ENGINE BREAK-IN PROCEDURE FOR RE-BUILT/REPLACEMENT POWER HEADS

(See owners manual for new engine requirements.)

THE FIRST 10 HOURS ARE THE MOST IMPORTANT HOURS OF YOUR NEW ENGINES LIFE.

PLEASE FOLLOW THESE INSTRUCTIONS VERY CAREFULLY TO AID IN PROTECTING YOUR SAFETY AND THE PROPER BREAK-IN OF A RE-BUILT POWER HEAD ASSEMBLY.

COMPLETE ENGINE BREAK-IN TYPICALLY OCCURS AT ABOUT 20 HOURS.

PRELIMINARY PROCEDURES

(2 CYCLE) DOUBLE YOUR OIL MIXTURE WITH A MAJOR MANUFACTURER TCW-3 OIL 

(4 CYCLE) USE ENGINE OIL ADDITIVE SIMILAR TO, JOHNSON'S "LL5".

USE A MAJOR MANUFACTURER OF 91 TO 94 OCTANE FUEL

TRY TO STAY AWAY FROM FUEL PRODUCTS THAT HAVE ALCOHOL IN THEM.

REMOVE EXCESS WEIGHT FROM THE BOAT.

CHECK "ALL" FLUIDS, GAUGE OPERATION, AND BATTERY CONDITION BEFORE LAUNCHING.

PLAN YOUR MAIDEN VOYAGE FOR ANY DAY OTHER THAN A WEEKEND AND/OR HOLIDAY TO REDUCE CONGESTION AT THE DOCKS.

INITIAL BREAK-IN AND WARM UP PROCEDURE

START ENGINE AND WARM-UP FOR 20 MINUTES, IN NEUTRAL, (1100 TO 1300 RPM) AT DOCK. LIQUID COOLED ENGINES REQUIRE THAT THE ENGINE BE BROUGHT TO NORMAL OPERATING TEMPERATURE TO AVOID COLD SEIZURE THAT RESULTS FROM THE PISTON EXPANDING FASTER THAN THE CYLINDER LINER WHICH IS BEING LIQUID COOLED.

ALLOW 1 HOUR FOR BREAK-IN OF A NEW PISTON AND/OR RINGS AT JUST ABOVE IDLE SPEED, IN GEAR. (1100 TO 1500 RPM)

THE NEXT 60 MINUTES OPERATE THE ENGINE IN GEAR NO MORE THAN 3,000 R.P.M.

(4 CYCLE) CHANGE ENGINE OIL AT 5 HOURS.

PLEASE NOTE:

REGULARLY, CHECK ALL COOLING, OILING, WARNING, AND ELECTRICAL SYSTEMS, DURING THE BREAK-IN PERIOD.

USE ONLY ENOUGH THROTTLE TO PLANE THE BOAT AND THEN IMMEDIATELY, THROTTLE BACK TO LESS THAT 3,000 R.P.M. IF THE ENGINE REQUIRES MORE THAN 3/4 THROTTLE TO PLANE THE BOAT, DURING BREAK-IN, THEN EITHER THERE IS A MECHANICAL PROBLEM AND/OR THE ENGINE IS UNDERSIZED FOR THE BOAT.

AVOID OPERATING AT 3,000 TO 4,000 R.P.M. AT ALL TIMES. THIS IS THE ECONOMY RANGE. THE TIMING IS AT FULL ADVANCE; CARB OR FUEL INJECTION IS RUNNING LEAN. THIS PROMOTES HEAT WHICH LEADS TO PISTON DETONATION.

DO NOT RUN AT CONSTANT R.P.M. FOR PROLONGED PERIODS OF TIME

FOR THE 6TH HOUR ACCELERATE ENOUGH TO BRING THE BOAT UP ON PLANE QUICKLY AND BRING THE THROTTLE BACK TO MAINTAIN A PLANING ATTITUDE. DURING THIS PERIOD, VARY YOUR ENGINE SPEED BY ACCELERATING TO 3/4 THROTTLE FOR 1 TO 2 MINUTES, THEN BACK TO MINIMUM PLANING SPEED. 

