Mercury Racing HP525 EFI Bravo Sterndrive Series Operation, Maintenance & Warranty Manual

Mercury Racing HP525 EFI Bravo Sterndrive Series Operation, Maintenance & Warranty Manual

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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 & 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
operational instructions for the power package and all
related accessories before the boat is used.
eng
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
WARNING
!
Manual
and
i
thoroughly
understand
7406
the

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Summary of Contents for Mercury Racing HP525 EFI Bravo Sterndrive Series

  • Page 1 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! Mercury Racing, N7480 County Road "UU" Fond du Lac, WI 54935-9585 7406...
  • Page 2 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.
  • Page 3 © 2013 Mercury Marine, Fond du Lac, Wisconsin, USA. Printed in USA. Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo One, Bravo Two, Bravo Three, OptiMax, Sport‑Jet, K‑Planes, MerCathode,...
  • Page 5: Table Of Contents

    Warranty Information Warranty Registration United States and Canada....... 1 Transfer of Warranty..............2 Mercury Racing Division One‑Year Limited Warranty....3 Products Sold to Government Agencies........6 Three‑Year Limited Warranty Against Corrosion......7 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products..............10 E.P.A.
  • Page 6 Specifications Engine Identification..............28 Fuel Requirements..............29 Low Permeation Fuel Hose Requirement ......... 31 Crankcase Oil................31 Capacities.................. 33 General Engine Specifications........... 33 Engine Operating Limitations............. 34 Engine Break‑in................. 35 After Break‑In Period..............35 Operation Instrumentation................36 Warning System................ 36 Electrical System Overload Protection........
  • Page 7 Maintenance Service Responsibilities............. 60 Replacement Service Parts............61 Do‑It‑Yourself Maintenance Suggestions........61 Servicing High‑Horsepower Engines......... 63 Engine Maintenance Charts............63 Bravo Drive Maintenance Charts..........65 Checking Fluid Levels..............67 Changing Fluids................. 74 Lubrication................. 85 Propellers................... 88 Flushing the Power Package............. 96 Seawater Pump Impeller Inspection........
  • Page 8 Troubleshooting Engine Will Not Crank.............. 126 Engine Cranks But Will Not Start..........126 Engine Hard to Start, Runs Rough, Misses, and/or Backfires. 127 Low Engine Coolant (Closed Cooling) Temperature....127 Poor Performance..............128 Insufficient Engine Temperature..........128 High Engine Temperature............129 Low Engine Oil Pressure............
  • Page 9 Maintenance Log Maintenance Log..............137...
  • Page 11: Warranty Information

    WARRANTY INFORMATION Warranty Registration United States and Canada 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 12: Transfer Of Warranty

    WARRANTY INFORMATION Transfer of Warranty The limited 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. To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name, address and engine serial number to Mercury Marine’s Warranty Registration Department.
  • Page 13: Mercury Racing Division One-Year Limited Warranty

    WARRANTY INFORMATION Mercury Racing Division One‑Year Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products (and remanufactured products sold under the trade name "Pacemaker") to be free of defects in material and workmanship during the period described below.
  • Page 14 WARRANTY INFORMATION WHAT MERCURY WILL DO Mercury’s sole and exclusive obligation under this warranty is limited to, at our option, repairing a defective part, replacing such part or parts with new or Mercury Marine‑certified re‑manufactured parts, or refunding the purchase price of the Mercury product.
  • Page 15 WARRANTY INFORMATION WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items, tune ups, adjustments, normal wear and tear, damage caused by abuse, abnormal use, use of a propeller or gear ratio that does not allow the engine to run in its recommended wide‑open‑throttle RPM range, operation of the product in a manner inconsistent with the recommended operation/duty cycle section of the Warranty, Operation, and Maintenance Manual,...
  • Page 16: Products Sold To Government Agencies

    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 Outboard or Sterndrive product.
  • Page 17: Three-Year Limited Warranty Against Corrosion

    WARRANTY INFORMATION Three‑Year Limited Warranty Against Corrosion WHAT IS COVERED: Mercury Marine warrants that each new Mercury, Mariner, Mercury Racing Outboard, Sport Jet, M Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser inboard or sterndrive engine, Mercury Racing Bravo‑style sterndrive engine (Product) will not be rendered inoperative as a direct result of corrosion for the period of time described below.
  • Page 18 WARRANTY INFORMATION WHAT MERCURY WILL DO: Mercury's sole and exclusive obligation under this warranty is limited to, at our option, repairing a corroded part, replacing such part or parts with new or Mercury Marine‑certified re‑manufactured 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 19 WARRANTY INFORMATION Corrosion damage caused by stray electrical currents (on‑shore power connections, nearby boats, submerged metal) is not covered by this corrosion warranty and should be protected against by the use of a corrosion protection system, such as the Mercury Precision Parts or Quicksilver MerCathode system and/or galvanic Isolator.
  • Page 20: Warranty Coverage And Exclusions For Mercury Racing Sterndrive Products

