Page 1 Module H of Directive 2003/44/EC is: Det Norske Veritas Norway Notified Body Number: 0575 This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser. Patrick C. Mackey President ‑ Mercury Marine, Fond du Lac, WI USA...
Page 2 Exhaust Gas Emissions Certification Number The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury MerCruiser® power package. When contacting your Authorized Mercury 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.
Page 3: Read This Manual Thoroughly
We suggest that this manual remain with the product for ready reference whenever you are on the water. Thank you for purchasing one of our Mercury MerCruiser products. We sincerely hope your boating will be pleasant!
Page 4 WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
Page 5: Table Of Contents
Mercury Product Protection Plan: United States and What Mercury Will Do........13 Canada..............3 What Is Not Covered........13 Mercury MerCruiser Limited Warranty (Gasoline- Components Of The Emission Control System 13 Fueled Products Only) ..........4 Disclaimers And Limitations......14 3-Year Limited Warranty Against Corrosion....6 California Emission Control Warranty Statement.
Page 6 Starting and Stopping the Engine....47 Passenger Safety In Pontoon Boats And Deck Starting the Engine........47 Boats..............53 Stopping the Engine........48 Boats Having An Open Front Deck....53 Starting Engine After Stopped While In Boats With Front-Mounted, Raised Pedestal Gear..............
Page 7 Power Steering Fluid..........74 Engine Coupler..........90 Checking............74 Driveshaft Extension Models......90 Filling..............75 Propellers..............91 Changing............75 Propeller Repair..........91 Engine Coolant............75 Bravo Sterndrive Propeller Removal....91 Checking............75 Bravo One Models........91 Filling..............76 Bravo Two Models........93 Changing ............76 Bravo Three Models........94 Drive Unit Oil............76 Bravo Sterndrive Propeller Installation...96 Checking............76 Bravo One Models........96 Filling..............77...
Page 8 Poor Performance..........131 Steering Wheel Turns Hard Or Jerky....132 Excessive Engine Temperature......131 Power Trim Does Not Operate (Motor Does Not Insufficient Engine Temperature......132 Operate).............133 Low Engine Oil Pressure........132 Power Trim Does Not Operate (Motor Operates But Battery Will Not Come Up On Charge....132 Sterndrive Unit Does Not Move)......133 Remote Control Operates Hard, Binds, Has Excessive Free-play Or Makes Unusual...
Page 9 Mercury Product Protection Plan: United States and What Is Not Covered ........13 Canada..............3 Components Of The Emission Control System Mercury MerCruiser Limited Warranty (Gasoline- ..............13 Fueled Products Only) ......... 4 Disclaimers And Limitations ......14 3-Year Limited Warranty Against Corrosion..6...
Page 10: Warranty Registration: United States And Canada
A temporary Owner Warranty Registration Card will be presented to you when you purchase the product. Upon receipt of the Warranty Registration Card at the factory, Mercury MerCruiser will send you an owner resource guide that includes your warranty registration confirmation. If you do not receive your owner resource guide within 60 days from date of new product sale, please contact your selling dealer.
Page 11: Transfer Of Warranty
Section 1 - Warranty The warranty registration card identifies your name and address, product model and serial numbers, date of sale, type of use, and the selling distributor’s and dealer’s code number, name, and address. The distributor or dealer also certifies that you are the original purchaser and user of the product.
Page 12: Mercury Mercruiser Limited Warranty (Gasoline-Fueled Products Only)
One‑, two‑, three‑, four‑, or five‑ year term plans can be purchased up to 12 months after the original engine registration date. See your participating Mercury MerCruiser dealer for complete program details. Mercury MerCruiser Limited Warranty (Gasoline‑Fueled Products Only)
Page 13 Section 1 - Warranty Conditions That Must Be Met in Order to Obtain Warranty Coverage Warranty coverage is available only to retail customers that purchase from a dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the pre‑delivery inspection process specified by Mercury Marine is completed and documented.
Page 14: 3-Year Limited Warranty Against Corrosion
Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing, Sport Jet, M Jet Drive, Tracker by Mercury Marine Outboard, MerCruiser Inboard or Sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
Page 15: 4-Year Limited Corrosion Warranty: Seacore Sterndrive Models With Gas Engines
This limited corrosion warranty provides coverage for four (4) years from either the date on which the MerCruiser SeaCore engine, transom, and sterndrive package is first sold or the date on which it is first put into service, whichever occurs first. The repair or replacement of parts or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
Page 16: Global Warranty Charts
Section 1 - Warranty This limited warranty does not cover the following: • Electrical system corrosion • Corrosion resulting from damage • Corrosion that causes purely cosmetic damage • Abuse or improper service • Corrosion to accessories, instruments, and steering systems •...
Page 17: Commercial Application Warranty Chart
Section 1 - Warranty Commercial Application Warranty Chart Limited Corrosion Commercial Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...
Page 18: Government Application Warranty Chart
Section 1 - Warranty Government Application Warranty Chart Limited Corrosion Government Application: Standard Factory Limited Warranty by Region & Boat Brand Warranty Non-Certified Boat Brand Certified Boat Brand All Boat Brands Standard Region Standard SeaCore Horizon Standard SeaCore Horizon SeaCore Scorpion Scorpion Horizon...
