Mercury 540 Bravo Manual
  1. Manuals
  2. Brands
  3. Mercury Manuals
  4. Boating Equipment
  5. 540 Bravo
  6. Manual

Mercury 540 Bravo Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Thank You
for your purchase of one of the finest marine power packages available. It
incorporates numerous design features to ensure 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.
The Operation, Maintenance and Warranty Manual contains specific
instructions for using and maintaining your product. We suggest that this
manual remain with the product for ready reference whenever you are on
the water.
Again, thank you for purchasing one of our Mercury Marine products. We
sincerely hope your boating will be pleasant!
Warranty Message
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.
The product you have purchased comes with a limited warranty from
Mercury Marine; the terms of the warranty are set forth in the Warranty
Information section of this manual. The warranty statement contains a
description of what is covered, what is not covered, the duration of
coverage, how to best obtain warranty coverage, important disclaimers
and limitations of damages, and other related information. Please review
this important information.
Safety Alerts and Notices
Throughout this publication, dangers, warnings, cautions, and notices,
accompanied by the international HAZARD symbol
the operator and technician to special instructions concerning a particular
service or operation that may be hazardous if performed incorrectly or
carelessly. Observe these safety alerts carefully.
These safety alerts alone cannot eliminate the hazards they signal. Strict
compliance to these special instructions when performing the service, and
common sense operation are major accident prevention measures.
Indicates a hazardous situation which, if not avoided, will result in death
or serious injury.
eng
WARNING
!
DANGER
!
i
!
, are used to alert

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 540 Bravo and is the answer not in the manual?

Questions and answers

Related Manuals for Mercury 540 Bravo

Summary of Contents for Mercury 540 Bravo

  • Page 1 The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Information section of this manual. The warranty statement contains a...
  • Page 2 California to cause cancer, birth defects or other reproductive harm. Copyright and Trademark Information © MERCURY MARINE. All rights reserved. Reproduction in whole or in part without permission is prohibited. Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves...

  • Page 3: Table Of Contents

    Warranty Information Warranty Registration United States and Canada..........1 Transfer of Warranty................... 1 Mercury Racing Division One Year Limited Warranty United States and Canada ..........................2 Products Sold to Government Agencies............. 4 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products ..........................
  • Page 4 Operation Instrumentation....................30 Warning System....................30 Electrical System Overload Protection............. 31 Remote Controls (Console Mounted Zero Effort)..........36 Starting, Shifting, and Stopping................ 37 Operation Chart....................38 Freezing Temperature Operation..............39 Drain Plug and Bilge Pump................39 Launching And Boat Operation Care..............39 Conditions Affecting Operation Weight Distribution....................
  • Page 5 Maintenance Service Responsibilities..................43 Replacement Service Parts................43 Do‑It‑Yourself Maintenance Suggestions............44 Servicing High‑Horsepower Engines..............45 Engine Maintenance Charts................45 Bravo Drive Maintenance Charts..............47 Checking Fluid Levels..................50 Closed Cooling System..................54 Changing Fluids....................57 Lubrication......................63 Propellers......................66 Flushing the Power Package................
  • Page 6 Owner Service Assistance Local Repair Service..................107 Service Away from Home................107 Parts and Accessories Inquiries..............107 Service Assistance..................107 Mercury Marine Service Offices..............107 Ordering Literature United States and Canada................109 Outside The United States and Canada............109 Maintenance Log...

  • Page 7: Warranty Information

    Outside United States and Canada–Check with your local distributor. 1. You may change your registered address at any time, including at time of warranty claim, by calling Mercury Marine or sending a letter or fax with your name, old address, new address, and engine serial number to Mercury Marine’s warranty registration department.

  • Page 8: Mercury Racing Division One Year Limited Warranty United States And Canada

    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 Mercury Marine specified predelivery inspection process is completed and documented.
  • Page 9 • Improper service • Use of an accessory or part that was not manufactured or sold by Mercury Marine and that damages the Mercury product • Operation with fuels, oils, or lubricants that are not suitable for use with the product.

  • Page 10: Products Sold To Government Agencies

    RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Products Sold to Government Agencies Contact the Mercury Racing Sales Department for a copy of the Government Agencies Warranty Packet Kit, which explains the conditions required for government agencies to receive warranty when purchasing Mercury Racing...