    The provisions set forth following have been incorporated by reference into the Mercury Racing Division Three‑Year Limited Warranty Against Corrosion Failure, the Mercury Racing Division 90‑Day, Six‑Month and One‑Year Limited Warranties.
  • Page 21: E.p.a. Emission Controls

    WARRANTY INFORMATION 5. Labor performed by other than an authorized dealer may be covered only under following circumstances: When performed on an emergency basis providing there are no authorized dealers in the area who can perform the work required or have no facilities to haul out, etc., and prior factory approval has been given to have the work performed at this facility.
  • Page 22 WARRANTY INFORMATION EMISSION CONTROL SYSTEM COMPONENTS The emission‑related warranty covers all components whose failure would increase an engine's emission of any regulated component including the following list of components: 1. Fuel metering system a. Carburetor and internal parts (or fuel pressure regulator or fuel injection system) b.
  • Page 23 WARRANTY INFORMATION d. Lower exhaust pipe e. Tailpipe 7. Catalysts or thermal reactor system a. Catalytic converter b. Thermal reactor c. Exhaust manifold d. Exhaust valves 8. Evaporative System a. Carbon Canister(s) b. Fuel tanks c. Purge valve(s) 9. Miscellaneous items used in above systems a.
  • Page 24: 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 25: High-Speed And High-Performance Boat Operation

    GENERAL INFORMATION Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable power and load as determined by the manufacturer following certain federal guidelines. If in doubt, contact your dealer or the boat manufacturer.
  • Page 26: Lanyard Stop Switch

    GENERAL INFORMATION Lanyard Stop Switch The purpose of a lanyard stop switch is to turn off the engine when the operator moves far enough away from the operator's position (as in accidental ejection from the operator's position) to activate the switch. A lanyard stop switch can be installed as an accessory ‑...
  • Page 27: Trailering The Boat

    GENERAL INFORMATION WARNING Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator. Accidental or unintended activation of the switch during normal operation is also a possibility.
  • Page 28: Exhaust Emissions

    GENERAL INFORMATION Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water. 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.
  • Page 29 GENERAL INFORMATION POOR VENTILATION Under certain running and/or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat. Although the occurrence is rare, on a very calm day, swimmers and passengers in an enclosed area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.
  • Page 30: Wave And Wake Jumping

    GENERAL INFORMATION GOOD VENTILATION Ventilate passenger area, open side curtains, or forward hatches to remove fumes. 5448 Wave and Wake Jumping Operating recreational boats over waves and wake is a natural part of boating. However, when this activity is done with sufficient speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat enters the water.
  • Page 31: Impact With Underwater Hazards

    GENERAL INFORMATION There is another less common hazardous result from allowing your boat to launch off a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.
  • Page 32: Operating In Shallow Water

    GENERAL INFORMATION • A rapid reduction in speed. This will cause occupants to be thrown forward, or even out of the boat. • Impact damage to the sterndrive and/or boat. Keep in mind, the most important thing you can do to help reduce injury or impact damage during an impact is control the boat speed.
  • Page 33 GENERAL INFORMATION Extreme care should be exercised when operating a boat equipped with only low water inlets while maneuvering in shallow water. Due to a small amount of total water inlet area, there is high suction at the water inlets. These inlets will easily clog with bottom contact and are susceptible to clogging when operated in shallow or weedy water.
  • Page 34: Safe Boating Suggestions

    GENERAL INFORMATION NOTE: Engine block pressure at the gauge can still be low if the line to the gauge is clogged. 7759 Dual Water Inlet Gear Case Strut inlets Low water inlets 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.
  • Page 35 GENERAL INFORMATION • Spare propeller, thrust hubs and an appropriate wrench. • Tools for necessary minor repairs; first aid kit and book. • Anchor, extra anchor line; water‑proof storage containers. • Manual bilge pump and extra drain plugs; compass and map or chart of area.
  • Page 36 GENERAL INFORMATION Make sure everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the back of seats, gunwales, transom, bow, decks, raised fishing seats, any rotating fishing seat;...
  • Page 37: Stolen Power Package

    GENERAL INFORMATION 1. There is loss of life or probable loss of life 2. There is personal injury requiring medical treatment beyond first aid 3. There is damage to boats or other property where the damage value exceeds $500.00 4. There is complete loss of the boat IMPORTANT: Seek further assistance from local law enforcement for a complete list of rules and regulations.
  • Page 38: Specifications

