Page 1 OPERATION & MAINTENANCE MANUAL 5.7L/5.7LX/7.4L Bravo One/Two/Three 1996, Brunswick Corporation 90-806294962 196...
Page 2 Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A. 1996, Brunswick Corporation The following are registered trademarks of Brunswick Corporation: Auto- blend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury Marine, Quicksilver, Ride-Guide, and Thruster.
Page 3 CA310 MERCRUISER Division of Mercury Marine Stillwater, OK, U.S.A. SPECIFICATIONS MODEL ..MCM 5.7 LITRE LX DISPLACEMENT ..350 CID IGNITION TIMING ..10 BTDC CYL.
Page 4: Table Of Contents
CB538 TABLE OF CONTENTS Page Welcome! ..........Read This Manual Thoroughly .
Page 5 Page Maintenance ..........Maintenance Aids .
Page 6: Welcome
CA165 WELCOME! You have selected one of the finest marine power packages available. It incorporates numerous design features to assure operating ease and durability. 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.
Page 7: Read This Manual Thoroughly
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, WARNINGS and CAUTIONS, accompanied by the International Hazard Symbol , may be used to alert the installer/user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly.
Page 8: Lanyard Stop Switch
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.
Page 9 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.
Page 10: Safe Boating Suggestions
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.
Page 11 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.
Page 12 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.
Page 13: Protecting People In The Water
CA282 Protecting People In The Water While You Are Cruising It is very difficult for a person standing or floating in the water to take quick action to avoid a boat heading in his/her direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Page 14: Conditions Affecting Operation
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.
Page 15 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 housing or propeller.
Page 16: Propeller Selection
CA294 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open-throttle revolutions per minute (RPM). Use an accurate service tachometer to verify engine operating RPM. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s).
Page 17: How Elevation And Climate Affect Performance
CA12 How Elevation And Climate Affect Performance Elevation has a very noticeable effect on the wide-open-throttle power of an engine. Since air (containing oxygen) gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the density of air.
Page 18: Important Information
CA13 Important Information Operation And Maintenance OWNER/OPERATOR RESPONSIBILITIES It is the operator’s responsibility to perform all safety checks; to ensure that all lubrication and maintenance instructions are complied with for safe operation and to return the unit to an Authorized MerCruiser Dealer for a periodic checkup. Normal maintenance service and replacement parts are the responsibility of the owner/operator and as such, are not considered defects in workmanship or material within the terms of the warranty.
Page 19: Freezing Temperature Operation
CA318 Freezing Temperature Operation IMPORTANT: It boat is operated during periods of freezing temperature, precautions must be taken to prevent freezing damage to power package. Refer to “COLD WEATHER or EXTENDED STORAGE” for draining instructions. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty.
Page 20: Emissions Information
CA331 Emissions Information Your engine may be equipped with special design features and special tuning to minimize the emission output from the engine. If so, it is very important that you strictly adhere to the following: Recommended maintenance schedules particularly the ignition system.
Page 21: Launching And Boat Operation Care
CA20 Launching And Boat Operation Care CAUTION During launching from a trailer, if the unloading ramp is steep or the trailer bed must be tilted, the boat may enter the water rapidly and at a steep angle. This may force water through the exhaust system into the cylinders.
Page 22: Replacement Service Parts
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 components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.
Page 23: Do-It-Yourself Maintenance Suggestions
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 ignition and special carburetion provide greater fuel economies, but also are more complex for the untrained mechanic.
Page 24: 20-Hour Break-In Period
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.
Page 25: 20-Hour Checkup
CB256 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. Check all fluid levels. Cooling System: Inspect all hoses for damage and deterioration; check all hose clamps for adequate tightness.
Page 26 CA26 70515 70516 70514 70517 70523 70522 70518 70520 70521 70519...
Page 27: Operation
CA27 Operation Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instruments 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 appear on your style gauges.
Page 28 CB218 70516 70518 71987...
Page 29 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.
Page 30 CA29 71466 70525 70528 70527 71341 70526...
Page 31: Electrical System Overload Protection
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 replacing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead.
Page 32 CB181...
Page 33: Remote Controls (Panel Mounted)
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 other than shown, consult your dealer for a description and/or demonstration of the control.
Page 34 CB183...
Page 35: Remote Controls (Console Mounted)
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”...
Page 36 CB185 71339 70537...
Page 37: Remote Controls (Two Lever)
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 NEUTRAL. CAUTION Never shift unit into or out of gear unless throttle lever is a idle RPM.
Page 38 CA34 3 TO 5 71338...
