1988-1998 Mercruiser Bravo I II III Outdrives Sterndrives Service & Repair Manual

Printed in U.S.A. 90-17431--4 MARCH 1998 1998, Mercury Marine Number 11 Bravo Sterndrives SERVICE MANUAL

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 Page 0 90-17431--4 MARCH 1998 MerCruiser #11 Bravo Sterndrives 90-17431--4 MerCruiser #11 Bravo Sterndrives 90-17431--4

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 90-17431--4 MARCH 1998 Page i Notice Throughout this publication “Warnings” and “Cautions” (accompanied by the International HAZARD symbol ! ) are used to alert the mechanic 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 WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION 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 operation and/or maintenance. Notice To Users of This Manual This service manual has been written and published by the service department of the manufacturer to aid our dealers’ mechanics and company service personnel when servicing the product described herein. It is assumed that these personnel are familiar with the servicing procedures of this product, or like or similar products. That they have been trained in the recommended servicing procedures of these products which includes the use of mechanics’ common hand tools from other suppliers. We could not possibly know of and advise the service trade of all conceivable procedures by which a service might be performed and of all possible hazards and/or results of each method. We have not undertaken any such wide evaluation. Therefore, anyone who uses a service procedure and/or tool which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the product’s safety will be endangered by the service procedure selected. 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 dealers contracted by us to sell and/or service these products.

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 Page ii 90-17431--4 MARCH 1998 Replacement Parts WARNING Electrical system components on gasoline engines and MerCruiser Sterndrives are designed and manufactured to comply with U.S. Coast Guard Rules and Regula- tions to minimize risks of fire or explosion. Use of replacement electrical systems components, which do not comply to these rules and regulations, could result in a fire or explosion hazard and should be avoi- ded. When servicing electrical systems, it is extremely important that all components are properly installed and tightened. If not, any electrical component opening would permit sparks to ignite fuel vapors from fuel system leaks, if they exist or de- velop. WARNING Electrical system components on diesel engines are not external ignition pro- tected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VA- PORS FROM ENGINE COMPARTMENT (ref: 33 CFR). Failure to comply could result in fire, explosion and/or severe personal injury. Models Covered in This Manual MODEL SERIAL NUMBER Bravo One Sterndrive Unit B664190 and Above Bravo Two Sterndrive Unit B892613 and Above Bravo Three Sterndrive Unit D763691 and Above Bravo Transom Assembly (Standard) * B673048 and Above Bravo Transom Assembly (High Performance) D796083 and Above Bravo Transom Assembly (Magnum) K104738 and Above * Some “Standard” Bravo Transom Assemblies could have been converted to “High Performance” Transom As- semblies by use of a High Performance Gimbal Ring Kit (822374A2). Refer to Transom Assembly sections of this manual for identification information. NOTICE Refer to appropriate engine service manual for engine repair.

