Mercury BRAVO, 90-863160 Service Manual
Number 28
Printed in U.S.A. 90-863160 MA Y 2000
2000, Mercury Marine
BRAVO STERNDRIVES
SERVICE
MANUAL
90- i
MerCruiser #28 Bravo Sterndrives
90-863160
MerCruiser #28 Bravo Sterndrives
90-863160
90-863160 MAY 2000 Page i
Notice
Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol
) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or
carelessly. OBSERVE THEM CAREFULLY!
These “Safety Alerts” alone cannot eliminate the hazards that they signal. Strict compliance
to these special instructions when performing the service, plus “Common Sense” operation,
are major accident prevention measures.
DANGER
DANGER - Immediate hazards which WILL result in severe personal injury or death.
WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal i n jury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
Notice to Users of This Manual
This service manual has been written and published by the Service Department of Mercury
Marine to aid our dealers’ mechanics and company service personnel when servicing the
products described herein.
It is assumed that these personnel are familiar with the servicing procedures of these products, or like or similar products manufactured and marketed by Mercury Marine, that they
have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of the possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool, which is not recommended by the manufacturer, first must
completely satisf y h i m s e l f t h a t n e i t h e r h i s n o r t h e p r o d u c t s s a f e t y w i l l b e e ndangered by the
service procedure selected.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at the time of publication. As required, revisions to this
manual will be sent to all dealers contracted by us to sell and/or service these products.
It should be kept in mind, while working on the product, that the electrical system and ignition
system are capable of violent and damaging short circuits or severe electrical shocks. When
performing any work where electrical terminals could possibly be grounded or touched by
the mechanic, the battery cables should be disconnected at the battery.
Any time the intake or exhaust openings are exposed during service they should be covered
to protect against accidental entrance of foreign material which could enter the cylinders and
cause extensive internal damage when the engine is started.
Page ii 90-863160 MAY 2000
It is important to note, during any maintenance procedure replacement fasteners must have
the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial
lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal
injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for re-use, care should be taken to
select a replacement that matches the original.
We reserve the right to make changes to this manual without prior notification.
Refer to dealer service bulletins for other pertinent information concerning the products
described in this manual.
Engine Mechanical Components
Many of the engine mechanical components are designed for marine applications. Unlike
automotive engines, marine engines are subjected to extended periods of heavy load
and wide-open-throttle operation and, therefore, require heavy-duty components. Special
marine engine parts have design and manufacturing specifications which are required to
provide long life and dependable performance. Marine engine parts also must be able to
resist the corrosive action of salt or brackish water that will rust or corrode standard automotive parts within a short period of time.
Failure to use recommended Quicksilver service replacement parts can result in poor engine performance and/or durability, rapid corrosion of parts subjected to salt water and
possibly complete failure of the engine.
Use of parts other than recommended service replacement parts, will void the warranty on
those parts which are damaged as a result of the use of other than recommended replacement parts.
Replacement Parts
WARNING
Electrical, ignition and fuel system components on MerCruiser Engines and Sterndrives are designed and manufactured to comply with U.S. Coast Guard Rules
and Regulations to minimize risks of fire or explosion.
Use of replacement electrical, ignition or fuel system components, which do not
comply to th e s e rules and regulations, could result in a fire or explosion hazard and
should be avoided.
When servicing the electrical, ignition and fuel systems, it is extremely important
that all components are properly installed and tightened. If not, any electrical or ignition component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they existed.
1
2
3
4
5
6
7
8
Important Information
Removal, Installation and
Adjustment
Sterndrive Unit
Transom Assembly
Power Trim
Steering Systems
Corrosion Protection
Drives
90-863160 MAY 2000 Page iii
Service Manual Outline
Section 1 - Important Information
A - General Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal, Installation and Adjustment
A - All Models
Section 3 - Sterndrive Unit
A - Drive Shaft Housing
B - Gear Housing - Bravo One
C - Gear Housing - Bravo Two
D - Gear Housing - Bravo Three
Section 4 - Transom Assembly
A - Service Procedures Requiring Minor Disassembly
B - Service Procedures Requiring Major Disassembly
Section 5 - Power Trim
A - Oildyne Power Trim Pump
B - Trim Cylinders
C - Dual Power Trim Control
D - Auto Trim II
Section 6 - Steering Systems
A - Power Steering
B - Compact Hydraulic Steering
Section 7 - Corrosion Protection
A - All Models
Section 8 - Drives
A - All Models
Page iv 90-863160 MAY 2000
Table of Contents
IMPORTANT INFORMATION
Section 1A - General Information
How To Use This Manual 1A-2. . . . . . . . . . . . . . .
Page Numbering 1A-2. . . . . . . . . . . . . . . . . . .
How to Read a Parts Manual 1A-3. . . . . . . . . . .
Introduction 1A-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Directional References 1A-4. . . . . . . . . . . . . . . . .
Propeller Rotation 1A-4. . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit 10-Hour Break-In Period
(New or With Replacement Gears) 1A-5. . . . . .
Serial Number Locations and Engine
Designation Decal 1A-5. . . . . . . . . . . . . . . . . . . .
Section 1B - Maintenance
Lubricants / Sealants / Adhesives 1B-2. . . . . . .
Maintenance Schedules 1B-3. . . . . . . . . . . . . . . .
Maintenance Intervals 1B-3. . . . . . . . . . . . . . .
Gas Sterndrive 1B-3. . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance * 1B-3. . . . . . . . . . . . . .
Gas Sterndrive(Continued) 1B-4. . . . . . . . . . . . .
Scheduled Maintenance * 1B-4. . . . . . . . . . . .
Specifications 1B-5. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification 1B-5. . . . . . . . . . . . . . . . . . .
Fluid Capacities 1B-5. . . . . . . . . . . . . . . . . . . . . . .
Lubrication 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Pivot Points 1B-5. . . . . . . . . . . . . .
Propeller Shaft 1B-6. . . . . . . . . . . . . . . . . . . . .
Steering System 1B-6. . . . . . . . . . . . . . . . . . . .
Tie Bar Pivot Points 1B-7. . . . . . . . . . . . . . . . .
Transom Gimbal Housing Assembly Swivel
Shaft and Gimbal Bearing 1B-7. . . . . . . . . . . .
Checking and Adding Sterndrive Oil 1B-8. . . . .
Inspection 1B-9. . . . . . . . . . . . . . . . . . . . . . . . .
Changing Sterndrive Oil 1B-10. . . . . . . . . . . . . . .
General Maintenance 1B-12. . . . . . . . . . . . . . . . .
Maintaining Power Package Exterior Sur-
faces 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Head and Remote Control Mainte-
nance 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Quicksilver MerCathode System . .
1B-12
Maintaining Anodic Plate 1B-12. . . . . . . . . . .
Boat Bottom Care 1B-12. . . . . . . . . . . . . . . . .
Anti-fouling Paint 1B-12. . . . . . . . . . . . . . . . . .
Maintaining Ground Circuit Continuity 1B-13
Power Package Layup 1B-13. . . . . . . . . . . . . . . .
Engine 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive 1B-13. . . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 1B-14. . . . . .
Engine 1B-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive 1B-14. . . . . . . . . . . . . . . . . . . . . . . .
Section 1C - Troubleshooting
Table of Contents 1C-1. . . . . . . . . . . . . . . . . . . . .
Troubleshooting 1C-2. . . . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit Troubleshooting 1C-2. . . . . . . . .