Page 19: Mercury Installation Quality Certification Program 10 California Emissions Limited Warranty
California Emissions Limited Warranty NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 20: Duration Of Coverage
Duration Of Coverage NOTE: Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model...
Page 21: What Mercury Will Do
Section 1 - Warranty What Mercury Will Do Mercury Marine's sole and exclusive obligation under this warranty is limited to, at our expense and at our option, repairing or replacing defective parts with new or Mercury Marine certified re‑manufactured parts, or refunding the purchase price of the Mercury product.
Page 22: Components Of The Emission Control System 13 Disclaimers And Limitations
Mercury Marine. 1. Mercury Marine does not establish model years for the Mercury MerCruiser product line. In order to comply with CARB warranty regulations, and for that limited purpose only, model year shall have the same meaning as calendar year. As an example, 2003 model year products refers to products manufactured during calendar year 2003.
Page 23: Owner's Warranty Responsibilities
A tamper‑resistant Emission Control Information label is affixed in a visible location to the engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions statement, the label lists the engine serial number, family, FEL (emission level), date of manufacture (month, year), and the engine displacement.
Page 24: Owner Responsibility
Beginning January 1, 2003, one Three‑Star label will be included with each factory‑certified Mercury MerCruiser engine. All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low Emission rating. The Three‑Star label identifies that these engines meet the California Air Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission standards.
Page 25 Section 1 - Warranty The Three‑Star label will be affixed on the left side of the hull as shown. XX 1234 XX mc79531 Recommended location Secondary location One Star - Low emission The one‑star label identifies personal watercraft, outboard, sterndrive and inboard engines that meet the Air Resources Board's Personal Watercraft and Outboard marine engine 2001 exhaust emission standards.
Page 26 Section 1 - Warranty Notes: Page 18 90-864839061 NOVEMBER 2006...
Page 27: Section 2 - Getting To Know Your Power Package
Section 2 - Getting to Know Your Power Package Section 2 - Getting to Know Your Power Package Table of Contents Identification............20 Slim Binnacle Console Mount Features - Single Engine Serial Number Decal......20 Engine............31 Bravo Sterndrive Serial Number and Console Mount Features- Dual Engine..32 Identification..........20 Synchronizing Dual Engines......33...
Page 28: Identification
Section 2 - Getting to Know Your Power Package Identification The serial numbers are the manufacture's keys to numerous engineering details which apply to your MerCruiser power package. When contacting MerCruiser about service, always specify model and serial numbers. Engine Serial Number Decal The serial number decal is located on top of the engine.
Page 29: Bravo Transom Serial Number
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for authorized MerCruiser Dealers. 25907 Bravo sterndrive serial number stamping...
Page 30: Lanyard Stop Switch
Section 2 - Getting to Know Your Power Package The serial number is also stamped on the gimbal housing. This is used as a permanent reference for authorized MerCruiser Dealers. 25905 Gimbal housing with serial number stamping Transom assembly serial Number...
Page 31: Instrumentation
Section 2 - Getting to Know Your Power Package The lanyard is a cord usually between 122 and 152 cm (4 and 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and a snap on the other end for attaching to the operator.
Page 32: Digital Gauges
Section 2 - Getting to Know Your Power Package Your power package may be connected to the Mercury SC5000 SmartCraft System View display. The display monitors and reports information ranging from basic operating data to engine alarm data. The SC5000 System View Display is a comprehensive boat information center. System View allows the boat operator to receive a wealth of critical operational information, displayed clearly and instantly at the helm on the LCD display.
Page 33: Analog Gauges
Section 2 - Getting to Know Your Power Package Analog Gauges The following is a brief explanation of the instrumentation typically found on some boats. The owner/operator should be familiar with all instruments and their functions. Because of the large variety of instrumentation and manufacturers, you should have your boat dealer explain the particular gauges and normal readings for your boat.
Page 34: Panel Mount Features
Section 2 - Getting to Know Your Power Package PANEL MOUNT FEATURES mc77019-1 Neutral lock button Control handle tension adjustment screw Throttle only button Control handle Lanyard stop switch Trim/tilt button Neutral Lock Button - Prevents accidental shift and throttle engagement. Neutral lock button must be pushed into move the control handle out of neutral.
Page 35: Console Mount Features
Section 2 - Getting to Know Your Power Package CONSOLE MOUNT FEATURES mc79503-1 Throttle Only Button Power Trim Switch Control Handle Trailer Switch Throttle Only Button - Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle only button can be depressed only when the remote control handle is in the neutral position.
Page 36: Zero Effort Features
Section 2 - Getting to Know Your Power Package Zero Effort Features 5656 Shift ever Trim/tilt switch Throttle lever Shift Lever - Shift functions are controlled by the movement of the shift lever. Shift into reverse by moving the shift lever to its aft position. Shift into neutral by moving the shift lever to its center position.
