GASOLINE ENGINES BRAVO MODELS

INDEX

The following are registered trademarks of

Brunswick Corporation: Merc, MerCathode,

MerCruiser, Mercury, Mercury Marine,

Quicksilver, and Ride-Guide.

GASOLINE ENGINES BRAVO MODELS

NOTICE to INSTALLER

After Completing Installation, These Instructions Should Be Placed With The Product For The

Owner’s Future Use.

NOTICE to COMMISSIONING DEALER

Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product

Owner.

Table of Contents

General Information

. . . . . . . . . . . . . . . . . . . . .

Notice to Boat Manufacturer/Installer . . . .

Bravo Three Notice: Trim-In Limit Pin . . .

MCM 454 & 502 Magnum MPI Application

Recommendations . . . . . . . . . . . . . . . . . . .

Multiple Steering Tie Bar Arrangements

Quicksilver Products

.

. . . . . . . . . . . . . . . . . .

Installation Products

Torque Specifications

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

Serial Number Decal Placement . . . . . . . .

Corrosion Protection

Antifouling Paint

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Installation Requirements

Boat Construction

. . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . .

Exhaust System . . . . . . . . . . . . . . . . . . . . . .

Fuel Delivery System . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EFI Electrical System Precautions . . . . . .

Instrumentation . . . . . . . . . . . . . . . . . . . . . . .

Power Trim Control . . . . . . . . . . . . . . . . . . .

Power Trim Pump Location . . . . . . . . . . . .

Propeller Selection . . . . . . . . . . . . . . . . . . . .

Hot Water Heater Installation

Recommendation . . . . . . . . . . . . . . . . . . . .

Seawater Connections - General

Finding Crankshaft Vertical Centerline

Finding Crankshaft Horizontal

Centerline (“X” Dimension)

. . .

. . . . . . . . . . . .

Cutting Transom

. . . . . . . . . . . . . . . . . . . . . . . .

Checking Transom Thickness

Installing Transom Assembly

Installing Gimbal Housing

. . . . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . .

27

Information . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Throttle/Shift Remote Control and Cables 30

Steering Helm and Cable

Transom Cutout

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . .

30

32

33

34

36

37

Installing Inner Transom Plate

Installing Power Trim Pump

Installing Steering System

. . . . . . . . . .

. . . . . . . . . . . .

. . . . . . . . . . . . .

24

25

25

26

37

37

39

40

41

14

20

22

24

10

10

8

9

4

5

6

7

7

8

2

2

3

90-860172001 APRIL 2000 Printed in U.S.A. -



2000, Mercury Marine

Hydraulic (Helm) Steering . . . . . . . . . . . . .

Connecting Speedometer Pickup . . . . . . .

Connecting Drive Unit Gear Lube

Monitor Hose

Engine Installation

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Driveshaft Extension Models

Engine Preparation

. . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

41

44

Transom Preparation . . . . . . . . . . . . . . . . . .

Installing Engine/Alignment . . . . . . . . . . . .

Coolant Recovery System (If Equipped)

Engine Connections

.

. . . . . . . . . . . . . . . . . . . . .

Quick Drain Oil Installation . . . . . . . . . . . . . . .

Shift/Throttle Cables Installation and

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing Sterndrive Unit Shift Cable

Troubleshooting Shift Problems

. . . .

. . . . . . . . .

63

63

67

Throttle Cable Installation and Adjustment 69

Sterndrive Unit Installation

. . . . . . . . . . . . . . . . 76

Predelivery Preparation

Battery Connection

. . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . .

Power Trim Pump . . . . . . . . . . . . . . . . . . . .

84

84

84

Trim Position Sender Adjustment

Power Steering

. . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

85

87

Propeller Installation (Bravo One and Two) 87

Propeller Installation (Bravo Three) . . . . . 89

47

49

53

54

62

45

46

46

46

Test Running Engine . . . . . . . . . . . . . . . . . .

Boat-ln-The-Water Tests . . . . . . . . . . . . . . .

Cold Weather or Extended Storage

Draining Instructions . . . . . . . . . . . . . . . . . .

90

92

94

Quicksilver Instrumentation Wiring Diagrams 100

Power Trim System Wiring Diagram . . . . . . .

102

MerCathode System Wiring Diagram . . . . . .

103

MCM Gasoline Engine Wiring Diagrams

Water Flow Diagrams

. . . .

. . . . . . . . . . . . . . . . . . . .

Predelivery Inspection

. . . . . . . . . . . . . . . . . . .

104

112

116

Page 1 of 116


General Information

Notice to Boat Manufacturer/Installer

Throughout this publication, “Warnings” and “Cautions” (accompanied by the International

Hazard Symbol

!

) are used to alert the manufacturer or installer to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. –– Observe Them Carefully!

These “Safety Alerts,” alone, cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus “common sense” operation, are major accident prevention measures.

WARNING

Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION

Hazards or unsafe practices which could result in minor personal injury or product or property damage.

IMPORTANT: Indicates information or instructions that are necessary for proper installation and/or operation.

This installation requirements manual has been written and published by Mercury Marine to aid the boat manufacturer involved in the application and installation of the products described herein.

It is assumed that these personnel are familiar with marine product application and the installation procedures of these products, or like or similar products manufactured and marketed by Mercury Marine. Furthermore, it is assumed that they are familiar with, if not trained in, the recommended installation procedures of these products.

We could not possibly know of and advise the marine trade of all conceivable applications and installations which might be achieved, and of the possible hazards and/or results of each conceivable application or installation. We have not undertaken any such wide evaluation. Therefore, any manufacturer which, or person who, applies or installs the product in a manner which does not fulfil the requirements listed herein, first must completely satisfy themselves that neither their safety nor the product will be endangered by the application or installation procedure selected.

It is the responsibility of the OEM to select the appropriate engine/transom/drive package

(including the correct gear ratio and propeller) for a given boat. Making an appropriate selection requires knowledge of the boat (weight, length, hull design, intended use and duty cycle, desired speed, etc.) that is uniquely in the possession of the OEM. While Mercury employs people capable of assisting the OEM on such issues, the final decision rests with the OEM.

Mercury recommends that any new or unique hull/power package combination be thoroughly water tested prior to sale, to verify (among other things) that the boat performs as desired, and that the engine runs in the appropriate rpm range.

It is recommended that a Mercury Marine Field Product Engineer be contacted for assistance if specific application or installation problems are encountered.

All information, illustrations, and specifications contained in this manual are based on the latest product information available at time of publication. As required, revisions to this manual will be sent to all OEM boat companies.

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Page 2 of 116

INDEX


Bravo Three Notice: Trim-In Limit Pin Insert

NOTE: Bravo One, Two and Three Models are equipped with a Trim-In Limit Pin Insert.

It has been brought to our attention that some boats (predominantly deep-Vee heavy boats) will roll up on their side under certain, specific, operating conditions. The roll can be either to port or starboard and may be experienced while moving straight ahead, or while making a turn. The roll occurs most frequently at or near maximum speed, with the sterndrive unit trimmed at or near full trim-in. While the boat will not roll completely over, the roll may be sufficient to unseat the operator or passengers, and thereby create an unsafe situation.

The roll is caused by stern-lift created from excessive sterndrive unit trim-in. Under these extreme stern-lift / bow-down conditions instability can be created which may cause the boat to roll. Weight distribution to the stern can reduce stern-lift and, in some circumstances, help to control the condition. Weight distribution in the bow, port or starboard, may worsen the condition.

The Trim-In Limit Pin Insert reduces stern-lift by preventing the sterndrive unit from reaching the last few degrees of full trim under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The need for this Trim-In Limit Pin, and its effectiveness, can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer.

WARNING

It is recommended that only qualified personnel adjust the Trim-In Limit Insert. Boat must be water tested after adjusting the device to ensure that the modified trim-in range does not cause the boat to exhibit an undesirable boat handling characteristic if the sterndrive unit is trimmed In at higher speeds. Increased Trim-In range may cause handling problems on some boats which could result in personal injury.

Page 3 of 116


MCM 454 & 502 MPI Application Recommendations

BOAT TYPES

The MCM 454 and 502 MPI models are recommended for use in most sport boat applications with the exception of the following.

•

Bravo applications which require that the sterndrive unit be mounted more than 3 in.

(75mm) above the standard “X” dimension (i.e., catamarans, certain stepped bottom boats, etc.). For those applications, we recommend our Performance Products models with a Super Speedmaster sterndrive unit which are designed specifically for surfaced propeller operation.

•

Applications which require other than standard Quicksilver propellers to get the boat up on plane or to keep the propeller from ventilating when up on plane.

•

Boats that require that the engine be run above 3200 rpm to keep them on plane.

•

Racing applications or other highly abusive applications where the boat and the sterndrive units will come out of the water frequently. These, again, are applications where we recommend our Performance Products models with Super Speedmaster sterndrive units.

INDEX

STEERING

Mercury MerCruiser power packages come standard with Mercury MerCruiser’s internal power steering. This durable system provides precise effortless steering control and is recommended for most sport boat applications. On certain applications, however, Mercury

MerCruiser recommends the use of an external power steering system where the power steering cylinders connect directly to the sterndrive unit on the outside of the boat. This arrangement gives additional support for even tighter, more firm steering control, and is recommended for the following applications:

•

High speed single or twin engine applications and/or boats with unusual handling characteristics. It is virtually impossible to give a specific recommendation as to when external power steering should be used, as this varies from boat design to boat design. Generally speaking, it is recommended to use external power steering on boats which run in excess of 70 MPH. However, there are boats which run 60 MPH that would benefit from the use of external power steering. Because of the many variables involved, the final decision as to whether or not external power steering is required rests with the boat manufacturer and must be made after a thorough test and evaluation of each specific boat. If there is any question whether or not external power steering is necessary, Mercury MerCruiser recommends that it be installed.

•

Any Hi-Performance sport boat powered by three or more engines.

•

Offshore boats or other applications where the boat and sterndrive units may come out of the water occasionally.

•

All III SSM and V SSM High Performance Sterndrive applications.

External power steering systems are generally either mechanical cable actuated or hydraulic actuated. If cable actuation is selected, combining dual steering cables with an internal control valve kit (Part Number 89645A35) will provide an even tighter feel (less steering backlash). This kit cannot be used with hydraulic actuation.

Page 4 of 116

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External power steering and hydraulic helm systems can be obtained from the following after market suppliers:

Latham Marine Inc.

280 S.W. 32nd Court

Ft. Lauderdale, FL 33315

Phone: (305) 462-3055

Fax: (305) 462-3081

Mayfair Marine Machine

12890 N. W. 30th Avenue

Opalocka, FL 33054

Phone: (305) 681-1815

On dual or triple engine high speed applications, Mercury MerCruiser recommends the use of a Quicksilver Priority Valve Kit (Part Number 79691A4). This kit allows two power steering pumps to be used and helps to ensure that power assist will be maintained if one engine or power steering pump should stop functioning (engine runs out of fuel, etc.).

ENGINE MOUNTS

The 454 and 502 models come standard with heavy-duty pedestal-type front engine mounts. These mounts include provisions for isolating engine vibrations and can be used in most sport boat applications. On offshore boats or boats which will be used in rough water areas, however, Mercury MerCruiser recommends the use of a solid plate engine mount.

Multiple Sterndrive Steering - Tie Bar Arrangements

With multiple sterndrives it is important to consider which of several possible steering systems should be selected.

CAUTION

Failure to observe the recommended Tie Bar Arrangements could result in serious damage to the steering and/or trim system components. This damage could adversely affect control of the boat.

INTERNAL TIE BAR ONLY

At the lower end of the performance spectrum (boats not capable of speeds in excess of

60 MPH) the basic internal tie bar is recommended. It connects the slave sterndrive to the sterndrive that is directly connected to the factory power steering output. This internal tie bar is available in a variety of lengths from the sterndrive manufacturer.

Page 5 of 116


INTERNAL AND EXTERNAL TIE BAR

As a boat moves into a moderate performance range (60-70 MPH) or for a reduction in steering backlash, an external tie bar should be added. External tie bars are usually designed to attach at the aft power trim cylinder bosses which is an excellent location because of its proximity to the propeller. HOWEVER, because of the potential overstress that can occur if one sterndrive is trimmed much differently than the other, a dual trim control kit (Part Number 90362A3) should be installed so as to limit this potential tilt differential to about 20

°

.

IMPORTANT: Mercury Marine does not recommend the use of an external tie bar

ONLY with no internal tie bar when using the internal power steering system. This can cause excessive loads on the steering components on the sterndrive connected to the internal power steering system. These increased loads can damage the steering components, resulting in increased play in the steering of the boat.

INDEX

EXTERNAL POWER STEERING

When boat speeds move past 70 MPH or if additional steering backlash reduction is desired, external power steering is recommended. This normally will include an external tie bar mounted at the same general location of the power steering cylinders, which are generally attached at the top of the sterndrive’s drive shaft housing. With this steering system, no internal tie bar should be used. These steering cylinders can be attached either inboard (between) or outboard of the sterndrives.

EXTERNAL POWER STEERING WITH LOW EXTERNAL TIE BAR

For the fastest boats (over 80 MPH) or for the ultimate in steering backlash reduction, use external power steering, BUT (where mechanically possible) with the external tie bar mounted at the trim cylinder boss location (as previously described in “Internal and External

Tie Bar” statements). Again this system does not use an internal tie bar.

Quicksilver Products

ACCESSORIES

Quicksilver remote controls, steering systems, propellers, etc. are available for this product.

Refer to “Quicksilver Accessories Guide” for complete listing.

This “Guide” is available from:

Attn: Parts Department

Mercury Marine

W6250 W. Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54936-1939

OR –

Outside of U.S.A., order through

Distribution Center, or Distributor.

Page 6 of 116

INDEX


Installation Products

Description

Quicksilver Engine Coupler Spline Grease

Quicksilver 2-4-C Marine Lubricant With Teflon

Quicksilver U-Joint and Gimbal Bearing Grease

Quicksilver Special Lubricant 101

Quicksilver Liquid Neoprene

Quicksilver Power Trim and Steering Fluid

Dexron III - Automatic Transmission Fluid

Quicksilver Perfect Seal

Transom Drilling Fixture

Engine Alignment Tool

Shift Cable Adjustment Tool

Engine Mount Drilling Fixture

Part Number

92-816391A4

92-825407A3

92-828052A2

92-13872A1

92-25711-2

92-90100A12

Obtain Locally

92-34227-1

91-43693A2

91-805475A1

91-12427

91-806794A1

Torque Specifications

Description lb-in.

Torque lb-ft Nm

sterndrive Unit Gear Lube Monitor - 90

°

Hose Barb Fitting

Speedometer Pickup Barb Fitting

Exhaust Pipe or Block-off Plate

Power Steering Hydraulic Hose Fittings

Power Trim Pump Hose Fittings

Propeller Nut (Bravo One and Two)

1

Front

Propeller Nuts (Bravo Three)

1

Rear Engine Mounts

Steering Cable Coupler Nut

Steering System (Pivot Bolts)

Sterndrive Unit Fasteners

Transom Assembly Fasteners

Seawater Pickup Fitting

Power Trim Cylinder Fasteners

Fuel Line Inlet Fitting

Rear

80 9

13

125

23

23

55

100

60

38

35

25

50

23

45

Tighten until they contact.

5

See Note.

68

31

81

51

47

34

1.5

31

31

14

75

136

1

: Amount specified is MINIMUM.

NOTE: Refer to Fuel Delivery System - “Special Information For All Gasoline Engines.”

