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MerCruiser Horizon 5.7 - User Manual

MerCruiser Horizon 5.7
110 pages
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© 2007 Mercury Marine 5.7, 6.2 MPI & Horizon 5.7, 6.2
*864197072*
90-864197072 1107
NOTE: The following applies to CE marked products only.
Declaration of Conformance – Mercury MerCruiser
This sterndrive or inboard engine when installed in accordance to Mercury
MerCruisers’ instructions complies with the requirements of the following directives
by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement Standards Applied
Owner’s manual (A.2.5) ISO 10240
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4) ISO 8665
Inboard Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO 10133
Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469
Electrical System (A.5.3) ISO 10133; ISO 8846
Steering system (A.5.4)
Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
Exhaust emission requirements (B.2) ISO 8178
Owner’s manual (B.4) ISO 8665
Noise emission levels (C.1) ISO 14509
Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031
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 above. This 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.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard EN 50081‑1
Generic immunity standard EN 50082‑1
Vehicles, boats and internal combustion engine
driven devices Radio disturbance characteristics
SAE J551 (CISPR 12)
Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
The notified body responsible for surveillance of the quality system under Full Quality Assurance
Module H of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
Patrick C. Mackey
President ‑ Mercury Marine, Fond du Lac, WI USA

Table of Contents

Questions and Answers

  • K
    Kristi JonesAug 4, 2025
    Why my MerCruiser Horizon 5.7 will not start?
    • E
      Erica CastroAug 4, 2025
      If your MerCruiser Engine won't start or is hard to start: * Check the lanyard stop switch. * Ensure you are following the correct starting procedure. * Verify there is sufficient fuel supply by filling the fuel tank or opening the valve. * Replace the fuel filter if it's clogged. * Drain and refill the fuel tank with fresh fuel if the current fuel is stale or contaminated. * Replace any kinked fuel lines or clear obstructions from the fuel line or tank vent line using compressed air. * Check the wire connections. * If these steps don't resolve the issue, it could be a faulty ignition system component or an EFI system fault, which may require professional service.
  • V
    vcastroAug 9, 2025
    What to do if MerCruiser Horizon 5.7 Engine runs rough?
    • T
      Timothy JohnsonAug 9, 2025
      If your MerCruiser Engine runs rough, misses, or backfires, consider these potential causes and solutions: * Replace the fuel filter if it is clogged. * If the fuel is stale or contaminated, drain the tank and fill it with fresh fuel. * Replace any kinked fuel lines or clear obstructions from the fuel or fuel tank vent line using compressed air. * Clean the flame arrestor. For issues related to low idle speed, a faulty ignition system component, or an EFI System fault, consult a qualified technician.
  • E
    Erica WhiteAug 13, 2025
    How to improve poor performance of MerCruiser Horizon 5.7 Engine?
    • J
      Jeff RodriguezAug 13, 2025
      If your MerCruiser Engine is showing poor performance, here are a few things to investigate: * Inspect the throttle cable and linkages to ensure the throttle is fully opening. * Consider replacing the propeller if it's damaged or improper. * Drain excessive bilge water and identify the cause of entry. * Reduce the load or redistribute it more evenly if the boat is overloaded or improperly loaded. * Clean the flame arrestor. * Clean or repair the boat bottom if it's fouled or damaged. If the issue persists, it may be related to ignition problems, engine overheating or EFI System fault, which may require professional service.
  • T
    Terrence CookAug 17, 2025
    What to do if the MerCruiser Horizon 5.7 Engine starter motor won't crank or cranks slowly?
    • M
      Mr. Cameron LeeAug 17, 2025
      If the MerCruiser Engine's starter motor won't crank the engine or cranks it slowly, here's what to check: * Ensure the battery switch is turned on. * Confirm the remote control is in the neutral position. * Inspect and reset any open circuit breakers, or replace blown fuses. * Examine all electrical connections and wires, especially battery cables; clean and tighten any loose or dirty connections. * Test the battery and charge it if necessary, replace it if it's bad. * Verify that the lanyard stop switch is not activated.
  • D
    davisaustinAug 22, 2025
    Why MerCruiser Horizon 5.7 Engine does not recharge?
    • M
      Michael GatesAug 22, 2025
      If your MerCruiser Engine is not recharging, consider the following: * Turn off any non-essential accessories to reduce the current draw from the battery. * Replace or adjust the alternator drive belt if it is loose or in poor condition. * Test the battery and replace it if necessary. * Check all associated electrical connections and wires, especially battery cables, for looseness or dirtiness; clean and tighten faulty connections and repair or replace any damaged wiring. * Test the alternator output; replace the alternator if necessary.
  • C
    Carlos EricksonAug 26, 2025
    Why is the MerCruiser Horizon 5.7 wheel difficult to turn?
    • M
      Michael ClarkAug 26, 2025
      If the wheel of your MerCruiser is jerking or difficult to turn: * Check the power steering pump fluid level for leaks and refill the system with fluid if needed. * Replace or adjust the drive belt if it's loose or in poor condition. * Lubricate the steering components. For loose or missing steering fasteners or parts, or contaminated power steering fluid, consult a qualified technician.
  • M
    Megan DixonAug 30, 2025
    Why MerCruiser Horizon 5.7 remote control is difficult to move?
    • J
      Jennifer CoxAug 30, 2025
      If the remote control for your MerCruiser Engine is difficult to move, has excessive play, or makes excessive sounds: * Lubricate the shift and throttle linkage fasteners. * Remove any obstruction in the shift or throttle linkages. For loose or missing shift and throttle linkages, or a kinked shift or throttle cable, consult a qualified technician.