Important Information Removal, Installation and Adjustment Sterndrive Unit Transom Assembly Power Trim Steering Systems Corrosion Protection Accessories 8 2 3 4 6 7 1 5 BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 90-17431--4 MARCH 1998 Page iii Service Manual Outline Section 1 - General Information A - Important Information B - Maintenance C - Troubleshooting Section 2 - Removal, Installation and Adjustments A - All Models Section 3 - Sterndrive Unit A - Drive Shaft Housing B - Gear Housing - Bravo One C - Gear Housing - Bravo Two D - Gear Housing - Bravo Three Section 4 - Transom Assembly A - Service Procedures Requiring Minor Disassembly B - Service Procedures Requiring Major Disassembly Section 5 - Power Trim A - Oildyne Power Trim Pump B - Trim Cylinders C - Dual Power Trim Control D - Auto Trim II Section 6 - Steering Systems A - All Models Section 7 - Corrosion Protection A - All Models Section 8 - Accessories A - All Models

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 Page iv 90-17431--4 MARCH 1998 Table of Contents GENERAL INFORMATION Section 1A - Important Information How To Use This Manual 1A-2 . . . . . . . . . . . . . . . How To Read Parts Manual 1A-3 . . . . . . . . . . . . Introduction 1A-4 . . . . . . . . . . . . . . . . . . . . . . . . . . Directional References 1A-4 . . . . . . . . . . . . . . . . . Propeller Rotation 1A-4 . . . . . . . . . . . . . . . . . . . . . Sterndrive Unit 10-Hour Break-In Period (New or With Replacement Gears) 1A-5 . . . . . . Serial Number Locations and Engine Designation Decal 1A-5 . . . . . . . . . . . . . . . . . . . . Section 1B - Maintenance Maintenance Schedules 1B-2 . . . . . . . . . . . . . . . Maintenance Intervals 1B-2 . . . . . . . . . . . . . . . Scheduled Maintenance That Can Be Performed By Owner/Operator 1B-2 . . . . . . . Scheduled Maintenance That Can Be Performed by Dealer 1B-3 . . . . . . . . . . . . . . . Specifications 1B-5 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specification 1B-5 . . . . . . . . . . . . . . . . Quicksilver Maintenance Products 1B-5 . . . . Fluid Capacities 1B-5 . . . . . . . . . . . . . . . . . . . . Lubricating Shift Cable Pivot Points 1B-6 . . . . . Lubricating Propeller Shaft 1B-6 . . . . . . . . . . . . . Lubricating Steering System 1B-6 . . . . . . . . . . . . Lubricating Tie Bar Pivot Points 1B-7 . . . . . . . . . Models With Control Valve Mounted On Starboard Transom Assembly 1B-7 . . . . . . . Models With Control Valve Mounted On Port Transom Assembly 1B-7 . . . . . . . . . . . . Lubricating Transom Gimbal Housing Assembly Swivel Shaft and Gimbal Bearing 1B-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and Adding Sterndrive Oil 1B-8 . . . . . Models Without Drive Unit Gear Lube Monitor 1B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . Models With Gear Lube Monitor 1B-9 . . . . . . Checking Lubricant for Water 1B-10 . . . . . . . Changing Lubricant 1B-12 . . . . . . . . . . . . . . . . General Maintenance 1B-14 . . . . . . . . . . . . . . . . . Maintaining Power Package Exterior Surfaces 1B-14 . . . . . . . . . . . . . . . . . . . . . . . . . Steering Head and Remote Control Maintenance 1B-14 . . . . . . . . . . . . . . . . . . . . . Checking Quicksilver MerCathode System 1B-14 . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining Anodic Trim Tab or Plate 1B-14 . Checking Optional Quicksilver Anti-Corrosion Anode Kit 1B-15 . . . . . . . . . . . Boat Bottom Care 1B-15 . . . . . . . . . . . . . . . . . Antifouling Paint 1B-15 . . . . . . . . . . . . . . . . . . . Maintaining Ground Circuit Continuity 1B-15 Power Package Layup (Out of Season Storage) 1B-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 1B-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive 1B-16 . . . . . . . . . . . . . . . . . . . . . . . . Power Package Recommissioning 1B-16 . . . . . Engine 1B-16 . . . . . . . . . . . . . . . . . . . . . . . . . . . Sterndrive 1B-16 . . . . . . . . . . . . . . . . . . . . . . . . Section 1C - Troubleshooting Sterndrive Unit Troubleshooting 1C-2 . . . . . . . . . Sterndrive Unit Will Not Slide Into Bell Housing 1C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Moves 1C-2 . . Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Does Not Move 1C-3 . . . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Shifts Hard 1C-3 . . . . . . . . . . . . . . . Drive Unit In Gear, Will Not Shift Out Of Gear 1C-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Noise 1C-4 . . . . . . . . . . . . . . . . Drive Shaft Housing Noise 1C-4 . . . . . . . . . . . Bravo Power Shift 1C-7 . . . . . . . . . . . . . . . . . . . . . System Does Not React 1C-7 . . . . . . . . . . . . . System Binds 1C-7 . . . . . . . . . . . . . . . . . . . . . . Performance Troubleshooting 1C-8 . . . . . . . . . . . Low Full-Throttle Engine RPM 1C-8 . . . . . . . . High Full-Throttle Engine RPM 1C-8 . . . . . . . Propeller Ventilating/Cavitating 1C-8 . . . . . . . Poor Boat Performance And/Or Poor Maneuverability-Bow Too Low 1C-9 . . . . . . . Poor Boat Performance And/Or Poor Maneuverability-Bow Too High 1C-9 . . . . . . . Power Steering 1C-10 . . . . . . . . . . . . . . . . . . . . . . Hard Steering - RideGuide Steering System 1C-10 . . . . . . . . . . . . . . . . . . . . . . . . . . Hard Steering (Engine Running) - Power Steering System 1C-10 . . . . . . . . . . . . Power Steering System External Fluid Leaks 1C-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Trim Electrical System 1C-11 . . . . . . . . . . Power Trim System Wiring Diagram 1C-15 . . . . Power Trim Hydraulic System 1C-16 . . . . . . . . . . Power Trim Hydraulic Schematic 1C-19 . . . . . . . Auto Trim Electrical System 1C-20 . . . . . . . . . . . Auto Trim II System Wiring Diagram 1C-26 . . . . Corrosion Protection 1C-27 . . . . . . . . . . . . . . . . . .

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 90-17431--4 MARCH 1998 Page v REMOVAL, INSTALLATION AND ADJUSTMENTS Section 2A - All Models Installation Specifications 2A-2 . . . . . . . . . . . . . . Torque Specifications 2A-2 . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 2A-2 . . . . . . . . Special Tools 2A-2 . . . . . . . . . . . . . . . . . . . . . . . Transom Specifications 2A-3 . . . . . . . . . . . . . . Checking Transom Thickness 2A-3 . . . . . . . . Special Information 2A-4 . . . . . . . . . . . . . . . . . . . . Bravo Three Notice: Trim-In Limit Blocks or Limit Spacer 2A-4 . . . . . . . . . . . . . . Sterndrive Unit Removal 2A-6 . . . . . . . . . . . . . . . Transom Assembly Removal 2A-8 . . . . . . . . . . . Transom Assembly Installation 2A-15 . . . . . . . . . Sterndrive Unit Installation 2A-27 . . . . . . . . . . . . Shift Cable Installation and Adjustment 2A-34 . