Brunswick bravo one, Operation & Maintenance Manual

Page 1: ...OPERATION MAINTENANCE MANUAL 1996 Brunswick Corporation 90 806294962 196 5 7L 5 7LX 7 4L Bravo One Two Three ...

Page 2: ...ting your Authorized MerCruiser Dealer about service always specify model and serial numbers The description and specifications contained herein were in effect at the time this guide was approved for printing Mercury Marine whose policy is one of continuous improvement reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring o...

Page 3: ...rcury Marine Stillwater OK U S A SPECIFICATIONS MODEL MCM 5 7 LITRE LX DISPLACEMENT 350 CID IGNITION TIMING 10 BTDC CYL FIRING ORDER 1 8 4 3 6 5 7 2 SPARK PLUGS AC MR43T ENGINE ROTATION LH MAX W O T RPM 4400 4800 IDLE RPM IN NEUTRAL 650 PLUG GAP 035 For Fuel and Oilrequirements refer to Operations Maintenance Manual SERIAL NUMBERS ...

Page 4: ...Emissions Information 18 Attention Required After Submersion 18 Trailering Boat 18 Launching And Boat Operation Care 19 Stolen Power Package 19 Replacement Service Parts 20 Do It Yourself Maintenance Suggestions 21 20 Hour Break In Period 22 After Break In Period 22 20 Hour Checkup 23 Operation 25 Instrumentation 25 Electrical System Overload Protection 29 Models With Mercathode System 29 Remote C...

Page 5: ...f Test Probes 95 Miscellaneous Maintenance 96 Cold Weather Or Extended Storage 98 Power Package Lay Up 98 Draining Instructions 101 Battery Winter Storage 112 Power Package Recommissioning 112 Troubleshooting 113 Warranty Information 120 Owner Warranty Registration 120 International Owner Registration 121 Warranty Policies 122 Mercruiser Limited Warranty Gasoline Engines 122 Mercruiser Internation...

Page 6: ...ny boating seasons To ensure maximum performance and carefree use we ask that you thoroughly read this manual The Operation and Maintenance Manual contains specific instructions for using and maintaining your product We suggest that this manual remain with the product for ready reference whenever you are on the water Thank you for purchasing one of our MerCruiser products We sincerely hope your bo...

Page 7: ...structions while performing the service plus common sense operation are major accident prevention measures WARNING WARNING Hazards or unsafe practices which could result in severe personal injury or death CAUTION CAUTION Hazards or unsafe practices which could result in mi nor personal injury or product or property damage IMPORTANT Indicates information or instructions that are necessary for prope...

Page 8: ...ble so as to minimize the likelihood of lanyard entanglement with nearby objects It is made as long as it is in its stretched condition to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the normal operator s position If for any reason it is desired to have a shorter functional lanyard this may be accomplished by using up length in the...

Page 9: ...ld cause any or all of the following potentially hazardous situations 1 Loss of balance and falling forward of unstable boat passengers a particular concern in bow rider type boats 2 Loss of power and directional control in heavy seas strong current or high winds 3 Loss of control when docking While activation of the lanyard stop switch will result in immediate power shut down a boat can continue ...

Page 10: ...y Information booklet It lists regional sources of safety cruising and local navigation and is available at no charge by writing to Sources of Waterway Information National Marine Manufacturers Association 410 N Michigan Avenue Chicago IL 60611 U S A Perform safety checks and required maintenance Follow a regular schedule and ensure that all repairs are properly made Check safety equipment on boar...

Page 11: ...es refer to your boat capacity plate When in doubt contact your dealer or the boats manufacturer Know your boat s operating and loading limitations Make sure everyone in the boat is properly seated Don t allow anyone to sit or ride on any part of the boat that was not intended for such use This includes backs of seats gunwales transom bow decks raised fishing seats any rotating fishing seat anywhe...

Page 12: ...hould always have the down skier in sight and never back up to the skier or anyone in the water Report accidents Boat operators are required by law to file a Boating Accident Report with their state boating law enforcement agency when their boat is involved in certain boating accidents A boating accident must be reported if 1 there is loss of life or probable loss of life 2 there is personal injur...

Page 13: ...re allowing people to swim or be in the water near your boat WARNING Stop your engine immediately whenever anyone in the water is near your boat Serious injury to the person in the water is likely if contacted by a rotating propeller a moving boat a moving gear case or any solid device rigidly attached to a moving boat or gear case CA283 High speed And High performance Boat Operation If your boat ...

Page 14: ...ming off plane Shifting weight to front bow will Improve ease of planing Improve rough water ride At extremes can cause boat to veer back and forth bow steer CA8 Bottom Of Boat To maintain maximum speed the following conditions of the boat bottom should be observed A Clean free of barnacles and marine growth B Free of distortion nearly flat where it contacts the water C Straight and smooth fore an...

Page 15: ...or gear housing B Bent propeller blade or damaged gear housing skeg C Raised burrs or sharp edges on propeller or gear housing CA10 Ventilation Ventilation is caused by surface air or exhaust gases which are introduced around the propeller resulting in propeller speedup and a reduction in boat speed Excessive ventilation is annoying and usually caused by A Drive unit trimmed out too far B A missin...

Page 16: ...nd of the recommended wide open throttle operating RPM range with a normal load High RPM caused by an excessive trim angle should not be used in determining correct propeller selection If full throttle operation is below the recommended range the propeller must be changed to prevent loss of performance and possible engine damage On the other hand operating an engine above the recommended operating...

Page 17: ...is speed for the boater but the coming of cool dry weather In pointing out the practical consequences of weather effects an engine running on a hot humid summer day may encounter a loss of as much as 14 of the horsepower it would produce on a dry brisk spring or fall day With the drop in available horsepower this propeller will in effect become too large Consequently the engine operates at less th...

