine overheating are not covered by Mercury MerCruiser Warranty.
a Quick-connect fitting stored in the boat

a - Quick‑connect fitting (water hose end)
25900
20. Insert the dust cover in the flush socket on the engine.
a a - Dust cover
b - Flush socket
b
43065
IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage. If
the unit is to be stored out of the water, open the seacock.
21. Open the seacock, if equipped, or reconnect the alternative water inlet source prior to operating the engine.
Cold Weather or Extended Storage

IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized
Mercury MerCruiser dealer. Damage caused by freezing temperatures is not covered by the Mercury MerCruiser
Limited Warranty.
90-8M0032375 AUGUST 2013 Page 25 / 36

NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the
seawater section of the cooling system immediately after operation or before any length of storage in freezing
temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water
from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose
disconnected and plugged.
NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the
operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturer's
instructions, be used in the seawater section of the cooling system for freezing temperatures or extended
storage. Ensure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in
marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.
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.
2. If the boat is to be placed in storage with the fuel containing alcohol in fuel tanks (if fuel without alcohol is not
available): Fuel tanks should be drained as low as possible and Mercury/Quicksilver Gasoline Stabilizer for
Marine Engines added to any fuel remaining in the tank. Refer to Operators Manual Section 4 for additional
information.
3. Flush the cooling system. Refer to the Operators Manual Section 6.
4. Supply cooling water to engine. Refer to the Operators Manual Section 6.
5. Operate the engine sufficiently to bring it up to normal operating temperature and allow fuel with Mercury/
Quicksilver Gasoline Stabilizer to circulate through the fuel system. Shut off the engine.
6. Change the oil and oil filter.
7. Prepare the engine and fuel system for storage. Refer to Engine and Fuel System Preparation.
8. Drain the engine seawater cooling system. Refer to Draining the Seawater System.
NOTICE
Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the
seawater section of the cooling system immediately after operation or before any length of storage in freezing
temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water
from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose
disconnected and plugged.
9. For additional assurance against freezing and rust, after draining, fill the seawater cooling system with
propylene glycol mixed to the manufacturer's recommendation to protect engine to the lowest temperature to
which it will be exposed during freezing temperatures or extended storage.
10. Store the battery according to the manufacturer's instructions.
Engine and Fuel System Preparation
! WARNING
! WARNING
Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite
resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package.
1. In a 23 Liter (6 US gal) remote fuel tank mix:
Page 26 / 36 90-8M0032375 AUGUST 2013

a. 19 Liter (5 US gal) regular unleaded (90 RON) 87 octain gasoline

b. 1.89 Liter (2 U S qts) Premium Plus 2‑Cycle TC‑W3 Outboard Oil
c. 150 ml (5 oz) Fuel System Treatment and Stabilizer or 30 ml (1 oz) Fuel System Treatment and
Stabilizer Concentrate

Premium Plus 2-cycle
115 Fuel system 92-858026K01
TC-W3 Outboard Oil
Fuel System Treatment &
124 Fuel system 92-8M0047932
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 five minutes minimum.
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 engines fuel system
to become completely dry.
7. Replace the water separating fuel filter element. Refer to Section 5 for proper procedure.
Draining the Seawater System

! CAUTION
Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink.
Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and
ensure the bilge pump is operational before draining. Do not operate the engine with the drain system open.
IMPORTANT: Only drain the seawater section of the closed cooling system.
IMPORTANT: The boat must be as level as possible to ensure complete draining of the cooling system.
Your power package is equipped with a drain system. Refer to Drain System Identification to determine which
instructions apply to your power package.
IMPORTANT: The engine must not be operating at any point during the draining procedure.
Drain System Identification

Air-Actuated Single-Point Drain System
a
a - Manual pressure release valve
b - Threaded cap for air connection
b c - Green indicators
c
43070
90-8M0032375 AUGUST 2013 Page 27 / 36

a b 50873
a - Starboard side air‑actuated drain location

b - Port side air‑actuated drain location
Manual Drain System
a b
50874
a - Starboard side blue drain plugs

b - Port side blue drain plug
Air‑Actuated Single‑Point Drain System

Boat in the Water
NOTE: This procedure is written for the air pump that was shipped with the engine from the factory. However,
any air source can be used.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Obtain the air pump.
3. Remove the threaded cap from the air connection.
4. Ensure that the lever on top of the air pump is against the handle (horizontal).
Page 28 / 36 90-8M0032375 AUGUST 2013

