Gearcase Break In Procedures

LOWER UNIT AND STERNDRIVE

  1. Gearcase assemblies are shipped without oil.
  2. Fill unit with manufacturer's required gear oil to recommended level.
  3. Adjust RPM at idle to manufacturer's specifications.
  4. Proper shift adjustment is essential.
  5. JUMPING OUT OF GEAR:If the unit will not stay in gear, the clutch dog has probably been rounded off. Rounded clutch dogs are caused by, but not limited to, improper shift cable adjustment, inadequate shift travel, idle RPM too high, and / or shifting too slow Rounded clutch dogs are NOT covered by warranty.
  6. Avoid full throttle starts.
  7. DO NOT operate at constant speed for extended periods.
  8. Shift into forward gear a minimum of 10 times during break-in, with moderate engine speed after each shift.
  9. DO NOT exceed 75% of full throttle during the first five hours of operation.
  10. During the next 5 hours, full throttle should not be maintained for long periods.

OMC AND MERCRUISER STERNDRIVE SERVICE NOTICE

When purchasing either an upper or lower assembly separately, the opposite piece must be disassembled and cleaned by the service center in order to validate the warranty. This provision is due to the cross contamination of the oil.

BREAK-IN PROCEDURES

THE FIRST 10 HOURS OF YOUR NEW ENGINE'S LIFE ARE VERY IMPORTANT. PLEASE USE THE FOLLOWING INFORMATION AS A GUIDELINE.
  • Do not perform break-in on water hose.
  • Double your oil with a major manufacturer TCW-3 oil. (Excludes direct injected engines.)
  • Use a mid-grade octane major manufacturer fuel without alcohol.
  • Liquid cooled engines should be slowly brought up to normal operating temperature to avoid cold seizure.
  • For the first hour, operate the engine at a varied speed of 700-1500 RPM to break-in new pistons and rings.
  • During the next 6 hours, operate the engine in gear at no more than 3,000 RPM. Accelerate using only enough throttle to bring the boat up on plane quickly and bring the throttle back to maintain a minimum plane speed.
  • Vary your engine speed by accelerating to 3/4 throttle for 1 to 2 minutes, then back to minimum plane speed.
  • During the final 3 hours you may operate the boat at wide-open throttle for periods of less than 2 minutes.
  • It is very Important to avoid operating at a constant speed of 3,000 to 4,000 RPM or continuous full throttle for the first 10 hours. This is the economy range in which the timing is at full advance and carburetor or fuel injec- tion is running lean. This could lead to overheating and piston detonation.
  • Cylinder heads should be re-torqued after the 10 hour break-in period.