Page 18: ...imum performance and dependability and will keep your overall operating expenses at a minimum See your Authorized MerCruiser Dealer for service aids CA14 DEALER RESPONSIBILITIES In general a dealer s responsibilities to the customer include predelivery inspection and preparation such as Make sure that the boat is properly equipped Prior to delivery make certain that the MerCruiser power package an...

Page 19: ...e unit to return to original operating position preventing loss of steering control and engine overspeed Use extreme caution when operating in shallow water or where underwater objects are known to be present Use extreme care to prevent striking submerged object while operating in REVERSE No impact protection is provided in REVERSE If drive unit should strike a submerged object stop engine as soon...

Page 20: ...that must be supplied by the boat owner operator is the exhaust elbow test probes These test probes should have been provided with your power package They should be carried aboard your boat at all times Refer to Emissions Testing procedure found later in this manual CA18 Attention Required After Submersion Before recovery contact an MerCruiser Dealer After recovery immediate service by an Authoriz...

Page 21: ...n this instance water may enter the cylinders through the exhaust system When backing up rapidly the same situation may occur as stated in the preceding paragraph In any of these situations water entering the engine could cause severe damage to internal parts Refer to Attention Required After Submersion CA21 Stolen Power Package If your power package is stolen immediately advise the local authorit...

Page 22: ...or most of their life They are also expected to operate in both fresh and saltwater environments These conditions require numerous special parts Care should be exercised when replacing marine engine parts as specifications are quite different from those of the standard automotive engine For example one of the most important and probably the least suspected special replacement part is the cylinder ...

Page 23: ...u have these special tools and or equipment You can cause damage to the product in excess of the cost a dealer would charge you Also if you partially disassemble an engine or drive assembly and are unable to repair it the dealer s mechanic must reassemble the components and test to determine the problem This will cost you more than taking it to the dealer immediately upon having a problem It may b...

Page 24: ...ible 5 minutes at a time maximum Avoid full throttle acceleration from IDLE speed Do not operate at full throttle until engine reaches normal operat ing temperature Frequently check crankcase oil level Add oil if needed It is normal for oil consumption to be high during break in period After 20 hour break in period drain crankcase oil and replace oil filter see MAINTENANCE Fill crankcase with corr...

Page 25: ...inspect for loose damaged or missing parts Steering System Lubricate and inspect for loose damaged or missing parts Inspect all drive belts Check engine alignment Include proper lubrication of U joint and splined shaft Complete External Engine Exhaust System Inspect for damage and deterioration check all hose clamps for adequate tightness Retorque gimbal ring clamping screws to 50 55 lb ft 67 74 N...

Page 26: ...24 CA26 70514 70515 70516 70523 70517 70522 70518 70521 70520 70519 1 2 3 4 5 6 7 8 9 10 ...

Page 27: ...will appear on your style gauges 1 Speedometer Indicates boat speed 2 Tachometer Indicates engine RPM 3 Oil Pressure Gauge Indicates engine oil pressure 4 Battery Meter Indicates battery voltage 5 Water Temperature Gauge Indicates engine operating temperature 6 Fuel Gauge Indicates fuel tank volume 7 Power Trim Gauge Indicates drive unit angle trim up out and down in 8 Hour Meter Records engine ru...

Page 28: ...26 CB218 70516 1A 1B 1C 71987 70518 ...

Page 29: ...ion switch is first turned to the run position prior to cranking the engine Once the engine starts the buzzer should stop CAUTION Avoid engine damage Do not operate engine once the buzzer has sounded EXCEPT TO AVOID A HAZARDOUS SITUATION The Audio Warning System will not protect the engine from damage It is designed to warn the operator that a problem has occurred When the buzzer sounds with the e...

Page 30: ...28 CA29 71466 70525 70528 70527 70526 1 2 5 4 3 71341 ...

Page 31: ...ker If breaker will not reset electrical overload has not been eliminated Further checks must be made on electrical system 2 A 20 amp fuse may be located in ignition switch I terminal lead to protect electrical system Check for blown fuse if key Is turned to START and nothing happens and circuit breaker is not tripped 3 The Power Trim System is protected from overload by 110 amp fuse and a 20 amp ...

Page 32: ...30 CB181 1 4 5 2 3 6 7 ...

Page 33: ...ing procedures 4 Trailer Switch Used to raise drive unit for trailering launching breaching or shallow water operation See Power Trim for detailed trailer switch operation 5 Lanyard Stop Switch Turns ignition Off whenever the operator when attached to the lanyard moves far enough away from the operator s position to activate the switch See Lanyard Stop Switch at the front of this manual for safety...

Page 34: ...32 CB183 1 4 2 6 3 2 4 3 1 6 5 5 ...

Page 35: ...depressed only when the remote control handle is in the Neutral position and should only be used to assist in starting the engine 3 Control Handle Tension Adjustment Screw This screw can be adjusted to Increase or Decrease the tension on the control handle cover must be removed to adjust This will help prevent Creep of the remote control handle Turn screw Clockwise to increase tension and Counterc...

Page 36: ...34 CB185 3 4 70537 71339 1 2 ...

Page 37: ... be increased or decreased 3 FRICTION Screw adjusts control handle friction so motor speed can be set and driver does not have to hold handle Turn screw clockwise to increase friction Do not thread screw all the way out 4 DETENT Screw controls the effort needed to move control handle out of NEUTRAL To increase tension turn screw clockwise to decrease turn screw counterclockwise Do not thread screw...

Page 38: ...36 CA34 71338 1 3 TO 5 ...

