GASOLINE ENGINE STERNDRIVE MODELS INSTALLATION MANUAL

Transcription

1 The following re registered trdemrks of Brunswik Corportion: Mer, MerCthode, Merury MerCruiser, Merury, Merury Mrine, Quiksilver, Ride-Guide, Thruster nd Merury Preision Prts. GASOLINE ENGINE STERNDRIVE MODELS INSTALLATION MANUAL Models Covered Alph Brvo Model Seril Numer or Yer 4.3L MPI 5.0L MPI 0M nd Aove 350 MAG MPI 4.3L MPI 5.0L MPI 350 MAG MPI MX 6.2 MPI Model Seril Numer or Yer 0M nd Aove Horizon Model 350 MAG MPI Horizon MX 6.2 MPI Horizon Seril Numer or Yer 0M nd Aove Notie NOTICE After ompleting instlltion, these instrutions should e pled with the produt for the owner s future use. NOTICE Predelivery preprtion instrutions must e performed efore delivering ot to the produt owner. Pge 1 of 148 Printed in U.S.A , Merury Mrine FEBRUARY 2002

2 Gsoline Sterndrive Instlltion Mnul Tle Of Contents Generl Informtion Notie to Bot Mnufturer/Instller Torque Speifitions Lurints / Selnts / Adhesives Speil Tools Alph Notie: Inresed Trim-In Rnge Cpility Brvo Three Notie: Trim-In Limit Insert Quiksilver Produts Aessories Seril Numer Del Plement Corrosion Protetion Anti-fouling Pint Bot Constrution Trnsom Thikness nd Surfe Engine Bed Crnkshft Vertil Centerline Crnkshft Horizontl Centerline (X-Dimension) Trnsom Cutout Sewter Connetions - Generl Informtion Sewter Pikup Preliminry Connetions Power Trim Pump Fuel Inlet Fitting Inline Fuel Filter Trnsom Connetions Instlling Giml Housing Instlling Inner Trnsom Plte Conneting Speedometer Pikup Fluid Connetions Instlling Steering System Trnsom Preprtion Drive Shft Extension Models Engine Preprtion Engine Instlltion Exhust System Methods for Mesuring Exhust Elow Height Exhust System Hose / Tue Connetions Engine Alignment Hot Wter Heter Instlltion Eletril Connetions Instlling Continuity Wire Instrumenttion Connetions Trim Position Sender Connetions MerCthode Connetions Audio Wrning System Connetions Power Trim Pump Connetions Fluid Connetions Ger Lue Monitor Hose Power Steering Hoses Brvo Models nd Alph Sewter Cooled Models Using Sterndrive Wter Pikups Alph or Brvo Models Using Alterntive Wter Pikups Coolnt Reovery System Shift Cle Instlltion Alph Models - Drive Unit Not Instlled Brvo Models Throttle Cle Instlltion nd Adjustment Sterndrive Unit Instlltion Alph Models Brvo Models All Models Speedometer Connetion Alph Models Brvo Models Shift Cle Instlltion Alph Models - Drive Unit Instlled Trouleshooting Shift Prolems Predelivery Preprtion Power Steering Fluid Filling Coolnt Reovery Bottle Power Trim Pump Trim Position Sender Adjustment Propeller Seletion Propeller Instlltion Bttery Fuel System Test Running Engine Bot In The Wter Tests Cold Wether nd Extended Storge Drining Instrutions Identifition Bot In Wter Bot Out Of The Wter All Models Instrumenttion Power Trim System MerCthode System ECM 555 EFI System Engine Wiring Digrms Wter Flow Digrms Predelivery Inspetion Pge 2 of

3 Generl Informtion Gsoline Sterndrive Instlltion Mnul Notie to Bot Mnufturer/Instller Throughout this pulition, Wrnings nd Cutions (ompnied y the Interntionl Hzrd Symol! ) re used to lert the mnufturer or instller to speil instrutions onerning prtiulr servie or opertion tht my e hzrdous if performed inorretly or relessly. Oserve Them Crefully! These Sfety Alerts, lone, nnot eliminte the hzrds tht they signl. Strit ompline to these speil instrutions when performing the servie, plus ommon sense opertion, re mjor ident prevention mesures. WARNING Hzrds or unsfe prties whih ould result in severe personl injury or deth. CAUTION Hzrds or unsfe prties whih ould result in minor personl injury or produt or property dmge. IMPORTANT: Indites informtion or instrutions tht re neessry for proper instlltion nd/or opertion. NOTE: Refer to the Merury MerCruiser Produt Applitions Mnul - Gsoline Sterndrive Models for pplition reommendtions. This instlltion mnul hs een written nd pulished y Merury MerCruiser to id the ot mnufturer (OEM) in the instlltion of the produts desried herein. It is ssumed tht these personnel re fmilir with mrine produt instlltion. Furthermore, it is ssumed tht they re fmilir with, if not trined in, the reommended instlltion proedures of Merury MerCruiser produt. We ould not possily know of or dvise the mrine trde of ll oneivle instlltions nd of the possile hzrds nd/or results of eh instlltion. Therefore, the OEM is responsile for ny instlltion tht does not fulfil the requirements of this mnul. It is the responsiility of the ot mnufturer to selet the pproprite engine/trnsom/drive pkge (inluding the orret ger rtio nd propeller) for given ot. Merury MerCruiser reommends tht ny new or unique hull/power pkge omintion e thoroughly wter tested prior to sle, to verify tht the ot performs s desired, nd tht the engine opertes in the pproprite rpm rnge. It is reommended tht Merury MerCruiser Sles Applition Engineer (SAE) e ontted for ssistne. All informtion, illustrtions nd speifitions ontined in this mnul re sed on the ltest produt informtion ville t time of pulition. As required, revisions to this mnul will e sent to ll OEM ot ompnies Pge 3 of 148

4 Gsoline Sterndrive Instlltion Mnul Torque Speifitions NOTE: Seurely tighten ll fsteners not listed elow. Desription Nm l-in. l-ft Ger Lue Monitor Fitting 9 80 Speedometer Pikup Br Fitting Exhust Pipe or Blok-off Plte Power Steering Hydruli Hose Fittings Power Trim Pump Hose Fittings Propeller Nut Alph One, Brvo One nd Brvo Two Front Propeller Nut Brvo Three Rer Propeller Nut Brvo Three Rer Engine Mounts Steering Cle Coupler Nut Steering System (Pivot Bolts) Sterndrive Unit Fsteners Trnsom Assemly Fsteners Sewter Pikup Fitting 5 45 Finger-tight + 1-3/4 to Fuel Inlet Fitting 2-1/4 turns with wrenh. Do NOT overtighten. 1 Amount speified is MINIMUM. Pge 4 of

5 Lurints / Selnts / Adhesives Gsoline Sterndrive Instlltion Mnul Desription Where Used Prt Numer Engine Coupler Spline Grese 2-4-C Mrine Lurint With Teflon Coupler Splines Drive Unit Pilot U-Joint O rings Drive Shft Splines Anhor Pins Trim Cylinder Hrdwre A1 O-ring Sels A1 Shift Cle End Propeller Splines Pivot Bolts Power Steering Bushings Speil Lurint 101 Clevis Pin A1 Steering Cle End Propeller Splines Dexron III - Automti Trnsmission Fluid Power Steering Pump Otin Lolly Power Trim nd Steering Fluid Power Steering Pump Power Trim Pump A12 Liquid Neoprene Bttery Terminls MerCthode Connetions Speedometer Br Fitting Fuel Inlet Fitting Lotite 565 PST Sewter Inlet Hose Fitting Threds Otin Lolly Sewter Inlet Plsti Plug Threds Lotite 271 Sewter Inlet Nut SAE 30W Engine Oil Power Trim Pump Shift Cle Pivot Points Otin Lolly SAE 10W40 Engine Oil Power Trim Pump Otin Lolly Mrine Culking Sewter Inlet Mounting Surfes Otin Lolly Power Tune Exhust Tues Quiksilver High Performne Ger Lue Sterndrive Unit Silione Selnt Or Equivlent Srew Shft Otin Lolly Equivlent produts my e used Pge 5 of 148

6 Gsoline Sterndrive Instlltion Mnul Speil Tools Desription Prt Numer Trnsom Drilling Fixture A2 Engine Alignment Tool A1 Shift Cle Adjustment Tool Engine Mount Drilling Fixture A1 Tpered Insert Tool Shift Shft Slide Stilizer Tool A1 Alph Notie: Inresed Trim-In Rnge Cpility The Alph trim ylinders provide the pility for n inresed trim-in rnge. A sper n e removed from the trim ylinders to inrese the trim-in rnge y pproximtely 1-1/2 degrees. This will improve the elertion on some ots y foring the ow down more quikly. If the spers re to e removed, the ot must e wter tested to ensure tht the inresed trim-in rnge does not use ny undesired ot hndling hrteristis (ow-steer, hine-wlk, et.) if the sterndrive is trimmed in while the ot is operted t higher speeds. The ot should e tested under ll oneivle lod onditions nd mneuvers to ensure tht the dditionl trim-in does not pose prolem. The finl deision nd responsiility for use of the dditionl trim-in rnge is left up to the ot mnufturer. WARNING It is reommended tht only qulified personnel djust the Trim-In Limit Sper. Bot must e wter tested fter djusting or removing the devie to ensure tht the modified trim-in rnge does not use the ot to exhiit n undesirle ot hndling hrteristi if the sterndrive unit is trimmed in t higher speeds. Inresed trim-in rnge my use hndling prolems on some ots tht ould result in personl injury. Pge 6 of

7 Brvo Three Notie: Trim-In Limit Insert Gsoline Sterndrive Instlltion Mnul NOTE: Brvo One, Two nd Three Models re equipped with Trim-In Limit Insert. It hs een rought to our ttention tht some ots (predominntly deep-vee hevy ots) will roll up on their side under ertin, speifi, operting onditions. The roll n e either to port or strord nd my e experiened while moving stright hed, or while mking turn. The roll ours most frequently t or ner mximum speed, with the sterndrive unit trimmed t or ner full trim-in. While the ot will not roll ompletely over, the roll my e suffiient to unset the opertor or pssengers, nd therey rete n unsfe sitution. The roll is used y stern-lift reted from exessive sterndrive unit trim-in. Under these extreme stern-lift / ow-down onditions instility n e reted whih my use the ot to roll. Weight distriution to the stern n redue stern-lift nd, in some irumstnes, help to ontrol the ondition. Weight distriution in the ow, port or strord, my worsen the ondition. The Trim-In Limit Insert redues stern-lift y preventing the sterndrive unit from rehing the lst few degrees of full trim under. While this devie should redue the rolling tendeny, it my not eliminte the tendeny entirely. The need for this Trim-In Limit Insert, nd its effetiveness, n only e determined through ot testing nd is ultimtely the responsiility of the ot mnufturer. Quiksilver Produts WARNING It is reommended tht only qulified personnel djust the Trim-In Limit Insert. Bot must e wter tested fter djusting the devie to ensure tht the modified trim-in rnge does not use the ot to exhiit n undesirle ot hndling hrteristi if the sterndrive unit is trimmed In t higher speeds. Inresed trim-in rnge my use hndling prolems on some ots whih ould result in personl injury. Aessories Quiksilver guges, remote ontrols, steering systems, propellers nd other essories re ville for this produt. Merury MerCruiser reommends the use of Quiksilver prts on ll pplitions. Refer to Merury Preision Prts / Quiksilver Aessories Guide for omplete listing. This Guide is ville from: Merury Mrine Attn: Prts Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du L, WI Outside of U.S.A., order through Distriution Center or Distriutor Pge 7 of 148

