Mercury BRAVO Service Manual

Page iv 90-863160 MAY 2000
Table of Contents
IMPORTANT INFORMATION
Section 1A - General Information
How To Use This Manual 1A-2. . . . . . . . . . . . . . .
Page Numbering 1A-2. . . . . . . . . . . . . . . . . . .
How to Read a Parts Manual 1A-3. . . . . . . . . . .
Introduction 1A-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Directional References 1A-4. . . . . . . . . . . . . . . . .
Propeller Rotation 1A-4. . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit 10-Hour Break-In Period
(New or With Replacement Gears) 1A-5. . . . . .
Serial Number Locations and Engine
Designation Decal 1A-5. . . . . . . . . . . . . . . . . . . .
Section 1B - Maintenance
Lubricants / Sealants / Adhesives 1B-2. . . . . . .
Maintenance Schedules 1B-3. . . . . . . . . . . . . . . .
Maintenance Intervals 1B-3. . . . . . . . . . . . . . .
Gas Sterndrive 1B-3. . . . . . . . . . . . . . . . . . . . . . . .
Routine Maintenance * 1B-3. . . . . . . . . . . . . .
Gas Sterndrive(Continued) 1B-4. . . . . . . . . . . . .
Scheduled Maintenance * 1B-4. . . . . . . . . . . .
Specifications 1B-5. . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification 1B-5. . . . . . . . . . . . . . . . . . .
Fluid Capacities 1B-5. . . . . . . . . . . . . . . . . . . . . . .
Lubrication 1B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Pivot Points 1B-5. . . . . . . . . . . . . .
Propeller Shaft 1B-6. . . . . . . . . . . . . . . . . . . . .
Steering System 1B-6. . . . . . . . . . . . . . . . . . . .
Tie Bar Pivot Points 1B-7. . . . . . . . . . . . . . . . .
Transom Gimbal Housing Assembly Swivel
Shaft and Gimbal Bearing 1B-7. . . . . . . . . . . .
Checking and Adding Sterndrive Oil 1B-8. . . . .
Inspection 1B-9. . . . . . . . . . . . . . . . . . . . . . . . .
Changing Sterndrive Oil 1B-10. . . . . . . . . . . . . . .
General Maintenance 1B-12. . . . . . . . . . . . . . . . .
Maintaining Power Package Exterior Sur-
faces 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Head and Remote Control Mainte-
nance 1B-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Quicksilver MerCathode System . .
1B-12
Maintaining Anodic Plate 1B-12. . . . . . . . . . .
Boat Bottom Care 1B-12. . . . . . . . . . . . . . . . .
Anti-fouling Paint 1B-12. . . . . . . . . . . . . . . . . .
Maintaining Ground Circuit Continuity 1B-13
Power Package Layup 1B-13. . . . . . . . . . . . . . . .
Engine 1B-13. . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive 1B-13. . . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 1B-14. . . . . .
Engine 1B-14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Sterndrive 1B-14. . . . . . . . . . . . . . . . . . . . . . . .
Section 1C - Troubleshooting
Table of Contents 1C-1. . . . . . . . . . . . . . . . . . . . .
Troubleshooting 1C-2. . . . . . . . . . . . . . . . . . . . . . .
Sterndrive Unit Troubleshooting 1C-2. . . . . . . . .
Sterndrive Unit Will Not Slide Into
Bell Housing 1C-2. . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Does Not Shift Into Gear;
Remote Control Shift Handle Moves 1C-2. .
Drive Unit Does Not Shift Into Gear;
Remote Control Shift Handle Does
Not Move 1C-3. . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Shifts Hard 1C-3. . . . . . . . . . . . . . .
Drive Unit In Gear, Will Not Shift
Out Of Gear 1C-3. . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Noise 1C-4. . . . . . . . . . . . . . . .
Drive Shaft Housing Noise 1C-4. . . . . . . . . . .
Drive Shaft Housing Noise
(Continued) 1C-5. . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Housing Noise
(Continued) 1C-6. . . . . . . . . . . . . . . . . . . . . . .
Power Shift 1C-7. . . . . . . . . . . . . . . . . . . . . . . . . . .
System Does Not React 1C-7. . . . . . . . . . . . .
System Binds 1C-7. . . . . . . . . . . . . . . . . . . . . .
Performance Troubleshooting 1C-8. . . . . . . . . . .
Low WOT Engine RPM 1C-8. . . . . . . . . . . . . .
High WOT Engine RPM 1C-8. . . . . . . . . . . . .
Propeller Ventilating/Cavitating 1C-8. . . . . . .
Poor Boat Performance And/Or Poor
Maneuverability-Bow Too Low 1C-9. . . . . . .
Poor Boat Performance And/Or Poor
Maneuverability-Bow Too High 1C-9. . . . . . .
Power Steering 1C-10. . . . . . . . . . . . . . . . . . . . . .
Hard Steering - Helm And Cable 1C-10. . . . .
Hard Steering (Engine Running)
- Power Steering System 1C-10. . . . . . . . . . .
Power Steering System External
Fluid Leaks 1C-10. . . . . . . . . . . . . . . . . . . . . . .
Compact Hydraulic Steering 1C-11. . . . . . . . . . .
Important Information 1C-11. . . . . . . . . . . . . .
Helm Becomes Jammed During Filling 1C-11
System Difficult To Fill 1C-11. . . . . . . . . . . . . .
Steering Hard To Turn 1C-11. . . . . . . . . . . . . .
Helm Unit Bumpy
- Requires Too Many Turns 1C-11. . . . . . . . .
Power Trim Electrical System 1C-12. . . . . . . . . .
Power Trim System Wiring Diagram 1C-16. . . .
Power Trim Hydraulic System 1C-17. . . . . . . . . .
Power Trim Hydraulic Schematic 1C-21. . . . . . .
Auto Trim II Electrical System 1C-22. . . . . . . . . .
Auto Trim II System Wiring Diagram 1C-28. . . .
Corrosion Protection 1C-29. . . . . . . . . . . . . . . . . .

Mercury BRAVO Specifications

General

Brand	Mercury
Model	BRAVO
Category	Engine
Language	English