Page 7 of 116


Serial Number Decal Placement

There are three sets of engine, transom assembly and sterndrive serial number decal strips provided with each power package. One set should be used for each of the following:

•

Engine Specification Decal

•

Warranty Registration Card

•

Operation, Maintenance and Warranty Manual identification page.

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Corrosion Protection

Mercury MerCruiser power packages are equipped with anodes, to help protect them from galvanic corrosion under moderate conditions. However, for severe conditions, or if using a stainless steel propeller, it is recommended that a Quicksilver Anti-Corrosion Anode Kit and/or a MerCathode System be installed (some models have a MerCathode System as standard equipment). A MerCathode Monitor also is available to allow the operator to check the operation of the MerCathode System with the push of a button. (Refer to “Quicksilver

Accessories Guide” for part numbers.)

Boats which are connected to AC shore power, require additional protection to prevent destructive low voltage galvanic currents from passing through the shore power ground wire.

A Quicksilver Galvanic Isolator can be installed to block the passage of these currents while still providing a path to ground for dangerous fault (shock) currents. (Refer to “Quicksilver

Accessories Guide” for part number.)

IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode

System and anodes may be unable to handle the increased galvanic corrosion potential.

Page 8 of 116

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Anti-fouling Paint

IMPORTANT: Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty.

Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and boat transom but you must observe the following precautions:

IMPORTANT: DO NOT paint anodes or MerCathode System reference electrode and anode, as this will render them ineffective as galvanic corrosion inhibitors.

IMPORTANT: If anti-fouling protection is required for boat hull or boat transom, copper or tin base paints, if not prohibited by law, can be used. If using copper or tin based anti-fouling paints, observe the following:

•

Avoid an electrical interconnection between the Mercury MerCruiser Product,

Anodic Blocks, or MerCathode System and the paint by allowing a minimum of

1-1/2 in. (40mm) UNPAINTED area on transom of the boat around these items.

a b

71176

a -

Painted Boat Transom

b -

Minimum 1 1/2 in (40 mm) UNPAINTED Area Around Transom Assembly

NOTE: Sterndrive unit and transom assembly can be painted 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, MerCathode system or items specified by boat manufacturer.

Page 9 of 116


Installation Requirements

Boat Construction

TRANSOM THICKNESS AND SURFACE

IMPORTANT: Transom thickness and surface plane (flatness) must be controlled where the sterndrive unit mounts.

Transom thickness and surface must conform to the following:

Thickness

Parallelism

Flatness

Angle

Transom Specifications

Between 2 - 2-1/4 in. (51 - 57 mm)

Inner and outer surfaces must be parallel within 1/8 in. (3 mm)

Transom surfaces in area where transom assembly will be mounted (includes vertical as well as horizontal dimensions):

Inner Surface – Flat within1/8 in. (3 mm)

Outer Surface – Flat within1/16 in. (2 mm)

10-16 Degrees

INDEX

a b e d d c

22170

72700

a -

Transom Thickness

b -

Inner Surface

c -

Outer Surface

d -

Transom Plate Coverage

e -

Transom Angle

ENGINE BED

Engine bed must position engine so that a minimum of 1/4 in. (6mm) up and down adjustment still exists on mounts after performing final engine alignment. This is necessary to allow for realigning engine in the future.

NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure that the front and rear mount locations in the vessel are in parallel planes. This may be checked by tying a string from the left front mount location to the right rear mount location and another from right front to left rear. The strings should touch where they cross.

Page 10 of 116

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ENGINE COMPARTMENT

WARNING

Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when constructing the engine compartment.

Care must be exercised in the design and construction of the engine compartment. Seams must be located so that any rain water, which may leak through the seams, is directed away from the air intake system. Water that runs onto the air intake may enter the engine and

cause serious damage to internal engine parts.

Over the last several years, engine compartments have been designed to be quieter. The most common material used to deaden the engine sound is some type of insulation material.

Normally, the quieter the engine compartment is, the more insulation material used which results in less air space inside. The less air space inside the engine compartment, the hotter the inside air temperature. Attention must be given to the air temperature that is inside this engine compartment while the engine is running or after a period of time after the engine is shut off (heat soak). Refer to the following information on Engine Compartment Ventilation.

ENGINE COMPARTMENT VENTILATION

General Information

According to Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations the engine compartment ventilation system has multiple tasks. Included are the following:

1. To supply the engine with combustion air.

2. To maintain a low temperature in the engine compartment.

3. To vent the air and fumes in the engine compartment.

Fresh air should enter the engine compartment as low as possible and the heated air should be discharged from the highest point.

When sufficient ventilation is not provided, too much heat can build-up inside of engine compartment and cause vapor locking. The engine will not want to restart after it has been shut off for a short period of time. If it does restart, the engine will quit when given the throttle to get the boat up on plane or to pull up a water skier.

For engines utilizing fuels containing alcohol and the newer “reformulated gasolines” (See

OEM Service Bulletin 95-2.) proper ventilation is more critical to prevent vapor locking.

If a separate air shaft (or similar) is used to provide engine compartment ventilation or additional ventilation, care must be taken to prevent seawater and spray from entering it.

Page 11 of 116


Combustion Air Requirements

Engine compartments with natural draft ventilation must have vent openings of sufficient size and location to accomplish the tasks previously outlined.

IMPORTANT: The size of ventilation openings must be increased if any auxiliary equipment is located in the engine compartment.

The combustion air requirement (per engine) for the specified engines at Wide Open

Throttle are given in the chart below:

INDEX

Combustion Air Requirements (Per Engine) and Ventilation Information

Model

3.0L

Engine Air

Requirements at W O T

251 ft.

3

(0.118 m

/Min.

3

/sec.)

MINIMUM

Combustion Air Vent

Area Per Engine

1

25 in

2

(161 cm

2

)

Engine Physical

Volume

2.4 ft.

3

(68.0 l)

4.3L

4.3LH

4.3L EFI

364 ft.

(0.172m

3

3

/Min.

/sec.)

36 in

2

(232 cm

2

)

4.6 ft.

3

(130.3 l)

5.0L

5.0L EFI

5.7L

5.7L EFI

350 Mag MPI

MX6.2L MPI

454 Mag MPI

7.4L MPI

502 Mag MPI

424 ft.

(0.200 m

3

3

/Min

/sec.)

486 ft.

3

/Min.

(0.229 m

3

/sec.)

506 ft.

3

/Min.

(0.239 m

3

/sec.)

545 ft.

3

/Min.

(0.257 m

3

/sec.)

657 ft.

3

(0.310 m

/Min.

3

/sec.)

726 ft.

(0.342m

3

3

/Min.

/sec.)

42 in

49 in

51 in

55 in

66 in

73 in

2

2

2

2

2

2

(271 cm

2

(316 cm

2

(329 cm

2

(355 cm

2

(426 cm

2

(471 cm

2

)

)

)

)

)

)

5.0 ft.

3

(141.6 l)

5.0 ft.

3

(141.6 l)

5.8 ft.

3

(164 l)

5.8 ft.

3

( 164 l)

6.0 ft.

3

(170 l)

6.0 ft.

3

(170 l)

1

: For engine combustion air only - NOT total engine compartment ventilation requirement.

IMPORTANT: The amount of vent area required, according to boating standards

(NMMA, ABYC, etc.) and Coast Guard regulations, for complete (total) engine compartment ventilation must include the engine combustion air vent area plus the engine compartment ventilation requirements.

The pressure differential between outside and inside the engine compartment must not exceed the following value.

Maximum Pressure Differential at Wide Open Throttle

2 in. (51 mm) of water (measured with a manometer)

Page 12 of 116

INDEX


Compartment Temperature - Specifications

Air temperatures inside engine compartments have been measured in excess of 200

°

F (82

°

C). The long term effect to fuel system components running at these excessive temperatures is not known at this time.

According to specification SAE J1223 for Marine Carburetors:

“The carburetor shall be capable of operation throughout an ambient (air temperature) range from +20

°

to +176

°

F (–7

°

to +80

°

C) without failure.”

Carburetors, throttle body injection (TBI) units and components for multi-port EFI systems used by Mercury MerCruiser meet this specification.

Under the hottest outside air temperature condition at which the boat will be operated, the air temperature inside the engine compartment, measured at the flame arrestor, shall not exceed176

°

F (80

°

C). Also, the temperature of the fuel being supplied to the engine shall not exceed 110

°

F (43

°

C) at any location between the fuel tank and the engine’s fuel pump.

Since many factors influence engine compartment temperature, temperature measurements should always be carried out.

Test as follows:

1. The boat being tested shall be a standard production boat fitted as it would be for delivery to a dealer.

2. Temperature test meter used shall be of the type that can be read without opening the engine cover.

3. During the test, in Step 4, engine compartments are to remain closed. No outside air is to be forced into the engine compartment during the test and the bilge blower should not be running.

4. Engine Running and Heat Soak Test:

a. Use 1 meter and 2 thermo couple. Place one thermo couple at the flame arrestor to measure the inlet air temperature. Place the second thermo couple at the fuel pump to measure the inlet fuel temperature. A third thermo couple is needed if the fuel supply line between the tank and the fuel pump is higher than the fuel pump.

Place the third thermo couple at the highest point of the supply line to measure the temperature of the fuel at that point.

b. Start engine to warm it up. After engine is at its normal operating temperature, run engine at 1500 rpm (in neutral gear) for 15 minutes. Record both temperature readings at 5 minute intervals.

c. After 15 minutes running at 1500 rpm, shut engine off and continue to record both temperature readings at 5 minute intervals for the next 45 minutes.

d. After the 45 minute heat soak test, start engine and idle (in neutral gear) for 20 minutes. Continue to record both temperature readings at 5 minute intervals.

IMPORTANT: If the temperature at either location exceeds specifications, the engine compartment will need additional ventilation until both temperatures remain below these specifications.

Page 13 of 116


Exhaust System

MEASURING PROCEDURE

1. Fill all fuel, water, gray water and heater tanks to maximum capacity.

NOTE: Weight can be added in these locations to simulate full loaded condition.

2. Add maximum allowable cargo weight to boat in areas where it will be stowed, including refrigerator and lockers.

3. Add 190 lb (86 kg) of weight in all locations where each passenger will sit during normal operation.

4. Measure exhaust elbow height. Also, measure exhaust system slope on applications with through the hull or through the transom exhaust.

a

INDEX

72429

b

Using A Universal Protractor (Inclinometer) To Measure Slope a -

Protractor

b -

Exhaust Hose Or Tube

75203

5. Follow instructions a. or b.: a. On applications with through the propeller exhaust: Proceed to Step 6.

b. On applications with through the hull or through the transom exhaust:

(1.) Move load weight to bow to simulate greatest “bow-down” attitude the boat will encounter in normal operation.

(2.) Recheck exhaust system slope.

(3.) Proceed to Step 6.

Page 14 of 116

INDEX


6. On all applications: a. Move load weight and cargo weight to stern of boat to simulate greatest “stern-down” attitude the boat will encounter such as when loading.

IMPORTANT: Be sure to consider swim platform loading and PWCs.

b. Recheck exhaust system measurements.

7. Measurements must be equal to or greater than, the following:

On All Applications:

Minimum Exhaust Elbow Height from Top of Elbow to Waterline

All V6 and V8

Model Measurement

13 in. (330 mm)

a b c d

71533

MCM 454/502 MPI Engine Shown (All V-6 and V-8 Engines Similar) a -

Top Of Transom

b -

Highest Point On Exhaust Elbow

c -

Measurement

d -

Waterline

Additional Requirements for Through The Hull and

Through The Transom Exhaust System Applications:

Minimum Continuous Downward Slope (Exhaust Hoses, Collector, Etc.)

All Sterndrive

Model / Application Measurement

6

°

Page 15 of 116


8. If measurements are less than shown in Step 7., exhaust elbow risers must be installed to achieve proper dimension.

INDEX

a b c d e

70621

Typical Riser Installation a -

Exhaust Elbow

b -

Restrictor Gasket

c -

Riser

d -

Open Gasket (4 Slots)

e -

Exhaust Manifold

Additional information:

•

No risers are available for the V6 engine with Single-Piece Exhaust Manifolds.

•

Up to a maximum of 9 in. (229 mm) of riser height can be added, except on those engines listed previously.

Page 16 of 116

INDEX


THROUGH THE TRANSOM OR HULL EXHAUST

NOTICE

Refer to Exhaust Resonators in this SECTION for additional information on 454 and

502 cid (7.4 L and 8.2 L) engine exhaust requirements.

When designing and installing an exhaust system, in addition to other model specific requirements, Mercury MerCruiser requires the following to be observed:

•

Exhaust fittings (flanges and outlets) must be of proper size to accommodate 4 in.

(102 mm) inner diameter exhaust hoses.

•

Exhaust fittings must be equipped with internal water shutters.

•

An exhaust flapper must be used over each outlet.

•

Exhaust outlet must be slightly above the water line with boat at rest in the water and a full load aboard.

•

Exhaust hoses, collectors and pipes must not be higher than exhaust elbows at any point.

•

The drop in the exhaust system must be continuously sloping so that a low spot does not exist at any point in the exhaust hose or pipe.

•

The exhaust system on Mercury MerCruiser engines must have a minimum of 6

° downward slope between the exhaust elbow outlet and the exhaust outlet of the boat.

•

The exhaust system on Mercury MerCruiser engines must have a minimum of 4 in.

(102 mm) of vertical drop between the exhaust elbow outlet and the exhaust outlet of the boat.

e a d c b

75203

Example Of Sterndrive (MCM) Through The Transom or Hull Exhaust Models a -

Minimum Continuous Exhaust System Slope

b -

Exhaust Hose

c -

Exhaust Fitting

d -

Flapper

e -

Exhaust Elbow

f -

Minimum Exhaust System Vertical Drop

•

Back pressure must not exceed 2 psi (14 kPa) when measured at exhaust elbow outlets.

Page 17 of 116


EXHAUST RESONATOR

The exhaust resonators (provided with the engine package or available separately) are designed to provide increased resistance to water ingestion due to the tuning effects of the exhaust system. Quicksilver resonators are designed to break up the exhaust pulses.

CAUTION

Avoid severe engine damage. Water ingestion by the 454 and 502 cid (7.4L

and 8.2L) engines may occur in some instances without the use of specially designed exhaust resonators. Install exhaust resonators in the exhaust system when specified.

IMPORTANT: Exhaust resonators must be installed on 7.4L MPI, 454 Mag MPI and 502

Mag MPI Models of sterndrive engines with through the transom (or through the hull) exhaust

On 454 and 502 cid (7.4 and 8.2L) sterndrive engines using through the transom or hull exhaust systems, special care must be exercised in system design and construction to prevent an adverse tuning effect on engine exhaust output.

Exhaust system tuning can be affected by various factors that are beyond the control of

Mercury MerCruiser. Following are several factors that can affect exhaust system tuning:

•

Type and configuration of exhaust outlet.

•

Length of exhaust hose.

•

Amount of back-pressure in exhaust system.

Exhaust Resonator Kit use on Sterndrive Models:

CAN Be Used With:

1. Transom mounted muffler tips.

2. Waterlift mufflers or other mufflers that are mounted outboard of exhaust elbows.

3. Open exhaust.

CANNOT Be Used With:

1. Silent Choice Exhaust System.

2. Below swim platform exhaust.

3. Mufflers that mount between exhaust elbow and exhaust tip.

INDEX

Page 18 of 116

INDEX


INSTALLATION

The resonator is installed in exhaust hose with open end toward exhaust elbow. Resonator is positioned so that inside flat surface is approximately 17 in. (432 mm) from front edge of exhaust hose, but no closer than 2 in. (51 mm) to exhaust outlet on sterndrive. The

17 in. (432 mm) dimension can be reduced, if necessary, to a minimum of no less than

13 in. (330 mm).

