Bravo 3 Outdrive Repair Manual

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Courses are offered in the U.S.A. Tell someone where you are going and when you expect to return. Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat. Just shifting the drive unit into neutral is not sufficient. Watch fallen skiers. At extremes can cause boat to porpoise. Causes bow to bounce in choppy water. Increases danger of following wave splashing into boat when coming off plane. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear hous- ing or propeller. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from ex- cessive engine RPM. Since air (containing oxygen) gets thinner as eleva- tion increases, the engine begins to starve for air. Humidity, baromet- ric pressure and temperature do have a noticeable effect on the density of air. Refer to “COLD WEATHER or EX- TENDED STORAGE” for draining instructions. CA17 Drive Unit Impact Protection The Power Trim hydraulic system is designed to provide impact pro- tection for drive unit. After recovery, immediate service by an Authorized MerCruiser Dealer is required to prevent serious damage to power package. CA19 Trailering Boat Boat can be trailered with drive unit in “up” or “down” position. Ade- quate road clearance is required between road and gear housing skeg when trailering with drive unit in “down”. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors. Use of replacement electrical, ignition or fuel system compo- nents, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided. Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of machinery.
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Electronic ig- nition and special carburetion provide greater fuel economies, but also are more complex for the untrained mechanic. Correct break-in is essential to obtain mini- mum oil consumption and maximum engine performance. Dur- ing this break-in period, the following rules must be observed: Do not operate below 1500 RPM for extended periods of time for first 10 hours. The boat owner is responsible for any charges. Change crankcase oil and filter.Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings that will ap- pear on your style gauges. The audio warning system buzzer will sound if one of the following occur: A Insufficient Oil Pressure B Excessive Engine Temperature C Insufficient Drive Lubricant NOTE: To provide a test of the system, the audio warning buzzer will sound when the ignition switch is first turned to the run position, prior to cranking the engine. The cause must be found and corrected before replac- ing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown.Move lever forward to shift to FORWARD gear. Move lever backward to shift to REVERSE gear. Lever in full vertical position shifts to NEU- TRAL. Also, the Power Trim system “Trailering” feature allows the op- erator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 RPM engine speed), shallow water operation. Should this happen, release button and allow motor to cool for about one minute. Circuit breaker will reset and Power Trim operation may be resumed. Should this happen, release button and allow motor to cool for about one minute. Should this happen, release button(s) and allow motor to cool for about one minute.
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If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. IMPORTANT: Observe the following: Do not start engine without water being supplied to seawater pickup pump (to prevent pump or engine damage). Be prepared to decrease engine speed to 1000-1500 RPM as soon as engine starts. F Turn ignition key to START Release key when engine starts and allow switch to return to RUN position.Turn battery Check Turn bat- switch ON, if so. Engine damage resulting from use of improper gasoline is considered misuse of engine, and damage caused thereby will not be covered under the limited warranty. FUEL RATINGS MerCruiser engines will operate satisfactorily when using a major brand of unleaded gasoline as follows:. We do not know what percentage your boat’s fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boats fuel system components (fuel tanks,fuel lines, and fittings). See “Cold Weather or Extended Storage” later in this manual. CA43 Crankcase Oil To help obtain optimum engine performance and to provide maxi- mum protection, we strongly recommend the use of Quicksilver 4-Cycle Marine Engine Oil. IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed.Areas where temperatures generally do not go below 32 F (0 C), rust inhibitor and tap water is acceptable. SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL 20-Hour Checkup (See At First 20 Hours of Operation NOTE 1) Seawater Pickup Pump Whenever Insufficient Seawater Flow -Disassemble and is Suspected. SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL Engine Alignment - Check Every 100 Hours of Operation or Engine Coupling, Once Yearly, Whichever Occurs Universal Joint Shaft First. Splines - Lubricate Universal Joint Cross Every 200 Hours of Operation or.