8 Gsoline Sterndrive Instlltion Mnul Seril Numer Del Plement There re 3 sets of engine, trnsom ssemly nd sterndrive seril numer del strips provided with eh power pkge. 1 should e used for eh of the following: Engine Speifition Del Wrrnty Registrtion Crd Opertion, Mintenne nd Wrrnty Mnul identifition pge. Affix engine seril numer del to speifition / seril numer del in position shown. -Engine Seril Numer Lotion Corrosion Protetion Merury MerCruiser power pkges re equipped with nodes to help protet them from glvni orrosion under moderte onditions. However, for severe onditions or if using stinless steel propeller, it is reommended tht Quiksilver Anti-Corrosion Anode Kit nd/or MerCthode System e instlled (some models hve MerCthode System s stndrd equipment). A MerCthode Monitor lso is ville to llow the opertor to hek the opertion of the MerCthode System with the push of utton. (Refer to Merury Preision Prts / Quiksilver Aessories Guide for prt numers.) Bots whih re onneted to AC shore power require dditionl protetion to prevent destrutive low voltge glvni urrents from pssing through the shore power ground wire. A Quiksilver Glvni Isoltor n e instlled to lok the pssge of these urrents while still providing pth to ground for dngerous fult (shok) urrents. (Refer to Merury Preision Prts / Quiksilver Aessories Guide for prt numer.) IMPORTANT: If AC shore power is not isolted from ot ground, the MerCthode System nd nodes my e unle to hndle the inresed glvni orrosion potentil. Refer to Mrine Corrosion Protetion Guide P/N for speifi informtion out mrine orrosion. Pge 8 of

9 Anti-fouling Pint Gsoline Sterndrive Instlltion Mnul IMPORTANT: Corrosion dmge tht results from the improper pplition of nti-fouling pint will not e overed y the limited wrrnty. Pinting Bot Hull or Bot Trnsom: Anti-fouling pint my e pplied to ot hull nd ot trnsom ut you must oserve the following preutions: IMPORTANT: Do NOT pint nodes or MerCthode System referene eletrode nd node, s this will render them ineffetive s glvni orrosion inhiitors. IMPORTANT: If nti-fouling protetion is required for ot hull or ot trnsom, opper or tin se pints, if not prohiited y lw, n e used. If using opper or tin sed nti-fouling pints, oserve the following: Avoid n eletril interonnetion etween the Merury MerCruiser Produt, Anodi Bloks, or MerCthode System nd the pint y llowing minimum of 1-1/2 in. (40 mm) UNPAINTED re on trnsom of the ot round these items Pinted Bot Trnsom -Minimum 1-1/2 in. (40 mm) UNPAINTED Are Around Trnsom Assemly NOTE: Sterndrive unit nd trnsom ssemly n e pinted with good qulity mrine pint or n nti-fouling pint tht DOES NOT ontin opper, tin, or ny other mteril tht ould ondut eletril urrent. Do NOT pint drin holes, nodes, MerCthode system or items speified y ot mnufturer Pge 9 of 148

10 Gsoline Sterndrive Instlltion Mnul Bot Constrution Trnsom Thikness nd Surfe IMPORTANT: Trnsom thikness nd surfe plne (fltness) must e ontrolled where the sterndrive unit mounts. Thikness Prllelism Fltness Angle Trnsom Speifitions Between 2-2-1/4 in. (51-57 mm) for 8 in. (203 mm) to either side of the vertil enterline Inner nd outer surfes must e prllel within 1/8 in. (3 mm) Trnsom surfes in re where trnsom ssemly will e mounted (inludes vertil s well s horizontl dimensions): Inner Surfe Flt within1/8 in. (3 mm) Outer Surfe Flt within1/16 in. (2 mm) Degrees e d d Trnsom Thikness -Inner Surfe -Outer Surfe d-trnsom Plte Coverge e -Trnsom Angle Mesuring Thikness -Mesuring Fltness -Suitle Mndrel To Chek For Uniform Trnsom Thikness Pge 10 of

11 Engine Bed Gsoline Sterndrive Instlltion Mnul Differene Between Strord nd Port Engine Mount Mount Adjustment Up nd Down (minimum) 22-1/2 in. (572 mm) 1/4 in. (6 mm) NOTE: Although the engine mounts llow some djustment, it is good prtie to ensure tht the front nd rer mount lotions in the vessel re prllel nd in the sme plne. This my e heked y tying string from the left front mount lotion to the right rer mount lotion nd nother from right front to left rer. The strings should touh where they ross. Crnkshft Vertil Centerline 1. Lote nd mrk ot vertil enterline on trnsom Vertil Centerline 2. For Dul Engines: Lote nd mrk rnkshft vertil enterlines on trnsom Crnkshft Vertil Centerline -Minimum Distne Between Crnkshft Vertil Centerlines -Crnkshft Vertil Centerlines Must Be An Equl Distne From Bot Vertil Centerline Minimum Distne Between Crnkshft Vertil Centerlines (Dul Side-By-Side) Model in. (mm) 262 id / 4.3L 305 id / 5.0L 33 (838) 350 id / 5.7L 377 id / 6.2L Pge 11 of 148

12 Gsoline Sterndrive Instlltion Mnul Crnkshft Horizontl Centerline (X-Dimension) 90 DEGREE TOOL METHOD X-Dimension n e mesured y the 90 degree Tool Method or y the Tpe Mesure Method. 1. Construt 90 degree tool /16 in. (345 mm) -Mesurement: 4 ft (1.2 m) To Lower Drive Unit - Sutrt from dimension. To Rise Drive Unit - Add to dimension. IMPORTANT: This dimension should only e rised or lowered fter proper testing Single Engine Dul Engine 2. Ple 90 degree tool long ot ottom t vertil enterline. 3. Lote the point t whih top of tool ontts trnsom on vertil enterline. This is the rnkshft horizontl enterline or X-Dimension. 4. Drw line perpendiulr to vertil enterline t rnkshft horizontl enterline. Pge 12 of

13 TAPE MEASURE METHOD Gsoline Sterndrive Instlltion Mnul 1. Determine X-Dimension from the following hrt. Trnsom Angle (degrees) This dimension should only e rised or lowered fter proper testing /16 in. (364 mm) /4 in. (362 mm) /16 in. (360 mm) /8 in. (359 mm) /16 in. (357 mm) in. (356 mm) /16 in. (354 mm) 2. Mesure up from the ot ottom the mount shown on the hrt for the pproprite trnsom ngle Single Engine Dul Engine 3. Drw line perpendiulr to vertil enterline t rnkshft horizontl enterline Pge 13 of 148

14 Gsoline Sterndrive Instlltion Mnul Trnsom Cutout IMPORTANT: The following instrutions will provide sterndrive unit mounting lotion tht is suitle for most ots. Best mounting lotion for prtiulr ot, however, n e determined only y testing. 1. Below 25 mph (40 km/h): Sutrt 1/2 in. (13 mm) from X-Dimension. 2. Hevy Duty Applitions: Sutrt 1 in. (25 mm) from X-Dimension. 3. Aove 25 mph (40 km/h): Use X-Dimension shown. 4. Aove 50 mph (80 km/h): The X-Dimension n e inresed to improve performne in some pplitions. However, pulling power for skiing will derese. During testing, X-Dimension should e inresed 1/2 in. (13 mm) t time until desired performne is hieved ut in no se should it ever e inresed y more thn: Alph Brvo One nd Three Brvo Two Mximum Inrese In X-Dimension 2-1/2 in. (64 mm) 3 in. (76 mm) 1 in. (25 mm) Extreme re should e tken when rising drive unit to ensure tht wter supply does not eome erted. Use ler wter inlet hose to monitor inoming wter nd monitor engine temperture guge to ensure engine does not overhet. In pplitions where ooling wter to the engine is supplied y through the hull or through the trnsom fitting, the sterndrive height will not use ooling wter ertion. IMPORTANT: Dmge to Merury MerCruiser produts used y too high of n instlled height will not e overed y Merury MerCruiser wrrnty. Pge 14 of

15 Gsoline Sterndrive Instlltion Mnul 5. Cut out trnsom using the Templte or the Trnsom Drilling Fixture Kit (purhsed seprtely) Trnsom Cutout Templte Trnsom Drilling Fixture Kit 6. Follow instrutions indited on templte or provided with drilling fixture. 7. Ensure tht enterlines on either the templte or trnsom drilling fixture lign with lines previously mrked on trnsom. 8. Drill 1/4 in. (6 mm) pilot holes for hole sw guide t 60 degree ngle nd ut on the line when mking trnsom utout. If utout is mde inorretly, drive unit steering lever my ontt trnsom, thus limiting steering trvel. 9. Sel inside edge of trnsom utout opening with suitle selnt to prevent wter sorption nd deteriortion of trnsom. 10. Cut drin hole nd instll drin plug flnge with pproprite fsteners Pge 15 of 148

16 Gsoline Sterndrive Instlltion Mnul Sewter Connetions - Generl Informtion Sewter Pikup This setion overs through the hull nd through the trnsom wter inlets only. For informtion on sterndrive wter inlet onnetions, refer to the pproprite setion fter engine instlltion. IMPORTANT: Sel the inside edges of ny hole mde through the hull with suitle selnt to prevent wter sorption nd deteriortion. THROUGH THE HULL MOUNTED 1. Sel inside edges of 1-3/4 in. (44 mm) hole in hull using suitle seler. 2. Apply mrine ulking (seler) to mounting surfe on sewter pikup where hull ontt will our when instlled. Desription Where Used Prt Numer A Mrine Culking Mounting Surfes Otin Lolly IMPORTANT: Sewter inlet slots must fe forwrd - prllel with the flow of wter. 3. Ensure slots in sewter pikup re fing forwrd (towrd ow of ot) nd instll sewter pikup through hull. 4. Fsten pikup with 4 pproprite mounting srews (if so designed). 5. Apply mrine ulking s needed inside ot. Apply selnt to threds of nut nd instll on pikup on inside of ot nd torque nut. d B A Sewter Pikup -Sewter Inlet Slots -Mounting Srew Holes (If Equipped) d-nut Desription Where Used Prt Numer A Mrine Culking Mounting Surfes Otin Lolly B Lotite 271 Sewter Inlet Nut Desription Nm l-in. l-ft Nut NOTE: If pikup eing instlled does not hve mounting srews on underside where mounted to hull, e ertin, fter nut is torqued, tht slots re still fing forwrd. Pge 16 of

17 TRANSOM MOUNTED Gsoline Sterndrive Instlltion Mnul 1. Sel the inside edges of the 1-1/2 in. (38 mm) hole hose fitting. 2. Ensure tht the hose fitting nd plsti plug re in ple nd threds hve een seled prior to tightening eh seurely. NOTE: Use shrp knife or wood hisel to remove exess plsti plug mteril so tht plug is flush with pikup sting. 3. Position 1 flt wsher nd 1 ruer O-ring on eh 5/16 in. x 4 in. (102 mm) long, round hed srew. Cot eh srew shft with selnt. 4. Ple new gsket on pikup housing nd hold pikup in ple on trnsom. Instll 4 round hed srews (with wshers nd O-rings in ple) into pikup mounting holes nd through drilled 21/64 in. (8 mm) holes in trnsom. A d e f B A g h j i Hose Fitting -Nut (4) -Gsket d-o-ring (4) e -Wsher (4) f -Srew (4) g-plsti Pug h-pikup i -Sreen j -Srew (2) Desription Where Used Prt Numer A Lotite 565 PST Hose Fitting Threds Plsti Plug Threds Otin Lolly B Silione Selnt Or Equivlent Srew Shft Pge 17 of 148

18 Gsoline Sterndrive Instlltion Mnul NOTE: Some instlltions my hve 7/32 in. (5 mm) holes drilled in trnsom using four 5/16 in. dimeter stinless steel lg olts in ple of round hed srews. In ny se, flt wshers nd O-rings re required s outlined Wter Pikup Instlled on Trnsom -Digonl Mount - Leding Edge Of Pikup 1/8 in. (3.2 mm) From Bot Bottom. -Vertil Mount - Corner Of Leding Edge Of Pikup 1/8 in. (3.2 mm) From Bot Bottom 5. Seure wter pikup from inside with loknuts nd wshers (unless using lg olts). 6. Tighten fsteners seurely. Preliminry Connetions Power Trim Pump 1. Selet n pproprite mounting lotion for the trim pump tht: Is within length limits of lk nd gry hydruli hoses oming from giml housing ssemly. Is lose to the ttery so tht trim pump ttery leds n e onneted. Allows esy ess to trim pump oil fill nd vent lotions. Is in n re where pump will not e exposed to wter. Prevents the power steering ooster ylinder from oming in ontt with the trim pump when the steering wheel is turned in either diretion (right or left). NOTE: Templte provides mounting hole lotion for floor or trnsom mounting. 2. Remove the p plug. 3. Mount the pump in the desired lotion. Pge 18 of