5. Install the air pump on the air connection.
a
b a - Lever
b - Air pump
c - Air connection
43077
6. Pull the lever on the air pump (vertical) to seal the pump to the connection.
7. 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.
b a- Manual release valve

a
b- Air pump lever (locked)
c- Air connection
d- Green indicators extended
d
43557
8. Verify that water is draining from each opening. If not, use the Manual Drain System instructions.
a b 50873

9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators
extended.
10. For DTS engines, pull the lanyard stop switch (if equipped), or disable the ignition circuit by pulling the fuse
marked "CD."
90-8M0032375 AUGUST 2013 Page 29 / 36

11. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do
not allow engine to start.
12. Remove the air pump from the air connection 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.
14. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer
extended.
a - Manual release valve pull ring

a b - Threaded cap on air connection
c - Green indicators
43558
15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose 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.
1. Place the boat on a level surface and ensure the boat is level.
2. Obtain the air pump.
3. Ensure that the lever on top of the pump is flush with the handle (horizontal).
4. Install the air pump on the air connection.
a
b a - Lever
b - Air pump
c - Air connection
43077
5. Pull the lever on the air pump (vertical) to seal the pump to the air connection.
Page 30 / 36 90-8M0032375 AUGUST 2013

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.
b a- Manual release valve

a
b- Air pump lever (locked)
c- Air connection
d- Green indicators extended
d
43557
7. Verify that water is draining from each opening. If not, use the Manual Drain System instructions.
a b 50873

8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators
extended.
marked "CD."
10. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pump. Do
not allow engine to start.
11. Remove the air pump from the air manifold and return it to the mounting bracket.
12. 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.
90-8M0032375 AUGUST 2013 Page 31 / 36

13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer
extended.
a - Manual release valve pull ring

a b - Threaded cap
c - Green indicators
43558
Manual Drain System

Boat in the Water
NOTE: Use this procedure if the air‑actuated single‑point drain system fails.
NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are
disconnected.
1. Close the seacock (if equipped) or remove and plug the water inlet hose.
2. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side) and port side blue
drain plug.
a b
50874

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain
system open while transporting the boat or while performing other maintenance to ensure that all water is
drained.
marked "CD."
6. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup
pump. Do not allow the engine to start.
7. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain
plugs.
8. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 32 / 36 90-8M0032375 AUGUST 2013


NOTE: Use this procedure if the air‑actuated single‑point drain system fails.
NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are
disconnected.
1. Place the boat on a level surface to ensure complete draining of the system.
2. Remove two blue drain plugs from the seawater pickup pump (front, starboard side) and port side blue drain
plug.
a b
50874

3. Verify that water is draining from each opening.

4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain
system open while transporting the boat or while performing other maintenance to ensure that all water is
drained.
marked "CD."
6. Crank the engine over slightly with the starter motor to purge any water trapped in the seawater pickup
pump. Do not allow the engine to start.
7. Prior to launching the boat or starting the engine, close the drain system by installing the four blue drain
plugs.
Draining Water from the Cool Fuel Module

Mercury MerCruiser recommends draining the Gen 3 Cool Fuel Module if it is equipped with a drain plug.
1. Remove the drain plug from the Gen 3 Cool Fuel Module and allow the water to completely drain from the
module.
2. Inspect the drain plug and the O‑ring for damage. Replace if needed.
90-8M0032375 AUGUST 2013 Page 33 / 36

3. Place the O‑ring on the drain plug and apply Perfect Seal to the threads. Install the drain plug in the module
drain hole. Tighten the drain plug to finger‑tight.
a - Gen 3 Cool Fuel Module

b - Drain plug
c - O‑ring
b 50410

19 Perfect Seal Drain plug threads 92-34227Q02
Draining the Sterndrive

NOTE: This procedure is needed only for salty, brackish, mineral laden, or polluted water applications; and for
freezing temperatures or extended storage.
1. Insert a small wire repeatedly to make sure that vent holes, water drain holes, and passages are
unobstructed and open.
Sterndrive water drain holes

a - Speedometer pitot tube
b - Anode cavity vent hole
c - Anode cavity drain passage
b d - Gear housing water drain hole (1
each ‑ port and starboard)
d c e - Gear housing cavity vent hole (Bravo
II only)
e a
14627
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail
when returned to service and allowing water to enter the boat. Store the sterndrive in the full down position.
2. Lower the sterndrive unit to the full down/in position.
3. For additional assurance against freezing and rust, after draining, fill the cooling system with propylene glycol
mixed to the manufacturer's recommendation to protect engine to the lowest temperature to which it will be
exposed during freezing temperatures or extended storage
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers
instructions, be used in the seawater section of the cooling system for freezing temperatures or extended
storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use
in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.
Page 34 / 36 90-8M0032375 AUGUST 2013