Page 39: Power Trim
CA284 Power Trim Power Trim allows the operator to adjust the drive angle, while underway, to provide the ideal boat angle for varying load and water conditions. Also, the Power Trim system “Trailering” feature allows the operator to raise and lower the drive unit for trailering, beaching, launching and low speed (below 1200 RPM engine speed), shallow water operation.
Page 40 CB187 73976 73977...
Page 41 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.
Page 42 CB190 73979 73978...
Page 43 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.
Page 44 CB192 70540 70540 70540...
Page 45 CB193 POWER TRIM OPERATION - THREE BUTTON TRIM PANEL (USED ON MODELS WITH TWO-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.
Page 46: Starting, Shifting And Stopping
CA40 Starting, Shifting And Stopping WARNING Before starting engine, operate bilge blower for at least five minutes 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).
Page 47 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.
Page 48: Operation Chart
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. engine. If not normal, stop engine. Turn battery Check Turn switch ON, if so...
Page 49: Specifications
CA261 Specifications Fuel Recommendations IMPORTANT: Use of improper gasoline can damage your engine 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: USA and Canada - having a posted pump Octane Rating of...
Page 50 The fuel system components on your 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. Contact your boat manufacturer for specific recommendations on the boats fuel system components (fuel tanks,fuel lines, and fittings).
Page 51: Crankcase Oil
CA43 Crankcase Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle Marine Engine Oil. If not available, a good grade, straight weight, detergent automotive oil of correct viscosity, with an API classification of CD or SG, may be used.
Page 52: Engine
CB533 Engine Specifications 7.4L 5.7L 5.7LX MODEL Propshaft Horsepower (212 (BSO/SAV Rating) Propshaft Kilowatts (BSO/SAV Rating) (158 350 C.I.D. 454 C.I.D. Displacement (5.7 L) (7.4 L) Engine Type 4.00 in. (101.6mm) Bore 3.48 in. (88.39 mm) Stroke Compression Ratio 9.3:1 8.0:1 180 psi (1241 kPa) Compression Pressure...
Page 53: Tune-Up
CB352 Tune-Up Specifications 5.7L 5.7LX 7.4L MODEL Spark Plug Type AC-MR43T or Champion RV15YC4 or NGK BR6FS .035 in. (0.9mm) Spark Plug Gap Timing @ Idle RPM BTDC 1-8-4-3-6-5-7-2 Firing Order Electrical System 12-Volt Negative (-) Ground Alternator 55 Amps Minimum Recommended Minimum 375 cca,...
Page 54: Capacities
NOTE: All capacities are given in approximate U. S. Quarts (Liters). MODEL 5.7L 5.7LX 7.4L Crankcase Oil 5-1/2 Capacity (6-2/3) (5-1/3) w/New Filter Bravo One 2-3/4 (2-1/3) Drive Unit Oil Bravo Two Capacity 3-1/3 (3) (w/Reservoir) Bravo Three Seawater Cooling System...
Page 55: Maintenance
CA290 Maintenance WARNING Always disconnect battery cables from battery before working around electrical system components to prevent injury to yourself or damage to electrical system. IMPORTANT: Refer to MAINTENANCE CHART for complete listing of all scheduled maintenance to be performed. Some listings can be done by owner/operator, while others should be performed by an Authorized MerCruiser Dealer.
Page 56 Crankcase Oil - Quicksilver 4-Cycle Marine Engine Oil (Refer to SPECIFICATIONS for alternatives and oil recommendations for varying 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.
Page 57: Maintenance Chart
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...
Page 58 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...
Page 59 CA254 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.
Page 60 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 or...
Page 61 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 Operation or 60 Days, Whichever System-Inspect for Occurs First external Freshwater use: Every 100 Hours damage,deterioration Operation Days,...
Page 62 CB32 70544 70543 71448 71341 70548 70546 70547 70545...
Page 63: Checking Fluid Levels
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.
Page 64 CB207 71987 71773 70551 70979...
Page 65 CB547 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.
Page 66 CA62 70571 70572 71344 71345 70544...
Page 67: Changing Fluids
CA63 Changing Fluids See MAINTENANCE CHART for lubricant change frequency. Lubricant 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 intervals by your Authorized MerCruiser Dealer. CHANGING CRANKCASE OIL AND FILTER IMPORTANT: Change oil when engine is warm from operation.
Page 68 CB354 70569 70568 70570 72522 71987...
Page 69 Lube in drive unit. Remove OIL FILL/DRAIN screw and sealing washer (Refer to A, B, or C as appropriate). A BRAVO ONE MODELS – Remove propeller, place drive unit in full “down” position, remove OIL FILL/DRAIN SCREW and sealing washer.
Page 70 CB177 71903 71904 71901 70556 71359...
