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Mercury 3.0L Carbureted Alpha, Installation Manual

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Mercury 3.0L Carbureted Alpha Installation Manual Download Page 43

GASOLINE STERNDRIVE INSTALLATION MANUAL

90-860172011

Page 43 of 137

Exhaust System

CAUTION

It is the responsibility of the boat manufacturer or installing dealer to properly lo-
cate the engine and install the exhaust system. Improper installation may allow wa-
ter to enter the exhaust manifolds and combustion chambers and severely damage
the engine. Damaged caused by the water in the engine will not be covered by Mer-
cury MerCruiser Warranty, unless this damage is the result of defective parts.

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.

77981

a

b

Using A Universal Protractor (Inclinometer) To Measure Slope

a -

Protractor

b -

Exhaust Hose Or Tube

Summary of Contents for 3.0L Carbureted Alpha

Page 1: ...ision Parts GASOLINE ENGINE STERNDRIVE MODELS INSTALLATION MANUAL Models Covered Alpha Model Serial Number or Year 3 0L 4 3L 5 0L 0M093621 and Above 5 7L Bravo Model Serial Number or Year 4 3L 5 0L 0M093633 and Above 5 7L Notice NOTICE After completing installation these instructions should be placed with the product for the owner s future use NOTICE Predelivery preparation instructions must be pe...

Page 2: ...rning System Connections 58 Power Trim Pump Connections 59 Fluid Connections 61 Gear Lube Monitor Hose 61 Power Steering Hoses 62 Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water Pickups 62 Alpha or Bravo Models Using Alternative Water Pickups 63 Coolant Recovery System 66 Shift Cable Installation 67 Alpha Models Drive Unit Not Installed 67 Bravo Models 72 Throttle Cable Instal...

Page 3: ...en and published by Mercury Marine to aid the boat manufacturer OEM in the installation of the products described herein It is assumed that these personnel are familiar with marine product installation Furthermore it is assumed that they are familiar with if not trained in the recommended installation procedures of Mercury MerCruiser product We could not possibly know of or advise the marine trade...

Page 4: ...raulic Hose Fittings 31 23 Power Trim Pump Hose Fittings 14 125 Propeller Nut Alpha One Bravo One and Bravo Two1 75 55 Front Propeller Nut Bravo Three 136 100 Rear Propeller Nut Bravo Three 81 60 Rear Engine Mounts 51 38 Steering Cable Coupler Nut 48 35 Steering System Pivot Bolts 34 25 Sterndrive Unit Fasteners 68 50 Transom Assembly Fasteners 31 23 Seawater Pickup Fitting 5 45 Fuel Inlet Fitting...

Page 5: ...ng Pump Obtain Locally Power Steering Pump Power Trim and Steering Fluid Power Trim Pump 92 90100A12 Battery Terminals Liquid Neoprene MerCathode Connections 92 25711 2 Speedometer Barb Fitting Fuel Inlet Fitting Loctite 592 PST Seawater Inlet Hose Fitting Threads Obtain Locally Seawater Inlet Plastic Plug Threads Loctite 271 Seawater Inlet Nut 92 809820 Power Trim Pump SAE 30W Engine Oil Shift Ca...

Page 6: ...water tested to ensure that the increased trim in range does not cause any undesired boat handling characteristics bow steer chine walk etc if the sterndrive is trimmed in while the boat is operated at higher speeds The boat should be tested under all conceivable load conditions and maneuvers to ensure that the additional trim in does not pose a problem The final decision and responsibility for us...

Page 7: ...n Limit 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 Insert and its effectiveness can only be determined through boat testing and is ultimately the responsibility of the boat manufacturer WARNING It is r...

Page 8: ...ome 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 Mercury Precision Parts Quicksilver Accessories Guide for part numbers Boats which are connected to AC shore power require additional protection to prevent destructive low voltage galvan...

Page 9: ...oat 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 40 mm UNPAINTED area on transom of the boat around these items 71176 a b a Painted ...

Page 10: ...terline Parallelism Inner and outer surfaces must be parallel within 1 8 in 3 mm Flatness 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 Angle 10 16 Degrees 22170 c a b e d d 72700 a Transom Thickness b Inner Surface c Outer Surface d Transom Plate Coverage...

Page 11: ...ight rear mount location and another from right front to left rear The strings should touch where they cross Crankshaft Vertical Centerline 1 Locate and mark boat vertical centerline on transom 71620 a a Vertical Centerline 2 For Dual Engines Locate and mark crankshaft vertical centerlines a on transom 22033 b a a c c a Crankshaft Vertical Centerline b Minimum Distance Between Crankshaft Vertical ...

Page 12: ...t 1 2 m To Lower Drive Unit Subtract from dimension a To Raise Drive Unit Add to dimension a IMPORTANT This dimension should only be raised or lowered after proper testing 71622 71623 Single Engine Dual Engine 2 Place 90 degree tool along boat bottom at vertical centerline 3 Locate the point at which top of tool contacts transom on vertical centerline This is the crankshaft horizontal centerline o...

Page 13: ... or lowered after proper testing 16 14 5 16 in 364 mm 15 14 1 4 in 362 mm 14 14 3 16 in 360 mm 13 14 1 8 in 359 mm 12 14 1 16 in 357 mm 11 14 in 356 mm 10 13 15 16 in 354 mm 2 Measure up from the boat bottom the amount shown on the chart for the appropriate transom angle 71622 71623 Single Engine Dual Engine 3 Draw a line perpendicular to vertical centerline at crankshaft horizontal centerline ...