Page 37: Panel Mount Features
Section 2 - Getting to Know Your Power Package Panel Mount Features 3409 Lanyard stop switch Control handle Shift lock Trim/tilt switch Throttle only button Start/stop button Detent tension adjustment screw Control handle friction adjustment screw Lanyard Stop Switch - Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch.
Page 38: Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Console Mount Features ‑ Single Engine 3410 Control handle Trim/tilt switch Active light Neutral light Select key Arrow trackpad Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 39: Slim Binnacle Console Mount Features - Single Engine
Section 2 - Getting to Know Your Power Package Slim Binnacle Console Mount Features ‑ Single Engine START STOP 14637 Control handle Trim/tilt switch Active light Neutral light Start/stop button Throttle only/station select key Detent tension adjustment Control handle friction adjustment screw Control Handle - Operation of the shift and throttle are controlled by the movement of the control handle.
Page 40: Console Mount Features- Dual Engine
Section 2 - Getting to Know Your Power Package Console Mount Features‑ Dual Engine SYNC ACTIVE THROTTLE ONLY STATION SELECT 3411 Trim/tilt switch Arrow trackpad Control handles Sync light Active light Throttle only/station select key Neutral light Detent tension adjustment Select key Control handle friction adjustment screw...
Page 41: Synchronizing Dual Engines
Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine. Synchronizing of engines will automatically engage when the speed of both engines are over 900 RPM for two seconds and remote control handles are positioned within 5°...
Page 42: Synchronizing Dual Helms Prior To Station Transfer
Section 2 - Getting to Know Your Power Package 3. Press throttle only/station select button once. The "ACTIVE" light will illuminate to indicate the remote control station is in control of the engine. SYNC ACTIVE ACTIVE THROTTLE THROTTLE ONLY ONLY STATION SELECT STATION SELECT 3433...
Page 43: Power Trim
Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed (below 1200 RPM engine speed) and shallow water operation.
Page 44: Single Engine Trim/Trailer
Section 2 - Getting to Know Your Power Package • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
Page 45: Trim Delta
Section 2 - Getting to Know Your Power Package Trim Delta Trim delta controls the distance between the individual adjacent drive angles when trimming. The trim delta limit is preset, and will not allow extreme drive angle differences that could damage tie bars. If the maximum trim delta limit is met, the drive furthest in the trim process "up or down", will stop trimming until the adjacent drive is back within the delta limit.
Page 46 Section 2 - Getting to Know Your Power Package 2. A 90 amp fuse is located on the large post of the starter solenoid. This fuse is designed to protect the engine wiring harness if an electrical overload occurs. mc74907-1 3.
Page 47: Audio Warning System
Audio Warning System Your Mercury MerCruiser power package may be equipped with an Audio Warning System. The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred.
Page 48: Testing The Audio Warning System
When the alarm has sounded, do not operate engine except to avoid a hazardous situation. If the alarm sounds, stop the engine immediately. Investigate cause and correct it, if possible. If the cause cannot be determined, contact your authorized Mercury MerCruiser dealer. Testing The Audio Warning System 1.
Page 49 Section 2 - Getting to Know Your Power Package In addition, depending on the gauge package, there will be warning icons and fault messages on the dash mounted gauges. 90-864839061 NOVEMBER 2006 Page 41...
Page 50 Section 2 - Getting to Know Your Power Package Notes: Page 42 90-864839061 NOVEMBER 2006...
Page 51: Section 3 - On The Water
Section 3 - On The Water Section 3 - On The Water Table of Contents Safe Boating Suggestions........44 While You Are Cruising ........ 52 Be Alert To Carbon Monoxide Poisoning... 45 While Boat Is Stationary ....... 52 Good Ventilation ........... 46 High-Speed And High-Performance Boat Operation Poor Ventilation ...........
Page 52: Safe Boating Suggestions
Know and obey all nautical rules and laws of the waterways. • Mercury MerCruiser strongly recommends that all powerboat operators complete a boating safety course. Courses are offered in the U.S.A. by: The U.S. Coast Guard Auxiliary, The Power Squadron, The Red Cross and your state or provincial boating law enforcement agency.
Page 53: Be Alert To Carbon Monoxide Poisoning
Most boats are rated and certified for maximum load (weight) capacities (refer to your boat capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if full of water. When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer.
Page 54: Good Ventilation
Section 3 - On The Water Good Ventilation Ventilate the passenger area, open the side curtains or forward hatches to remove fumes. 1. Example of desired air flow through the boat. mc79553-1 Poor Ventilation Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide.
Page 55: Operation Chart
Section 3 - On The Water OPERATION CHART Operation Chart BEFORE STARTING AFTER STARTING WHILE UNDERWAY AFTER STOPPING Observe all gauges to Observe all gauges to check condition of Turn ignition key to the Install bilge drain plug. check condition of engine. If engine.
Page 56: Stopping The Engine
If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer. Page 48 90-864839061 NOVEMBER 2006...
Page 57: Freezing Temperature Operation
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 58: Starting And Stopping The Engine
NOTE: MerCruiser DTS models are equipped with SmartStart. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process.
