Mercury BRAVO Service Manual

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. . . . . . . . . . . .

Mercury BRAVO Specifications

General

Brand	Mercury
Model	BRAVO
Category	Engine
Language	English