    SPECIFICATIONS Engine Identification Model: HP525 EFI 502 C.I.D. Displacement: SERIAL NUMBERS 4800 - 5200 Max WOT RPM: NGK BPR6ES Spark Plugs: ENGINE Spark Plug Gap: 0.035 Inch Spark Timing: **non-adjustable 87 (R+M)/2 or DRIVE Fuel Octane: 92 RON International Engine Oil: **Quicksilver 25W40 Dex-Cool ®...
  • Page 39: Fuel Requirements

    SPECIFICATIONS Running Rotation: _________________________ Hull Identification Number: _________________________ Boat Model & Length: _________________________ MODEL (HALF) YEAR IDENTIFICATION • Changed the engine harness from 10 pin to 14 pin. • Relocated the ignition coils and fuel filter for clearance of the tailpipe in staggered engine installations.
  • Page 40 • Deterioration of rubber or plastic parts. 2. 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 combustion chambers.
  • Page 41: Low Permeation Fuel Hose Requirement

    SPECIFICATIONS • Fuel permeation through rubber fuel lines. • Starting and operating difficulties. IMPORTANT: Operating a Mercury Marine engine with gasoline containing alcohol creates unique problems as a result of long storage periods common to a boat. Cars normally consume alcohol‑blend fuels before they absorb enough moisture to cause problems;...
  • Page 42 SPECIFICATIONS IMPORTANT OIL PRACTICES Do Not Use • Straight weight oils • Non‑detergent oils • Oils containing solid additives • Multi‑viscosity oils other than the ones recommended • Low quality oils Do Not Mix • Different brands of oils, straight weight or multi‑viscosity •...
  • Page 43: Capacities

    SPECIFICATIONS Capacities Model HP525 EFI 7.6 L (8 U.S. qts) Crankcase Oil Capacity with New Filter Bravo ‑ Drive Unit Oil Capacity (with Monitor) 2.65 L (2.8 U.S. qts) Bravo III XR ‑ Drive Unit Oil Capacity (with Monitor) 2.8 L (3 U.S. qts) Closed Cooling System 13 L (14 U.S.
  • Page 44: Engine Operating Limitations

    SPECIFICATIONS Engine Operating Limitations Maximum wide open throttle (W.O.T.) RPM 4800 ‑ 5300 RPM 5400 RPM Rev limit Idle RPM in gear 700 RPM Idle RPM out of gear 750 RPM 163 L/hr (43 gals/hr) at 5200 Maximum fuel system flow rate Fuel pressure at Sea Level 262‑296 kPa (38‑43 psi) Coolant thermostat initially opens at...
  • Page 45: Engine Break-In

    SPECIFICATIONS Engine Break‑in IMPORTANT: Failure to follow the engine break‑in procedures can result in poor performance throughout the life of the engine and can cause engine damage. Always follow break‑in procedures. 5 Hr. Break‑in Procedure • Allow engine to warm‑up for 30‑60 seconds. •...
  • Page 46: Operation

    OPERATION Instrumentation Mercury Racing requires that the following critical engine functions be monitored: • Oil pressure • Engine RPM • Oil temperature • Water temperature • System voltage • Guardian fault messages The use of SmartCraft instrumentation will display all of the above critical engine functions as well as others not listed.
  • Page 47 OPERATION Fault Type and Related Warning Signal • Critical ‑ Steady horn • Severe ‑ 5 beeps, each 3 seconds long • Warning ‑ 3 beeps, each 1.5 seconds long • Caution ‑ 2 beeps, each 1 second long • To stop an activated horn warning, turn off the engine.
  • Page 48 OPERATION Guardian Activated and Engine Monitor Power Possible Cause Horn Display Reduced Engine Overspeed Steady Horn Low Seawater Pressure Steady Horn Seawater Pressure 3 Beeps‑1.5 Sec. Sensor Failure Long Coolant Overheat Steady Horn Coolant Temperature 3 Beeps‑1.5 Sec. Sensor Failure Long Low Oil Pressure Steady Horn...
  • Page 49: Electrical System Overload Protection