19 Fuel Inlet Fitting Gsoline Sterndrive Instlltion Mnul IMPORTANT: The following informtion is provided to ensure proper instlltion of rss fittings or plugs instlled into fuel pump or fuel filter se: Use #565 Lotite Pipe Selnt with Teflon on threds of fuel inlet fittings or plugs. DO NOT USE TEFLON TAPE. Fuel inlet fittings or plugs should first e threded into fuel pump or fuel filter se until finger-tight. Fuel inlet fittings or plugs should then e tightened n dditionl 1-3/4 to 2-1/4 turns using wrenh. DO NOT OVERTIGHTEN. To prevent over-tightening when instlling fuel line, the rss fittings should e held with suitle wrenh s fuel inlet fittings re tightened seurely. WARNING Boting stndrds (NMMA, ABYC nd others) nd Cost Gurd regultions must e dhered to when instlling fuel delivery system. WARNING Avoid gsoline fire or explosion. Improper instlltion of rss fittings or plugs into fuel pump or fuel filter se n rk sting nd/or use fuel lek. 1. Remove plsti plug from fuel inlet hole. 2. Apply selnt to threds of fuel inlet fitting. DO NOT USE TEFLON TAPE. 3. Instll fuel inlet fitting. To prevent rking the sting or using fuel leks, turn fuel inlet fitting in y hnd until finger-tight, then tighten onnetor to 1-3/4 to 2-1/4 turns with wrenh. DO NOT OVERTIGHTEN. A A Models With Boost Pump -Fuel Inlet Fitting Models Without Boost Pump Desription Where Used Prt Numer A Lotite 565 Fuel Inlet Fitting Otin Lolly Pge 19 of 148

20 Gsoline Sterndrive Instlltion Mnul Inline Fuel Filter INSTALLATION IMPORTANT: If the engine is equipped with oost pump, n inline filter must e instlled etween the fuel tnk nd the oost pump. NOTE: Per ABYC nd Cost Gurd regultions, the fuel filter does not need to e grounded. WARNING Avoid injury or deth nd power pkge dmge from n eletril shok, fire or explosion. Alwys disonnet oth ttery les from the ttery efore serviing the power pkge. 1. Disonnet oth ttery les from the ttery. 2. Instll ot fuel line from the tnk to the engine. 3. With the engine instlled, lote setion of the fuel line in serviele lotion, leving enough room for filter, onnetions nd rket mounting. 4. Remove 76 mm (3 in.) of fuel line in mounting lotion. 5. Selet pproprite size onnetor for the fuel line nd instll the onnetor on the filter. IMPORTANT: Use of fittings other thn those supplied y Merury MerCruiser is eptle s long s they do not exeed the mximum speified fuel pressure drop. Refer to the Merury MerCruiser Applitions Mnul for more informtion on fuel pressure speifitions. 6. Apply selnt to the mle pipe threds on the onnetors. Desription Where Used Prt Numer Lotite 565 Mle Threds Otin lolly 7. Torque onnetors. Desription Nm l-in. l-ft Connetors Insert filter into the mounting lip Inline Filter -Connetors -Mounting Clip IMPORTANT: Per Cost Gurd Regultion(CFD ), eh fuel filter nd striner must e supported on the engine or the ot struture independent from its fuel line onnetions, unless the fuel filter or striner is inside fuel tnk. Pge 20 of

21 Gsoline Sterndrive Instlltion Mnul 9. Instll nd torque srew nd wsher through the mounting lip into the stringer. Desription Nm l-in. l-ft Srew, Mounting Clip Instll nd torque hose lmps over hose nd insert rs into hose Fuel Line Stringer Clips -Fuel Line Desription Nm l-in. l-ft Hose Clmps Inspet the fuel line stringer lips to ensure tht the reommended length etween lips hs not een exeeded. The mximum llowle length is 45.7 mm (18 in.). 12. Pressurize the fuel system nd hek for leks. Relieve pressure nd then hek for leks gin. SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS CAUTION The eletri fuel pump nd ftory instlled wter seprting fuel filter hve een refully designed to funtion properly together. Do NOT instll dditionl fuel filters nd/or wter seprting fuel filters etween fuel tnk nd engine. The instlltion of dditionl filters my use: Fuel Vpor Loking Diffiult Wrm-Strting Piston Detontion Due to Len Fuel Mixture Poor Driveility Pge 21 of 148

22 Gsoline Sterndrive Instlltion Mnul Trnsom Connetions Instlling Giml Housing 1. Crefully remove trnsom ssemly from shipping rton. 2. Remove nd red ll tgs tthed to trnsom ssemly. -Dust Cover -Shipping Hrdwre Remove the shipping hrdwre. 4. Remove the dust over if ot will e shipped with drive instlled. 5. Retin the seril numer envelope. Pge 22 of

23 Instlling Inner Trnsom Plte Gsoline Sterndrive Instlltion Mnul 1. Insert wires, hoses nd shift le through pproprite openings in inner trnsom plte. 2. Position giml housing on trnsom nd hold in ple. IMPORTANT: Tighten the trnsom ssemly fsteners using n X-pttern torque sequene, strting from the middle fsteners. Tighten in smll inrements nd go round the pttern severl times until the proper torque is hieved. 3. Seure trnsom ssemly with hrdwre s shown. Torque the hrdwre. Desription Nm l-in. l-ft Trnsom Assemly Hrdwre Atth ontinuity wires. IMPORTANT: Steering lever ontinuity iruit wire must e positioned s shown to void stressing wire when steering lever moves Loknuts And Flt Wshers (8). -Torque Sequene -Continuity Wire Pge 23 of 148

24 Gsoline Sterndrive Instlltion Mnul Conneting Speedometer Pikup CAUTION Exess wter in ilge n dmge engine or use ot to sink. Do NOT remove plug from speedometer pikup tue fitting unless onnetion is to e utilized. The onnetion for the speedometer pikup n e essed through hole nd fitting in the inner trnsom plte. 1. Remove plug from speedometer pikup tue fitting Plug -Inner Trnsom Plte Fitting 2. Apply selnt to threds of r fitting. Instll nd torque the r fitting. A Br Fitting Desription Where Used Prt Numer A Lotite 565 Speedometer Br Fitting Otin Lolly Desription Nm l-in. l-ft Br Fitting Connet 5/32 in. (4 mm) speedometer hose (not provided) hose from speedometer to r fitting. Seure hose with tie strp. 4. Seure the hose to the trnsom with the hose lip nd srew tht re provided in the prts g. NOTE: The hose must not ome into ontt with the steering system omponents or the engine oupler nd drive shft. Pge 24 of

25 Fluid Connetions Gsoline Sterndrive Instlltion Mnul 1. Connet the ger lue monitor hose to the quik relese 90 degree fitting. CAUTION Avoid sterndrive unit dmge. Quik relese utton on ger lue monitor 90 degree hose fitting my not lok on giml housing if touhing or depressed y wter inlet fitting or lok-off plte, if equipped. Filure to do so ould result in loose 90 degree fitting using loss of ger lue nd dmge to drive unit. 2. Connet 90 degree fitting to the giml housing. d Hose -Quik Relese 90 Fitting -Giml Housing Fitting d-ger Lue Monitor NOTE: The quik relese utton on hose fitting must e positioned wy from wter inlet fitting, or lok-off plte if equipped. Relese utton must not ontt wter fitting or lok-off plte, if equipped. NOTE: The hose must not ome into ontt with the steering system omponents or the engine oupler nd drive shft. 3. Selet mounting lotion for oolnt reovery ottle nd mounting rket tht meets ll of the following: Within limits of ler plsti tuing. Level with or ove the het exhnger fill nek. Aessile for oserving oolnt level nd filling Pge 25 of 148

26 Gsoline Sterndrive Instlltion Mnul 4. Mount oolnt reovery ottle nd mounting rket in desired lotion using two 3/4 in. (19 mm) long srews nd flt wshers. 5. Route plsti tuing to reovery ottle. Ensure tht tuing is positioned wy from ny moving prts. Cut plsti tuing s required nd onnet to ottom onnetion on reovery ottle nd seure with tuing lmp provided. 6. Fsten plsti tuing to ot, s neessry, with 2 hose lips nd 1/2 in. (13 mm) long srews (provided). -Reovery Bottle And Mounting Brket -Srews And Flt Wshers -Plsti Tuing d-tuing Clmp d Pge 26 of

27 Instlling Steering System Gsoline Sterndrive Instlltion Mnul HYDRAULIC (HELM) STEERING POWER STEERING If your power pkge is equipped with Compt Hydruli Steering, refer to the Compt Hydruli Steering Instlltion Instrutions. Complete the instlltion of the hydruli steering system efore proeeding to Trnsom Preprtion. NOTE: For dul instlltions, power steering unit n e mounted on port or strord trnsom ssemly. Mesure ext distne etween power pkge enterlines. Selet tie r from Merury Preision Prts / Quiksilver Aessory Guide. Refer to tie r instlltion instrutions efore proeeding. 1. Inspet the ushings for deris. Lurite the ushings. A Bushings -Shipping Hrdwre Desription Where Used Prt Numer A Speil Lurint 101 Bushings A1 2. Remove shipping hrdwre. 3. Remove the otter pins. 4. Loosen the upper nd lower pivot olts nd ensure tht the threds re well lurited.. Add lurint s neessry. Desription Where Used Prt Numer Speil Lurint 101 Pivot Bolts A Pge 27 of 148

28 Gsoline Sterndrive Instlltion Mnul 5. Instll steering ssemly s follows:. Position steering ssemly so tht pivot olts will enter ushings in pivot lok or power steering ontrol vlve.. Instll upper nd lower pivot olts long with t wshers. Ensure tht t wsher tngs strddle the ridge on inner trnsom plte.. Turn pivot olts ll the wy in y hnd to ensure proper lignment. d. Ensure steering ssemly pivots freely. 6. Torque pivot olts. Bend t wsher tngs ginst orresponding flts on olt heds. -T Wshers -Ridge -Pivot Bolts Desription Nm l-in. l-ft Pivot Bolts NOTE: It my e neessry to tighten further to lign flts on pivot olt with tngs on t wsher. Pge 28 of

29 CAUTION Gsoline Sterndrive Instlltion Mnul MOVING THE CONTROL VALVE RAM with the hoses disonneted will expel fluid from the ontrol vlve ports. Wer eye protetion. 7. The ontrol vlve rm my e stiff nd diffiult to move when you ttempt to pull it out or push it in for instlltion. Move the ssemly in the diretions shown elow Control Vlve Ports 8. Connet levis to steering lever. Lurite levis pin. Ensure to spred oth ends of otter pin. NOTE: Mke sure to insert levis pin from the top to ensure tht otter pin hole is s shown in the digrm. -Clevis -Steering Lever -Clevis Pin d-cotter Pin d Desription Where Used Prt Numer A Speil Lurint 101 Clevis Pin A Pge 29 of 148

30 Gsoline Sterndrive Instlltion Mnul IMPORTANT: Quiksilver Ride Guide steering le hs self-loking oupler nut nd does not require n externl loking sleeve or loking plte. -Self-Loking Coupler Nut CAUTION Steering le outer sing must e free to move k nd forth for steering system to funtion properly. Do NOT fsten ny items to steering le. 9. Cot steering le end with lierl mount of lurint. 10. Instll steering le nd seure with hrdwre. g A e f h d d Steering Cle -Grese Fitting -Cle Coupler Nut d-cle Guide Tue e -Steering Cle End f -Clevis g-clevis Pin h-cotter Pin Desription Where Used Prt Numer A Speil Lurint 101 Steering Cle End A1 Pge 30 of