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SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER TASK INTERVAL Saltwater use: Every 50 Hours of Engine Exhaust System- Operation or 60 Days, Whichever Inspect for external Occurs First damage,deterioration Freshwater use: Every 100 Hours and restrictions. Allow approximately five minutes for oil to drain into oil pan. Boat must be at rest in water. Remove dipstick. Wipe clean and reinstall fully into dipstick tube. Remove dipstick and observe oil level. Oil level must be between FULL and ADD. Lubri- cant should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. Coolant in closed cooling system should be changed at specified in- tervals by your Authorized MerCruiser Dealer. Remove OIL VENT screw and sealing washer. Allow oil to drain completely. Gasoline is extremely flammable and highly explosive under certain con- ditions. Be sure ignition key is OFF. Do not smoke or allow spark or open flame in area when changing fuel filter. Wipe up any spilled fuel immediately. WARNING Do not grease steering cable while extended. Hydraulic lock could occur and cause loss of steering control. NOTE: If steering cable does not have grease fitting, inner wire of cable cannot be greased. For propeller shaft lubrication, see PROPELLER.A minimum of 55 lbs. ft. (75 N m) torque is required. CB157 REMOVAL (BRAVO THREE) Place wood block between propeller blades and anti-ventilation plate to prevent rotation. Turn aft propeller shaft nut counterclockwise to remove nut. Slide forward thrust hub onto propeller shaft, with tappered side toward propeller hub (Toward end of shaft). To avoid possible injury, remove pro- peller. CAUTION Do not run engine above 1500 RPM when flushing.All drive belts must be periodically inspected for condition and ten- sion. Perform the following inspections of alternator drive belt, power steering pump drive belt (if so equipped) and seawater pickup pump drive belt. B Install new anodes and tighten securely.
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CB329 NOTE: Bravo Three Models may be equipped with one or two pro- peller anodes. Propeller Anodes (Bravo Three Model) - are located in the splash plate, just above the propellers. To replace the propeller anodes: A Remove the bolts that secure the anodes to the splash plate. Painting Boat Hull or Boat Transom: Antifouling paint may be applied to boat hull and boat transom but you must observe the fol- lowing precautions: IMPORTANT: DO NOT paint anodes or MerCathode System ref-. Recharge every 30 to 45 days, or when specific gravity drops below battery manufactur- er’s specifications. Refer to specific instructions and warnings accompanying your bat- tery. If this information is not available, observe the following precau- tions when handling a battery. Free of distortion, nearly flat where it contacts water. Straight and smooth, fore and aft. ANTIFOULING PAINTS See Antifouling Paint recommendations and related information on previous pages. CAUTION DO NOT operate engine without water flowing thru seawater pickup pump, as pump impeller may be damaged and subse- quent overheating damage to engine or stern drive unit may re- sult. While operating en- gine at fast idle (1000-1500 RPM), fog internal surfaces of engine by squirting approximately 8 ounces (227 g) of Quicksilver Storage Seal (or if not available, SAE 20W motor oil) into carburetor bores. Stall engine by squirting last 2 ounces (57 g) of Storage Seal (or oil) rapidly into carburetor. Make sure that speedometer pitot tube, trim tab cavity vent hole, and trim tab cavity drain passage are unobstructed. After cooling system has been drained completely, install drain plugs, reconnect hoses and tighten all hose clamps securely. CAUTION If boat is to remain in water after draining seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to tow from the drain holes or removed hoses.
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Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do not allow en- gine to start. CB309 Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not in- stall battery until all maintenance has been performed on en- gine. Check that all cooling system hoses are connected properly and hose clamps are tight. Turn switch on. Remote control not in neu- Position control lever in tral position. neutral. Open circuit breaker or Check and reset circuit blown fuse. Faulty fuel pump. Check sight tube for fuel. Have Authorized Mer-. Check that it opens when engine warms up. Idle speed too low. Check idle speed and ad- just, if necessary. Check (causing it to become for cause of excessive oil aerated). (improper filling, bad fuel pump, etc.). Loose or missing shift and Check all linkages. If any throttle linkage fasteners.Replace fuse. Loose or dirty electrical Check all associated elec- connections or damaged trical connections wiring.Clean and tighten faulty connection. Repair or replace wiring. Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move) Possible Cause. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address. If purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Company. Mercury Marine products are built using the most advanced corro- sion protection process available. This manufacturing system, com- plemented by dealer and customer participation in an anti-corrosion preventive maintenance program, provides protection against repair costs incurred by the effects of marine corrosion. These certain types of corrosion damage are: damage due to stray electrical currents (on-shore power con- nections, nearby boats, submerged metal), or improper application of copper base anti-fouling paint.

