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Mercury 540 Bravo User Manual

Mercury 540 Bravo
116 pages
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Thank You
for your purchase of one of the finest marine power packages available. It
incorporates numerous design features to ensure operating ease and
durability.
With proper care and maintenance, you will thoroughly enjoy using this
product for many boating seasons. To ensure maximum performance and
carefree use, we ask that you thoroughly read this manual.
The Operation, Maintenance and Warranty 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.
Again, thank you for purchasing one of our Mercury Marine products. We
sincerely hope your boating will be pleasant!
Warranty Message
!
WARNING
The operator (driver) is responsible for the correct and safe operation of
the boat, the equipment aboard and the safety of all occupants aboard.
We strongly recommend that the operator read this Operation,
Maintenance and Warranty Manual and thoroughly understand the
operational instructions for the power package and all related
accessories before the boat is used.
The product you have purchased comes with a limited warranty from
Mercury Marine; the terms of the warranty are set forth in the Warranty
Information section of this manual. The warranty statement contains a
description of what is covered, what is not covered, the duration of
coverage, how to best obtain warranty coverage, important disclaimers
and limitations of damages, and other related information. Please review
this important information.
Safety Alerts and Notices
Throughout this publication, dangers, warnings, cautions, and notices,
accompanied by the international HAZARD symbol
!
, are used to alert
the operator and technician to special instructions concerning a particular
service or operation that may be hazardous if performed incorrectly or
carelessly. Observe these safety alerts carefully.
These safety alerts alone cannot eliminate the hazards they signal. Strict
compliance to these special instructions when performing the service, and
common sense operation are major accident prevention measures.
!
DANGER
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
eng i
© 2014 Mercury Marine
540 Bravo Sterndrive Models 90-8M0086929 414

Table of Contents

Questions and Answers:

Mercury 540 Bravo Specifications

General IconGeneral
BrandMercury
Model540 Bravo
CategoryBoating Equipment
LanguageEnglish

Summary

Thank You and Warranty Overview

Safety Alerts and Notices

Explains hazard symbols and safety precautions for safe operation.

Mercury Racing Division Warranty Details

Warranty Coverage and Duration

Outlines what is covered, duration, and conditions for obtaining warranty.

Warranty Coverage: Obtaining and Exclusions

How to Obtain Warranty Coverage

Instructions for customers to get warranty service and access the product.

What Is Not Covered by Warranty

Lists items and damages excluded from the limited warranty.

Warranty: Voiding and Limitations

What Will Void the Warranty

Explains actions or uses that will void the product warranty.

Warranty: Exclusions for Sterndrive Products

General Exclusions from Warranty

Lists common services and damages not covered by the warranty.

California Emission Control Warranty Statement

Emission Control Systems Warranty

Explains warranty for California-certified engines' emission control systems.

Emission Control Warranty: Duration and Access

Duration of Emission Control Warranty

Specifies warranty periods for emission control components.

How to Obtain Emission Warranty Coverage

Process for accessing warranty service for emission systems.

Mercury Racing Warranty: Actions and Exclusions

What Mercury Racing Will Do

Outlines Mercury Racing's warranty obligations for repairs or replacements.

What Is Not Covered by Warranty

Lists items, damages, and expenses excluded from warranty.

California Emission Control Warranty: Rights and Responsibilities

Your Warranty Rights and Obligations

Explains owner's rights and responsibilities for emission control warranty.

Manufacturer's Warranty Coverage

Details coverage periods for emission control parts.

Owner's Warranty Responsibilities

Defines owner's duties for engine maintenance and warranty presentation.

EPA Emission Controls Warranty

EPA Emission Controls Introduction

Compliance with EPA regulations for emission control systems.

General Information: Exhaust Emissions Safety

Carbon Monoxide Poisoning Risk

Warns about carbon monoxide from engine exhaust and health risks.

General Information: Underwater Hazard Safety

General Information: Shallow Water Operation Safety

Specifications: Fuel Hose and Crankcase Oil

Specifications: General Engine Data

General Engine Specifications

Provides detailed technical specifications for the engine.