Page 14: ...ng testing X Dimension should be increased 1 2 in 13 mm at a time until desired performance is achieved but in no case should it ever be increased by more than Maximum Increase In X Dimension Alpha 2 1 2 in 64 mm Bravo One and Two 3 in 76 mm Bravo Three 1 in 25 mm Extreme care should be taken when raising drive unit to ensure that water supply does not become aerated Use clear water inlet hose to ...

Page 15: ...enterlines on either the template or transom drilling fixture align with lines previously marked on transom 8 Drill 1 4 in 6 mm pilot holes for hole saw guide at a 60 degree angle and cut on the line when making transom cutout If cutout is made incorrectly drive unit steering lever may contact transom thus limiting steering travel 9 Seal inside edge of transom cutout opening with a suitable sealan...

Page 16: ...ng sealer to mounting surface on seawater pickup where hull contact will occur when installed IMPORTANT Seawater inlet slots must face forward parallel with the flow of water 3 Ensure slots in seawater pickup are facing forward toward bow of boat and install seawater pickup through hull 4 Fasten pickup with four appropriate mounting screws if so designed 72639 a b c d A a Seawater Pickup b Seawate...

Page 17: ...rew Shaft NOTE Use a sharp knife or wood chisel to remove excess plastic plug material so that plug is flush with pickup casting 3 Position one flat washer and one rubber O ring on each 5 16 in x 4 in 102 mm long round head screw Coat each screw shaft with sealant 4 Place new gasket on pickup housing and hold pickup in place on transom Install four round head screws with washers and O rings in pla...

Page 18: ... unless using lag bolts 6 Tighten fasteners securely Preliminary Connections Power Trim Pump 1 Select an appropriate mounting location for the trim pump that Is within length limits of black and gray hydraulic hoses coming from gimbal housing assembly Is close to the battery so that trim pump battery leads can be connected Allows easy access to trim pump oil fill and vent locations Is in an area w...

Page 19: ...itable wrench as fuel inlet fittings are tightened securely WARNING Boating standards NMMA ABYC and others and Coast Guard regulations must be adhered to when installing fuel delivery system WARNING Avoid gasoline fire or explosion Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and or cause a fuel leak 1 Remove plastic plug from fuel inlet hol...

Page 20: ...ilters 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 Transom Connections Installing Gimbal Housing 1 Carefully remove transom assembly from shipping carton 2 Remove and read all tags attached to transom assembly 22027 b a a Dust Cover b Shipping Hardware 3 Remove ...

Page 21: ...from the middle fasteners 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 the hardware Description Nm lb in lb ft Transom Assembly Hardware 31 23 4 Attach continuity wires IMPORTANT Steering lever continuity circuit wire must be positioned as shown to avoid stressing wire when steering l...

Page 22: ...m lb in lb ft J Clip Fasteners 5 45 Connecting Speedometer Pickup CAUTION Excess water in bilge can damage engine or cause boat to sink Do not remove plug from speedometer pickup tube fitting unless connection is to be utilized 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 70037 a b...

Page 23: ... and screw that are provided in the parts bag NOTE The hose must not come into contact with the steering system components or the engine coupler and drive shaft Fluid Connections 1 Connect the gear lube monitor hose to the quick release 90 degree fitting CAUTION Avoid sterndrive unit damage Quick release button on gear lube monitor 90 degree hose fitting may not lock on gimbal housing if touching ...

Page 24: ...ithin limits of clear plastic tubing Level with or above the heat exchanger fill neck Accessible for observing coolant level and filling 4 Mount coolant recovery bottle and mounting bracket in desired location using two 3 4 in 19 mm long screws and flat washers 5 Route plastic tubing to recovery bottle Ensure that tubing is positioned away from any moving parts Cut plastic tubing as required and c...

Page 25: ... can be mounted on port or starboard transom assembly Measure exact distance between power package centerlines Select a tie bar from Mercury Precision Parts Quicksilver Accessory Guide Refer to tie bar installation instructions before proceeding 1 Inspect the bushings for debris Lubricate the bushings 73898 a A b a Bushings b Shipping Hardware Description Where Used Part Number A Special Lubricant...

Page 26: ...b 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 6 Torque pivot bolts Bend tab washer tangs against corresponding flats on bolt heads 73900 73899 b c a a c a Tab Washers b Ridge c Pivot Bolts Description Nm lb in lb ft Pivot Bolts 34 25 NOTE It may be necess...

Page 27: ...pull it out or push it in for installation Move the assembly in the directions shown below 74145 74144 a a a Control Valve Ports 8 Connect clevis to steering lever Lubricate clevis pin Be sure to spread both ends of cotter pin NOTE Make sure to insert clevis pin from the top to ensure that cotter pin hole is as shown in the diagram 71904 a b c d a Clevis b Steering Lever c Clevis Pin d Cotter Pin ...

Page 28: ... be free to move back and forth for steering system to function properly Do not fasten any items to steering cable 9 Coat steering cable end with a liberal amount of lubricant 10 Install steering cable and secure with hardware 71901 71906 73901 71903 e f h g d c b a d A 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 ...

Page 29: ...sing a suitable wrench hold the flat surfaces on the cable guide tube in the vertical posi tion Torque coupler nut Be certain the flat surfaces are still aligned vertically after torque is applied to coupler nut Description Nm lb in lb ft Coupler Nut 47 35 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 ste...

Page 30: ... locking requirements 4 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 asse...

Page 31: ...nder 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 74145 74144 a a a Control Valve Ports IMPORTANT Newer style Quicksilver Ride Guide steering cable has a self locking coupler nut and does not require an external locking sleeve or locking plate 22060 a a Self Locking Coupler Nut ...

