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Mercury BRAVO User Manual

Mercury BRAVO
116 pages
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90-860172001 APRIL 2000 Printed in U.S.A. - 2000, Mercury Marine Page 1 of 116
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, and Ride-Guide.
GASOLINE ENGINES BRAVO MODELS
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owners Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information 2. . . . . . . . . . . . . . . . . . . . .
Notice to Boat Manufacturer/Installer 2. . . .
Bravo Three Notice: Trim-In Limit Pin 3. . .
MCM 454 & 502 Magnum MPI Application
Recommendations 4. . . . . . . . . . . . . . . . . . .
Multiple Steering Tie Bar Arrangements 5.
Quicksilver Products 6. . . . . . . . . . . . . . . . . .
Installation Products 7. . . . . . . . . . . . . . . . . .
Torque Specifications 7. . . . . . . . . . . . . . . . .
Serial Number Decal Placement 8. . . . . . . .
Corrosion Protection 8. . . . . . . . . . . . . . . . . .
Antifouling Paint 9. . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 10. . . . . . . . . . . . . . . .
Boat Construction 10. . . . . . . . . . . . . . . . . . . .
Exhaust System 14. . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 20. . . . . . . . . . . . . . . . .
Battery 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFI Electrical System Precautions 24. . . . . .
Instrumentation 24. . . . . . . . . . . . . . . . . . . . . . .
Power Trim Control 25. . . . . . . . . . . . . . . . . . .
Power Trim Pump Location 25. . . . . . . . . . . .
Propeller Selection 26. . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation
Recommendation 27. . . . . . . . . . . . . . . . . . . .
Seawater Connections - General
Information 29. . . . . . . . . . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and Cables 30
Steering Helm and Cable 30. . . . . . . . . . . . . .
Transom Cutout 32. . . . . . . . . . . . . . . . . . . . . . . . .
Finding Crankshaft Vertical Centerline 33. . .
Finding Crankshaft Horizontal
Centerline (“X” Dimension) 34. . . . . . . . . . . .
Cutting Transom 36. . . . . . . . . . . . . . . . . . . . . . . .
Checking Transom Thickness 37. . . . . . . . . . . . .
Installing Transom Assembly 37. . . . . . . . . . . . .
Installing Gimbal Housing 37. . . . . . . . . . . . . .
Installing Inner Transom Plate 39. . . . . . . . . .
Installing Power Trim Pump 40. . . . . . . . . . . .
Installing Steering System 41. . . . . . . . . . . . .
Hydraulic (Helm) Steering 41. . . . . . . . . . . . .
Connecting Speedometer Pickup 44. . . . . . .
Connecting Drive Unit Gear Lube
Monitor Hose 45. . . . . . . . . . . . . . . . . . . . . . . .
Engine Installation 46. . . . . . . . . . . . . . . . . . . . . . .
Driveshaft Extension Models 46. . . . . . . . . . .
Engine Preparation 46. . . . . . . . . . . . . . . . . . .
Transom Preparation 47. . . . . . . . . . . . . . . . . .
Installing Engine/Alignment 49. . . . . . . . . . . .
Coolant Recovery System (If Equipped) 53.
Engine Connections 54. . . . . . . . . . . . . . . . . . . . .
Quick Drain Oil Installation 62. . . . . . . . . . . . . . .
Shift/Throttle Cables Installation and
Adjustments 63. . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Sterndrive Unit Shift Cable 63. . . .
Troubleshooting Shift Problems 67. . . . . . . . .
Throttle Cable Installation and Adjustment 69
Sterndrive Unit Installation 76. . . . . . . . . . . . . . . .
Predelivery Preparation 84. . . . . . . . . . . . . . . . . .
Battery Connection 84. . . . . . . . . . . . . . . . . . .
Power Trim Pump 84. . . . . . . . . . . . . . . . . . . .
Trim Position Sender Adjustment 85. . . . . . .
Power Steering 87. . . . . . . . . . . . . . . . . . . . . . .
Propeller Installation (Bravo One and Two) 87
Propeller Installation (Bravo Three) 89. . . . .
Test Running Engine 90. . . . . . . . . . . . . . . . . .
Boat-ln-The-Water Tests 92. . . . . . . . . . . . . . .
Cold Weather or Extended Storage
Draining Instructions 94. . . . . . . . . . . . . . . . . .
Quicksilver Instrumentation Wiring Diagrams 100
Power Trim System Wiring Diagram 102. . . . . . .
MerCathode System Wiring Diagram 103. . . . . .
MCM Gasoline Engine Wiring Diagrams 104. . . .
Water Flow Diagrams 112. . . . . . . . . . . . . . . . . . . .
Predelivery Inspection 116. . . . . . . . . . . . . . . . . . .