  • Page 11: Warranty Coverage And Exclusions For Mercury Racing Sterndrive Products

    6. Use of other than Mercury Precision or Quicksilver parts when making warranty repairs.

  • Page 12: California Emission Control Warranty Statement

    Mercury Racing for certification from the California Air Resources Board, for the period of time, and under the conditions identified below.
  • Page 13 The customer must provide Mercury Racing with a reasonable opportunity to repair and reasonable access to the product for warranty service. Warranty claims shall be made by delivering the product for inspection to a Mercury dealer authorized to service the product. If purchaser cannot deliver the product to such a dealer, please notify Mercury Racing and Mercury Racing will then arrange for the inspection and any covered repair.
  • Page 14 Mercury Marine‑certified remanufactured parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without assuming an obligation to modify products previously manufactured.

  • Page 15: California Emission Control Warranty Rights And Obligations

    Mercury Racing recommends that you retain all receipts covering maintenance on your sterndrive engine, but Mercury Racing cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance.

  • Page 16: E.p.a. Emission Controls

    INTRODUCTION Consistent with the obligations created by 40 CFR Part 1045, Subpart B, Mercury Marine provides an emission warranty of three years or 480 hours of engine use, whichever occurs first, to the retail purchaser for electrical components of the emission control system, and one year or 150 hours of engine use, whichever occurs first, to the retail purchaser for mechanical components of the emission control system.
  • Page 17 WARRANTY INFORMATION a. PCV valve b. Oil filler cap 6. Exhaust system a. Exhaust manifold b. Exhaust elbow c. Intermediate exhaust elbow d. Lower exhaust pipe e. Tailpipe 7. Catalysts or thermal reactor system a. Catalytic converter b. Thermal reactor c.

  • Page 18: General Information

    GENERAL INFORMATION Before Operating Your Boat Read this manual carefully. Safety and operating information that is practiced along with using good common sense can help prevent personal injury and product damage. If you have any questions, contact your dealer. This manual as well as safety labels posted on the engine package use safety alerts to draw your attention to special safety instructions that must be followed.

  • Page 19: High-Speed And High-Performance Boat Operation

    For additional information, obtain a copy of our High‑Performance Boat Operation booklet from your dealer, distributor, or Mercury Marine. Paddle Wheel and Water Temperature Sensors Paddle wheels cannot be utilized on vessels that are capable of speeds in excess of 50 mph.

  • Page 20: Trailering The Boat

    GENERAL INFORMATION WARNING If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard. WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation.

  • Page 21: Exhaust Emissions

    GENERAL INFORMATION Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the propeller to rotate. This neutral propeller rotation can cause serious injury. WHILE BOAT IS STATIONARY WARNING A spinning propeller, a moving boat, or any solid device attached to the boat...
  • Page 22 GENERAL INFORMATION Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing).

  • Page 23: Wave And Wake Jumping

    GENERAL INFORMATION 2. Examples of poor ventilation while the boat is moving: 21628 Operating the boat with the trim angle of the bow too high Operating the boat with no forward hatches open (station wagon effect) Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating.

  • Page 24: Impact With Underwater Hazards

    Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package. After striking a submerged object, stop the engine as soon as possible and inspect it for any broken or loose parts.

  • Page 25: Operating In Shallow Water

    GENERAL INFORMATION The boat should also be checked for any hull fractures, transom fractures, or water leaks. Operating a damaged sterndrive could cause additional damage to other parts of the sterndrive, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

  • Page 26: Safe Boating Suggestions

    GENERAL INFORMATION 2. Bring the boat up on plane but operate at a moderate speed until the engine temperature and block water pressure returns to normal. NOTE: Engine block pressure at the gauge can still be low if the line to the gauge is clogged.
  • Page 27 GENERAL INFORMATION • Manual bilge pump and extra drain plugs; compass and map or chart of area. • Spare operating equipment; batteries, bulbs, fuses, etc. • Transistor radio and drinking water. Know signs of weather change and avoid foul weather and rough‑sea boating.