Page 32: ...cant 101 c Install steering cable and secure with hardware as shown on following pages NOTICE to INSTALLER Refer to Installation Requirements Steering Helm and Cable for steering cable selection and coupler nut locking requirements IMPORTANT Slight feedback in the steering system could be encountered if the cable guide tube flat surfaces are not positioned vertically 50627 70018 50926 a b c d e f ...

Page 33: ...turers also make cables with self locking coupler nut 22060 a a Quicksilver RideGuide 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 such as a locking sleeve must be used b a Example Of External Locking Device a Steering Cable b Locking Sleeve CAUTION If steering cable with im...

Page 34: ... mm Minimum Flat f 7 64 in 3 1 mm Minimum Radius g 5 8 in 15 9 mm Maximum 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 Minimum to 9 in 228 mm Maximum Travel Each Side of Mid Travel Position 4 in 102 mm Minimum to ...

Page 35: ...atches and O ring must be properly seated in groove or water and exhaust may leak into boat 22059 b a a Gimbal Housing Mating Surface b O ring 1 Ensure mating surfaces are clean and o ring is properly seated 2 Loosen hose clamps and remove exhaust pipe and bellows from engine 75819 74768 a b c c d b a b c d 3 0L Model V6 and V8 Models a Exhaust Pipe b Bellows c Clamps d Shipping Plug ...

Page 36: ...ue bolts 50684 b a a Exhaust Pipe b Bolts And Lockwashers 4 Description Nm lb in lb ft Bolts 31 23 4 Through the Transom Exhaust Models Install block off plate as shown using four bolts and lockwashers Torque bolts 22057 b a a Bolts And Lockwashers 4 b Block Off Plate Description Nm lb in lb ft Bolts 31 23 NOTE Through the Transom exhaust fittings can be installed at this time ...

Page 37: ...0172011 Page 37 of 137 5 Position rear engine mount attaching hardware on inner transom plate mounts as shown 22054 a 50634 a b 3 0L Models a Exhaust Pipe b Bolts and Lockwashers 4 50628 c b a a Fiber Washers b Double Wound Lockwashers c Locknuts ...

Page 38: ... BE INSTALLED for a slight increase in performance 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 2 If required install exhaust tube on gimbal ho...

Page 39: ...ion b After battery cables are connected apply a thin coat of sealant to the terminals Description Where Used Part Number A Liquid Neoprene Battery Terminals 92 25711 2 c Be sure to slide rubber boot over positive terminal after making connection 5 Drape battery cables over top of engine to prevent interference during installation IMPORTANT There is a fuse located at the starter solenoid DO NOT re...

Page 40: ...ling to lifting eyes on engine and adjust so that engine is level when suspended CAUTION Center lifting eye on top of thermostat housing is used for engine alignment only Do not use to lift entire engine 50636 50626 50632 CAUTION b b a 3 0L Models a Center Lifting Eye b Engine Lifting Eyes 74498 CAUTION 74760 74754 a b b V6 and V8 Models a Center Lifting Eye b Engine Lifting Eyes 3 Loosen the engi...

Page 41: ...ow c Exhaust Tube Description Where Used Part Number A Power Tune Exhaust Tubes 92 802878 57 7 If equipped with quick drain oil a Push end of oil drain hose out of boat hull through flange b Pull oil drain hose out until it is 6 in 152 mm from the propeller c Move alignment clip on the oil drain hose and squeeze to position it on the hose just inside of the boat hull against the flange d Connect b...

Page 42: ...ar engine mounting bolts and hardware and torque Do not relieve hoist tension 72535 a f b g e d c a Rear Engine Mount b Inner Transom Plate Mount c Bolt d Washer e Spacer f Fiber Washer g Double Wound Lockwasher Description Nm lb in lb ft Rear Engine Mounting Bolts 51 38 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 d...

Page 43: ...amage is the result of defective parts 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 duri...

Page 44: ...oat to stimulate greatest stern down attitude the boat will encounter such as when loading IMPORTANT Be sure to consider swim platform loading and personal watercraft 8 Recheck exhaust system measurements Minimum Exhaust Elbow Height from Top of Elbow to Waterline Model Measurement All V6 and V8 13 in 330 mm 77956 70082 13 330 c d b a a Top Of Transom b Highest Point On Exhaust Elbow c Measurement...

Page 45: ...s are less than specified exhaust elbow risers must be installed to achieve proper dimension 77991 a b c d e Typical Riser Installation a Exhaust Elbow b Restrictor Gasket c Riser d Open Gasket 4 Slots e Exhaust Manifold NOTE Up to a maximum of 9 in 229 mm of riser height can be added ...

Page 46: ...sure that the boat is level from side to side using a level or inclinometer Then measure the distance between the straight edge and the outside waterline 4 The difference between these two measurements is the exhaust elbow height above the water line Refer to Measuring Procedures and compare measurement to specifications 72700 b c d a e 76859 a Waterline b Top Of Exhaust Elbow c Straight Edge d Me...

Page 47: ... to the top of the exhaust elbow 4 Coil excess hose in bilge of boat keeping it below the water line 5 Lower open end of hose and siphon water until it starts to come out of the hose Put a finger over the hose and lift open end until it is at the top of the exhaust elbow 6 Slowly take finger off end of hose to let the water level stabilize The water will seek the level of the water outside the boa...

Page 48: ... spots which could eventually result in burned through exhaust hoses Exhaust hoses and or tubes must be cor rectly connected to exhaust elbows so that they do not restrict the flow of discharge water from exhaust elbow 71653 Correct Connection Incorrect Connection IMPORTANT Exhaust hoses tubes should be secured at each connection with at least 2 hose clamps 1 Tighten all exhaust hose and or exhaus...