Sterndrive Unit Will Not Slide Into
Bell Housing 1C-2. . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Does Not Shift Into Gear;
Remote Control Shift Handle Moves 1C-2. .
Drive Unit Does Not Shift Into Gear;
Remote Control Shift Handle Does
Not Move 1C-3. . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Shifts Hard 1C-3. . . . . . . . . . . . . . .
Drive Unit In Gear, Will Not Shift
Out Of Gear 1C-3. . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Noise 1C-4. . . . . . . . . . . . . . . .
Drive Shaft Housing Noise 1C-4. . . . . . . . . . .
Drive Shaft Housing Noise
(Continued) 1C-5. . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Housing Noise
(Continued) 1C-6. . . . . . . . . . . . . . . . . . . . . . .
Power Shift 1C-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
System Does Not React 1C-7. . . . . . . . . . . . .
System Binds 1C-7. . . . . . . . . . . . . . . . . . . . . .
Performance Troubleshooting 1C-8. . . . . . . . . . .
Low WOT Engine RPM 1C-8. . . . . . . . . . . . . .
High WOT Engine RPM 1C-8. . . . . . . . . . . . .
Propeller Ventilating/Cavitating 1C-8. . . . . . .
Poor Boat Performance And/Or Poor
Maneuverability-Bow Too Low 1C-9. . . . . . .
Poor Boat Performance And/Or Poor
Maneuverability-Bow Too High 1C-9. . . . . . .
Power Steering 1C-10. . . . . . . . . . . . . . . . . . . . . .
Hard Steering - Helm And Cable 1C-10. . . . .
Hard Steering (Engine Running)
- Power Steering System 1C-10. . . . . . . . . . .
Power Steering System External
Fluid Leaks 1C-10. . . . . . . . . . . . . . . . . . . . . . .
Compact Hydraulic Steering 1C-11. . . . . . . . . . .
Important Information 1C-11. . . . . . . . . . . . . .
Helm Becomes Jammed During Filling 1C-11
System Difficult To Fill 1C-11. . . . . . . . . . . . . .
Steering Hard To Turn 1C-11. . . . . . . . . . . . . .
Helm Unit Bumpy
- Requires Too Many Turns 1C-11. . . . . . . . .
Power Trim Electrical System 1C-12. . . . . . . . . .
Power Trim System Wiring Diagram 1C-16. . . .
Power Trim Hydraulic System 1C-17. . . . . . . . . .
Power Trim Hydraulic Schematic 1C-21. . . . . . .
Auto Trim II Electrical System 1C-22. . . . . . . . . .
Auto Trim II System Wiring Diagram 1C-28. . . .
Corrosion Protection 1C-29. . . . . . . . . . . . . . . . . .
90-863160 MAY 2000 Page v
REMOVAL, INSTALLATION AND ADJUSTMENT
Section 2A - All Models
Torque Specifications 2A-2. . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 2A-2. . . . . . .
Tools 2A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transom Specifications 2A-3. . . . . . . . . . . . . . . .
Checking Transom Thickness 2A-3. . . . . . . .
Special Information 2A-4. . . . . . . . . . . . . . . . . . . .
Bravo Three Notice:
Trim-In Limit Insert 2A-4. . . . . . . . . . . . . . . . .
Sterndrive Unit Removal 2A-6. . . . . . . . . . . . . . .
Transom Assembly Removal 2A-8. . . . . . . . . . . .
Transom Assembly Installation 2A-12. . . . . . . . .
Sterndrive Unit Installation 2A-22. . . . . . . . . . . . .
Shift Cable Installation
and Adjustment 2A-29. . . . . . . . . . . . . . . . . . .
Troubleshooting Shift Problems 2A-33. . . . . .
STERNDRIVE UNIT
Section 3A - Drive Shaft Housing
Specifications 3A-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3A-2. . . . . . . . . . . . . . .
Tools 3A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Preloads 3A-3. . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 3A-3. . . . .
Drive Shaft Housing Exploded View 3A-4. . . . . .
Complete Housing 3A-4. . . . . . . . . . . . . . . . . .
Exploded Parts View (Clutch) 3A-6. . . . . . . . . . .
Exploded Parts View (Shifter) 3A-7. . . . . . . . . . .
Standard Bravo U-joint Assembly 3A-8. . . . .
Bravo X, XZ, XR and Diesel
Bravo U–joint Assembly 3A-9. . . . . . . . . . . . .
Drive Shaft Housing and Gear
Case Separation 3A-10. . . . . . . . . . . . . . . . . . . . .
Drive Unit Gear Ratio Identification 3A-10. . .
Bravo One 3A-10. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Two 3A-10. . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three 3A-11. . . . . . . . . . . . . . . . . . . . . .
Bravo XZ 3A-11. . . . . . . . . . . . . . . . . . . . . . . . .
Bravo XR 3A-12. . . . . . . . . . . . . . . . . . . . . . . . .
Diesel Bravo One X 3A-12. . . . . . . . . . . . . . . .
Diesel Bravo Two X 3A-12. . . . . . . . . . . . . . . .
Diesel Bravo Three X 3A-13. . . . . . . . . . . . . .
Separate Housings 3A-14. . . . . . . . . . . . . . . .
Drive Shaft Housing Disassembly 3A-17. . . . . .
Shifter Repair 3A-22. . . . . . . . . . . . . . . . . . . . . . . .
Shifter Inspection 3A-25. . . . . . . . . . . . . . . . . . . . .
Shifter Reassembly 3A-26. . . . . . . . . . . . . . . . . . .
U-Joint and Pinion Gear 3A-30. . . . . . . . . . . . . . .
Inspection 3A-30. . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3A-30. . . . . . . . . . . . . . . . . . . . . .
Reassembly 3A-34. . . . . . . . . . . . . . . . . . . . . .
Gear Disassembly,
Inspection and Reassembly 3A-42. . . . . . . . . . .
Disassembly 3A-42. . . . . . . . . . . . . . . . . . . . . .
Inspection 3A-44. . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 3A-44. . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Housing and Top Cover -
Bearings and Bearing Sleeves 3A-47. . . . . . . . .
Inspection 3A-47. . . . . . . . . . . . . . . . . . . . . . . .
Bearing Sleeve Removal (Top Cover) 3A-47
Bearing Sleeve Removal
(Drive Shaft Housing) 3A-48. . . . . . . . . . . . . .
Roller Bearing Removal 3A-49. . . . . . . . . . . .
Steel Bearing Adaptor Removal 3A-51. . . . .
Steel Bearing Adaptor Installation 3A-52. . . .
Bearing Sleeve Installation 3A-53. . . . . . . . . .
Roller Bearing Installation 3A-54. . . . . . . . . . .
Drive Shaft Housing Reassembly 3A-55. . . . . . .
Install Gear Housing To Drive
Shaft Housing 3A-66. . . . . . . . . . . . . . . . . . . . .
Page vi 90-863160 MAY 2000
Section 3B - Gear Housing - Bravo One
Specifications 3B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3B-2. . . . . . . . . . . . . . .
Bearing Preloads 3B-2. . . . . . . . . . . . . . . . . . .
Gear Ratio - Teeth Per Gear
(Gear Housing) 3B-2. . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 3B-2. . . . . . .
Tools 3B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo One Gear Housing Exploded View 3B-4.
Drive Shaft Components 3B-4. . . . . . . . . . . . .