Damage caused by neglect, lack of maintenance, accident, ab- normal operation or improper installation or service. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty.In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 West Pioneer Road P.O. Box 1939. Mercury Marine does not sell to unauthorized dealers or retail cus- tomers. When inquiring on parts and accessories, the dealer re- quires the motor model and serial number(s) to order the correct parts. Any problems with service, sales, warranty or operation of your MerCruiser power package will be resolved by your dealer. He also is your primary source of information on your boat, power package and trailer. This is the reason we request you use the preceding steps in sequence when you have a problem or complaint. Our expe- rience has shown that this is the most expedient and successful pro- cedure to follow to ensure satisfaction to our customers. Parts Manual - shows the exploded view of the engine or stern drive with corresponding part number. Operation and maintenance manual (Owner’s Guide) - explains basic operation and maintenance. Drive Shaft Housing Numbers on the heads of the met- ric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Sections and parts are listed at front of this manual. Page Numbering Two number groups appear at the bottom of each page. If NSS (not sold separately) sometimes GM part number will be given in description column. QTY.: The quantity that must be ordered. It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products. During the next 5 hours, operate at intermittent full throttle.

In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed. In some cases, this may allow for more tasks to be performed in a single visit to the servicing dealer, rather than multiple visits. Lubricate U-joints splines. Lubricate gimbal bearing and engine coupler. Check continuity circuit for loose or damaged connec- tions. Test MerCathodeR unit output on Bravo Models. Retorque engine mounts. Check spark plugs, wires, distributor cap and ignition timing. Check and adjust idle speed. Fluid Capacities NOTICE Unit Of Measurement: U.S. Quarts (Liters) All capacities are approximate fluid measures. Model Bravo One Bravo Two Bravo Three Sterndrive Unit Oil Capacity 88 (2603) 104 (3076) If cable is lubricated while extended, hydraulic lock of cable could occur. CAUTION If more than 2 fl. oz. (59 ml) of oil is required to fill sterndrive unit, an oil leak may exist. If water runs out sterndrive unit is leaking and must be resealed. Follow instructions on can for proper application. Entire power package should be cleaned and external surfaces that have become bare should be repainted with Quicksilver Primer and Spray Paint at recommended intervals. Refer to SECTION 1B. U-joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to ser- vice. Referrals to specific sections of this manual are made where special tests or repair procedure are to be performed. Because of the relationship between Power Package components (engine and sterndrive), it will be necessary in some cases to simultaneously refer to the appropriate Engine Service Manual for further troubleshooting information. Properly reassemble control box. Install Propeller incorrectly installed.Inspect and replace if necessary. Rotate shaft back and forth.This could affect engine to transom Repair boat as necessary. Squirt oil on fitting and hose connections and on the shift Vacuum leaks.

If oil is sucked in at any point, a vacuum leak exists. Properly adjust drive unit trim angle. Damaged propeller. Repair or replace. Water test boat using a lower pitch Improper propeller pitch. propeller. Properly adjust drive unit trim angle. Redistribute boat load to stern. If bow overweight is caused by permanently Boat is bow heavy.Replace cable. (Refer to SECTION 2) Steering cable too short (sharp bends) Select and install proper length cable.The following is offered as a guide only and neither Mercury MerCruiser nor the helm manufacturer are responsible for any consequences resulting from incorrect repairs. If no voltage is connections. Check for battery voltage at terminal Faulty solenoid. Connect a continuity meter between leads and 17. Check for cause of low oil level and Oil level low. correct. Add oil to pump and bleed system. Replace pick-up screens. Trim Pump Runs Slowly In Both Directions Cause Special Instructions Check the condition of the oil It may be. Mode switch wiring harness connector Secure connection 47.If no voltage is indicated, replace switch. Check leads for loose or Open circuit in wiring harness. Faulty control module. Replace. Check voltage at terminal 44. READINGS Potential Diagnosis Drive is corroding. Below 850 millivolts (Refer to “Drive Corroding”) Saltwater Between 850 - 1100 Drive is protected. Fastener Location lb-in.Increased trim IN range may cause handling problems on some boats which could result in personal injury. IMPORTANT: On Bravo One, Two and Three Models, the Trim-In Limit Insert, must be properly positioned before installing the trim cylinder anchor pin in the following steps. CAUTION Avoid speedometer hose fitting damage. Disconnect the speedometer hose fitting from the drive shaft housing before removing the sterndrive unit. 3. Cap hoses and plug pump fitting holes. 76631 Sta-Strap Trim Limit Switch Wires Hydraulic Hoses 5. Remove transom locknuts and washers. 73902 Locknuts and Washers (8) 13.