Page 59: Stopping The Engine
Section 3 - On The Water CAUTION Shifting the drive system at RPMs greater than engine idle speed may cause internal damage to the drive system. Shift the drive system only when the engine is at idle RPM. STOPPING THE ENGINE 1.
Page 60: Trailering The Boat
Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury MerCruiser Limited Warranty.
Page 61: High-Speed And High-Performance Boat Operation
Section 3 - On The Water High‑Speed And High‑Performance Boat Operation If your boat is considered a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you never operate it at its high speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat.
Page 62: Wave And Wake Jumping
Section 3 - On The Water Wave And Wake Jumping WARNING Avoid serious injury or death from being thrown within or out of a boat when it lands after jumping a wave or wake. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to any boat hand hold.
Page 63: Drive Unit Impact Protection
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Page 64: Conditions Affecting Operation
Section 3 - On The Water CAUTION Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be sucked into the water inlets restricting or shutting off the water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water.
Page 65: Elevation And Climate
Section 3 - On The Water Elevation And Climate Elevation and climate changes will affect the performance of your power package. Loss of performance can be caused by: • Higher elevations • Higher temperatures • Low barometric pressures • High humidity For you to have optimum engine performance under changing weather conditions, it is essential that the engine be propped to allow the engine to operate at or near the top end of the specified maximum RPM range with a normal boat load during your normal boating...
Page 66: After Break-In Period
End of First Season Checkup At the end of the first season of operation, contact an authorized Mercury MerCruiser dealer to discuss and/or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
Page 67 Section 4 - Specifications Section 4 - Specifications Table of Contents Fuel Requirements..........60 Fluid Specifications........62 Fuel Ratings ..........60 Engine............62 Using Reformulated (Oxygenated) Gasolines Bravo Sterndrives..........62 (USA Only) ........... 60 Power-Assisted Steering and Power Trim Fluids Gasolines Containing Alcohol ...... 60 ..............63 Engine Oil............
Page 68: Fuel Requirements
The fuel system components on your Mercury MerCruiser engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand.
Page 69: Engine Oil
To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of the following oils listed in the order of recommendation: 1. MerCruiser / Quicksilver Synthetic Blend, NMMA FC‑W rated, 4 cycle oil. 2. MerCruiser / Quicksilver 25W40 NMMA FC‑W rated oil.
Page 70: Fluid Specifications (496)
Capacity Fluid Type Mercury/Quicksilver Synthetic Blend Engine oil (with filter) 8.5 liters (9 U.S. qt.) MerCruiser Engine Oil 25W‑40 Seawater cooling system (winterization use 20 liters (21 U.S. qt.) Propylene Glycol and Purified Water only) Mercury Extended Life Coolant/ Antifreeze or Extended Life Ethylene Closed cooling system 18 liters (19 U.S.
Page 71: Power-Assisted Steering And Power Trim Fluids
Section 4 - Specifications Power‑Assisted Steering and Power Trim Fluids APPROVED POWER-ASSISTED STEERING FLUIDS Description Part Number Power Trim and Steering Fluid 92‑858074K01 Dexron III Automatic Transmission Fluid Obtain Locally APPROVED POWER TRIM FLUIDS Description Part Number Power Trim and Steering Fluid 92‑858074K01 SAE Engine Oil 10W 30 Obtain locally...
Page 72 Section 4 - Specifications Notes: Page 64 90-864839061 NOVEMBER 2006...
Page 73: Section 5 - Maintenance
Section 5 - Maintenance Section 5 - Maintenance Table of Contents Owner/Operator Responsibilities......67 Water-Separating Fuel Filter (496)..... 83 Dealer Responsibilities........67 Water-Separating Fuel Filter......83 Maintenance............67 GEN III Models..........84 Do It Yourself Maintenance Suggestions... 68 Removal ..........84 Inspection............68 Installation ..........
Page 74: Section 5 - Maintenance
Section 5 - Maintenance Page 66 90-864839061 NOVEMBER 2006...
Page 75: Owner/Operator Responsibilities
• Ensure that the boat is properly equipped. • Prior to delivery, make certain that the Mercury MerCruiser power package and other equipment are in proper operating condition. • Make all necessary adjustments for maximum efficiency. •...
Page 76: Do It Yourself Maintenance Suggestions
Transmission (Inboard models only) Do It Yourself Maintenance Suggestions Present day marine equipment, such as your Mercury MerCruiser power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 77: Maintenance Schedule - Sterndrive Models
Scheduled Maintenance NOTE: Only perform maintenance which applies to your particular power package. AFTER THE INITIAL 20 HOUR BREAK-IN PERIOD To help extend the life of your Mercury MerCruiser power package, the following is reccommended: • Change the engine oil and filter.
Page 78: Every 200 Hours Or 3 Years
Section 5 - Maintenance • Driveshaft extension models: Lubricate the driveshaft U‑joints, and tailstock input and output bearings. EVERY 200 HOURS OR 3 YEARS • Inspect the U‑joints, the splines and the bellows. Check the clamps. Check the engine alignment. Lubricate the U‑joint splines and cross bearing, if equipped with a grease fitting.
