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Mercury HP 500 EFI Bravo XR/XZ/III User Manual

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Warranty Message
The product you have purchased comes with a limited war-
ranty 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 limita-
tions of damages, and other related information. Please
review this important information.
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 and Maintenance
Manual and thoroughly understand the operational in-
structions for the power package and all related acces-
sories before the boat is used.
The engine exhaust from this product contains chemi-
cals known to the state of California to cause cancer,
birth defects or other reproductive harm.
The description and specifications contained herein were in effect at the time
this guide was approved for printing. Mercury Marine, whose policy is one of
continuous improvement, reserves the right to discontinue models at any
time, or to change specifications or designs, without notice and without incur-
ring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A.
2001, Mercury Marine
The following are registered trademarks of Brunswick Corporation: Auto-
blend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury
Marine, Mercury Precision Parts, Mercury Racing, Quicksilver, Ride-Guide,
and Thruster.
WARNING
WARNING
Printed in U.S.A.

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Summary of Contents for Mercury HP 500 EFI Bravo XR/XZ/III

  • Page 1 The description and specifications contained herein were in effect at the time this guide was approved for printing. Mercury Marine, whose policy is one of continuous improvement, reserves the right to discontinue models at any time, or to change specifications or designs, without notice and without incur- ring obligation.
  • Page 2 –2 500 EFI Bravo...
  • Page 3 Again, thank you for purchasing one of our MerCruiser prod- ucts. We sincerely hope your boating will be pleasant! Mercury Racing, N7480 County Road “UU” Fond du Lac, WI 54935-9585 500 EFI Bravo...
  • Page 4 IDENTIFICATION RECORD PLEASE RECORD THE FOLLOWING INFORMATION: Engine Model/Horsepower: Engine S/N: Transom Assembly S/N: Stern Drive S/N & Gear Ratio: Propeller Number/Pitch: Hull ID Number: Boat Model & Length: SERIAL NUMBERS The serial numbers are the manufacturer’s keys to numerous engineering details ...
  • Page 5 500 EFI Bravo...

  • Page 6: Table Of Contents

    ....... . Mercury RACING DIVISION One Year Limited Warranty 3 Year Limited Warranty Against Corrosion (Worldwide)
  • Page 7 TABLE OF CONTENTS Page Operation (cont.) Remote Controls (Console Mounted Zero Effort) ..Power Trim ........Starting, Shifting and Stopping .
  • Page 8 TABLE OF CONTENTS Page Cold Weather or Extended Storage Power Package Lay-up ......Draining Instructions .

  • Page 9: Warranty Information

    WARRANTY INFORMATION Warranty Registration UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Regis- tration Card completely and mails it to the factory immediately upon sale of the new product. It identifies name and address of the original purchaser, product model and serial number(s), date of sale, type of use and selling dealer’s code, name and address.
  • Page 10 WARRANTY INFORMATION Warranty Registration (cont.) OUTSIDE THE UNITED STATES AND CANADA It is important that your selling dealer fills out the Warranty Regis- tration Card completely and mails it to the distributor or Marine Power Service Center responsible for administering the warranty registration/claim program for your area.

  • Page 11: Transfer Of Warranty

    There is no charge for this service. For products purchased outside the United States and Canada, con- tact the distributor in your country, or the Mercury Marine Service Of- fice closest to you. 500 EFI Bravo...

  • Page 12: Mercury Racing Division One Year Limited Warranty

    Mercury RACING DIVISION One Year Limited Warranty WHAT IS COVERED Mercury Marine warrants its new products to be free of defects in ma- terial and workmanship during the period described below. DURATION OF COVERAGE This Limited Warranty provides coverage for one (1) year from either...
  • Page 13 Mercury dealer authorized to service the product. If purchas- er cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any cov- ered repair. Purchaser in that case shall pay for all related transporta- tion charges and/or travel time.
  • Page 14 WARRANTY INFORMATION Mercury RACING DIVISION One Year Limited Warranty (cont.) 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 (see the Operation, Maintenance &...
  • Page 15 STATE AND COUNTRY TO COUNTRY. PRODUCTS SOLD TO GOVERNMENT AGENCIES Contact the Mercury Racing Sales Department for a copy of the Gov- ernment Agencies Warranty Packet Kit which explains the conditions required for government agencies to receive warranty when pur- chasing Mercury Racing Outboard or Sterndrive product.

  • Page 16: Year Limited Warranty Against Corrosion (Worldwide)

    WARRANTY COVERAGE Warranty coverage is available only to retail customers that pur- chase from a Dealer authorized by Mercury Marine to distribute the product in the country in which the sale occurred, and then only after the Mercury Marine specified pre-delivery inspection process is completed and documented.
  • Page 17 Mercury dealer authorized to service the product. If purchas- er cannot deliver the product to such a dealer, written notice must be given to Mercury. We will then arrange for the inspection and any cov- ered repair. Purchaser in that case shall pay for all related transporta- tion charges and/or travel time.
  • Page 18 Mercury Precision Parts or Quicksilver MerCathode system and/or Galvanic Isolator. Corrosion damage caused by improper application of copper base anti-fouling paints is also not covered by this limited warranty.