Bravo One and Diesel Bravo One X
Propeller Shaft Components 3B-6. . . . . . . . .
Bravo XZ and Bravo XR Propeller
Shaft Components 3B-8. . . . . . . . . . . . . . . . .
Pre-Disassembly Inspection 3B-10. . . . . . . . . . .
Drive Shaft Housing and Gear Housing
Separation 3B-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Disassembly 3B-13. . . . . . . . . . . .
Drive Shaft And Pinion Bearing 3B-19. . . . . . . .
Inspection and Cleaning 3B-19. . . . . . . . . . . .
Drive Shaft Disassembly 3B-19. . . . . . . . . . . .
Pinion Bearing Removal 3B-20. . . . . . . . . . . .
Pinion Bearing Installation 3B-21. . . . . . . . . .
Drive Shaft Reassembly 3B-22. . . . . . . . . . . .
Bearing Carrier Inspection 3B-23. . . . . . . . . .
Bearing Carrier Disassembly 3B-23. . . . . . . .
Bearing Carrier Reassembly 3B-24. . . . . . . .
Propeller Shaft 3B-25. . . . . . . . . . . . . . . . . . . . . . .
Inspection 3B-25. . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Bearing Removal 3B-25. . . .
Propeller Shaft Bearing Installation 3B-26. . .
Driven Gear Bearing 3B-26. . . . . . . . . . . . . . . . . .
Inspection 3B-26. . . . . . . . . . . . . . . . . . . . . . . .
Driven Gear Bearing Removal 3B-27. . . . . . .
Driven Gear Bearing Installation 3B-27. . . . .
Driven Gear Bearing Cup
Removal and Inspection 3B-28. . . . . . . . . . .
Driven Gear Bearing Cup Installation 3B-28.
Speedometer Water Passage 3B-29. . . . . . . . . .
Pickup Inspection and Cleaning 3B-29. . . . .
Water Passage Seal Replacement 3B-30. . .
Gear Housing Reassembly And
Shimming 3B-31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo XZ and XR Heavy Duty
Propeller Shaft 3B-45. . . . . . . . . . . . . . . . . . . . . .
Gear Housing
Disassembly/Reassembly 3B-45. . . . . . . . . .
Installing Bearing Carrier 3B-45. . . . . . . . . . .
Installing Propeller Hub Assembly 3B-47. . . .
Section 3C - Gear Housing - Bravo Two
Specifications 3C-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3C-2. . . . . . . . . . . . . . .
Bearing Preloads 3C-2. . . . . . . . . . . . . . . . . . .
Gear Ratio - Teeth per Gear
(Gear Housing) 3C-2. . . . . . . . . . . . . . . . . . . .
Lubricants/Sealants/Adhesives 3C-2. . . . . . . . . .
Tools 3C-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Two Gear Housing Exploded View 3C-4.
Drive Shaft and Propeller
Shaft Components 3C-4. . . . . . . . . . . . . . . . .
Pre-Disassembly Inspection 3C-6. . . . . . . . . . . .
Drive Shaft Housing and Gear
Housing Separation 3C-7. . . . . . . . . . . . . . . . . . .
Gear Housing Disassembly 3C-8. . . . . . . . . . . . .
Drive Shaft and Pinion Bearing 3C-14. . . . . . . . .
Inspection and Cleaning 3C-14. . . . . . . . . . . .
Drive Shaft Disassembly 3C-15. . . . . . . . . . . .
Pinion Bearing Removal 3C-16. . . . . . . . . . . .
Pinion Bearing Installation 3C-17. . . . . . . . . .
Drive Shaft Reassembly 3C-18. . . . . . . . . . . .
Bearing Carrier 3C-19. . . . . . . . . . . . . . . . . . . . . .
Inspection 3C-19. . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3C-20. . . . . . . . . . . . . . . . . . . . . .
Reassembly 3C-21. . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 3C-23. . . . . . . . . . . . . . . . . . . . . . .
Inspection 3C-23. . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Bearing Removal 3C-24. . . .
Propeller Shaft Bearing Installation 3C-24. . .
Driven Gear Bearing 3C-25. . . . . . . . . . . . . . . . . .
Inspection 3C-25. . . . . . . . . . . . . . . . . . . . . . . .
Driven Gear Bearing Removal 3C-25. . . . . . .
Driven Gear Bearing Installation 3C-26. . . . .
Driven Gear Bearing Cup Removal
and Inspection 3C-26. . . . . . . . . . . . . . . . . . . .
Driven Gear Bearing Cup Installation 3C-27.
Speedometer Water Passage 3C-27. . . . . . . . . .
Pickup Inspection and Cleaning 3C-27. . . . .
Water Passage Seal Replacement 3C-28. . .
Gear Housing Reassembly and
Shimming 3C-29. . . . . . . . . . . . . . . . . . . . . . . . . . .
90-863160 MAY 2000 Page vii
Section 3D - Gear Housing - Bravo Three
Table of Contents 3D-1. . . . . . . . . . . . . . . . . . . . .
Specifications 3D-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 3D-2. . . . . . . . . . . . . . .
Bearing Preloads 3D-2. . . . . . . . . . . . . . . . . . .
Gear Ratio - Teeth per Gear
(Gear Housing) 3D-2. . . . . . . . . . . . . . . . . . . .
Torque Conversion Chart For
Bearing Carrier 3D-3. . . . . . . . . . . . . . . . . . . .
Torque Conversion Chart For
Bearing Retainer Nut 3D-3. . . . . . . . . . . . . . .
Torquing Outer Prop Shaft Bearing
Retainer and Bearing Carrier 3D-4. . . . . . . .
Lubricants/Sealants/Adhesives 3D-4. . . . . . . . . .
Tools 3D-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Three Gear Housing
Exploded View 3D-6. . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft and Propeller Shaft
Components 3D-6. . . . . . . . . . . . . . . . . . . . . . .
Pre-Disassembly Inspection 3D-8. . . . . . . . . . . .
Gear Housing Disassembly 3D-9. . . . . . . . . . . . .
Driveshaft And Pinion Bearing 3D-16. . . . . . . . .
Inspection and Cleaning 3D-16. . . . . . . . . . . .
Drive Shaft Disassembly 3D-17. . . . . . . . . . . .
Drive Shaft Reassembly 3D-17. . . . . . . . . . . .
Pinion Bearing 3D-18. . . . . . . . . . . . . . . . . . . . . . .
Removal 3D-18. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3D-19. . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 3D-19. . . . . . . . . . . . . . . . . . . . . . .
Inspection 3D-19. . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 3D-20. . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Spline Lash Check 3D-21. . .
Outer Propeller Shaft Servicing 3D-23. . . . . .
Front Driven Gear And Bearing 3D-24. . . . . . . .
Inspection 3D-24. . . . . . . . . . . . . . . . . . . . . . . .
Bearing Removal 3D-24. . . . . . . . . . . . . . . . . .
Bearing Installation 3D-24. . . . . . . . . . . . . . . .
Bearing Cup Removal 3D-25. . . . . . . . . . . . . .
Bearing Cup Installation 3D-25. . . . . . . . . . . .
Bearing Carrier Seal And Bearing 3D-26. . . . . .
Inspection 3D-26. . . . . . . . . . . . . . . . . . . . . . . .
Removal 3D-26. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 3D-26. . . . . . . . . . . . . . . . . . . . . . . .
Speedometer Water Passage 3D-27. . . . . . . . . .
