. OPERATION & MAINTENANCE MANUAL 7.4L Bravo Three 1995, Brunswick Corporation 60 595. MerCruiser Dealer about service, always specify model and serial numbers. The description and specifications contained herein were in effect at the time this guide was approved for printing.

• Mercruiser Bravo Iii Lower Unit
• Mercruiser Bravo Iii Outdrive
• Mercruiser Bravo Iii Shift Cable

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Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incurring obligation. 2 71350 ABC12345Z123 7175 71360. CB390 Table Of Contents Page Welcome!. Read This Manual Thoroughly. Page Maintenance.Maintenance Aids. CA165 Welcome! You have selected one of the finest marine power packages available.

It in- corporates numerous design features to assure operating ease and durabil- ity. With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

DOWNLOAD MERCRUISER ENGINE & STERNDRIVE REPAIR MANUALS. 1963-1973 MerCruiser Repair Manual Engines & Drives. Mercury Mercruiser 4.3L MPI Alpha and Bravo Service.

CA166 Read This Manual Thoroughly IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR DEALER FOR A DEMONSTRATION OF ACTUAL STARTING AND OPERATING PROCEDURES. NOTICE Throughout this publication, and on your power package, WARN- INGS and CAUTIONS, accompanied by the International Hazard Symbol, may be used to alert the installer/user to special instruc- tions concerning a particular service or operation that may be haz. CA280 Lanyard Stop Switch 74608 Some boats come equipped with a lanyard stop switch. A lanyard stop switch can also be installed as an accessory. The purpose of this switch is to turn off the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. ADVANTAGES: The purpose of a lanyard stop switch is to stop the engine ignition whenever the operator (when attached to the lanyard) moves far enough away from the operator’s position to activate the switch. This would occur if the operator falls or moves within the boat a sufficient distance from the operator’s position.

CA281 Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.

Courses are offered in the U.S.A. Know signs of weather change and avoid foul weather and rough-sea boating. 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.

Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 25 miles per hour (40 km/hr) in 5 seconds will overtake a fallen skier who was 200 feet in front of you. Watch fallen skiers.

For additional information, obtain a copy of our “Hi-Performance Boat Operation” booklet (Part Number 90-86168-3) from your dealer, distributor, or Mercury Marine. Conditions Affecting Operation Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) will: Generally increases speed and engine RPM. 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 Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or propeller.

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. IMPORTANT: The engines covered in this manual are equipped with an RPM rev-limiter that is set to an upper (or limited) RPM amount.

This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from ex- cessive engine RPM. CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle pow- er of an engine. 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. CA13 Important Information Operation And Maintenance OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks; to en- sure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized Mer- Cruiser Dealer for a periodic checkup. CA15 Freezing Temperature Operation IMPORTANT: It boat is operated during periods of freezing tem- perature, precautions must be taken to prevent freezing dam- age to power package.

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. CA18 Attention Required After Submersion Before recovery, contact a MerCruiser Dealer. 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”. Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported.

This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors. CA22 Replacement Service Parts WARNING Electrical, ignition and fuel system components on MerCruiser gasoline power packages are designed and manufactured to comply with U.S. Coast Guard rules and regulations to minimize risks of fire or explosion. 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. CA23 Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of machinery.

Electronic ig- nition and special carburetion provide greater fuel economies, but also are more complex for the untrained mechanic. CA24 20-Hour Break-In Period IMPORTANT: The first 20 hours of operation is the engine break-in period. 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. CB270 20-Hour Checkup After first 20 hours of operation, an Authorized MerCruiser Dealer should be contacted for the following maintenance.

The boat owner is responsible for any charges. Change crankcase oil and filter. Retorque intake manifold to 35 lb.ft. Check all fluid levels.

CA26 6 7 2 0 9. CA27 Operation Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instru- ments and their functions on the boat.

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. CB218 8 71987. CB200 Audio Warning System Your MerCruiser power package is equipped with an Audio Warning System. 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. CB125 5 8 6.

CA30 Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. 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. CB182 Remote Controls (Panel Mounted) Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. If boat is equipped with a remote control oth- er than shown, consult your dealer for a description and/or demon- stration of the control. CB184 Remote Controls (Console Mounted) Control Handle(s) - Operation of the the shift and throttle are controlled by the movement of the control handle. “Push” the control handle forward from “Neutral” with a quick firm motion to the first det- ent for “Forward”.