Page 39: ...ance is obtained with the drive unit adjusted so the boat bottom will run at a 3 to 5 angle to the wa ter Trimming Drive Unit UP OUT Can Lower the bow Generally increase top speed Increase clearance over submerged objects or a shallow bottom Cause boat to accelerate and plane off slower In excess cause boat porpoising bouncing or propeller ventila tion Cause engine overheating if trimmed UP OUT to...

Page 40: ...38 CB187 1 3 2 6 4 5 73976 73977 ...

Page 41: ...ler Position Press button until drive unit reaches desired height 2 Trim Up Out Press UP on Trim switch until drive unit reaches desired trim position 3 Lower Drive Unit Press DOWN on Trim switch until drive unit reaches desired position CB189 POWER TRIM OPERATION CONSOLE MOUNT REMOTE CONTROL SINGLE ENGINE VERSION 4 Trailer Position Press button until drive unit reaches desired height 5 Trim Up Ou...

Page 42: ...40 CB190 4 2A 1 1 2B 3 73978 73979 ...

Page 43: ...on until drive unit reaches desired height for trailering drive units 2 Two Button Trim Control Dual Buttons in Handle used to control both drive units from the handle Press UP on button s to trim drive unit UP OUT Press down on button s to trim drive unit DOWN IN A Forward Trim Button Used to trim the port drive unit B Rear Trim Button Used to trim the starboard drive unit 3 Three Button Trim Con...

Page 44: ...42 CB192 70540 70540 70540 1 2 3 ...

Page 45: ...release button s and allow motor to cool for about one minute Circuit breaker will reset and Power Trim operation may be resumed 1 Trailer Position Simultaneously press the UP button top along with the UP OUT button center until drive unit reaches desired trail er position 2 Trim Drive Unit UP OUT Press center UP OUT button until drive unit reaches desired trim position 3 Trim Drive Unit IN DOWN P...

Page 46: ...0 seconds When engine starts quickly reduce throttle setting to avoid exceeding 1500 RPM Never shift drive unit unless engine is at Idle RPM 1 Perform the following as appropriate A Check all items listed in OPERATION CHART B Perform any other necessary checks as indicated by your dealer or specified in your boat owner s manual C Place drive unit in full down in position D Place control handle in ...

Page 47: ...mediately and determine cause J Be sure charging system is functioning correctly K Observe power package for fuel oil water and exhaust leaks L To shift drive unit return control throttle lever to NEUTRAL Move control shift lever with a firm quick motion forward to shift to FORWARD gear or backward to shift to REVERSE After shifting drive unit advance throttle to desired setting M Move control shi...

Page 48: ... ON if so equipped Check for fuel oil water fluid and exhaust leaks etc Turn battery switch OFF if so equipped Operate bilge blowers if so equipped Check shift and throttle control operation Close fuel valve Open fuel shutoff valve Check steering operation Close seacock if so equipped Open seacock if so equipped Flush cooling system if in saltwater area Place drive unit in full down in position Pe...

Page 49: ...soline CA291 USING REFORMULATED OXYGENATED GASOLINES USA ONLY This type of gasoline is required in certain areas of the USA The two types of oxygenates used in these fuels is Alcohol Ethanol or Ether MTBE or ETBE If Ethanol is the oxygenate that is used in the gasoline in your area refer to Gasolines Containing Alcohol also These Reformulated Gasolines are acceptable for use in your MerCruiser eng...

Page 50: ...cted for leakage softening hardening swelling or corrosion Any sign of leakage or deterioration requires replacement before further engine operation Because of possible adverse effects of alcohol in gasoline it is recommended that only alcohol free gasoline be used where possible If only fuel containing alcohol is available or if the presence of alcohol is unknown increased inspection frequency fo...

Page 51: ...ankcase oil selection Oil filter should always be changed with oil In those areas where recommended straight weight oil is not available a multiviscosity 20W 40 SG or CD or as a second but less preferable choice 20W 50 SG or CD may be used IMPORTANT The use of non detergent oils multi viscosity oils other than 20W 40 or 20W 50 low quality oils or oils which contain solid additives are specifically...

Page 52: ...C Thermostat 5 7L 210 1 157 1 4200 4600 RPM 300 1 Propshaft Kilowatts BSO SAV Rating Propshaft Horsepower BSO SAV Rating 7 4L 250 1 212 2 186 1 158 2 2241 8 0 1 454 C I D 7 4 L 1 Power Rated in Accordance with NMMA National Marine Manufacturers Association rating procedures 2 Power Rated in Accordance with BSO SAV rating procedures This rating procedure is used to certify that the engine complies ...

Page 53: ...ating 10 BTDC 1 1 8 4 3 6 5 7 2 12 Volt Negative Ground Electrical System 55 Amps Alternator 5 7L 1 A special procedure must be followed to check or adjust Timing Consult your Authorized MerCruiser Dealer before attempting this procedure AC MR43T or Champion RV15YC4 or NGK BR6FS Minimum 375 cca 475 mca or 90 Ah Minimum 450 cca 575 mca or 90 Ah ...

Page 54: ...er Bravo One 2 3 4 2 1 3 Drive Unit Oil Capacity w Reservoir 5 1 2 5 1 3 Bravo Two 3 1 3 3 7 6 2 3 Seawater Cooling System 2 15 14 20 19 Closed Cooling System 20 19 18 17 5 7L Bravo Three 3 3 1 Always use dipstick to determine exact quantity of oil required 2 Seawater Cooling System capacity information is for winterization use only ...