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting Shift Problems 2A-38 . . . . . STERNDRIVE UNIT Section 3A - Drive Shaft Housing Specifications 3A-2 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 3A-2 . . . . . . . . . . . . . . . Special Tools 3A-2 . . . . . . . . . . . . . . . . . . . . . . . Bearing Preloads 3A-2 . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3A-3 . . . . . . . . Drive Shaft Housing Exploded View 3A-4 . . . . . Complete Housing 3A-4 . . . . . . . . . . . . . . . . . . Exploded Parts View (Clutch) 3A-6 . . . . . . . . . . . Exploded Parts View (Shifter) 3A-7 . . . . . . . . . . . U-Joint Assembly 3A-8 . . . . . . . . . . . . . . . . . . . Drive Shaft Housing and Gear Case Separation 3A-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Unit Gear Ratio Identification 3A-9 . . . Bravo One 3A-9 . . . . . . . . . . . . . . . . . . . . . . . . . U-Joint Identification 3A-9 . . . . . . . . . . . . . . Number Of Teeth Per Gear - Drive Shaft Housing 3A-9 . . . . . . . . . . . . . Bravo Two 3A-9 . . . . . . . . . . . . . . . . . . . . . . . . . U-Joint Identification 3A-9 . . . . . . . . . . . . . . Number Of Teeth Per Gear - Drive Shaft Housing 3A-10 . . . . . . . . . . . . Bravo Three 3A-10 . . . . . . . . . . . . . . . . . . . . . . U-Joint Identification 3A-10 . . . . . . . . . . . . . Number Of Teeth Per Gear - Drive Shaft Housing 3A-10 . . . . . . . . . . . . Bravo Drive/Unit Housing Comparison and Identification 3A-10 . . . . . . . . . . . . . . . . . . Changes 3A-10 . . . . . . . . . . . . . . . . . . . . . . . Identification 3A-11 . . . . . . . . . . . . . . . . . . . Drive Shaft Housing 3A-11 . . . . . . . . . . . . . Gear Housing 3A-11 . . . . . . . . . . . . . . . . . . Separate Housings 3A-17 . . . . . . . . . . . . . . . . Special Information - Latest Changes to Gear Assembly, Cone Clutch and Shifter Assembly 3A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear, Clutch and Shifter Kits 3A-20 . . . . . . . . Cone Clutch and Cam Kit 3A-22 . . . . . . . . . . . Yoke and Cam Kit 3A-23 . . . . . . . . . . . . . . . . . Drive Shaft Housing Disassembly 3A-25 . . . . . . Shifter Repair 3A-29 . . . . . . . . . . . . . . . . . . . . . . . . Shifter Inspection 3A-31 . . . . . . . . . . . . . . . . . . . . Shifter Reassembly 3A-32 . . . . . . . . . . . . . . . . . . . U-Joint and Pinion Gear Inspection, Disassembly and Reassembly 3A-36 . . . . . . . . . Inspection 3A-36 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 3A-37 . . . . . . . . . . . . . . . . . . . . . . Reassembly 3A-39 . . . . . . . . . . . . . . . . . . . . . . Clutch Disassembly, Inspection and Reassembly 3A-43 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 3A-43 . . . . . . . . . . . . . . . . . . . . . . Inspection 3A-46 . . . . . . . . . . . . . . . . . . . . . . . . Reassembly 3A-46 . . . . . . . . . . . . . . . . . . . . . . Drive Shaft Housing and Top Cover - Bearings and Bearing Sleeves 3A-49 . . . . . . . . Inspection 3A-49 . . . . . . . . . . . . . . . . . . . . . . . . Bearing Sleeve Removal (Top Cover) 3A-49 Bearing Sleeve Removal (Drive Shaft Housing) 3A-50 . . . . . . . . . . . . . . . . . . . . . . . . . Roller Bearing Removal 3A-51 . . . . . . . . . . . . Bearing Sleeve Installation 3A-52 . . . . . . . . . Roller Bearing Installation 3A-53 . . . . . . . . . . Drive Shaft Housing Reassembly 3A-54 . . . . . . Torque Conversion Chart For U-joint Retainer 3A-57 . . . . . . . . . . . . . . . . Torquing Bravo U-joint Bearing Retainer Nut 3A-57 . . . . . . . . . . . . . . . . . . .

