Mercury 540 Bravo

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a - Starboard side air‑actuated drain location

b - Port side air‑actuated drain location

55483

COLD WEATHER OR EXTENDED STORAGE

90 eng

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Table of Contents3
Warranty Registration United States and Canada7
Transfer of Warranty7
Warranty Information7
Mercury Racing Division One Year Limited Warranty United States and Canada8
Products Sold to Government Agencies10
Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products11
California Emission Control Warranty Statement12
California Emission Control Warranty Rights and Obligations15
E.P.A. Emission Controls16
Before Operating Your Boat18
Boat Horsepower Capacity18
General Information18
High-Speed and High-Performance Boat Operation19
Paddle Wheel and Water Temperature Sensors19
Lanyard Stop Switch19
Trailering the Boat20
Protecting People in the Water20
Exhaust Emissions21
Wave and Wake Jumping23
Impact with Underwater Hazards24
Operating in Shallow Water25
Safe Boating Suggestions26
Stolen Power Package28
Engine Identification29
Fuel Requirements29
Specifications29
Low Permeation Fuel Hose Requirement31
Crankcase Oil31
Capacities32
General Engine Specifications33
Engine Operating Limitations34
Engine Break-In34
After Break-In Period35
Instrumentation36
Warning System36
Operation36
Electrical System Overload Protection37
Remote Controls (Console Mounted Zero Effort)42
Starting, Shifting, and Stopping43
Operation Chart44
Freezing Temperature Operation45
Drain Plug and Bilge Pump45
Launching and Boat Operation Care45
Weight Distribution46
Bottom of Boat46
Cavitation46
Ventilation46
Conditions Affecting Operation46
Propeller Selection47
Conditions that Lower Engine Performance47
Service Responsibilities49
Replacement Service Parts49
Do-It-Yourself Maintenance Suggestions50
Servicing High-Horsepower Engines51
Engine Maintenance Charts51
Bravo Drive Maintenance Charts53
Checking Fluid Levels56
Closed Cooling System60
Changing Fluids63
Lubrication69
Propellers72
Flushing the Power Package75
Cleaning Seawater (Raw Water) Section of Oil Cooler79
Changing Positive Crankcase Ventilation Valve80
Cleaning the Flame Arrestor80
Serpentine Drive Belt82
Water-Separating Fuel Filter85
Corrosion and Corrosion Protection87
Battery93
Bottom of Boat93
Inspection and Maintenance94
Attention Required after Submersion94
Draining the Seawater System95
Drain System Identification95
Cold Weather or Extended Storage95
Air-Actuated Single-Point Drain System97
Manual Drain System102
Draining Water from the Cool Fuel Module104
Battery Storage105
Recommissioning the Power Package105
Engine will Not Crank107
Engine Cranks but will Not Start107
Troubleshooting107
Engine Hard to Start, Runs Rough, Misses, And/Or Backfires108
Low Engine Coolant (Closed Cooling) Temperature108
Poor Performance109
Insufficient Engine Temperature109
High Engine Temperature109
Low Engine Oil Pressure110
Battery will Not Come up on Charge110
Power Trim Does Not Operate (Motor Doesn't Run)110
Power Trim Does Not Operate (Motor Runs but Drive Unit Does Not Move)111
Electrical Analog Trim Gauge Malfunction111
Remote Control Operates Hard, Binds, Has Excessive Free-Play or Makes Unusual Sounds111
Steering Wheel Turns Hard or Jerky112
Seawater Pressure Is below Specification112
Seawater Pressure Is above Specification112
Local Repair Service113
Service Away from Home113
Parts and Accessories Inquiries113
Service Assistance113
Mercury Marine Service Offices113
Owner Service Assistance113
United States and Canada115
Outside the United States and Canada115
Ordering Literature115
Maintenance Log116

Mercury 540 Bravo - Page 96

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