  • Page 28: Stolen Power Package

    If your power package is stolen, immediately advise the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This Stolen Power Package information is placed into a file at...

  • Page 29: Specifications

    Look for a smartphone link on the upper corner of the information label to access quick product information. Fuel Requirements Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness.
  • Page 30 Mercury Racing does not recommend using leaded gasoline. Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the...

  • Page 31: Low Permeation Fuel Hose Requirement

    SPECIFICATIONS The fuel system components on your Mercury engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat’s fuel system will withstand. Fuel containing alcohol may increase: • Corrosion of metal parts.

  • Page 32: Capacities

    SPECIFICATIONS IMPORTANT OIL PRACTICES Do Not Use • Straight weight oils • Nondetergent oils • Oils containing solid additives • Multiviscosity oils other than the ones recommended • Low quality oils Do Not Mix • Different brands of oils, straight weight or multiviscosity •...

  • Page 33: General Engine Specifications

    SPECIFICATIONS General Engine Specifications 403 kW, 540 HP Crankshaft horsepower Displacement 8.57 L (523 cid) Cylinder arrangement Bore 116 mm (4.560 in.) Stroke 102 mm (4.00 in.) Compression ratio 8.6:1 Alternator 95 amp/1238 watt Battery requirements Group 31M, 1150 CCA (minimum) Electrical system 12‑volt negative (–) ground Ignition type...

  • Page 34: Engine Operating Limitations

    SPECIFICATIONS Engine Operating Limitations Maximum wide‑open throttle (WOT) RPM 5000–5400 RPM 5600 RPM Rev limit Idle RPM in gear 700 RPM Idle RPM out of gear 800 RPM 155 L/hr (41 gals/hr) at 5200 Maximum fuel system flow rate Fuel pressure at idle 300 kPa (43.5 psi) Fuel pressure at wide‑open throttle 270 kPa (39.2 psi)

  • Page 35: After Break-In Period

    Frequently check engine oil level. Add oil if needed. It is normal for oil consumption to be high during break‑in period. After Break‑In Period To help extend the life of your power package, Mercury Marine recommends the following: After 5 hr. Break‑in •...

  • Page 36: Operation

    59 seconds off. • To stop the warning horn, turn off the engine. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem as soon as possible.

  • Page 37: Electrical System Overload Protection

    • If the beeping does not reoccur, the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault. If the propulsion control module (PCM) detects a fault signal from an engine sensor, it records a fault code.
  • Page 38 OPERATION NOTE: In an emergency, when you must operate the engine and cannot locate the cause for the high current draw, turn off or disconnect all accessories connected to the engine and instrumentation wiring. Reset the circuit breaker. If the breaker remains open, the electrical overload has not been eliminated. Contact your authorized dealer.
  • Page 39 OPERATION Four fuses protect the main power, fuel pump, ignition, and accessory circuits. Four 10‑amp fuses protect the O sensors. These are located near the 14‑pin harness connector. 50401 Good fuse Bad fuse Alternator and fuel pump circuit—20‑amp fuse Power to 14‑pin helm harness—20‑amp fuse ECM driver power, fuel pump relay, coils, and start relay (DTS—...
  • Page 40 OPERATION The clean power harness connected to the engine starting battery minimizes voltage drop to the electrical system and is protected by a 5‑amp fuse. a b c d e Paddle wheel and tank level connector Diagnostic connector 14‑pin harness connector Clean power harness connector Transom harness connector 43057...
  • Page 41 OPERATION The emissions control system is protected by a 5‑amp fuse located in the clean power harness. 43608 5‑amp fuse Positive battery terminal (harness lead with fuse) Negative battery terminal A 20‑amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system.

  • Page 42: Remote Controls (Console Mounted Zero Effort)

    OPERATION The power trim system is protected from overload by both a 110‑amp fuse and a 20‑amp spade fuse on the power trim pump. The trim pump may also have an in‑line circuit protection device in the power trim positive lead near the battery switch or battery connection.

  • Page 43: Starting, Shifting, And Stopping

    OPERATION 2. The throttle control handle friction is adjustable using a 5/16 in. hex head wrench; clockwise increases friction. Trim switch Port friction adjustment Starboard friction adjustment 45691 Starting, Shifting, and Stopping WARNING Explosive fumes contained in the engine compartment can cause serious injury or death from fire or explosion.