  • Page 19: Warranty Coverage And Exclusions For Mercury Racing Outboard And Sterndrive Products

    The provisions set forth following have been in- corporated by reference into the Mercury Racing Division Three Year Limited Warranty Against Corrosion Failure, the Mercury Racing Division 90 Day and One Year Limited Warranties.
  • Page 20 Use of other than Mercury Precision or Quicksilver parts when making warranty repairs. Engine noise does not necessarily indicate a serious engine problem.

  • Page 21: General Information

    GENERAL INFORMATION oba1 Boater’s Responsibilities The boat driver is responsible for correct and safe operation of the boat and safety of its occupants and general public. It is strongly rec- ommended that each operator (driver) read and understand this en- tire manual before operating the outboard.

  • Page 22: Boat Horsepower Capacity

    GENERAL INFORMATION US COAST GUARD CAPACITY MAXIMUM HORSEPOWER XXX MAXIMUM PERSON CAPACITY (POUNDS) MAXIMUM WEIGHT CAPACITY obc1 Boat Horsepower Capacity Do not overpower or overload your boat. Most boats will carry a required capacity plate indicating the maximum acceptable pow- er and load as determined by the manufacturer following certain federal guidelines.

  • Page 23: Lanyard Stop Switch

    GENERAL INFORMATION gob8 obg6 Lanyard Stop Switch WARNING Should the operator fall out of the boat, the possibility of seri- ous injury or death from being run over by the boat can be greatly reduced by stopping the engine immediately. Always properly connect both ends of the stop switch lanyard to the stop switch and the operator.

  • Page 24: Trailering Boat

    GENERAL INFORMATION Lanyard Stop Switch (Continued) WARNING Avoid serious injury or death from deceleration forces result- ing from in accidental stop switch activation. The boat opera- tor should never leave the operator’s station without first dis- connecting the stop switch lanyard cord from themself. Accidental or unintended activation of the Lanyard Stop Switch dur- ing normal operation is a possibility and could cause any, or all, of the following potentially hazardous situations:...

  • Page 25: Protecting People In The Water

    GENERAL INFORMATION gob3 Protecting People In The Water WHILE YOU ARE CRUISING It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction even at slow speed. Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
  • Page 26 GENERAL INFORMATION Courtesy of ABYC 500 EFI Bravo...

  • Page 27: Carbon Monoxide Risk

    GENERAL INFORMATION Carbon Monoxide Risk WARNING Avoid the combination of a running engine and poor ventila- tion. Prolonged exposure to carbon monoxide in sufficient concentration can lead to unconsciousness, brain damage, or death. Carbon monoxide is a deadly gas that is odorless, colorless and tasteless and is present in the exhaust fumes of all internal combustion engines.

  • Page 28: Wave And Wake Jumping

    GENERAL INFORMATION Wave And Wake Jumping Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re-enters the water.

  • Page 29: Impact With Underwater Hazards

    GENERAL INFORMATION Impact With Underwater Hazards Reduce speed and proceed with caution whenever you’re driving a boat in shallow water areas or in areas where the waters are sus- pected of having underwater obstacles that could be struck by the sterndrive or the boat bottom.
  • Page 30 GENERAL INFORMATION Impact With Underwater Hazards (cont.) Striking a floating/underwater object may result in an infinite number of situations. Some of these situations could result in the following: • The boat could move suddenly in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

  • Page 31: Operating In Shallow Water

    GENERAL INFORMATION CA802 Operating In Shallow Water CAUTION Serious engine damage could occur by failing to follow these instructions. Sand, silt or mud could be sucked into the water inlets restricting or shutting off the water supply to the engine. Low Water Inlet Gear Cases: Extreme care should be exercised when operating a boat equipped with only low water inlets while maneuvering in shallow water.

  • Page 32: Safe Boating Suggestions

    GENERAL INFORMATION Safe Boating Suggestions In order to safely enjoy the waterways, familiarize yourself with local and other governmental boating regulations and restrictions, and consider the following suggestions. • Know and obey all nautical rules and laws of the waterways. Boat operators should complete a boating safety course.
  • Page 33 GENERAL INFORMATION Safe Boating Suggestions (Continued) • Know signs of weather change and avoid foul weather and rough-sea boating. • Tell someone where you are going and when you expect to return. • Passenger boarding. Stop the engine whenever passengers are boarding, unloading or are near the back (stern) of the boat.

  • Page 34: Stolen Power Package

    Mercury Marine of the model and serial number(s) and to whom the recovery is to be reported. This “Stolen Motor” information is placed into a file at Mercury Marine to aid authorities and dealers in recovery of stolen motors.

  • Page 35: Specifications

    ca261hp SPECIFICATIONS Fuel Requirements WARNING FIRE AND EXPLOSION HAZARD: Fuel leakage from any part of fuel system can be a fire and explosion hazard which can cause serious bodily injury or death. Careful periodic inspec- tion of entire fuel system is mandatory, particularly after stor- age.
  • Page 36 SPECIFICATIONS USING REFORMULATED (OXYGENATED) GASOLINES (USA ONLY) This type of gasoline is required in certain areas of the US. 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 “Gasolines Containing Alcohol”...
  • Page 37 SPECIFICATIONS GASOLINE CONTAINING ALCOHOL MAY INCREASE: • Corrosion of metal parts. • Deterioration of rubber or plastic parts. • Fuel permeation through rubber fuel lines. • Starting and operating difficulties and decrease in performance. Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol-free gasoline be used where possible.