Page 49: ...nufacturer Alignment tools other than Quicksilver Alignment Tool may cause improper alignment and damage to gimbal bearing and or engine coupler 2 Attempt to insert the solid end of the alignment tool through the gimbal bearing and into the engine coupler splines 3 If the tool does not fit remove it and carefully raise or lower the front end of the engine using the center alignment eye and attempt...

Page 50: ...ily SLIDES FREELY WITH TWO FINGERS all the way into and out of engine coupler splines Do not check by turning the alignment tool 22029 a b a Alignment Tool Use Only Recommended Alignment Tool b Insert This End Of Alignment Tool Through Gimbal Housing Assembly 27647 c b a a Alignment Tool b Gimbal Bearing c Engine Coupler ...

Page 51: ...o stringer This allows for future adjustments 5 3 0L Center Mount Model a Set the engine on the stringer b Relieve the hoist tension c Attach the hoist to the center alignment eye d Fasten front mount to the stringer e Recheck alignment f Tighten locknut and jam nut securely 22054 a b c d e b 3 0L Center Mount Model a Front Mount b Attaching Bolts and Flat Washers c Adjusting Nut d Locknut e Jam N...

Page 52: ... front engine mounts until they rest on boat stringers b Relieve hoist tension entirely and fasten both front mounts to boat stringer using ap propriate hardware c Tighten the bottom nut to hold the engine in place Then release the tension 77968 a b c d 77970 a 3 0L Side Mount Model a Engine Mount b Bolt c Lockwasher d Tab Washer 77913 c b a V6 and V8 Models a Engine Mount b Bottom Nut Not Visible...

Page 53: ...engine MUST NOT EXCEED 5 8 in 16 mm inside diameter ID Make heater connections ONLY at locations shown Refer to manufacturers instructions for complete installation information and procedures Do not reposition engine temperature switch 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...

Page 54: ...r Cooling If Location Is Available a Location For Hot Water Supply 71758 a Seawater Cooling Alternate Location a Location For Hot Water Supply 74639 a a b b Closed Cooling Models If Location Is Available a Location for Hot Water Supply Bayonet Fitting Replaces Brass Plug b Thermostat Housing ...

Page 55: ...Electrical Connections IMPORTANT When routing all wire harnesses and hoses be sure they are routed and secured to avoid coming in contact with hot spots on engine and to avoid contact with moving parts Installing Continuity Wire 1 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 c...

Page 56: ... Voltmeter IMPORTANT Connect fused accessory panel 40 amp current draw maximum must be connected as shown in the wiring diagrams 1 Route instrumentation wiring harness back to engine making sure that harness does not rub or get pinched If an extension harness is required be sure to secure connection properly 2 Fasten harnesses to boat at least every 18 in 460 mm using appropriate fasteners 3 Place...

Page 57: ... 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 22232 a b c d a ORANGE Lead From Electrode On Transom Assembly b RED PURPLE Wire To Positive Battery Terminal ...

Page 58: ...red location and secure to wire bundle with tie strap provided 3 Connect PURPLE wire from alarm to any PURPLE wire terminal on instrument gauge or ignition switch Tighten connection securely 4 Connect TAN BLUE wire from alarm to TAN BLUE wire from instrument harness 5 Place the small transparent decals on the bottom of the water temperature and the oil pressure gauges 6 Place the large decal on th...

Page 59: ... Torque fittings Description Nm lb in lb ft Fittings 14 125 2 Connect power trim pump control harness to trim pump 3 Connect trim limit switch wires and secure with wire retainer and tie strap 75126 50630 75127 50632 a c e f g b d a Black Hose Fitting UP Circuit b Gray Hose Fitting DOWN Circuit c Control Harness d Tie Strap e Trim Limit Switch Wire With Blue Sleeve To BLUE WHITE Harness Wire f Tri...

Page 60: ...Page 60 of 137 90 860172011 4 Unscrew fill cap and remove cap plug from fill neck and discard Install fill cap 50630 a b a Caplug b Fill Cap 5 Connect power trim pump wires to battery 76631 a b a Positive Battery Lead b Negative Battery Lead ...

Page 61: ...g step If hose is kinked gear lube monitor will not function properly and damage to drive unit could occur 1 Route hose to gear lube monitor and cut off excess hose Hose can be routed on outside of remote oil filter or the hole in the front lifting eye bracket 2 Connect hose and secure with hose clamp IMPORTANT Hose must not come in contact with steering system components or the engine coupler U j...

Page 62: ...to cross thread or overtighten fittings 1 Route hoses Secure hoses to avoid contact with moving components 2 Connect power steering hoses to control valve Torque both fittings Description Nm lb in lb ft Fittings 31 23 3 Use extra hose clips to secure hose to transom NOTE Power Steering Fluid can be added at this point if desired Bravo Models and Alpha Seawater Cooled Models Using Sterndrive Water ...

Page 63: ...nit for cooling CAUTION Avoid overheating sterndrive The seawater inlet holes must be allowed to flow water without being obstructed or overheating damage to sterndrive may result Do not dead end seawater hose from bell housing Cut hose as recommended in procedures 1 Remove the existing water fitting and gasket Discard the screws and washers 50663 a b a Water Fitting b Screws And Lockwashers 2 Rem...

Page 64: ... Gasket c Screw d Lockwasher Description Nm lb in lb ft 1 Screw Water Fitting 5 45 4 Move the trim limit switch wires and speedometer hose aside Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered insert was removed in Step 2 22101 c 71184 a b d e a Trim Limit Switch Wires b Speedometer Hose c Gimbal Housing d Water Hose e Taper...

Page 65: ...cutting the water hose The existing tie strap and clip can be reused if they are moved and repositioned after the hose is cut 5 Cut completely through the water hose 5 in 127 mm in front of the aft end of the hose where it is fitted into the bell housing in the area shown DO NOT damage the U joint bellows Discard loose hose piece 6 Secure the trim limit switch wires and speedometer hose to the rem...