CB186 Remote Controls (Two Lever) Shift Lever - shifts unit into gear with full lever movement. 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.

Mercruiser Bravo Iii Lower Unit

CA34 3 - 5 71338. CA284 Power Trim Power Trim allows the operator to adjust the drive angle, while under- way, to provide the ideal boat angle for varying load and water condi- tions. 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. CB188 POWER TRIM OPERATION - PANEL MOUNT REMOTE CONTROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. 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. CA285 POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON AND THREE BUTTON VERSIONS) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute. CB192 0 70540. CB193 POWER TRIM OPERATION - THREE BUTTON TRIM PANEL (USED ON MODELS WITHTWO-LEVER CONTROL) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button(s) and allow motor to cool for about one minute.

CA40 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five min- utes to remove any explosive fumes from engine compartment. 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). FLOODED ENGINE - Move control/throttle lever to full throttle. 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.

Move control/ throttle lever back to decrease engine RPM to 1000-1500 RPM if necessary. CA41 Operation Chart BEFORE AFTER WHILE AFTER STARTING STARTING UNDERWAY STOPPING Open engine Observe all Observe all Turn ignition hatch. Gauges to gauges to key OFF.

Monitor check engine condition of condition. If not normal, stop engine. Turn battery Check Turn bat- switch ON, if so.

CA261 Specifications Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your en- gine seriously. 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. The fuel system components on your MerCruiser engine will with- stand up to 10% alcohol content in the gasoline. 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). Quicksilver Gasoline Stabilizer for Marine Engines (92-817529A12) is highly recommended for addition during storage periods.

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. CB175 Engine Specifications 7.4L Bravo Three MODEL Propshaft Horsepower Propshaft Kilowatts 454 C.I.D. Displacement (7.4 L) Engine Type 4.25 in. Bore (108mm) 4.00 in. Stroke (101.6mm) Compression Ratio 8.6:1 150 psi Compression Pressure (1035 kPa) Maximum RPM @ 4200-4600 RPM.

CB391 Tune-Up Specifications 7.4L Bravo Three MODEL AC-MR43T or Spark Plug Type Champion RV15YC4 or NGK BR6FS Spark Plug Gap.035 in. (.9mm) Timing @ Idle RPM 10 BTDC Firing Order 1-8-4-3-6-5-7-2 Electrical System 12-Volt Negative (-) Ground Alternator 55 Amps. CB19 Capacities 7.4L Bravo Three MODEL Crankcase Oil 7 U.S.

Capacity (6.6 L) w/New Filter Drive Unit Oil Capacity 3 U.S. (2.9 L) (w/Reservoir) Seawater Cooling 20 U.S. System (18.9 L) 28 U.S. Closed Cooling (26.5 L) System Always use dipstick to determine exact quantity of oil required. CA290 Maintenance WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to your- self or damage to electrical system.

IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed. Some list- ings can be done by owner/operator, while others should be performed by an Authorized MerCruiser Dealer. Crankcase Oil - Quicksilver 4-Cycle Marine Engine Oil (Refer to SPECIFICATIONS for alternatives and oil recommendations for va- rying ambient temperatures.) Closed Cooling System Coolant - 50/50 mixture of ethylene glycol antifreeze (must meet GM specification 1825 M) and tap water. Areas where temperatures generally do not go below 32 F (0 C), rust inhibitor and tap water is acceptable.

CB26 Maintenance Chart Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR TASK INTERVAL Engine Crankcase Oil - Check level Closed Cooling Coolant - Check level Power Steering Fluid - Check level Stern Drive Unit Oil - Check level Battery - Check level. CB27 Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR TASK INTERVAL Drive Belts (All) - Every 100 Hours of Operation or Inspect condition and 120 Days, Whichever Occurs First. Check tension Propeller Shaft - Saltwater use: Every 50 Hours of Lubricate.

CB258 Only perform maintenance which applies to your particular power package. 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. CB29 Only perform maintenance which applies to your particular power package.