  • Page 44: Operation Chart

    OPERATION FLOODED ENGINE Before trying a restart, check for full battery voltage (13.8–14.2 volts). Move control/throttle lever to full throttle. Be prepared to decrease the engine speed to idle as soon as the engine starts. STARTING PROCEDURE 1. Turn the key switch to "START." Release the key and allow the switch to return to the "RUN"...

  • Page 45: Freezing Temperature Operation

    The seawater section of the engine must be drained after use to prevent freezing. Damage caused by freezing is not covered by Mercury Racing's Limited Warranty.

  • Page 46: 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) may: • Increase speed and engine RPM. • Cause the boat to porpoise. • Cause the bow to bounce in choppy water. •...

  • Page 47: Propeller Selection

    Specified engine wide‑open throttle (WOT) and operating RPM range are listed in Specifications. IMPORTANT: All Mercury Racing engines have an RPM rev‑limiter that is set to an upper (or limited) RPM. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine RPM.
  • Page 48 CONDITIONS AFFECTING OPERATION EXAMPLE: An engine running at an elevation of 2,438 m (8,000 ft) will have over a 30% power loss while engine power on a hot and humid day can be reduced by as much as 14%. These losses apply to both normally aspirated and supercharged engines.

  • Page 49: Service Responsibilities

    • Perform all safety checks. • Return the unit to an authorized Mercury Marine dealer for a periodic checkup. Proper maintenance and care of your power package will ensure optimum performance and dependability, and will keep your overall operating expenses at a minimum.

  • Page 50: Do-It-Yourself Maintenance Suggestions

    It is difficult for them to diagnose a problem over the telephone. • Your authorized Mercury Marine dealer is there to service your power package. They have qualified factory‑trained mechanics. Mercury Marine recommends that you have the dealer do periodic maintenance checks on your power package.

  • Page 51: Servicing High-Horsepower Engines

    Failure to follow the detailed maintenance and service schedule as written and supplied by Mercury Marine could lead to catastrophic engine failure and increased owner expense. Engine Maintenance Charts NOTE: Only perform maintenance which applies to your particular power package.
  • Page 52 MAINTENANCE Interval Task Perform all 25‑hour maintenance items. Serpentine and drive belts (all) ‑ Inspect condition and check tension. Cooling system hoses and clamps ‑ Inspect for damage and deterioration. Check clamps for tightness. Electrical system ‑ Check for loose or damaged wiring. Every 50 hours or once a year, Continuity circuit ‑...

  • Page 53: Bravo Drive Maintenance Charts

    MAINTENANCE Interval Task Power package exterior surfaces ‑ Clean and paint. Check engine cylinder compression. Oil coolers for the engine and power steering ‑ Clean seawater section. Flame arrestor and crankcase Every 100 hours of operation or once a ventilation hose ‑ Inspect, clean, year, whichever occurs first.
  • Page 54 MAINTENANCE Interval Task Gear housing water pickups ‑ Check for marine growth or debris. Every 25 hours of operation or once Anodes ‑ Inspect for erosion. every 30 days, whichever occurs first. Sterndrive unit oil ‑ Check level. Trim pump ‑ Check oil level. Saltwater use: Every 50 hours of operation or 60 days, whichever occurs Propeller shaft ‑...
  • Page 55 MAINTENANCE Interval Task Perform all 25 hour maintenance items. Shift cable and linkage ‑ Lubricate and inspect for loose, damaged, or missing parts. Engine coupler and universal joint shaft splines and O‑rings ‑ Lubricate. Sterndrive unit ‑ Oil change. Sterndrive unit universal joint cross bearings ‑...