Page 55: ...y NOTE Maintenance points are color coded for ease of identifica tion See the decal on engine for identification Maintenance Aids 1 Power Steering System Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid ATF 2 All Pivot Points SAE 30W motor oil 3 Fogging Winterizing Engine Quicksilver Storage Seal or SAE 20W motor oil 4 Exposed portion of Steering Cable and Prope...

Page 56: ...stem Coolant 50 50 mixture of ethylene glycol antifreeze must meet GM specification 1825 M and tap water Areas where temperatures generally do not go below 32 F 0 C rust inhibitor and tap water is acceptable 11Gasoline Stabilizer Quicksilver Gasoline Stabilizer for Marine Engines 12Grease Fittings on Drive Shaft Extension Models Quicksilver U Joint and Gimbal Bearing Grease ...

Page 57: ... Crankcase Oil Check level Closed Cooling Coolant Check level Power Steering Fluid Check level Stern Drive Unit Oil Check level Battery Check level and inspect for damage Fuel Pump Sight Tube Check that no fuel is present Power Trim Pump Oil Check level Anodes Inspect for erosion Gear Housing Water Pickups Check for marine growth or debris Weekly TASK INTERVAL ...

Page 58: ... All Inspect condition and check tension Propeller Shaft Lubricate Power Package Exterior Surfaces Spray with rust preventative Power Package Exterior Surfaces Clean and paint Cooling System Flush seawater section INTERVAL Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Operation or 120 Days Whichever Occurs First Once a Year Saltwater ...

Page 59: ...pect Positive Crankcase Venti lation PCV Valve Change Stern Drive unit Oil Change Gimbal Ring Clamping Screws Retorque to 50 55 lb ft 67 74 N m Rear Engine Mounts Check torque to 35 40 lb ft 47 54 N m Gimbal Bearing Lubricate Cooling System Clean inspect Every 100 Hours of Operation or Once Yearly Whichever Occurs First TASK INTERVAL At First 20 Hours of Operation Whenever Insufficient Seawater Fl...

Page 60: ...nspect for loose damaged or missing parts Electrical System Check for loose or damaged wiring Cooling System Hoses and Clamps Inspect for damage and deterioration Check clamps for tightness Continuity Circuit Check components for loose connections broken or frayed wires TASK INTERVAL Saltwater use Every 50 Hours of Operation or 60 Days Whichever Occurs First Freshwater use Every 100 Hours of Opera...

Page 61: ...l filters Replace Steering Head and Remote Control Inspect and lubricate Quicksilver MerCathode System Test output Closed Cooling Coolant Test for alkalinity Heat Exchanger Clean seawater section Carburetor Inspect and adjust Drive Unit Bellows and Clamps Inspect Closed Cooling Coolant Replace TASK INTERVAL Once a Year Every Two Years Saltwater use Every 50 Hours of Operation or 60 Days Whichever ...

Page 62: ...60 CB32 71341 1 2 3 4 4 5 6 71448 70543 70544 70548 70547 70546 70545 ...

Page 63: ...k 4 Remove FILLCAP DIPSTICK and observe level Add specified fluid if required Reinstall FILLCAP DIPSTICK IMPORTANT If fluid is not visible in pump contact your Autho rized MerCruiser Dealer CA56 CHECKING ENGINE COOLANT CLOSED COOLED MODELS ONLY WARNING Do not remove coolant cap when engine is hot Coolant may discharge vio lently 5 Check coolant level in coolant recovery bottle Add specified coolan...

Page 64: ...62 CB207 2 A B 70979 70551 1 2 71987 71773 ...

Page 65: ... a seal may be leaking Damage to drive unit may occur due to lack of lubrica tion Contact your Authorized MerCruiser Dealer for service CB41 CHECKING POWER TRIM PUMP FLUID Place drive unit in full down in position 2 Remove fill cap from reservoir and observe oil level Level must be up to but not over bottom of filler neck Add Quicksilver Power Trim and Steering Fluid or SAE 10W 30 motor oil if req...

Page 66: ...64 CA62 71345 1 2 3 2 70571 70572 71344 70544 ...

Page 67: ...h engine at normal operating temperature remove dipstick Install Quicksilver Crankcase Oil Pump onto dipstick tube Insert hose end of crankcase oil pump into an appropriate container and using pump handle pump until crankcase is empty Remove crankcase oil pump 2 Turn oil filter counterclockwise to left remove and discard old oil filter and old sealing ring Coat sealing ring on new filter with moto...

Page 68: ...66 CB354 1B 1A 2 70570 70569 70568 1C 72522 3 71987 ...

Page 69: ...rCruiser Dealer Lower drive unit so anti ventilation plate is level Fill drive unit through OIL FILL DRAIN hole with Specified Gear Lube until an air free stream of lubricant flows from OIL VENT hole Remove tube from OIL FILL DRAIN hole Quickly install sealing washer and OIL FILL DRAIN screw Tighten securely 3 Fill gear lube monitor with Specified Gear Lube When oil starts to run out the vent hole...

Page 70: ...68 CB177 4 5 70556 71359 1 3 71903 71904 71901 2 ...

Page 71: ...ntrol NOTE If steering cable does not have grease fitting inner wire of cable cannot be greased 2 With steering cable fully extended lubricate exposed part of cable with Special Lubricant 101 3 Lubricate steering system pivot points with SAE 30W motor oil On dual engine boats lubricate all pivot points including tie bar pivot points with SAE 30W motor oil CA72 SHIFT CABLE 4 Lubricate pivot points ...

Page 72: ...70 CB429 6 8B 10 70558 71346 71347 70559 9 71569 8A ...

Page 73: ...e removed to lubricate U joints Contact your authorized MerCruiser dealer for this ser vice CAUTION Speedometer water hose must be disconnected from drive unit BEFORE removing drive unit Failure to do this will result in a broken fitting if drive unit is removed CB428 ENGINE COUPLER 8 Lubricate engine coupler splines with Quicksilver Engine Coupler Spline Grease P N 92 816391A4 A 5 7L B 5 7LX and ...