Page 71: Lubrication
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.
Page 72 CB429 70558 70559 71346 71569 71347...
Page 73 CB355 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.
Page 74 CB155 70561 72239...
Page 75: Propeller
Periodically check propeller nut for tightness during boating season. A minimum of 55 lbs. ft. (75 N.m) torque is required. CB156 REMOVAL (BRAVO ONE AND TWO) Place wood block between propeller blade and anti-ventilation plate to prevent rotation Straighten bent tabs on tab washer.
Page 76 CB158 70561...
Page 77 CB357 INSTALLATION (BRAVO ONE AND TWO) IMPORTANT: If reusing tab washer, carefully inspect tabs for cracks or other damage. Replace tab washer if condition is questionable. Apply a liberal coat of one of the following Quicksilver lubricants to propeller shaft: Anti-Corrosion Grease, Special Lubricant 101, or 2-4-C Marine Lubricant with Teflon.
Page 78 CB150 72239...
Page 79 CB358 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 Lubricant with Teflon, or Anti-Corrosion Grease. Slide forward thrust hub onto propeller shaft, with tappered side toward propeller hub (Toward end of shaft).
Page 80 CB63 70565 70564 71353 71170...
Page 81: Flushing Cooling System
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.
Page 82 CB442 70566 71355 74789 70567 71334 71334...
Page 83: Cleaning Seawater (Raw Water) Section Of Heat
CB443 Cleaning Seawater (Raw Water) Section Of Heat Exchangers - Closed Cooling Models Only Seawater section of heat exchanger should be cleaned at least once a year or whenever decreased cooling efficiency is noticed. HEAT EXCHANGER Remove end plate(s), O-rings and gaskets. Inspect O-rings and gaskets for deterioration and replace if necessary.
Page 84 CB74 70562 70353 70351 70351 71349 70563...
Page 85: Drive Belts
CB76 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 tension. Perform the following inspections of alternator drive belt, power steering pump drive belt (if so equipped) and seawater pickup pump drive belt.
Page 86 CB78 70573 71345 50681 71169...
Page 87: Water Separating Fuel Filter
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.
Page 88 CB226 73919 71176 70577 70575 70578...
Page 89: Corrosion And Corrosion Protection
CB228 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 saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals.
Page 90 CB333 71966 72032 71804 72029...
Page 91 B Install new anodes and tighten securely. CB161 Propeller Anode (Bravo One Models) - is located in front of the propeller, between the front side of the propeller and the gear housing. Refer to “Propeller” section in this manual for propeller removal and installation.
Page 92 CB95 71176...
Page 93 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...
Page 94 CA97 “SEE CAUTION” 71918 71925...
Page 95: Emissions
CB454 Emissions CA399 The following information applies only to engines with a special emissions kit installed. If the kit has been installed, your engine complies with “Stage 1” Bodensee and Swiss Regulations. CA398 SEALED CARBURETOR MIXTURE SCREWS The carburetor on this engine has seals on the carburetor mixture screws.
Page 96 CA101 71926 71921 71923 71919...
Page 97: Emissions Testing
CA100 EMISSIONS TESTING Your engine is equipped with special design features and special tun- ing to minimize the emission output from the engine. You should fol- low: Recommended maintenance schedules particularly as to the igni- tion system. Proper engine tuning procedures to ensure these features remain in good operating order.
Page 98: Miscellaneous Maintenance
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 manufacturer’s specifications. Refer to specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.
Page 99: Inspection And Maintenance
CA104 Bottom Of Boat To maintain maximum speed, the following conditions of the boat bottom 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.
Page 100: Cold Weather Or Extended Storage
CA378 Cold Weather Or Extended Storage Power Package Lay Up IMPORTANT: MerCruiser strongly recommends that this service should be performed by an Authorized MerCruiser Dealer. Damage caused by freezing IS NOT covered by the MerCruiser Limited Warranty. CAUTION DO NOT operate engine without water flowing thru seawater pickup pump, as pump impeller may be damaged and subsequent overheating damage to engine or stern drive unit may result.
Page 101 Remove flame arrestor and restart engine. While operating engine 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.
Page 102 CB431 71332 74158 71448...
Page 103: Draining Instructions
CB432 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.
Page 104 CB433 71334 74811 74152 74493 74793 71758 71217...
Page 105 CB434 Loosen hose clamps and disconnect the following hoses: NOTE: It may be necessary to lift or bend hoses to allow water to drain completely. Crank engine over slightly to purge any water trapped in seawater pickup pump. Do not allow engine to start. Disconnect both upper and lower hoses from seawater pump.
Page 106 CB111 70583...
