Mercury BRAVO User Manual

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
Owner’s 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. . . . . . . . . . . . . . . . . . .

Mercury BRAVO Specifications

General

Brand	Mercury
Model	BRAVO
Category	Engine
Language	English