  • Page 38: Crankcase Oil

    SPECIFICATIONS Crankcase Oil OIL RECOMMENDATIONS PREFERRED OILS CLASSIFICATION Quicksilver 4-Cycle Marine Engine Oil SH, SG, CF/CF-2 (25W-40) Premium grade multi-viscosity 20W-50 au- SH, SG, CF/CF-2 tomotive oil OTHER RECOMMENDATIONS IF PREFERRED OILS ARE NOT AVAILABLE Premium multi-viscosity 20W-40 automo- SH, SG, CF/CF-2 tive oil Straight weight detergent automotive oil of SH, SG, CF/CF-2...

  • Page 39: Temperature/Oil Viscosity Chart

    SPECIFICATIONS Crankcase Oil (con’t) TEMPERATURE/OIL VISCOSITY CHART Straight Weight Oils SH, SG, CF/CF-2 Multi-viscosity Quicksilver 25W 40 Oils SH, SG, 20W 50 CF/CF-2 ° F +100 ° Capacities MODEL 500 EFI Crankcase Oil Ca- 8 US qts (7.6 L) pacity w/New Filter Bravo XR/XZ - Drive Unit Oil Capacity (w/ 2.8 US qts (2.65 L)

  • Page 40: Engine Specifications

    SPECIFICATIONS Engine Specifications NOTE: Where applicable, specifications are derived at sea level. MODEL 500 EFI Displacement 502 (8.2) cid/L Propshaft Horsepower Propshaft Kilowatts Bore 4.47 in. (113.5 mm) Stroke 4.00 in. (101.6 mm) Compression Ratio 8.75:1 Compression 175 psi (1207 kPa) Pressure Maximum rpm @ 4800-5200...

  • Page 41: Tune Up Specifications

    SPECIFICATIONS Engine Specifications (cont.) MODEL 500 EFI Oil Pressure 30 psi (207 kPa) @ Idle rpm (Hot) Min. Oil Pressure 45 psi Min. (310 kPa) @ W.O.T. Engine Oil Temp. 170°-180°F (77° –82°C) @ 5200 rpm Thermostat 140°F (61°C) Engine Water Pres- 20 psi min.-30 psi max.
  • Page 42 SPECIFICATIONS Tune Up Specifications (cont.) MODEL 500 EFI Electrical System 12-Volt Negative (-) Ground Alternator 50 Amps Valve Lash 1 turn down from zero lash Recommended Minimum Battery Rating 550 CCA or 700 mca or 120 Amp/Hrs LH ROTATION FRONT Firing Order 1-8-4-3-6-5-7-2 500 EFI Bravo...

  • Page 43: Engine Break-In

    OPERATION Engine Break-in CAUTION Severe damage to the engine can result by not complying with the Engine Break-in Procedure. 5 HR. BREAK-IN PROCEDURE • Allow engine to warm-up for 30 - 60 seconds. • Do not exceed 3/4 throttle. • Avoid full throttle acceleration from IDLE speed.
  • Page 44 CA26 OPERATION 70516 70514 70515 70519 70518 70518 70522 70517 70521 70523 500 EFI Bravo...

  • Page 45: Instrumentation

    OPERATION Instrumentation The following is a brief explanation of instrumentation typically found on some boats. The owner/operator should be familiar with all instru- ments and their functions on the boat. Speedometer - indicates boat speed. Tachometer - indicates engine rpm. Oil Pressure Gauge - indicates engine oil pressure.
  • Page 46 OPERATION CB218 70518 70516 70517 500 EFI Bravo...

  • Page 47: Audio Warning System

    OPERATION Audio Warning System Your MerCruiser power package may be equipped with an Audio Warning System. NOTE: Testing the System: The buzzer will sound when the ignition switch is turned to the RUN position, prior to cranking the engine. Once the engine starts, the buzzer should stop. CAUTION Avoid engine damage.
  • Page 48 OPERATION 70525 40671 70528 70526 500 EFI Bravo...

  • Page 49: Electrical System Overload Protection

    OPERATION Electrical System Overload Protection If an electrical overload occurs, a fuse will blow or the circuit breaker will trip open. The cause must be found and corrected before replac- ing fuse or resetting circuit breaker. A circuit breaker provides protection for engine wiring harness and instrumentation power lead.
  • Page 50 OPERATION CB181 500 EFI Bravo...

  • Page 51: Remote Controls (Panel Mounted)

    OPERATION CB182 Remote Controls (Panel Mounted)  Your boat may be equipped with one of many Quicksilver remote controls available. All controls feature an integral safety switch that allows starting engine in NEUTRAL only. Also, all controls may not have all features shown. If boat is equipped with a remote control other than shown, consult your dealer for a description and/or demonstration of the control.
  • Page 52 OPERATION CB183 500 EFI Bravo...

  • Page 53: Remote Controls (Console Mounted)

    OPERATION CB184 Remote Controls (Console Mounted) Control Handle(s) - Operation of the shift and throttle are con- trolled by the movement of the control handle. “Push” the control handle forward from “Neutral” with a quick firm motion to the first detent for “Forward”...
  • Page 54 OPERATION 500 EFI Bravo...