Page 107 CB435 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 flow from the drain holes or removed hoses.
Page 108 CB113 71170 70584 71334 70586 71217...
Page 109 CB436 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 engine to start.
Page 110 CB437 74073 71515...
Page 111 CB438 DRAINING CLOSED COOLING (COOLANT) MODELS (CONTINUED) On 7.4L (With Front-Mounted Engine Oil And Side-Mounted Power Steering Cooler) Models: Ensure engine is as level as possible to ensure complete draining of cooling system. Remove drain plug from port and starboard exhaust manifolds. Repeatedly clean out all drain holes using a stiff piece of wire.
Page 112 CB439 71170 74793 71217...
Page 113 CB440 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 engine to start.
Page 114: Battery Winter Storage
CA115 Battery Winter Storage Follow battery manufacturer’s instructions for storage. CA116 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.
Page 115: Troubleshooting
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. neutral. Open circuit breaker or Check and reset circuit blown fuse.
Page 116 Engine Will Not Start, Or Is Hard To Start Possible Cause Remedy Improper starting proce- Read starting procedure. dure. Empty fuel tank or fuel Fill tank or open valve. shutoff valve closed. Faulty fuel pump. Check sight tube for fuel. Have Authorized Mer-...
Page 117: Poor Performance
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.
Page 118 Excessive Engine Temperature Possible Cause Remedy Seacock closed. Open. Drive belt loose or in poor Replace and/or adjust belt. condition. Seawater pickups Remove obstruction. structed. Faulty thermostat. Replace. Coolant level low in closed Check for cause of low cooling section coolant level and repair.
Page 119: Low Engine Oil Pressure
Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crank- Check and add oil. case. 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.).
Page 120: Steering Wheel Turns Hard Or Jerky
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.
Page 121 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...
Page 122: Warranty Information
CA320 Warranty Information Owner Warranty Registration UNITED STATES AND CANADA ONLY It is important that your selling dealer fills out the Warranty Registration 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.
Page 123: International Owner Registration
International Owner Registration OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area. The Warranty Registration Card identifies your name and address, product model and serial number(s), date of sale, type of use and the selling distributor’s/dealer’s code number, name...
Page 124: Warranty Policies
Warranty Policies Mercruiser Limited Warranty - Gasoline Engines UNITED STATES AND CANADA ONLY I. We warrant each new production (not those made for high performance 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.
Page 125 V. Claim shall be made under this warranty by delivering the Product 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. We shall then arrange for the inspection and repair, provided such service is covered under this warranty.
Page 126: Mercruiser International Warranty - Gasoline Engines
Mercruiser International Warranty - Gasoline Engines OUTSIDE THE UNITED STATES AND CANADA I. We warrant each new production (not those made for high performance 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.
Page 127 MAY NOT APPLY TO YOU. VIII. This warranty gives you specific legal rights, and you may also have other legal rights which vary from country to country. MARINE POWER INTERNATIONAL Division of Brunswick Corporation Fond du Lac, Wisconsin 54935 U.S.A.
Page 128: Year Limited Warranty Against Corrosion Failure
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 production MerCruiser (Product) sold with a one year limited Product warranty or the Bravo and TRS Drive Units on performance Products that have a 90 day limited warranty rendered inoperative as a direct result of corrosion, provided the following simple precautionary steps which are specified in...
Page 129 IV. ALL INCIDENTAL AND/OR CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM THIS WARRANTY. WARRANTIES OF MERCHANTABILITY AND FITNESS ARE EXCLUDED FROM THIS WARRANTY. IMPLIED WARRANTIES ARE LIMITED TO THE LIFE OF THIS WARRANTY. SOME STATES (OR COUNTRIES) DO NOT ALLOW LIMITATIONS ON HOW LONG IMPLIED WARRANTY...
Page 130: Warranty Coverage
OWNER’S RESPONSIBILITY Protection against certain types of corrosion damage must be provided 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 connections, nearby boats, submerged metal), or improper application of copper base anti-fouling paint.
Page 131 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 connection with normal services. Damage caused by neglect, lack of maintenance, accident, ab- normal operation or improper installation or service, or freezing temperatures.
Page 132 Engine noise does not necessarily indicate a serious engine problem. 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.
Page 133: Transferable Warranty
Transferable Warranty The product warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited warranty. This will not apply to products used for commercial applications. Direct Sale By Owner The second owner can be registered as the new owner and retain the unused portion of the limited warranty by sending the former owner’s plastic Owner Warranty Registration Card and a copy of the bill of sale to show proof of ownership.