  • Page 56: Checking Fluid Levels

    MAINTENANCE Interval Task Power package exterior surfaces ‑ Clean and paint. Steering head and remote control ‑ Inspect and lubricate. Drive unit bellows and clamps ‑ Inspect. Every 100 hours of operation or once a Propeller shaft bearing ‑ Inspect by year, whichever occurs first.
  • Page 57 MAINTENANCE 2. Remove the dipstick and check the oil level. The oil level must be between the "FULL" and "ADD" mark. FULL 53509 IMPORTANT: Do not overfill crankcase oil. 3. If the oil level is below the "ADD" mark, remove the oil filler cap. Add the specified oil to bring the level up to, but not over, the "FULL"...
  • Page 58 Stop the engine and position the drive unit straight back. IMPORTANT: If fluid is not visible in the reservoir, contact your authorized Mercury MerCruiser dealer. 1. Remove the fill cap/dipstick and observe the level. The oil level must be at the lower mark when the engine is cold and at the upper mark when the engine is warm.
  • Page 59 IMPORTANT: If more than 59 ml (2 fl oz) of gear lube is required to fill the monitor, a seal may be leaking. Damage to the drive unit may occur due to lack of lubrication. Contact your authorized Mercury MerCruiser dealer for service.

  • Page 60: Closed Cooling System

    MAINTENANCE NOTE: Ensure that the cap plug has been removed and discarded from the filler neck at first use. Cap plug 7978 Tube Ref Description Where Used Part No. Power Trim and Power trim pump reservoir 92-858074K01 Steering Fluid 3. Add Power Trim and Steering Fluid, if required, to bring the level to the bottom of the filler neck.
  • Page 61 MAINTENANCE NOTE: All factory‑installed closed cooling systems come filled with Extended Life Coolant. This antifreeze requires draining and replacing every five years or 1000 hours of operation, whichever comes first. The color of this antifreeze is orange. Any "top‑off" fluid used must be Extended Life Coolant. Tube Ref Description Where Used...
  • Page 62 MAINTENANCE NOTICE Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed. The coolant section of the closed cooling system must be filled with a 50/50 mixture of Extended Life Antifreeze/Coolant and distilled water.

  • Page 63: Changing Fluids

    9. Maintain the coolant level in the reservoir at or near the "FULL" mark with the engine cold. DRAINING Contact your authorized Mercury MerCruiser dealer. CLEANING Contact your authorized Mercury MerCruiser dealer. Changing Fluids See the Maintenance Chart for the lubricant change frequency.
  • Page 64 MAINTENANCE 4. Remove the crankcase oil pump. 5. Place a container beneath the oil filter. NOTE: To allow the oil to drain from the filter, loosen the filter just enough to break the internal vacuum. Let the oil drain back into the system for 15 minutes prior to complete removal of the filter.
  • Page 65 MAINTENANCE CRANKCASE OIL AND FILTER (BOAT OUT OF THE WATER) WARNING Performing tests with the engine running may cause the propeller to rotate and result in serious injury or death. Use caution when performing a test that requires the engine running, and remove the propeller to avoid injury. NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine.
  • Page 66 25W-40 Engine Oil DRIVE UNIT OIL (BRAVO ONE XR MODELS) Mercury Racing Gear Oil is now available for use in your drive unit. This oil will increase the service life of your drive unit when used in place of other oils. Do not mix Mercury Racing Gear Oil with any other oil.
  • Page 67 2. Remove the oil vent screw and sealing washer. Allow the oil to drain completely. IMPORTANT: If any water drained from the oil fill/drain hole, or if the oil appears milky, the drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7987 Sealing washer Oil vent screw...
  • Page 68 MAINTENANCE 4. Fill the drive unit through the oil fill/drain hole with Mercury Racing Gear Oil until an air‑free stream of lubricant flows from the oil vent hole. 7988 Oil fill/drain screw Tube Ref Description Where Used Part No. SAE 85W90...

  • Page 69: Lubrication

    8. Continue adding gear lube until the oil level is at the top line marked "COLD FILL" on the bottle. 9. Lubricate the neck of the O‑ring with Mercury Racing Gear Oil to ensure ease of installation and removal of the cap.
  • Page 70 MAINTENANCE Lubricate the gimbal bearing with 2‑4‑C with PTFE lubricant. Gimbal bearing grease fitting mc77068-1 Tube Ref Description Where Used Part No. 2-4-C with PTFE Gimbal bearing 92-802859A 1 ENGINE COUPLER Lubricate the engine coupler and shaft splines with Engine Coupler Spline Grease.
  • Page 71 MAINTENANCE Tube Ref Description Where Used Part No. Engine Coupler Engine coupler and shaft splines 8M0071842 Spline Grease DRIVESHAFT EXTENSION MODELS Lubricate driveshaft grease fittings at the transom end with 2‑4‑C with PTFE lubricant. 8015 8016 Tube Ref Description Where Used Part No.