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. CB254 Only perform maintenance which applies to your particular power package. 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. CB33 3 3 6 5. CA54 Checking Fluid Levels CHECKING CRANKCASE OIL Stop engine. 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. CB40 CHECKING DRIVE UNIT OIL Check gear lube monitor oil level; keep oil level at or near “Fill” line.

Check for water at bottom of monitor and/or if oil appears a milk- tan, contact your Authorized MerCruiser Dealer immediately; both conditions indicate a water leak somewhere in the drive unit. CA63 Changing Fluids See MAINTENANCE CHART for lubricant change frequency. 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. CB49 CHANGING DRIVE UNIT OIL IMPORTANT: Use only Quicksilver High Performance Gear Lube in drive unit. Place drive unit in full trim limit (out) position, remove OIL FILL/ DRAIN SCREW and sealing washer.

Remove OIL VENT screw and sealing washer. Allow oil to drain completely. CB79 3 71169.

CB82 Water Separating Fuel Filter WARNING Be careful when changing water separating fuel filter. 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. CB177 4 6 71359. CA286 Lubrication STEERING SYSTEM If Steering Cable Has Grease Fittings: With cable fully retracted into cable housing, lubricate fitting with 2-4-C Marine Lubricant with Teflon.

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. CB372 DRIVE UNIT AND TRANSOM ASSEMBLY Lubricate gimbal bearing with Quicksilver U-joint and Gimbal Bearing Grease. For propeller shaft lubrication, see PROPELLER. NOTE: Engine coupling and shaft splines are greased with Quicksil- ver Engine Coupler Spline Grease, P/N 92-816391A4; universal joints are greased with Quicksilver U-joint and Gimbal Bearing Grease. CB373 72239. Periodically check propeller nut for tightness during boating season.

A minimum of 55 lbs. (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. CB150 72239.

CB345 INSTALLATION (BRAVO THREE) Apply a liberal coat of one of the following Quicksilver lubricants to both propeller shafts: Special Lubricant 101, 2-4-C Marine Lubri- cant with Teflon, or Anti-Corrosion Grease. Slide forward thrust hub onto propeller shaft, with tappered side toward propeller hub (Toward end of shaft). CB65 Flushing Cooling System WARNING When flushing, be certain the area around propeller is clear, and no one is standing nearby. To avoid possible injury, remove pro- peller. CAUTION Do not run engine above 1500 RPM when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine and/or drive unit to overheat. CB71 Cleaning Seawater (Raw Water) Section Of Heat Exchanger And Oil/Power Steering Cooler - Closed Cooling Models Only Seawater sections of heat exchanger and oil/power steering cooler should be cleaned at least once a year or whenever decreased cool- ing efficiency is noticed.

HEAT EXCHANGER Remove end plate(s), O-rings and gaskets. CB75 3 1 70563. CB77 Drive Belts WARNING Make sure engine is shut off and ignition key is removed before inspecting belts. 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. CB88 7 70578.

CB383 Corrosion And Corrosion Protection Whenever two or more dissimilar metals (like those found on the stern drive) are submerged in a conductive solution, such as saltwa- ter, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between met- als. CB384 4 72029. A Remove two screws from each anode. B Install new anodes and tighten securely. 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.

CB392 74631. CA168 In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: IMPORTANT: Corrosion damage that results from the improper application of anti-fouling paint will not be covered by the lim- ited warranty. 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. CA103 Miscellaneous Maintenance Battery All lead acid batteries discharge when not in use. 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. CA104 Bottom Of Boat To maintain maximum speed, the following conditions of the boat bot- tom should be observed: Clean, free of barnacles and marine growth.

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. CA278 Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT: This service should be performed by an Autho- rized MerCruiser Dealer. 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.

Remove flame arrestor and restart engine. 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. CB241 74073. CB242 Draining Instructions DRAINING SEAWATER (RAW-WATER) COOLED MODELS 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 flow from the drain holes or removed hoses. CB108 Loosen hose clamps and remove the following hoses: From engine circulating pump. From oil/power steering fluid cooler.

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.

CB111 70583. CB112 DRAINING CLOSED COOLING (COOLANT) MODELS IMPORTANT: Drain seawater section of closed cooling system only.

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. CB117 Loosen hose clamps and remove the following hoses: NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do not allow en- gine to start.

CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. 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.