Page 74: ...72 CB155 2 70561 7 5 72239 ...

Page 75: ... wood block between propeller blade and anti ventilation plate to prevent rotation Straighten bent tabs on tab washer 2 Turn propeller shaft nut counterclockwise to remove nut 3 Slide tab washer spline washer continuity washer propeller and thrust hub off propeller shaft CB157 REMOVAL BRAVO THREE 4 Place wood block between propeller blades and anti ventilation plate to prevent rotation 5 Turn aft ...

Page 76: ...74 CB158 1 2 3 4 5 70561 ...

Page 77: ...ler hub with stepped side toward propeller hub 3 Align splines and place propeller and thrust hub on propeller shaft 4 Place continuity washer spline washer and tab washer onto shaft 5 Install propeller nut Tighten nut securely A minimum of 55 lbs ft 75 N m torque is required Bend three tabs on tab washer down into grooves in spline washer After first use bend the three tabs straight retighten pro...

Page 78: ...76 CB150 6 7 9 10 12 72239 11 8 ...

Page 79: ...eller on propeller shaft 9 Install propeller nut Tighten nut securely A minimum of 100 lbs ft 136 N m torque is required Check propeller at least after 20 hours of operation Do not operate with loose propeller 10Slide aft thrust hub onto propeller shaft with tappered side toward propeller hub Toward end of shaft 11Align splines and place propeller on propeller shaft 12Install propeller nut Tighten...

Page 80: ...78 CB63 1 2 3 70565 71353 70564 4 71170 ...

Page 81: ...ition install flushing attachment and lower drive unit to full down in position 1 Install Quicksilver flushing attachment or equivalent over water intake openings in gear housing 2 Connect hose between flushing attachment and water tap 3 With drive unit in normal operating position partially open water tap about 1 2 maximum Place remote control in NEUTRAL idle speed position and start engine Opera...

Page 82: ...80 CB442 70566 1B 2 70567 1C 74789 3 1A 71355 71334 4 71334 ...

Page 83: ...ine oil cooler OIL COOLER AND POWER STEERING COOLER 2 7 4L Model With Side Mounted Engine Oil and Power Steering Cooler Remove end plates and gaskets Inspect gaskets for deterioration and replace if necessary Inspect for blockage Clean as needed Install gaskets and end plates Tighten screws securely 3 7 4L Model With Front Mounted Engine Oil Cooler and Side Mounted Power Steering Cooler These mode...

Page 84: ...82 CB74 5 1 3 2 7 4 70351 70562 71349 70563 6 70353 70351 ...

Page 85: ... excessive wear or damage 2 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 2 in 13mm 3 Power Steering Pump Drive Belt Inspect drive belt for excessive wear or damage 4 Check belt tension by depressing upper strand of belt at point shown Belt should depress 1 4 in 6mm 5 Seawater Pickup Pump Drive Belt Inspect drive belt for excessive wear or damage 6 Mode...

Page 86: ...84 CB78 71345 50681 70573 1 2A 71169 2B ...

Page 87: ...discard Coat sealing rings on new filter with motor oil Thread filter clockwise onto bracket and tighten securely by hand Do not use a filter wrench Start and run engine Check filter connection for gasoline leaks If leaks exist recheck filter installation lf leaks continue stop engine immediately and contact your Authorized MerCruiser Dealer WARNING Make sure no leaks exist before closing engine h...

Page 88: ...86 CB226 70578 70577 70575 2 3 4 71176 1 73919 ...

Page 89: ...ficial anodes if eroded 50 or more 1 Universal Anodic Plate serves as a sacrificial anode Remove plug from drive shaft housing to access attaching screw and insert 1 2 inch socket Unthread attaching screw and remove universal anodic plate Do not remove screw Install new anodic plate and tighten screw securely Install plug 2 Anodic Plate serves as a sacrificial anode Unscrew both attaching screws a...

Page 90: ...88 CB333 71966 72032 1 2 71804 72029 3B 3A 3B ...

Page 91: ... in this manual for propeller removal and installation To replace the propeller anode A Remove propeller B Remove two screws from anode C Install new anode and tighten securely D Reinstall propeller See Propeller Installation for proper tighten ing CB335 3 Propeller Anode s Bravo Three Model are located in the splash plate just above the propellers To replace the propeller anodes NOTE Your stern d...

Page 92: ...90 CB95 1 2 71176 3 ...

Page 93: ...observe the following 2 Avoid any electrical interconnection between the MerCruiser Product Anodic Blocks or MerCathode System and the paint by allowing a minimum of 1 1 2 in 40mm UNPAINTED area on transom of the boat around these items 3 Painting Drive Unit or Transom Assembly Drive unit and transom assembly should be painted with a good quality marine paint or an anti fouling paint that DOES NOT...

Page 94: ...92 CA97 1 71925 71918 SEE CAUTION ...

Page 95: ...ixture set ting Tampering with the mixture setting on this engine could affect the ex haust emissions level thus voiding the emissions certification These seals shouldonly be removed by an authorized dealer or emissions testing agency CA99 CHANGING POSITIVE CRANKCASE VENTILATION VALVE PCV This engine is equipped with a positive crankcase ventilation valve PCV This valve should be changed every 100...

Page 96: ...94 CA101 2 71926 71921 71923 71919 4 3 ...