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 Page vi 90-17431--4 MARCH 1998 Section 3B - Bravo One Gear Housing Specifications 3B-2 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 3B-2 . . . . . . . . . . . . . . . Preloads 3B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3B-2 . . . . . . . . Special Tools 3B-3 . . . . . . . . . . . . . . . . . . . . . . . Gear Ratio - Teeth per Gear (Gear Housing) 3B-3 . . . . . . . . . . . . . . . . . . . . . . . . . . Bravo One Gear Housing Exploded View 3B-4 Drive Shaft Components 3B-4 . . . . . . . . . . . . Propeller Shaft Components 3B-6 . . . . . . . . . Pre-Disassembly Inspection 3B-8 . . . . . . . . . . . . Drive Shaft Housing and Gear Housing Separation 3B-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Disassembly 3B-10 . . . . . . . . . . . . Component Servicing 3B-15 . . . . . . . . . . . . . . . . . Drive Shaft and Pinion Bearing Inspection and Cleaning 3B-15 . . . . . . . . . . . Drive Shaft Disassembly 3B-15 . . . . . . . . . . . . Pinion Bearing Removal 3B-16 . . . . . . . . . . . . Pinion Bearing Installation 3B-17 . . . . . . . . . . Drive Shaft Reassembly 3B-18 . . . . . . . . . . . . Bearing Carrier Inspection 3B-19 . . . . . . . . . . Bearing Carrier Servicing 3B-19 . . . . . . . . . . . Propeller Shaft Inspection 3B-21 . . . . . . . . . . Propeller Shaft Bearing Removal 3B-21 . . . . Propeller Shaft Bearing Installation 3B-22 . . Driven Gear Bearing Removal and Inspection 3B-22 . . . . . . . . . . . . . . . . . . . . . . . . Driven Gear Bearing Removal 3B-22 . . . . . . . Driven Gear Bearing Installation 3B-23 . . . . . Driven Gear Bearing Cup Removal and Inspection 3B-23 . . . . . . . . . . . . . . . . . . . . Driven Gear Bearing Cup Installation 3B-24 . Speedometer Water Tube Pickup Inspection and Cleaning 3B-24 . . . . . . . . . . . Speedometer Water Tube Seal Replacement 3B-25 . . . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly and Shimming 3B-26 . Driven Gear Shimming for Models with Shims 3B-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . Driven Gear Shimming for Models with Load Ring 3B-37 . . . . . . . . . . . . . . . . . . . . . . . . Section 3C - Bravo Two Gear Housing Specifications 3C-2 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 3C-2 . . . . . . . . . . . . . . . Preloads 3C-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3C-2 . . . . . . . . Special Tools 3C-3 . . . . . . . . . . . . . . . . . . . . . . . Gear Ratio - Teeth per Gear (Gear Housing) 3C-3 . . . . . . . . . . . . . . . . . . . . Bravo Two Gear Housing Exploded View 3C-4 . . Drive Shaft and Propeller Shaft Components 3C-4 . . . . . . . . . . . . . . . . . . . . . . Pre-Disassembly Inspection 3C-6 . . . . . . . . . . . . Drive Shaft Housing and Gear Housing Separation 3C-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear Housing Disassembly 3C-8 . . . . . . . . . . . . . Component Servicing 3C-13 . . . . . . . . . . . . . . . . . Drive Shaft and Pinion Bearing Inspection and Cleaning 3C-13 . . . . . . . . . . . Drive Shaft Disassembly 3C-13 . . . . . . . . . . . . Pinion Bearing Removal 3C-14 . . . . . . . . . . . . Pinion Bearing Installation 3C-15 . . . . . . . . . . Drive Shaft Reassembly 3C-16 . . . . . . . . . . . . Bearing Carrier Inspection 3C-17 . . . . . . . . . . Bearing Carrier Servicing 3C-18 . . . . . . . . . . . Propeller Shaft Inspection 3C-20 . . . . . . . . . . Propeller Shaft Bearing Removal 3C-21 . . . . Propeller Shaft Bearing Installation 3C-22 . . Driven Gear Bearing Removal and Inspection 3C-22 . . . . . . . . . . . . . . . . . . . . . . . . Driven Gear Bearing Installation 3C-23 . . . . . Driven Gear Bearing Cup Removal and Inspection 3C-23 . . . . . . . . . . . . . . . . . . . . Driven Gear Bearing Cup Installation 3C-24 . . Speedometer Water Tube Pickup Inspection and Cleaning 3C-24 . . . . . . . . . . . Speedometer Water Tube Seal Replacement 3C-25 . . . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly and Shimming 3C-25 . . . . . . . . . . . . . . . . . . . . . . . . . . .