Summary

Declaration of Conformance - Mercury MerCruiser

Recreational Craft Directive 94;25;EC; 2003;44;EC

Lists applicable requirements and standards for Recreational Craft Directive.

Electromagnetic Compatibility Directive 89;336;EC, 92;31;EEC and 93;68;EEC

Details standards for EMC compliance, including emissions and immunity.

Identification Record

Warranty Message

Read This Manual Thoroughly

Global Warranty Charts

Consumer Application Warranty Chart

Details standard factory limited warranty by region and boat brand.

Commercial Application Warranty Chart

Government Application Warranty Chart

Warranty Registration: United States and Canada

Warranty Registration: Outside the United States and Canada

Mercury MerCruiser Limited Warranty (Gasoline-Fueled Products Only)

What Is Covered

Details what Mercury Marine warrants regarding defects in material and workmanship.

Duration of Coverage

Explains the warranty periods for recreational and commercial use.

Conditions That Must Be Met in Order to Obtain Warranty Coverage

What Is Not Covered

DISCLAIMERS AND LIMITATIONS

3‑Year Limited Warranty Against Corrosion

What Is Covered

Details what Mercury Marine warrants against corrosion.

Consumer Application Warranty Chart

Emission Control Information Label

Lanyard Stop Switch

Instrumentation

Remote Controls (Non-DTS Models)

Remote Controls (DTS Models)

Synchronizing Dual Engines

Dual Helm Station Transfer

Electrical System Overload Protection

Audio Warning System

Engine Guardian Strategy

Explains how Engine Guardian protects the engine by reducing power.

Transmission Guardian Strategy

Warning Horn Signals

Safe Boating Suggestions

Be Alert to Carbon Monoxide Poisoning

Poor Ventilation

Basic Boat Operation (Non-DTS Models)

Stopping the Engine

Basic Boat Operation (DTS Models)

Starting and Stopping the Engine

Step-by-step guide for starting and stopping DTS model engines.

Protecting People in the Water

While Boat Is Stationary

Advises on safety when people are in the water while the boat is stopped.

High‑Speed and High‑Performance Operation

Passenger Safety in Pontoon Boats and Deck Boats

Wave and Wake Jumping

Impact with Underwater Hazards

Conditions Affecting Operation

Cavitation

Explains cavitation and its common causes.

Getting Started

20‑Hour Break‑In Period

Outlines essential rules for the engine break-in period.

Fuel Requirements

Fuel Ratings

Specifies the required octane ratings for unleaded gasoline in USA/Canada and abroad.

Engine Oil

Engine Specifications

Fluid Specifications

Engine

Lists approximate fluid capacities and types for the engine system.

Transmission

Owner;Operator Responsibilities

Inspection

Maintenance Schedule-Inboard Models

Routine Maintenance

Lists routine maintenance tasks performed daily, weekly, and monthly.

Scheduled Maintenance

Lists scheduled maintenance tasks based on hours or time intervals.

Filling

Changing Oil and Filter

CHANGING FILTER

Transmission Fluid

Checking While the Engine is Warm

Details checking transmission fluid level when the engine is warm.

Checking While Engine is Cold

Details checking transmission fluid level when the engine is cold.

Engine Coolant

Cleaning the Flame Arrestor

Positive Crankcase Ventilation Valve (PCV)

Water‑Separating Fuel Filter

GEN III Models

REMOVAL

Step-by-step instructions for removing the GEN III fuel filter assembly.

INSTALLATION

Lubrication

Serpentine Drive Belt

Checking

Details how to inspect the serpentine drive belt for wear and tension.

Replacing Belt and;or Adjusting Tension

Provides instructions for replacing or adjusting the serpentine drive belt.

Flushing The Power Package

ENGINE AND FUEL SYSTEM PREPARATION

Draining the Seawater System

MANUAL SINGLE POINT DRAIN SYSTEM

THREE POINT MANUAL DRAIN SYSTEM

MULTI-POINT DRAIN (MPD) SYSTEM

Air‑Actuated Single‑Point Drain System

Manual Single‑Point Drain System

Three‑Point Manual Drain System

BOAT IN THE WATER

Procedures for draining the three-point manual system while boat is in water.

Multi‑Point Drain (MPD) System

BOAT OUT OF THE WATER

Procedures for draining the MPD system while boat is out of water.

Battery Storage

Power Package Recommissioning

Diagnosing EFI Problems

Diagnosing DTS Problems

Engine Guardian System

Starter Motor Will Not Crank Engine, Or Cranks Slow

Engine Will Not Start or Is Hard to Start

Engine Runs Rough, Misses, or Backfires

Poor Performance

Excessive Engine Temperature

Insufficient Engine Temperature

Low Engine Oil Pressure

Battery Will Not Recharge

Remote Control Is Difficult to Move, Has Excessive Play, or Makes Unusual Sounds

Steering Wheel Jerks or Is Difficult to Turn

Owner Service Assistance

Attention Required after Submersion

Outlines immediate steps required after a boat submersion incident.

MerCruiser Horizon 5.7 Specifications

General IconGeneral
BrandMerCruiser
ModelHorizon 5.7
CategoryEngine
LanguageEnglish

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