Page 97: ...or this en gine The only item that must be supplied by the boat owner op erator is the exhaust elbow test probes These test probes should have been provided with your power package They should be carried aboard you boat at all times 2 Remove plugs from both exhaust elbows 3 Install exhaust elbow adapter fittings into elbows Apply Loctite Pipe Sealant with Teflon to threads that go into elbow Tight...

Page 98: ...teries also produce hydrogen and oxygen gases when being charged This explosive gas escapes fill vent cell caps and may form an explosive atmosphere around the battery for several hours after it has been charged Sparks or flames can ignite the gas and cause an explosion which may shatter the battery and could cause blindness or other serious injury Safety glasses and rubber gloves are recommended ...

Page 99: ...n CA105 Inspection And Maintenance Inspect power package often and at regular intervals to help maintain its top operating performance and correct potential problems before they occur The entire power package should be checked carefully including all accessible engine parts Check for loose damaged or missing parts hoses and clamps tighten or replace as required Check plug leads and electrical lead...

Page 100: ...damage to engine or stern drive unit may result IMPORTANT Before starting engine a water source must be attached to the seawater intake openings in gear housing Fol low all warnings and flushing attachments procedures stated in FLUSHING COOLING SYSTEM 1 Run engine sufficiently to bring it up to normal operating temperature Shut off engine and change oil and oil filter 2 Flush cooling system Refer ...

Page 101: ...hol and a sufficient amount of Quicksilver Gasoline Stabilizer for Marine Engines to treat gasoline Follow instructions on container 5 If boat is to be placed in storage with fuel containing alcohol in fuel tanks carburetors must be run dry at idle RPM Fuel tanks should be drained completely and Quicksilver Gasoline Stabilizer for Marine Engines added to any fuel remaining in the tank Also refer t...

Page 102: ...100 CB431 2 2 74158 71332 3 5 71448 ...

Page 103: ...mage to engine 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs from cylinder block as follows A 5 7L and 7 4L Models Port Starboard from cylinder block B 5 7LX Models Port Side from cylinder block C 5 7LX Models Starboard Side from Y fitting Do not disturb the Y fitting when removing the drain plug There is an ignition control Knock Sensor...

Page 104: ...102 CB433 8 71217 71758 9B 7B 74152 74811 6 9A 74493 7C 74793 7A 71334 ...

Page 105: ... IMPORTANT MerCruiser recommends that propylene glycol a nontoxic and environmentally safe antifreeze be used in the seawater section of the cooling system for cold weather or extended storage Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines Be certain to follow the propylene glycol manufacturer s recommendations 9 For additional...

Page 106: ...104 CB111 2 70583 ...

Page 107: ...mply may result in trapped water causing freeze and or corrosion damage to engine IMPORTANT Closed cooling section must be kept filled year round with recommended coolant If engine will be exposed to freezing temperatures make sure closed cooling section is filled with an ethylene glycol antifreeze and water solution properly mixed to protect engine to lowest temperature to which it will be expose...

Page 108: ...106 CB113 71170 70584 4A 6 71334 70586 5A 4B 5B 7 71217 ...

Page 109: ...id cooler A 5 7L and 5 7 LX B 7 4 L with side mounted engine oil and power steering cooler 6 Disconnect T Fitting to Heat Exchanger Hose from Heat Ex changer 7 Make sure that speedometer pitot tube trim tab cavity vent hole and trim tab cavity drain passage are unobstructed After seawater section of cooling system has been drained completely coat threads of drain plugs with Quicksilver Perfect Sea...

Page 110: ...108 CB437 71515 74073 2 4 ...

Page 111: ...level as possible to ensure complete draining of cooling system 2 Remove drain plug from port and starboard exhaust manifolds 3 Repeatedly clean out all drain holes using a stiff piece of wire Do this until entire system is drained 4 Remove end caps from the heat exchanger IMPORTANT Use compressed air to blow any remaining water from the tubes in the heat exchanger ...

Page 112: ...110 CB439 71170 6 7 5 71217 74793 ...

Page 113: ... end of power steering fluid cooler 7 Make sure that speedometer pitot tube trim tab cavity vent hole and trim tab cavity drain passage are unobstructed 8 After seawater section of cooling system has been drained completely reconnect all hoses reinstall heat exchanger end caps with new gaskets and reinstall drain plugs After draining perform all checks inspections lubrication and fluid changes out...

Page 114: ...al system damage will result 2 Install fully charged battery Clean battery cable clamps and terminals and reconnect cables see CAUTION listed above Tighten each cable clamp securely when connecting 3 Coat terminal connections with a battery terminal anti corrosion agent 4 Perform all checks in OPERATION CHART in the BEFORE STARTING column CAUTION Refer to FLUSHING COOLING SYSTEM before starting en...

Page 115: ...l connections or damaged wiring Bad battery Turn switch on Position control lever in neutral Check and reset circuit breaker or replace fuse Check all electrical con nections and wires espe cially battery cables Clean and tighten faulty connection Test and replace if bad 113 CB215 Troubleshooting Starter Motor Will Not Crank Engine Or Cranks Slow ...

Page 116: ...ure Fill tank or open valve Check sight tube for fuel Have Authorized Mer Cruiser Dealer replace pump if fuel is present Check that choke is closed when engine is cold Check that it opens when engine warms up Do not attempt to start en gine for at least 5 minutes Refer to STARTING PROCEDURES Service ignition system Replace filters If contaminated drain tank Fill with fresh fuel Replace kinked line...

Page 117: ... if necessary Service ignition system Replace filters If contaminated drain tank Fill with fresh fuel Replace kinked line or blow out line with compressed air to remove obstruction Clean flame arrestor Poor Performance Possible Cause Remedy Throttle not fully open Damaged or improper pro peller Excessive bilge water Boat overloaded or load improperly distributed Boat bottom fouled or dam aged Flam...