31 STEERING HELM AND CABLE Gsoline Sterndrive Instlltion Mnul IMPORTANT: Slight feedk in the steering system ould e enountered if the le guide tue flt surfes re not positioned vertilly. 11. Using suitle wrenh hold the flt surfes on the le guide tue in the vertil position. Torque oupler nut. Be ertin the flt surfes re still ligned vertilly fter torque is pplied to oupler nut. Desription Nm l-in. l-ft Steering Cle Coupler Nut CAUTION Steering le outer sing must e free to move k nd forth for steering system to funtion properly. Do NOT fsten ny items to steering le. Trnsom ssemly is shipped with the steering le guide tue preset for les with end dimensions tht omply with ABYC stndrds s outlined in the NMMA ertifition hndook. The steering le oupler nut must lso hve mens of loking it to the guide tue, s speified in ABYC requirements. WARNING Filure to use steering le loking devie ould use loss of steering, whih ould use dmge to the ot nd/or injury. NOTE: All urrent prodution Quiksilver RideGuide steering les hve self-loking oupler nut nd do not require n externl loking devie. (Other le mnufturers lso mke les with self-loking oupler nut.) -Quiksilver RideGuide Steering Cle Self-Loking Coupler Nut (Identified By Groove) IMPORTANT: If using steering le tht does not hve self-loking oupler nut, n externl loking devie suh s loking sleeve must e used. Exmple Of Externl Loking Devie -Steering Cle -Loking Sleeve Pge 31 of 148

32 Gsoline Sterndrive Instlltion Mnul CAUTION If steering le with improper dimensions is instlled, severe dmge to trnsom ssemly nd/or steering system my result. 1. Steering le must e the orret length, prtiulrly when instlled in lrger ots. 2. Avoid shrp ends, kinks or loops in le. 3. Fully extended steering le end dimension must e s shown. STEERING CABLE SPECIFICATIONS IMPORTANT: Power steering pump lugging (squeling) in hrd right turn (ginst lok) my men steering le hs een instlled tht does not hve the orret dimensions. e f g d CL k l j i h Coupler Nut - 7/8-14 UNF - 28 Thred -11-3/4 in. (298 mm) Minimum -Interfe Point d-1/2 in. (12.7 mm) Mximum e -27/64 in. (10.7 mm) Minimum Flt f -7/64 in. (3.1 mm) Minimum Rdius g-5/8 in. (15.9 mm) Mximum Dimeter End Fitting h-3/8 in. (9.5 mm) i -3/8 in. (9.8 mm) Dimeter Through Hole (Chmfered Eh Side) j -1-3/8 in. (34.9 mm) Mx k -5/8 in. (15.9 mm) Dimeter Tue l -Cle Trvel: Mid-Trvel Position /8 in. (429 mm) Totl Trvel To Be 8 in. (203 mm) Minimum to 9 in. (228 mm) Mximum Trvel Eh Side of Mid-Trvel Position - 4 in. (102 mm) Minimum to 4-1/2 in. (114 mm) Mximum Pge 32 of

33 Trnsom Preprtion Gsoline Sterndrive Instlltion Mnul IMPORTANT: Exhust pipe nd giml housing mting surfes must e len nd free of niks nd srthes nd O-ring must e properly seted in groove or wter nd exhust my lek into ot. -Giml Housing Mting Surfe -O-ring Ensure mting surfes re len nd o-ring is properly seted. 2. Loosen hose lmps nd remove exhust pipe nd ellows from engine. 3. Through the Prop Exhust Models: Instll exhust pipe ssemly s shown, using 4 olts nd lokwshers. Torque olts Exhust Pipe -Bolts And Lokwshers (4) Desription Nm l-in. l-ft Bolts Pge 33 of 148

34 Gsoline Sterndrive Instlltion Mnul 4. Through the Trnsom Exhust Models: Instll lok-off plte s shown, using 4 olts nd lokwshers. Torque olts. -Blok-Off Plte -Bolts And Lokwshers Desription Nm l-in. l-ft Bolts NOTE: Through the Trnsom exhust fittings n e instlled t this time. 5. Position rer engine mount tthing hrdwre on inner trnsom plte mounts s shown Fier Wshers -Doule-Wound Lokwshers -Loknuts Pge 34 of

35 BRAVO MODELS Gsoline Sterndrive Instlltion Mnul IMPORTANT: When instlling through the trnsom exhust, it is reommended tht the exhust ellows on the trnsom ssemly e removed. This is neessry to void reting vuum t the exhust outlet in the propeller t higher ot speeds. This vuum ould degrde propeller performne on some ots. 1. If required, remove nd disrd lmps nd ellows from giml housing. IMPORTANT: When instlling through the propeller exhust: With Brvo One nd Brvo Two Sterndrives n exhust tue MAY BE INSTALLED for slight inrese in performne. With most Brvo Three Sterndrive Models n exhust tue MAY BE INSTALLED for slight inrese in performne. With Silent Choie Exhust System the exhust ellows must e removed nd n exhust tue MUST BE INSTALLED. With ny pplition, instlltion of n exhust tue will inrese exhust noise. NOTE: Exhust tue prts re provided with Brvo Three Sterndrive. They re loted in the sterndrive unit ox. 2. If required, instll exhust tue on giml housing s follows:. Remove nd disrd lmps nd exhust ellows. CAUTION Exhust tue lmp my orrode if grounding lip is not instlled.. Instll grounding lip on tue. NOTE: Bellows dhesive is not used when instlling n exhust tue.. Position tue so tht SIDE mrkings on tue re fing towrd the right nd left sides. d. Instll nd torque the lmp. e d Exhust Tue -Clmp -SIDE Mrking d-exhust Tue e -Grounding Clip Desription Nm l-in. l-ft Clmp Pge 35 of 148

36 Gsoline Sterndrive Instlltion Mnul Drive Shft Extension Models Engine Preprtion If your power pkge is equipped with drive shft extension, refer to the Drive Shft Extension Instlltion Instrutions ( ) inluded with your engine pkge. 1. Remove nd red ll tgs tthed to engine. 2. Remove the plug from the engine oupler. 3. Remove ll hrdwre tht seures engine to shipping ontiner. 4. Connet ttery les to engine. Ensure to oserve the following:. Mke sure tht grounding stud nd strter solenoid terminl re free of pint or ny other mteril tht ould use poor eletril onnetion.. After ttery les re onneted, pply thin ot of selnt to the terminls. Desription Where Used Prt Numer Liquid Neoprene Bttery Terminls Ensure to slide ruer oot over positive (+) terminl fter mking onnetion. 5. Drpe ttery les over top of engine to prevent interferene during instlltion. IMPORTANT: There is fuse loted t the strter solenoid. Do NOT remove this fuse. The positive ttery le must e onneted to the sme stud s the fuse. d Positive (+) Bttery Cle -Strter Solenoid -90 Amp Fuse - Do NOT Remove d-ruer Boot Lotion 6. Remove shipping plug from oupler nd lurite splines. Desription Where Used Prt Numer Engine Coupler Spline Grese Coupler Splines A4 7. Instll quik oil drin hose plug in oil drin hose. 8. Instll the fuel inlet fitting. Pge 36 of

37 Engine Instlltion Gsoline Sterndrive Instlltion Mnul NOTE: An engine mount drilling fixture ( A1) n e used to lign nd djust engine mounts. Refer to instrutions with fixture for proper use. 1. Remove the engine over. 2. Atth suitle sling to lifting eyes on engine nd djust so tht engine is level when suspended. CAUTION Center lifting eye on top of thermostt housing is used for engine lignment only. Do NOT use to lift entire engine. -Front Lifting Eye -Rer Lifting Eye -Center Lifting Eye Loosen the engine mount djustment nut. 4. Lift engine into position in ot using n overhed hoist. NOTE: If drin plugs on the sewter pump interfere with instlltion, remove them nd instll rss plugs Pge 37 of 148

38 Gsoline Sterndrive Instlltion Mnul 5. Line up the intermedite elows with the exhust tues. 6. Spry lurint into the exhust tues to ssist with intermedite elow instlltion into exhust tues. A -Bullhorn -Intermedite Elow -Exhust Tue Desription Where Used Prt Numer A Power Tune Exhust Tues Push end of oil drin hose out of ot hull through flnge. 8. Pull oil drin hose out until it is 6 in. (152 mm) from the propeller. 9. Move lignment lip on the oil drin hose nd squeeze to position it on the hose just inside of the ot hull ginst the flnge. 10. Connet ilge drin plug to oil drin hose plug using lip. d Oil Drin Hose -Alignment Clip -Clip d-bilge Drin Plug Pge 38 of

39 Gsoline Sterndrive Instlltion Mnul 11. Push oil drin hose through flnge into ot hull. 12. Instll ilge drin plug in hull. 13. Align rer engine mounts with inner trnsom plte mounts while simultneously ligning exhust tue with intermedite elows. 14. Instll oth rer engine mounting olts nd hrdwre nd torque. Do NOT relieve hoist tension. d e g f -Rer Engine Mount -Inner Trnsom Plte Mount -Bolt d-wsher e -Sper f -Fier Wsher g-doule-wound Lokwsher Desription Nm l-in. l-ft Rer Engine Mounting Bolts IMPORTANT: If quik drin oil fitting is within 1/2 in. (6 mm) of ot ottom, remove fitting nd instll drin plug from prts g diretly into oil pn. 15. Ensure quik drin oil fitting is more thn 1/2 in. (6 mm) ove the ot ottom. 16. Atth the front mounts to the stringers. 17. Tighten the rer engine mounts Pge 39 of 148

40 Gsoline Sterndrive Instlltion Mnul Exhust System CAUTION It is the responsiility of the ot mnufturer or instlling deler to properly lote the engine nd instll the exhust system. Improper instlltion my llow wter to enter the exhust mnifolds nd omustion hmers nd severely dmge the engine. Dmged used y the wter in the engine will not e overed y Merury MerCruiser Wrrnty, unless this dmge is the result of defetive prts. MEASURING PROCEDURE 1. Fill ll fuel, wter, gry wter nd heter tnks to mximum pity. NOTE: Weight n e dded in these lotions to simulte full loded ondition. 2. Add mximum llowle rgo weight to ot in res where it will e stowed, inluding refrigertor nd lokers. 3. Add 190 l (86 kg) of weight in ll lotions where eh pssenger will sit during norml opertion. 4. Mesure exhust elow height. Also, mesure exhust system slope on pplitions with through the hull or through the trnsom exhust. Using A Universl Protrtor (Inlinometer) To Mesure Slope -Protrtor -Exhust Hose Or Tue On pplitions with through the propeller exhust: Proeed to Step On pplitions with through the hull or through the trnsom exhust:. Move lod weight to ow to simulte gretest ow-down ttitude the ot will enounter in norml opertion.. Rehek exhust system slope. 7. Move lod weight nd rgo weight to stern of ot to stimulte gretest stern-down ttitude the ot will enounter suh s when loding. IMPORTANT: Ensure to onsider swim pltform loding nd personl wterrft. Pge 40 of

41 8. Rehek exhust system mesurements. Gsoline Sterndrive Instlltion Mnul Minimum Exhust Elow Height from Top of Elow to Wterline Model Mesurement All V6 nd V8 13 in. (330 mm) 13 [330] d Top Of Trnsom -Highest Point On Exhust Elow -Mesurement d-wterline Additionl requirements for through the hull or trnsom exhust system pplitions: Minimum Continuous Downwrd Slope (Exhust Hoses, Colletor, Et.) Model Mesurement (degrees) All Sterndrive Pge 41 of 148

42 Gsoline Sterndrive Instlltion Mnul 9. If mesurements re less thn speified, exhust elow risers must e instlled to hieve proper dimension. Ê No Riser 3 Inh Riser 6 Inh Riser 1 -Exhust Mnifold 2 -Restritor Gsket 3 -Exhust Elow 4-3 Inh Riser 5-6 Inh Riser 6 -Open Gsket 7 -Plug 8 -Bolt, Mnifold-To-Cylinder Hed 9 -Bolt, Exhust Elow-To-Exhust Mnifold 10 - Stud 11 - Nut And Wsher, Exhust Elow-To-3 Inh Riser 12 - Bolt, 6 Inh Riser-To-Exhust Mnifold 13 - Hose Fitting 14 - Pipe Plug NOTE: Up to mximum of 9 in. (229 mm) of riser height n e dded. Pge 42 of

