Mercury Racing HP565 Manual
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Mercury Racing HP565 Manual

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Declaration of Conformity for Recreational Craft
Propulsion Engines with the Requirements of Directive
94/25/EC as Amended by 2003/44/EC
Manufacturer:
Mercury Racing
N7480 County Road UU
Fond du Lac, WI 54937–9385
USA
Authorized Representative:
Brunswick Marine EMEA, Inc.
Parc Industriel de Petit-Rechain
Verviers, 4800,
Belgium
Notified Body for Exhaust Emission Assessment:
Det Norske Veritas AS
Veritasveien 1
Hovik, 1322,
Norway
ID Number: 0575
Conformity Assessment Module used for Exhaust
Emissions: H
Other Community Directives Applied: Electromagnetic
Compatibility Directive 2004/108/EC
Description of Engine(s) and Essential Requirements
Engine Type:
z or sterndrive without integral
exhaust
eng
Fuel Type: Combustion Cycle
Petrol
i
4‑Stroke

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  • Page 1 Declaration of Conformity for Recreational Craft Propulsion Engines with the Requirements of Directive 94/25/EC as Amended by 2003/44/EC Manufacturer: Mercury Racing N7480 County Road UU Fond du Lac, WI 54937–9385 Authorized Representative: Brunswick Marine EMEA, Inc. Parc Industriel de Petit-Rechain...
  • Page 2 Identification of Engines Covered by This Declaration of Conformity Module H Engine Model or Unique Engine Identification certificate Family Number or Family Code number: Starting Serial Number: MCM 520 CE RCD‑H‑2 0M968960 Other Please specify in Normative Technic more detail Stds.
  • Page 3 Identification of Sterndrive Systems Covered by This Declaration of Conformity EC Type (examination Unique Sterndrive certificate or Sterndrive Identification Number type‑approval certificate number) Bravo Integrated Starting Serial Number: HSSMECR002 & Transom System 0M968960 IGPMECR002 (ITS) Other Normative Technic Stds. Details Document/ al File Method...
  • Page 4 Regulatory contact: Engineering–Regulations Mercury Racing N7480 County Road UU Fond du Lac, WI 54937-9385 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.
  • Page 5 Warranty Message WARNING The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
  • Page 6 Printed in U.S.A. © 2013, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Verado, Vazer, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, SmartCraft, VesselView, Quicksilver, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation.

  • Page 7: Table Of Contents

    Warranty Information Warranty Registration United States and Canada....... 1 Transfer of Warranty..............2 Mercury Racing Division Two‑Year Limited Warranty....3 Products Sold to Government Agencies........6 Three‑Year Limited Warranty Against Corrosion......6 Warranty Coverage and Exclusions for Mercury Racing Sterndrive Products..............10 California Emission Control Warranty Statement......
  • Page 8 Specifications Engine Identification..............36 Fuel Requirements..............37 Low Permeation Fuel Hose Requirement ......... 39 Crankcase Oil................39 Capacities.................. 40 General Engine Specifications........... 40 Engine Operating Limitations............. 41 Engine Break‑in................. 42 After Break‑In Period..............42 Operation Instrumentation................43 Warning System................ 43 Electrical System Overload Protection........
  • Page 9 Maintenance Service Responsibilities............. 59 Replacement Service Parts............60 Do‑It‑Yourself Maintenance Suggestions........60 Servicing High‑Horsepower Engines......... 62 Engine Maintenance Charts............62 Bravo Drive Maintenance Charts..........64 Checking Fluid Levels..............67 Closed Cooling System............. 72 Changing Fluids................. 76 Lubrication................. 85 Propellers................... 87 Flushing the Power Package.............
  • Page 10 Troubleshooting Engine Will Not Crank.............. 128 Engine Cranks But Will Not Start..........128 Engine Hard to Start, Runs Rough, Misses, and/or Backfires. 129 Low Engine Coolant (Closed Cooling) Temperature....129 Poor Performance..............130 Insufficient Engine Temperature..........130 High Engine Temperature............131 Low Engine Oil Pressure............
  • Page 11 Maintenance Log Maintenance Log..............139...

  • Page 13: 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 14: 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 15: Mercury Racing Division Two-Year Limited Warranty

    WARRANTY INFORMATION Mercury Racing Division Two‑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 16 WARRANTY INFORMATION WHAT MERCURY WILL DO Mercury Marine’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 17 WARRANTY INFORMATION This limited warranty also does not cover damage caused by any of the following: 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 this manual, neglect, accident, submersion, improper installation (proper installation specifications and...