CB215 Troubleshooting Starter Motor Will Not Crank Engine, Or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neu- Position control lever in tral position.

Open circuit breaker or Check and reset circuit blown fuse. Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Improper starting proce- Read starting procedure. Empty fuel tank or fuel Fill tank or open valve.

Shutoff valve closed. Faulty fuel pump. Check sight tube for fuel. Have Authorized Mer. Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Choke not operating prop- Check that choke is closed erly.

When engine is cold. Check that it opens when engine warms up. Idle speed too low. Check idle speed and ad- just, if necessary. Excessive Engine Temperature Possible Cause Remedy Seacock closed. Drive belt loose or in poor Replace and/or adjust belt.

Seawater pickups Remove obstruction. Faulty thermostat. Coolant level low in closed Check for cause of low cooling section coolant level and repair. Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crank- Check and add oil. Check and remove re- Excessive oil in crankcase quired amount of oil. Check (causing it to become for cause of excessive oil aerated).

(improper filling, bad fuel pump, etc.). Remote Control Operates Hard, Binds, Has Excessive Free–play Or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on Lubricate. Shift and throttle linkage fasteners. Loose or missing shift and Check all linkages. If any throttle linkage fasteners.

Are loose or missing, see Authorized MerCruiser Dealer immediately. Power Trim Does Not Operate (Motor Doesn’t Run) Possible Cause Remedy Blown fuse.

Replace fuse. Loose or dirty electrical Check all associated elec- connections or damaged trical connections wiring. Wires (especially battery cables).

Clean and tighten faulty connection. Repair or replace wiring. Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move) Possible Cause. CA262 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Regis- tration Card completely and mails it to the factory immediately upon sale of the new product.

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. International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Regis- tration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. Warranty Policies Mercruiser Limited Warranty - Gasoline Engines UNITED STATES AND CANADA ONLY I. We warrant each new production (not those made for high per- formance purposes) MerCruiser Stern Drive Power Package, Inboard Engine and accessories attached thereto, (hereafter referred to as “Product”) to be free from defects in material and workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us. Claim shall be made under this warranty by delivering the Prod- uct for inspection to a MerCruiser dealer authorized to service the Purchaser’s product. If purchaser cannot deliver Product to such authorized dealer, he may give notice in writing to the Company. Mercruiser International Warranty - Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA I.

We warrant each new production (not those made for high per- formance purposes) MerCruiser Stern Drive Power Package, Inboard Engine and accessories attached thereto, (hereafter referred to as “Product”) to be free from defects in material and workmanship, but only when the consumer sale is made in the country to which distribution is authorized by us. Purchaser must provide “proof of purchase” and substantiate “date of purchase” by presenting the “Purchaser’s Copy” of the “Warranty Registration Card” or the plastic “Warranty Registra- tion Card” to the dealer authorized to service the Product.

Lf ei- ther of these items is not available purchaser must provide a copy of the original ”Bill of Sale”. 3 Year Limited Warranty Against Corrosion Failure (Applicable In The United States, Canada And Australia) I. We warrant parts and assemblies of each 1988 and newer pro- duction MerCruiser (Product) sold with a one year limited Prod- uct warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inopera- tive as a direct result of corrosion, provided the following simple precautionary steps which are specified in Owner’s Manuals. Warranty, contained in this manual, which paragraphs are in- corporated herein by reference. 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. OWNER’S RESPONSIBILITY Protection against certain types of corrosion damage must be pro- vided by using such systems as the Quicksilver MerCathode System and/or Galvanic Isolator.

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. Warranty Does Not Apply To The Following: Minor adjustments and tune-ups, including checking, cleaning or adjusting spark plugs, ignition components, carburetor settings, filters, belts, controls, and checking lubrication made in connec- tion with normal services.

Damage caused by neglect, lack of maintenance, accident, ab- normal operation or improper installation or service. Engine noise does not necessarily indicate a serious engine prob- lem. If diagnosis indicates a serious internal engine condition which could result in a failure, condition responsible for noise should be corrected under the warranty. Lower unit and/or propeller damage caused by striking a sub- merged object is considered a marine hazard. Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership. In the United States and Canada, mail to: Mercury Marine Attn: Warranty Registration Department W6250 West Pioneer Road P.O.