  • Page 55: Remote Controls (Console Mounted Zero Effort)

    OPERATION CB184 Remote Controls (Console Mounted Zero Effort) Throttle Control Lever(s) - Operation of the throttle is controlled by the movement of the longer control lever(s). “Pushing” the control lever forward increases engine speed. Detentes are used to give the movement of the lever a “notched” precise feel. The detentes also help to hold the lever at the desired engine rpm to reduce operator fatigue.
  • Page 56 OPERATION CA34 ° 3 - 5 500 EFI Bravo...

  • Page 57: Power Trim

    OPERATION 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. CAUTION Engine must maintain a minimum of 20 psi of water pressure and should not exceed 30 psi maximum at 4800 to 5200 RPM as measured at the lower block drain position (either side of the block).
  • Page 58 OPERATION Power Trim (cont.) Trimming Drive Unit DOWN/IN Can: • Help the boat accelerate and plane off quicker. • Generally improve the ride in choppy water. • In most cases, reduce boat speed. • If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane.
  • Page 59 NOTES 500 EFI Bravo...
  • Page 60 OPERATION CB187 73976 73977 500 EFI Bravo...
  • Page 61 OPERATION POWER TRIM OPERATION - PANEL MOUNT REMOTE CON- TROL IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 62 OPERATION CB190 73979 500 EFI Bravo...
  • Page 63 OPERATION POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (TWO BUTTON VERSION) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 64 OPERATION CB190 73978 500 EFI Bravo...
  • Page 65 OPERATION POWER TRIM OPERATION - DUAL ENGINE CONSOLE MOUNT REMOTE CONTROL (THREE BUTTON VERSION) IMPORTANT: If TRAILER button is held depressed after drive unit reaches end of upward travel, an internal circuit breaker will open and pump will stop. Should this happen, release button and allow motor to cool for about one minute.
  • Page 66 OPERATION 500 EFI Bravo...
  • Page 67 OPERATION POWER TRIM OPERATION - ZERO EFFORT CONTROL WITH INTEGRAL TRIM SWITCH The Bravo Heavy Duty Transom Assembly does not have an electri- cal trim limit switch or trim position sender, therefore the following precautions must be observed. WARNING Avoid personal injury or damage to stern drive unit. Without a Trim Limit Switch, the drive unit can be trimmed up/out be- yond the position where the drive unit has side support from the gimbal ring at any throttle setting.

  • Page 68: Starting, Shifting And Stopping

    OPERATION Starting, Shifting and Stopping WARNING Before starting engine, operate bilge blower for at least five minutes to remove any explosive fumes from engine compart- ment. If boat is not equipped with a bilge blower, open engine hatch and leave open while starting engine. IMPORTANT: Observe the following: •...
  • Page 69 OPERATION Starting, Shifting and Stopping (cont.) • Turn ignition key to START. Release key when engine starts and allow switch to return to RUN position. • Check oil pressure gauge immediately after engine starts. If oil pressure is not within specified range (see SPECIFICATIONS), stop engine immediately and determine cause.

  • Page 70: Starting/Operation Chart Checklist

    OPERATION CA41 Starting/Operation Chart Checklist Before After While After Starting Starting Underway Stopping Observe all Observe all gauges to Shift to Neu- gauges to Open engine check condi- tral. Turn igni- monitor engine hatch tion of engine. tion key OFF. condition.

  • Page 71: Drain Plug And Bilge Pump

    OPERATION CA408 Drain Plug and Bilge Pump The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug and/or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not rise to come in contact with your power package.

  • Page 72: Conditions Affecting Operation

    CONDITIONS AFFECTING OPERATION Weight Distribution Positioning of weight (passengers and gear) inside the boat has the following effects: Shifting weight to rear (stern) will: • Generally increases speed and engine rpm. • At extremes can cause boat to porpoise. • Causes bow to bounce in choppy water.

  • Page 73: Cavitation

    CONDITIONS AFFECTING OPERATION Cavitation Cavitation occurs when water flow cannot follow the contour of a fast-moving underwater object, such as a gear housing or propeller. Cavitation permits the propeller to speed up, but the boat speed to reduce. Cavitation can seriously erode the surface of the gear housing or propeller.

  • Page 74: Propeller Selection

    CONDITIONS AFFECTING OPERATION CA294 Propeller Selection IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open-throttle rpm. Use an accurate service tachometer to verify engine operating rpm. It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s).

  • Page 75: Conditions That Lower Engine Performance

    CONDITIONS AFFECTING OPERATION Conditions That Lower Engine Performance The following conditions lower engine performance and cannot be compensated by the engine fuel or electronic management systems. 1. Above sea level elevations 2. High temperature. 3. Low barometric pressure. 4. High humidity. These conditions (1 through 4 above) reduce air density to the engine which in turn lowers the following: •...

  • Page 76: Maintenance

    ca425hp MAINTENANCE Operation And Maintenance OWNER/OPERATOR RESPONSIBILITIES It is the owner/operator’s responsibility to perform the following: • Perform all safety checks. • Make sure lubrication and maintenance instructions are complied with for safe operation. • Return the unit to an Authorized MerCruiser Dealer for a periodic checkup.