Page 79: Engine Oil
Section 5 - Maintenance Date Maintenance Performed Engine Hours Engine Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat.
Page 80: Changing Oil And Filter
3. Replace the fill cap. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W‑40 Changing Oil and Filter Refer to the Maintenance schedule for the change interval. Engine oil should be changed before placing the boat in storage.
Page 81: Engine Oil Drain Pump
Section 5 - Maintenance 4. Place the oil drain hose in a suitable container. 5. Remove the drain plug from the oil drain hose. 6. After oil has drained completely, install the drain plug in the oil drain hose. 7. Push the hose through bilge drain and install the plug. ENGINE OIL DRAIN PUMP 1.
Page 82: Power Steering Fluid
OK range. All Models Capacity Fluid Type 8.5 liters Mercury/Quicksilver Synthetic Blend MerCruiser Engine Oil Engine Oil (With Filter) (9 U.S. Quart) 25W‑40 7. Start the engine, run the engine for three minutes, and check for leaks. Stop the engine.
Page 83: Filling
Section 5 - Maintenance 3. Fill to full line with specified fluid. IMPORTANT: If fluid is not visible in pump, contact your authorized Mercury MerCruiser dealer. Filling 1. Remove the fill cap/dipstick and observe the level. 2. Add the specified fluid to bring the fluid level up to the proper range.
Page 84: Filling
92-877770K1 Coolant 3. Install the fill cap onto the coolant recovery bottle. Changing Contact your authorized Mercury MerCruiser dealer. Drive Unit Oil CAUTION ENVIRONMENTAL HAZARD! Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat.
Page 85: Filling
If any water is visible at the bottom of the monitor or appears at the oil fill/drain plug and/or if oil appears discolored, contact your authorized Mercury MerCruiser dealer immediately. Both conditions may indicate a water leak somewhere in the sterndrive unit.
Page 86: Changing
Section 5 - Maintenance Changing 1. Remove the gear lube monitor from the bracket. 8530 Gear lube monitor 2. Empty the contents into a suitable container. 3. Install the gear lube monitor in the bracket. 4. Bravo One Models: Remove the propeller, lower the sterndrive unit to the full down/ in position, remove the oil fill/drain screw and sealing washer and drain the oil.
Page 87 IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the sterndrive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7. Lower the sterndrive unit so that the propeller shaft is level. Fill the sterndrive unit, through the oil fill/drain hole, with specified gear lubricant until an air‑free stream of...
Page 88: Power Trim Fluid
Power Trim and Steering Fluid Power trim pump 92-858074K01 3. Install the cap. Changing Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your authorized Mercury MerCruiser dealer. Page 80 90-864839061 NOVEMBER 2006...
Page 89: Battery
Section 5 - Maintenance Battery Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery. WARNING Avoid serious injury from fire or explosion. Do not use jumper cables and a booster battery to start engine.
Page 90: Cleaning The Iac Muffler
Section 5 - Maintenance 1. Remove the engine cover. 2. Loosen the flame arrestor clamp and remove the flame arrestor. WARNING Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. Never use gasoline as a cleaning solvent. 3.
Page 91: Water-Separating Fuel Filter (496)
Section 5 - Maintenance 2. Remove the IAC muffler. 18495 IAC muffler installed in the throttle body IAC muffler 3. Inspect the IAC muffler for damage such as, holes, cracks or deterioration. Replace the IAC muffler if damaged. IMPORTANT: Do not use cleaner containing methyl ethyl ketone. IMPORTANT: Do not get cleaner on electrical connections.
Page 92: Gen Iii Models
O‑ring REMOVAL 1. Allow the engine to cool down. NOTE: Mercury MerCruiser recommends that the engine be shut off for 12 hours prior to filter removal. 2. Close fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness.
Page 93: Installation
10. Start the engine. Check for gasoline leaks around the fuel filter assembly. If leaks exist, stop the engine immediately. Recheck the filter installation, clean spilled fuel and properly ventilate the engine compartment. If leaks continue, stop engine immediately and contact your authorized Mercury MerCruiser dealer. Lubrication Steering System WARNING Do not grease the steering cable while it is extended.
Page 94 Section 5 - Maintenance 1. If Steering Cable Has Grease Fittings: Turn steering wheel until steering cable is fully retracted into cable housing. Apply approximately 3 pumps of grease from a typical hand‑operated grease gun. 6221 Steering cable grease fitting Tube Ref No.
Page 95: Throttle Cable
3. Lubricate the steering pin. mc71904-1 Steering pin Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Steering pin 92‑883725K01 Oil SAE25W‑40 4. On dual engine boats: Lubricate the tie bar pivot points. Tube Ref. No. Description Where Used Part No.