    OPERATION Guardian Activated and Engine Monitor Power Possible Cause Horn Display Reduced Battery Range high or 3 Beeps‑1.5 Sec. Long Low Drive Lube or Transmission Oil 2 Beeps‑1 Sec. Long Temperature too high Lanyard Switch activated 2 Beeps‑1 Sec. Long Electrical System Overload Protection If an electrical overload occurs, a fuse or circuit breaker opens.
  • Page 50 OPERATION 4. The power trim system is protected from overload by a 110 amp fuse and a 20 amp in‑line fuse on power trim pump. 10121 20 AMP Fuse 110 AMP fuse...
  • Page 51 OPERATION 5. Bravo Drive:The MerCathode System has a 20 amp in‑line fuse in the wire which connects to the positive (+) terminal on the controller. If fuse is blown, the MerCathode system will not operate and a loss of corrosion protection will result. 20 amp in‑line fuse MERCATHODE 7775...
  • Page 52 OPERATION IMPORTANT: Always check the ground connections and power leads for corrosion and tightness. If the ground leads are loose or dirty, current will not flow. 14325 Battery lead cover Battery connection 110 AMP fuse Starter solenoid Starter motor Flywheel housing Ground connections 7.
  • Page 53: Remote Controls

    OPERATION Remote Controls All controls feature an integral safety switch that allows starting the engine in neutral only. If the boat is equipped with a remote control other than that shown, consult your dealer for a description and/or demonstration of the control.
  • Page 54 OPERATION 7820...
  • Page 55 OPERATION Neutral Lock Bar ‑ Prevents accidental shift and throttle engagement. The neutral lock bar must be pulled up to move the control handle out of neutral. Throttle Only Button ‑ Allows throttle advancement without shifting the engine by disengaging the shift mechanism from the control handle.
  • Page 56: Remote Controls (Console Mounted Zero Effort)

    OPERATION Remote Controls (Console Mounted Zero Effort) 1. Control the throttle by moving the longer control lever(s) or, to increase speed, push the control lever forward. Detents give the movement of the lever a notched, precise feel. The detents also help hold the lever at the desired engine RPM to reduce operator fatigue.
  • Page 57: Power Trim

    OPERATION 3. See Power Trim section for detailed power trim operating procedures. 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. IMPORTANT: Each boat manufacturer has the option as to how the power trim will function on their particular boat.
  • Page 58 OPERATION • In excess, cause boat porpoising (bouncing) or propeller ventilation. 7419 Trimming Drive Unit Down/In Can: 7420 • Help the boat accelerate and plane off quicker. • Generally improve the ride in choppy water. • In most cases, reduce boat speed. •...
  • Page 59 OPERATION POWER TRIM OPERATION Dual Engine Console Mount Remote Control (Two Button Version) WARNING Excessive trim can cause serious injury or death at high speeds, and single‑ram trim systems do not provide a trim‑out limiting device or trim indicator. Use caution when trimming with a single‑ram trim system and never trim out beyond the unit's side support flanges while the boat is underway or at engine speeds above 1200 RPM.
  • Page 60 OPERATION 7867...
  • Page 61 OPERATION Control ‑ Used to control both drive units from the handle. Press up on the button(s) to trim drive unit up or out. Press down on button(s) to trim drive unit down or in. Trailer Button ‑ Press button until drive unit reaches desired height for trailering drive units.
  • Page 62: Starting, Shifting And Stopping

    OPERATION NOTE: The word trim is usually considered the first 20° up/out movement from vertical position. 7868 Trailering and trimming up/out position ‑ Press (top) up/out portion of switch until drive unit reaches desired trim/trailering position. Trim drive unit in/down position ‑ Press (bottom) in/ down portion of switch until drive unit reaches desired trim position.
  • Page 63 OPERATION IMPORTANT: Observe the following: • Do not start the engine without supplying water to the seawater pickup pump (to prevent pump or engine damage). • Do not operate the starter motor continuously for more than 30 seconds. • Never shift the drive unit unless the engine is at idle RPM. Perform the following as appropriate: Check all items listed in Operation Chart.
  • Page 64: Operation Chart

    OPERATION • Check the oil pressure gauge immediately after the engine starts. If oil pressure is not within the specified range, see Specifications, stop the engine immediately, and determine cause. • If engine is cold, make sure engine is idling smoothly before operating boat.
  • Page 65: 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 66: Drain Plug And Bilge Pump

    Engine components will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Racing Limited Warranty. Launching And Boat Operation Care...
  • Page 67: 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 68: Ventilation

    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 69: Conditions That Lower Engine Performance

    CONDITIONS AFFECTING OPERATION • Operating in warmer weather and greater humidity. • Operating in a higher elevation. • Operating with a damaged propeller or dirty boat bottom. • Operating with increased load (additional passengers, pulling skiers, etc.). Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems.
  • Page 70: Maintenance

    MAINTENANCE Service Responsibilities OWNER/OPERATOR RESPONSIBILITIES It is the owner/operator's responsibility to perform the following: • 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 71: Replacement Service Parts