  • Page 77: Replacement Service Parts

    ca425hp MAINTENANCE Replacement Service Parts WARNING Electrical, ignition and fuel system components on MerCruis- er gasoline power packages are designed and manufactured to comply with US Coast Guard rules and regulations to mini- mize risks of fire or explosion. Use of replacement electrical, ignition or fuel system compo- nents, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoided.

  • Page 78: Do-It-Yourself Maintenance Suggestions

    ca425hp MAINTENANCE Do-It-Yourself Maintenance Suggestions If you are one of those persons who likes to do-it-yourself, here are some suggestions for you. • Present-day marine equipment, such as your MerCruiser power package, are highly technical pieces of machinery. Electronic ig- nition and special fuel delivery systems provide greater fuel econ- omies, but also are more complex for the untrained mechanic.
  • Page 79 MerCruiser Service Manual(s) be purchased and read thoroughly. Maintenance Aids Mercury Precision Power Trim and Power Steering Steering Fluid or Dexron III automatic System...
  • Page 80 ca425hp MAINTENANCE Maintenance Aids (cont.) Gasoline Stabilizer Gasoline Stabilizer and Conditioner Engine Coupler and Engine Coupler Spline Grease P/N Splined Shaft 92-816391A4 Thread Sealant Loctite Pipe sealant P/N 92-809822 500 EFI Bravo...

  • Page 81: Maintenance Charts

    MAINTENANCE CA426hp Maintenance Charts SCHEDULED MAINTENANCE TO BE PERFORMED BY OWNER/OPERATOR Task Interval Engine Crankcase Oil - Check every 3 hrs. of operation Check Level Power Steering Fluid - Check level Stern Drive Unit Oil - Check Level Battery - Check level and Weekly inspect for damage Power Trim Pump Oil -...
  • Page 82 MAINTENANCE Maintenance Charts (cont.) Only perform maintenance which applies to your particular power package. SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER Task Interval Whenever Insufficient Seawater Seawater Pickup Pump - Flow is Suspected. (If Operating Temperature Exceeds Normal Disassemble and Inspect Range) Every 25 Hours of Operation or Crankcase Oil and Filter -...
  • Page 83 MAINTENANCE Maintenance Charts (cont.) SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER (CONT.) Task Interval Ignition System - Clean and inspect condition Flame Arrestor and Crank- case Ventilation Hose - Clean and inspect Every 100 Hours of Operation or Engine Alignment - Check Once Yearly, Whichever Occurs First.
  • Page 84 MAINTENANCE Maintenance Charts (cont.) SCHEDULED MAINTENANCE TO BE PERFORMED BY DEALER (CONT.) Task Interval Continuity Circuit - Check components for loose con- nections, broken or frayed wires Saltwater use: Every 50 Hours of Operation or 60 Days, Whichever 60 D Whi h Shift and Throttle Cable Occurs First...
  • Page 85 NOTES 500 EFI Bravo...
  • Page 86 MAINTENANCE 70543 40556 Quicksilver Power Trim and Steering Fluid (92-90100A12) 500 EFI Bravo...

  • Page 87: Checking Fluid Levels

    MAINTENANCE Checking Fluid Levels CHECKING CRANKCASE OIL ENGINE CRANKCASE OIL MUST BE CHECKED AT INTERVALS SPECIFIED IN “MAINTENANCE CHART”. It is normal for an engine to use a certain amount of oil in the process of lubricating and cooling the engine. Oil consumption will be higher on these engines which utilize forged (rather than cast) aluminum pistons to withstand the higher stresses created by their higher horsepower output.
  • Page 88 MAINTENANCE Quicksilver High Performance Gear Lube (92-816026A2) CB42 CHECKING SEAWATER/FUEL PUMP OIL IMPORTANT: Oil must be changed at specified intervals. Refer to Maintenance Chart for specific requirements. Use only Quicksilver High Performance Gear Lube in pump. Remove fill screw (top) and check oil level. Oil must come up to fill hole.
  • Page 89 NOTES 500 EFI Bravo...
  • Page 90 MAINTENANCE 71987 70979 70551 Quicksilver High Performance Gear Lube (92-816026A2) Quicksilver Power Trim and Steering Fluid (92-90100A12) 500 EFI Bravo...
  • Page 91 MAINTENANCE CA433 CHECKING DRIVE UNIT OIL NOTE: Oil level will fluctuate during operation. Oil level should be checked with cold engine before starting. Check gear lube monitor oil level; keep oil level at or near “Full” line. Check for water at bottom of monitor and/or if oil appears a milky tan, contact your Authorized MerCruiser Dealer immedi- ately;...
  • Page 92 MAINTENANCE 70571 500 EFI Bravo...