Inspection and Cleaning 3D-27. . . . . . . . . . . .
Seal Removal 3D-28. . . . . . . . . . . . . . . . . . . . .
Seal Installation 3D-28. . . . . . . . . . . . . . . . . . .
Gear Housing Reassembly and
Shimming 3D-29. . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Backlash 3D-36. . . . . . . . . . . . . . . .
Installing Gear Housing On Drive
Shaft Housing 3D-42. . . . . . . . . . . . . . . . . . . .
Propeller Installation 3D-43. . . . . . . . . . . . . . . . . .
TRANSOM ASSEMBLY
Section 4A - Service Procedures Requiring Minor Disassembly
Bravo Transom Assembly Specifications 4A-2.
Torque Specifications 4A-2. . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 4A-2. . . . .
Tools 4A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo Transom Assembly
Exploded Views 4A-4. . . . . . . . . . . . . . . . . . . . . .
Inner Transom Plate Components 4A-4. . . .
Bell Housing Components 4A-5. . . . . . . . . . .
Gimbal Ring Components 4A-6. . . . . . . . . . . .
Gimbal Housing Components 4A-8. . . . . . . .
Special Information 4A-10. . . . . . . . . . . . . . . . . . .
Trim Limit Switch 4A-10. . . . . . . . . . . . . . . . . .
Trim Position Sender 4A-10. . . . . . . . . . . . . . .
Removal 4A-10. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-12. . . . . . . . . . . . . . . . . . . . . . . .
Trim Position Sender Adjustment 4A-16. . . .
Trim Limit Switch Adjustment 4A-16. . . . . . . .
High Performance Transom
Assembly - Without Electrical
Trim Sender and Trim Limit Switch 4A-18. .
Gimbal Bearing 4A-19. . . . . . . . . . . . . . . . . . . . . .
Inspection 4A-19. . . . . . . . . . . . . . . . . . . . . . . .
Removal 4A-19. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-20. . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable 4A-22. . . . . . . . . . . . . . . . . . . . . . . . . .
Removal 4A-22. . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation 4A-23. . . . . . . . . . . . . .
Exhaust Bellows (If Equipped) 4A-27. . . . . . . . .
Removal 4A-27. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-27. . . . . . . . . . . .
Installation 4A-28. . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Tube (If Equipped) 4A-30. . . . . . . . . . . .
Removal 4A-30. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection 4A-30. . . . . . . . . . . .
Installation 4A-31. . . . . . . . . . . . . . . . . . . . . . . .
Water Hose and Water Fitting 4A-32. . . . . . . . . .
Removal 4A-32. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 4A-33. . . . . . . . . . . . . . . . . . . . . . . .
Crimp Clamp Tool 4A-35. . . . . . . . . . . . . . . . . . . .
Page viii 90-863160 MAY 2000
Section 4B - Service Procedures Requiring Major Disassembly
Bravo Transom Assembly Specifications 4B-2.
Torque Specifications 4B-2. . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 4B-2. . . . .
Special Tools 4B-2. . . . . . . . . . . . . . . . . . . . . . .
Bravo Transom Assembly
Exploded Views 4B-4. . . . . . . . . . . . . . . . . . . . . .
Inner Transom Plate Components 4B-4. . . .
Bell Housing Components 4B-5. . . . . . . . . . .
Gimbal Ring Components 4B-6. . . . . . . . . . . .
Gimbal Housing Components 4B-8. . . . . . . .
Bell Housing Removal 4B-10. . . . . . . . . . . . . . . .
Access Plug Kit Installation 4B-14. . . . . . . . . . . .
Gimbal Ring, Swivel Shaft and
Steering Lever Removal 4B-16. . . . . . . . . . .
Gimbal Ring Servicing 4B-20. . . . . . . . . . . . . .
Gimbal Housing Servicing 4B-26. . . . . . . . . . . . .
U-joint Bellows Replacement 4B-26. . . . . . . .
Shift Cable Bellows Replacement 4B-29. . . .
Exhaust Bellows Replacement 4B-32. . . . . .
Speedometer Hose Replacement 4B-34. . . .
Gear Lube Monitor System
Components 4B-35. . . . . . . . . . . . . . . . . . . . . .
Trim Position Sender and Trim Limit
Switch Wire Replacement 4B-38. . . . . . . . . .
Gimbal Ring / Swivel Shaft and
Steering Lever Installation 4B-39. . . . . . . . . . . .
Bell Housing Installation 4B-45. . . . . . . . . . . . . . .
Standard Transom Assembly 4B-45. . . . . . . .
High Performance Transom Assembly 4B-46
Standard And High Performance
Transom Assemblies 4B-47. . . . . . . . . . . . . .
Shift Cable Installation 4B-51. . . . . . . . . . . . . . . .
Bravo Access Plug Drilling Template 4B-55. . . .
Crimp Clamp Tool 4B-57. . . . . . . . . . . . . . . . . . . .
POWER TRIM
Section 5A - Oildyne Power Trim Pump
Trim Pump Specifications 5A-2. . . . . . . . . . . . . .
Valve Pressure Specifications 5A-2. . . . . . . .
Electrical Specification 5A-2. . . . . . . . . . . . . .
Torque Specification 5A-2. . . . . . . . . . . . . . . .
Special Tools 5A-2. . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 5A-2. . . . .
Trim Pump Exploded View 5A-3. . . . . . . . . . . . . .
Oildyne Trim Pump 5A-3. . . . . . . . . . . . . . . . .
Maintaining Power Trim Pump Oil Level 5A-4. .
Air Bleeding Power Trim System 5A-5. . . . . . . .
Bleeding OUT/UP Trim Circuit 5A-5. . . . . . . .
Bleeding IN/DOWN Trim Circuit 5A-5. . . . . .
Testing Power Trim Pump 5A-6. . . . . . . . . . . . . .
Test Gauge 5A-6. . . . . . . . . . . . . . . . . . . . . . . .
Internal Restriction Test 5A-7. . . . . . . . . . . . .
OUT/UP Pressure Test 5A-8. . . . . . . . . . . . . .
IN/DOWN Pressure Test 5A-10. . . . . . . . . . . .
Trim Pump Hydraulic System 5A-11. . . . . . . .
Trim Cylinder Internal Leak Test 5A-12. . . . . . . .
Trim Cylinder Shock Piston Test 5A-15. . . . .
Motor and Electrical Bench Tests 5A-16. . . . . . .
Trim Pump Motor Test (In Boat) 5A-16. . . . .
Trim Pump Motor Test (Out of Boat) 5A-18. .
Solenoid Test (Pump In Boat) 5A-19. . . . . . .
Solenoid Test (Pump Out of Boat) 5A-20. . . .
110 Amp Fuse Test (Pump in Boat) 5A-22. .
110 Amp Fuse Test (Pump
Out of Boat) 5A-22. . . . . . . . . . . . . . . . . . . . . .
20 Amp Fuse Test 5A-23. . . . . . . . . . . . . . . . .
Trim Pump Removal 5A-23. . . . . . . . . . . . . . . . . .
Hydraulic Repair 5A-25. . . . . . . . . . . . . . . . . . . . .
Disassembly 5A-25. . . . . . . . . . . . . . . . . . . . . .
Filter Replacement 5A-27. . . . . . . . . . . . . . . . .
UP Pressure Relief
Valve Replacement 5A-28. . . . . . . . . . . . . . . .