  • Page 72: Propellers

    MAINTENANCE Propellers BRAVO 1 XR MODEL PROPELLERS WARNING Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from starting.
  • Page 73 MAINTENANCE 2. Install the Bravo XR replaceable hub propeller components in the order shown: 8020 Propeller shaft Prop hub assembly Propeller assembly Washer Belleville washer Washer Locknut 3. After first use: Retighten propeller nut. Description lb‑in. lb‑ft Propeller nut –...
  • Page 74 MAINTENANCE Removal 1. Place a wood block between the propeller blade and the anti‑ventilation plate to prevent rotation. Wood block Propeller nut 7448 2. Remove the propeller nut.

  • Page 75: Flushing The Power Package

    Propeller assembly Washer Belleville washer Washer Locknut NOTE: Some damaged propellers can be repaired. See your authorized Mercury Marine dealer. Flushing the Power Package The following procedure explains flushing the power package through the sterndrive water pickups. FLUSHING ATTACHMENTS Flushing Device 91‑44357Q 2...
  • Page 76 MAINTENANCE Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases. 9194 Flushing Kit 91‑849996T 1 Use for flushing gearcases with low water inlets. 9195 Flushing Attachment 91‑843122A01 Attaches to the water intakes;...
  • Page 77 MAINTENANCE STERNDRIVE WATER PICKUPS There are three types of water pickups available on Mercury MerCruiser sterndrives: low water, dual water, and side pickups. Dual water pickups require the flushing attachment (91‑44357Q 2) and the flush seal kit (91‑881150K 1). The High‑Performance low water pickup drive requires the flushing attachment (91‑849996T 1) while the SportMaster low water pickup...
  • Page 78 MAINTENANCE NOTE: Flushing is needed only for salty, brackish, mineral‑laden or polluted water applications. Flushing is recommended after each outing. NOTICE Flushing the engine with the boat in the water can cause seawater to flow into the engine, resulting in engine damage. Close the seacock before flushing the engine.

  • Page 79: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE 10. Shut off the water and remove the flushing attachment. Cleaning Seawater (Raw Water) Section of Oil Cooler NOTICE An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat.

  • Page 80: Changing Positive Crankcase Ventilation Valve

    Install new PCV valve into hose, and install into intake manifold. • Ensure that the valve is tightly seated in manifold. Use only Mercury MerCruiser replacement parts. Cleaning the Flame Arrestor WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.
  • Page 81 MAINTENANCE 1. Loosen the flame arrestor clamp, and remove the flame arrestor. 50396 Flame arrestor Flame arrestor clamp 2. Clean the flame arrestor with solvent and dry with compressed air, or set aside and allow to air dry completely. 3. Install the flame arrestor and tighten the clamp to the specified torque. Description lb‑in.

  • Page 82: Serpentine Drive Belt

    MAINTENANCE Serpentine Drive Belt INSPECTION WARNING Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before inspecting the belts. 50406 Alternator pulley Idler pulley Power steering pump pulley Water circulating pump pulley Crankshaft pulley Tensioner pulley...
  • Page 83 MAINTENANCE Belt routing diagram CHECKING Inspect the drive belt for: • Proper belt tension deflection • Excessive wear • Cracks • Fraying • Glazed surfaces • Proper tension Use moderate thumb pressure on the belt at the location with the longest distance between two pulleys.
  • Page 84 MAINTENANCE CAUTION Rapid release of the belt tensioner, or allowing the tensioner to snap back quickly, could cause injury or product damage. Relieve the spring tension slowly. 1. Use a breaker bar and appropriate socket to relieve the tensioner. Rotate the tensioner away from belt until it stops.

  • Page 85: Water-Separating Fuel Filter

    MAINTENANCE Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors.
  • Page 86 MAINTENANCE 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 the fuel supply valve, if equipped. 3. Disconnect the Cool Fuel Module harness from the engine wiring harness.