A clamp is then installed and tightened around the hose so that it clamps around center of resonator. This position is 1 in. (25 mm) less than the position of the resonator as discussed in the previous paragraph.

g c f e a b d

75203

Through The Transom Exhaust With Resonator a -

Exhaust Resonator

b -

Exhaust Hose

c -

Dimension To Inside Flat Surface Of Resonator Approximately 17 in. (432 mm),

But No Less Than 13 in. (330 mm)

d -

No Less Than 2 in. (51 mm) Between Fitting And Resonator

e -

Clamp Position - Around Center Of Resonator

f -

Exhaust Fitting

g -

Exhaust Elbow

454 AND 502 MAG BRAVO MODEL EXHAUST RECOMMENDATION

IMPORTANT: To get maximum performance from Magnum Bravo Models, through the transom or hull exhaust is required.

NOTE: If noise regulations do not allow the use of through the transom or hull exhaust, an exhaust pipe kit (Quicksilver Part Number 44266A6) must be installed for through the prop exhaust. This kit also contains an exhaust tube that is used in place of the exhaust bellows.

IMPORTANT: It is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats.

Page 19 of 116


Fuel Delivery System

WARNING

Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be adhered to when constructing the engine compartment.

GENERAL

INDEX

The main concern of a boat’s fuel system is safety; this must be achieved through a technically sound installation and constant inspection.

The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.

The fuel tank is an integrated component of the boat. Refer to the special information on service and maintenance, which you have received from the tank manufacturer.

Only a few points related to function and safety are listed here [Refer to boating standards

(NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:

•

All connections should be on the upper side of the tank.

•

The drain plug at the lowest point on the tank serves to permit the removal of water and sediment.

•

The filler pipe outer diameter should be at least 2 in. (50 mm).

•

The tank breather pipe must have an inner diameter of at least 1/2 in. (13 mm) and must be fitted with a swan neck to prevent water from entering the tank.

It is recommended that the exact route and length of the fuel lines be established at the first installation of the engine to prevent problems later in connecting them to the engine.

All fuel lines must be well secured. The holes where the lines run through the bulkheads should be carefully rounded off or protected with rubber grommets. This prevents damage to the lines from abrasion.

The following, but not limited to the following, additional fuel connection related points, ap-

plying to all engines unless otherwise stated, must be considered [Refer to boating standards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:

1. On Gasoline Engines: Fuel tank should be mounted below carburetor level (if possible) or gravity feed may cause carburetor fuel inlet needle to unseat and flooding may result.

2. Fuel pickup should be at least 1 in. (25 mm) from the bottom of fuel tank to prevent picking up impurities.

3. On Gasoline Engines: The maximum measured vacuum at the engine’s fuel inlet must not exceed 2 in. Hg or 1 psi (6.9 kPa) at 600, 3000, full throttle rpm, and idle rpm.

IMPORTANT: Vacuum reading higher than specified can cause vapor locking with some of today’s fuels. It can also cause poor engine performance because of fuel starvation.

4. On Gasoline Engines: Fuel lines used must be Coast Guard approved (USCG Type

A1).

Diameter of fittings and lines must not be smaller than 5/16 in. (8 mm) ID on 262 CID/4.3L

and 305 CID/5.0L and 350 CID/5.7L engines.

Diameter of fittings and lines must not be smaller than 3/8 in. (10 mm) I.D. on 377 CID/6.2L,

454 CID/7.4L and 502 CID/8.2L engines.

5. On Multi-Engine Gasoline Installations: It is best to use a fuel pickup and supply line for each engine. If a single pickup and line is used, line must not be smaller than 1/2 in.

(13mm) I.D.

Page 20 of 116

INDEX


6. Larger diameter (than previously specified) lines and fittings must be used on installations requiring long lines or numerous fittings.

7. Fuel line(s) should be installed free of stress and firmly secured to prevent vibration and/ or chafing.

8. Sharp bends in fuel lines should be avoided.

9. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine to absorb deflection when engine is running.

SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS

CAUTION

The electric fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together. Do not install additional fuel filters and/or water separating fuel filters between fuel tank and engine.

The installation of additional filters may cause:

•

Fuel Vapor Locking

•

Difficult Warm-Starting

•

Piston Detonation Due to Lean Fuel Mixture

•

Poor Driveability

SPECIAL INFORMATION FOR ALL GASOLINE ENGINES

WARNING

Avoid gasoline fire or explosion. Gasoline is extremely flammable and highly explosive under certain conditions. NEVER use gasoline as a cleaning solvent.

IMPORTANT: The following information is provided to ensure proper installation of brass fittings or plugs installed into fuel pump or fuel filter base:

•

Use #592 Loctite Pipe Sealant with Teflon on threads of brass fittings or plugs. DO

NOT USE TEFLON TAPE.

•

Brass fittings or plugs should first be threaded into fuel pump or fuel filter base until finger tight.

•

Fittings or plugs should then be tighten an additional 1-3/4 to 2-1/4 turns using a wrench. DO NOT OVERTIGHTEN.

•

To prevent over-tightening when installing a fuel line, the brass fittings should be held with a suitable wrench as fuel line connectors are tightened securely.

Page 21 of 116


Battery

IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and

Coast Guard regulations must be adhered to when installing battery. Be sure battery cable installation meets the pull test requirements and that positive battery terminal is properly insulated in accordance with regulations.

IMPORTANT: It is recommended (required in some states) that battery be installed in an enclosed case. Refer to regulations for your area.

IMPORTANT: Engine electrical system is negative (–) ground.

Select a battery that meets all of the following specifications:

•

12-volt marine type.

•

Tapered post connectors or side terminal connectors.

IMPORTANT: Do NOT use a battery with wing nut connectors.

•

Battery capacity rating of at least:

Gasoline Engines

INDEX

Engine

(Cyl./Type)

V6 EFI

V6 Carb

V8 Carb

V8 Carb

V8 EFI

V8 MPI

V8 MPI

V8 MPI

cid (l)

262 (4.3)

262 (4.3)

305 (5.0)

350 (5.7)

305 (5.0)

350 (5.7)

377 (6.2)

454 (7.4)

502 (8.2)

Minimum Required Cranking Battery Size

550 cca/700 mca/120 Ah

375 cca/475 mca/90 Ah

550 cca/700 mca/120 Ah

650 cca/825 mca/150 Ah

BATTERY CABLES

Select proper size positive (+) and negative (–) battery cables, using chart. Battery should be located as close to engine as possible.

IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as it may cause corrosion and a subsequent failure.

Gasoline Engines

Cable Length

Up to 3-1/2 ft. (1.1m)

3-1/2 - 6 ft. (1.1-1.8m)

6 - 7-1/2 ft. (1.8-2.3m)

7-1/2 - 9-1/2 ft. (2.3-2.9m)

9-1/2 - 12 ft. (2.9-3.7m)

12 - 15 ft. (3.7-4.6m)

15 - 19 ft. (4.6-5.8m)

Cable Gauge

4 (25mm

2

)

2 (35mm

2

)

1 (50mm

2

)

0 (50mm

2

)

00 (70mm

2

)

000 (95mm

2

)

0000 (120mm

2

)

Page 22 of 116

INDEX


MULTIPLE EFI ENGINE BATTERY PRECAUTIONS

Situation

Alternators: Alternators are designed to charge the battery that supplies electrical power to the engine that the alternator is mounted on. When batteries for two different engines are connected, one alternator will supply all of the charging current for both batteries. Normally, the other engine’s alternator will not be required to supply any charging current.

EFI Electronic Control Module (ECM): The ECM requires a stable voltage source. During multiple engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine’s battery. The voltage may go below the ECM’s minimum required voltage.

Also, the alternator on the other engine may now start charging. This could cause a voltage spike in the engine’s electrical system.

In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine just appears to have an ignition miss.

Recommendations

Batteries: Boats with multi-engine EFI power packages require each engine be connected to its own battery. This ensures that the engine’s Electronic Control Module (ECM) has a stable voltage source.

Battery Switches: Battery switches should always be positioned so each engine is running off its own battery. DO NOT operate engines with switches in BOTH or ALL position. In an emergency, another engine’s battery can be used to start an engine with a dead battery.

Battery Isolators: Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.

NOTE: Sure Power Industries Inc., Model 32023A meets this design specification.

1. The boat may have 2 engines connected to a single Model 32023A battery isolator.

2. The Model 32023A battery isolator is connected to 2 banks of batteries.

3. Each bank contains 2 batteries with the cranking battery for 1 engine in each bank.

4. The second battery in each bank is connected in parallel to the cranking battery.

5. The Model 32023A battery isolator is designed for this type of use; 2 battery banks, 2 charging sources, 120 amps (maximum alternator output).

6. When the engines are running, either engine’s alternator could be charging either bank of batteries through the Model 32023A battery isolator.

Any other manufacturer’s battery isolator that is the same type as the Sure Power Inc.,

Model 32023A could also be used.

Generators: The generator’s battery should be considered another engine’s battery.

Page 23 of 116


EFI Electrical System Precautions

NOTE: All references to EFI models apply to all EFI and MPI engines.

CAUTION

Avoid damage to the EFI electrical system components: Refer to the following precautions when working on or around the EFI electrical harness, or when adding other electrical accessories:

•

DO NOT tap accessories into engine harness.

•

DO NOT puncture wires for testing (Probing).

•

DO NOT reverse battery leads.

•

DO NOT splice wires into harness.

•

DO NOT attempt diagnostics without proper, approved Service Tools.

INDEX

Instrumentation

We recommend the use of Quicksilver Instrumentation and Wiring Harnesses which have been specifically designed for compatibility with our engines, and to the same high quality and performance standards. Refer to Mercury Precision Parts / Quicksilver Accessories

Guide for selection.

Refer to Instrumentation Wiring Diagrams for specific wiring diagrams.

GAUGES

ABYC standards recommend a group of four gauges.

The basic four gauges that must be used with the engine are:

1. Tachometer

2. Oil Pressure

3. Water Temperature

4. Voltmeter

Page 24 of 116

INDEX


HARNESSES

CAUTION

If Quicksilver wiring harness is used and a fused accessory panel is to be installed

(40-amp current draw maximum), be sure to connect it as shown in the wiring diagrams. Do not connect accessory panel at any other location, as wires in wiring harness may not be of sufficient size to handle current load.

Instrumentation wiring extension harnesses that can be routed from instruments to engine are available in several lengths. Refer to Mercury Precision Parts / Quicksilver Accessories

Guide.

When designing the craft and harness wiring, consider the following:

•

Ensure that the harnesses will not be rubbed or pinched.

•

Avoid routing the harness in areas where it could be damaged or short circuited later in the assembly process, such as when a screw is inserted, or a hole is drilled.

IMPORTANT: Harness receptacles can be damaged by overtightened clamps.

•

If an extension harness is required, be certain to secure connection properly. All cannon plug style electrical connectors, including the one at the engine, should be secured with a hose clamp to avoid a loose connection or water entry.

•

It is an ABYC recommendation that harnesses be fastened to boat at least every 18 in.

(460 mm).

Power Trim Control

Any of the Quicksilver panel or in-handle type trim controls (that are specified for use with

Mercury MerCruiser sterndrives) can be used with this Power Trim system. Install trim control in accordance with instructions that accompany it.

Power Trim Pump Location

Select an appropriate mounting location for the trim pump that meets the following requirements:

•

Within length limits of black and gray hydraulic hoses coming from gimbal housing assembly.

•

Close to the battery so that trim pump battery leads can be connected.

•

Allow easy access to trim pump oil fill and vent locations.

•

Area where pump will not be exposed to water.

•

Trim pump must be mounted so that when steering wheel is turned in either direction

(right or left), the power steering booster cylinder does not come in contact with trim pump.

•

Pump can be mounted on floor or transom.

Page 25 of 116


Propeller Selection

GENERAL INFORMATION

IMPORTANT: Installed propeller must allow engine to run at its specified maximum wide-open-throttle revolutions per minute (rpm). Use an accurate service tachometer to verify engine operating rpm.

It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power package with the correct propeller(s). Specified engine wide-open-throttle (WOT) and operating rpm range are listed in the “Operation, Maintenance and Warranty Manual” attached to the engine.

Select a propeller that will allow the engine power package to operate at or near the top end of the recommended wide-open-throttle operating rpm range with a normal load. High rpm, caused by an excessive trim angle, should not be used in determining correct propeller selection.

There is a change in rpm between propeller pitches that is generalized in the following chart:

MCM Models

Gasoline

Pitch Change

2 in.

RPM Change

150-200

If full throttle operation is below the recommended range, the propeller must be changed to prevent loss of performance and possible engine damage. On the other hand, operating an engine above the recommended operating rpm range will cause higher than normal wear and/or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:

•

Warmer weather and greater humidity cause an rpm loss.

•

Operating in a higher elevation causes an rpm loss.

•

Operating with increased load (additional passengers, pulling skiers, etc.)

For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. However, do not operate at full throttle when using the lower pitch propeller but not pulling skiers.

Because of the many variables of boat design, only testing will determine the best propeller for a particular application. Available propellers are listed in the “Quicksilver Accessories

Guide.”

See “BOAT-IN-THE-WATER TESTS, Maximum rpm Test” in the power package Installation

Manual.

INDEX

Page 26 of 116

INDEX


RPM REV-LIMITER

IMPORTANT: When selecting a propeller consider this additional information, if applicable:

The engines listed in the following chart are equipped with a rpm rev-limiter that is set to an upper (or limited) rpm amount. This limit is slightly above the normal operating range of the engine and is designed to help prevent damage from excessive engine rpm. Once the rpm drop into the recommended operating rpm range normal engine operation resumes.

Engine Rev-Limiter

Engine Recommended Operating

RPM Range

Rev-Limit RPM Setting Model

4.3L

4.3LH

4.3L EFI

5.0L

5.0L EFI

5.7L

5.7L EFI

MX 6.2L MPI

7.4L MPI

350 Mag MPI

454 Mag MPI

502 Mag MPI

4400-4800

4800-5200

4200-4600

4600-5000

4950

5350

4680

5080

Hot Water Heater Installation Recommendation

IMPORTANT: When connecting a cabin heater or hot water heater, certain requirements must be met:

•

Supply hose (from engine to heater) and return hose (from heater to engine)

MUST NOT EXCEED 5/8 in. (16 mm) I.D. (inside diameter).

•

Make heater connections ONLY at locations indicated in the following information.

•

Refer to manufacturers’ instructions for complete installation information and procedures.

•

Do not reposition engine temperature switch; it must remain where installed by factory.

CAUTION

Avoid a performance loss and/or possible engine damage. Engine coolant must flow continuously from the engine intake manifold to the engine water circulating pump. NEVER close-off or block the coolant flow to or from a heater.

All heater installations must be plumbed in series with the supply and return connections.

Page 27 of 116


CAUTION

Avoid engine overheating which could result in engine damage. On models equipped with Closed Cooling, an air pocket may form in the closed cooling system if some coolant is lost from the system and the cabin heater or hot water is mounted higher than the fill cap on the heat exchanger. Heater must be mounted lower than the fill cap of the heat exchanger on models so equipped.