Battery Storage
Whenever the battery will be stored for an extended period of time, be sure the cells are full of water and the
battery is fully charged and in good operating condition. It should be clean and free of leaks. Follow the battery
manufacturer's instructions for storage.
Recommissioning the Power Package

1. Ensure that all cooling system hoses are connected properly and hose clamps are tight.
! CAUTION
Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or
can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.
2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables.
Tighten each cable clamp securely when connecting.
3. Coat the terminal connections with a battery terminal anticorrosion agent.
4. Perform all the checks in the Before Starting column of the Operation Chart.
NOTICE
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.
90-8M0032375 AUGUST 2013 Page 35 / 36

NOTES:
Page 36 / 36 90-8M0032375 AUGUST 2013

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Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K-planes, Mariner,

STERNDRIVE 8.2 MAG MODELS

Notice to Boat Manufacturer/Installer

IMPORTANT: Identifies information essential to the successful completion of the task.

Page i © 2013 Mercury Marine 90-8M0032375 AUGUST 2013

Copyright and Trademark Information

SECTION 1 - IMPORTANT INFORMATION 1

90-8M0032375 AUGUST 2013 Page 1 / 10

Lubricants, Sealants, Adhesives

Remote Controls and Instrumentation for the DTS System

Page 2 / 10 90-8M0032375 AUGUST 2013

Quick Response (QR) Code

Serial Number Decal Strips

Engine Serial Number

a b c a - Flywheel housing cover

90-8M0032375 AUGUST 2013 Page 3 / 10

Bravo Sterndrive Serial Number and Identification

Bravo sterndrive information on ground plate

Bravo sterndrive serial number stamping

Page 4 / 10 90-8M0032375 AUGUST 2013

Bravo Transom Serial Number

Transom Serial No. xxxxxxxxx

Bravo transom assembly decal

Serial number location on gimbal housing

Bravo Three Notice: Trim‑In Limit Insert (Non‑DTS)

90-8M0032375 AUGUST 2013 Page 5 / 10

Multiple Sterndrive Steering Tie Bar Arrangements

Internal Power‑Assisted Steering with Internal Tie Bar Only

Internal Power‑Assisted Steering with Internal and External Tie Bar

External Power Steering

External Power Steering With Low External Tie Bar

SeaCore Components and Castings

Page 6 / 10 90-8M0032375 AUGUST 2013

Stainless Steel Fasteners

Tube Ref No. Description Where Used Part No.

90-8M0032375 AUGUST 2013 Page 7 / 10

a - Painted boat transom

c a a - MerCathode reference electrode

Page 8 / 10 90-8M0032375 AUGUST 2013

Emission Control Information Label

ECI Label Standard of Compliance

EMISSION CONTROL INFORMATION

90-8M0032375 AUGUST 2013 Page 9 / 10

Page 10 / 10 90-8M0032375 AUGUST 2013

SECTION 2 - BOAT CONSTRUCTION

90-8M0032375 AUGUST 2013 Page 1 / 4

Checking Transom Thickness

Boat Type Recommendation

Page 2 / 4 90-8M0032375 AUGUST 2013

90-8M0032375 AUGUST 2013 Page 3 / 4

Page 4 / 4 90-8M0032375 AUGUST 2013

SECTION 3 - EXHAUST SYSTEM

90-8M0032375 AUGUST 2013 Page 1 / 14

Exhaust system design and installation can affect:

Exhaust System Connections

Exhaust Emissions Sampling

Page 2 / 14 90-8M0032375 AUGUST 2013

Carbon Monoxide Exposure

Stay Clear of Exhaust Areas

90-8M0032375 AUGUST 2013 Page 3 / 14

Example of desired air flow through the boat:

a a - Operating the engine when the

2. Examples of poor ventilation while the boat is moving:

a a - Operating the boat with