Table of Contents
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Owner and Operator Responsibilities................................... 42
Dealer Responsibilities......................................................... 42
Maintenance......................................................................... 42
Do-It-Yourself Maintenance Suggestions............................. 42
General Inspection............................................................... 42
Engine Cover........................................................................ 43
Removal......................................................................... 43
Cleaning......................................................................... 43
Inspection...................................................................... 43
Installation...................................................................... 43
Maintenance Schedules-Alpha and Bravo Models............ 43
Routine Maintenance-Alpha and Bravo Models.......... 43
Maintenance Log........................................................... 45
Engine Oil............................................................................. 47
Specifications................................................................. 47
Oil Level-Overfilled...................................................... 47
Checking........................................................................ 47
Filling............................................................................. 48
Changing Oil and Filter.................................................. 49
Alpha Sterndrive Gear Lube................................................. 52
Sterndrive Gear Lube.................................................... 52
Checking........................................................................ 52
Filling............................................................................. 53
Changing....................................................................... 54
Bravo Sterndrive Gear Lube................................................. 56
Sterndrive Gear Lube.................................................... 56
Checking........................................................................ 56
Filling............................................................................. 56
Changing....................................................................... 57
Power Trim Fluid.................................................................. 60
Checking........................................................................ 60
Filling............................................................................. 60
Changing....................................................................... 61
Power-Assisted Steering Fluid............................................. 61
Checking........................................................................ 61
Filling............................................................................. 62
Changing....................................................................... 62
Engine Coolant..................................................................... 62
Checking........................................................................ 62
Filling............................................................................. 63
Changing....................................................................... 63
Air Filter................................................................................ 64
Removal......................................................................... 64
Inspection...................................................................... 64
Installation...................................................................... 64
Water-Separating Fuel Filter................................................ 65
Draining......................................................................... 66
Replacing....................................................................... 66
Filling............................................................................. 68
Fuel System.......................................................................... 69
Priming........................................................................... 69
Filling (Bleeding)............................................................ 70
90-8M0069751
APRIL 2012
eng
Section 5 - Maintenance
Seawater System................................................................. 70
Replacing the Engine Coolant.............................................. 80
Corrosion Protection............................................................. 82
Lubrication............................................................................ 91
Maintaining Torques............................................................. 97
Propellers............................................................................. 98
Drive Belts.......................................................................... 105
Battery................................................................................ 107
Fuel Tank Cleaning and Flushing.................................. 70
Draining the Seawater System...................................... 70
Sterndrive Water Inlets Check....................................... 72
Checking the Seawater Pickups.................................... 73
Cleaning the Seawater Strainer..................................... 73
Engine Seawater Pump Inspection................................ 80
Alpha Sterndrive Seawater Pump Inspection................ 80
Draining the Closed-Cooling System............................. 80
Filling the Closed Cooling System................................. 81
General Information....................................................... 82
Engine Corrosion Protection Components.................... 82
Removal ................................................................ 82
Cleaning and Inspection ........................................ 83
Installation ............................................................. 84
Sterndrive Corrosion Protection Components............... 85
Alpha Sterndrive Continuity Circuit Inspection............... 88
Continuity Circuit-Bravo Sterndrive............................. 88
MerCathode................................................................... 90
Painting Your Power Package....................................... 90
Steering System............................................................ 91
Throttle Cable................................................................ 93
Shift Cable..................................................................... 93
Transom Assembly........................................................ 94
Engine Coupler.............................................................. 94
Driveshaft Extension Models......................................... 94
Sterndrive, Bellows, and Engine Alignment................... 95
Alpha Gimbal Ring Clamp Bolt...................................... 97
Bravo Gimbal Ring U-bolt Nuts...................................... 97
Engine Mounts............................................................... 98
Alpha Propeller Removal............................................... 98
Alpha Propeller Installation............................................ 99
Bravo Diesel Sterndrive Propeller Removal.................. 99
Bravo One Models ............................................... 100
Bravo Two Models ............................................... 100
Bravo Three Models ............................................ 101
Bravo Diesel Sterndrive Propeller Installation............. 102
Bravo One Models ............................................... 102
Bravo Two Models ............................................... 103
Bravo Three ......................................................... 104
QSD 2.0 Drive Belts..................................................... 105
Power-Assisted Steering Pump Belt Inspection.......... 106
Serpentine Belt Inspection........................................... 106
Battery Precautions for Multiple Engines .................... 107
Section 5 - Maintenance
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