INDEX

SUPPLY HOSE CONNECTION a

Page 28 of 116

75473

Seawater Cooling - If Location Is Available a -

Location For Hot Water Supply

a

71758

Seawater Cooling - Alternate Location a -

Location For Hot Water Supply (Install Bayonet Fitting Here)

b a b

74639

Closed Cooling Models - If Location Is Available a -

Location for Hot Water Supply (Bayonet Fitting Replaces Brass Plug)

b -

Thermostat Housing

a

74973

INDEX


RETURN HOSE CONNECTION a

75480

Seawater or Closed Cooling System a -

Location For Hot Water Return

Seawater Connections - General Information

SEAWATER PICKUP HOSE

Seawater inlet hose connections must be made with wire reinforced hose of adequate wall thickness to prevent it from collapsing from pump suction. Be sure to secure hose connections with hose clamps. Secure hose to prevent contact with any moving parts of the engine.

Select the proper hose from the following chart:

Gasoline Engines

Seawater Pickup Hose Inner Diameter

1-1/4 in. (32 mm)

SEACOCK SIZE

Seacock used must have an internal cross-sectional area equal to or greater than seawater inlet hose to prevent restricting water flow. Install valve in an area where it will be easily accessible and supported adequately to prevent hose fatigue. A brass ball or gate valve is required. Select a proper seacock based on the following chart:

Seacock Size

(Internal Cross-Sectional Area Equal to or Greater Than Size Shown)

Gasoline Engines 1-1/4 in. (32 mm)

SEAWATER STRAINER

Strainer used must be of sufficient size to ensure that an adequate supply of water will be maintained for cooling the engine. Select a proper seawater strainer based on the following chart:

Gasoline Engines

Seawater Strainer Minimum Flow Rate

1

30 (114)

1

Amounts listed are in gallons per minute and (liters per minute).

Install seawater strainer in an area where it will be easily accessible for inspection and cleaning. Strainer should be installed in water inlet hose after the seacock (water inlet valve) to allow operator to shut off water when cleaning strainer.

Page 29 of 116


Throttle/Shift Remote Control and Cables

To ensure proper shift and throttle operation, we recommend the use of a Quicksilver remote control and cables. Refer to “Quicksilver Accessories Guide” for selection. However, if a control other than Quicksilver is to be used, control must provide a shift cable travel (at the shift plate end) of 2-7/8 in. (73 mm) to 3-1/8 in. (80 mm) with a 15-20 lb. (6.8-9 kg) load applied to the cable end guide.

INDEX

Steering Helm and Cable

Transom assembly is shipped with the steering cable guide tube preset for cables with end dimensions that comply with ABYC standards as outlined in the NMMA certification handbook. The steering cable coupler nut must also have a means of locking it to the guide tube as specified in ABYC requirements.

WARNING

Failure to use a steering cable locking device could cause loss of steering, which could cause damage to the boat and/or injury.

NOTE: All current production Quicksilver Ride Guide steering cables have a self-locking coupler nut and do not require an external locking device. (Other cable manufacturers also make cables with self-locking coupler nut.)

a

22060

a -

Quicksilver Ride Guide Steering Cable Self-Locking Coupler Nut (Identified by

Groove)

IMPORTANT: If using a steering cable that does not have a self-locking coupler nut, an external locking device must be used.

Page 30 of 116

a b

Example Of External Locking Device a -

Steering Cable

b -

Locking Sleeve

CAUTION

POWER STEERING EQUIPPED UNITS ONLY: If steering cable with improper dimensions is installed, severe damage to transom assembly and/or steering system may result.

1. Steering cable must be the correct length, particularly when installed in larger boats.

2. Avoid sharp bends, kinks or loops in cable.

3. Fully extended steering cable end dimension must be as shown.

INDEX


STEERING CABLE SPECIFICATIONS

IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against lock) may mean a steering cable has been installed that does not have the correct dimensions.

a c b d e g f k l j i h a -

Coupler Nut - 7/8 - 14 UNF - 28 Thread

b -

11-3/4 in. (298 mm) Min.

c -

Interface Point

d -

1/2 in. (12.7 mm) Max.

e -

27/64 in. (10.7 mm) Min. Flat

f -

7/64 in. (3.1 mm) Min. Radius

g -

5/8 in. (15.9 mm) Max. Diameter End Fitting

h -

3/8 in. (9.5 mm)

i -

3/8 in. (9.8 mm) Diameter Through Hole (Chamfered Each Side)

j -

1-3/8 in. (34.9 mm) Max.

k -

5/8 in. (15.9 mm) Diameter Tube

l -

Cable Travel:

Mid-Travel Position - 16-7/8 in. (429 mm)

Total Travel To Be 8 in. (203 mm) Min. to 9 in (228 mm) Max.

Travel Each Side of Mid-Travel Position - 4 in. (102 mm ) Min.,

4-1/2 in. (114 mm) Max.

21435

Page 31 of 116


Transom Cutout

NOTICE to INSTALLER

Before Starting Installation Read “General Information” and “Installation Requirements” Sections Completely.

IMPORTANT: The following instructions will provide a sterndrive unit mounting location that is suitable for most boats. Best mounting location for a particular boat, however, can be determined only by testing.

1. Below 25 m.p.h. (40 km/h): Subtract 1/2 in. (13mm) from “X” Dimension shown.

2. Heavy Duty Applications: Subtract 1 in. (25mm) from “X” Dimension shown.

3. Above 25 m.p.h. (40 km/h): Use “X” Dimension shown.

4. Above 50 m.p.h. (80 km/h): The “X” Dimension can be increased to improve performance in some applications, but pulling power (for skiing) will decrease. During testing, the “X” Dimension should be increased 1/2 in. (13mm) at a time until desired performance is achieved but in no case should it ever be increased by more than:

Bravo

Bravo Three

Maximum Increase In “X” Dimension

One

3 in. (76 mm) maximum

Two

1 in. (25 mm) maximum

In ALL sterndrive applications, extreme care should be taken when raising sterndrive unit to ensure that water supply does not become aerated. Use clear water inlet hose to monitor incoming water and monitor engine temperature gauge to ensure engine does not overheat.

In applications where cooling water to the engine is supplied by a through the hull

or through the transom fitting, the sterndrive height will not cause cooling water aeration.

IMPORTANT: Damage to Mercury MerCruiser products caused by too high of an installed height will not be covered by Mercury MerCruiser warranty.

INDEX

Page 32 of 116

INDEX


Finding Crankshaft Vertical Centerline

SINGLE ENGINE

Locate and mark vertical centerline on transom.

a

71620

a -

Vertical Centerline

DUAL ENGINE

1. Locate and mark boat vertical centerline “

a

” on transom.

a

71620

a -

Vertical Centerline

2. Locate and mark crankshaft vertical centerlines “

a

” on transom.

b a a c c

22033

a -

Draw Crankshaft Vertical Centerline Through Desired Mounting Locations

b -

Minimum Distance between Crankshaft Vertical Centerlines

c -

Crankshaft Vertical Centerlines Must Be an Equal Distance from Boat Vertical

Centerline

Minimum Distance Between Crankshaft

Vertical Centerlines (Dual Side-By-Side) Chart

Model Measurement [ in. (mm) ]

V6 (4.3L)

V8 (5.0L, 5.7L and 6.2L)

V8 (7.4L)

33 (838)

33 (838)

36-1/2 (927)

Page 33 of 116


Finding Crankshaft Horizontal Centerline (“X” Dimension)

“X” Dimension can be measured by the “90

°

Tool Method” or by the “Tape Measure Method.”

INDEX

90

°

TOOL METHOD

1. Construct 90

°

tool.

a

90

°

b

71621

a -

Dimension From Chart Below

b -

Measurement: 4 Ft. (1.2 M)

To Lower Sterndrive Unit - Subtract from dimension “

a

.”

To Raise Sterndrive Unit - Add to dimension “

a

.”

90

°

TOOL VERTICAL DIMENSION CHART

Sterndrive Unit Location

Bravo One/Two/Three 13-9/16 in. (345 mm)

IMPORTANT: This dimension should only be raised or lowered after proper testing.

2. Determine “X” Dimension location of crankshaft centerline(s).

b c c b a

71623

71622

a

Single Engine Dual Engine a -

Place 90

°

Tool Along Boat Bottom At Vertical Centerline

b -

Point At Which Top Of Tool Contacts Transom On Vertical Centerline Is Crankshaft Horizontal Centerline

c -

Draw A Line Perpendicular To Vertical Centerline At Crankshaft Horizontal

Centerline

Page 34 of 116

INDEX


TAPE MEASURE METHOD

Transom angle must be known, then measure “X” Dimension with tape measure.

1. Determine “X” Dimension from the following chart.

Tape Measure Method Charts

Model Bravo One / Two / Three

Transom Angle This dimension should only be raised or lowered after proper testing.

16

°

14-5/16 in. (364 mm)

15

°

14

°

13

°

14-1/4 in. (362 mm)

14-3/16 in. (360 mm)

14-1/8 in. (359 mm)

12

°

11

°

10

°

14-1/16 in. (357 mm)

14 in. (356 mm)

13-15/16 (354 mm)

2. Measure and layout horizontal centerlines as shown.

b b c c d d a a

71623

71622

Single Engine Dual Engine a -

“x” Dimension (From Chart) That Corresponds To Transom Angle - Measure Up

From Boat Bottom With Tape Measure

b -

Crankshaft Horizontal Centerline

c -

Vertical Centerline

d -

Draw A Line Perpendicular To Vertical Centerline At Crankshaft Horizontal

Centerline

Page 35 of 116


Cutting Transom

Transom cutout can be made by either using the Template [shipped with transom assembly] or the Transom Drilling Fixture Kit (purchased separately).

Follow instructions indicated on template or provided with drilling fixture.

IMPORTANT:

w

Be certain that centerlines on either the template or transom drilling fixture align with lines previously marked on transom.

w

Be sure to drill 1/4 in. pilot holes (for hole saw guide) at a 60

5

angle and to cut on the line when making transom cutout. If cutout is made incorrectly, sterndrive unit steering lever may contact transom, thus limiting steering travel.

w

Seal inside edge of transom cutout opening with a suitable sealant to prevent water absorption and deterioration of transom.

INDEX

Transom Cutout Template

90-79135--3

50017

Page 36 of 116

Transom Drilling Fixture Kit

22056

INDEX


Checking Transom Thickness

Ensure transom surface thickness and flatness conform to minimums specified in “Installation Requirements” listed previously.

a b c

70004

a -

Measuring Thickness

b -

Measuring Flatness

c -

Suitable Mandrel To Check For Uniform Transom Thickness

75479

NOTE: Transom must be between 2 in. (51 mm) and 2-1/4 in. (57 mm) a distance of

8” (203 mm) to either side of the vertical centerline.

Installing Transom Assembly

Installing Gimbal Housing

1. Carefully remove transom assembly from shipping carton.

2. Remove and read all tags which are attached to transom assembly.

IMPORTANT: When installing through the transom exhaust, it is recommended that the exhaust bellows on the transom assembly be removed. This is necessary to avoid creating a vacuum at the exhaust outlet in the propeller at higher boat speeds. This vacuum could degrade propeller performance on some boats.

3. If required, remove and discard clamps and bellows from gimbal housing.

IMPORTANT: When installing through the propeller exhaust:

•

With Bravo One and Bravo Two Sterndrives an exhaust tube MAY BE INSTALLED for a slight increase in performance.

•

With most Bravo Three Sterndrive Models an exhaust tube MAY BE INSTALLED for a slight increase in performance. On the following Bravo Three Models, the exhaust bellows must be removed and an exhaust tube MUST BE INSTALLED:

w

MCM 7.4L MPI

w

MCM 454 Mag MPI

w

MCM 502 Mag MPI

Page 37 of 116


•

With a Silent Choice Exhaust System the exhaust bellows must be removed and an exhaust tube MUST BE INSTALLED.

•

With any application, installation of an exhaust tube will increase exhaust noise.

NOTE: Exhaust tube parts are provided with a Bravo Three Sterndrive. They are located in the sterndrive unit box.

4. If required, install exhaust tube on gimbal housing as follows: a. Remove and discard clamps and exhaust bellows.

INDEX

CAUTION

Exhaust tube clamp may corrode if grounding clip is not installed.

b. Install grounding clip on tube.

NOTE: Bellows adhesive is not used when installing an exhaust tube.

c. Position tube so that “SIDE” markings on tube are facing toward the right and left sides.

d. Install clamp.

e. Tighten clamp. Torque to 35 lb-in. (4 Nm).

e d

22184

c a b

22184

a -

Exhaust Tube

b -

Clamp

c -

“SIDE” Marking

d -

Exhaust Tube

e -

Grounding Clip

Page 38 of 116

INDEX


Installing Inner Transom Plate

1. Insert wires, hoses and shift cable through appropriate openings in inner transom plate.

2. Position gimbal housing on transom and hold in place.

IMPORTANT: Tightening the transom assembly fasteners using an X-pattern torque sequence as defined in the illustration below. Tighten in small increments and go around the pattern several times until the proper torque is achieved.

3. Secure transom assembly with hardware as shown. Torque to 23 lb-ft (31 Nm).

IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering lever moves.

5

7

b

3

1

8

a

2

6

4

a

71626

71628

a

70005

a -

Locknuts And Flat Washers (8).

b -

Torque Sequence

71627

a

71629

Page 39 of 116


Installing Power Trim Pump

NOTE: See 90-863152 for mounting hole template.

1. Mount pump in desired location.

IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from leaking out of system. Be careful not to cross-thread or overtighten hose fittings.

2. Connect hydraulic hoses to trim pump. Torque fittings to 125 lb-in. (14 Nm).

3. Connect power trim pump control harness to trim pump.

4. Connect trim limit switch wires and secure with wire retainer and sta-strap.

INDEX

d c

75126

75127

b f g a e

50632

50630

a -

Black Hose Fitting (UP Circuit)

b -

Gray Hose Fitting (DOWN Circuit)

c -

Control Harness

d -

Sta-Strap

e -

Trim Limit Switch Wire (with Blue Sleeve) To BLUE/WHITE Harness Wire

f -

Trim Limit Switch Wire (with Purple Sleeve) To PURPLE/WHITE Harness Wire

g -

Wire Retainer And Sta-Strap

Page 40 of 116

INDEX


Installing Steering System

HYDRAULIC (HELM) STEERING

If your power package is equipped with Compact Hydraulic Steering (Helm Steering), refer to the “Compact Hydraulic Steering Installation Instructions” in the box with the Hydraulic

Steering components. Complete the installation of the Hydraulic Steering system before proceeding to “Connecting Speedometer Pickup.”

POWER STEERING

NOTE: For Dual Installations: Power steering unit can be mounted on port or starboard transom assembly. Measure exact distance between power package centerlines. Select a tie bar from Quicksilver Accessory Guide. Refer to tie bar installation instructions before proceeding.

1. Inspect bushings for debris. Lubricate bushings with Special Lubricant 101.

B a

73898

a -

Bushings

b -

Special Lubricant 101

2. Remove upper and lower pivot bolts and ensure threads are well lubricated with Special

Lubricant 101.

3. Install steering assembly as follows: a. Position steering assembly so that pivot bolts will enter bushings in pivot block or power steering control valve.

b. Install upper and lower pivot bolts along with tab washers. Ensure that tab washer tangs straddle the ridge on inner transom plate.

c. Turn pivot bolts all the way in by hand to ensure proper alignment.

d. Ensure steering assembly pivots freely.

b c

73899

a a c

73900

a -

Tab Washers

b -

Ridge

c -

Pivot Bolts

Page 41 of 116


4. Torque pivot bolts to 25 lb-ft (34 Nm). Bend washer tabs against corresponding flats on bolt heads.

5. The cylinder ram may be stiff and difficult to move when you attempt to pull it out or push it in for installation. First move the spool assembly in the direction(s) shown below.