  • Page 18: 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 19 WARRANTY INFORMATION DURATION OF COVERAGE: This limited corrosion warranty provides coverage for three (3) years from either the date the product is first sold, or the date on which the product is first put into service, whichever occurs first. The repair or replacement of parts, or the performance of service under this warranty does not extend the life of this warranty beyond its original expiration date.
  • Page 20 WARRANTY INFORMATION HOW TO OBTAIN WARRANTY COVERAGE: The customer must provide Mercury 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, written notice must be given to Mercury.
  • Page 21 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 22: 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 23 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 24: 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 25 WARRANTY INFORMATION DURATION OF COVERAGE This limited warranty provides coverage for the components of the emissions control systems. Specific emission control related parts on new high performance sterndrive engines greater than 500 horsepower are warranted for a period of three years or 480 hours (as determined by the engine’s ECM‑integrated hour meter), whichever first occurs, for electronic emission‑related components including, but not limited to, sensors (e.g., oxygen...
  • Page 26 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. The purchaser, in that case, shall pay for all related transportation charges and/or travel time.
  • Page 27 California Air Resources Board may be grounds for disallowing a warranty claim, at the discretion of Mercury Racing. Failures of warranted parts caused by the use of a non‑exempted add‑on or modified part will not be covered.

  • Page 28: California Emission Control Warranty Rights And Obligations

    In California, new sterndrive engines must be designed, built and equipped to meet the State's stringent anti‑smog standards. Mercury Racing must warrant the emission control system on your sterndrive engine for the periods of time listed below, provided there has been no abuse, neglect, or improper maintenance of your sterndrive engine.
  • Page 29 As the sterndrive engine owner, you should however be aware that Mercury Racing may deny you warranty coverage if your sterndrive engine or a part has failed due to abuse, neglect, improper maintenance, or unapproved modifications.

  • Page 30: E.p.a. Emission Controls

    WARRANTY INFORMATION 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 31 WARRANTY INFORMATION c. Spark control system d. Ignition coil or control module e. Ignition wires 4. Lubrication system a. Oil pump and internal parts b. Oil injectors c. Oil meter 5. Positive crankcase ventilation (PCV) system a. PCV valve b. Oil filler cap 6.
  • Page 32 WARRANTY INFORMATION NOTE: The EPA emission‑related warranty does not cover components whose failure would not increase an engine's emissions on any regulated pollutant.

  • Page 33: 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 34: 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 35: 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 36: 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 37: 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 38 GENERAL INFORMATION STAY CLEAR OF EXHAUST AREAS 41127 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 39 GENERAL INFORMATION Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains, or is near, a running engine may be exposed to a hazardous level of carbon monoxide. 1.

  • Page 40: Wave And Wake Jumping

    GENERAL INFORMATION 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 41: Impact With Underwater Hazards

    GENERAL INFORMATION Impact With Underwater Hazards IMPORTANT: Operating in shallow waters can severely damage the boat or power package. Maintain a minimum safe speed when operating the vessel in shallow waters or in areas with underwater obstacles. Reduce speed and proceed with caution whenever you drive a boat in shallow water areas, or in areas where you suspect underwater obstacles may exist which could be struck by the sterndrive or the boat bottom.

  • Page 42: Operating In Shallow Water

    GENERAL INFORMATION WARNING 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 43 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 44: 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 45 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 46 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 47: 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 48: Specifications

    SPECIFICATIONS Engine Identification 53399 Record the following information for future use: Engine Model/Horsepower: ________________________ Engine Serial Number: ________________________ Transom Assembly Serial Number: ________________________ Propeller Number & Pitch: _________________________ Sterndrive Serial Number & Gear Ratio: ________________________ Running Rotation: _________________________ Hull Identification Number: _________________________ Boat Model &...

  • Page 49: Fuel Requirements

    Unleaded regular NOTE: *Research Octane Number 1. 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 50 SPECIFICATIONS USING REFORMULATED (OXYGENATED) FUELS (USA ONLY) This type of fuel is required in certain areas of the U.S. The two types of oxygenates used in these fuels are alcohol (ethanol) or ether (MTBE or ETBE). If ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section.

  • Page 51: Low Permeation Fuel Hose Requirement

    23 °C as specified in SAE J 1527 ‑ marine fuel hose. Crankcase Oil OIL RECOMMENDATIONS Preferred Oils NMMA Classification Mercury Racing 4‑Stroke Oil, 25W‑50 Synthetic Blend, ® FC‑W or 25W‑40 Sterndrive/Inboard Oil Use a new oil filter with every oil change...