Page 66: ...olant recovery system will not operate properly without proper sealing Plastic tubing MUST seal completely at connections 1 Connect plastic tubing to bayonet fitting on heat exchanger Secure with tubing clamp provided 70548 a b a Plastic Tubing b Tubing Clamp 1 Remove cap from coolant recovery reservoir and fill to FULL mark with coolant solution 2 Reinstall cap ...

Page 67: ... 8 in 80 mm with a 15 20 lb 6 8 9 kg load applied to the cable end guide NOTE On engines with Alpha drives the measurement indicated above can be taken by installing the remote control shift cable and using the shift assist assembly provided to place the proper load on the shift cable 1 Place a mark on the tube against the edge of the cable end guide 50368 a a d e b c a a Shift Assist Assembly b R...

Page 68: ... assembly is not used Spacer Kit 23 11284A1 50310 d a c b a Clevis Pin b Washer c Spacer d Cotter Pin NOTE Do not discard shift assist assembly until after it is used in step 3 following IMPORTANT Shift cable must be connected at the remote control for the appropriate rotation LH or RH drive unit as explained following RIGHT HAND ROTATION Control cable will have to be installed in remote control s...

Page 69: ...ed 1 Remove shift cable attaching hardware 50308 a c b a Cotter Pin b Clevis Pin And Cotter Pin c Washer And Locknut 2 Place remote control shift lever in NEUTRAL position 3 Temporarily install clevis pin through remote control shift cable end guide shift assist assembly end and into hole in shift lever Then adjust brass barrel so that hole in barrel aligns with anchor stud 50308 d a b c e a Clevi...

Page 70: ...hrough the top of the barrel retainer 5 Install drive unit shift cable as shown Secure brass barrel in barrel retainer with cotter pin and spread both prongs Secure cable end guide with washers one on each side of end guide and locknut Tighten locknut until it contacts then loosen 1 2 turn 75415 b a Without Shift Assist Assembly a Cotter Pin b Locknut And Washers ...

Page 71: ...eners will have to be removed again to properly adjust shift cables under Shift Cable Installation section of this manual 50308 e b a d c With Shift Assist Assembly a Remote Control Shift Cable b Shift Assist Assembly c Clevis Pin And Cotter Pin d Large I D Washer e Small I D Washer And Locknut 50310 e d f i h g b c a Without Shift Assist Assembly a Remote Control Shift Cable b Pin c Cotter Pin Ex...

Page 72: ...r is placed in FORWARD remote control is set up for LEFT HAND LH propeller rotation 71656 A B 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 71656 A IMPORTANT When installing shift cables be sure that...

Page 73: ...ece of tape over the barrel retainer 71659 8 Locate center of remote control and control cable play backlash IMPORTANT Be sure to keep center mark c aligned with control cable end guide edge when making the following adjustment 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...

Page 74: ... 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 11 Remove control cable end guide from shift lever by removing anchor pin 71660 a b c d e a Control Cable End Guide b Anchor Pin c Backlash Center d Control Cable Barrel e Stud 12 Install control...

Page 75: ...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 71662 a b c RH Rotation Bravo One Two Three 71663 a b c d LH Rotation Bravo One And Two a Adjustment Tool b Barrel Retainer c Shift Lever Stud d Shift Lever Adjustment Slot 18 Remove adjustment too...

Page 76: ... installation 4 Secure throttle cable with hardware as shown DO NOT overtighten as cable must pivot freely Tighten until nut contacts then loosen 1 2 turn 5 Place remote control throttle lever in the wide open throttle WOT position Ensure that throttle shutters are completely open 6 Return remote control throttle lever to idle position and ensure that throttle lever contacts idle speed adjustment ...

Page 77: ...stop nuts and flat washers 2 Remove gear lube monitor cap Fill with lubricant 77108 a a Gear Lube Monitor Description Where Used Part Number A High Performance Gear Lube Gear Lube Monitor 92 802853A1 3 Push dribble valve stem in until gear lube appears 75531 a a Dribble Valve Stem 4 Once gear lube appears release dribble valve stem 5 Fill monitor to FULL mark 6 Replace monitor cap ...

Page 78: ...dels Ensure that rubber gasket and water passage O ring are properly positioned in bell housing 75531 a b a Rubber Gasket b Water Passage O ring 8 Coat sterndrive unit pilot U joint O rings and drive shaft splines 70114 a b c b A A A A a Sterndrive Unit Pilot b O rings c Splines Description Where Used Part Number Drive Unit Pilot A Engine Coupler Spline Grease U Joint O rings 92 816391A4 Drive Sha...

Page 79: ...a Drive Shaft Bellows Alpha Models 1 Position bell housing shift shaft coupler so that slot in coupler is positioned straight fore and aft Do this by placing remote control shift lever in FORWARD gear position for RH drive or REVERSE gear position for LH drive unit 75525 a b c d a Shift Shaft b Shift Shaft Coupler c Shift Slide d Slot ...

Page 80: ... roller into shift shaft lever Snap the Shift Shaft Slide Stabilizer Tool onto stud directly below shift slide and position as shown 50629 75198 75199 c c a b a Shift Shaft Lever b Roller c Shift Shaft Slide Stabilizer Tool Description Part Number Shift Shaft Slide Stabilizer Tool 91 809815A1 3 Position drive unit shift shaft so that it is straight forward by turning shift shaft CLOCKWISE while si...

Page 81: ...aight back over top of acceleration plate Be careful not to scratch acceleration plate or trim cylinders b Guide U joint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into drive shaft housing Make sure shift slide remains upright and engaged with bell housing shift shaft lever c Remove Shift Slide Stabilizer Tool d Slide drive unit all the way into b...