INDEX

a a

74145

74144

a -

Control Valve Ports

6. Connect clevis to steering lever. Lubricate clevis pin with Special Lubricant 101. Be sure to spread both ends of the cotter pin.

c b a a -

Clevis

b -

Steering Lever

c -

Clevis Pin

d -

Cotter Pin

d

71904

Page 42 of 116

INDEX


7. Connect steering cable as follows: a. Remove shipping cap from both ends of steering cable guide tube.

b. Coat steering cable end with a liberal amount of Special Lubricant 101.

c. Install steering cable and secure with hardware as shown.

g h

71906

e f d

73901

c a b

71901

d

71903

a -

Steering Cable

b -

Grease Fitting

c -

Cable Coupler Nut

d -

Cable Guide Tube

e -

Steering Cable End

f -

Clevis

g -

Clevis Pin

h -

Cotter Pin d. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical position. Torque coupler nut to 35 lb-ft (47 Nm). Be certain the flat surfaces are

still aligned vertically after torque is applied to coupler nut.

CAUTION

Steering cable outer casing must be free to move back and forth for steering system to function properly. Do not fasten any items to steering cable.

Page 43 of 116


Connecting Speedometer Pickup

IMPORTANT: Do not remove plug from speedometer pickup tube fitting unless connection is to be utilized, as water leakage into boat will occur, especially while underway.

The connection for the speedometer pickup can be accessed through a hole and fitting in the inner transom plate.

1. Remove plug from speedometer pickup tube fitting.

INDEX

a b

70037

a -

Plug

b -

Inner Transom Plate Fitting

2. Apply Perfect Seal to threads of barb fitting. Install and torque to 13 Ib-in. (1.5 Nm).

a

70015

a -

Barb Fitting

3. Connect a 5/32 in. (4 mm) speedometer hose (not provided) hose from speedometer to barb fitting. Secure hose with cable tie.

a

70015

a -

5/32 in. (4 mm) Inner Diameter Speedometer Hose Fitting

4. Secure the hose to the transom with the hose clip and screw that are provided in the parts bag.

Page 44 of 116

INDEX


Connecting Sterndrive Unit Gear Lube Monitor Hose To Gimbal Housing

1. Connect the gear lube monitor hose to a quick release 90

°

fitting.

2. Connect fitting to the gimbal housing.

IMPORTANT: Hose must not come in contact with steering system components or the engine coupler, U-joint shaft or drive shaft.

d c a b

74235

a -

Hose

b -

90

°

Hose Fitting

c -

Gimbal Housing Fitting

d -

Gear Lube Monitor

75874

75313

NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting, or block-off plate, if equipped. Release button must not contact water fitting, or blockoff plate if equipped.

CAUTION

Avoid sterndrive unit damage. Quick release button on gear lube monitor 90

°

hose fitting may not lock on gimbal housing if touching or depressed by water inlet fitting, or block-off plate, if equipped. Ensure quick release button does not contact block-off plate, or water inlet fitting if equipped. Failure to do so could result in a

loose 90

°

fitting causing a loss of gear lube and damage to sterndrive unit.

a e c b d f d

71998

Block-Off Plate Installation Shown (Similar For Models With Water Fitting) a -

Block-Off Plate (Or Water Inlet Fitting If Equipped)

b -

Star Washer And Screw

c -

90

°

Hose Fitting

d -

Quick Release Button

e -

ACCEPTABLE Positions

f -

NOT ACCEPTABLE Position

NOTE: The hose must not come into contact with the steering system components or the engine coupler and drive shaft.

Page 45 of 116


Engine Installation

Driveshaft Extension Models

If your power package is equipped with a driveshaft extension, refer to the Driveshaft Extension Installation Instructions (90-862858) included with your engine package.

INDEX

Engine Preparation

1. Remove and read all tags attached to engine.

2. Remove all hardware that secures engine to shipping container.

3. Connect battery cables to engine. Be sure to observe the following: a. Make sure that grounding stud and starter solenoid terminal are free of paint or any other material that could cause a poor electrical connection.

b. After battery cables are connected, apply a thin coat of Liquid Neoprene to the terminals.

c. Be sure to slide rubber boot over positive (+) terminal after making connection.

4. Drape battery cables over top of engine to prevent interference during installation.

IMPORTANT: There is a fuse located at the starter solenoid. DO NOT remove this fuse.

The positive battery cable must be connected to the same stud as the fuse.

a d c b

72052

a -

Negative (–) Battery Cable

b -

Positive (+) Battery Cable

c -

Starter Solenoid

d -

90 Amp Fuse - DO NOT Remove

e -

Rubber Boot

a

71651

Page 46 of 116

INDEX


5. Remove shipping plug from coupler and lubricate splines with Quicksilver Engine Coupler Spline Grease, P/N 816391A4.

6. Loosen hose clamps and remove exhaust pipe and bellows from engine.

c b c b a d

50724

a -

Exhaust Pipe

b -

Bellows

c -

Clamps

d -

Shipping Plug

Transom Preparation

IMPORTANT: Exhaust pipe and gimbal housing mating surfaces must be clean and free of nicks and scratches and O-ring must be properly seated in groove, or water and exhaust may leak into boat.

a b

22059

a -

Gimbal Housing Mating Surface

b -

O-Ring

Page 47 of 116


1. Depending upon boat configuration, follow instructions a. or b.: a. Through the Prop Exhaust Models: Install exhaust pipe assembly as shown, using four bolts and lockwashers. Torque bolts to 23 lb-ft (31 Nm).

b. Through the Transom Exhaust Models: Install block off plate as shown, using four bolts and lockwashers. Torque bolts to 23 lb-ft (31 Nm).

INDEX

d c

22028

e

50628

b b f a a -

Exhaust Pipe

b -

Bolts And Lockwashers (4)

c -

Fiber Washers

d -

Double-Wound Lockwashers

e -

Locknuts

f -

Block-Off Plate

50684

22057

NOTE: Through the Transom exhaust fittings can be installed at this time.

2. Position rear engine mount attaching hardware on inner transom plate mounts as shown.

Page 48 of 116

INDEX


Installing Engine/Alignment

NOTE: An engine mount drilling fixture (91-806794A1) can be used to align and adjust en-

gine mounts. Refer to instructions with fixture for proper use.

1. Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when suspended.

CAUTION

Center lifting eye (if equipped), on top of thermostat housing, is used for engine alignment only. Do not use to lift entire engine.

b a b

!

CAUTION

74498

74760

74754

e f g c k i h j d

22032

50682

V6 and V8 Models a -

Center Lifting Eye (see CAUTION above)

b -

Engine Lifting Eyes

c -

Rear Engine Mount

d -

Inner Transom Plate Mount

e -

Bolt

f -

Washer

g -

Spacer

h -

Fiber Washer

i -

Double-Wound Lockwasher

j -

Exhaust Pipe Bellows

k -

Exhaust Tube

2. Lift engine into position (in boat) using an overhead hoist.

3. Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tube with exhaust pipe bellows.

Page 49 of 116


4. Install both rear engine mounting bolts and hardware as shown. Torque to 38 lb-ft

(51 Nm). Do not relieve hoist tension.

5. Align engine as follows: a. Fold perforated area in bell housing dust cover.

INDEX

a

22027

a -

Dust Cover

CAUTION

DO NOT use an alignment tool from another manufacturer. Alignment tools other than Quicksilver Alignment Tool may cause improper alignment and damage to gimbal bearing and/or engine coupler.

CAUTION

To avoid damage to gimbal bearing, engine coupler,or alignment tool:

•

DO NOT attempt to force alignment tool!

•

DO NOT raise or lower engine with alignment tool inserted (or partially inserted) in gimbal bearing or engine coupler.

b. Attempt to insert the solid end of the alignment tool through the gimbal bearing and into the engine coupler splines.

CAUTION

Avoid damage to exhaust system. On V6 Models with one-piece exhaust manifolds, stress can be placed on the lower exhaust pipe if front of engine is raised too high while performing engine alignment. Ensure that engine is not raised higher than the top of engine mount adjusting stud.

a

75129

Page 50 of 116

a -

Do Not Raise Above Top Of Stud

INDEX


c. If the tool does not fit, remove it and carefully raise or lower the front end of the engine as necessary, and attempt to insert the alignment tool.

d. Repeat step c. until the alignment tool installs easily (SLIDES FREELY WITH TWO

FINGERS) all the way into and out of engine coupler splines. Do not check by turning.

b a a -

Alignment Tool (Use Only Recommended Alignment Tool)

b -

Insert This End Of Alignment Tool Through Gimbal Housing Assembly

22029

b c a

27647

a -

Alignment Tool

b -

Gimbal Bearing

c -

Engine Coupler

IMPORTANT: Finished boat stringer must position engine so that a minimum mount adjustment exists after front mount is adjusted down to stringer. This allows for future adjustments.

IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in direction required to align engine.

6. Adjust front engine mounts until they rest on boat stringers.

7. Relieve hoist tension entirely and fasten both front mounts to boat stringer using appropriate hardware.

Page 51 of 116


8. Recheck alignment with alignment tool. Tool must enter coupling splines freely. If not, readjust front mounts.

9. When alignment is correct, tighten locknut securely. Recheck alignment.

10. Bend tab down on adjusting nut.

INDEX

a b c e d

71649

a -

Nut And Lockwasher

b -

Adjustment Nut

c -

Turn Adjustment Nut In This Direction (Counterclockwise) To Raise Front Of

Engine

d -

Slotted Hole Toward Front Of Engine. Attach Mounts To Stringers Using 3/8 In.

(9mm) Lag Bolts

e -

Tab Washer

11. Remove alignment tool and fold bell housing dust cover flap back into place and tape shut for boat shipment. Dust cover flap will have to be removed before operating engine.

Page 52 of 116

INDEX


Coolant Recovery System (If Equipped)

1. Connect plastic tubing to bayonet fitting on heat exchanger. Secure with tubing clamp provided.

b a

70548

a -

Plastic Tubing

b -

Tubing Clamp

2. Select a mounting location for coolant recovery bottle and mounting bracket that meets all of the following: a. Within limits of clear plastic tubing.

b. Level with heat exchanger fill neck if possible.

c. Accessible for observing coolant level and filling.

3. Mount coolant recovery bottle and mounting bracket in desired location using two

3/4 in. long screws and flat washers.

4. Route plastic tubing to recovery bottle. Ensure that tubing is positioned away from any moving parts. Cut plastic tubing as required and connect to bottom connection on recovery bottle and secure with tubing clamp provided.

5. Fasten plastic tubing to boat, as necessary, with 2 hose clips and 1/2 in. long screws

(provided).

b b a c d a -

Recovery Bottle and Mounting Bracket

b -

Screws and Flat Washers

c -

Plastic Tubing

d -

Tubing Clamp

71712

CAUTION

Avoid engine overheating and subsequent damage to engine. The coolant recovery system will not operate properly without proper sealing. Plastic tubing MUST seal

completely at connections.

Page 53 of 116


Engine Connections

IMPORTANT: When routing all wire harnesses and hoses, ensure they are routed and secured to avoid coming in contact with hot spots on engine or moving parts.

1. Connect water hose to water tube and secure with hose clamp.

INDEX

c a b

72040

a -

Water Inlet Fitting

b -

Hose

c -

Hose Clamp

2. Connect continuity circuit wire from engine to transom assembly.

IMPORTANT: Do not attach any accessory ground (–) wires to transom plate ground point. Accessory ground wires can only be attached to ground stud on engine.

a d c b

72052

a -

Rubber Boot

b -

Positive (+) Battery Cable

c -

Starter Solenoid

d -

90 Amp Fuse DO NOT Remove

e -

Negative (–) Battery Cable

e

71651

Page 54 of 116

INDEX


IMPORTANT: Avoid using excessive hose when routing it to gear lube monitor. Hose should be routed directly to oil reservoir in as straight a line as possible to avoid low spots (traps) in the system.

CAUTION

Ensure hose is not kinked when connecting in the following step. If hose is kinked, gear lube monitor will not function properly and damage to sterndrive unit could occur.

3. Route hose to gear lube monitor and cut off excess hose. Connect hose and secure with hose clamp. Secure hose with the J-Clip that is attached to the valve cover.

a c b

71991

a

75444

454 CID/7.4L and 502 CID/8.2L Models a -

Gear Lube Monitor

b -

Hose

c -

J-Clip on Valve Cover

a

75847

76230

262cid/4.3L With Single Piece Manifolds 305 CID/5.0L and 350 CID/5.7L Models a -

Gear Lube Monitor

Page 55 of 116


CAUTION

Route hoses exactly as shown below. This will help avoid stress on the hose fittings and will help avoid kinks in the hose.

IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid leakage.

IMPORTANT: Be careful not to cross-thread or overtighten fittings.

4. Route hoses over top edge of transom plate. Secure hoses to avoid contact with moving components.

5. Connect power steering hoses to control valve. Torque both fittings to 23 lb-ft (31 Nm).

INDEX

a b

75117

a -

Rear Fitting (Pressure Hose)

b -

Front Fitting (Return Hose)

6. Use extra hose clips to secure hose to transom.

Page 56 of 116

INDEX


7. Connect fuel line to appropriate location as shown. Refer to the following caution for proper tightening.

CAUTION

Remove plastic plug from fuel inlet hole. Apply #592 Loctite Pipe Sealant with Teflon to threads of fuel inlet line connector. DO NOT USE TEFLON TAPE. To prevent cracking the casting and/or fuel leaks, turn inlet connector in by hand until finger tight, then tighten connector to 1-3/4 to 2-1/4 turns with wrench. DO NOT OVER-

TIGHTEN. Inspect for fuel leaks when first starting engine.

a b

Models with Cool Fuel System a -

Fuel Inlet Hose Connects Here

b -

Fuel Filter Cover

75036

Carbureted Models a -

Fuel Inlet Hose Connects Here

a

75429

Page 57 of 116


8. Depending upon boat configuration, follow instructions a., b. or c.:

CAUTION

Avoid exhaust hose failure. Discharge water from exhaust elbow must flow around entire inside diameter of hose to avoid causing hot spots which could eventually result in burned-through exhaust hoses. Exhaust hoses and/or tubes must be correctly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow.

INDEX

71653

Correct Connection Incorrect Connection

a. V8 Models - Through-Transom Exhaust: Tighten all exhaust hose and/or exhaust tube clamps securely.

a a -

Hose Clamps

73961

Page 58 of 116

INDEX


b. V8 Models - Through The Prop Exhaust: Tighten all exhaust tube hose clamps securely.

b a

22059

a -

Hose Clamps

b -

Exhaust Tube c. V6 Models - Through The Prop Exhaust (One-Piece Exhaust Manifolds):

Tighten all exhaust tube hose clamps securely.

a b

74773

a -

Hose Clamps

b -

Bellows

9. Connect instrumentation wiring harness to engine. Secure connection with hose clamp.

a

Typical a -

Wiring Harness Connector

74754

Page 59 of 116


10. Connect power trim pump wires to battery.

a

Page 60 of 116

b

76631

a -

Positive Battery Lead

b -

Negative Battery Lead

11. Connect trim position sender wires (from transom assembly) to engine harness.

12. Connect wires to MerCathode controller assembly as shown. Apply a thin coat of Liquid

Neoprene to all connections.

IMPORTANT: Opposite end of red/purple wire must be connected directly to battery positive (+) terminal. DO NOT connect it to a switched positive (+) circuit. MerCathode system must function continuously for proper corrosion protection.

a b c d a -

Orange Lead - From Electrode On Transom Assembly

b -

Red/Purple Wire - Connect (Other End) To Positive (+) Battery Terminal

c -

Black Wire - From Engine Harness

d -

Brown Wire - From Electrode On Transom Assembly

22232

INDEX

INDEX


13. Installing Audio Warning Horn: a. Select a location for audio warning horn which meets all of the following:

•

Horn can be easily heard yet is out of sight.