Page 118: ...sure in closed cooling section If Equipped Closed cooling section dirty If Equipped Faulty seawater pickup pump Seawater discharge re stricted or plugged Open Replace and or adjust belt Remove obstruction Replace Check for cause of low coolant level and repair Fill system with proper coolant solution Clean heat exchanger Check for leaks Clean in spect and test pressure cap Clean Repair Clean exhau...

Page 119: ...rade and vis cosity oil Determine cause for dilution excessive id ling faulty fuel pump etc Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from battery Loose or dirty electrical connections or damaged wiring Alternator drive belt loose or in poor condition Unacceptable battery condition Turn off non essential ac cessories Check all associated elec trical connection...

Page 120: ...ized MerCruiser Dealer immediately Remove obstruction Straighten cable or have dealer replace cable if damaged beyond repair Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level Drive belt loose or in poor condition Insufficient lubrication on steering system compo nents Loose or missing steering fasteners or parts Contaminated power steering fluid Refill sy...

Page 121: ...eplace fuse Check all associated elec trical connections and wires especially battery cables Clean and tighten faulty connection Repair or replace wiring Power Trim Does Not Operate Motor Runs But Drive Unit Does Not Move Possible Cause Remedy Trim pump oil level low Drive unit binding in gimbal ring Fill pump with oil Check for obstruction ...

Page 122: ...ranty claims will not be accepted without presentation of this card A temporary Owner Warranty Registration Card will be presented to you when you purchase the product It is valid only for 30 days from date of sale while your plastic Owner Warranty Registration Card is being processed Should your product need service during this period present the temporary registration card to the dealer He will ...

Page 123: ...ealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on the card to prepare the warranty claim form s In some countries the Marine Power Service Center will issue you a permanent plastic Warranty Registration Card within 30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor dealer If you receive a plas...

Page 124: ...d workmanship it does not apply to normal worn parts adjustments tune ups or to damage caused by 1 Neglect lack of maintenance accident abnormal operation or improper installation or service 2 Use of an accessory or part not manufactured or sold by us 3 Operation with fuels oils or lubricants which are not suitable for use with the Product 4 Participating in or preparing for racing or other compet...

Page 125: ...d Warranty claims will not be accepted without presentation of the Warranty Registration Card VI Our obligation under this Warranty shall be limited to repairing a defective part or at our option refunding the purchase price or replacing such part or parts as shall be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the ri...

Page 126: ...moval of parts or 6 Water entering engine cylinder s through exhaust system or carburetor s III Reasonable access must be provided to the Product for warranty service This warranty will not apply to 1 Haul out launch towing and storage charges telephone or rental charges of any type inconvenience or loss of time or income or other consequential damages or 2 Removal and or replacement of boat parti...

Page 127: ...ll be necessary to remedy any malfunction resulting from defects in material or workmanship as covered by this Warranty We reserve the right to improve the design of any Product without assuming any obligation to modify any Product previously manufactured VII ALL INCIDENTAL AND OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS...

Page 128: ... of sacrificial anodes specified lubrication and touch up of nicks and scratches have been implemented on a timely basis 2 Recommended corrosion prevention devices have been employed details below II This warranty shall become effective upon receipt of a completed standard Product warranty registration card and shall remain effective for a period of three years from the date of purchase III This w...

Page 129: ...hts and you may also have other legal rights which vary from state to state or country to country VI Other details of this warranty are contained in paragraphs IV V and VI of the United States and Canada Product Warranty and paragraphs III IV V and VI of the International Product Warranty contained in this manual which paragraphs are incorporated herein by reference Mercury Marine products are bui...

Page 130: ...n damage that results from the improper application of copper base paint will not be covered by this limited warranty TRANSFER OF WARRANTY This Limited Warranty is transferable to subsequent purchasers for the remainder of the unused portion of the 3 year limited warranty Warranty Coverage The purpose of this section is to help eliminate some of the more common misunderstandings regarding warranty...

Page 131: ...ested by customer other than that necessary to satisfy the warranty obligation Labor performed by other than an Authorized Dealer may be covered only under following circumstances When performed on emergency basis providing there are no Authorized Dealers in area who can perform the work required or have no facilities to haul out etc and prior factory approval has been given to have the work perfo...

Page 132: ... where lead is thrown out of commutator because of excess cranking Valve or valve seat grinding required because of wear Failure of any parts caused by lack of cooling water which results from starting power package out of water foreign material blocking inlets or power package being mounted too high Use of fuels and lubricants which are not suitable for use with or on the product Our limited warr...

Page 133: ... a copy of the bill of sale to show proof of ownership In the United States and Canada mail to Mercury Marine Attn Warranty Registration Department W6250 West Pioneer Road P O Box 1939 Fond du Lac WI 54936 1939 A new Owner Warranty Registration Card will be issued with the new owner s name and address Registration records will be changed on the factory computer registration file There is no charge...

Page 134: ...tion Plan provides coverage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty The optional Q Guard Product Protection Plan is the only Factory Plan available for your engine Two three or four year term plans can be purchased up to 180 days after the original engine purchase date See your participating MerCruiser dealer for complete program ...

Page 135: ...Authorized Dealer Refer to the Yellow Pages of the telephone directory If for any reason you cannot obtain service contact the nearest Regional Service Center Outside the United States and Canada contact the nearest Marine Power International Service Center Parts And Accessories Inquiries All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local Author...

Page 136: ...P ONE DISCUSS YOUR PROBLEM WITH ONE OF THE DEALERSHIP MANAGEMENT PERSONNEL Misunderstandings or complaints can be quickly resolved by the dealer If you are unable to obtain satisfaction contact the dealership s owner STEP TWO IF YOU REQUIRE ADDITIONAL ASSISTANCE TO RESOLVE YOUR CONCERN CONTACT YOUR NEAREST MERCRUISER SERVICE CENTER Provide the following important information Your name address and ...