Page 96: Shift Cable - Typical
Pivot points Guide contact surfaces Tube Ref. No. Description Where Used Part No. Synthetic Blend MerCruiser Engine Shift cable pivot points & guide 92‑883725K01 Oil SAE25W‑40 contact surfaces Sterndrive Unit and Transom Assembly 1. Lubricate gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
Page 97: Sterndrive U-Joint Shaft Splines And O-Rings (Sterndrive Unit Removed)
Section 5 - Maintenance Sterndrive U‑joint Shaft Splines And O‑rings (Sterndrive Unit Removed) 1. Coat sterndrive U‑joint O‑rings and driveshaft splines with grease. 8591 Driveshaft splines U‑joint O‑rings (3) Tube Ref No. Description Where Used Part No. Driveshaft splines and U-joint Engine Coupler Spline Grease 92-802869A1 O-rings...
Page 98: Engine Coupler
Section 5 - Maintenance NOTE: Bravo Models ‑ The coupler and shaft splines can be lubricated without removing the sterndrive unit. Apply lubricant from a typical hand‑operated grease gun until a small amount of grease begins to push out. Engine Coupler 1.
Page 99: Propellers
92-802870A1 Grease driveshaft grease fittings Propellers Propeller Repair Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. Bravo Sterndrive Propeller Removal WARNING Avoid Injury: Remote Control must be in neutral and ignition key removed from switch before removing and/or installing propeller.
Page 100 Section 5 - Maintenance 2. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate. 4826 Wood block Propeller nut under socket Propeller 3. Turn the propeller shaft nut counterclockwise and remove the nut. 4. Slide the propeller and the attaching hardware from the propeller shaft. 5301 Bravo One models Propeller shaft splines...
Page 101: Bravo Two Models
Section 5 - Maintenance 19816 Bravo One XR models Propeller shaft Washer Propeller hub insert with snubbers Washer Propeller Propeller nut Thrust washer BRAVO TWO MODELS 1. Straighten the bent tabs of the tab washer on the propeller shaft. 4750 Prop Tab bent down Tab washer...
Page 102: Bravo Three Models
Section 5 - Maintenance 2. Place a block of wood between the propeller blade and the sterndrives anti‑ventilation plate. 4826 Wood block Propeller nut under socket Propeller 3. Turn propeller shaft nut counterclockwise to remove nut. 4. Slide the propeller and attaching hardware from the propeller shaft. 8566 Bravo Two Propeller shaft splines...
Page 103 Section 5 - Maintenance 3. Remove the propeller shaft anode. 19058 Propeller Propeller shaft anode screw Propeller shaft nut Flat washer Propeller shaft anode Star washer 4. Turn aft propeller shaft nut counterclockwise to remove nut. 5. Slide propeller and thrust hub off propeller shaft. 6.
Page 104: Bravo Sterndrive Propeller Installation
Section 5 - Maintenance Bravo Sterndrive Propeller Installation WARNING Ensure that remote control is in NEUTRAL position and ignition key is removed from switch prior to installing propeller. WARNING A rotating propeller can cause injury. Place a block of wood between the anti‑ventilation plate and the propeller to protect hands from the propeller blades, and to prevent the propeller from rotating when removing or installing the propeller nut.
Page 105 Section 5 - Maintenance 3. Torque the propeller nut. 5301 Typical Bravo One models Propeller shaft splines Drive sleeve adapter Forward thrust hub Tab washer Flo‑Torque II drive hub Propeller nut Propeller 19816 Bravo One XR models Propeller shaft Washer Propeller hub insert with snubbers Washer Propeller...
Page 106: Bravo Two Models
Section 5 - Maintenance 5. Bend the 3 tabs down into the grooves. 4750 Prop Tab bent down Tab washer Propeller nut Drive sleeve adapter BRAVO TWO MODELS IMPORTANT: Use the correct rotation propeller. The propeller rotation MUST match the direction of rotation of the propeller shaft.
Page 107: Bravo Three
Section 5 - Maintenance Description lb. in. lb. ft. Bravo Two propeller nut Then align tabs with groves 4. Continue to tighten the propeller nut until the 3 tabs on the tab washer align with the grooves on the spline washer. 5.
Page 108 Section 5 - Maintenance 6. Align splines and install aft propeller. 7. Install propeller nut and torque. NOTE: The propeller torque stated is a minimum torque value. Description lb. in. lb. ft. Bravo Three rear propeller nut 8. Install propeller shaft anode and screw and torque. 5304 Bravo Three Rear propeller nut...
Page 109: Serpentine Drive Belt
Section 5 - Maintenance Serpentine Drive Belt WARNING Avoid possible serious injury. Make sure that the engine is turned off and the ignition key is removed before inspecting belts. 8118 Belt Routing Diagram Idler pulley Seawater pump pulley Water circulating pump pulley Power steering pump pulley Crankshaft pulley Tensioner pulley...
Page 110 Loose brackets, bracket failure, accessory drive component movement, incorrect belt length, or belt failure can cause the tensioner to contact the limits. See your authorized MerCruiser dealer for service if these conditions exist. CAUTION The belt tensioner assembly contains a high tension spring. Rapid release of the tensioner, or allowing the tensioner to snap back quickly, could injure the operator or cause product damage.
Page 111: Corrosion Protection
The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This is known as galvanic corrosion. For more information contact your authorized Mercury MerCruiser dealer and refer to the Mercury Precision Parts / Marine Corrosion Protection Guide (90‑881813003).