Specifications: Engine Operating Limits and Break-in

Engine Operating Limitations

Lists RPM limits, pressures, and temperatures for engine operation.

Operation: Instrumentation and Warning Systems

Warning System and Engine Guardian

Explains audible alerts and engine protection features.

Operation: Engine Faults and Electrical Protection

Operation: Controls and Starting Procedures

Starting, Shifting, and Stopping

Guides on safely starting, shifting gears, and stopping the engine.

Operation: Engine Starting Guidelines

Conditions Affecting Operation: Propellers and Performance

Propeller Selection Guidelines

Choosing the correct propeller for optimal engine RPM and performance.

Maintenance: Responsibilities and Parts

Maintenance: Engine Servicing

Maintenance: Bravo Drive Servicing

Maintenance: Fluid Level Checks

Crankcase Oil Level Check

Instructions for checking and maintaining engine crankcase oil level.

Maintenance: Steering and Pump Fluids

Maintenance: Drive Unit and Trim Pump Fluids

Maintenance: Cooling System Requirements

Closed Cooling System Coolant Requirement

Specifies the type of antifreeze required for the closed cooling system.

Maintenance: Coolant Level and Filling

Checking Coolant Level

How to check the coolant level in the reservoir.

Filling the Closed Cooling System

Procedure for filling the closed cooling system with coolant.

Maintenance: Fluid Changes

Crankcase Oil and Filter Change (Boat in Water)

Detailed steps for changing engine oil and filter in water.

Maintenance: Crankcase Oil and Filter (Boat Out of Water)

Crankcase Oil and Filter Change (Boat Out of Water)

Steps for changing engine oil and filter when the boat is out of water.

Maintenance: Propeller Installation and Removal

Bravo XR Propeller Installation

Guides on installing Bravo XR propellers and components.

Maintenance: Flushing Procedures and Attachments

Maintenance: Sterndrive Water Pickups

Maintenance: Cooling System Flushing

Maintenance: Cooler Cleaning Procedures

Cleaning Seawater Section of Oil Cooler

How to clean the seawater section of the engine oil cooler.

Maintenance: Serpentine Drive Belt Inspection

Serpentine Drive Belt Inspection

How to inspect the serpentine drive belt for wear and tension.

Maintenance: Drive Belt Checking and Replacement

Checking the Drive Belt Condition

Details on inspecting belt tension, wear, and cracks.

Replacing the Serpentine Belt

Steps for replacing the serpentine drive belt.

Maintenance: Water-Separating Fuel Filter Service

Water-Separating Fuel Filter Removal

Procedure for removing the water-separating fuel filter element.

Water-Separating Fuel Filter Installation

Steps for installing a new water-separating fuel filter element.

Maintenance: Corrosion Protection

Corrosion and Corrosion Protection

Explains galvanic corrosion and methods for protection.

Maintenance: Sacrificial Anodes

Sacrificial Anodes Function and Replacement

Explains how sacrificial anodes protect against galvanic corrosion and how to replace them.

Maintenance: Inspection and Submersion Procedures

Attention Required After Submersion

Critical steps for servicing after the engine is submerged.

Cold Weather Storage: Seawater System Draining

Draining the Seawater System

Procedures for draining the seawater system to prevent freezing.

Cold Weather Storage: Manual Drain Systems

Cold Weather Storage: Draining Boat Out of Water

Cold Weather Storage: Battery and Recommissioning

Recommissioning the Power Package

Steps to prepare the power package after storage.

Troubleshooting: Engine Cranking Issues

Engine Will Not Crank

Possible causes and remedies for an engine that won't crank.

Engine Cranks But Will Not Start

Common causes and solutions for an engine that cranks but doesn't start.

Troubleshooting: Engine Performance Issues

Troubleshooting: Engine Temperature and Performance

Troubleshooting: Oil Pressure and Battery Charging

Troubleshooting: Power Trim and Gauge Issues

Troubleshooting: Steering and Water Pressure

Owner Service Assistance: Getting Help

Local Repair Service Recommendations

Advises on using authorized dealers for service.

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