  • Page 52: Capacities

    SPECIFICATIONS Capacities Model HP565 7.6 L (8 U.S. qts) Crankcase Oil Capacity with New Filter 2.65 L (2.8 U.S. qts) Bravo ‑ Drive Unit Oil Capacity (with Monitor) 2.8 L (3 U.S. qts) Bravo III XR ‑ Drive Unit Oil Capacity (with Monitor) Closed‑Cooling System...

  • Page 53: Engine Operating Limitations

    SPECIFICATIONS Engine Operating Limitations Maximum wide‑open throttle (WOT) RPM 4800–5200 RPM 5500 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 54: 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 55: Operation

    OPERATION Instrumentation Mercury Racing requires that the following critical engine functions be monitored: • Oil pressure • Engine RPM • 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 56 OPERATION • OBDM Stage 1: 5 seconds on 1 cycle followed by 60 seconds off. • OBDM Stage 2: 0.5 seconds on and 0.5 seconds off for 1 cycle followed by 60 seconds off. • Severe Stage 1: 6 seconds on and 6 seconds off for 2 cycles followed by 59 seconds off.

  • Page 57: Electrical System Overload Protection

    OPERATION • SysVolt_RangeHigh • SysVolt_RangeLow • IAT_RangeHigh • IAT_RangeLow • StbdECT_RangeHigh • StbdECT_RangeLow • EncoderFault • CrankCamTrigger NOTICE The engine must start to clear the fault using the following procedure. To clear the fault, the engine must be started three times. If the horn still sounds after three start cycles, the fault still exists.
  • Page 58 OPERATION NOTE: The circuit breaker is located at the starboard rear of the engine in the electrical center. 53508 A 90‑amp fuse, located on the large post of the starter solenoid, protects the engine wiring harness if an electrical overload occurs.
  • Page 59 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)–20‑amp fuse Trim down relay (DTS), trim up relay, and injectors circuit–...
  • Page 60 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...
  • Page 61 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 62 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 63: Remote Controls (Console Mounted Zero Effort)

    OPERATION The Quicksilver MerCathode System has a 5‑amp in‑line fuse in the wire which connects to the positive (+) terminal on controller. If the fuse is open, the system will not operate and will not protect against corrosion. Remote Controls (Console Mounted Zero Effort) 1.

  • Page 64: Operation Chart

    OPERATION Place the control handle in neutral. COLD OR WARM ENGINE EFI engines require no throttle advance to start. The boat can be operated after the engine has started and is idling smoothly. NOTE: Engines that have not been started for extended periods or have had fuel filter changes may not stay running on the first few initial attempts to start.

  • 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 RPM loss may require changing to a lower pitch propeller due to the following conditions: • Operating in warmer weather and greater humidity. • Operating in a higher elevation. • Operating with a damaged propeller or dirty boat bottom. •...
  • Page 70 CONDITIONS AFFECTING OPERATION Some boat performance can be regained by dropping to a lower pitch propeller, but engine performance will remain lower. In some cases, a gear ratio reduction may be more beneficial. To optimize engine performance, prop the engine to allow operation at or near the top end of the recommended maximum RPM range at wide open throttle with a normal boat load.

  • Page 71: Service Responsibilities

    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 72: 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 73 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 74: Servicing High-Horsepower Engines

    MAINTENANCE Maintenance Charts (on following pages) IMPORTANT: Refer to for complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner/operator, while others should be performed by an authorized Mercury Marine dealer. Before attempting maintenance or repair procedures not covered in this manual, Mercury Marine recommends purchasing a Mercury Marine Service Manual.
  • Page 75 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 76: Bravo Drive Maintenance Charts

    MAINTENANCE Interval Task Saltwater use:Every 50 hours of Power package exterior surfaces ‑ operation or every 60 days, whichever Spray with rust preventative. occurs first. Power package exterior surfaces ‑ Clean and paint. Check engine cylinder compression. Oil coolers for the engine and power steering ‑...
  • Page 77 MAINTENANCE Interval Task Check prior to every use and every 3 Drive, transom, and propeller ‑ hours of operation. Inspect 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.
  • Page 78 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 79: 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 80 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.
  • Page 81 MAINTENANCE Tube Description Where Used Part No. Ref No. 25W50 Synthetic Blend 4-Stroke Engine crankcase 8M0078013 Racing Engine 25W-50 Verado Engine 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 82 NOTE: If the gear oil is green, use High Performance Gear Lube. If the gear oil is amber, use Mercury Racing Gear Oil. IMPORTANT: If more than 59ml (2 fl oz) of gear lube is required to fill the monitor, a seal may be leaking.
  • Page 83 MAINTENANCE Tube Description Where Used Part No. Ref No. SAE 85W90 Mercury Gear lube monitor 8M0078015 Racing Gear High Performance Gear lube monitor 92-858064K01 Gear Lubricant POWER TRIM PUMP FLUID 1. Place the drive unit in the full down/in position. 2.