    MAINTENANCE Replacement Service Parts WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards.
  • Page 72 MAINTENANCE • Present‑day marine equipment, such as your Mercury Marine power package, are highly technical pieces of machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but increased complexity for the untrained mechanic. • Do not attempt any repairs that are not covered in this manual unless you are aware of the precautions and procedures required.
  • Page 73: Servicing High-Horsepower Engines

    MAINTENANCE Mercury Marine recommends that you have the dealer do periodic maintenance checks on your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of any problems occurring during your boating season when you want trouble‑free boating pleasure.
  • Page 74 MAINTENANCE Interval Task Crankcase oil and filter ‑ Change. Check the oil level in the sea pump/fuel pump and inspect for fuel contamination. Every 25 hours of operation or once Battery ‑ Check water level and every 30 days, whichever occurs first. inspect for damage.
  • Page 75: 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 or year, whichever occurs first.
  • Page 76 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 Propeller shaft ‑...
  • Page 77: 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 78 MAINTENANCE 2. Remove the dipstick and check the oil level. The oil level must be between the "FULL" and "ADD" mark. Dipstick with "FULL" FULL and "ADD" marks 19674 IMPORTANT: Do not overfill crankcase oil. 3. If the oil level is below the "ADD" mark, remove the oil filler cap, (port or starboard).
  • Page 79 MAINTENANCE 25W-50 Verado Crankcase 92-858084K01 FourStroke Outboard Oil MerCruiser 4- cycle 25W40 Engine crankcase 92-858048K01 Engine Oil POWER STEERING PUMP 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.
  • Page 80 MAINTENANCE 2. Add power steering fluid if required. 3. Re‑install the fill cap/dipstick. SEAWATER/FUEL PUMP OIL IMPORTANT: Oil must be changed at specified intervals. Refer Maintenance Chart for specific requirements. Use only High Performance Gear Lube in pump. 1. Remove fill screw (top) and check oil level. 2.
  • Page 81 MAINTENANCE Tube Description Where Used Part No. Ref No. High Performance Seawater/fuel pump 92-858064K01 Gear Lubricant ENGINE COOLANT CAUTION A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.
  • Page 82 MAINTENANCE 3. Inspect the cap for damage and replace if necessary. DRIVE UNIT OIL NOTE: Oil level will fluctuate during operation. Oil level should be checked with cold engine before starting. 1. Check gear lube monitor oil level; keep oil level at or near the "FULL"...
  • Page 83 MAINTENANCE High Gear lube monitor if fluid is Performance 92-858064K01 green Gear Lubricant POWER TRIM PUMP FLUID 1. Place drive unit in full down/in position. 2. Remove fill cap from reservoir and observe oil level. Level must be up to, but not over bottom of filler neck. NOTE: Ensure that the cap plug has been removed and discarded from filler neck.
  • Page 84: Changing Fluids

    MAINTENANCE Changing Fluids See the Maintenance Chart for lubricant change frequency. Lubricant should be changed before placing the boat in storage. Power trim or power steering fluids do not require changing. CRANKCASE OIL AND FILTER (BOAT IN THE WATER) IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
  • Page 85 MAINTENANCE 7. Coat the sealing ring on the new filter with motor oil and install a new sealing ring and filter. 8. Tighten the filter securely. Do not overtighten. 9. Remove the oil filler cap (port or starboard). Add oil to bring the level up to, but not over, the "FULL"...
  • Page 86 MAINTENANCE NOTICE Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
  • Page 87 MAINTENANCE 6. Place an appropriate container directly under the oil drain hose. 7. Using two wrenches, separate the oil drain hose plug from the oil drain hose and allow the crankcase oil to drain until empty. 8. Place a container below the oil filter. NOTE: To allow the oil to drain from the filter, loosen the filter enough to break the internal vacuum .
  • Page 88 MAINTENANCE 25W-50 Verado Crankcase 92-858084K01 FourStroke Outboard Oil MerCruiser 4- cycle 25W40 Engine crankcase 92-858048K01 Engine Oil DRIVE UNIT OIL (BRAVO ONE XR MODELS) IMPORTANT: Use only High Performance Gear Lube in the drive unit. 1. Remove the propeller, place the drive unit in full down position, remove the oil fill/drain screw and sealing washer, and drain the oil.
  • Page 89 MAINTENANCE IMPORTANT: If any water drained from the oil fill/drain hole, or if oil appears milky, drive unit is leaking and should be checked immediately by your authorized Mercury MerCruiser dealer. 7987 Sealing washer Oil vent screw 3. Adjust the drive unit so the propeller shaft is level. 4.
  • Page 90 MAINTENANCE Tube Description Where Used Part No. Ref No. SAE 85W90 Mercury Drive unit 8M0078015 Racing Gear 5. Remove the tube from the oil fill/drain hole. Quickly install the sealing washer and the oil fill/drain screw. Tighten securely. 6. Add the specified gear lube to the monitor bottle. 7.
  • Page 91 MAINTENANCE IMPORTANT: Recheck the reservoir bottle oil level after the first use. 11. Grease the propeller shaft heavily with Extreme grease. Re‑install the propeller and torque the nut to specifications. 7990 Tube Description Where Used Part No. Ref No. Extreme 8M0071842 Grease Description...
  • Page 92 MAINTENANCE DRIVE UNIT OIL (BRAVO III XR) 1. Remove the gear lube monitor bottle from the bracket. Gear lube monitor bottle 7333 Tube Description Where Used Part No. Ref No. SAE 85W90 Mercury Gear lube monitor bottle 8M0078015 Racing Gear 2.
  • Page 93 MAINTENANCE 5. Remove the oil fill/drain screw and sealing washer and drain the oil. mc79507-1 Oil fill/drain screw Sealing washer 6. Remove the oil vent screw and sealing washer. Allow the oil to drain completely. IMPORTANT: If any water drains 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.
  • Page 94 MAINTENANCE 8. Fill drive unit, through the oil fill/drain hole until an air‑free stream of lubricant flows from the oil vent hole. Oil fill/drain screw Sealing washer 18912 Tube Description Where Used Part No. Ref No. SAE 85W90 Mercury Drive unit 8M0078015 Racing Gear 9.
  • Page 95: Lubrication