Page 112: Anodes And Mercathode System Locations 103 Checking The Quicksilver Mercathode System
The MerCathode system should be tested to ensure adequate output. Perform the test where boat is moored, using the reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer for service and information . Page 104 90-864839061 NOVEMBER 2006...
Page 113: Power Package Exterior Surfaces
Section 5 - Maintenance Reference Electrode 91‑76675T 1 Senses and electrical current in the water when testing the MerCathode system. Use to check hull potential. 9188 Power Package Exterior Surfaces 1. Spray the entire power package at recommended intervals with Corrosion Guard. Follow the instructions on the can for proper application.
Page 114 • Avoid an electrical interconnection between the Mercury MerCruiser Product, Anodic Blocks, or MerCathode System and the paint by allowing a minimum of 40 mm (1‑1/2 in.) UNPAINTED area on transom of the boat around these items.
Page 115: Sterndrive Surface Care
Section 5 - Maintenance Do not power‑wash a sterndrive that has a MerCathode assembly. Doing so can damage the coating on the reference wire of the MerCathode assembly and increase corrosion. 21563 Reference electrode Anode plate Sterndrive Surface Care 21083 Standard Bravo sterndrive Sacrificial trim cylinder anode Stainless steel hoses...
Page 116: Flushing The Power Package
The flushing procedures for these systems are separated into two categories: sterndrive water pickups and alternative water pickups. Consult your authorized Mercury MerCruiser dealer for further explanation. IMPORTANT: Bravo models equipped with closed cooling require dual water pickups and must be equipped with a through‑hull or through‑transom pickup in addition to the...
Page 117: Sterndrive Water Pickups
9194 STERNDRIVE WATER PICKUPS There are two types of water pickups available on Mercury MerCruiser sterndrives: dual water, and side pickups. Dual water pickups require the flushing attachment (44357Q 2) and the flush seal kit (881150K 1), and side pickups require the flushing attachment (44357Q 2).
Page 118 Section 5 - Maintenance If not equipped with a seacock, disconnect the hose from the alternative water pickup and plug both ends. If there is not a hose running to the transom, refer to Alternative Water Pickups. 3. If flushing the cooling system with the boat in the water: Raise sterndrive to trailer position.
Page 119: Alternative Water Pickups
Section 5 - Maintenance ALTERNATIVE WATER PICKUPS IMPORTANT: Two water sources are needed for this procedure. NOTE: Flushing is needed only for salty, brackish, mineral laden or polluted water applications. Flushing is recommended after each outing for best results. IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through‑hull water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.
Page 120: Procedure
Section 5 - Maintenance CAUTION Avoid engine damage from overheating. If the engine is operated above 1500 RPM during flushing, suction created by the seawater pickup pump may collapse the flushing water hose causing the engine to overheat. 9. Slowly advance throttle until engine reaches 1300 RPM (+/‑100 RPM). CAUTION Engine overheating can cause engine damage.
Page 121 Section 5 - Maintenance 2. Close the seacock, if equipped. 18510 For visual clarity, the secock shown is not installed Hose fitting to engine Handle (closed position) Seacock To water source pickup attachment 3. If equipped with an alternative water pickup and not equipped with a seacock, disconnect the water hose from the alternative water pickup and plug both ends, excluding the Bravo sterndrive.
Page 122 Section 5 - Maintenance 7. Snap the quick‑connect fitting with the water hose into the flush socket on the engine. 18489 Water hose Flush socket Quick‑connect fitting (water hose end) 8. Open the water source of the water hose to a full flow. 9.
Page 123 IMPORTANT: Do not store the quick‑connect fitting in the flush socket on the engine. Doing so would allow the seawater pump to suck air during engine operation causing an overheating problem. Damages due to engine overheating are not covered by Mercury MerCruiser Warranty. 25900 Quick‑connect fitting stored in the boat Quick‑connect fitting (water hose end)
Page 124 Section 5 - Maintenance 20. Insert the dust cover in the flush socket on the engine. 18490 Dust cover installed in the flush socket Dust cover Flush socket IMPORTANT: If the unit is to be stored in the water, the seacock should remain closed until time of usage.
Page 125 Section 6 - Storage Section 6 - Storage Table of Contents Cold Weather or Extended Storage....118 Boat in the Water ......... 121 Preparing Power Package for Storage..118 Boat out of the Water ......123 Engine and Fuel System Preparation . . 119 Manual Drain System........125 Draining the Seawater System......
Page 126: Cold Weather Or Extended Storage
Section 6 - Storage Cold Weather or Extended Storage IMPORTANT: Mercury MerCruiser strongly recommends that this service should be performed by an authorized Mercury MerCruiser dealer. Damage caused by freezing temperatures IS NOT covered by the Mercury MerCruiser Limited Warranty. CAUTION Seawater that is trapped in or remains in the cooling system seawater section during cold weather or winter storage can freeze resulting in cooling system or engine damage.
Page 127: Engine And Fuel System Preparation
Section 6 - Storage ENGINE AND FUEL SYSTEM PREPARATION WARNING Avoid serious injury or death from a gasoline fire or explosion; gasoline is extremely flammable and highly explosive under certain conditions. When servicing the fuel system components ensure that the engine is cool, the ignition switch is in the off position, and that the lanyard stop switch, if equipped, is in the off position.