Page 134: Q-Guard Product Protection Plan
Q-Guard Product Protection Plan United States And Canada Only (Certain performance products,triple engine installations, and commercial applications are excluded) The Mercury Marine Q-Guard Product Protection Plan provides coverage against unexpected mechanical electrical breakdowns that may occur beyond the standard limited warranty. The optional Q-Guard Product Protection Plan is the only Factory Plan available for your engine.
Page 135: Owner Service Assistance
Owner Service Assistance Local Repair Service Always return your MerCruiser powered boat to your local Authorized Dealer, should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools and equipment and the genuine Quicksilver parts and accessories* to properly service your engine should the need occur.
Page 136 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...
Page 137 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 experience has shown that this is the most expedient and successful procedure to follow to ensure satisfaction to our customers.
Page 138: Service Centers
Service Centers UNITED STATES MerCruiser 3003 N. Perkins Road Stillwater, OK 74075-2299 Telephone (405) 743-6566 Fax (405) 743-6570 CANADA Mercury Marine 1156 Dundas Highway East Mississauga, Ontario L4Y 2C2 Canada Telephone (905) 270-4481 Fax (905) 270-4510 MEXICO, CENTRAL AMERICA, SOUTH AMERICA, CARIBBEAN Marine Power International 9350 SW 72nd St.
Page 139 AUSTRALIA, PACIFIC Marine Power International Pty. Ltd. P. B. 1420 132-140 Frankston Road Dandenong, Victoria 3164 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...
Page 140: Customer Service Literature
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 54936-1939 Outside the United States and Canada, contact the nearest Marine Power International Service Center for further information.
Page 141: General Maintenance Parts
CB430 General Maintenance Parts Engine Parts Part 5.7L Bravo Oil Filter 14957 Spark Plug 33-59571 Distributor Cap 805759A2 Ignition Coil 392-805570A2 Spark Plug Wire Set 84-816761A17 Thermostat 160 F 807252--2 27-33179--2, Thermostat Gaskets 27-53045--1 Alternator Belt 57-49213A1 Power Steering Belt 57-816295T 10.
Page 142 Engine Parts 5.7LX Bravo 7.4L Bravo 14957 14957 33-59571 33-59571 805759A2 805759A2 392-805570A2 392-805570A2 84-816761A17 84-816608A61 807252--2 807252--2 27-33179--2, 27-33179--2 27-53045--1 27-53045--1 57-48120A1 57-48122 57-816295T 57-816295T (7” Pulley) 57-74271T 57-13457T 35-807172 35-807172 92-816096A12 92-816096A12 92-86145A12 92-86145A12 92-17955A12 92-17955A12 92-817529A12 92-817529A12 92-17885A12 92-17885A12 92-815869A12...
Page 143: General Maintenance Parts
CB364 General Maintenance Parts Drive Parts Part Bravo One Propeller Nut 11-52707A1 Front Propeller Nut Rear Propeller Nut Front Thrust Hub Rear Thrust Hub Rear Propeller Washer 12-31211A2 Tab Washer 14-816629 Grounding Washer 13-42351--1 Thrust Hub 13171 10. Decal Set 37-15167A90 11.
Page 144 Drive Parts (Continued) Bravo Two Bravo Three 11-54034 11-805092 11-805093 11-805100T 11-805101T 12-55073A2 14-34817 13-42351--1 55074T 37-13722A90 37-15167A90 821630A1 821630A1 76214A5 76214A5 806190A1 806190A1 821631A1 821631A1 10-14834A1 10-14834A1 25-805726 25-805726 10-79953 10-79953 25-805726 25-805726 16755 16755...
Page 145 Drive Parts (Continued) Part Bravo One 21. Drive Mounting O-ring 25-45710 22. Trim Pump 20 Amp Fuse 88-79091 23. Trim Pump 10 Amp Fuse 88-79023A10 24. 2-4-C Marine Lubricant 92-825407A3 with Teflon 25. U-Joint and Gimbal 92-828052A2 Bearing Grease 26. Engine Coupler Spline...
Page 146 Drive Parts (Continued) Bravo Two Bravo Three 25-45710 25-45710 88-79091 88-79091 88-79023A10 88-79023A10 92-825407A2 92-825407A2 92-828052A2 92-828052A2 92-816391A4 92-816391A4 92-816026A1 92-816026A1 92-78373-12 92-78373-12...
Page 147: Literature Order Form
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.
Page 148 Please Return with Payment to: Mercury Marine Attn: Publications Dept. P.O. Box 1939 Fond du Lac, WI 54936-1939 Ship To: (Please Print or Type - This is your Shipping Label) Name Address City State Method of Payment: (No Cash or C.O.D.) Personal Check Cashiers Check Money Order...

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