Annual (or 100 Hours) Mercruiser Service Checklist.

Check Before Running

• Inspect engine and accessories for visible damage
• Engine alignment check
• Rear engine mounts torque (SD)
• Gimbal ring clamping screws torque
• Seawater pickup pump – disassemble and inspect
• Drain gear housing & refill with appropriate Quicksilver Gear Lube (SD)
• Transmission fluid level (IB)
• Lubricate all drive unit grease fittings including gimbal bearing and drive coupler (SD)
• Drive unit bellows and clamps – inspect (SD)
• Ground wire circuit continuity – check for loose connections
• Service battery and terminals and al electrical connections
• Inspect fuel line and connections, replace fuel filters
• Crankcase oil and filter change
• Closed cooling coolant – replace, inspect pressure cap, hoses and clamps (ISE)
• Heat exchanger – clean seawater section & check sacrificial anodes (ISE)
• Engine exhaust system – inspect
• Drive belts check tension
• Flame arrestor / crankcase ventilation host / air filter clean / inspect
• Lubricate Shift – throttle linkage and steering cable
• Power – steering fluid level (SD)
• Check compressions – replace spark plugs if required
• Inspect spark plug wires and distributor cap and rotor
• Lubricate propeller shaft, drive shaft & shift shaft splines (SD)
• Retorque cylinder head if applicable
• Check for diagnostic codes (ISE)
• Check operation of injectors

Check While Running

• Starter neutral safety switch operation
• Water pump operation
• Water, fuel, oil, exhaust leaks
• Instrument operation / instrument operation second station . Audio warning system operation (ISE)
• Idle – RPM (use workshop tachometer)
• Forward – Neutral – Reverse gear operation
• Forward – Neutral – Reverse gear operation, stop/start second station (ISE)
• Lanyard safety switch operation
• Power trim operation (SD)
• Trim tab adjustment (ISE)
• Steering operation
• WOT – RPM (measuring with workshop tachometer)
• Check timing

Check After Running

• Oil, fuel or water leakage
• All fluid levels
• Propeller nut torque (SD)

Important

• Spray engine with Quicksilver Corrosion Guard
• Inspect corrosion control anodes
• Quicksilver MerCathode system – test output (ISE)
• Check / Reset diagnostic codes (ISE)
• Extend storage procedure completed

Standard Times

• 4 Cylinder: 3.5 Hours
• V6: 4.0 Hours
• V8 Stern drive: 4.0 Hours
• V8 In board: 3.0 Hours
• In line DIESEL Stern drive: 5.0 Hours
• In line DIESEL In board: 4.0 Hours
• V8 DIESEL Stern drive: 5.0 Hours
• V8 DIESEL In board: 4.0 Hours

NOTE: Additional work may be required dependent on product application and usage. Add .5 hour for 4 stroke Optimax

Annual (or each 100 Hours of use) Outboard Service Checklist.

Check Before Running

• Inspect outboard motor and accessories for visible damage
• Drain gear housing and refill with gear lube
• Lubricate all grease fittings transom clamp screws, throttle/shift linkage (pivot points)
• Lubricate steering cable. Clean and lubricate cable end at engine
• Service water pump & inspect thermostats
• Remove and inspect propeller. Grease propeller shaft spline
• Torque propeller shaft nut to specification
• Check all electrical connections. Clean and reseal, if required
• Service battery terminals
• Torque cyclinder head screws to specifications
• Remove and inspect spark plugs, protectors and leads. Check compression
• Remove engine deposits with Quicksilver Power Tune engine cleaner
• Inspect fuel tank, fuel lines and connections
• Clean or replace fuel filters and oil injection filter
• Replace fueld pump diaphragm and check carburetor float levels
• Check carburetor throttle butterfly synchronization
• Check primary and secondary throttle butterfly pickups and full throttle stop
• Check oil level and operation of power trim system and power trim gauge
• Change engine oil and replace oil filter (4 stroke only)
• Check and adjust valve clearance, if necessary (4 stroke only)
• Inspect timing belt (4 stroke only)

Optimax Models (use Digical Diagnostic Terminal)

• Check audible warning system
• Check Diagnostic Codes
• Check ECM sensors & operation
• Check TPS setting
• Check DFI fuel & air pressure

Check While Running

• Water pressure, operation of water pump and cooling system
• Throttle, gear shift and reverse lock operation
• Alternator is charging
• Carburetor mixture and idle speed
• Operation of oil injection and low warning system
• Operation os steering system, remote controls and gauges
• Check maximum timing

Important

• Spray powerhead with Quicksilver Corrosion Guard to protect electric connections and exposed metal surfaces from corrosion
• Inspect corrosion control anodes and system, replace trim tab, if required
• Owner should follow recommendations in Operation and Maintenance Manual until next scheduled service

Standard Times

• 2 – 5: 1.5 Hours
• 6 – 25: 2.0 Hours
• 30 – 40: 2.5 Hours
• 50-90: 3.0 Hours
• 100 – 125: 3.5 Hours
• 135 – 250: 4.0 Hours

NOTE: Additional work may be required dependent on product application and usage. Add .5 hour for 4 stroke Optimax