Table of Contents

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Mercury BRAVO Specifications

General IconGeneral
BrandMercury
ModelBRAVO
CategoryEngine
LanguageEnglish

Summary

General Information

Notice to Boat Manufacturer/Installer

Alerts about hazards and special instructions for installation.

Bravo Three Notice: Trim-In Limit Pin Insert

WARNING: Adjusting Trim-In Limit

Warning about adjusting the Trim-In Limit Insert and testing.

Multiple Sterndrive Steering - Tie Bar Arrangements

CAUTION: Tie Bar Arrangements

Caution regarding damage from incorrect tie bar arrangements.

Torque Specifications

Corrosion Protection

Corrosion Protection Measures

Information on anodes, MerCathode System, and Galvanic Isolator.

Installation Requirements

ENGINE COMPARTMENT

Fuel Delivery System

GENERAL Fuel System Information

General safety and installation points for the fuel system.

SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS

SPECIAL INFORMATION FOR ALL GASOLINE ENGINES

Gasoline Engine Fitting Installation Safety

Important safety information for installing brass fittings into fuel system.

Battery

MULTIPLE EFI ENGINE BATTERY PRECAUTIONS

EFI Electrical System Precautions

EFI Electrical System Precautions

Precautions for working with EFI electrical systems and accessories.

HARNESSES

Propeller Selection

GENERAL INFORMATION on Propeller Selection

Importance of selecting a propeller for correct engine RPM at WOT.

RPM REV-LIMITER

CAUTION: Engine Overheating

Engine Overheating Caution

Caution about engine overheating with closed cooling systems.

Steering Helm and Cable

CAUTION: Power Steering Cable Dimensions

Caution regarding improper steering cable dimensions for power steering units.

STEERING CABLE SPECIFICATIONS

Transom Cutout

Transom Cutout Procedure

Instructions for determining and making the transom cutout for sterndrive.

Finding Crankshaft Vertical Centerline

Finding Crankshaft Horizontal Centerline (“X” Dimension)

TAPE MEASURE METHOD

Cutting Transom

Cutting Transom Procedure

Instructions for cutting the transom using a template or fixture.

Checking Transom Thickness

Installing Transom Assembly

Installing Gimbal Housing (continued)

Installing Inner Transom Plate

Installing Power Trim Pump

Installing Steering System (continued)

Connecting Steering Cable

Connecting Sterndrive Unit Gear Lube Monitor Hose To Gimbal Housing

Engine Installation

Installing Engine/Alignment

Installing Engine/Alignment (continued)

Installing Engine/Alignment (continued)

CAUTION: Alignment Tool Usage

Caution against using non-Quicksilver alignment tools.

Coolant Recovery System (If Equipped)

CAUTION: Coolant System Sealing

Caution on the importance of proper sealing for the coolant recovery system.

Engine Connections

Engine Connections (continued)

CAUTION: Exhaust Hose Failure

Caution to avoid exhaust hose failure by ensuring proper water discharge.

Installing Audio Warning Horn

WARNING: Horn Placement

Warning about horn placement in engine or fuel compartments.

Shift/Throttle Cables Installation and Adjustments

Installing Sterndrive Unit Shift Cable

Procedure for adjusting the sterndrive unit shift cable.

Shift/Throttle Cables Installation and Adjustments (continued)

CAUTION: Control Cable Barrel

Caution regarding removal of control cable barrel without removing end guide.

Shift/Throttle Cables Installation and Adjustments (continued)

Troubleshooting Shift Problems

Troubleshooting Shift Problems

Tips for troubleshooting hard shifting or ratcheting issues.

Troubleshooting Shift Problems (continued)

Throttle Cable Installation and Adjustment

Throttle Cable Installation and Adjustment (continued)

Sterndrive Unit Installation

Sterndrive Unit Installation (continued)

Sterndrive Unit Installation (continued)

Predelivery Preparation

Battery Connection Procedure

Connecting engine and power trim pump battery cables.

Predelivery Preparation (continued)

Trim Position Sender Adjustment

Adjusting the trim position sender to show correct readings.

