Mercury MerCruiser 8.1S User Manual

90-863080002 JANUARY 2001 Printed in U.S.A. -  2001, Mercury Marine Page 1 of 58
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, RideGuide and MMPP.
GASOLINE ENGINE 8.1S INBOARD MODELS
INSTALLATION MANUAL
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owner’s Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information 2. . . . . . . . . . . . . . . . . . . .
Notice to Installer 2. . . . . . . . . . . . . . . . . . . . .
Quicksilver Products 3. . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 3. . . . . . .
Torque Specifications 3. . . . . . . . . . . . . . . . .
Serial Number Decal Placement 4. . . . . . . .
Engine Rotation 4. . . . . . . . . . . . . . . . . . . . . .
Transmissions 4. . . . . . . . . . . . . . . . . . . . . . . . .
Velvet Drive Transmissions 4. . . . . . . . . . . .
ZF / Hurth Transmissions 5. . . . . . . . . . . . . .
Propeller Rotation 6. . . . . . . . . . . . . . . . . . . .
Installation Requirements 9. . . . . . . . . . . . . .
Engine Bed 9. . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Compartment 9. . . . . . . . . . . . . . . . .
Exhaust System 12. . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 16. . . . . . . . . . . . . . . . .
Battery 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFI Electrical System Precautions 20. . . . . .
Instrumentation 20. . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 21. . . . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and Cables 22
Seawater Connections 22. . . . . . . . . . . . . . . .
Hot Water Heater 23. . . . . . . . . . . . . . . . . . . . .
Engine Installation 24. . . . . . . . . . . . . . . . . . . . .
Engine Oil Dipstick Location 24. . . . . . . . . . .
Battery Cable Connection 24. . . . . . . . . . . . . .
Engine Mount Pre-Adjustment 25. . . . . . . . . .
Initial Engine Alignment 26. . . . . . . . . . . . . . .
Final Engine Alignment 29. . . . . . . . . . . . . . . .
Engine Connections 34. . . . . . . . . . . . . . . . . . . .
Seawater Pickup Pump Connection 34. . . . .
Fuel Supply Connection 34. . . . . . . . . . . . . . .
Audio Warning System Connection 35. . . . .
Electrical Connections 36. . . . . . . . . . . . . . . . .
Exhaust System 37. . . . . . . . . . . . . . . . . . . . . .
Shaft Log Seal Connection 38. . . . . . . . . . . . .
Shift Cable Installation And Adjustment 39.
Velvet Drive Transmissions
- 5000 Series 39. . . . . . . . . . . . . . . . . . . . . . .
Velvet Drive Transmissions - 72C In-Line 43
Hurth Transmissions 47. . . . . . . . . . . . . . . . . .
Predelivery Preparation 52. . . . . . . . . . . . . . . . .
Battery Connection 52. . . . . . . . . . . . . . . . . . .
Test Running Engine 52. . . . . . . . . . . . . . . . . .
Boat In The Water Tests 52. . . . . . . . . . . . . . .
Cold Weather and
Extended Storage Draining 53. . . . . . . . . . . .
Coolant And Water Flow Diagrams 56. . . . . .
Predelivery Inspection 58. . . . . . . . . . . . . . . . . .

Mercury MerCruiser 8.1S Specifications

General

Brand	Mercury
Model	MerCruiser 8.1S
Category	Engine
Language	English