    MAINTENANCE Lubrication SHIFT CABLE 1. Lubricate pivot points with 4 Cycle 25W40 motor oil. 7997 Tube Description Where Used Part No. Ref No. MerCruiser 4- cycle 25W40 Pivot points 92-858048K01 Engine Oil THROTTLE CABLE 1. Lubricate pivot points with 4 Cycle 25W40 motor oil. 8008 Tube Description...
  • Page 96 MAINTENANCE DRIVE UNIT AND TRANSOM ASSEMBLY IMPORTANT: Disconnect the speedometer hose fitting from the driveshaft housing prior to removing the sterndrive unit to prevent damage to the fitting. IMPORTANT: Sterndrive must be removed to lubricate U‑joints. Contact your authorized Mercury MerCruiser dealer for this service.
  • Page 97 MAINTENANCE ENGINE COUPLER 1. Lubricate the engine coupler and shaft splines with engine coupler spline grease. 8014 Tube Description Where Used Part No. Ref No. Engine Coupler Engine coupler and shaft 8M0071842 Spline Grease splines DRIVE SHAFT EXTENSION MODELS 1. Lubricate drive shaft grease fittings at the transom end with 2‑4‑C with PTFE lubricant.
  • Page 98: Propellers

    MAINTENANCE 8016 Tube Description Where Used Part No. Ref No. 2-4-C Marine Lubricant with Drive shaft grease fittings 92-802859A 1 PTFE 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 99 MAINTENANCE • Fresh Water: Anti‑Corrosion Grease or Optimal Paste White T‑Grease 2. Install the Bravo XR replaceable hub propeller components in the order shown: 8020 Propshaft Prop hub assembly Propeller assembly Washer Belleville washer Washer Locknut Tube Description Where Used Part No.
  • Page 100 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. Turn the propeller shaft nut counter‑clockwise to remove.
  • Page 101 MAINTENANCE 3. Remove the washers and propeller with the prop hub assembly. 8018 Propshaft Prop hub assembly Propeller assembly Washer Belleville washer Washer Locknut NOTE: Some damaged propellers can be repaired. See your authorized Mercury Marine dealer. BRAVO III XR MODEL PROPELLERS Removal WARNING Rotating propellers can cause serious injury or death.
  • Page 102 MAINTENANCE 1. Place a wood block between the propeller blade and the anti‑ventilation plate to prevent rotation. 2. Remove the screw and washers securing the propeller shaft anode. 3. Remove the propeller shaft anode. 5303 Propeller Propeller shaft nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer...
  • Page 103 MAINTENANCE NOTE: Some damaged propellers can be repaired. Contact your authorized Mercury MerCruiser dealer. 5304 Rear propeller nut Rear propeller Rear propeller thrust hub Front propeller nut Front propeller Front propeller thrust hub Propeller shaft anode screw Flat washer Star washer Propeller shaft anode Installation NOTICE...
  • Page 104 MAINTENANCE IMPORTANT: Mercury Marine designed the Bravo III XR propellers as matched sets. Do not operate the drive without a front and rear XR propeller of the same pitch. Do not mix Bravo III XR propellers with non‑XR propellers or use a non‑XR propeller on a Bravo XR drive.
  • Page 105 MAINTENANCE Tube Description Where Used Part No. Ref No. Special Propeller shaft - Fresh water 802859A1 Lubricant 101 use only Anti-Corrosion Propeller shaft - Saltwater use Obtain Locally Grease 2-4-C Marine Propeller shaft - Fresh water Lubricant with 92-802859A 1 use only PTFE 3.
  • Page 106: Flushing The Power Package