43 Methods for Mesuring Exhust Elow Height Gsoline Sterndrive Instlltion Mnul STRAIGHT EDGE METHOD 1. Ple stright edge ross ot. 2. With the stright edge ove the engine s shown, mesure the distne etween the stright edge nd the top of the exhust elow. 3. Mke sure tht the ot is level from side to side, using level or inlinometer. Then, mesure the distne etween the stright edge nd the outside wterline. 4. The differene etween these 2 mesurements is the exhust elow height ove the wter line. Refer to Mesuring Proedures nd ompre mesurement to speifitions. d e Wterline -Top Of Exhust Elow -Stright Edge d-mesurement Between Stright Edge And Top Of Exhust Elow e -Mesurement Between Stright Edge And Wter Line Pge 43 of 148

44 Gsoline Sterndrive Instlltion Mnul CLEAR HOSE METHOD 1. Otin 5/16 3/8 in. (8 10 mm) long hose pproximtely 15 ft (4.5 m) long. Put metl fitting or weight on 1 end of the hose to keep tht end of the hose elow the wter line. 2. Put the weighted end of the hose over the port or strord side of the ot, keeping it in line with the engine s exhust elow. 3. Route the reminder of the hose towrd the engine s exhust mnifold nd elow. Ensure tht this open end setion of the hose is s vertil s possile from the ot s ilge to the top of the exhust elow 4. Coil exess hose in ilge of ot, keeping it elow the wter line. 5. Lower open end of hose nd siphon wter until it strts to ome out of the hose. Put finger over the hose nd lift open end until it is t the top of the exhust elow. 6. Slowly tke finger off end of hose to let the wter level stilize. The wter will seek the level of the wter outside the ot. Keep hose lose to exhust elow nd s vertil s possile. 7. Mke sure tht the ot is level (side to side) using level or inlinometer. 8. The mesurement etween wter in hose nd top of exhust elow is the exhust elow height. e d -Wterline -Top Of Exhust Elow -Cler Plsti Hose d-weight e -Mesurement - Wterline To Top Of Exhust Elow Pge 44 of

45 Exhust System Hose / Tue Connetions CAUTION Gsoline Sterndrive Instlltion Mnul Avoid exhust hose filure. Dishrge wter from exhust elow must flow round entire inside dimeter of hose to void using hot spots whih ould eventully result in urned-through exhust hoses. Exhust hoses nd/or tues must e orretly onneted to exhust elows so tht they do not restrit the flow of dishrge wter from exhust elow Corret Connetion Inorret Connetion IMPORTANT: Exhust hoses/tues should e seured t eh onnetion with t lest 2 hose lmps. 1. Tighten ll exhust hose nd/or exhust tue lmps seurely. -Hose Clmps Pge 45 of 148

46 Gsoline Sterndrive Instlltion Mnul Engine Alignment 1. Ensure tht the dust over is removed or folded k out of the wy. -Dust Cover CAUTION Do NOT use n lignment tool from nother mnufturer. Alignment tools other thn Quiksilver Alignment Tool my use improper lignment nd dmge to giml ering nd/or engine oupler. 2. Attempt to insert the solid end of the lignment tool through the giml ering nd into the engine oupler splines. 3. If the tool does not fit, remove it nd refully rise or lower the front end of the engine using the enter lignment eye nd ttempt to insert the lignment tool. NOTE: It my e neessry to hit the lignment tool with synthne hmmer to set the giml ering to the oupler. 4. If neessry lightly tp the sides of the lignment tool t 90 degree inrements to help lign the giml ering. -Alignment Tool (Use Only Reommended Alignment Tool) -Insert This End Of Alignment Tool Through Giml Housing Assemly -90 Degree Inrements Pge 46 of

47 Gsoline Sterndrive Instlltion Mnul 5. Repet step 3 nd 4 until the lignment tool instlls esily (SLIDES FREELY WITH 2 FINGERS) ll the wy into nd out of engine oupler splines. Do NOT hek y turning the lignment tool. -Alignment Tool (Use Only Reommended Alignment Tool) -Insert This End Of Alignment Tool Through Giml Housing Assemly Alignment Tool -Giml Bering -Engine Coupler Pge 47 of 148

48 Gsoline Sterndrive Instlltion Mnul IMPORTANT: Finished ot stringer must position engine so tht minimum mount djustment exists fter front mount is djusted down to stringer. This llows for future djustments. IMPORTANT: Turn oth front engine mount djustment nuts n equl mount in diretion required to lign engine. 6. Adjust front engine mounts until they rest on ot stringers. 7. Relieve hoist tension entirely nd fsten oth front mounts to ot stringer using pproprite hrdwre. 8. Tighten the ottom nut to hold the engine in ple. Then relese the tension. d Engine Mount -Stringer -Bottom Nut (Not Shown) d-t 9. Rehek lignment with lignment tool. Tool must enter oupling splines freely. If not, redjust front mounts. 10. When lignment is orret, tighten loknut seurely. Rehek lignment. 11. Bend t down on djusting nut. 12. Remove lignment tool. If not instlling drive, fold ell housing dust over flp k into ple nd tpe shut for ot shipment. Dust over flp will hve to e removed efore operting engine. 13. Hook up the ground stud. 14. Connet the trim pump sender wires. 15. Instll the wter inlet hose onto the trnsom. Pge 48 of

49 Hot Wter Heter Instlltion SUPPLY HOSE CONNECTION Gsoline Sterndrive Instlltion Mnul IMPORTANT: When onneting in heter or hot wter heter: Supply hose (from engine to heter) nd return hose (from heter to engine) MUST NOT EXCEED 5/8 in. (16 mm) inside dimeter (ID). Mke heter onnetions ONLY t lotions shown. Refer to mnufturers instrutions for omplete instlltion informtion nd proedures. Do NOT reposition engine temperture swith. CAUTION Avoid performne loss nd/or possile engine dmge. Engine oolnt must flow ontinuously from the engine intke mnifold to the engine wter irulting pump. NEVER lose-off or lok the oolnt flow to or from heter. CAUTION Avoid engine overheting whih ould result in engine dmge. On models equipped with Closed Cooling, n ir poket my form in the losed ooling system if some oolnt is lost from the system nd the in heter or hot wter is mounted higher thn the fill p on the het exhnger. Heter must e mounted lower thn the fill p of the het exhnger on models so equipped. NOTE: Some models my e equipped with dditionl fittings Sewter Cooled Models Closed Cooled Models All Models -Lotion For Hot Wter Supply Pge 49 of 148

50 Gsoline Sterndrive Instlltion Mnul RETURN HOSE CONNECTION -Lotion For Hot Wter Return Eletril Connetions Instlling Continuity Wire CAUTION Avoid dmge to the EFI eletril system omponents: Refer to the following preutions when working on or round the EFI eletril hrness, or when dding other eletril essories: Do NOT tp essories into engine hrness. Do NOT punture wires for testing (Proing). Do NOT reverse ttery leds. Do NOT splie wires into hrness. Do NOT ttempt dignostis without proper, pproved Servie Tools. IMPORTANT: When routing ll wire hrnesses nd hoses, ensure they re routed nd seured to void oming in ontt with hot spots on engine nd to void ontt with moving prts. 1. Connet ontinuity iruit wire from engine to trnsom ssemly. IMPORTANT: Do NOT tth ny essory ground ( ) wires to trnsom plte ground point. Aessory ground wires n only e tthed to ground stud on engine. -Continuity Wire Pge 50 of

51 Instrumenttion Connetions Gsoline Sterndrive Instlltion Mnul We reommend the use of Quiksilver Instrumenttion nd Wiring Hrnesses. On dul sttion pplitions, oil pressure nd wter temperture senders (on engine) must e hnged. Refer to Merury Preision Prts / Quiksilver Aessories Guide for seletion. The 4 si guges tht must e used with the engine re: Thometer Oil Pressure Wter Temperture Voltmeter IMPORTANT: Connet fused essory pnel (40-mp urrent drw mximum) must e onneted s shown in the wiring digrms. 1. Route instrumenttion wiring hrness k to engine, mking sure tht hrness does not ru or get pinhed. If n extension hrness is required, ensure to seure onnetion properly. 2. Fsten hrnesses to ot t lest every 18 in. (460 mm), using pproprite fsteners. 3. Ple hose lmp over instrumenttion wiring hrness. 4. Connet the instrumenttion wiring hrness to engine hrness plug t lotion shown. -Engine Hrness Plug Tighten hose lmp to seure wiring hrness to engine hrness plug Pge 51 of 148

52 Gsoline Sterndrive Instlltion Mnul Trim Position Sender Connetions 1. Connet trim position sender wires (from trnsom ssemly) to engine hrness. Use the ORG/GRY wire for nlog guges nd the ORG/WHT wire for digitl guges. ORG/WHT BLK BLK BLK Engine Hrness Bullet Connetor -Trnsom Assemly Bullet Connetor MerCthode Connetions The MerCthode ontroller ssemly is loted on the k of the front lifting eye. The upper hose must e disonneted from the thermostt housing for ess. 1. Connet wires to MerCthode ontroller ssemly s shown. Apply thin ot of Liquid Neoprene to ll onnetions. IMPORTANT: Opposite end of RED/PURPLE wire must e onneted diretly to ttery positive (+) terminl. Do NOT onnet it to swithed positive (+) iruit. MerCthode system must funtion ontinuously for proper orrosion protetion. A d -ORANGE Led - From Anode On Trnsom Assemly -RED/PURPLE Wire - To Positive (+) Bttery Terminl -BLACK Wire - From Engine Hrness d-brown Wire - From Eletrode On Trnsom Assemly Desription Where Used Prt Numer A Liquid Neoprene MerCthode Connetions Pge 52 of

53 Audio Wrning System Connetions WARNING Gsoline Sterndrive Instlltion Mnul Alrm is not externl ignition-proof, therefore, Do NOT mount lrm in engine or fuel tnk omprtments. 1. Selet lotion for udio wrning lrm whih meets ll of the following: lrm n e esily herd, yet is out of sight lrm n e esily essed for instlltion nd mintenne lrm will remin dry lrm is within length limits of the 18 in. purple lrm wire tht onnets to the I terminl or 12 volt soure on swithed side of ignition swith. NOTE: The terminl to whih wire is tthed must hve no voltge when ignition swith is in the OFF position. 2. Ple lrm in desired lotion nd seure to wire undle with tie-strp provided. 3. Connet PURPLE wire from lrm to ny PURPLE wire terminl on instrument guge or ignition swith. Tighten onnetion seurely. 4. Connet TAN/BLUE wire from lrm to TAN/ BLUE wire from instrument hrness. 5. Ple the smll (trnsprent) dels on the ottom of the wter temperture nd the oil pressure guges. 6. Ple the lrge del on the instrument pnel or other pproprite lotion in esily viewed y the opertor. ALARM INDICATES LOW OIL OR OVERHEATING APPLY THE PROPER DECAL TO THE DASHBOARD OR OTHER APPROPRIATE LOCATION: 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) Smll Del (Trnsprent) -Lrger Del 7. Test udio wrning system during Predelivery Preprtion setion Pge 53 of 148

54 Gsoline Sterndrive Instlltion Mnul Power Trim Pump Connetions IMPORTANT: Mke hydruli onnetions s quikly s possile to prevent oil from leking out of system. Be reful not to ross-thred or overtighten hose fittings. 1. Connet hydruli hoses to trim pump. Torque fittings. Desription Nm l-in. l-ft Fittings Connet power trim pump ontrol hrness to trim pump. 3. Connet trim limit swith wires nd seure with wire retiner nd tie-strp. d f g e Blk Hose Fitting (UP Ciruit) -Gry Hose Fitting (DOWN Ciruit) -Control Hrness d-tie-strp e -Trim Limit Swith Wire (With Blue Sleeve) To BLUE/WHITE Hrness Wire f -Trim Limit Swith Wire (With Purple Sleeve) To PURPLE/WHITE Hrness Wire g-wire Retiner And Tie Strp Pge 54 of