Separate the inner transom plate from the gimbal housing assembly. 90-863160 MAY 2000 Page 2A-11. Position the steering lever ground wire as shown or the wire may fatigue and break. 22028 Steering Lever Transom Plate Continuity Wire 1. Install the transom assembly. Tighten locknuts evenly, starting from the center and working outward. Connect gear lube monitor hose. 3. Install water inlet fitting with gasket. Torque bolts and star washers to 45 lb-in. (5 Nm). 76640 Hose To Gear Lube Monitor Hose Clamp. Tighten securely and position as shown. 76656 Water Bypass Fitting 6. Connect water hoses to appropriate fittings. Tighten hose clamps securely. 76641 Seawater Hose To Engine Seawater Pump Seawater Pickup Hose. Torque bolts to 23 lb-ft (31 Nm). 22028 Typical V6 and V8 Gasoline Engines Exhaust Pipe Bolts (4) 76657 71945 Typical Diesel Engine Exhaust Pipe Bolts (4) Page 2A-16. Torque bolts to 23 lb-ft (31 Nm). 76638 Block-Off Plate Bolts IMPORTANT: Make hydraulic hose connections as quick as possible to prevent oil from leaking out of the system. Tighten the two pivot bolts by hand. At the same time, move the steering assembly slightly to ensure proper pin engagement into the pivot bushings. Secure the pin in the clevis with a cotter pin. Spread the cotter pin ends. 71901 Rear Clevis Pin Clevis Cotter Pin Steering Cable End. Route hoses as appropriate to avoid contact with the steering system components. 73860 Models With One Hose Routed Behind Power Steering Control Valve Rear Pressure Hose Front Return Hose 74248. Refer to the appropriate engine service manual. NOTE: If the engine was removed and the shift cable was disconnected, reinstall and adjust the shift cable before proceeding. 2. Ensure that the surface is not damaged. 24725 Drive Shaft Bellows Edge 5. The jaws will open. Lubricate the underside of the lower lip of the shift linkage assembly with Quicksilver Special Lubricant 101. 22025 Shift Linkage Assembly Jaws Open Underside of Lower Lip.

Refer to “Special Information” at the front of this section before reinstalling the Trim-In Limit Insert. 11. Ensure that the Trim-In Limit Insert is positioned as shown for the appropriate Bravo model. 75157. Be sure to install the bushings with the small diameter end facing outward. 22029 Anchor Pin Large I.D. Locate the opening in the forward end of the anti-ventilation plate. b. IMPORTANT: Front propeller on Bravo Three sterndrive unit is always LH rotation and rear propeller is always RH rotation. Shift cable end guide must move in direction “A”, when control lever is placed in FORWARD gear position. Hold tool in place over the barrel retainer with a piece of tape. LH ROTATION BRAVO ONE AND TWO MODELS: Forward slot in tool should fit over shift lever stud. If slot does not fit over stud, loosen shift lever stud and slide stud up or down, until slot in tool fits over stud. The cables must have room to move up and down when the control handle is shifted into either forward or reverse. Bravo One U-JOINT IDENTIFICATION RATIO U-JOINT SHAFT MARKING 1.65:1. Do not replace vent screw until reassembly. 76805 Screws Rear Cover Vent Hole 3. If linkage binds; move assembly from side to side while pulling. 76837 Shift Linkage 8. Remove yoke and cam assembly. 76838 Yoke and Cam Assembly 90-863160 MAY 2000. NOTE: In steps 10 and 12, be sure to note proper order and position of thrust races, thrust bearings and clutch assembly for later reassembly. 76841 Upper Thrust Race Thrust Bearing. Discard cotter pin. 22099 Link Bar Cotter Pin. Apply Loc- tite 271 to outside diameter of seal before installation. Install cotter pin and spread ends. 22099 Link Bar Shift Lever. Remove remaining components. 76861 Standard Bravo Shown Drive Gear and Bearing Assembly Washer CAUTION DO NOT damage spacer when removing first bearing from pinion gear, spacer must be used in reassembly.