  • Page 93: Changing Fluids

    MAINTENANCE CA63 Changing Fluids See MAINTENANCE CHART for lubricant change frequency. Lubri- cant should be changed before placing boat in storage. Power Trim or Power Steering fluids do not require changing. CHANGING CRANKCASE OIL AND FILTER IMPORTANT: Change oil when engine is warm from operation. Warm oil flows more freely, carrying away more impurities.
  • Page 94 MAINTENANCE XR and XZ Models 50132 70568 Anti-Corrosion Grease (92-78376A6) Quicksilver High Performance Gear Lube (92-816026A2) 500 EFI Bravo...
  • Page 95 MAINTENANCE CHANGING DRIVE UNIT OIL (XR, XZ MODELS) IMPORTANT: Use only Quicksilver High Performance Gear Lube in drive unit. Remove propeller, place drive unit in full “down” position, remove OIL FILL/DRAIN SCREW and sealing washer, and drain oil. Remove OIL VENT screw and sealing washer. Allow oil to drain completely.
  • Page 96 MAINTENANCE Bravo III CB688 71987 72522 77106 Anti-Corrosion Grease (92-78376A6) Quicksilver High Performance Gear Lube (92-816026A2) 500 EFI Bravo...
  • Page 97 IMPORTANT: If any water drained from OIL FILL/DRAIN hole, or if oil appears milky, drive unit is leaking and should be checked immediately by your Authorized Mercury MerCruiser Dealer. 6 Lower drive unit so propeller shaft is level. Fill drive unit, through OIL FILL/DRAIN hole, with Specified Gear Lube until an air-free stream of lubricant flows from OIL VENT hole.

  • Page 98: Lubrication

    MAINTENANCE 70556 25W40 Motor Oil (92-90024) Lubrication SHIFT CABLE Lubricate pivot points with SAE 25W40 motor oil. THROTTLE CABLE Lubricate pivot points with SAE 25W40 motor oil. 500 EFI Bravo...
  • Page 99 NOTES 500 EFI Bravo...
  • Page 100 MAINTENANCE 70559 70558 71346 71347 2-4-C With Teflon (92-825407A12) Quicksilver Spline Grease (92-816391A4) 500 EFI Bravo...
  • Page 101 MAINTENANCE Lubrication (cont.) DRIVE UNIT AND TRANSOM ASSEMBLY Lubricate gimbal bearing with 2-4-C with Teflon Lubricant P/N (92-825407A12). NOTE: Engine coupling and shaft splines are greased with Engine Coupler Spline Grease, P/N 92-816391A4; universal joints are greased with Quicksilver 2-4-C with Teflon Lubricant P/N (92-825407A12).
  • Page 102 MAINTENANCE XR, XZ Models 500 EFI Bravo...

  • Page 103: Propellers

    MAINTENANCE CB421hp Propellers (XR, XZ Models) WARNING Avoid Injury: Remote Control must be in NEUTRAL and igni- tion key removed from switch before removing and/or install- ing propeller. WARNING Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.
  • Page 104 MAINTENANCE XR, XZ Models Anti-Corrosion Grease (92-78376A6) 500 EFI Bravo...
  • Page 105 MAINTENANCE CB421hp Propellers (XR, XZ Models)(cont.) INSTALLATION Install Bravo XR/XZ Replaceable Hub Propeller Compo- nents in Order shown: Apply Lubricant to entire exposed surface of Propshaft. Salt Water: Anti-Corrosion Grease (92-78376A-6) Fresh Water: Anti-Corrosion Grease or Optimal Paste White T Grease (92-847206) Install prop hub assembly into propeller if removed Propeller Assembly Washer...
  • Page 106 NOTES 500 EFI Bravo...
  • Page 107 MAINTENANCE CB421hp Propellers (Bravo III) WARNING Avoid Injury: Remote Control must be in NEUTRAL and igni- tion key removed from switch before removing and/or install- ing propeller. WARNING Avoid Injury: Place a block of wood between anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from rotating when removing propeller nut.
  • Page 108 MAINTENANCE CB150 Bravo III Models 77107 500 EFI Bravo...
  • Page 109 MAINTENANCE CB421hp Propellers (Bravo III)(cont.) CA820 INSTALLATION 1 Apply a liberal coat of one of the following Quicksilver lubricants to both propeller shafts: Special Lubricant 101, 2-4-C Marine Lubri- cant with Teflon, or Anti-Corrosion Grease. 2 Slide forward thrust hub onto propeller shaft, with tapered side to- ward propeller hub (toward end of shaft).
  • Page 110 MAINTENANCE 500 EFI Bravo...

  • Page 111: Flushing Cooling System

    MAINTENANCE Flushing Cooling System WARNING To avoid possible injury when flushing remove propeller. CAUTION Do not run engine above 1500 rpm when flushing. Suction created by seawater pickup pump may collapse flushing hose, causing engine and/or drive unit to overheat. Watch temperature gauge on dash to ensure that engine does not overheat.
  • Page 112 MAINTENANCE 500 EFI Bravo...

  • Page 113: Cleaning Seawater (Raw Water) Section Of Oil Cooler

    MAINTENANCE CB73 Cleaning Seawater (Raw Water) Section of Oil Cooler CAUTION When cleaning engine oil or power steering coolers with the boat in the water; be sure to close off the water supply from the seawater pump to the cooler or water may enter the boat when end plates or hoses are removed.
  • Page 114 MAINTENANCE -Crankshaft Pulley -Water Circulating Pulley -Alternator Pulley -Power Steering Pump Pulley -Idler Pulley (Adjustment Pulley) -Seawater Pump Pulley -Belt Tension Gauge - Check for belt tension here • New Belt - 120 lbs.(530 N.) • Used Belt - 80 lbs. (350 N.) 500 EFI Bravo...