•

A location which is accessible for installation or maintenance.

•

A location where horn will not get wet.

•

A location such that the PURPLE wire can be connected to an “I” terminal (terminal with

PURPLE wire attached to it) on one of the gauges or to a 12 volt source on switched side of ignition switch.

WARNING

Horn is not external ignition proof, therefore, DO NOT mount horn in engine or fuel tank compartments as this would be a fire or explosion hazard.

b. Select a desired location and secure to wire bundle with sta-strap provided.

c. Connect PURPLE wire from horn to any PURPLE wire terminal on instrument gauge or ignition switch. Tighten connection securely (refer to Wiring Diagram).

d. Connect TAN/BLUE wire from horn to TAN/ BLUE wire from instrument harness

(refer to Wiring Diagram).

e. Place the small (transparent) decals on the bottom of the water temperature gauge and the oil pressure gauge.

f.

Select the decal labeled “All units equipped with gear lube monitor having low oil level switch” from the sheet included and install this decal on the instrument panel or other appropriate location in easy view of the operator.

ALARM INDICATES LOW

OIL OR OVERHEATING

a

APPLY THE PROPER DECAL TO THE DASHBOARD

OR OTHER APPROPRIATE LOCATION: b

AUDIO WARNING HORN WILL SOUND WHEN:

1. ENGINE OIL PRESSURE IS TOO LOW

2. ENGINE TEMP. IS TOO HIGH, OR

3. DRIVE OIL LEVEL IS TOO LOW

TO TEST AUDIO WARNING HORN:

TURN KEY TO “ON” POSITION (ENGINE OFF)

75430

Choose Appropriate Decal for Your Package a -

Small Decal (Transparent)

b -

Larger Decal g. Test audio warning system during “Predelivery Preparation” section.

Page 61 of 116


Quick Drain Oil Installation (If Equipped)

1. Install flange over cable.

2. Fasten flange to hull with appropriate fasteners (not provided).

3. Install bilge drain plug in hull.

d e a b c

76882

a -

Bilge Drain Plug

b -

Tether

c -

Quick Oil Drain Hose Plug

d -

Flange

e -

Toward Interior Of Boat

4. Install quick oil drain hose plug in oil drain hose.

IMPORTANT: If Quick Drain Oil Fitting is within 1/2 in. (6 mm) of boat bottom, remove fitting and install drain plug from parts bag directly into oil pan.

INDEX

Page 62 of 116

INDEX


Shift/Throttle Cables Installation and Adjustments

Installing Sterndrive Unit Shift Cable

NOTE: Using Adjustment Tool (91-12427), shift cables can be adjusted without or with the sterndrive installed, using the following procedure.

IMPORTANT: Sterndrive unit propeller rotation is determined by the shift cable installation in the remote control.

•

Bravo One/Two - If shift cable end guide moves in direction A when control lever is placed in Forward, remote control is set up for RIGHT HAND (RH) propeller rotation.

•

Bravo One/Two - If shift cable end guide moves in direction B when control lever is placed in Forward, remote control is set up for LEFT HAND (LH) propeller rotation.

A

B

71656

Arrow Indicates Direction Of Motion

•

Bravo Three - Front propeller on sterndrive unit is always LH Rotation and rear propeller is always RH Rotation. Shift cable end guide must move in direction A , when control lever is placed in Forward gear position.

A

71656

IMPORTANT: When installing shift cables, be sure that cables are routed in such a way as to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to shift cables.

1. Install shift cable into remote control. (Refer to appropriate remote control instructions.)

2. Loosen stud and move it to dimension, as shown. Retighten stud.

a b a -

Stud

b -

3 in. (76 mm) (Center Of Pivot Bolt To Center Of Stud)

71657

Page 63 of 116


3. Install sterndrive unit shift cable.

b c a

71658

a -

Washers (2)

b -

Lock Nut - Tighten Until Contact. Then Back Off 1/2 Turn

c -

Cotter Pin - Insert From Top And Spread Both Ends

4. Place adjustment tool over sterndrive unit shift cable, as shown. Hold tool in place, using a piece of tape over the barrel retainer.

INDEX

Page 64 of 116

71659

5. Locate center of remote control and control cable play (backlash).

a. Shift remote control to neutral.

b. Push in on control cable end with enough pressure to remove play and mark position

a

on tube.

c. Pull out on control cable end with enough pressure to remove play and mark position

b

on tube.

d. Measure distance between marks

a

and

b

and mark position

c

half-way between marks

a

and

b

.

c b a

71656

IMPORTANT: Be sure to keep center mark c aligned with control cable end guide edge when making the following adjustment.

6. Adjust control cable as follows:

INDEX


a. Temporarily install control cable end guide into shift lever and insert anchor pin.

b. Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud. Ensure that backlash center mark is aligned with edge of control cable end guide.

CAUTION

DO NOT attempt to install or remove control cable barrel from stud without first removing end guide anchor pin from shift lever and removing cable. Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur.

c. Remove control cable end guide from shift lever by removing anchor pin.

b a c d e

71660

a -

Control Cable End Guide

b -

Anchor Pin

c -

Backlash Center

d -

Control Cable Barrel

e -

Stud

7. Install control cable.

c b a

71661

a -

Lock Nut - Tighten Until Contacts

b -

Washers - Both Sides Of Barrel

c -

Anchor Pin

d -

Cotter Pin (Not Visible) - Spread Both Ends

Page 65 of 116


8. Remove adjustment tool.

9. Shift remote control lever into full forward position. Place end of adjustment tool in barrel retainer.

RH rotation Bravo One, Two and Three Models: Rear slot in tool should fit over shift lever stud.

LH rotation Bravo One And Two: Forward slot in tool should fit over shift lever stud.

If slot does not fit over stud, loosen shift lever stud and slide stud up or down until slot in tool fits over stud. When adjustment is correct, retighten stud.

INDEX

c a

RH Rotation Bravo One, Two, Three d a c

LH Rotation Bravo One And Two a -

Adjustment Tool

b -

Barrel Retainer

c -

Shift Lever Stud

d -

Shift Lever Adjustment Slot

10. Remove adjustment tool.

11. Lubricate shift cable pivot points with 30W oil.

b b

71662

71663

Page 66 of 116

INDEX


Troubleshooting Shift Problems

NOTE: The following information is provided to assist an installer in troubleshooting if hard shifting or chucking/racheting is encountered when shifting into forward gear.

1. When installing the control box in the side panel of the boat, make sure that the cables have enough clearance to operate. This is necessary because the cables move up and down when the shift handle is moved. If the control box is mounted too far back toward any fiberglass structure, the cables will be interfered with; this will cause very hard shifting.

NOTE: The control box housing can be rotated in 30

°

increments to improve cable routing.

74688

Proper Cable Bend

74689

Improper Cable Bend

2. Ensure that the shift cable from the control box has a minimum 8 in. (203 mm) radius bend when led through the side gunnel of the hull. Extremely sharp bends will cause stiff shifting.

3. Before installing the shift cable into the control box, extend the stainless rod eye end of the cable and grease it with 2-4-C Marine Lubricant with Teflon. Move it back and forth to allow even distribution of the grease.

22005

Page 67 of 116


4. Do not strap or clamp the control cables to any other cables or rigid structure within

3 ft. (915 mm)of the control box.

5. Be sure the cable is not allowed to be kinked.

6. Make sure there is proper clearance for cable movement when the control box is installed in the side panel. The cables must have room to move up and down when the control handle is shifted into either forward or reverse.

7. Check to make sure that the engine was not set down on the intermediate shift cable during installation, as this will crush the inner cable tubing and cause improper and / or stiff shifting.

8. DO NOT fasten the shift cable with straps or clamps to any other cable within 5 ft.

(1.5 m) of the shift plate.

9. DO NOT fasten the shift cable to the transom with any type of plastic clips or fasteners within 5 ft. (1.5 m) of the shift plate.

10. DO NOT overtighten the throttle or shift cable attaching nuts at the engine end. Barrel and cable end must be free to rotate on the mounting stud.

NOTE: Lubricate attaching points with motor oil.

11. Check the intermediate shift cable routing from the transom assembly to the shift plate as follows: a. Route the cable through the transom above the exhaust pipe and turn it toward the starboard side of the boat between the exhaust pipe and the engine flywheel housing.

b. Then route the cable under the starboard rear engine mount and turn it toward the transom.

c. Then route the cable up behind the power steering valve and loop it over to the shift plate on the engine and connect it to the anchor points on the shift plate.

Following this routing will prevent the engine coupler from damaging the cable.

INDEX

Page 68 of 116

74904

V6 and V8 (except 7.4L) Models

75767

7.4L Mag MPI Models

NOTE: A final check of the adjustments should be made with the boat in the water and engine running. If this cannot be done or is not done at your manufacturing facility, arrangement should be made with the dealer to do this as part of the pre-delivery inspection.

INDEX


Throttle Cable Installation and Adjustment

CARBURETED MODELS

1. Place remote control handle(s) in neutral/idle position.

IMPORTANT: Be sure that cable is routed to avoid sharp bends and/or contact with moving parts. DO NOT fasten any items to throttle cable. Outer cable must be free to move when cable is actuated.

2. Install cable end guide on throttle lever and then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on the cable to avoid slack in cable when moving remote control lever.) Adjust barrel on throttle cable to align with anchor stud.

3. Secure throttle cable with hardware as shown. DO NOT Overtighten as cable must pivot freely. Tighten until nut contacts, then loosen 1/2 turn

4. Place remote control throttle lever in the wide open throttle (WOT) position. Ensure that throttle shutters are completely open.

5. Return remote control throttle lever to idle position and ensure that throttle lever contacts idle speed adjustment screw.

g e d f c b

2 BBL V6 and V8 Models a -

Cable End Guide

b -

Throttle Lever Screw

c -

Locknut and Flat Washer (Small)

d -

Throttle Lever

e -

Idle Speed Adjustment Screw

f -

Idle Cam

g -

Throttle Bracket

h -

Cable Barrel

i -

Flat Washer and Locknut (Large)

j -

Throttle Cable Anchor Stud

a i j h

76900

Page 69 of 116

GASOLINE ENGINES BRAVO MODELS c d a b

72014

e

70392

g f

71159

4 BBL V6 Models a -

Cable End Guide

b -

Flat Washer And Locknut – Tighten Until Nut Contacts, Then Loosen 1/2 Turn

c -

Cable Barrel

d -

Throttle Lever [Contacts

e

In Idle Position]

e -

Idle Speed Adjustment Screw

f -

Throttle Shaft Lever [Contacts

g

At WOT Position]

g -

Carburetor Body Casting

INDEX

Page 70 of 116

INDEX


4.3L EFI, 5.0L EFI, 5.7L EFI, MX 6.2L MPI AND 350 MAG MPI MODELS

1. Place remote control handle(s) in neutral idle position.


2. Install cable end guide on throttle lever, then push cable barrel end lightly toward throttle lever end. (This will place a slight preload on shift cable to avoid slack in cable when moving remote control lever). Adjust barrel on throttle cable to align with hole in anchor plate. Ensure hole in barrel positions cable as shown.

a c b

71711

a -

Flat Washer And Locknut

b -

Cable Barrel

c -


3. Secure throttle cable with hardware as shown and tighten until nut contacts, then loosen

1/2 turn.

4. Place remote control throttle level in the wide open throttle (WOT) position. Ensure that throttle plates are completely open.

5. Return remote control throttle lever to idle position and ensure that throttle lever is completely closed.

Page 71 of 116


454 MAG MPI AND 502 MAG MPI MODELS



2. Remove flame arrestor.

INDEX

c b

75142

a

75113

a -

Flame Arrestor

b -

Screws

c -

Vent Hose

NOTE: If boat is equipped with Quicksilver Zero Effort Controls, the throttle cable mounting stud must be in the outer hole on the throttle lever.

a

73855

a -

Position For Zero Effort Controls

Page 72 of 116

INDEX



b a

71711

a -

Cable Barrel

b -

Anchor Plate

4. Secure throttle cable with hardware as shown and tighten securely.

5. Place remote control throttle lever in the wide open throttle (WOT) position. Ensure that throttle plates are completely open.

6. Return remote control throttle lever to idle position and ensure that throttle shutters are completely closed.

g d b c

71761

a e f

75143

a -

Cable End Guide

b -

Cable Barrel

c -

Bolt

d -

Locknut

e -

Throttle Lever

f -


g -

Throttle Plates

Page 73 of 116


7. Reinstall flame arrestor and tighten screws securely. Connect crankcase vent hose to flame arrestor as shown.

INDEX

a

75115

a -

Crankcase Vent Hose

7.4L MPI MODELS


2. Remove starboard side engine cover.


3. Remove flame arrestor.

a b

75447

a -

Flame Arrestor

b -

Screws

Page 74 of 116

INDEX



a b

75455

a -

Cable Barrel

b -

Anchor Plate

5. Secure throttle cable with hardware as shown and tighten securely.

a a

75454

a -

Washer And Locknut

6. Place remote control throttle lever in the wide open throttle (WOT) position. Ensure that throttle plate is completely open.

a a -

Throttle Plate

75453

Page 75 of 116


7. Return remote control throttle lever to idle position and ensure that throttle plate is completely closed.

INDEX

a

75452

a -

Throttle Plates

8. Reinstall flame arrestor and tighten clamp securely.

Sterndrive Unit Installation

1. Remove trim cylinder support and dust cover from bell housing studs. Retain elastic stop nuts and flat washers.

2. Remove monitor cap and fill gear lube monitor.

a

75404

a -

Gear Lube Monitor

Page 76 of 116

3. Push in on dribble valve until gear lube appears.

INDEX

GASOLINE ENGINES BRAVO MODELS a

72471

a -

Dribble Valve

4. Once gear lube appears, release dribble valve.

5. Fill monitor to FILL mark.

6. Replace monitor cap.

7. Coat studs with 2-4-C Marine Lubricant with Teflon.

a

77066

a -

Studs (6)

Page 77 of 116


8. Lubricate U-joint shaft splines and U-joint shaft O-rings with Quicksilver Engine Coupler

Spline Grease.

INDEX

a b

Typical a -

Splines

b -

O-rings

9. Check drive shaft bellows for cleanliness and absence of debris.

a

72458

72472

a -

Drive shaft Bellows

Page 78 of 116

INDEX


10. Lubricate O-ring seals with 2-4-C Marine Lubricant with Teflon.

a a -

O-Ring Seals

11. Pull out shift linkage as far as it moves. Jaws will open, as shown.

a

72183

72460

a -

Shift Linkage

IMPORTANT: As sterndrive is inserted into sterndrive unit, entry of the bell housing shift cable must be closely checked to make sure cable enters the jaws of shift linkage assembly in the sterndrive.

Page 79 of 116


12. Place Remote Control in neutral position.

NOTE: As bell housing shift cable enters the shift linkage assembly, it pushes the assembly back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps

“

A

”, “

B

” and “

C

.”

INDEX

A

B

Page 80 of 116

C

72467

IMPORTANT: If Bell Housing Shift Cable “ b ” does not line up to properly enter jaws of shift linkage assembly “ a ,” cable will have to be aligned manually.

b a

72457

a -

Shift Linkage Assembly

b -

Shift Cable

13. Place drive shaft housing in position on bell housing and install sterndrive unit, as follows: a. Position trim cylinders so they point straight backwards.

b. Position sterndrive unit so that universal joint shaft aligns with bell housing bore.

c. Guide U-joint shaft through bearing in gimbal housing and into engine coupler. Make sure that shift linkage jaws engage the bell housing shift cable assembly.

d. If necessary, rotate propeller shaft counterclockwise slightly (using a propeller) to align U-joint shaft splines with splines in engine coupling, then slide sterndrive unit all the way into bell housing.