55 Gsoline Sterndrive Instlltion Mnul 4. Unsrew fill p nd remove p plug from fill nek nd disrd. Instll fill p. -Cplug -Fill Cp Connet power trim pump wires to ttery. -Positive Bttery Led -Negtive Bttery Led Pge 55 of 148

56 Gsoline Sterndrive Instlltion Mnul Fluid Connetions Ger Lue Monitor Hose Power Steering Hoses IMPORTANT: Avoid using exessive hose when routing it to ger lue monitor. Hose should e routed diretly to oil reservoir in s stright line s possile to void low spots (trps) in the system. CAUTION Ensure hose is not kinked when onneting in the following step. If hose is kinked, ger lue monitor will not funtion properly nd dmge to drive unit ould our. IMPORTANT: Hose must not ome in ontt with steering system omponents or the engine oupler, U-joint shft or drive shft. CAUTION Route hoses extly s shown elow. This will help void stress on the hose fittings nd will help void kinks in the hose. IMPORTANT: Mke hydruli onnetions s quikly s possile to prevent fluid lekge. IMPORTANT: Be reful not to ross-thred or overtighten fittings. 1. Route hoses. Seure hoses to void ontt with moving omponents. 2. Connet power steering hoses to ontrol vlve. Torque oth fittings. Desription Nm l-in. l-ft Fittings Use extr hose lips to seure hose to trnsom. NOTE: Power Steering Fluid n e dded t this point, if desired. Pge 56 of

57 Gsoline Sterndrive Instlltion Mnul Brvo Models nd Alph Sewter Cooled Models Using Sterndrive Wter Pikups 1. Connet wter hose to wter inlet fitting. d e e -Hose -Hose Clmp -Hose Clip d-wter Inlet Fitting e -Bolts And Str Wshers Seure with hose lmp Pge 57 of 148

58 Gsoline Sterndrive Instlltion Mnul Alph or Brvo Models Using Alterntive Wter Pikups A wter inlet lok-off kit must e used if the sterndrive unit wter pikup will not e used to supply wter to the engine. When instlling the lok-off plte, it is neessry to ut the wter hose tht is loted etween the ell housing nd the giml housing. This llows wter to ontinue to irulte through the sterndrive unit for ooling. CAUTION Avoid overheting sterndrive. The sewter inlet holes must e llowed to flow wter without eing ostruted or overheting dmge to sterndrive my result. Do NOT ded-end sewter hose from ell housing. Cut hose s reommended in proedures. 1. Remove the existing wter fitting nd gsket. Disrd the srews nd wshers Wter Fitting -Srews And Lokwshers 2. Remove the tpered insert in the giml housing using the tpered insert tool ( ). Disrd the insert. -Tpered Insert -Tpered Insert Tool -Giml Housing Cross-Setionl View Desription Prt Numer Tpered Insert Tool Pge 58 of

59 Gsoline Sterndrive Instlltion Mnul 3. Instll the lok-off plte with new gsket. Seure with srews nd lokwshers. Torque the srews. d Blok-Off Plte -Gsket -Srew d-lokwsher Desription Nm l-in. l-ft 1 Srew, Wter Fitting Move the trim limit swith wires nd speedometer hose side. Reh etween the giml housing nd the ell housing nd deth the wter hose from the giml housing where the tpered insert ws removed in Step 2. d e Trim Limit Swith Wires -Speedometer Hose -Giml Housing d-wter Hose e -Tpered Insert Pge 59 of 148

60 Gsoline Sterndrive Instlltion Mnul WARNING Avoid wter lekge into ot. Dmge to U-joint ellows ould result in wter entering the ot. Do NOT dmge the U-joint ellows when removing setion of the wter hose tthed etween the giml housing nd ell housing. NOTE: Move the trim limit swith wires nd speedometer hose to void dmging them when utting the wter hose. The existing tie strp nd lip n e reused if they re moved nd repositioned fter the hose is ut. 5. Cut ompletely through the wter hose 5 in. (127 mm) in front of the ft end of the hose where it is fitted into the ell housing. in the re shown. Do NOT dmge the U-joint ellows. Disrd loose hose piee. 6. Seure the trim limit swith wires nd speedometer hose to the remining setion of wter hose using existing tie strp nd lip. e f d Tie Strp -Clip -Wter Inlet Hose d-speedometer Hose e -Trim Limit Wire Hrness f -Cutting Are Pge 60 of

61 Coolnt Reovery System Gsoline Sterndrive Instlltion Mnul CAUTION Avoid engine overheting nd susequent dmge to engine. The oolnt reovery system will not operte properly without proper seling. Plsti tuing MUST sel ompletely t onnetions. 1. Connet plsti tuing to yonet fitting on het exhnger. Seure with tuing lmp provided Plsti Tuing -Tuing Clmp 2. Remove p from oolnt reovery reservoir nd fill to FULL mrk with oolnt solution. 3. Reinstll p Pge 61 of 148

62 Gsoline Sterndrive Instlltion Mnul Shift Cle Instlltion Alph Models - Drive Unit Not Instlled We reommend the use of Quiksilver remote ontrol nd le. Refer to Merury Preision Prts / Quiksilver Aessories Guide for seletion. However, if ontrol other thn Quiksilver is to e used, ontrol must provide shift le trvel (t the shift plte end) of 2-7/8 in. (73 mm) to 3-1/8 in. (80 mm) with l. (6.8-9 kg) lod pplied to the le end guide. NOTE: On engines with Alph drives, the mesurement indited ove n e tken y instlling the remote ontrol shift le nd using the shift ssist ssemly (provided) to ple the proper lod on the shift le. 1. Ple mrk on the tue ginst the edge of the le end guide. d e -Shift Assist Assemly -Remote Control Shift Cle - In FORWARD Ger Position -Edge Of Cle End Guide d-remote Control Shift Cle - In REVERSE Ger Position e -Mesurement Tken From Mrk To Edge Of Cle End Guide: 2-7/8 in. (73 mm) to 3-1/8 in. (80 mm) Alph Shift Plte Pge 62 of

63 Gsoline Sterndrive Instlltion Mnul IMPORTANT: If ot is eing equipped with REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS, the shift ssist ssemly tht is shipped with the engine should NOT e used. The use of the shift ssist ssemly with this type of remote ontrol n use the shift lever to move out of ger unexpetedly. The following kit will hve to e ordered to onnet remote ontrol shift le when shift ssist ssemly is not used. Sper Kit A1 d Clevis Pin -Wsher -Sper d-cotter Pin SCALE Pge 63 of 148

64 Gsoline Sterndrive Instlltion Mnul NOTE: Do NOT disrd shift ssist ssemly until fter it is used in step 3., following. IMPORTANT: Shift le must e onneted t the remote ontrol for the pproprite rottion (LH or RH) drive unit, s explined following: RIGHT HAND ROTATION - Control le will hve to e instlled in remote ontrol so tht le end will move in diretion A when shift hndle is pled in the FORWARD position. LEFT HAND ROTATION - Control le will hve to e instlled in remote ontrol so tht le end will move in diretion B when shift hndle is pled in the FORWARD position. A B IMPORTANT: Use the following proedure to temporrily instll shift les if ot will e shipped without drive unit instlled. Refer to Shift Cle Instlltion for shift le djustment proedure one drive unit is instlled. 1. Remove shift le tthing hrdwre. -Cotter Pin -Clevis Pin And Cotter Pin -Wsher And Loknut SCALE Pge 64 of

65 Gsoline Sterndrive Instlltion Mnul 2. Ple remote ontrol shift lever in NEUTRAL position. 3. Temporrily instll levis pin through remote ontrol shift le end guide, shift ssist ssemly end nd into hole in shift lever. Then djust rss rrel so tht hole in rrel ligns with nhor stud. e d Clevis Pin -Shift Cle End Guide -Shift Assist Assemly End d-shift Lever e -Brss Brrel (On Stud) 4. Remove remote ontrol shift le nd shift ssist ssemly. IMPORTANT: Instll the otter pin through the top of the rrel retiner. 5. Instll drive unit shift le s shown. Seure rss rrel in rrel retiner with otter pin nd spred oth prongs. Seure le end guide with wshers (1 on eh side of end guide) nd loknut. Tighten loknut until it ontts, then loosen 1/2 turn. Without Shift Assist Assemly -Cotter Pin -Loknut And Wshers Pge 65 of 148

66 Gsoline Sterndrive Instlltion Mnul 6. Instll remote ontrol shift le (with or without shift ssist ssemly s pplile) nd seure with hrdwre s shown. Tighten loknut finger-tight only nd Do NOT spred otter pin ompletely. (Remote ontrol shift le fsteners will hve to e removed gin to properly djust shift les under Shift Cle Instlltion setion of this mnul.) d e With Shift Assist Assemly -Remote Control Shift Cle -Shift Assist Assemly -Clevis Pin And Cotter Pin d-lrge I.D. Wsher e -Smll I.D. Wsher And Loknut d e f h i g Without Shift Assist Assemly -Remote Control Shift Cle -Pin -Cotter Pin (Existing) d-spring (Existing) e -Wsher (Existing) f -Wsher g-sper h-wsher (Existing) i -Loknut (Existing) Pge 66 of

67 Brvo Models Gsoline Sterndrive Instlltion Mnul NOTE: Using Adjustment Tool ( ), shift les n e djusted without or with the sterndrive instlled, using the following proedure. IMPORTANT: Sterndrive unit propeller rottion is determined y the shift le instlltion in the remote ontrol. Brvo One/Two - If shift le end guide moves in diretion A when ontrol lever is pled in FORWARD, remote ontrol is set up for RIGHT HAND (RH) propeller rottion. Brvo One/Two - If shift le end guide moves in diretion B when ontrol lever is pled in FORWARD, remote ontrol is set up for LEFT HAND (LH) propeller rottion. A B Arrow Indites Diretion Of Motion Brvo Three - Front propeller on sterndrive unit is lwys LH Rottion nd rer propeller is lwys RH Rottion. Shift le end guide must move in diretion A, when ontrol lever is pled in FORWARD ger position. A IMPORTANT: When instlling shift les, ensure tht les re routed in suh wy s to void shrp ends nd/or ontt with moving prts. Do NOT fsten ny items to shift les. 1. Instll shift le into remote ontrol. (Refer to pproprite remote ontrol instrutions.) 2. Remove the guide. 3. Loosen stud nd move it to dimension, s shown. Retighten stud Stud -3 in. (76 mm) (Center Of Pivot Bolt To Center Of Stud) Pge 67 of 148

68 Gsoline Sterndrive Instlltion Mnul 4. Instll sterndrive unit shift le. 5. Tighten loknut until it ontts nd then loosen 1/2 turn. 6. Insert otter pin from top nd spred ends. -Wshers (2) -Loknut -Cotter Pin Ple djustment tool over sterndrive unit shift le, s shown. Hold tool in ple, using piee of tpe over the rrel retiner. SCALE Pge 68 of

69 Gsoline Sterndrive Instlltion Mnul 8. Lote enter of remote ontrol nd ontrol le ply (klsh). IMPORTANT: Ensure to keep enter mrk ligned with ontrol le end guide edge when mking the following djustment.. Shift remote ontrol to NEUTRAL.. Push in on ontrol le end with enough pressure to remove ply nd mrk position on tue.. Pull out on ontrol le end with enough pressure to remove ply nd mrk position on tue. d. Mesure distne etween mrks nd nd mrk position hlf-wy etween mrks nd Temporrily instll ontrol le end guide into shift lever nd insert nhor pin. 10. Adjust ontrol le rrel so tht hole in rrel enters with vertil enterline of stud. Ensure tht klsh enter mrk is ligned with edge of ontrol le end guide. CAUTION Do NOT ttempt to instll or remove ontrol le rrel from stud without first removing end guide nhor pin from shift lever nd removing le. Attempting to end ontrol le to instll or remove rrel will ple undue stress on le end guide nd shift lever nd dmge to oth ould our Pge 69 of 148