    MAINTENANCE 11. If a propeller shaft anode is reinstalled, apply Loctite Threadlocker 271 to the threads of the propeller shaft anode screw. 5303 Propeller Propeller shaft nut Propeller shaft anode Propeller shaft anode screw Flat washer Star washer Tube Description Where Used Part No.
  • Page 107 MAINTENANCE FLUSHING ATTACHMENTS Flushing Device 91‑44357Q 2 Attaches to the water intakes; provides a fresh water connection when flushing the cooling system or operating the engine. 9192 Dual Water Pick‑up Flush Gearcase Seal 91‑881150K 1 Blocks off the front water inlet holes on the dual water inlet gearcases.
  • Page 108 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 drive requires flushing attachment (91‑843122A01).
  • Page 109 MAINTENANCE 19310 SportMaster Low Water Pickup 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 110: Seawater Pump Impeller Inspection

    MAINTENANCE 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 111: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE 1. Inspect seawater pump impeller if insufficient seawater flow occurs (if operating temperature exceeds normal range). Seawater pump 8022 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 112: Changing Positive Crankcase Ventilation Valve

    MAINTENANCE 3. Flush passages with fresh water. 4. Inspect gaskets for deterioration and replace if necessary. 5. Install gaskets and end plates. Tighten screws securely. POWER STEERING COOLER NOTE: The power steering cooler is located on the lower port side of the engine. 1.
  • Page 113: Serpentine Drive Belt

    MAINTENANCE • 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. Serpentine Drive Belt DRIVE BELT ROUTING AND TENSION WARNING Inspecting the belts with the engine running may cause serious injury or death.
  • Page 114 MAINTENANCE 6. Run the engine for a short period of time and re‑check tension. 6163 Crankshaft pulley Circulating pump pulley Alternator pulley Power steering pulley (Non‑power steering models have an idler pulley) Idler pump Seawater pump pulley Belt tension gauge Description New Belt Used Belt...
  • Page 115: Changing Fuel Filters

    MAINTENANCE INSPECTING BELT NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable. The belt will have to be replaced for the following conditions: •...
  • Page 116 MAINTENANCE 1. Remove the water separating fuel filter and sealing ring from mounting bracket and discard. Water separating fuel filter Sealing ring Mounting bracket 6152 2. Coat the sealing ring on new filter with motor oil. IMPORTANT: Do not use a filter wrench to tighten the filter. 3.
  • Page 117 MAINTENANCE FUEL FILTER ELEMENT 1. Remove the fuel line from the filter head. Fuel filter head Fuel line Fuel filter element 2. Turn the filter head and remove. 3. Remove the internal filter element. 4. Insert the new filter element. 5.
  • Page 118: Corrosion And Corrosion Protection

    MAINTENANCE Corrosion and Corrosion Protection Whenever two or more dissimilar metals (like those found on the sterndrive) 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 119 MAINTENANCE NOTE: This test should be made where 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 120 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 III 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 121 MAINTENANCE 4. Anodic block kit (Optional) ‑ is mounted to 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 122 MAINTENANCE a. Remove the propeller. b. Remove the two screws from the anode. c. Install a new anode and tighten securely. d. Reinstall the propeller. See Propeller Installation for proper torque. Bearing carrier anode 5644 7. Propshaft Anode (XR Bravo III) ‑ is located behind the aft propeller.
  • Page 123 MAINTENANCE e. Apply threadlocker to the threads of the screw and install the screw to secure the anode. Tighten to the torque specification. 5303 Propeller Propshaft nut Propshaft anode Propshaft anode screw Flat washer Star washer Tube Ref Description Where Used Part No.
  • Page 124 MAINTENANCE 2. If using copper or tin based anti‑fouling 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 125: Battery

    MAINTENANCE PAINTING THE DRIVE UNIT OR TRANSOM ASSEMBLY Paint the drive unit and transom assembly with a good quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct electrical current. Do not paint drain holes, anodes, or items specified by the boat manufacturer.
  • Page 126: Bottom Of Boat

    MAINTENANCE WARNING Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.
  • Page 127: Cold Weather Or Extended Storage