DOWN Pressure Relief
Valve Replacement 5A-29. . . . . . . . . . . . . . . .
Thermal Relief Valve Replacement 5A-30. . .
Pump Replacement 5A-30. . . . . . . . . . . . . . . .
Adapter Replacement 5A-31. . . . . . . . . . . . . .
Adapter Repair 5A-33. . . . . . . . . . . . . . . . . . . .
Pump Shaft Oil Seal Replacement 5A-37. . .
Motor Repair 5A-39. . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 5A-39. . . . . . . . . . . . . . . . . . . . . .
Armature Tests 5A-42. . . . . . . . . . . . . . . . . . . . . . .
Continuity Test 5A-42. . . . . . . . . . . . . . . . . . . .
Test for Shorts 5A-43. . . . . . . . . . . . . . . . . . . .
Cleaning Commutator 5A-43. . . . . . . . . . . . . .
Field Tests 5A-43. . . . . . . . . . . . . . . . . . . . . . . . . .
Test for Open Circuit 5A-43. . . . . . . . . . . . . . .
Test for Short in Field 5A-44. . . . . . . . . . . . . .
Thermal Switch Continuity Test 5A-45. . . . . .
Brush Replacement 5A-46. . . . . . . . . . . . . . . .
Reassembly 5A-49. . . . . . . . . . . . . . . . . . . . . . . . .
Trim Pump Installation 5A-55. . . . . . . . . . . . . . . .
Trim Pump Wiring Diagrams 5A-56. . . . . . . . . . .
Model With Three-Button
Trim/Trailer Panel 5A-56. . . . . . . . . . . . . . . . .
Model With Trim In Handle and
Trailer Switch Separate 5A-57. . . . . . . . . . . .
90-863160 MAY 2000 Page ix
Section 5B - Trim Cylinders
Specifications 5B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 5B-2. . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 5B-2. . . . .
Special Tools 5B-2. . . . . . . . . . . . . . . . . . . . . . . . .
Trim Cylinder Exploded Views 5B-3. . . . . . . . . . .
Bravo Trim Cylinders 5B-3. . . . . . . . . . . . . . . .
Bravo Trim System Components 5B-4. . . . . .
Power Trim Hydraulic Schematic 5B-5. . . . . . . .
Special Information 5B-6. . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In
Limit Insert 5B-6. . . . . . . . . . . . . . . . . . . . . . . .
Trim Cylinder Internal Leak Test 5B-7. . . . . . . . .
Trim Cylinder Shock Piston Test 5B-7. . . . . . . . .
Trim Cylinder Repair 5B-7. . . . . . . . . . . . . . . . . . .
Removal 5B-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 5B-9. . . . . . . . . . . . . . . . . . . . . . .
Reassembly 5B-14. . . . . . . . . . . . . . . . . . . . . .
Installation 5B-21. . . . . . . . . . . . . . . . . . . . . . . .
Section 5C - Dual Power Trim Control
Important Information 5C-2. . . . . . . . . . . . . . . . . .
Testing Dual Power Trim System 5C-2. . . . . . . .
Relay Test 5C-2. . . . . . . . . . . . . . . . . . . . . . . . .
Diode Module Test 5C-3. . . . . . . . . . . . . . . . . .
Trailer Switch Test 5C-4. . . . . . . . . . . . . . . . . .
Starboard Trim Switch Test 5C-4. . . . . . . . . .
Port Trim Switch Test 5C-4. . . . . . . . . . . . . . . .
Dual Power Trim System Component
Repair 5C-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Information 5C-5. . . . . . . . . . . . . . .
Relay Replacement 5C-5. . . . . . . . . . . . . . . . .
Diode Module Replacement 5C-7. . . . . . . . . . . .
Removal 5C-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C-7. . . . . . . . . . . . . . . . . . . . . . . . .
Trim Control Panel Switch(es)
Replacement 5C-8. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 5C-8. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 5C-9. . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams 5C-10. . . . . . . . . . . . . . . . . . . . .
Dual Trim Harnesses 5C-10. . . . . . . . . . . . . . .
Electrical Box Wiring 5C-11. . . . . . . . . . . . . . .
Section 5D - Auto Trim II
Auto Trim II System 5D-2. . . . . . . . . . . . . . . . . . .
Description 5D-2. . . . . . . . . . . . . . . . . . . . . . . .
Auto Trim II Operation 5D-2. . . . . . . . . . . . . . . . .
Auto Mode Operation 5D-3. . . . . . . . . . . . . . .
“Manual” Mode Operation 5D-4. . . . . . . . . . . .
Electrical System Overload Protection 5D-6. . .
Auto Trim Limit Adjustment 5D-6. . . . . . . . . . . . .
Adjusting Sterndrive Unit Trim Angle 5D-7. .
Control Module Adjustment 5D-9. . . . . . . . . . . . .
Trim Position Indicator Adjustment 5D-10. . . . . .
Wiring Diagram 5D-11. . . . . . . . . . . . . . . . . . . . . .
STEERING SYSTEMS
Section 6A - Power Steering
Specifications 6A-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 6A-2. . . . . . . . . . . . . . .
Special Tools 6A-2. . . . . . . . . . . . . . . . . . . . . . .
Lubricants/Sealants/Adhesives 6A-2. . . . . . .
Description 6A-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Valve 6A-3. . . . . . . . . . . . . . . . . . . . . . .
Power Steering System 6A-4. . . . . . . . . . . . . . . .
RIGHT TURN 6A-4. . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System 6A-5. . . . . . . . . . . . . . . .
LEFT TURN 6A-5. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System 6A-6. . . . . . . . . . . . . . . .
NEUTRAL 6A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Helm and Cable 6A-7. . . . . . . . . . . . . . .
Steering Cable Specifications 6A-8. . . . . . . .
Filling and Air Bleeding Power
Steering System 6A-9. . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Level 6A-9. . . . . . . . . . . . . . . .
Engine Cold 6A-9. . . . . . . . . . . . . . . . . . . . . . . .
Filling and Bleeding 6A-10. . . . . . . . . . . . . . . .
Power Steering Assembly 6A-11. . . . . . . . . . . . .
Removal 6A-11. . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A-12. . . . . . . . . . . . . . . . . . . . . . . .
Power Steering System Pressure Test 6A-15
Pump Pressure Test 6A-17. . . . . . . . . . . . . . .
Power Steering Pump 6A-19. . . . . . . . . . . . . . . . .
Removal 6A-19. . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Valve Servicing 6A-20. . . . . . . .
Pump Shaft Oil Seal Replacement 6A-21. . .
Disassembly 6A-23. . . . . . . . . . . . . . . . . . . . . .
Cleaning And Inspection 6A-26. . . . . . . . . . . .
Reassembly 6A-26. . . . . . . . . . . . . . . . . . . . . .
Installation 6A-32. . . . . . . . . . . . . . . . . . . . . . . .
Multiple Sterndrive Steering
Tie Bar Arrangements 6A-33. . . . . . . . . . . . .
Determining Tie Bar Length 6A-34. . . . . . . . .
Selection 6A-35. . . . . . . . . . . . . . . . . . . . . . . . .
Installation 6A-35. . . . . . . . . . . . . . . . . . . . . . . .
Page x 90-863160 MAY 2000
Section 6B - Compact Hydraulic Steering
Important Information About
Thru-Transom Exhaust 6B-2. . . . . . . . . . . . . . . .
Torque Specifications 6B-2. . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 6B-2. . . . . . .