70 Gsoline Sterndrive Instlltion Mnul 11. Remove ontrol le end guide from shift lever y removing nhor pin. d e SCALE Control Cle End Guide -Anhor Pin -Bklsh Center d-control Cle Brrel e -Stud Instll ontrol le. 13. Instll wsher nd loknut. 14. Tighten loknut until it ontts nd then loosen 1/2 turn. 15. Insert otter pin from top nd spred ends. d Loknut -Wshers - Both Sides Of Brrel -Anhor Pin d-cotter Pin (Not Shown) Pge 70 of

71 Gsoline Sterndrive Instlltion Mnul 16. Remove djustment tool. 17. Shift remote ontrol lever into full FORWARD position. Ple end of djustment tool in rrel retiner. RH rottion Brvo One, Two nd Three Models: Rer slot in tool should fit over shift lever stud. LH rottion Brvo One And Two: Forwrd slot in tool should fit over shift lever stud. If slot does not fit over stud, loosen shift lever stud nd slide stud up or down until slot in tool fits over stud. When djustment is orret, retighten stud. RH Rottion Brvo One, Two, Three d LH Rottion Brvo One And Two -Adjustment Tool -Brrel Retiner -Shift Lever Stud d-shift Lever Adjustment Slot Remove djustment tool. 19. Lurite shift le pivot points. Desription Where Used Prt Numer SAE 30W Engine Oil Shift Cle Pivot Points Otin Lolly Pge 71 of 148

72 Gsoline Sterndrive Instlltion Mnul Throttle Cle Instlltion nd Adjustment 1. Ple remote ontrol hndles in NEUTRAL / IDLE position. IMPORTANT: Ensure tht le is routed to void shrp ends nd/or ontt with moving prts. Do NOT fsten ny items to throttle le. Outer le must e free to move when le is tuted. 2. Adjust le so tht it n e pled on oth studs simultneously. 3. Ple le over studs. Do NOT djust le fter instlltion. 4. Seure throttle le with hrdwre s shown nd tighten seurely. Loosen loknut 1/2 turn. Typil -Flt Wsher And Loknut -Cle Brrel -End Guide Pge 72 of

73 Gsoline Sterndrive Instlltion Mnul 5. Ple remote ontrol throttle lever in the wide open throttle (WOT) position. Ensure tht throttle pltes re ompletely open. -Throttle Plte Return remote ontrol throttle lever to IDLE position nd ensure tht throttle lever is ompletely losed. -Throttle Plte Pge 73 of 148

74 Gsoline Sterndrive Instlltion Mnul Sterndrive Unit Instlltion 1. Remove trim ylinder support nd dust over from ell housing studs. (Retin elsti stop nuts nd flt wshers.) 2. Remove ger lue monitor p. Fill with lurint. A -Cp Desription Where Used Prt Numer A High Performne Ger Lue Ger Lue Monitor 3. Push drile vlve stem in until ger lue ppers. -Drile Vlve Stem One ger lue ppers, relese drile vlve stem. 5. Fill monitor to FULL mrk. 6. Reple monitor p. Pge 74 of

75 Gsoline Sterndrive Instlltion Mnul IMPORTANT: Ruer gsket must e properly positioned in ell housing ore efore instlling drive unit or wter my lek into ot. 7. Alph Models: Ensure tht ruer gsket nd wter pssge O-ring re properly positioned in ell housing. -Ruer Gsket -Wter Pssge O-ring Cot sterndrive unit pilot, U-joint O-rings nd drive shft splines. A A A A Sterndrive Unit Pilot -O-rings -Splines Desription Where Used Prt Numer Drive Unit Pilot A Engine Coupler Spline Grese U-Joint O rings A4 Drive Shft Splines Pge 75 of 148

76 Gsoline Sterndrive Instlltion Mnul 9. Ensure tht the u-joint ellows re len nd free of deris. -U-joint Bellows Alph Models 1. Position ell housing shift shft oupler so tht slot in oupler is positioned stright fore nd ft. Do this y pling remote ontrol shift lever in: FORWARD ger position for RH drive or REVERSE ger position for LH drive unit. d -Shift Shft -Shift Shft Coupler -Shift Slide d-slot Pge 76 of

77 Gsoline Sterndrive Instlltion Mnul IMPORTANT: Shift slide ssemly is free to rotte on ore wire. Ensure tht shift slide remins in upright position nd is properly engged with shift shft lever roller while instlling drive unit. 2. Engge shift shft roller into shift shft lever. Snp the Shift Shft Slide Stilizer Tool onto stud diretly elow shift slide nd position s shown Shift Shft Lever -Roller -Shift Shft Slide Stilizer Tool Desription Prt Numer Shift Shft Slide Stilizer Tool A1 3. Position drive unit shift shft so tht it is stright forwrd y turning shift shft CLOCKWISE while simultneously turning propeller shft COUNTERCLOCKWISE Drive Unit Shift Shft Pge 77 of 148

78 Gsoline Sterndrive Instlltion Mnul IMPORTANT: Ensure to instll RH or LH drive unit on the pproprite trnsom ssemly when mking dul engine instlltions. The LH rottion drive unit n e identified y the del on the k side of the upper drive shft housing, whih sttes: Alph One - Counter Rottion 4. Ple gsket on ell housing. -Gsket Instll sterndrive unit s follows:. Position trim ylinder stright k (over top of elertion plte). Be reful not to srth elertion plte or trim ylinders.. Guide U-joint shft through giml ering nd into engine oupler while simultneously guiding shift slide into drive shft housing. Mke sure shift slide remins upright nd engged with ell housing shift shft lever.. Remove Shift Slide Stilizer Tool. d. Slide drive unit ll the wy into ell housing. IMPORTANT: If drive unit will not slide ll the wy into ell housing, ensure tht the shift shft nd ouplers re positioned properly. Do NOT fore drive unit into position Gsket -Shift Slide -Shift Slide Stilizer Tool Pge 78 of

79 Gsoline Sterndrive Instlltion Mnul e. If neessry, rotte propeller shft COUNTERCLOCKWISE slightly to help lign U-joint shft splines with engine oupler splines. Then slide drive unit ll the wy into ell housing. f. Seure drive unit to ell housings using fsteners s shown. Torque the fsteners. -Loknut And Flt Wshers -Loknut And Continuity Ciruit Wsher (No Flt Wsher At This Lotion) Brvo Models Desription Nm l-in. l-ft Fsteners Return remote ontrol shift lever to the NEUTRAL position. 1. Lurite O-ring sels. -O-ring Sels A Desription Where Used Prt Numer A 2-4-C Mrine Lurint With Teflon O ring Sels A Pge 79 of 148

80 Gsoline Sterndrive Instlltion Mnul 2. Pull out shift linkge s fr s it moves. Jws will open Shift Linkge IMPORTANT: As sterndrive is inserted into sterndrive unit, entry of the ell housing shift le must e losely heked to mke sure le enters the jws of shift linkge ssemly in the sterndrive. 3. Ple remote ontrol in NEUTRAL position. NOTE: As ell housing shift le enters the shift linkge ssemly, it pushes the ssemly k into the sterndrive housing, nd the jw loses, seuring the le, s shown in steps A, B nd C. A B C Pge 80 of

81 Gsoline Sterndrive Instlltion Mnul IMPORTANT: If Bell Housing Shift Cle does not line up to properly enter jws of shift linkge ssemly, le will hve to e ligned mnully. -Shift Linkge Assemly -Shift Cle Ple drive shft housing in position on ell housing nd instll sterndrive unit, s follows:. Remove the nuts from the trim ylinders.. Position trim ylinders so they point stright kwrds.. Position sterndrive unit so tht universl joint shft ligns with ell housing ore. d. Guide U-joint shft through ering in giml housing nd into engine oupler. Mke sure tht shift linkge jws engge the ell housing shift le ssemly. e. If neessry, rotte propeller shft COUNTERCLOCKWISE slightly (using propeller) to lign U-joint shft splines with splines in engine oupling, then slide sterndrive unit ll the wy into ell housing. 5. Seure sterndrive unit to ell housing with 5 flt wshers nd 6 loknuts nd torque. -Loknut Only -Loknuts And Flt Wshers Desription Nm l-in. l-ft Sterndrive-To-Bell Housing Pge 81 of 148

82 Gsoline Sterndrive Instlltion Mnul IMPORTANT: On Brvo One, Two nd Three Models, the Trim-In Limit Insert must e properly positioned efore instlling the trim ylinder nhor pin in the following steps. 6. Ensure tht the Trim-In Limit Insert is positioned s shown for the pproprite Brvo model. Brvo One nd Two (Positioned Forwrd) Brvo Three (Positioned Aft) -Trim-In Limit Insert IMPORTANT: The position of the Trim-In Limit Insert on the Brvo Three sterndrive unit should only e hnged fter the ot hs een properly tested. Refer to Trim-In Limit Sttement. IMPORTANT: To id in instlling ruer ushings, use wter nd sop solution. Do NOT use oil or grese. Pge 82 of

83 All Models Gsoline Sterndrive Instlltion Mnul 1. Instll trim ylinders on ft end of sterndrive unit with hrdwre s shown. 2. Instll plsti ps nd tighten hnd tight only. NOTE: Upon instlltion of hrdwre pply lurint to ll omponents exept plsti ps. A A d e Alph Models -Aft Anhor Pin -Bushings -Flt Wshers d-e-ring Clips e -Plsti Cps A d e A f Brvo Models -Aft Anhor Pin -Lrge l.d. Flt Wshers (2) -Ruer Bushings (4) d-smll l.d. Flt Wshers (2) e -Loknuts (2) f -Plsti Cps (2) Desription Where Used Prt Numer A 2-4-C Mrine Lurint With Teflon 3. Position the drive unit seril numer del. Trim Cylinder Hrdwre A Pge 83 of 148

84 Gsoline Sterndrive Instlltion Mnul Speedometer Connetion Alph Models 1. Rise drive to gin ess to re etween giml housing nd sterndrive, immeditely ove the trnsom end of the nti-ventiltion plte. 2. Align plsti slots on mle nd femle portions nd insert. 3. Push down to seure Mle End Of Speedometer Tue Fitting -Femle Portion Tue Fitting, Mle End -Topside Portion, Femle End Pge 84 of

85 Brvo Models Gsoline Sterndrive Instlltion Mnul 1. Rise sterndrive to gin ess to re etween giml housing nd sterndrive, immeditely top the trnsom end of the nti-ventiltion plte. 2. Insert speedometer tue fitting into opening on topside of nti-ventiltion plte, in position shown. -Tue Fitting -Opening 3. With fitting fully seted, turn hndle to left to tightly seted position, s shown Hndle Pge 85 of 148

86 Gsoline Sterndrive Instlltion Mnul Shift Cle Instlltion Alph Models - Drive Unit Instlled IMPORTANT: Shift le djustment for right hnd (RH) rottion drive unit is different thn the proedure for djusting left hnd (LH) rottion drive unit. Ensure to refer to the pproprite proedure when performing the following steps. IMPORTANT: Drive unit must e instlled. IMPORTANT: Do NOT run engine. 1. Remove remote ontrol shift le nd shift ssist ssemly (if instlled). With Shift Assist Assemly -Shift Assist Assemly -Remote Control Shift Cle Without Shift Assist Assemly 2. Ensure shift lever djustle stud is t ottom of slot Adjustle Stud Pge 86 of

87 Gsoline Sterndrive Instlltion Mnul 3. Shift remote ontrol s stted in. or. following:. Right Hnd (RH) Rottion Drive Unit - FORWARD ger, pst detent, into WOT position.. Left Hnd (LH) Rottion Drive Unit - REVERSE ger, pst detent, into WOT position. (RH) (LH) Ple drive unit into ger y pushing in on drive unit shift le while simultneously rotting propeller shft COUNTERCLOCKWISE until shft stops. This will ensure full luth enggement. Mintin light pressure on the drive unit shift le to hold it t the end of its trvel (this removes ll slk from the le). IMPORTANT: Do NOT use exessive fore when holding pressure on the drive unit shift le. Exessive fore would e indited y movement of the shift utout swith. -Propeller Shft - Rotte COUNTERCLOCKWISE Pge 87 of 148