Page 82: ...Secure drive unit to bell housings using fasteners as shown Torque the fasteners 22062 a b a Locknut And Flat Washers b Locknut And Continuity Circuit Washer No Flat Washer At This Location Description Nm lb in lb ft Fasteners 68 50 6 Return remote control shift lever to the NEUTRAL position Bravo Models 1 Lubricate O ring seals 72183 a A a O ring Seals Description Where Used Part Number A 2 4 C M...

Page 83: ...rndrive 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 3 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 72467 A C B ...

Page 84: ...ards c Position sterndrive unit so that universal joint shaft aligns with bell housing bore d 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 e If necessary rotate propeller shaft COUNTERCLOCKWISE slightly using a propeller to align U joint shaft splines with splines in engine coupling then...

Page 85: ... In Limit Insert is positioned as shown for the appropriate Bravo model 75157 a Bravo One and Two Positioned Forward 75158 a Bravo Three Positioned Aft a Trim In Limit Insert IMPORTANT The position of the Trim In Limit Insert on the Bravo Three sterndrive unit should only be changed after the boat has been properly tested Refer to Trim In Limit Statement IMPORTANT To aid in installing rubber bushi...

Page 86: ... components except plastic caps 70026 70027 b c d e a b a A A Alpha Models a Aft Anchor Pin b Bushings c Flat Washers d E ring Clips e Plastic Caps 71668 71669 a c c d e f c b A A Bravo Models 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 Description Where Used Part Number A 2 4 C Marine Lubricant With Teflon Trim Cylinder ...

Page 87: ... to area between gimbal housing and sterndrive immediately above the transom end of the anti ventilation plate 2 Align plastic slots on male and female portions and insert 3 Push down to secure 75502 75508 75486 a b a Male End Of Speedometer Tube Fitting b Female Portion 75513 b a a Tube Fitting Male End b Topside Portion Female End ...

Page 88: ...gimbal housing and sterndrive immediately atop the transom end of the anti ventilation plate 2 Insert speedometer tube fitting into opening on topside of anti ventilation plate in position shown 22025 a b a Tube Fitting b Opening 3 With fitting fully seated turn handle to left to a tightly seated position as shown 22025 a a Handle ...

Page 89: ... LH rotation drive unit Be sure to refer to the appropriate procedure when performing the following steps IMPORTANT Drive unit must be installed IMPORTANT DO NOT run engine 1 Remove remote control shift cable and shift assist assembly if installed 75414 50310 b a b With Shift Assist AssemblyWithout Shift Assist Assembly a Shift Assist Assembly b Remote Control Shift Cable 2 Ensure shift lever adju...

Page 90: ...into gear by pushing in on drive unit shift cable while simultaneously rotating propeller shaft COUNTERCLOCKWISE until shaft stops This will ensure full clutch engagement Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel this removes all slack from the cable IMPORTANT Do not use excessive force when holding pressure on the drive unit shift cable Excessive ...

Page 91: ...o maintain light pressure on drive unit shift cable 50309 a b c d a End Guide b Brass Barrel c Shift Lever Clevis Pin Hole d Stud 6 Temporarily install remote control shift cable on stud and install clevis pin 50308 b a a Remote Control Shift Cable b Clevis Pin 7 Shift remote control as stated in a or b following a Right Hand RH Rotation Drive Unit REVERSE gear past detent into WOT position b Left...

Page 92: ...nsure adjustable stud is at bottom of slot in shift lever b Check remote control for proper shift cable output 3 in 76 mm 1 8 in 3 mm c If a and b are correct ensure drive unit shift cable is not crushed or kinked If drive unit shift cable is binding the shift cutout switch plunger pin will move off center when shifting into and out of FORWARD and REVERSE NOTE If shift cable was damaged during ins...

Page 93: ...oints will not align push in or pull out on end of shift assist assembly to install Do not attempt to readjust shift cable 50308 50310 c b d a f g e c d a h i j i g i With Shift Assist Assembly Without Shift Assist Assembly a Remote Control Shift Cable b Shift Assist Assembly c Clevis Pin d Cotter Pin Spread Both Prongs e Large I D Washer f Small I D Washer g Locknut Tighten Until Contacts Then Lo...

Page 94: ...oosen adjustable stud on shift lever and move it up in slot until clutch engages with FORWARD gear Retighten stud Shift remote control several times and stop in FORWARD to recheck shift cutout switch position Pin must be centered 13 Two Lever Remote Control with Separate Shift and Throttle Levers a RIGHT HAND RH propeller rotation drive unit While turning propeller shaft CLOCKWISE move remote cont...

Page 95: ...earance 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 degree increments to improve cable routing 74688 Proper Cable Bend 74689 Improper Cable Bend 2 Make s...

Page 96: ...nstalled 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 Ensure 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...

Page 97: ...ard rear engine mount and turn toward the transom c The cable should then go up behind the power steering valve and loop over to the shift plate on the engine where it is connected to the anchor points on the shift plate Following this routing will prevent the engine coupler from damaging the cable 74903 74901 3 0L Model V6 and V8 Models NOTE A final check of the adjustments should be made with th...

Page 98: ...ese procedures completed Power Steering Fluid IMPORTANT Use only specified lubricant 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 and check fluid level using dipstick Add fluid as required NOTE Be prepared to add fluid to pump when first starting engine 71672 76859 a a b a Fill Cap b ...

Page 99: ...rive unit in the full DOWN IN position IMPORTANT Use only specified lubricant 2 If not previously done unscrew fill cap and remove cap plug from fill neck and discard Install fill cap 50630 a b a Cap Plug b Fill Cap 3 Raise and lower sterndrive unit to the full UP OUT position 6 to 10 times to purge air from system Check oil level visually with drive unit in the full DOWN IN position Oil level sho...