Removal 6B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing The Steering Cylinder 6B-4. . . . . . . . .
Filling And Purging The System 6B-6. . . . . . . . .
Twin Station and/or Twin Cylinder 6B-6. . . . .
Single Station With Single Cylinder 6B-7. . . .
Purging 6B-8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting The Clevis 6B-10. . . . . . . . . . . . . . . .
Hydraulic Fluid Level 6B-11. . . . . . . . . . . . . . . . . .
Setting Fluid Level 6B-11. . . . . . . . . . . . . . . . .
Maintaining Fluid Level 6B-11. . . . . . . . . . . . .
System Check 6B-11. . . . . . . . . . . . . . . . . . . . .
CORROSION PROTECTION
Section 7A - All Models
Specifications 7A-2. . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools 7A-2. . . . . . . . . . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 7A-2. . . . .
Continuity Circuit 7A-2. . . . . . . . . . . . . . . . . . . . . .
Trim Cylinder Anodes 7A-5. . . . . . . . . . . . . . . . . .
Anodic Plate 7A-6. . . . . . . . . . . . . . . . . . . . . . . . . .
Bravo One Sterndrive Units 7A-6. . . . . . . . . .
Bravo Two Sterndrive Units 7A-8. . . . . . . . . .
Bravo Three Sterndrive Units 7A-8. . . . . . . . .
Integral MerCathode System 7A-9. . . . . . . . . . . .
Removing Electrode Assembly 7A-9. . . . . . .
Installing Electrode Assembly 7A-10. . . . . . . . . .
Connect Electrical Leads to
Controller Assembly 7A-12. . . . . . . . . . . . . . .
Wiring Diagrams 7A-13. . . . . . . . . . . . . . . . . . . . .
MerCathode Monitor 7A-13. . . . . . . . . . . . . . .
MerCathode Controller 7A-14. . . . . . . . . . . . .
Quicksilver Isolator 7A-15. . . . . . . . . . . . . . . . . . .
Corrosion Protection Testing
and Troubleshooting 7A-15. . . . . . . . . . . . . . . . .
Test Equipment Set-Up 7A-18. . . . . . . . . . . . .
Low Readings 7A-19. . . . . . . . . . . . . . . . . . . . .
Low Readings (continued) 7A-20. . . . . . . . . .
High Reading 7A-21. . . . . . . . . . . . . . . . . . . . .
Normal Reading But Corrosion
is Evident 7A-21. . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES
Section 8A - All Models
Specifications 8A-2. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications 8A-2. . . . . . . . . . . . . . .
Lubricants / Sealants / Adhesives 8A-2. . . . .
Power Shift (P/N 38638A4) 8A-2. . . . . . . . . . . . .
Description 8A-2. . . . . . . . . . . . . . . . . . . . . . . .
General Information 8A-3. . . . . . . . . . . . . . . . .
Checking Vacuum Drop-Off 8A-5. . . . . . . . . .
Power Shift Cylinder Repair 8A-6. . . . . . . . . . . .
Removal 8A-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 8A-6. . . . . . . . . . . . . . . . . . . . . . .
Reassembly 8A-9. . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Replacement and Adjustment 8A-14
Installation Preparation 8A-14. . . . . . . . . . . . .
Shift Cable Barrel Adjustment 8A-14. . . . . . .
Installing Input Cable 8A-15. . . . . . . . . . . . . . .
Installing Output Cable 8A-16. . . . . . . . . . . . .
Attach Dust Cover 8A-16. . . . . . . . . . . . . . . . .
Mounting Power Shift Cylinder 8A-17. . . . . . .
Connecting Vacuum Hose to Engine 8A-17.
1
A
GENERAL INFORMATION
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1A-1
IMPORTANT INFORMATION
Section 1A - General Information
Table of Contents
How To Use This Manual 1A-2. . . . . . . . . . . . . . .
Page Numbering 1A-2. . . . . . . . . . . . . . . . . . .
How to Read a Parts Manual 1A-3. . . . . . . . . . .
Introduction 1A-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Directional References 1A-4. . . . . . . . . . . . . . . . .
Propeller Rotation 1A-4. . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit 10-Hour Break-In Period
(New or With Replacement Gears) 1A-5. . . . . .
Serial Number Locations and Engine
Designation Decal 1A-5. . . . . . . . . . . . . . . . . . . .
IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28
Page 1A-2 90-863160 MAY 2000
How To Use This Manual
This manual is divided into sections that represent major components and systems. Some
sections are further divided into parts that more fully describe the component. Sections and
parts are listed at front of this manual.
Page Numbering
Two number groups appear at the bottom of each page. Following is an example and
description.
a
b
c
d
e
f
g
a-Section Number
b-Section Part
c-Page Number
d-Manual Part Number
e-Revision Number
f-Month Printed
g-Year Printed
GENERAL INFORMATION
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1A-3
How to Read a Parts Manual
Power Steering Pump Assembly
1
2
3
4
5
6
7
8
9
10
REF.
NO.
PART NO. SYM. QTY. DESCRIPTION
1
90507A12 1 PUMP ASSEMBLY-Power Steering
2
36-95805 1 CAP
3
73873A1 1 PULLEY
4
16-41877 1 STUD
5
57-65607T 1 V-BELT
6
32-806684 1 HOSE-Pressure (FITTINGS ON BOTH ENDS)
7
25-89879 1 O-RING
8
25-806232 1 O-RING
9
13-35048 1 LOCKWASHER (3/8 in.)
10
61990 1 CABLE TIE
REF. NO. : Number shown next to part on exploded view
PART NO. : Mercury Part Number for ordering. If NSS (not sold separately) sometimes GM
part number will be given in description column.
QTY. : The quantity that must be ordered.
DESCRIPTION : Description of part, what parts are included with a part (all indented items
come with the main item above the indented parts), serial number information, and special
information.
IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28
Page 1A-4 90-863160 MAY 2000
Introduction
This comprehensive overhaul and repair manual is designed as a service guide for the
MerCruiser models previously listed. It provides specific information, including procedures
for disassembly, inspection, assembly and adjustment, to enable dealers and service
mechanics to repair these products.
Before attempting repairs, that procedure should first be read through to help understand
the methods and tools used and the cautions and warnings required for safety.
Directional References
Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this
service manual, all directional references are given as they appear when viewing boat from
stern, looking toward bow.
72000
STARBOARD
(RIGHT)
PORT
(LEFT)
FORE or BOW
(FRONT)
AFT or STERN
(REAR)
Propeller Rotation
Propeller rotation for sterndrive can be right hand or left hand rotation as viewed from the
aft end of the propeller.
Right Hand Rotation Left Hand Rotation
GENERAL INFORMATION
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1A-5
Sterndrive Unit 10-Hour Break-In Period (New or With
Replacement Gears)
1. Avoid full throttle starts.
2. DO NOT operate at any one constant speed for extended periods of time.
3. DO NOT exceed 75% of full throttle during the first 5 hours. During the next 5 hours,
operate at intermittent full throttle.
4. Drive unit should be shifted into forward gear a minimum of 10 times during break-in,
with run-in time at moderate rpm after each shift.