United States And Canada Only (Certain performance products,triple engine installations, and com- mercial applications are excluded) The Mercury Marine Q-Guard Product Protection Plan provides cov- erage against unexpected mechanical and electrical breakdowns that may occur beyond the standard limited warranty. Only Authorized Dealers can pur- chase genuine Quicksilver parts and accessories from the factory. 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. Resolving A Problem Your satisfaction and goodwill are of primary importance to your dealer and to MerCruiser. 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.

Please bear in mind that Service Centers resolve all problems through the dealership using the dealer’s facilities, equipment and personnel. 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. UNITED STATES MerCruiser 3003 N. Perkins Road Stillwater, OK Telephone (405) 743-6566 Fax (405) 743-6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga, Ontario L4Y 2C2 Canada Telephone (416) 270-4481 Fax (905) 270-4510 MEXICO, CENTRAL AMERICA, SOUTH AMERICA, CARIBBEAN Marine Power International 9350 SW 72nd St. AUSTRALIA, PACIFIC Marine Power International Pty.

P.O.Box 80,132-140 Frankston Road Dandenong, Victoria 3175 Australia Telephone (61) (3) 791-5822 Fax (61) (3) 791-5880 ASIA Marine Power International Ltd. Block 1002 Jalan Bukit Merah #07-08 Redhill Industrial Estate JTC Flatted Factories Singapore 0315 Telephone (65) 270-7680 Fax (65) 270-7898. Customer Service Literature English language publications are available from: Mercury Marine Attn: Publications Department W6250 West Pioneer Road P.O. Box 1939 Fond du Lac, WI Outside the United States and Canada, contact the nearest Ma- rine Power International Service Center for further information.

CB393 General Maintenance Parts Engine Parts Part 7.4L Bravo III Oil Filter 14957 Spark Plug 33-59571 Distributor Cap 805759A2 Ignition Coil 392-805570A2 Spark Plug Wire Set 84-816608A61 Thermostat (160 F) 807252-2 Thermostat Gaskets 27-33179-2 27-53045-1 Alternator Belt 57-48122 Power Steering Belt 57-816295T (7”. Drive Parts Part Bravo III Front Propeller Nut 11-805092 Rear Propeller Nut 11-805093 Front Thrust Hub 11-805100T Rear Thrust Hub 11-805101T Decal Set 37-15167A90 D.S.H. Anodic Plate 821630A1 Anodic Plate (Propeller) 76214A5 Trim Cylinder Anodes 806190A1 Gimbal Housing Anode 821631A1 Drain Screw 10-14834A1 Drain Screw O-Ring. CC172 Literature Order Form Model Horsepower Serial Number Year Service Manual - shows the complete assembly and disassembly of the engine or stern drive. 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. Please Return with Payment to: Mercury Marine Attn: Publications Dept.

Box 1939 Fond du Lac, WI Ship To: (Please Print or Type - This is your Shipping Label) Name Address City State METHOD OF PAYMENT: (NO CASH OR C.O.D.).

NOTE: Not all models listed below, see links for additional MerCruiser Models Mercruiser GM V8 454 cid 7.4L 502 cid 8.2L Service Manual Service Manual Application: Gen. VI Engines Sterndrive (MCM) Models: MCM 454 Mag MPI (Serial Number 0L010029 & Up), MCM 502 Mag MPI (Serial Number 0L017000 & Up). Inboard (MIE) Models: MIE 454 Mag MPI Horizon (Serial Number 0L002200 & Up), MIE 8.2L MPI (Serial Number 0L002450 & Up).

L-29 Engines - Sterndrive (MCM) Model: MCM 7.4L MPI (Serial Number 0L010003 & Up). Inboard (MIE) Model: MIE 7.4L MPI (Serial Number 0L002006 & Up). 1 Service Manual Applications: 2001, 2002, 2003, 2004, 2005 and 2006 Mercury MerCruiser 5.0L, 5.7L, 6.2L MPI Gasoline Multiport Injection Engine. Service Manual #31 Part Number 90-864260.