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 90-17431--4 MARCH 1998 Page vii Section 3D - Bravo Three Gear Housing Specifications 3D-2 . . . . . . . . . . . . . . . . . . . . . . . . . Torque Specifications 3D-2 . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 3D-2 . . . . . . . . Bearing Preloads 3D-2 . . . . . . . . . . . . . . . . . . . Gear Ratio - Teeth per Gear (Gear Housing) 3D-3 . . . . . . . . . . . . . . . . . . . . Special Tools 3D-3 . . . . . . . . . . . . . . . . . . . . . . . Torquing Outer Prop Shaft Bearing Retainer and Bearing Carrier 3D-5 . . . . . . . . Bravo Three Gear Housing Exploded View 3D-6 Drive Shaft and Propeller Shaft Components 3D-6 . . . . . . . . . . . . . . . . . . . . . . Pre-Disassembly Inspection 3D-8 . . . . . . . . . . . . Gear Housing Disassembly 3D-9 . . . . . . . . . . . . . Component Servicing 3D-13 . . . . . . . . . . . . . . . . . Drive Shaft and Pinion Bearing Inspection and Cleaning 3D-13 . . . . . . . . . . . Drive Shaft Disassembly 3D-14 . . . . . . . . . . . . Pinion Bearing Removal 3D-14 . . . . . . . . . . . . Pinion Bearing Installation 3D-15 . . . . . . . . . . Drive Shaft Reassembly 3D-16 . . . . . . . . . . . . Propeller Shaft Disassembly 3D-17 . . . . . . . . Bearing Carrier Inspection 3D-18 . . . . . . . . . . Bearing Carrier Servicing 3D-18 . . . . . . . . . . . Propeller Shaft Inspection 3D-19 . . . . . . . . . . Outer Propeller Shaft Servicing 3D-19 . . . . . . Front and Rear Driven Gear and Bearing Inspection 3D-20 . . . . . . . . . . . . . . . . Front and Rear Driven Gear Bearing Replacement 3D-21 . . . . . . . . . . . . . . . . . . . . . Front Driven Gear Bearing Cup Removal and Inspection 3D-21 . . . . . . . . . . . Propeller Shaft Spline Lash Check 3D-22 . . . Front Driven Gear Bearing Cup Installation 3D-23 . . . . . . . . . . . . . . . . . . . . . . . Speedometer Water Tube Pickup Inspection and Cleaning 3D-23 . . . . . . . . . . . Speedometer Water Tube Seal Replacement 3D-24 . . . . . . . . . . . . . . . . . . . . . Gear Housing Reassembly and Shimming 3D-24 . Checking Backlash 3D-31 . . . . . . . . . . . . . . . . Installing Gear Housing On Drive Shaft Housing 3D-36 . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Installation 3D-38 . . . . . . . . . . . . . . . . . . TRANSOM ASSEMBLY Section 4A - Service Procedures Requiring Minor Disassembly Bravo Transom Assembly Specifications 4A-2 . Torque Specifications 4A-2 . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 4A-2 . . . . . . . . Special Tools 4A-2 . . . . . . . . . . . . . . . . . . . . . . . Bravo Transom Assembly Exploded Views 4A-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inner Transom Plate Components 4A-3 . . . . Bell Housing Components 4A-4 . . . . . . . . . . . Gimbal Ring Components 4A-5 . . . . . . . . . . . Gimbal Housing Components 4A-7 . . . . . . . . Special Information 4A-9 . . . . . . . . . . . . . . . . . . . . Trim Limit Switch 4A-9 . . . . . . . . . . . . . . . . . . . Trim Position Sender 4A-9 . . . . . . . . . . . . . . . . Removal 4A-10 . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A-12 . . . . . . . . . . . . . . . . . . . . . . . . Trim Limit Switch Adjustment 4A-16 . . . . . . . . High Performance Transom Assembly - Without Electrical Trim Sender and Trim Limit Switch 4A-17 . . . . . . . . . . . . . . . . . . Gimbal Bearing 4A-17 . . . . . . . . . . . . . . . . . . . . . . Inspection 4A-17 . . . . . . . . . . . . . . . . . . . . . . . . Removal 4A-18 . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A-19 . . . . . . . . . . . . . . . . . . . . . . . . Shift Cable 4A-20 . . . . . . . . . . . . . . . . . . . . . . . . . . Removal 4A-20 . . . . . . . . . . . . . . . . . . . . . . . . . Shift Cable Installation 4A-22 . . . . . . . . . . . . . Replacing Earlier Model Shift Cables with Later Model Shift Cables 4A-26 . . . . . . . Exhaust Bellows (If Equipped) 4A-28 . . . . . . . . . Removal 4A-28 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 4A-29 . . . . . . . . . . . . Installation 4A-29 . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Tube (If Equipped) 4A-31 . . . . . . . . . . . Removal 4A-31 . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Inspection 4A-31 . . . . . . . . . . . . Installation 4A-32 . . . . . . . . . . . . . . . . . . . . . . . . Water Hose and Water Fitting 4A-33 . . . . . . . . . . Removal 4A-33 . . . . . . . . . . . . . . . . . . . . . . . . . Installation 4A-34 . . . . . . . . . . . . . . . . . . . . . . . .

BRAVO STERNDRIVES SERVICE MANUAL NUMBER 11 Page viii 90-17431--4 MARCH 1998 Section 4B - Service Procedures Requiring Major Disassembly Bravo Transom Assembly Specifications 4B-2 . Torque Specifications 4B-2 . . . . . . . . . . . . . . . Lubricants/Sealers/Adhesives 4B-2 . . . . . . . . Special Tools 4B-2 . . . . . . . . . . . . . . . . . . . . . . . Bravo Transom Assembly Exploded Views 4B-4 Inner Transom Plate Components 4B-4 . . . . Bell Housing Components 4B-5 . . . . . . . . . . . Gimbal Ring Components 4B-6 . . . . . . . . . . . Gimbal Housing Components 4B-8 . . . . . . . . Bell Housing Removal 4B-10 . . . . . . . . . . . . . . . . Access Plug Kit Installation 4B-15 . . . . . . . . . . . . Gimbal Ring, Swivel Shaft and Steering Lever Removal 4B-17 . . . . . . . . . . . . . . . . . . . Gimbal Ring Servicing 4B-20 . . . . . . . . . . . . . . Gimbal Housing Servicing 4B-26 . . . . . . . . . . . . . U-joint Bellows Replacement 4B-26 . . . . . . . . Shift Cable Bellows Replacement 4B-28 . . . . Exhaust Bellows Replacement 4B-32 . . . . . . Speedometer Hose Replacement 4B-34 . . . . Gear Lube Monitor System Components 4B-36 . . . . . . . . . . . . . . . . . . . . Trim Position Sender and Trim Limit Switch Wire Replacement 4B-39 . . . . . . . . . . Gimbal Ring/Swivel Shaft/and Steering Lever Installation 4B-40 . . . . . . . . . . . . . . . . . . . . Bell Housing Installation 4B-46 . . . . . . . . . . . . . . Shift Cable Installation 4B-52 . . . . . . . . . . . . . . . . Bravo Access Plug Drilling Template 4B-56 . . . . POWER TRIM Section 5A - Oildyne Trim Pump Trim Pump Specifications 5A-2 . . . . . . . . . . . . . . Valve Pressure Specifications 5A-2 . . . . . . . . Electrical Specification 5A-2 . . . . . . . . . . . . . . Torque Specification 5A-2 . . . . . . . . . . . . . . . . Special Tools 5A-2 . . . . . . . . . . . . . . . . . . . . . . . Lubricants/Adhesives/Sealers 5A-2 . . . . . . . . Trim Pump Exploded View 5A-3 . . . . . . . . . . . . . Oildyne Trim Pump 5A-3 . . . . . . . . . . . . . . . . . Maintaining Power Trim Pump Oil Level 5A-4 . . Air Bleeding Power Trim System 5A-5 . . . . . . . . Bleeding OUT/UP Trim Circuit 5A-5 . . . . . . . . Bleeding IN/DOWN Trim Circuit 5A-6 . . . . . . Testing Power Trim Pump 5A-7 . . . . . . . . . . . . . . Test Gauge 5A-7 . . . . . . . . . . . . . . . . . . . . . . . . Internal Restriction Test 5A-8 . . . . . . . . . . . . . OUT/UP Pressure Test 5A-8 . . . . . . . . . . . . . . IN/DOWN Pressure Test 5A-10 . . . . . . . . . . . . Trim Pump Hydraulic System 5A-11 . . . . . . . . Trim Cylinder Internal Leak Test 5A-12 . . . . . . . . Trim Cylinder Shock Piston Test 5A-14 . . . . . Motor and Electrical Bench Tests 5A-15 . . . . . . . Trim Pump Motor Test (In Boat) 5A-15 . . . . . Trim Pump Motor Test (Out of Boat) 5A-16 . . Solenoid Test (Pump In Boat) 5A-17 . . . . . . . Solenoid Test (Pump Out of Boat) 5A-18 . . . 110 Amp Fuse Test (Pump in Boat) 5A-20 . . 110 Amp Fuse Test (Pump Out of Boat) 5A-21 . . . . . . . . . . . . . . . 20 Amp Fuse Test 5A-21 . . . . . . . . . . . . . . . . . Trim Pump Removal 5A-22 . . . . . . . . . . . . . . . . . . Hydraulic Repair 5A-23 . . . . . . . . . . . . . . . . . . . . . Disassembly 5A-23 . . . . . . . . . . . . . . . . . . . . . . Filter Replacement 5A-24 . . . . . . . . . . . . . . . . . UP Pressure Relief Valve Replacement 5A-25 . . . . . . . . . . . . . . . . . . . . . DOWN Pressure Relief Valve Replacement 5A-26 . . . . . . . . . . . . . . . . . . . . . Thermal Relief Valve Replacement 5A-27 . . Pump Replacement 5A-28 . . . . . . . . . . . . . . . . Adapter Replacement 5A-29 . . . . . . . . . . . . . . Adapter Repair 5A-30 . . . . . . . . . . . . . . . . . . . . Pump Shaft Oil Seal Replacement 5A-33 . . . Motor Repair 5A-35 . . . . . . . . . . . . . . . . . . . . . . . . Disassembly 5A-35 . . . . . . . . . . . . . . . . . . . . . . Armature Tests 5A-38 . . . . . . . . . . . . . . . . . . . . . . Continuity Test 5A-38 . . . . . . . . . . . . . . . . . . . . Test for Shorts 5A-39 . . . . . . . . . . . . . . . . . . . . Cleaning Commutator 5A-39 . . . . . . . . . . . . . . Field Tests 5A-39 . . . . . . . . . . . . . . . . . . . . . . . . . . Test for Open Circuit 5A-39 . . . . . . . . . . . . . . . Test for Short in Field 5A-40 . . . . . . . . . . . . . . Thermal Switch Continuity Test 5A-41 . . . . . . Brush Replacement 5A-42 . . . . . . . . . . . . . . . . Reassembly 5A-44 . . . . . . . . . . . . . . . . . . . . . . . . . Trim Pump Installation 5A-50 . . . . . . . . . . . . . . . . Trim Pump Wiring Diagrams 5A-51 . . . . . . . . . . . Model With Three-Button Trim/Trailer Panel 5A-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model With Trim In Handle and Trailer Switch Separate 5A-52 . . . . . . . . . . . . . . . . . .

1988-1998 Mercruiser Bravo I II III Outdrives Sterndrives Service & Repair Manual

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