INDEX


14. Secure sterndrive unit to bell housing with 5 flat washers and 6 locknuts. Torque to 50 Ib-ft (68 Nm).

b a

71244

a -

Do Not Install Flat Washer Here

b -

Elastic Stop Nuts (6) and Flat Washers (5)

IMPORTANT: On Bravo One, Two and Three Models, the Trim-In Limit Pin must be properly positioned before installing the trim cylinder anchor pin in the following steps.

15. Ensure that the Trim-In Limit Pin is positioned as shown for the appropriate Bravo model.

a

75157

Bravo One and Two (Positioned Forward) a

75158

Bravo Three (Positioned Aft) a -

Trim-In Limit Pin

Page 81 of 116


IMPORTANT: The position of the Trim-In Limit Pin on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested. Refer to statement at the front of this manual entitled; “Trim-In Limit Pin.”

IMPORTANT: To aid in installing rubber bushings, use a water and soap solution. DO

NOT use oil or grease.

16. Install trim cylinders on aft end of sterndrive unit with hardware as shown. Coat anchor pin threads with 2-4-C Marine Lubricant with Teflon and tighten nuts until they contact.

Install plastic caps and tighten hand tight only.

INDEX

b c c a d e c f

71668

71669

a -

Aft Anchor Pin

b -

Large l.D. Flat Washers (2)

c -

Rubber Bushings (4)

d -

Small l.D. Flat Washers (2)

e -

Locknuts (2)

f -

Plastic Caps (2)

17. Place sterndrive unit serial number decal as described in “General Information.”

18. On Bravo One and Two Sterndrive Units - Perform steps 19. through 21.

19. Raise sterndrive to gain access to area between gimbal housing and sterndrive, immediately atop the transom end of the anti-ventilation plate.

Page 82 of 116

INDEX


20. Insert speedometer tube fitting into opening on topside of anti-ventilation plate, in position shown.

a b

22025

a -

Tube Fitting

b -

Opening

21. With fitting fully seated, turn handle to left to a tightly seated position, as shown.

a

22025

a -

Handle

Page 83 of 116


Predelivery Preparation

NOTICE

Before starting Predelivery read “General Information” and “Installation Requirements” completely.

Once the power package installation is complete, the following final steps should be taken to prepare power package for delivery to the customer. It is the boat manufacturer’s responsibility to perform these procedures, or to make arrangement with the dealer to have these procedures completed.

Battery Connection

IMPORTANT: Engine electrical system is negative (–) ground.

1. Connect engine positive (+) battery cable (usually RED) to positive (+) battery terminal.

2. Connect engine negative (-) battery cable (usually BLACK) to negative (-) battery terminal.

3. Connect Power Trim pump BLACK (-) battery cable to negative (-) battery terminal and pump RED (+) battery cable to positive (+) battery terminal.

4. Make sure that all battery terminal connections are tight, then spray terminals with a battery connection sealant to help retard corrosion.

Power Trim Pump

NOTE: See 90-863152 for mounting hole template.

IMPORTANT: Check oil level with sterndrive unit in the full down position.

IMPORTANT: Use Quicksilver Power Trim and Steering Fluid, or SAE 10W-30 or

10W-40 engine oil in trim system.

1. Unscrew fill cap and remove caplug from fill neck and discard. Replace fill cap.

a

INDEX

50630

Page 84 of 116

a -

Caplug

INDEX


2. Raise and lower sterndrive unit (to the full up position) 6 to 10 times to purge air from system. Check oil level visually, (with sterndrive unit in the full down position). Oil level should be maintained at bottom lip of fill neck.

a

22031

a -

Fill Neck

3. Check all trim line connection points for leaks. If fluid is visible at fittings, tighten fitting(s).

Torque fitting(s) to 125 lb-in. (14 Nm).

Trim Position Sender Adjustment

1. Loosen both trim position sender attaching screws.

b a

71220

a -

Attaching Screws

b -

Trim Position Sender

Page 85 of 116


CAUTION

DO NOT start engine in the following step or damage to sterndrive unit and engine could result from lack of cooling water.

2. Turn ignition key to RUN position.

3. Trim sterndrive unit to the full DOWN/IN position.

4. Rotate trim position sender as required to show full DOWN/IN position on dashboard instrument as shown.

INDEX

a a -

Trim Gauge Needle

5. Tighten retaining screws and turn ignition key to the OFF position.

71671

b a

71220

a -

Retaining Screws

b -

Trim Position Sender

Page 86 of 116

INDEX


Power Steering Fluid

IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid or Dexron III automatic transmission fluid (ATF) in power steering system.

CAUTION

DO NOT RUN POWER STEERING DRY, or pump will be damaged.

1. Position sterndrive unit so that it is straight back.

2. Remove fill cap from power steering pump reservoir and check fluid level.

3. Add fluid as required.

NOTE: When first starting engine, be prepared to add fluid to pump.

a a b

71672

76859

a -

Fill Cap

b -

Dipstick

Propeller Installation (Bravo One and Two)

IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft.

WARNING

Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller.

WARNING

Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when tightening propeller nut.

1. To aid in future removal of the propeller, liberally coat propeller shaft splines with one of the following Quicksilver lubricants.

•


•

2-4-C Marine Lubricant with Teflon

IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are exposed through propeller nut after torquing it.

Page 87 of 116


2. Install propeller with attaching hardware as shown. Tighten nut a minimum of 55lb-ft

(75 Nm), then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer. Bend the 3 tabs down into grooves.

INDEX

a b c d

Bravo One a -

Apply Lubricant on Splines of Propeller Shaft

b -

Forward Thrust Hub

c -

Flo-Torque Drive Hub

d -

Propeller

e -

Drive Sleeve Adapter

f -

Tab Washer

g -

Locknut

e f g

76910

Page 88 of 116

a b

Bravo Two a -

Apply Lubricant on Splines of Propeller Shaft

b -

Forward Thrust Hub

c -

Propeller

d -

Continuity/Spline Washer

e -

Tab Washer

f -

Locknut

c d e f

70561

INDEX


Propeller Installation (Bravo Three)

IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller shaft.

WARNING

Be sure that remote control is in neutral position and ignition key is removed from switch prior to installing propeller.

WARNING

Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning when tightening propeller nut.

1. To aid in future removal of the propeller, liberally coat the propeller shaft splines with one of the following Quicksilver lubricants.

•


•

2-4-C Marine Lubricant with Teflon

2. Install propellers with attaching hardware as follows: a. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.

b. Align splines and place front propeller on propeller shaft.

c. Install front propeller locknut. Torque to 100 lb-ft (136 Nm).

d. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub.

e. Align splines and install aft propeller.

f.

Install propeller locknut. Torque to 60 lb-ft (81 Nm).

Bravo Three a -

Rear Propeller Locknut

b -

Rear Propeller

c -

Rear Propeller Thrust Hub

d -

Front Propeller Locknut

e -

Front Propeller

f -

Front Propeller Thrust Hub

f e d c b a

72239

Page 89 of 116


Test Running Engine

WARNING

If engine is to be tested with boat out of water, the propeller must be removed to avoid injury.

IMPORTANT: If using a test tank, ensure water level is above water intake holes.

INDEX

b a

70082

Typical a -

Minimum Water Level

b -

Water Intake Holes

IMPORTANT: If using flush test device, install over water intake holes and connect a water hose as shown. Do not use full water tap pressure. Also, do not run engine above 1500 rpm, as suction created could cause water hose to collapse causing water supply to be cut off.

a b a -

Flush Test Device

b -

Water Hose Hook-Up

70564

Page 90 of 116

INDEX


WARNING

Do not leave helm unattended when making test with boat in the water.

1. Ensure that cooling system drain plugs, petcocks and hoses are installed and tight.

NOTE: Refer to Operation, Maintenance and Warranty Manual for operating specifications.

Refer to the appropriate Mercury MerCruiser Service Manual for fluid capacity information.

2. Check crankcase oil level.

IMPORTANT: Oil level in monitor will rise and fall during sterndrive operation; always check oil level when sterndrive is cool and engine is shut down.

3. Check sterndrive unit oil level.

4. Check drive belt tension.

5. Test Audio Warning System.

6. Start engine and run at idle rpm until water temperature is normal.

7. Watch all gauges for normal readings.

8. Turn steering wheel starboard, then port, and ensure sterndrive unit turns the correct way.

9. Inspect engine compartment for water, oil, fuel and exhaust leaks.

10. Check power steering system for lugging condition.

a. Turn steering wheel LEFT/PORT until it stops and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes), check the following.

(1.) Check for an obstruction between gimbal ring and gimbal housing and all moving steering components.

(2.) Check that steering lever is not contacting cutout in transom. If contact is being made, modify cutout.

b. Turn steering wheel RIGHT/STARBOARD until it stops and continue to apply pressure. If pump lugs (engine rpm drops and/or power steering pump tone changes), check the following.

(1.) Check same items as (1.) and (2.) above.

(2.) Check steering cable end dimension with cable FULLY EXTENDED. (See

“Installation Requirements” for proper steering cable dimensions).

Page 91 of 116


11. Check power steering fluid level.

a. Turn off engine.

b. Remove cap/dipstick from power steering pump. Check fluid level and add as necessary.

INDEX

b a

71672

a -

Dipstick (Full When Cold Line)

b -

Dipstick (Full When Hot Line)

Boat-ln-The-Water Tests

ENGINE IDLE SPEED (ALL EFI MODELS)

CAUTION

Avoid engine damage. Ensure that cooling water is supplied to the engine if it will be run with boat out of the water. See instructions in the Operation, Maintenance and Warranty Manual entitled “Flushing Cooling System” for instructions on connecting flush device.

Engine should idle at rpm (as specified in“Operation, Maintenance and Warranty Manual) with engine at normal operating temperature. If idle speed is incorrect, proceed as follows:

1. Ensure that throttle cable has been adjusted properly.

2. If idle speed is still not correct, it may be necessary to perform EFI System Diagnostic

Tests on the idle circuit. Refer to the appropriate Mercury MerCruiser Service Manual for procedures.

Page 92 of 116

INDEX


ENGINE IDLE SPEED (CARBURETED MODELS)

CAUTION

Avoid engine damage. Ensure that cooling water is supplied to the engine if it will be run with boat out of the water. See instructions in the Operation, Maintenance and Warranty Manual entitled “Flushing Cooling System,” for instructions on connecting flush device.

The engines covered in this manual should idle at rpm (as specified in Operation, Maintenance and Warranty Manual) with engine at normal operating temperature. If idle speed is incorrect, proceed as follows:

1. Disconnect the throttle cable from carburetor.

2. Connect a shop tachometer to engine.

IMPORTANT: In order to properly set idle speed, the ignition module MUST BE locked in the Base Timing Mode. This is necessary because of the Idle Speed Control feature that exists in the ignition module. This must be done before the key switch is turned to the on or start position.

3. Using a jumper wire, connect the ignition system Timing Lead (PUR/WHT wire) to a good engine ground (–). This locks the ignition module into the Base Timing Mode. Refer to “Engine Wiring Harness” diagram in this manual.

4. Start engine and place the remote control lever in neutral gear, idle position.

5. Adjust idle speed to 650 rpm.

6. Stop engine. Readjust cable barrel and reinstall the throttle.

IMPORTANT: Throttle cable barrel must be adjusted properly.

IMPORTANT: Be sure to disconnect the jumper wire from the ignition system test lead before attempting to resume normal operations. If the jumper wire is left in place, the ignition module will operate in the Base Timing Mode. This means that the additional timing advance features would not be functioning.

7. Remove the jumper wire from the timing lead.

WIDE-OPEN-THROTTLE TEST

IMPORTANT: To run engine at full throttle before the break-in period is complete, follow this procedure.

•

Start engine and run at idle rpm until normal operating temperature is reached.

•

Run boat up on plane.

•

Advance engine rpm (in 200 rpm increments) until engine reaches its maximum rated rpm.

To test if the correct propeller has been installed, operate boat (with normal load on board) at WOT and check rpm with an accurate tachometer. Engine rpm should be near top of the specified range so that under a heavy load engine speed will not fall below specifications.

If engine speed is too high, replace propeller with a higher pitch propeller. Normally, a

300-400 rpm change exists between propeller pitches.

Page 93 of 116


Cold Weather or Extended Storage Draining Instructions

CAUTION

Sterndrive unit should be stored in full DOWN position. Universal Joint bellows may develop a “set” if unit is stored in raised position and may fail when unit is returned to service.

CAUTION

If Power Package will not be used for an extended period of time or will be exposed to freezing temperatures, drain water from seawater section of cooling system. Water MUST BE drained to prevent corrosion and freeze damage to engine.

CAUTION

If boat is to remain in water after draining, seawater inlet hose must be removed and plugged. The plug will prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses.

IMPORTANT: Boat must be as level as possible to ensure complete draining of cooling system.

Draining

SEAWATER (RAW-WATER) COOLED MODELS

CAUTION

If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur, allowing seawater to flow from the drain holes or removed hoses.

INDEX


CAUTION

Seawater section of cooling system MUST BE COMPLETELY drained for winter storage, or immediately after cold weather use, if the possibility of freezing temperatures exists. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by the

Mercury MerCruiser Limited Warranty.

Page 94 of 116

INDEX


1. Ensure engine is as level as possible to ensure complete draining of cooling system.

2. Remove drain plugs from the following locations, if equipped: a. Port and starboard side of cylinder block.

b. Bottom of exhaust manifold(s).

c. Starboard side Y-fitting.

d. Fuel cooler.

c

75432

b a

75081

d a -

Cylinder Block Drain Plugs

b -

Exhaust Manifold Drain Plugs

c -

Y-Fitting Drain Plug

d -

Fuel Cooler Drain Plug

3. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained.

NOTE: It may be necessary to lift or bend hoses to allow water to drain completely.

4. Models equipped with circulating pump hose drain plug: Remove drain plug.

5. Models without circulating pump hose drain plug: Loosen hose clamps and disconnect hose from thermostat housing or circulating pump. Allow water to drain.

a

74774

b a -

Thermostat Housing To Circulating Pump Hose

b -

Drain Plug Location, If Equipped

Page 95 of 116


6. Make sure gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed.

a

INDEX

c b d a -

Vent Holes

b -

Trim Tab Cavity Drain Holes

c -

Drain Hole

d -

Speedometer Pitot Hole

71216

7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. Do not allow engine to start.

8. After cooling system has been drained completely, install drain plugs, reconnect hoses and tighten all hose clamps securely.

IMPORTANT: Mercury 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 extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines.

Be certain to follow the propylene glycol manufacturer’s recommendations.

9. For additional assurance against freezing and rust, fill the cooling system with a mixture of antifreeze and tap water mixed to manufacturer’s recommendation to protect engine to the lowest temperature to which it will be exposed during cold weather or extended storage.

a. Remove thermostat housing or hose and fill with coolant until block and head are full. If thermostat housing was removed, reinstall and tighten cover bolts securely.

Page 96 of 116

75598 b. Remove water hose from exhaust manifold and fill manifold with coolant. Reinstall hose and tighten clamp securely.

Store boat with sterndrive unit in full DOWN/IN position.

INDEX


CLOSED COOLED (COOLANT) MODELS

The following information outlines the procedures for draining the seawater section of the closed cooling systems.

IMPORTANT: Drain seawater section of closed cooling system only.