Trim Position Sender Adjustment (continued)

CAUTION: Starting Engine

Caution against starting engine before checking cooling water.

Power Steering Fluid

CAUTION: Running Power Steering Dry

Caution against running the power steering pump dry.

Propeller Installation (Bravo One and Two)

Propeller Installation (Bravo One and Two)

Instructions for installing propellers on Bravo One and Two sterndrives.

Propeller Installation (Bravo One and Two) (continued)

Propeller Installation (Bravo Three)

Propeller Installation (Bravo Three)

Instructions for installing propellers on Bravo Three sterndrives.

WARNING: Propeller Installation Safety

Warning about propeller rotation and safety during installation.

Test Running Engine

Test Running Engine Procedure

Procedures for test running the engine with the boat in or out of water.

WARNING: Test Running Safety

Warning about removing the propeller when testing out of water.

Test Running Engine (continued)

WARNING: Unattended Helm

Warning against leaving the helm unattended during in-water testing.

Test Running Engine Checks

Checks for cooling system, oil levels, belt tension, and leaks.

Check Power Steering System for Lugging

Troubleshooting power steering lugging by checking for obstructions and cable dimensions.

Test Running Engine (continued)

Boat-In-The-Water Tests

ENGINE IDLE SPEED (ALL EFI MODELS)

Procedure for setting engine idle speed for EFI models.

ENGINE IDLE SPEED (CARBURETED MODELS)

ENGINE IDLE SPEED (CARBURETED MODELS)

Procedure for setting engine idle speed for carbureted models.

CAUTION: Engine Damage During Idle Test

Caution to ensure cooling water supply when running boat out of water.

WIDE-OPEN-THROTTLE TEST

WIDE-OPEN-THROTTLE TEST Procedure

Procedure for running engine at full throttle and checking propeller selection.

Cold Weather or Extended Storage Draining Instructions

CAUTION: Sterndrive Storage Position

Caution regarding storing the sterndrive unit in full DOWN position.

CAUTION: Freezing Temperatures

Caution to drain cooling system to prevent freeze damage.

Draining

SEAWATER (RAW-WATER) COOLED MODELS Draining

Procedures for draining the seawater cooling system.

Draining (continued)

CLOSED COOLED (COOLANT) MODELS

CLOSED COOLED (COOLANT) MODELS Draining

Procedures for draining the seawater section of closed cooling systems.

CAUTION: Freezing Damage Prevention

Caution about completely draining seawater cooling system for winter storage.

Quicksilver Instrumentation Wiring Diagrams

Quicksilver Instrumentation Wiring Diagrams (continued)

Power Trim System Wiring Diagram

MerCathode System Wiring Diagram

MCM Gasoline Engine Wiring Diagrams

MCM 4.3L/4.3LH Bravo Engines Wiring

Wiring diagrams for MCM 4.3L/4.3LH Bravo engines, showing component connections.

MCM Gasoline Engine Wiring Diagrams (continued)

MCM 5.0L and 5.7L Bravo Engines Wiring

Wiring diagrams for MCM 5.0L and 5.7L Bravo engines, showing component connections.

Starting and Charging System Harnesses for MCM Engines

Wiring diagrams for starting and charging systems for various MCM engine models.

MCM 7.4L MPI Starting and Charging System Harness

Wiring diagram for the starting and charging system of MCM 7.4L MPI engines.

MCM 4.3L EFI, 5.0L EFI, 5.7L EFI Bravo Engines - Fuel and Ignition System Harness

Fuel and ignition system harness diagram for MCM 4.3L/5.0L/5.7L EFI Bravo engines.

MCM 350 Mag MPI and MX 6.2L Engines - Fuel and Ignition System Harness

Fuel and ignition system harness diagram for MCM 350 Mag/6.2L MPI engines.

MCM 454 & 502 Mag MPI Models - Fuel and Ignition System Harness

Fuel and ignition system harness diagram for MCM 454/502 Mag MPI models.

Water Flow Diagrams

V8 Engines - Seawater (Raw Water) Cooling System

454 AND 502 CID BRAVO ENGINES

V6 and V8 Engines - Closed (Coolant) Cooling System

Predelivery Inspection

CHECK BEFORE RUNNING

Checklist for pre-run inspection items before starting the engine.

ON THE WATER TEST

Checklist for checks to be performed during the on-water test.

AFTER ON WATER TEST

Checklist for checks to be performed after the on-water test.

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