  • Page 84: Closed Cooling System

    MAINTENANCE NOTE: The fill cap is vented; check it frequently to ensure that the vent is open and unrestricted. Reservoir cap 7981 Closed Cooling System COOLANT REQUIREMENT 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.
  • Page 85 MAINTENANCE CHECKING COOLANT LEVEL 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. IMPORTANT: When reinstalling the coolant reservoir cap, ensure that it is tightened securely.
  • Page 86 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.
  • Page 87 MAINTENANCE 3. When refilling the coolant section after it has been completely drained, fill the reservoir to within 12 mm (0.50 in.) of the top of the reservoir neck before starting the engine. 4. Replace the pressure cap. NOTICE Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage.

  • Page 88: Changing Fluids

    MAINTENANCE CLEANING Contact your authorized Mercury MerCruiser dealer. Changing Fluids See the Maintenance Chart for the lubricant change frequency. The lubricant should be changed before placing the boat in storage. Power trim and power steering fluids do not require changing. CRANKCASE OIL AND FILTER (BOAT IN THE WATER) IMPORTANT: When changing the oil, make sure that the engine is near operating temperature.
  • Page 89 MAINTENANCE 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 completely removal of the filter. Crankcase oil filter 7984 6.
  • Page 90 MAINTENANCE MerCruiser 4- Cycle 25W-40 Crankcase 92-858048K01 Engine Oil 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.
  • Page 91 MAINTENANCE 4. Remove the bilge plug. The oil drain hose is tethered to the plug. 6150 Bilge drain plug Tether Oil drain plug Bilge drain flange Oil drain hose 5. Pull the oil drain hose through the bilge drain flange. 6.
  • Page 92 Engine Oil DRIVE UNIT OIL (BRAVO ONE XR MODELS) Mercury Racing Gear Lube 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 Lube with any other oil.
  • Page 93 MAINTENANCE 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. Oil fill/drain plug 7986 2. Remove the oil vent screw and sealing washer. Allow the oil to drain completely.
  • Page 94 MAINTENANCE 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 3. Adjust the drive unit so the propeller shaft is level. 4.
  • Page 95 MAINTENANCE Tube Description Where Used Part No. Ref No. High Performance Drive unit 92-858064K01 Gear Lubricant 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. Securely tighten the screw.
  • Page 96 MAINTENANCE 9. Lubricate the O‑ring on the neck with High Performance Gear Lubricant to ensure ease of installation and removal of the cap. 10. Install the filler cap, being careful to not over‑tighten. IMPORTANT: Check the reservoir bottle oil level after the first use.

  • Page 97: Lubrication

    MAINTENANCE Lubrication 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: The sterndrive must be removed in order to lubricate the U‑joints. Contact your authorized Mercury MerCruiser dealer for this service.
  • Page 98 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 99: 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 100 MAINTENANCE Tube Description Where Used Part No. Ref No. Extreme Exposed area of propshaft 8M0071842 Grease 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.
  • Page 101 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 102: Flushing The Power Package

    MAINTENANCE 3. Remove the washers and propeller with the prop hub assembly. 8018 Propeller shaft Propeller hub assembly 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.
  • Page 103 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 104 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 105 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 106 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 107: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE 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. Always close the water supply from the seawater pump, water inlet, or seacock when performing service or maintenance on the cooling system.

  • Page 108: Changing Positive Crankcase Ventilation Valve

    MAINTENANCE IMPORTANT: If the oil hoses need to be removed from the cooler, be prepared to cap or plug them to avoid draining the power steering reservoir. 8031 Hose clamps (2) 2. Re‑install cooler and tighten hose clamps securely. 3. Check power steering fluid level. 4.

  • Page 109: Cleaning The Flame Arrester

    MAINTENANCE Cleaning the Flame Arrester 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 110 MAINTENANCE Description lb‑in. lb‑ft Flame arrester clamp – 4. Install the silencer.

  • Page 111: 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...
  • Page 112 MAINTENANCE Tensioner pulley Seawater pump pulley 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 113 MAINTENANCE The belt tensioner operates within the limits of movement provided by the cast stops when the belt length and geometry are correct. If the tensioner contacts either of the cast stops during operation, check the mounting brackets and the belt length.