  • Page 87: Corrosion And Corrosion Protection

    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. Corrosion and Corrosion Protection...
  • Page 88 MAINTENANCE NOTE: This test should be made where the boat is moored, using a reference electrode and test meter. Contact your authorized Mercury MerCruiser dealer to arrange for this test. MerCathode Electrode assembly 9322 SACRIFICIAL ANODES Sacrificial anodes ‑ help protect the power package against galvanic corrosion by sacrificing its metal to be slowly eroded instead of the metal components on the power package.
  • Page 89 MAINTENANCE 2. Gear housing with integrated splash plate anode ‑ is located in the splash plate, just above the propellers. 6205 XR Bravo One XR Bravo Three Gear housing anode 3. SportMaster splash plate anode ‑ is located on the splash plate that is attached to the gear housing just above the propeller.
  • Page 90 MAINTENANCE 4. Anodic block kit (optional) ‑ is mounted to the boat transom. Acts as a sacrificial anode. Replace as required. Anodic block 8033 5. Trim cylinder anodes ‑ are mounted on each trim cylinder. To replace the trim cylinder anodes: a.
  • Page 91 MAINTENANCE d. Reinstall the propeller. See Propeller Installation for proper torque. Bearing carrier anode 5644 PAINTING THE BOAT HULL OR TRANSOM 1. If antifouling protection is required for boat hull or boat transom, copper or tin base paints can be used unless otherwise prohibited by law.
  • Page 92 MAINTENANCE 2. If using copper or tin based antifouling paints, avoid any electrical interconnection between the Mercury Marine product, anodic blocks, and the paint by allowing a minimum of 40 mm (1.5 in.) unpainted area on the transom of the boat around these items.

  • Page 93: Battery

    MAINTENANCE ADDITIONAL CORROSION PREVENTION TIPS 1. Spray the power package components on the inside of the boat every two to three weeks with Corrosion Guard to protect the finish from dulling and corrosion. External power package components may also be sprayed. Tube Ref Description Where Used...

  • Page 94: Inspection And Maintenance

    4. Repair nicks and corrosion damage on the power package's exterior finish. Attention Required After Submersion • Before recovery, contact an authorized Mercury Marine dealer. • After recovery, immediate service by an authorized Mercury Marine dealer is required to prevent serious damage to power package.

  • Page 95: Cold Weather Or Extended Storage

    COLD WEATHER OR EXTENDED STORAGE Draining the Seawater System CAUTION Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining.
  • Page 96 COLD WEATHER OR EXTENDED STORAGE 55483 Starboard side air‑actuated drain location Port side air‑actuated drain location...

  • Page 97: Air-Actuated Single-Point Drain System

    COLD WEATHER OR EXTENDED STORAGE MANUAL DRAIN SYSTEM 55189 Starboard side blue drain plugs Port side blue drain plug Air‑Actuated Single‑Point Drain System BOAT IN THE WATER NOTE: This procedure is written for the air pump that was shipped with the engine from the factory.
  • Page 98 COLD WEATHER OR EXTENDED STORAGE 7. Pump air into the system until both green indicators extend and water drains from both sides of the engine. The port side will begin draining before the starboard side. Manual release valve Air pump lever (locked) Air pump Air connection...
  • Page 99 12. Remove the air pump from the air connection and return it to the mounting bracket. 13. 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 100 COLD WEATHER OR EXTENDED STORAGE 3. Ensure that the lever on top of the air pump is flush with the handle (horizontal). 4. Install the air pump on the air connection. 5. Pull the lever on the air pump (vertical) to seal the pump to the air connection.
  • Page 101 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 102: Manual Drain System

    COLD WEATHER OR EXTENDED STORAGE 13. Before launching the boat, pull up on the manual release valve. Verify that the green indicators are no longer extended. 50399 Manual pressure release valve Threaded cap for air connection Green indicators Manual Drain System BOAT IN THE WATER NOTE: Use this procedure if the air‑actuated single‑point drain system fails.
  • Page 103 Port side blue drain plug 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 104: Draining Water From The Cool Fuel Module