  • Page 115: Drive Belt

    MAINTENANCE Drive Belt WARNING Make sure engine is shut off and ignition key is removed be- fore inspecting belts. Drive belt must be periodically inspected for condition and tension. Check for tension at location shown. 1 Inspect drive belt for proper tension and for the following: •...

  • Page 116: Fuel Filters

    MAINTENANCE 70573 CB172 Fuel Filters WARNING Avoid Fire or Explosion: Be careful when changing fuel filters. Gasoline is extremely flammable and highly explosive under certain conditions. Be sure ignition key is OFF. Do not smoke or allow spark or open flame in area when changing fuel filter. Wipe up any spilled fuel immediately.

  • Page 117: Corrosion And Corrosion Protection

    CAUTION Mercury Marine recommends a MerCathode System or Anti- Corrosion Kit be installed whenever using a stainless steel propeller, or if boat is equipped with stainless steel compo- nents (immersed below the waterline) that are connected into the engine ground system.
  • Page 118 MAINTENANCE 70575 72029 70578 70577 71966 72032 500 EFI Bravo...
  • Page 119 MAINTENANCE Corrosion and Corrosion Protection (cont.) Gear Housing Anode - is located in the splash plate, just above the propellers. Anodic Plate - serves as a sacrificial anode. Unscrew both at- taching screws and remove. Install a new anodic plate and tight- en securely.
  • Page 120 MAINTENANCE CB170 71176 500 EFI Bravo...
  • Page 121 MAINTENANCE Corrosion and Corrosion Protection (cont.) CA168 In addition to the corrosion protection devices, the following steps should be taken to inhibit corrosion: IMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty.

  • Page 122: Battery

    MAINTENANCE Battery All lead acid batteries discharge when not in use. Recharge every 30 to 45 days, or when specific gravity drops below battery manufactur- er’s specifications. Refer to specific instructions and warnings accompanying your bat- tery. If this information is not available, observe the following: WARNING Observe the following when jump starting, charging or handling a battery:...

  • Page 123: Bottom Of Boat

    MAINTENANCE CA104 Bottom of Boat To maintain maximum speed, the following conditions of the boat bottom should be observed: • Clean, free of barnacles and marine growth. • Free of distortion, nearly flat where it contacts water. • Straight and smooth, fore and aft. ANTIFOULING PAINTS See Antifouling Paint recommendations and related information on previous pages.

  • Page 124: Maintenance Log

    MAINTENANCE LOG oka1 Record here all maintenance performed on your Mercruiser Hi-Per- formance package. Be sure to save all work orders and receipts. Engine Date Maintenance Performed Hours 500 EFI Bravo...
  • Page 125 MAINTENANCE LOG Engine Date Maintenance Performed Hours 500 EFI Bravo...

  • Page 126: Cold Weather Or Extended Storage Power Package Lay-Up

    CB99 COLD WEATHER OR EXTENDED STORAGE Power Package Lay-up IMPORTANT: This service should be performed by an Autho- rized MerCruiser Dealer. CAUTION Avoid Engine or Stern Drive Damage: DO NOT operate engine without water flowing thru seawater pickup pump, as pump impeller may be damaged and subsequent overheating dam- age to engine or stern drive unit may result.
  • Page 127 COLD WEATHER OR EXTENDED STORAGE Power Package Lay-up (cont.) If boat is to be placed in storage with fuel containing alcohol in fuel tanks (if fuel without alcohol is not available): • Fuel tanks should be drained completely and Quicksilver Gaso- line Stabilizer and Conditioner added to any fuel remaining in the tank.
  • Page 128 COLD WEATHER OR EXTENDED STORAGE 500 EFI Bravo...

  • Page 129: Draining Instructions

    COLD WEATHER OR EXTENDED STORAGE Draining Instructions DRAINING SEAWATER (RAW-WATER) COOLED MODELS CAUTION If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent siphoning allowing seawater to flow from the drain holes or removed hoses. CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather...
  • Page 130 COLD WEATHER OR EXTENDED STORAGE Make sure the following passages are open and unobstructed: -Speedometer Pilot Tube -Trim Tab Cavity Vent Hole -Trim Tab Cavity Drain Passage 500 EFI Bravo...
  • Page 131 COLD WEATHER OR EXTENDED STORAGE Draining Instructions (cont.) IMPORTANT: MerCruiser recommends that propylene glycol (a nontoxic and environmentally safe) antifreeze be used in the seawater section of the cooling system for cold weather or ex- tended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

  • Page 132: Battery Winter Storage

    COLD WEATHER OR EXTENDED STORAGE Battery Winter Storage Follow battery manufacturer’s instructions for storage. Power Package Recommissioning WARNING To prevent possible injury or damage to equipment, do not in- stall battery until all maintenance has been performed on en- gine. Check that all cooling system hoses are connected properly and hose clamps are tight and any removed drain plugs are installed and tight.

  • Page 133: Troubleshooting

    CB119 TROUBLESHOOTING Starter Motor Will Not Crank Engine, or Cranks Slow Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral Position control lever in neutral. position. Open circuit breaker or blown Check and reset circuit breaker fuse.