Exact model application: Models Application: Sterndrive (MCM) starting with serial number OM300000 and above, 5.0L MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo, 350 MAG MPI Alpha and Bravo Horizon, MX 6.2 MPI, MX 6.2 MPI Horizon, Inboard and Dow Sports (MIE) starting with serial number OM310000, 350 MAG MPI Inboard, 350 MAG MPI Horizon Inboard, MX 6.2 MPI Inboard, MX 6.2 MPI Horizon Inboard and 350 MAG MPI Tow Sports. 1983-1990 MerCruiser R MR Alpha One & Alpha SS Sterndrive Manual Service Manual Application: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 MerCruiser #6 Service Manual for Sterndrive Units R-MR-Alpha One & Alpha One SS, MC 120R/140B/185R/488R/898R/228R/260R Serieal Number - 62289, MC 120MR/140MR/170MR/185MR/190MR/200MR/230MR/260MR/300 Tempest MR Serieal Number - 6849290 0A471374, MC Alpha One/Alpha One SS Serieal Number 0A471375 and Above. 1988-1998 MerCruiser Bravo Sterndrives Service Manual Sterndrive Service Manual Application: 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 & 1998 MerCruiser #11 Bravo, Bravo One Sterndrive Unit Serial # B664190 and Above, Bravo Two Sterndrive Unit Serial # B892613 and Above, Bravo Three Sterndrive Unit Serial # D763691 and Above, Bravo Transom Assembly (Standard) Serial #.

B673048 and Above, Bravo Transom Assembly (High Performance) Serial # D796083 and Above, Bravo Transom Assembly (Magnum) Serial # K104738 and Above. Some Standard Bravo Transom Assemblies could have been converted to High Performance Transom Assemblies by use of a High Performance Gimbal Ring Kit (822374A2). Refer to Transom Assembly sections of this manual for identification information. 1991 2007 MerCruiser ALPHA 1 Gen 2 Sterndrive Service Manual Service Manual Application: Mercury Mercruiser Service Manual #14 (#-14, Number 14) 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 & 2007 Alpha 1 Generations II (Gen 2, Gen II, Gen Two) Outdrive, Sterndrive (Stern Drive) Unit. Mercury Mercruiser Bravo + Sport Master Service Repair Manual Service Manual Application: All Bravo Models (Serial Number 0M100000 and Above) + Sport Master Models (Serial Number 0M052945 and Above). Mercury Mercruiser Bravo One,Two,Three + Transom Service Manual Service Manual Application: Bravo One, Bravo One X, Bravo One X Diesel, (Serial Number 0M198373 and Above).

Bravo One XR (Serial Number 0W240000 and Above). Bravo Two, Bravo Two X, Bravo Two X Diesel, Bravo Three, Bravo Three X, Bravo Three X Diesel (Serial Number 0M198373 and Above). Bravo Three XR (Serial Number 0W240000 and Above).

Transom Standard (Serial Number 0W173658 and Above) Transom High Performance(Serial Number 0W150260 and Above) Mercury Mercruiser D1.7L DTI Service Repair Manual Service Manual Application: D1.7L DTI ( Serial Number OM055001 and Above) Mercury Mercruiser In-ine Diesel D2.8L D4.2L D-Tronic Manual Service Manual Applicaiton: Sterndrive (MCM) Models: D2.8L D-Tronic (Serial Number 0K000001 and Above), D4.2L D-Tronic (Serial Number 0K000001 and Above). Inboard (MIE) Models: D2.8L D-Tronic (Serial Number 0K000001 and Above), D4.2L D-Tronic (Serial Number 0K000001 and Above). Introduction These manuals contains an introductory description on and procedures for the inspection, service and overhaul of its main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning the inboard engine or stern drive.

Read and refer to the other sections in this manual for information regarding proper inspection and service procedures. These manuals have been prepared using the latest information available at the time of publication. If a modification has been made since then, differences may exist between the content of these manuals and the actual inboard or stern drive. Illustrations in these manuals are used to show the basic principles of operation and work procedures. These manuals are intended for use by technicians who already possess the basic knowledge and skills to service inboard or stern drive motors and components. Persons without such knowledge and skills should attempt with caution to service any component or engine by relying on this manual only.

Never attempt to perform any work with out the assistance of a service manual. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may or may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers. Maintenance Schedules NOTE: Only perform maintenance which applies to your particular power package. Maintenance Intervals Maintenance intervals and the corresponding tasks to be performed, as shown in this current schedule or as found in a previously printed schedule, are generally based on an average boating application and environment. However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and the corresponding tasks to be performed.