Page 100: ...ne 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 71671 a a Trim Gauge Needle 5 Tighten retaining screws and turn ignition key to the OFF position 71220...

Page 101: ...rformance 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 Operat...

Page 102: ...ound Once the rpm drop into the recommended operating rpm range normal engine operation resumes Engine Rev Limiter Model Engine Recommended Operating RPM Range Rev Limit RPM Setting 3 0L 4400 4800 Not Applicable 4 3L 4400 4800 4950 5 0L 4400 4800 4950 5 7L 4400 4800 4950 Propeller Installation WARNING Be sure that remote control is in NEUTRAL position and ignition key is removed from switch prior ...

Page 103: ...nstallation is correct when at least 2 threads of propeller shaft are exposed through propeller nut after torquing it ALPHA MODELS 1 Install propeller with attaching hardware as shown Torque the nut then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer Bend the 3 tabs down into grooves 76910 a c e f g d b a Propeller Shaft Splines b Forward Thrust Hub c Flo To...

Page 104: ...splines of propeller shaft 3 Torque the nut then continue to tighten until 3 tabs on the tab washer align with grooves on spline washer Bend the 3 tabs down into grooves 76910 a b c f e g d Bravo One 70561 b d h f g a Bravo Two a Propeller Shaft Splines b Forward Thrust Hub c Flo Torque Drive Hub d Propeller e Drive Sleeve Adapter f Tab Washer g Locknut h Continuity Spline Washer Description Nm lb...

Page 105: ...eller shaft 3 Install front propeller locknut and torque Description Nm lb in lb ft Front Propeller Locknut 136 100 4 Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub 5 Align splines and install aft propeller 6 Install propeller locknut and torque 77107 f e d c b a Bravo Three a Rear Propeller Locknut b Rear Propeller c Rear Propeller Thrust Hub d Front Propeller Lo...

Page 106: ...ectors or side terminal connectors IMPORTANT DO NOT use a battery with wing nut connectors Battery capacity rating of at least Engine Cyl Type cid l Minimum Required Cranking Battery Size 4 In Line 181 3 0 V6 Carb 262 4 3 V8 Carb 305 5 0 375 cca 475 mca 90 Ah V8 Carb 350 5 7 BATTERY CABLES 1 Select proper size positive and negative battery cables using chart Battery should be located as close to e...

Page 107: ...removed to avoid injury CAUTION Overheating from insufficient cooling water will cause engine and drive damage Ensure that there is sufficient water always available at the water inlet holes during operation BOAT OUT OF THE WATER For engine operation tests with the boat out of the water IMPORTANT If using a flushing attachment over the water inlet holes and a water hose as shown do not use full wa...

Page 108: ... Testing TESTING 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 appropriate Mercury MerCruiser Operation Maintenance and Warranty Manual for operating specifications Refer to appropriate Mercury MerCruiser Service Manual for fluid capacity information 2 Check crankcase oi...

Page 109: ...e water level is above water intake holes 70082 b a a Minimum Water Level b Water Intake Holes CAUTION 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 77899 Dual Water Pickup Low Water Pickup S...

Page 110: ...r steering pump tone changes a Check for an obstruction between gimbal ring and gimbal housing and all moving steering components b Check that steering lever is not contacting cutout in transom If contact is being made modify cutout 12 Turn steering wheel STARBOARD until it stops and continue to apply pressure If pump lugs engine rpm drops and or power steering pump tone changes a Check same items...

Page 111: ...d 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 ...

Page 112: ...er with a higher pitch propeller Normally a 1 inch propeller pitch change causes an rpm change of 150 rpm 5 Shut off engine 6 Check coolant level and add coolant if necessary TRIM TAB ADJUSTMENT 3 0L MODELS ONLY IMPORTANT If power package is equipped with Power Steering set trim tab so trail ing edge is straight back No adjustment is needed Models with Manual Steering Operate boat at normal cruisi...

Page 113: ...ensure that engine does not stop 3 Check that shift cutout switch plunger pin is centered in notch of shift cutout lever with drive unit in FORWARD and REVERSE gear 75435 a a Cutout Switch Plunger Pin 4 If the proper results are not achieved in the previous steps shift cables must be readjusted 5 Shifting from FORWARD and REVERSE to NEUTRAL ensure drive unit is in NEUTRAL before remote control shi...

Page 114: ...er cold weather use if the possibility of freezing temper atures 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 Draining Instructions CAUTION Ensure that boat is out of the water or seacock is closed and bilge pump is operating before beginning procedure Excess ...

Page 115: ...ter temperature can exceed 160 F 71 C CAUTION Do not operate engine with blue drain hoses disconnected Hot water can discharge violently IMPORTANT Do NOT start or operate engine at any point in this procedure 1 Turn on bilge pump 2 Push quick connect fitting release buttons and remove blue drain hoses from the bracket 76242 a b a Quick Connect Fitting Release button b Blue Drain Hoses 3 Pull T han...

Page 116: ...lue Drain Hoses 6 Leave blue drain hoses disconnected until all water has drained from engine 7 Pull T handle until the quick connect fittings a on the blue drain hoses are within reach 76244 a a Quick Connect Fittings 8 Install quick connect fittings on the bracket Pull on the blue drain hoses to ensure they are firmly connected 9 Push down on handle and move into the slot on the bracket 10 Turn ...