Page 137: ...ESOLVED STEP THREE CONTACT CONSUMER AFFAIRS DEPARTMENT United States MERCRUISER 3003 N Perkins Road Stillwater OK 74075 2299 Telephone 405 743 6515 Canada Contact Nearest Regional Service Center Other Countries Contact the Nearest Marine Power International Service Center The customer service representatives will review all the facts involved If they feel some further action can be taken they will...

Page 138: ...uga Ontario L4Y 2C2 Canada Telephone 905 270 4481 Fax 905 270 4510 MEXICO CENTRAL AMERICA SOUTH AMERICA CARIBBEAN Marine Power International 9350 SW 72nd St Sunset Dr Suite 100 Miami FL 33173 U S A Telephone 305 596 9606 Fax 305 596 3869 EUROPE MIDDLE EAST AFRICA Marine Power Europe Inc Parc Industriel de Petit Rechain B 4800 Verviers Belgium Telephone 0 87 32 32 11 Fax 32 87 31 19 65 ...

Page 139: ...Fax 61 3 791 5880 ASIA Marine Power International Ltd Block 1002 Jalan Bukit Merah 07 08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone 65 270 7680 Fax 65 270 7898 JAPAN Marine Power International Japan No 27 2 Muramatsu Chisaki Shinden Shimizu City Shizuoka Prefecture Japan 424 Telephone 81 543 34 2500 Fax 81 543 34 2022 ...

Page 140: ...ad P O Box 1939 Fond du Lac WI 54936 1939 Outside the United States and Canada contact the nearest Marine Power International Service Center for further information When ordering be sure to 1 List your product model year and serial number s 2 Check the literature and quantities you want 3 Enclose full remittance in check or money order NO C O D s ...

Page 141: ...60 F 807252 2 7 Thermostat Gaskets 27 33179 2 27 53045 1 8 Alternator Belt 57 49213A1 9 Power Steering Belt 57 816295T 10 Sea Water Pump Belt 57 49213A1 11 Water Separating Filter 35 807172 12 Quicksilver Motor Oil 92 816096A12 13 Storage Seal 92 86145A12 14 Valvtane Plus 92 17955A12 15 Gasoline Stabilizer for Marine Engines 92 817529A12 16 Fuel System Cleaner 92 17885A12 17 Corrosion Guard Spray ...

Page 142: ...16608A61 6 807252 2 807252 2 7 27 33179 2 27 53045 1 27 33179 2 27 53045 1 8 57 48120A1 57 48122 9 57 816295T 57 816295T 7 Pulley 10 57 74271T 57 13457T 11 35 807172 35 807172 12 92 816096A12 92 816096A12 13 92 86145A12 92 86145A12 14 92 17955A12 92 17955A12 15 92 817529A12 92 817529A12 16 92 17885A12 92 17885A12 17 92 815869A12 92 815869A12 ...

Page 143: ...1211A2 7 Tab Washer 14 816629 8 Grounding Washer 13 42351 1 9 Thrust Hub 13171 10 Decal Set 37 15167A90 11 D S H Anodic Plate 821630A1 12 Anodic Plate Propeller 76214A5 13 Trim Cylinder Anodes 806190A1 14 Gimbal Housing Anode 821631A1 15 Bearing Carrier Anode 806188A1 16 Drain Screw 10 14834A1 17 Drain Screw O Ring 25 805726 18 Vent Screw 10 79953 19 Vent Screw O ring 25 805726 20 Bell Housing to ...

Page 144: ...00T 5 N A 11 805101T 6 12 55073A2 N A 7 14 34817 N A 8 13 42351 1 N A 9 55074T N A 10 37 13722A90 37 15167A90 11 821630A1 821630A1 12 76214A5 76214A5 13 806190A1 806190A1 14 821631A1 821631A1 15 N A N A 16 10 14834A1 10 14834A1 17 25 805726 25 805726 18 10 79953 10 79953 19 25 805726 25 805726 20 16755 16755 ...

Page 145: ... Pump 20 Amp Fuse 88 79091 23 Trim Pump 10 Amp Fuse 88 79023A10 24 2 4 C Marine Lubricant with Teflon 92 825407A3 25 U Joint and Gimbal Bearing Grease 92 828052A2 26 Engine Coupler Spline Grease 92 816391A4 27 High Performance Gear Lube 92 816026A1 28 Touch Up Spray Paint 92 78373 12 ...

Page 146: ... Bravo Two Bravo Three 21 25 45710 25 45710 22 88 79091 88 79091 23 88 79023A10 88 79023A10 24 92 825407A2 92 825407A2 25 92 828052A2 92 828052A2 26 92 816391A4 92 816391A4 27 92 816026A1 92 816026A1 28 92 78373 12 92 78373 12 ...

Page 147: ...sembly of the engine or stern drive Parts Manual shows the exploded view of the engine or stern drive with corresponding part number Operation and maintenance manual Owner s Guide explains basic operation and maintenance Manual Part Number Official Use Only Qty Price Each Total Price Service Manual Engine 90 30 00 Service Manual Drive 90 30 00 Service Manual Remote Control 90 30 00 Parts Manual En...

Page 148: ...eturn with Payment to Mercury Marine Attn Publications Dept P O Box 1939 Fond du Lac WI 54936 1939 Ship To Please Print or Type This is your Shipping Label Name Address City State Zip 146 Method of Payment No Cash or C O D Personal Check Cashiers Check Money Order Visa MasterCard ...