Page 128: Drain System Identification
Section 6 - Storage CAUTION Excess water in the bilge can damage the engine or cause the boat to sink. When the drain system is open, excess water can enter the bilge. Do not operate the engine with the drain system open. IMPORTANT: Only drain the seawater section of the closed cooling system.
Page 129: Manual Drain System
Section 6 - Storage MANUAL DRAIN SYSTEM 17255 Blue drain plug locations Air Actuated Single Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that is attached to the engine. However, any air source can be used. 1.
Page 130 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 131: Boat Out Of The Water
Section 6 - Storage 13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 6135 Green indicators 14. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
Page 132 11. Remove the air pump from the air manifold and return it to the mounting bracket. 12. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance. This helps ensure that all water is drained.
Page 133: Manual Drain System
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 134: Boat Out Of The Water
Blue drain plug locations 3. Verify that water is draining from each opening. 4. Allow the system to drain for a minimum of five minutes. Mercury MerCruiser recommends leaving the drain system open while transporting the boat or while performing other maintenance to ensure that all water is drained.
Page 135: Battery Storage
IMPORTANT: Mercury MerCruiser requires that propylene glycol antifreeze, mixed to the manufacturers instructions, be used in the seawater section of the cooling system for freezing temperatures or extended storage.
Page 136 Section 6 - Storage CAUTION Reversing the battery cables or connection order will damage the electrical system. When installing the battery, be sure to connect the positive (+) battery cable to the positive (+) battery terminal first, and the negative (–) battery cable to the negative (–) battery terminal second.
Page 137: Section 7 - Troubleshooting
Section 7 - Troubleshooting Section 7 - Troubleshooting Table of Contents Diagnosing EFI Problems......... 130 Low Engine Oil Pressure........132 Diagnosing DTS Problems....... 130 Battery Will Not Come Up On Charge....132 Engine Guardian System........130 Remote Control Operates Hard, Binds, Has Starter Motor Will Not Crank Engine, Or Cranks Excessive Free-play Or Makes Unusual Sounds Slow..............
Page 138: Diagnosing Efi Problems
Section 7 - Troubleshooting Diagnosing EFI Problems Your authorized Mercury MerCruiser dealer has the proper service tools for diagnosing problems on Electronic Fuel Injection (EFI) Systems. The Electronic Control Module (ECM) on these engines has the ability to detect some problems with the system when they occur, and store a Trouble Code in the ECM's memory.
Page 139: Engine Runs Rough, Misses And/Or Backfires
Section 7 - Troubleshooting Possible Cause Remedy Have EFI System checked by an authorized Mercury EFI system fault. MerCruiser dealer. Engine Runs Rough, Misses And/Or Backfires Possible Cause Remedy Clogged fuel filter. Replace filter. Stale or contaminated fuel. If contaminated, drain tank. Fill with fresh fuel.
Page 140: Insufficient Engine Temperature
Loose or missing shift and throttle linkages. see authorized Mercury MerCruiser dealer immediately. Straighten cable or have authorized Mercury Shift or throttle cable kinked. MerCruiser dealer replace cable if damaged beyond repair. Steering Wheel Turns Hard Or Jerky Possible Cause Remedy Low power steering pump fluid level.
Page 141: Power Trim Does Not Operate
Section 7 - Troubleshooting Power Trim Does Not Operate (Motor Does Not Operate) Possible Cause Remedy Replace fuse. Fuses may be located near the dash trim switch, at the trim pump, in the positive (red) Blown fuse. power trim battery lead near the battery switch, or a combination of these.
Page 142 Section 7 - Troubleshooting Notes: Page 134 90-864839061 NOVEMBER 2006...
Page 143: Section 8 - Customer Assistance Information
Section 8 - Customer Assistance Information Section 8 - Customer Assistance Information Table of Contents Owner Service Assistance........ 136 Parts And Accessories Inquiries ..137 Local Repair Service ........136 Resolving A Problem ........137 Service Away From Home ......136 Mercury Marine Service Offices ....
Page 144: Owner Service Assistance
These are but a few of the many special modifications that are required in Mercury MerCruiser marine engines to provide long life and dependable performance. 1. Quicksilver parts and accessories are engineered and built by Mercury Marine, specifically for Mercury MerCruiser sterndrives and inboards.
Page 145: Parts And Accessories Inquiries
Resolving A Problem Satisfaction with your Mercury MerCruiser product is very important to your dealer and to us. If you ever have a problem, question or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If additional assistance is required, take these steps: 1.
Page 146: Ordering Literature
• Year built United States and Canada For information on additional literature that is available for your particular Mercury MerCruiser power package and how to order that literature contact your nearest dealer or contact Mercury Marine Publications P.O. Box 1939...

MerCruiser 496 MAG Bravo User Manual

Section 3 - on the Water

Section 4 - Specifications

Section 5 - Maintenance

Section 7 - Troubleshooting

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