In some cases, this may allow for more individual tasks in a single visit to the servicing dealer. Therefore, it is very important that the boat owner and the servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, the environment and the maintenance requirements. Routine Maintenance Check the crankcase oil (interval can be extended based on experience).

If operating in salt, brackish or polluted waters, flush the cooling system after each use. Check the drive unit oil level, the trim pump oil level and the power steering pump fluid level. Check the water inlets for debris or marine growth. Check the seawater strainer and clean. Check the coolant level. Inspect the drive unit anodes and replace if 50 percent eroded.
Lubricate the propeller shaft and retorque the nut (if operating in only freshwater, this maintenance may be extended to every four months).

Mercruiser Bravo Iii Outdrive

Operating in Saltwater Only: treat the engine surface with corrosion guard.
Check the battery connections and the fluid level.
Ensure that the gauges and the wiring connections are secure.

Clean the gauges. Scheduled Maintenance Touch-up paint the power package and spray with corrosion guard. Change the crankcase oil and filter.
Change the drive unit oil and retorque the connection of the gimbal ring to the steering shaft. Replace the fuel filters.

Check the steering system and the remote control for loose, missing or damaged parts. Lubricate the cables and the linkages. Inspect the U-joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U-joint splines. Lubricate the gimbal bearing and the engine coupler.

Mercruiser Bravo Iii Shift Cable

Check the continuity circuit for loose or damaged connections. Test the MerCathode unit output on Bravo Models. Retorque the engine mounts.
Check the spark plugs, the wires and the distributor cap.

Clean the flame arrestor and the crankcase ventilation hoses. Replace the PCV valve.

Check the electrical system for loose, damaged or corroded fasteners. Inspect the condition and the tension of the belts.
Check the cooling system and exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. Disassemble and inspect the seawater pump and replace worn components.

Clean the seawater section of the closed cooling system. Clean, inspect and test the pressure cap.

Replace the coolant. Crankcase Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W-40 Marine Engine Oil. This oil is a special blend of 25-weight and 40-weight oils for marine engines.

If not available, a good grade, straight weight, detergent automotive oil of the correct viscosity, with an API classification of SH, CF/CF-2, may be used. In those areas where Quicksilver 4-Cycle 25W-40 Marine Engine Oil or a recommended straight weight oil are not available, a multi-viscosity 20W-40 or, as a second but less preferable choice, 20W-50, with API service ratings of SH, CF/CF-2 may be used. IMPORTANT: The use of non-detergent oils, multi-viscosity oils (other than Quicksilver 25W-40 or a good quality 20W-40 or 20W-50), synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. The chart below is a guide to crankcase oil selection. The oil filter should always be changed when changing the engine oil.

Used Spark Plug Analysis Spark plug condition can suggest a variety of possible engine malfunctions and indicate needed engine repairs. When the old plugs are replaced, replace the entire set. Perform plug service only on those plugs suitable for additional service, using the following procedures: 1. Remove any oil deposits with solvent and dry plugs thoroughly.

Open the electrode gap wide enough to permit cleaning and filing. Remove the combustion deposits from the firing end of the spark plug with a plug cleaner.

Use compressed air to remove abrasives. File the electrode surfaces to restore clean, sharp edges. Remove filings with compressed air. Reset the gap to specifications by bending only the side electrode with the proper tool. Normal Condition Few deposits are present and probably will be light tan or gray in color.

This plug shows that the plug heat range is compatible with the engine, and the engine is electrically and mechanically in good running condition. With proper plug servicing (clean, file and regap), this plug can be reinstalled with good results. Wet Fouling (Oil Deposits) The plug becomes shorted by excessive oil entering the combustion chamber, usually in the engine with many hours of operation. Worn piston rings, cylinder walls, valve guides or valve stem seals are causes of oil entering the combustion chamber. Only engine repairs will permanently relieve oil wet fouling. IMPORTANT: New engines or recently overhauled engines may wet foul the plugs before normal oil control is achieved with proper break-in procedures.

Such fouled plugs may be serviced (clean, file and regap) and reinstalled.