    Port side blue drain plug 4. Verify that water is draining from each opening. 5. 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 105: Battery Storage

    COLD WEATHER OR EXTENDED STORAGE 3. Place the O‑ring on the drain plug and apply Perfect Seal to the threads. Install the drain plug in the module drain hole. Tighten the drain plug to finger‑tight. 50410 Gen 3 Cool Fuel Module Drain plug O‑ring Tube Ref...
  • Page 106 COLD WEATHER OR EXTENDED STORAGE 2. Install a fully charged battery. Clean the battery cable clamps and terminals and reconnect the cables. Tighten each cable clamp securely when connecting. 3. Coat the terminal connections with a battery terminal anticorrosion agent. 4.

  • Page 107: Troubleshooting

    TROUBLESHOOTING Engine Will Not Crank Possible Causes Remedy Battery switch turned "OFF." Turn switch "ON." Gearshift not in neutral Position control lever to neutral. position. Open circuit breaker or blown Check and reset circuit breaker or replace fuse. fuse. Loose or dirty electrical Check all electrical connections and wires connections or damaged (especially battery cables).

  • Page 108: Engine Hard To Start, Runs Rough, Misses, And/Or Backfires

    TROUBLESHOOTING Possible Cause Remedy Replace kinked lines or blow out lines Fuel line or tank vent line kinked or with compressed air to remove restricted. obstruction. Crankshaft position sensor faulty. Test and replace if faulty. Test and replace if faulty. Do not Faulty fuel pressure regulator attempt to start the engine if the fuel diaphragm.

  • Page 109: Poor Performance

    TROUBLESHOOTING Poor Performance Possible Cause Remedy Inspect throttle cable and linkages for Throttle not fully open. proper operation. Damaged or wrong propeller. Replace propeller. Excessive bilge water. Drain and check for cause of entry. Boat overloaded or load Reduce load or redistribute load more improperly distributed.

  • Page 110: Low Engine Oil Pressure

    TROUBLESHOOTING Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in system. Check and add oil. Check and bring oil to required level. Excessive oil in system Check for cause of excessive oil (improper (causing it to become aerated). filling, defective fuel pump, etc.). Change oil and oil filter, using correct grade and viscosity oil.

  • Page 111: Power Trim Does Not Operate (Motor Runs But Drive Unit Does Not Move)

    Insufficient lubrication on shift and Lubricate. throttle linkage fasteners. Check all linkages. If any are loose Loose or missing shift and throttle or missing, see authorized Mercury linkage fasteners. Marine dealer immediately. Shift or throttle cable kinked. Replace cable. Friction adjustment excessive.

  • Page 112: Steering Wheel Turns Hard Or Jerky

    Check all parts and fasteners. If any Loose or missing steering fasteners are loose or missing, see authorized or parts. Mercury Marine dealer immediately. Contaminated power steering fluid. Drain and replace. Seawater Pressure Is Below Specification Possible Cause Remedy Check if seacock is completely open.

  • Page 113: Owner Service Assistance

    Satisfaction with your Sterndrive or Inboard product is very important to your dealer and to us. If you ever have a problem, question or concern about your Sterndrive or Inboard product, contact your dealer or any authorized Mercury Marine dealer. If additional assistance is required, take these steps.
  • Page 114 Japan Telephone +072 233 8888 Kisaka Co., Ltd. 4-130 Kannabecho Sakai-shi Sakai-ku 5900984 Osaka, +072 233 8833 Japan Asia, Singapore Telephone +65 65466160 Brunswick Asia Pacific Group T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive +65 65467789 Singapore, 508944...

  • Page 115: Ordering Literature

    Horsepower: Model: Serial Model year: Number: 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 Telephone Mail Mercury Marine Attn: Publications Department (920) 929‑5110 (920) 929‑4894...

  • Page 116: Maintenance Log

    MAINTENANCE LOG Maintenance Log Record all maintenance performed on your outboard here. Be sure to save all work orders and receipts. Date Maintenance Performed Engine Hours...

This manual is also suitable for:

Bravo sterndrive 520540 bravo sterndrive520 bravo sterndrive565 bravo sterndrive

Table of Contents