Page 117: ... 6 Shut off engine 7 Attach the female end of the water hose adapter fitting to a water supply 76287 8 Attach the CLOGGED blue drain hose to the male end on the water hose adapter fitting 9 Fully open the water supply and allow it to run for 1 minute 10 Turn off the water supply 11 Disconnect the water hose adapter from the blue drain hose and the water hose 12 Push down on T handle to force the b...

Page 118: ... bilge pump is operating before beginning procedures Excess water in bilge can damage engine or cause boat to sink 5 Turn on the bilge pump CAUTION Do not run engine above 1300 rpm Suction created by seawater pickup pump may collapse water supply hose causing engine to overheat WARNING Be certain the area around propeller is clear and no one is standing nearby To avoid possible injury remove prope...

Page 119: ...ed for winter storage or immediately after cold weather use if the possibility of freezing temper atures 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 1 Ensure engine is as level as possible to ensure complete draining of cooling system 2 Remove drain plugs fr...

Page 120: ...tat housing or circulating pump Allow water to drain 74774 a b a Thermostat Housing To Circulating Pump Hose b Drain Plug Location If Equipped 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 71216 a b c d a Vent Holes b Trim Tab Cavity Drain Holes c Drain Hole d Speedometer Pitot Hole 7 Crank engine over ...

Page 121: ...turer 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 hou...

Page 122: ...g of cool ing system CAUTION Seawater section of cooling system MUST BE COMPLETELY drained for winter storage or immediately after cold weather use if the possibility of freezing tempera tures 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 cooli...

Page 123: ...ttom of exhaust manifold s 3 Remove drain plug from fuel cooler 75039 a b a Fuel Cooler Drain Plug b Exhaust Manifold Drain Plug s 4 Remove end caps sealing washers and gaskets from heat exchangers 71515 a b c d 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...

Page 124: ...f cooling system has been drained completely reinstall all com ponents Reconnect all hoses and tighten hose clamps securely All Models 1 For additional assurance against freezing and corrosion fill the cooling system with a mixture of propylene glycol antifreeze and tap water mixed to manufacturer s recommendation to protect engine to the lowest temperature to which it will be exposed during cold ...

Page 125: ...GASOLINE STERNDRIVE INSTALLATION MANUAL 90 860172011 Page 125 of 137 THIS PAGE IS INTENTIONALLY BLANK ...

Page 126: ...37 90 860172011 Wiring Diagrams Instrumentation SINGLE STATION INSTALLATIONS TYPICAL 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 74583 f h i i i a b c d e j g ...

Page 127: ... 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 Alarm b Ta...

Page 128: ...LUE 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 b c d e f g h a 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 ...

Page 129: ...MerCathode System Wiring Diagram a b c 73596 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 d a Controller b 20 Amp Fuse c Electrode d BLACK Wire With Engine Harness or Separate ...

Page 130: ... 2 2 2 2 3 3 3 4 3 5 4 A B C D A Ignition Components 1 Distributor 2 Ignition Coil 3 Shift Cutout Switch 4 GRAY lead for use with Service Tachometer B Starting Charging and Choke Com ponents 1 Alternator 2 Electric Choke 3 Ground Stud 4 Starter Motor 5 Starter Slave Solenoid C Audio Warning Components 1 Water Temperature 2 Drive Unit Gear Lube Monitor 3 Oil Pressure Switch D Instrumentation Compon...

Page 131: ... 5 6 7 8 A B C D A Ignition Components 1 Distributor 2 Timing Lead 3 Shift Cutout 4 Ignition Coil B Starting Charging and Choke Com ponents 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 Instrumentatio...

Page 132: ... 1 3 2 8 A B C D A Ignition Components 1 Distributor 2 Timing Lead 3 Ignition Coil B Starting Charging and Choke Com ponents 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 ...

Page 133: ... 4 4 5 A B C D A Ignition Components 1 Distributor 2 Timing Lead 3 Ignition Coil 4 Knock Sensor B Starting Charging and Choke Com ponents 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 ...

Page 134: ...e and Exhaust Manifold 4 Exhaust Elbow 5 Power Steering Cooler If Equipped 6 Seawater Intake From Sterndrive 7 Engine Block and Cylinder Head Assembly A Water Flow With Thermostat Closed B Water Flow With Thermostat Open a To Exhaust Manifold b To Engine Circulating Pump c Inlet From Sterndrive d From Block and Cylinder Head A B 1 2 3 4 5 6 7 a a b b c c d d 76279 ...

Page 135: ...cu lar power package but the water flow paths remain similar on all engines 77992 9 10 1 2 3 4 5 6 7 8 1 Seawater Intake From Sterndrive 2 Seawater Pump Bravo Models 3 Power Steering Cooler If Equipped 4 Thermostat Housing and Cover Assembly 5 Engine Water Circulating Pump 6 Engine Block and Cylinder Head Assembly 7 Exhaust Manifold Typical 8 Restrictor Gasket 9 Exhaust Elbow Assembly Typical 10 W...

Page 136: ...he water and coolant flow paths remain similar on all engines 75005 10 1 2 3 4 5 6 7 8 9 10 1 Seawater Intake From Sterndrive 2 Power Steering Cooler 3 Fuel Cooler If Equipped 4 Heat Exchanger Typical 5 Thermostat Housing and Cover Assembly 6 Engine Water Circulating Pump 7 Engine Block and Cylinder Head Assembly 8 Exhaust Manifold Typical 9 Exhaust Elbow Assembly Typical 10 Overboard Water and Ex...

Page 137: ...All fuel connections tight Idle rpm within specifications Correct rotation propeller installed and torqued Throttle shift and steering system FORWARD NEUTRAL REVERSE fasteners tightened properly gear operation Throttle plates open and close Steering operation throughout completely range Crankcase oil level Acceleration from idle rpm Power trim oil level WOT rpm within specifications in FORWARD gea...

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