  • Page 134: Engine Runs Rough, Misses, And/Or Backfires

    TROUBLESHOOTING Engine Will Not Start, or Is Hard to Start (con’t) Lanyard Stop activated. Reset. Clogged fuel filters. Replace filters. If contaminated, drain tank. Fill Stale or contaminated fuel. with fresh fuel. Replace kinked lines or blow Fuel line or tank vent line out lines with compressed air kinked or clogged.

  • Page 135: Poor Performance

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

  • Page 136: Insufficient Engine Temperature

    TROUBLESHOOTING Insufficient Engine Temperature Possible Cause Remedy Faulty water thermostat. Replace. Faulty oil thermostat. Replace Faulty gauge or sender. Test with shop gauge. Low Engine Oil Pressure Possible Cause Remedy Insufficient oil in crankcase. Check and add oil. Check and remove required amount of oil.

  • Page 137: Power Trim Does Not Operate (Motor Doesn't Run)

    TROUBLESHOOTING Battery Will Not Come Up On Charge (cont.) Possible Cause Remedy Alternator drive belt loose or in Replace and/or adjust. poor condition. Unacceptable battery Test battery. condition. Power Trim Does Not Operate (Motor Doesn’t Run) Possible Cause Remedy Blown fuse. Replace fuse.

  • Page 138: Remote Control Operates Hard, Binds, Has Excessive Free

    TROUBLESHOOTING Remote Control Operates Hard, Binds, Has Ex- cessive Free-Play or Makes Unusual Sounds Possible Cause Remedy Insufficient lubrication on shift Lubricate. and throttle linkage fasteners. Check all linkages. If any are loose or missing, see Loose or missing shift and Authorized MerCruiser Dealer throttle linkage fasteners.

  • Page 139: Block Water Pressure Is Below Specification

    TROUBLESHOOTING Block Water Pressure Is Below Specification (DUAL WATER INLET GEARCASE) Possible Cause Remedy Lower the “X” dimension. Plug upper 4 strut water holes. Install low water pickup Insufficient water supply. gearcase. Install a transom or through-hull water pickup. Block Water Pressure Is Below Specification (LOW WATER INLET GEARCASE) Possible Cause Remedy...

  • Page 140: Water Flow Diagram

    WATER FLOW DIAGRAM Seawater Inlet Seawater Pickup Pump Fuel Cooler Engine Oil Cooler Power Steering Cooler Thermostat Housing Engine Circulating Pump To Exhaust Elbows To Exhaust Manifold To Engine Circulating Pump Coolant From Engine From Seawater Pickup Pump Coolant Flow with Thermostat Closed Coolant Flow With Thermostat Open...

  • Page 141: Wiring Diagrams

    WIRING DIAGRAMS Power Trim (Single Engine) BLK = Black BLU = Blue BRN = Brown GRY = Gray GRN = Green ORN = Orange PNK = Pink PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light DRK = Dark 22252...

  • Page 142: Power Trim (Dual Engine)

    WIRING DIAGRAMS Power Trim (Dual Engine) BLK = Black BLU = Blue GRN = Green PUR = Purple RED = Red WHT = White LIT = Light -Port Trim Pump -Starboard Trim Pump -To 12V Power Source -Console Mounted Port Trim Switch -Console Mounted Starboard Trim Switch -Diodes -20 Amp Fuse...

  • Page 143: Instrument Wiring Harness

    WIRING DIAGRAMS Instrument Wiring Harness BLK = Black BLU = Blue BRN = Brown GRY = Gray PUR = Purple RED = Red TAN = Tan WHT = White YEL = Yellow LIT = Light 74583 -Audio Warning Buzzer Ignition Switch -Tachometer Oil Temperature -Oil Pressure...

  • Page 144: Owner Service Assistance

    Refer to the Yellow Pages of the telephone directory. If, for any reason, you cannot obtain service, contact the nearest Mercury Marine Service Office. Outside the United States and Canada, contact the nearest Marine Power International Service Center.
  • Page 145 • Daytime telephone number • Model and serial number of your Engine and Drive Unit • The name and address of your dealership • Nature of problem Mercury Marine Service Offices are listed on the next pages. 500 EFI Bravo...

  • Page 146: Mercury Marine Service Offices

    (32) (87) 32 • 32 • 11 (32) (87) 31 • 19 • 65 Parc Industriel de Petit-Rechain B-4800 Verviers Belgium Mexico, Central America, South America, Caribbean Mercury Marine - Latin America (305) 385-9585 (305) 385-5507 & Caribbean 9010 S.W. 137th Ave. Suite 226 Miami, FL 33186 U.S.A.
  • Page 147 OWNER SERVICE ASSISTANCE Mercury Marine Service Offices (cont.) Telephone Mail Japan Mercury Marine - Japan 81-53-423-2500 81-53-423-2510 283-1 Anshin-cho Hamamatsu Shizuoka, 435-0005 Japan Asia, Singapore Mercury Marine Singapore (65) 546-6160 (65) 546-7789 72 Loyang Way Singapore 508762 500 EFI Bravo...

  • Page 148: Ordering Literature

    Serial Number_____________ Year_______ United States and Canada For information on additional literature that is available for your particular MerCruiser power package and how to order that literature contact your nearest dealer or contact: Mercury Marine Telephone Mail Mercury Marine Attn: Publications Department...

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