Serial Number Locations and Engine Designation Decal
a
Transom Assembly Serial Number Location
a-Transom Assembly Serial Number
b
a
Sterndrive Unit Serial Number Location - Port Side Decal
a-Sterndrive Unit Serial Number
b-Sterndrive Unit Gear Ratio
IMPORTANT INFORMATION SERVICE MANUAL NUMBER 28
Page 1A-6 90-863160 MAY 2000
THIS PAGE IS INTENTIONALLY BLANK
1
B
MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-1
IMPORTANT INFORMATION
Section 1B - Maintenance
Table of Contents
Lubricants / Sealants / Adhesives 1B-2. . . . .
Maintenance Schedules 1B-3. . . . . . . . . . . . .
Maintenance Intervals 1B-3. . . . . . . . . . . . .
Gas Sterndrive 1B-3. . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance * 1B-3. . . . . . . . . . . .
Gas Sterndrive(Continued) 1B-4. . . . . . . . . . .
Scheduled Maintenance * 1B-4. . . . . . . . .
Specifications 1B-5. . . . . . . . . . . . . . . . . . . . . . .
Torque Specification 1B-5. . . . . . . . . . . . . . . . .
Fluid Capacities 1B-5. . . . . . . . . . . . . . . . . . . . .
Lubrication 1B-5. . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Pivot Points 1B-5. . . . . . . . . . .
Propeller Shaft 1B-6. . . . . . . . . . . . . . . . . . .
Steering System 1B-6. . . . . . . . . . . . . . . . . .
Tie Bar Pivot Points 1B-7. . . . . . . . . . . . . . .
Transom Gimbal Housing Assembly Swivel
Shaft and Gimbal Bearing 1B-7. . . . . . . . .
Checking and Adding Sterndrive Oil 1B-8. . .
Inspection 1B-9. . . . . . . . . . . . . . . . . . . . . . .
Changing Sterndrive Oil 1B-10. . . . . . . . . . . . . .
General Maintenance 1B-12. . . . . . . . . . . . . . . .
Maintaining Power Package Exterior Sur-
faces 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Head and Remote Control Mainte-
nance 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Quicksilver MerCathode System . .
1B-12
Maintaining Anodic Plate 1B-12. . . . . . . . . .
Boat Bottom Care 1B-12. . . . . . . . . . . . . . . .
Anti-fouling Paint 1B-12. . . . . . . . . . . . . . . . .
Maintaining Ground Circuit Continuity 1B-13
Power Package Layup 1B-13. . . . . . . . . . . . . . .
Engine 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive 1B-13. . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 1B-14. . . .
Engine 1B-14. . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive 1B-14. . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-2 90-863160 MAY 2000
Lubricants / Sealants / Adhesives
Description Part Number
Quicksilver 4-Cycle 25W-40 Marine Engine Oil 92-802837A1
SAE 20W, 30W Or 40W Engine Oil Obtain Locally
Quicksilver High Performance Gear Lube 92-802854A1
Extended Life Ethylene Glycol Antifreeze Obtain Locally
Quicksilver Special Lubricant 101 92-13872A1
Quicksilver Engine Coupler Spline Grease 92-802869A1
Quicksilver Corrosion Guard Spray 92-802878 55
Quicksilver 2-4-C Marine Lubricant With Teflon 92-825407A3
Quicksilver U-Joint and Gimbal Bearing Grease 92-828052A2
Quicksilver Power Trim And Steering Fluid 92-802880A1
Exxon Unirex EP 2 Grease Obtain Locally
Quicksilver Hydraulic Fluid 64-826485A1
Texaco H015 92-862014A1
SeaStar Hydraulic Fluid HA5430
Approved Hydraulic
Chevron Aviation Fluid A
Steering Fluids
Mobil Aero HFA
Obtain Locally
Shell Aero 4
Fluid meeting MIL Specification H5606C
MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-3
Maintenance Schedules
Maintenance Intervals
Maintenance intervals and tasks, as shown in this schedule, or as found in previously
printed schedules, are based on an average boating application and environment.
However, individual operating habits and personal maintenance preferences can have an
impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser
has adjusted some maintenance intervals and corresponding tasks to be performed. In
some cases, this may allow for more tasks to be performed in a single visit to the servicing
dealer, rather than multiple visits. Therefore, the boat owner and servicing dealer must
discuss the current Maintenance Schedule and develop appropriate maintenance intervals
to coincide with the individual operating habits, environment and maintenance
requirements.
CAUTION
Always disconnect battery cables from battery BEFORE working around electrical
systems components to prevent injury to yourself and damage to electrical system
should a wire be accidentally shorted.
Gas Sterndrive
Routine Maintenance *
Each
Day
Start
Each
Day
End
Weekly
Every
Two
Months
Check crankcase oil (interval can be extended based on experience).
If operating in salt, brackish or polluted waters, flush cooling system after each use.
Check sterndrive unit oil level, trim pump oil level and steering fluid
level.
Check water pickups for debris or marine growth. Check water
strainer and clean. Check coolant level.
Inspect sterndrive unit anodes and replace if 50 percent eroded.
Inspect fuel pump sight tube (if equipped) and have pump replaced
if fuel is present.
Check battery connections and fluid level.
Lubricate propeller shaft and the retorque nut (if operating in only
freshwater, this maintenance may be extended to every four
months).
Operating in saltwater only: treat engine surface with corrosion
guard.
* Only perform maintenance that applies to your particular power package
Standard Models
Horizon Models
MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-4 90-863160 MAY 2000
Gas Sterndrive(Continued)
Scheduled Maintenance *
Annu-
ally
Every
100
hours or
Annually
Every
200
hours
or 3
years
Every
300
hours
or 3
years
Every
2
years
Every
5
years
Touch-up power package paint and spray with Corrosion Guard.
Change crankcase oil and filter.
Change sterndrive unit oil and retorque connection of
gimbal ring to steering shaft.
Replace fuel filter(s).
Check steering system and remote control for loose,
missing or damaged parts. Lubricate cables and linkages.
Inspect U-joints, splines and bellows. Check clamps.
Check engine alignment. Lubricate U-joints splines.
Lubricate gimbal bearing and engine coupler.
Check continuity circuit for loose or damaged connec-
tions. Test MerCathode unit output on Bravo Models.
Retorque engine mounts.
Check spark plugs, wires, distributor cap and ignition
timing. Check and adjust idle speed.
Clean flame arrestor and crankcase ventilation hoses.
Replace PCV valve.
Check electrical system for loose, damaged or corroded
fasteners.
Inspect condition and tension of belts.
Check cooling system and exhaust system hose clamps
for tightness. Inspect both systems for damage or leaks.
Disassemble and inspect seawater pump and replace
worn components.
Clean seawater section of closed cooling system.
Clean, inspect and test pressure cap.
Replace coolant.
* Only perform maintenance that applies to your particular power package
Standard Models
Horizon Models
Whichever Occurs First
Interval will be reduced if not using extended life coolant.
Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.
MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-5
Specifications
Torque Specification
Fastener Location lb-in. lb-ft Nm
Sterndrive Unit Fill/Drain Plug 40 4.5
Sterndrive Unit Vent Plug 40 4.5
We recommend the use of Quicksilver Maintenance Products where specified.
Fluid Capacities
NOTICE
Unit Of Measurement: U.S. Quarts (Liters)
All capacities are approximate fluid measures.
Model Bravo One Bravo Two Bravo Three
Sterndrive Unit Oil Capacity 88 (2603) 104 (3076) 96 (2839)
Lubrication
Shift Cable Pivot Points
22245
a
a-Pivot Points
MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-6 90-863160 MAY 2000
Propeller Shaft
77047
72239
a
a
a
77046
76910
Bravo One / Bravo Two Sterndrives Bravo Three Sterndrive/ Bravo XZ & XR
a-Propeller Shaft
Steering System
WARNING
Transom end of steering cable MUST BE fully retracted into cable housing when
lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could
occur.