  • Page 114: Water-Separating Fuel Filter

    MAINTENANCE 3. Remove the belt and route the replacement belt according to the belt routing diagram. 4. Carefully release the tensioner and ensure that the belt stays positioned properly. 5. Check the belt tension. Description 13 mm (½ in.) Deflection Water‑Separating Fuel Filter WARNING Fuel is flammable and explosive.
  • Page 115 MAINTENANCE GEN III MODELS Cool Fuel Module Cool Fuel Module harness Filter cap Filter assembly retaining screw Fuel filter element Filter cup Cool Fuel Module filter reservoir O‑ring 8837 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.
  • Page 116 MAINTENANCE 7. Unseat the filter assembly by grasping the filter assembly handle and pulling upward. Do not remove the filter assembly from the Cool Fuel Module at this time. 8. Allow any fuel that may be in the filter assembly to drain out through the bottom of the filter assembly and into the Cool Fuel Module filter reservoir.

  • Page 117: Corrosion And Corrosion Protection

    MAINTENANCE 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. 9. Supply cooling water to the engine. 10. Start the engine. Check for gasoline leaks around the fuel filter assembly.
  • Page 118 MAINTENANCE IMPORTANT: Mercury Marine recommends installing a MerCathode System or Anti‑Corrosion Kit be installed whenever using a stainless steel propeller, or if the boat is equipped with stainless steel components immersed below the waterline that are connected into the engine ground system. If a boat is equipped with stainless steel aft planes, a large anode should be installed on each to handle the increased galvanic corrosion potential.
  • Page 119 MAINTENANCE 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. These anodes are installed at different location on your power package. 1.
  • 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 PAINTING THE BOAT HULL OR TRANSOM 1.
  • Page 123 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 124: 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 125: 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 126: 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 127 COLD WEATHER OR EXTENDED STORAGE 53834 Starboard side air‑actuated drain location Port side air‑actuated drain location...

  • Page 128: Air-Actuated Single-Point Drain System

    COLD WEATHER OR EXTENDED STORAGE MANUAL DRAIN SYSTEM 53834 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. However, any air source can be used.
  • Page 129 COLD WEATHER OR EXTENDED STORAGE 6. Pull the lever on the air pump (vertical) to seal the pump to the connection. 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.
  • Page 130 COLD WEATHER OR EXTENDED STORAGE 8. Verify that water is draining from each opening. If not, use the Manual Drain System instructions. 53834 Starboard side air‑actuated drain location Port side air‑actuated drain location 9. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.
  • Page 131 COLD WEATHER OR EXTENDED STORAGE 14. 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 15. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine.
  • Page 132 COLD WEATHER OR EXTENDED STORAGE 6. 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 133 COLD WEATHER OR EXTENDED STORAGE 7. Verify that water is draining from each opening. If not, use the Manual Drain System instructions. 53834 Starboard side air‑actuated drain location Port side air‑actuated drain location 8. Allow the system to drain for a minimum of five minutes. Pump air as necessary to keep the green indicators extended.

  • Page 134: 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 135 COLD WEATHER OR EXTENDED STORAGE 2. Remove the two blue drain plugs from the seawater pickup pump (front, starboard side). 53834 Starboard side blue drain plugs Port side blue drain plug 3. Verify that water is draining from each opening. 4.
  • Page 136 COLD WEATHER OR EXTENDED STORAGE 8. Open the seacock, if equipped, or unplug and reconnect the water inlet hose prior to operating the engine. BOAT OUT OF THE WATER NOTE: Use this procedure if the air‑actuated single‑point drain system fails. NOTE: It may be necessary to lift, bend, or lower hoses to allow water to completely drain when hoses are disconnected.

  • Page 137: Draining Water From The Cool Fuel Module

    COLD WEATHER OR EXTENDED STORAGE 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. 6.

  • Page 138: 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 139 COLD WEATHER OR EXTENDED STORAGE CAUTION Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last. 2.

  • Page 140: 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 141: 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 142: 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 143: 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 144: 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 145: 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 146: 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 147: 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 148: Mercury Mercruiser Service Offices

    United States Telephone Mercury MerCruiser W6250 W. Pioneer Road (920) 929‑5040 Fond du Lac, WI 54936-1939, United States (Mercury Racing) Telephone Mercury Racing N7480 County Rd. UU (920) 924‑2088 (920) 924‑2096 Fond du Lac, WI 54935-9585...
  • Page 149 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 150: 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 151 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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