    COLD WEATHER OR EXTENDED STORAGE Power Package Lay‑up IMPORTANT: This service should be performed by an authorized Mercury MerCruiser dealer. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.
  • Page 128 COLD WEATHER OR EXTENDED STORAGE 6. Connect the remote outboard fuel tank to the inlet of the water separating fuel filter. IMPORTANT: If the boat is out of the water, follow instructions for running the engine on a flush device as found in the service manual.
  • Page 129: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE Draining Instructions NOTICE Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system.
  • Page 130 COLD WEATHER OR EXTENDED STORAGE • Bottom of power steering cooler (plastic wingnut plug) 8039 Exhaust manifold balance rail wingnut Fuel cooler wingnut Power steering cooler wingnut 2. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained. 3.
  • Page 131 COLD WEATHER OR EXTENDED STORAGE 4. After draining seawater cooling system, install drain plugs (Perfect Seal is not required on wing nut type plugs), reconnect hoses and tighten all hose clamps securely. 5. Make sure the following passages are open and unobstructed: Speedometer pitot tube Trim tab cavity vent hole...
  • Page 132: Battery Winter Storage

    COLD WEATHER OR EXTENDED STORAGE a. Remove seawater inlet hose leading to the seawater pump and place the hose into a container of ethylene glycol antifreeze to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage.
  • Page 133 COLD WEATHER OR EXTENDED STORAGE 1. Ensure that all cooling system hoses are connected properly and hose clamps are tight, all removed drain plugs have been installed and are tight. CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system.
  • Page 134 COLD WEATHER OR EXTENDED STORAGE PRIMING THE FUEL SYSTEM PRIOR TO STARTING 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.
  • Page 135 COLD WEATHER OR EXTENDED STORAGE 4. Cycle the ignition key switch to the "RUN" position for three seconds and then "OFF." 5. Repeat steps three and four, one to two more times. The object of this procedure is to prime the fuel system but not to the point of having the system completely full and the primer bulb hard and under pressure.
  • Page 136: 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 137: 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 138: 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 139: High Engine Temperature

    TROUBLESHOOTING High Engine Temperature Possible Cause Remedy Seacock closed. Open. Serpentine belt loose or in poor condition. Replace or adjust belt. Insufficient coolant in closed cooling Add coolant and check for leaks. system. Recirculating pump defective. Replace. Seawater pickups obstructed. Inspect.
  • Page 140: Battery Will Not Come Up On Charge

    TROUBLESHOOTING Battery Will Not Come Up On Charge Possible Cause Remedy Excessive current draw from Turn off non‑essential accessories. battery. Check all associated electrical connections and wires (especially Loose or dirty electrical battery cables). Clean and tighten faulty connections or damaged wiring. connections.
  • Page 141: Electrical Analog Trim Gauge Malfunction

    TROUBLESHOOTING Electrical Analog Trim Gauge Malfunction Possible Cause Remedy Check wires between the sender Gauge indicates off‑scale high with no and the trim module. self‑test function. Replace defective trim sender. Index the trim sender, test the trim Gauge does not indicate properly but sender circuit or replace defective the self test function works.
  • Page 142: Seawater Pressure Is Below Specification

    TROUBLESHOOTING Seawater Pressure Is Below Specification Possible Cause Remedy Check if seacock is completely open. Check supply hoses for obstruction. Insufficient water supply. Check for external water pick‑up obstruction. Check for sea strainer obstruction. Check condition of sea pump. Seawater Pressure Is Above Specification Possible Cause Remedy High boat speed causing high ram...
  • Page 143: Owner Service Assistance

    OWNER SERVICE ASSISTANCE Local Repair Service Always return your outboard to your local authorized dealer should the need for service arise. Only he has the factory trained mechanics, knowledge, special tools, equipment, and genuine parts and accessories to properly service your engine should the need occur.
  • Page 144: Mercury Mercruiser Service Offices

    • Nature of problem Mercury Mercruiser Service Offices For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence. United States (Mercury Racing) Telephone Mercury Racing N7480 County Rd. UU (920) 924‑2088 (920) 924‑2096...
  • Page 145 OWNER SERVICE ASSISTANCE Europe, Middle East, Africa Telephone Marine Power - Europe, Inc. Parc Industriel de Petit- Rechain B-4800 (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Verviers, Belgium Mexico, Central America, South America, Caribbean Telephone Mercury Marine 11650 Interchange Circle North...
  • Page 146: Ordering Literature

    ORDERING LITERATURE United States and Canada Before ordering literature, please have the following information about your power package available: Engine 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...
  • Page 147 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...

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