CAUTION

If boat is to remain in water after draining, seawater inlet hose must be removed and plugged to prevent a siphoning action that may occur allowing seawater to flow from the drain holes or removed hoses.


CAUTION

Seawater section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use if the possibility of freezing temperatures exist. Failure to comply may result in trapped water causing freeze and/or corrosion damage to engine. Damage caused by freezing IS NOT covered by the

Mercury MerCruiser Limited Warranty.

IMPORTANT: Closed cooling section must be kept filled year-round with recommended coolant. If engine will be exposed to freezing temperatures, make sure closed cooling section is filled with an ethylene glycol antifreeze and water solution properly mixed to protect engine to lowest temperature to which it will be exposed.

Quicksilver Premixed Marine Engine Coolant is already mixed.

Page 97 of 116


IMPORTANT: Do not use Propylene Glycol Antifreeze in the closed cooling section of the engine.

INDEX

1. Ensure engine is as level as possible to ensure complete draining of cooling system.

2. Remove drain plug(s) from bottom of exhaust manifold(s).

3. Remove drain plug from fuel cooler.

Page 98 of 116

b a a -

Fuel Cooler Drain Plug

b -

Exhaust Manifold Drain Plug(s)

4. Remove end caps, sealing washers and gaskets from heat exchangers.

75039

a c b d

71515

a -

Heat Exchanger

b -

Gaskets

c -

Sealing Washer

d -

End Cap

5. Repeatedly clean out drain holes using a stiff piece of wire. Do this until entire system is drained.

6. On models with seawater pickup pump, loosen clamps and remove both hoses.

a

71170

a -

Seawater Pickup Pump Hoses

INDEX


7. Crank engine over slightly with starter motor to purge any water trapped in seawater pickup pump. DO NOT allow engine to start.

8. Make sure gear housing water vent and drain holes, speedometer pitot hole and trim tab cavity vent and drain holes are open and unobstructed.

a c b d

71216

a -

Vent Holes

b -

Trim Tab Cavity Drain Holes

c -

Drain Hole

d -

Speedometer Pitot Hole

9. After seawater section of cooling system has been drained completely, reinstall all components. Reconnect all hoses and tighten hose clamps securely.

Store boat with sterndrive unit in full DOWN/IN position.

Page 99 of 116


Quicksilver Instrumentation Wiring Diagrams

MCM Gasoline Engine

SINGLE STATION INSTALLATIONS - TYPICAL a

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 OR LT = LIGHT

DRK = DARK

j

INDEX

b c d e i f h g i i

74583

Page 100 of 116

INDEX


Refer to gauge manufacturer’s instructions for specific connections.

NOTE:

1

Connect Wires Together with Screw and Hex Nut; Apply Liquid Neoprene to Connection and Slide Rubber Sleeve over Connection.

NOTE:

2

Power for a Fused Accessory Panel May Be Taken from This Connection. Load

Must Not Exceed 40 Amps. Panel Ground Wire Must Be Connected to Instrument Terminal

That Has an 8-Gauge Black (Ground) Harness Wire Connected to it.

NOTE:

3

Lanyard stop switch lead and neutral safety switch leads must be soldered and covered with shrink tube for a water proof connection. If an alternate method of connection is made, verify connection is secure and sealed for a water proof connection.

a -

Audio Warning Horn

b -

Tachometer

c -

Oil Pressure

d -

Water Temperature

e -

Battery Meter

f -

Ignition Switch

g -

Trim Indicator

h -

Read/Observe NOTE 1 and 2.

i -

Read/Observe NOTE 3.

j -

To Engine Wiring Harness

Page 101 of 116


Power Trim System Wiring Diagram

a b c f e d g h

Page 102 of 116

a -

20 Amp Fuse

b -

Ground Bolt (Floor Mount)

c -

UP Solenoid

d -

110 Amp Fuse

e -

DOWN Solenoid

f -

Trailer Switch

g -

Neutral Switch To Instrument Wiring Harness

h -

Trim Limit Switch

BLK = BLACK

BLU = BLUE

BRN = BROWN

GRY = GRAY

GRN = GREEN

ORN = ORANGE

PNK = PINK

PUR = PURPLE

RED = RED

TAN = TAN

WHT = WHITE

YEL = YELLOW

LT OR LIT = LIGHT

DRK = DARK

73962

INDEX

MerCathode System Wiring Diagram

a

INDEX

GASOLINE ENGINES BRAVO MODELS b c a -

Controller

b -

20 Amp Fuse

c -

Electrode

BLK = BLACK

BLU = BLUE

BRN = BROWN

GRY = GRAY

GRN= GREEN

ORN= ORANGE

PNK = PINK

PUR = PURPLE

RED = RED

TAN = TAN

WHT= WHITE

YEL = YELLOW

LT OR LIT=LIGHT

DRK = DARK

73596

Page 103 of 116


MCM Gasoline Engine Wiring Diagrams

MCM 4.3L/4.3LH Bravo Engines

1

2

A

1

3

3

C

2

1

3

D

2

1

8

2

B

3

4

7

5

6

A - Ignition Components

1 -

Distributor

2 -

Timing Lead

3 -

Ignition Coil

B - Starting, Charging and Choke Components

1 -

Alternator

2 -

Electric Choke

3 -

Ground Stud

4 -

Starter Motor

5 -

Oil Pressure Switch

6 -

Fuel Pump

7 -

Circuit Breaker

8 -

Starter Slave Solenoid

C - Audio Warning Components

1 -

Oil Pressure Switch

2 -

Drive Unit Gear Lube Monitor

3 -

Water Temperature Sender

D - Instrumentation Components

1 -

Oil Pressure Sender

2 -


3 -

Trim Sender

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

75549

INDEX

Page 104 of 116

MCM 5.0L and 5.7L Bravo Engines

3

INDEX


1

C

2

A

3

1

4

2

1

D

2

3

8

1

4

7

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

2

3

5

B

6

A - Ignition Components

1 -

Distributor

2 -

Timing Lead

3 -

Ignition Coil

4 -

Knock Sensor

B - Starting, Charging and Choke Components

1 -

Alternator

2 -

Electric Choke

3 -

Ground Stud

4 -

Starter Motor

5 -

Oil Pressure Switch

6 -

Fuel Pump

7 -

Circuit Breaker

8 -


C - Audio Warning Components

1 -

Oil Pressure Switch

2 -

Drive Unit Gear Lube Monitor

3 -


D - Instrumentation Components

1 -

Oil Pressure Sender

2 -


3 -

Trim Sender

75550

Page 105 of 116


MCM 4.3L EFI, 5.0L EFI, 5.7L EFI, 350 Mag MPI, 6.2L MPI, 454 Mag MPI and 502

Mag MPI - Starting and Charging System Harnesses

INDEX

A

1

1

B

2

c

C

1

4

5

b

2 3

90 Amp

Fuse

6

a

7

76061

A - Audio Warning Components

1 -

Oil Pressure Switch

B - Instrumentation Components

1 -

Oil Pressure Sender

2 -

Trim Sender

C - Charging and Starting Components

1 -

Alternator

2 -

Ground Stud

3 -

Starter

4 -

Circuit Breaker

5 -


6 -

Jumper Wire Connection

7 -

Battery

a -

Positive Power Wire To EFI System Harness

b -

Harness Connector To EFI System Harness

c -

Auxiliary Tachometer Lead

Page 106 of 116

MCM 7.4L MPI Starting and Charging System Harness

INDEX


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

A

1

B

2

1

c

4

5

1

3

6

90 Amp

Fuse

2

C

A - Audio Warning Components

1 -

Transmission Temperature Switch (If Equipped)

B - Instrumentation Components

1 -

Oil Pressure Sender - To Gauge

2 -

Trim Sender To Gauge

C - Charging and Starting Components

1 -

Alternator

2 -

Ground Stud

3 -

Starter

4 -

Circuit Breaker

5 -


6 -

Jumper Wire Connection

a -

Positive (+) Power Wire Connector To EFI System Harness

b -

Harness Connector To EFI System Harness

c -

Auxiliary Tachometer Lead

a b

75995

Page 107 of 116


MCM 4.3L EFI, 5.0L EFI and 5.7L EFI Bravo Engines - Fuel and Ignition System

Harness

NOTE: All BLACK wires with a ground symbol are interconnected within the EFI system harness.

NOTE: Component position and orientation shown is arranged for visual clarity and ease of circuit identification.

INDEX

22

21

17

7

9

12

5

10

20

6

13

8

2

11

16

15

18

19

14

1

(+)

(–)

4 3

76063

1 -

Fuel Pump

2 -

Throttle Body

3 -

Distributor

4 -

Coil

5 -

Manifold Air Temperature (MAT) Sensor

6 -

Data Link Connector (DLC)

7 -

Manifold Absolute Pressure (MAP) Sensor

8 -

Knock Sensor

9 -

Idle Air Control (IAC)

10 -

Throttle Position (TP) Sensor

11 -

Engine Coolant Temperature (ECT) Sensor

12 -

Electronic Control Module (ECM)

13 -


14 -

Fuel Pump Relay

15 -

Ignition/System Relay

16 -

Fuses (15 Amp) Fuel Pump, (15 Amp)

ECM/DLC/Battery, (10 Amp) ECM/Injector/

Ignition/Knock Module

17 -

Oil Pressure Sensor

18 -

Harness Connector To Starting/Charging

Harness

19 -

Positive (+) Power Wire To Engine Circuit

Breaker

20 -

Shift Plate

21 -

Gear Lube Monitor

22 -

Fuel Pressure Switch

Page 108 of 116

INDEX


MCM 350 Mag MPI and MX 6.2L Engines - Fuel and Ignition System Harness



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

8

7

6

20

10

19

18

17

16

5

21

9

4

13

12

14

15

11

1

(+)

(–)

3

1 -

Fuel Pump

2 -

Distributor

3 -

Coil

4 -

Knock Sensor (KS) Module

5 -


6 -


7 -


8 -


9 -


10 -


11 -

Fuel Pump Relay

12 -


2

76064

13 -

Fuse (15 Amp) Fuel Pump, Fuse (15 Amp)

ECM/DLC/Battery,Fuse (10 Amp) ECM/Injector/Ignition/Knock Module

14 -

Harness Connector To Starting/Charging Harness

15 -


Breaker

16 -

Shift Plate (Not used on Bravo models)

17 -

Oil Pressure (Audio Warning System)

18 -

Gear Lube Bottle

19 -

Fuel Pressure Switch

20 -


Page 109 of 116


MCM 454 & 502 Mag MPI Models - Fuel and Ignition System Harness



INDEX

2

16

2

5

19

17

3

19

10

18

8

7

4

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

9

6

15

13

12

14

11

1

75994

1 -

Fuel Pump

2 -

Distributor

3 -

Coil

4 -


5 -


6 -

Knock Sensor

7 -


8 -


9 -


10 -


11 -

Fuel Pump Relay

12 -


13 -


14 -


Breaker

15 -

Fuse (10 Amp) ECM / Injector / Ignition / Knock

Module

Fuse (15 Amp) Fuel Pump

Fuse (15 Amp) ECM/DLC/Battery

16 -

Gear Lube Monitor Bottle

17 -

Oil Pressure -Audio Warning Switch

18 -

Load Anticipation Circuit

19 -

Wires Not Used

Page 110 of 116

MCM 7.4L MPI Bravo - Fuel and Ignition System Harness

INDEX




4

2

17

6

3

7

18

8

9

11

5

15

16

10

1 -

Fuel Pump

2 -

Distributor

3 -

Coil

4 -

Gear Lube Monitor Bottle

5 -


6 -


7 -

Knock Sensor

8 -


9 -


10 -


11 -


12 -

Fuel Pump Relay

7

14

13

12

1

75993

13 -


14 -

Fuse (15 Amp) Fuel Pump

Fuse (15 Amp) ECM/DLC/Battery

Fuse (10 Amp) ECM/Injector/Ignition/Knock

Module

15 -


16 -


Breaker

17 -

OIl Pressure - Audio Warning Switch

18 -

Load Anticipation Circuit

Page 111 of 116


Water Flow Diagrams

262 CID BRAVO ENGINES

NOTE: Certain components in the following diagram may look different than on your particular power package, but the water flow paths remain similar on all engines.

1

INDEX

3

2

5

9

10

11

8

75148

6

1 -

Seawater Intake (From Sterndrive)

2 -

Seawater Pump

3 -

Power Steering Cooler, If Equipped

4 -

Fuel Cooler (EFI Models)

5 -

Thermostat Housing and Cover Assembly

6 -

Engine Water Circulating Pump

7 -

Engine Block and Cylinder Head Assembly

8 -

Exhaust Manifold, Typical

9 -

Restrictor Gasket

10 -

Exhaust Elbow Assembly, Typical

11 -

Water Flow Overboard

Page 112 of 116

7

4

INDEX


V8 Engines - Seawater (Raw Water) Cooling System

305 CID, 350 CID AND 6.2L BRAVO ENGINES


1

3

5

2

10

9

11

7

4

8

6

1 -


2 -

Seawater Pump

3 -


4 -

Fuel Cooler (EFI and MPI Models)

5 -


6 -


7 -


8 -


9 -

Restrictor Gasket

10 -


11 -


75149

Page 113 of 116


454 AND 502 CID BRAVO ENGINES


1

INDEX

3

6

2

10

11

12

8

9

5

7

1 -


2 -

Seawater Pump

3 -


4 -

Fuel Cooler

5 -

Engine Oil Cooler

6 -


7 -


8 -


9 -


10 -

Restrictor Gasket

11 -


12 -


4

Page 114 of 116

75151

INDEX


V6 and V8 Engines - Closed (Coolant) Cooling System

NOTE: Certain components in the following diagram may look different than on your particular power package, but the water and coolant flow paths remain similar on all engines.

10

11

5

6

4

1 -


2 -

Power Steering Cooler

3 -

Fuel Cooler, If Equipped

4 -

Heat Exchanger, Typical

5 -


6 -


7 -


8 -


9 -


10 -

Overboard (Water and Exhaust Discharge)

11 -

By-Pass Hose (454 and 502 CID Only)

3

7

1

2

9

10

8

75005

Page 115 of 116


Predelivery Inspection

Not Check/

Applicable Adjust

CHECK BEFORE RUNNING

Drain plug in and petcocks closed

Seawater inlet valve open

Engine mounts tight

Engine alignment

Drive unit fasteners torqued

Power trim cylinders fasteners tight

Battery fully charged and secured

All electrical connections tight

Exhaust system hose clamps tight

All fuel connections tight

Correct rotation propeller

(installed and torqued)

Throttle, shift and steering system fasteners tightened properly

Throttle plates open and close completely

Crankcase oil level

Power trim oil level

Sterndrive unit oil level

Power steering fluid level

Closed cooling level

Transmission fluid level

Alternator belt tension

Seawater pickup pump belt tension

Power steering pump belt tension

Audio warning system operation

Not Check/

Applicable Adjust

ON THE WATER TEST

Engine alignment (Inboards only)

Starter neutral safety

switch operation

Water pump operation

Instruments(s) operation

Fuel leaks

Oil leaks

Water leaks

Exhaust leaks

Ignition timing

Idle rpm, within specifications

Forward - Neutral - Reverse gear operation

Steering operation throughout range

Acceleration from idle rpm

WOT rpm within specifications (in forward gear)

Power trim operation

Trim tab adjustment

Boat handling

AFTER ON WATER TEST

Propeller nut torque

Fuel, oil, coolant, water and fluid leaks

Oil and fluid levels

Apply Quicksilver Corrosion Guard to engine package

INDEX

Page 116 of 116

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