88 Gsoline Sterndrive Instlltion Mnul 5. Lightly pull on remote ontrol shift le end guide (to remove slk from remote ontrol nd le) nd djust rss rrel s neessry to lign tthing points with shift lever levis pin hole nd stud. Ensure to mintin light pressure on drive unit shift le. d -End Guide -Brss Brrel -Shift Lever Clevis Pin Hole d-stud Temporrily instll remote ontrol shift le on stud nd instll levis pin. -Remote Control Shift Cle -Clevis Pin Shift remote ontrol s stted in. or. following:. Right Hnd (RH) Rottion Drive Unit - REVERSE ger, pst detent, into WOT position.. Left Hnd (LH) Rottion Drive Unit - FORWARD ger, pst detent, into WOT position. (RH) (LH) Pge 88 of

89 Gsoline Sterndrive Instlltion Mnul 8. To ensure full luth enggement, simultneously rotte propeller shft CLOCKWISE until shft stops. -Propeller Shft - Rotte CLOCKWISE 9. Chek shift interrupt swith plunger position. Pin must e entered Shift interrupt Swith Plunger Pin If plunger pin is not entered:. Ensure djustle stud is t ottom of slot in shift lever.. Chek remote ontrol for proper shift le output [3 in. (76 mm) ± 1/8 in. (3 mm)].. If. nd. re orret, ensure drive unit shift le is not rushed or kinked. (If drive unit shift le is inding, the shift utout swith plunger pin will move off enter when shifting into nd out of FORWARD nd REVERSE.) NOTE: If shift le ws dmged during instlltion, instll new shift le ssemly in ordne with instrutions ontined in sterndrive servie mnul, then repet shift le djustment proedure Pge 89 of 148

90 Gsoline Sterndrive Instlltion Mnul 11. After remote ontrol shift le hs een properly djusted, reinstll le nd shift ssist ssemly (if pplile) nd seure with hrdwre s shown. If shift ssist ssemly tthing points will not lign, push in or pull out on end of shift ssist ssemly to instll. Do NOT ttempt to redjust shift le. d e With Shift Assist Assemly -Remote Control Shift Cle -Shift Assist Assemly -Clevis Pin And Cotter Pin d-lrge I.D. Wsher e -Smll I.D. Wsher And Loknut d e f h i g Without Shift Assist Assemly -Remote Control Shift Cle -Pin -Cotter Pin (Existing) d-spring (Existing) e -Wsher (Existing) f -Wsher g-sper h-wsher (Existing) Pge 90 of

91 Gsoline Sterndrive Instlltion Mnul IMPORTANT: If n extr long remote ontrol shift le is used, there re lrge numer of ends in remote ontrol shift le or remote ontrol hs indequte output trvel, n dditionl djustment my e neessry. Refer to step 12. or 13. s pplile. 12. Remote Control with Single Lever Shift/Throttle Control:. RIGHT HAND (RH) propeller rottion drive unit - Shift remote ontrol into REVERSE ger, WOT position while simultneously rotting propeller shft CLOCKWISE. Cluth should engge nd use propeller shft to lok. If luth does not engge, loosen djustle stud on shift lever nd move it up in slot until luth engges with REVERSE ger. Retighten stud. Shift remote ontrol severl times nd stop in REVERSE to rehek shift utout swith position. Pin must e entered.. LEFT HAND (LH) propeller rottion drive unit - Shift remote ontrol into FORWARD ger, WOT position while simultneously rotting propeller shft CLOCKWISE. Cluth should engge nd use propeller shft to lok. If luth does not engge, loosen djustle stud on shift lever nd move it up in slot until luth engges with FORWARD ger. Retighten stud. Shift remote ontrol severl times nd stop in FORWARD to rehek shift utout swith position. Pin must e entered. 13. Two Lever Remote Control with Seprte Shift nd Throttle Levers:. RIGHT HAND (RH) propeller rottion drive unit - While turning propeller shft CLOCKWISE, move remote ontrol shift hndle into full REVERSE position. Cluth should engge efore shift lever omes to stop. If luth does not engge, loosen djustle stud on shift lever nd move it up in slot until luth engges with REVERSE ger. Retighten stud. Shift remote ontrol severl times nd stop in REVERSE to rehek shift utout swith position. Pin must e entered.. LEFT HAND (LH) propeller rottion drive unit - While turning propeller shft CLOCKWISE, move remote ontrol shift hndle into full FORWARD position. Cluth should engge efore shift lever omes to stop. If luth does not engge, loosen djustle stud on shift lever nd move it up in slot until luth engges with FORWARD ger. Retighten stud. Shift remote ontrol severl times nd stop in FORWARD to rehek shift utout swith position. Pin must e entered Adjustle Stud -Shift interrupt Swith Plunger Pin Pge 91 of 148

92 Gsoline Sterndrive Instlltion Mnul Trouleshooting Shift Prolems NOTE: The following informtion is provided to ssist n instller in trouleshooting if hrd shifting or huking/rheting is enountered when shifting into FORWARD ger. 1. When instlling the ontrol ox in the side pnel of the ot, mke sure tht the les hve enough lerne to operte. This is neessry euse the les move up nd down when the shift hndle is moved. If the ontrol ox is mounted too fr k towrd ny fierglss struture, the les will e interfered with; this will use very hrd shifting. NOTE: The ontrol ox housing n e rotted in 30 degree inrements to improve le routing. Proper Cle Bend Improper Cle Bend Mke sure tht when the shift le from the ontrol ox is led through the side gunnel of the hull, it does not hve ny extremely shrp ends in it s this will use stiff shifting. Pge 92 of

93 Gsoline Sterndrive Instlltion Mnul 3. Before instlling the shift le into the ontrol ox, extend the stinless rod eye end of the le nd grese it with 2-4-C Mrine Lurint with Teflon. Move it k nd forth to llow even distriution of the grese Desription Where Used Prt Numer 2-4-C Mrine Lurint With Teflon Shift Cle End A3 4. Do NOT strp or lmp the ontrol les to ny other les or rigid struture within 3 ft (914 mm) of the ontrol ox. 5. Ensure the le is not permnently kinked. 6. Mke sure there is proper lerne for le movement when the ontrol ox is instlled in the side pnel. The les must hve room to move up nd down when the ontrol hndle is shifted into either FORWARD or REVERSE. 7. Ensure tht the engine ws not set down on the intermedite shift le during instlltion, s this will rush the inner le tuing nd use improper nd / or stiff shifting. 8. Do NOT fsten the shift le with strps or lmps to ny other le within 5 ft (1.5 m) of the shift plte. 9. Do NOT fsten the shift le to the trnsom with ny type of plsti lips or fsteners within 5 ft (1.5 m) of the shift plte. 10. Do NOT overtighten the throttle or shift le tthing nuts t the engine end. Brrel nd le end must e free to rotte on the mounting stud. NOTE: Lurite tthing points with engine oil. Desription Where Used Prt Numer SAE 30W Engine Oil Shift Cle Pivot Points Otin Lolly Pge 93 of 148

94 Gsoline Sterndrive Instlltion Mnul 11. Chek the intermedite shift le routing from the trnsom ssemly to the shift plte s follows:. The le should ome through the trnsom, ove the exhust pipe nd mke turn towrd the strord side of the ot etween the exhust pipe nd the engine flywheel housing.. The le should then e routed under the strord rer engine mount nd turn towrd the trnsom.. The le should then go up ehind the power steering vlve nd loop over to the shift plte on the engine, where it is onneted to the nhor points on the shift plte. Following this routing will prevent the engine oupler from dmging the le NOTE: A finl hek of the djustments should e mde with the ot in the wter nd engine running. If this nnot e done or is not done t your mnufturing fility, rrngement should e mde with the deler to do this s prt of the pre-delivery inspetion. Pge 94 of

95 Predelivery Preprtion Gsoline Sterndrive Instlltion Mnul Power Steering Fluid One the power pkge instlltion is omplete, the following finl steps should e tken to prepre power pkge for delivery to the ustomer. It is the ot mnufturer s responsiility to perform these proedures, or to mke rrngement with the deler to hve these proedures ompleted. IMPORTANT: Use only speified lurint. CAUTION Do NOT RUN POWER STEERING DRY or pump will e dmged. 1. Position sterndrive unit so tht it is stright k. 2. Remove fill p from power steering pump nd hek fluid level using dipstik. Add fluid s required. NOTE: Be prepred to dd fluid to pump when first strting engine Fill Cp -Dipstik Desription Where Used Prt Numer Power Trim nd Steering Fluid A12 Dexron III - Automti Power Steering Pump Trnsmission Fluid Otin Lolly Pge 95 of 148

96 Gsoline Sterndrive Instlltion Mnul Filling Coolnt Reovery Bottle Power Trim Pump 1. Remove p from oolnt reovery reservoir nd fill to FULL mrk with oolnt solution. Reinstll p. 2. Rehek oolnt level fter first open-throttle ot test nd dd oolnt, if neessry. 3. Mintin oolnt level in oolnt reovery reservoir etween ADD nd FULL mrks with engine t norml operting temperture. 1. Chek oil level with sterndrive unit in the full DOWN/IN position. IMPORTANT: Use only speified lurint. 2. If not previously done, unsrew fill p nd remove p plug from fill nek nd disrd. Instll fill p. -Cp Plug -Fill Cp Rise nd lower sterndrive unit (to the full UP/OUT position) 6-10 times to purge ir from system. Chek oil level visully, (with drive unit in the full DOWN/IN position). Oil level should e mintined within the ADD nd FILL or MINIMUM nd MAXIMUM lines on the reservoir. -Fill Nek Chek ll trim line onnetion points for leks. If fluid is visile t fittings, tighten fittings. Torque fittings. Desription Nm l-in. l-ft Fittings Pge 96 of

97 Trim Position Sender Adjustment Gsoline Sterndrive Instlltion Mnul ANALOG GAUGES 1. Loosen oth trim position sender retining srews Retining Srews -Trim Position Sender CAUTION Do NOT strt engine in the following step or dmge to sterndrive unit nd engine ould result from lk of ooling wter. 2. Turn ignition key to RUN position. 3. Trim sterndrive unit to the full DOWN/IN position. 4. Rotte trim position sender s required to show full DOWN/IN position on dshord instrument s shown. -Trim Guge Needle Tighten retining srews nd turn ignition key to the OFF position Pge 97 of 148

98 Gsoline Sterndrive Instlltion Mnul DIGITAL GAUGES 1. Remove the trim position sender Retining Srews -Trim Position Sender 2. Remove the over from the trim sender Trim Position Sender -Rotor 3. Remove the existing rotor. 4. Apply lurint to the o-rings of the new rotor shft. 5. Instll the new rotor. 6. Reinstll the over. 7. Tighten the srews seurely. Pge 98 of

99 Gsoline Sterndrive Instlltion Mnul 8. Reinstll the trim sender s follows:. Ensure the sterndrive unit is in the full DOWN/IN position.. Align the index mrks on the rotor nd trim sender ody y turning the rotor. Propeller Seletion GENERAL INFORMATION -Index Mrks Instll the trim position sender nd seure with the tthing hrdwre. 9. Refer to the Merury SmrtCrft Opertor s Supplement ( ) for finl lirtion the trim position sender nd the Smrtrft guges. IMPORTANT: Instlled propeller must llow engine to operte t its speified mximum WOT rpm. Use n urte servie thometer to verify engine operting rpm. It is the responsiility of the ot mnufturer nd/or the selling deler to equip the power pkge with the orret propeller. Refer to Quiksilver pulition - Everything You Need To Know Aout Propellers P/N Speified engine WOT nd operting rpm rnge re listed in the Merury MerCruiser Opertion, Mintenne nd Wrrnty Mnul tthed to the engine. If full throttle opertion is elow the reommended rnge, the propeller must e hnged to prevent loss of performne nd possile engine dmge. On the other hnd, operting n engine ove the reommended operting rpm rnge will use higher thn norml wer nd/or dmge Pge 99 of 148