71901
b
76860
a
b
c
c
Control Valve
a-Steering Cable End
b-Pivot Point
c-Pivot Bolts
d-Adjusting Slots
MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-7
Tie Bar Pivot Points
MODELS WITH CONTROL VALVE MOUNTED ON STARBOARD TRANSOM ASSEMBLY
22079
22079
a
a
Starboard Engine Port Engine
a-Pivot Point
MODELS WITH CONTROL VALVE MOUNTED ON PORT TRANSOM ASSEMBLY
22079
22079
a
a
Starboard Engine Port Engine
a-Pivot Point
Transom Gimbal Housing Assembly Swivel Shaft and Gimbal Bearing
50072
b
a-Gimbal Bearing Grease Fitting
MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-8 90-863160 MAY 2000
Checking and Adding Sterndrive Oil
IMPORTANT: Position sterndrive unit in DOWN/IN position so that anti-ventilation
plate is level.
CAUTION
If more than 2 fl. oz. (59 ml) of oil is required to fill sterndrive unit, an oil leak may
exist. Find and correct cause of leak before unit is placed in operation.
NOTE: Sterndrive unit oil level is checked at gear lube monitor.
50323
a
a-Gear Lube Monitor Decal
IMPORTANT: Oil level in gear lube monitor will rise and fall during sterndrive
operation; always check oil level when sterndrive is cool and engine is shut down.
NOTE: Drive oil will purge from gear lube monitor if rubber seal is not in cap.
71990
a
a-Gear Lube Monitor
1. Fill gear lube monitor to FULL line on decal.
2. Ensure rubber seal is in place on square gear lube monitor cap.
3. Install gear lube monitor cap. Tighten cap 1/4 turn after cap contacts seal.
IMPORTANT: Do NOT overtighten cap.
4. Check oil level in gear lube monitor.
MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-9
Inspection
Periodically inspect lubricant for water to ensure that sterndrive unit seals are not leaking.
Check for water at bottom of gear lube monitor. If a water leak is indicated the sterndrive
unit must be resealed.
CAUTION
If more than 2 fl. oz. (59ml) of Quicksilver High Performance Gear Lube is required
to fill gear lube monitor, a seal may be leaking. Find and correct cause of leak before
unit is placed in operation.
IMPORTANT: If sterndrive unit has set overnight or longer, check for water in sterndrive unit, as follows:
1. Bravo I: Trim sterndrive unit to full DOWN/IN position.
70023
a
b
a-Oil Fill/Drain Plug
b-Sealing Washer
2. Bravo II and III: Trim sterndrive unit to full UP/OUT position.
22101
22103
a
b
a-Oil Fill/Drain Plug
b-Sealing Washer
3. Remove fill/drain plug to sample lubricant. If water runs out sterndrive unit is leaking and
must be resealed.
4. Reinstall fill/drain plug. Torque to 40 lb-in. (4.5 Nm).
MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-10 90-863160 MAY 2000
Changing Sterndrive Oil
CAUTION
If any water drains from fill/drain hole a leak in sterndrive unit may exist. Find and
correct cause of leak before placing unit back in operatIon.
CAUTION
DO NOT attempt to fill sterndrive unit through oil vent holes, as air will be trapped
in sterndrive unit and unit will be damaged from lack of lubrication.
1. Bravo I: Trim sterndrive unit to full DOWN/IN position.
70023
a
b
a-Oil Fill/Drain Plug
b-Sealing Washer
2. Bravo II and III: Trim sterndrive unit to full UP/OUT position.
22101
22103
a
b
a-Oil Fill/Drain Plug
b-Sealing Washer
3. Remove sterndrive unit gear lube monitor from bracket.
4. Remove cap, empty contents of gear lube monitor into suitable container and discard.
5. Clean gear lube monitor thoroughly.
6. Return gear lube monitor to bracket. Do not refill at this time.
MAINTENANCE
SERVICE MANUAL NUMBER 28
90-863160 MAY 2000 Page 1B-11
7. Check condition of hose and hose connections. Replace as necessary.
71990
a
a-Gear Lube Monitor
8. Remove sterndrive unit vent plug and fill/drain plug. Allow lubricant to drain completely.
9. If sterndrive unit is draining in full DOWN/IN position, trim to full UP/OUT position after
draining drain any remaining oil from internal driveshaft housing ledges.
10. Trim sterndrive unit to full DOWN/IN position (with anti-ventilation plate level) to
complete draining process.
c
a
b
a-Oil Vent Plug
b-Sealing Washer
c-Vent Hole
11. Using lubricant pump, fill sterndrive unit through fill/drain hole with lubricant until oil is
even with bottom edge of vent hole.
12. Without removing lubricant pump fitting from fill/drain hole, reinstall oil vent plug and
sealing washer. Torque to 40 lb-in. (4.5 Nm).
13. Continue filling drive until there is one inch of oil in the gear lube monitor.
14. Remove lubricant pump fitting and quickly reinstall fill/drain plug and sealing washer.
Torque to 40 lb-in. (4.5 Nm).
NOTE: Drive oil will purge from square gear lube monitor if rubber seal is not in cap.
15. Fill gear lube monitor to FULL line on decal.
16. Ensure rubber seal is in place on gear lube monitor cap.
17. Install gear lube monitor cap.
IMPORTANT: Do NOT
overtighten cap.
18. Check oil level in gear lube monitor.
19. Recheck oil level after first use.
MAINTENANCE SERVICE MANUAL NUMBER 28
Page 1B-12 90-863160 MAY 2000
General Maintenance
Maintaining Power Package Exterior Surfaces
Entire power package should be sprayed at recommended intervals with Quicksilver
Corrosion Guard. Follow instructions on can for proper application.
Entire power package should be cleaned and external surfaces that have become bare
should be repainted with Quicksilver Primer and Spray Paint at recommended intervals.
Steering Head and Remote Control Maintenance
Lubricate steering head and remote control with 2-4-C Marine Lubricant with T eflon. Inspect
steering head and remote control for ease of operation.
Checking Quicksilver MerCathode System
If boat is equipped with a Quicksilver MerCathode System, system should be tested to
ensure that it is providing adequate output to protect underwater metal parts on boat. Test
should be made where boat is moored, using Quicksilver Reference Electrode and Test
Meter. Refer to SECTION 7.
Maintaining Anodic Plate
Each sterndrive unit is equipped with a sacrificial anodic plate to help protect underwater
metal parts from galvanic corrosion. Because of its self-sacrificing nature, anodic plate
MUST BE replaced if eroded 50% or more. Refer to SECTION 7.
Boat Bottom Care
To achieve maximum performance and fuel economy, boat bottom MUST BE kept clean.
Accumulation of marine growth or other foreign matter can greatly reduce boat speed and
increase fuel consumption. To ensure best performance and efficiency, periodically clean
boat bottom in accordance with manufacturer ’s recommendations.
In some areas, it may be advisable to paint the bottom to help prevent marine growth. Refer
to the following information for special notes about the use of anti-fouling paints.
Anti-fouling Paint
IMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty.
Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and
boat transom but you must observe the following precautions:
IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and
anode, as this will render them ineffective as galvanic corrosion inhibitors.
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