AFTER ABOUT THE 6TH HOUR SLOWLY BRING THE BOAT TO FULL THROTTLE AND MAKE NOTE THAT POTENTIAL FULL THROTTLE RPM IS WITHIN SPECIFICATIONS. DO NOT EXCEED 1 MINUTE FOR THIS TEST. (DO NOT CONTINUE TO USE BOAT IF FULL THROTTLE ENGINE RPM IS OUT OF SPECIFICATION. CONTACT US FOR CORRECTIVE MEASURES.

FOR THE NEXT 4 HOURS OF OPERATION, CONTINUE TO CRUISE AT APPROXIMATELY 3/4TH THROTTLE OR LESS.

OCCASIONALLY REDUCE THROTTLE TO IDLE SPEED FOR A COOLING PERIOD.

DURING THE FINAL HOURS, YOU MAY OPERATE THE BOAT AT WIDE-OPEN THROTTLE FOR PERIODS OF LESS THAN 2 MINUTES.

(4 CYCLE) CHANGE ENGINE OIL AT 20 HOURS.

(2 CYCLE) DISCONTINUE ADDING EXTRA OIL TO YOUR FUEL AT ABOUT 15 HOURS. CONTINUE TO ADD EXTRA OIL TO THE FUEL IF YOU SUSPECT ANY OILING AND/OR OPERATIONAL PROBLEM.

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ENGINE TIPS FOR  REBUILT OMC ENGINES

~ Install .0002 larger main jets in carbs.
~ Max timing must be retarded 2 degrees
~ Use 92-94 octane premium gasoline
~ Re-torque cylinder heads to specs. After one hour running, let engine cool before re-torque.
 ~ Replace water pump and gaskets at time of power head replacement and every two years. We recommend installing water pressure gauge to monitor water flow in engine.
~ Check with OMC dealer and update to latest V.R.O. pump.
~ Check overheat alarm system and horn.
~ Clean and refill oil tank with TCW-3 oil.
~ Verify oil consumption by marking oil tank. This should be done while running double oil during break-in.
~ Run double oil for approximately 30-gallons of fuel, if running oil injection, add 1 pint of oil to 6 gallons of gas, if no oil injection, 1 quart of oil to 6 gallons of gas.
~ Max timing must be set with engine running over 4500 RP.M. under load.
DO NOT SET MAX TIMING STATIC.
~ On 3 cylinder engines, replace water pump with new high-pressure water pump.
~ On 3 cylinder engines, drill and relocate overboard sensors.
~ On 3 cylinder engines, check late OMC service bulletins and jet carburetors accordingly.

TIPS ON ALL RE-BUILT V-6 MERCURY ENGINES 1983 AND UP

~ Install .002 larger main jets in carbs.
~ Mar timing should be retarded by 2 degrees.
~ Remove advance box, if on motor.
~ Remove idle stabilizer if on motor.
~ Use 92-94 Octane premium fuel.
~ Re-torque heads to 40-ft. lbs. After first hour of running, check for later factory specs.
~ Use newest style of head gasket and replace gaskets every year to prevent head gasket failure. ~ Replace water pump impeller and gaskets every year to prevent head gasket failure.
~ Re-build carbs and fuel pump.
~ If oil injection is used, replace 2-PSI oil valve and check oil pump bushing and seal.
~ Clean and refill all oil tanks with TCW-3 oil.
~ Verify oil consumption by marking oil tank.
~ Check overheat alarm system and horn.
~ Make sure trigger wires are free moving for proper advance.
~ On 2.5 EFI engines fuel pressure should be 39-lbs minimum.
~ On 2.5 EFI engines, there can be as many as 7 fuel filters, remove the cone-shaped filter in the line below the electric pump.
~ Beware of possible problems with detonation sensor and module.
~ Check all late Mercury service bulletins.


VERY IMPORTANT!

IF YOU HAVE ANY PROBLEMS.
PLEASE DO NOT HESITATE TO CONTACT:
 AQUARIUS MARINE, INC.

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