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1 Declrtion of Conformnce Cummins MerCruiser Diesel This sterndrive or inord engine when instlled in ccordnce with Cummins MerCruiser Diesel instructions complies with the requirements of the following directives y meeting the ssocited stndrds, s mended: Recretionl Crft Directive 94/25/EC; 2003/44/EC Applicle Requirement Hndling chrcteristics (A.4) ISO 8665 Stndrds Applied Inord engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO Steering system (A.5.4) Exhust emission requirements (B.2) ISO 8178 Owner s mnul (B.4) ISO 8665 Noise emission levels (C.1) (sterndrive CE mrked products only) Applicle portions of: ISO 10592, ISO 8848 nd ABYC P 17 ISO Cummins MerCruiser Diesel declres tht our sterndrive or inord engines without integrl exhust, when instlled in recretionl crft in ccordnce with the mnufcturer's supplied instructions will meet the exhust emissions requirements of the directive mentioned ove. This engine must not e put into service until the recretionl crft in which it is to e instlled hs een declred in conformity, if so required, with the relevnt provision of the directive. Electromgnetic Comptiility Directive 89/336/EC, 92/31/EEC nd 93/68/EEC Generic emission stndrd EN Generic immunity stndrd EN Vehicles, ots nd internl comustion engine driven devices rdio disturnce chrcteristics Electrosttic dischrge testing SAE J551 (CISPR 12) EN ; EN ; EN For specific informtion regrding exhust or noise emissions nd power declrtion, plese refer to the Declrtion of Conformity supplied with ech Cummins MerCruiser Diesel engine. This declrtion is issued under the sole responsiility of Cummins MerCruiser Diesel. Jim Khleneck Director of Engineering Cummins MerCruiser Diesel, Chrleston, South Crolin U.S.A. Regultory contct: Engineering Mrine Emissions Cummins MerCruiser Diesel 4500 Leeds Avenue Chrleston, South Crolin USA (843) Identifiction Record Plese record the following informtion: Engine Model nd Horsepower Engine Seril Numer Trnsom Assemly Seril Numer (Sterndrive) Ger Rtio Sterndrive Unit Seril Numer / Mercury Mrine Diesel Sterndrive Brvo Models *CMD ,/, * CMD

2 Trnsmission Model (Inord) Ger Rtio Trnsmission Seril Numer Propeller Numer Pitch Dimeter Hull Identifiction Numer (HIN) Purchse Dte Bot Mnufcturer Bot Model Length Exhust Gs Emissions Certifiction Numer The seril numers re the mnufcturer s keys to numerous engineering detils tht pply to your Cummins MerCruiser Diesel power pckge. When contcting Cummins MerCruiser Diesel (CMD ) out service, lwys specify model nd seril numers. Descriptions nd specifictions contined herein were in effect t the time this guide ws pproved for printing. Cummins MerCruiser Diesel, whose policies re sed on continuous improvement, reserves the right to discontinue models t ny time or to chnge specifictions or designs without notice nd without incurring oligtion. Cummins MerCruiser Diesel, Chrleston, South Crolin, U.S.A. Printed in U.S.A. Mercury, Mercury Mrine, MerCruiser, Mercury MerCruiser, Mercury Rcing, Mercury Precision Prts, Mercury Propellers, Mriner, Quicksilver, #1 On The Wter, Alph, Brvo, Brvo Two, Pro Mx, OptiMx, Sport Jet, K Plnes, MerCthode, RideGuide, SmrtCrft, Zero Effort, M with Wves logo, Mercury with Wves logo, VesselView, nd SmrtCrft logo re ll registered trdemrks of Brunswick Corportion. Mercury Product Protection logo is registered service mrk of Brunswick Corportion. Welcome You hve selected one of the finest mrine power pckges ville. It incorportes numerous design fetures to ssure operting ese nd durility. With proper cre nd mintennce, you will thoroughly enjoy using this product for mny oting sesons. To ensure mximum performnce nd crefree use, we sk tht you thoroughly red this mnul. The Opertion, Mintennce nd Wrrnty Mnul contins specific instructions for using nd mintining your product. We suggest tht this mnul remin with the product for redy reference whenever you re on the wter. Thnk you for purchsing one of our Cummins MerCruiser Diesel products. We sincerely hope your oting will e plesnt! Cummins MerCruiser Diesel Wrrnty Messge The product you hve purchsed comes with limited wrrnty from Cummins MerCruiser Diesel; the terms of the wrrnty re set forth in the Wrrnty Sections of this mnul. The wrrnty sttement contins description of wht is covered, wht is not covered, the durtion of coverge, how to est otin wrrnty coverge, importnt disclimers nd limittions of dmges nd other relted informtion. Plese review this importnt informtion. Red This Mnul Thoroughly IMPORTANT: If you do not understnd ny portion of this mnul, contct your deler for demonstrtion of ctul strting nd operting procedures. Notice Throughout this puliction, nd on your power pckge, dngers, wrnings, cutions, nd notices, ccompnied y the Interntionl Hzrd Symol!, my e used to lert the instller nd user to specil instructions concerning prticulr service or opertion tht my e hzrdous if performed incorrectly or crelessly. Oserve them crefully. These Sfety Alerts lone cnnot eliminte the hzrds tht they signl. Strict complince with these specil instructions while performing the service, plus common sense opertion, re mjor ccident prevention mesures.

3 ! DANGER Indictes hzrdous sitution which, if not voided, will result in deth or serious injury.! WARNING Indictes hzrdous sitution which, if not voided, could result in deth or serious injury.! CAUTION Indictes hzrdous sitution which, if not voided, could result in minor or moderte injury. NOTICE Indictes sitution which, if not voided, could result in engine or mjor component filure. IMPORTANT: Identifies informtion essentil to the successful completion of the tsk. NOTE: Indictes informtion tht helps in the understnding of prticulr step or ction.! WARNING The opertor (driver) is responsile for the correct nd sfe opertion of the ot, the equipment ord nd the sfety of ll occupnts ord. We strongly recommend tht the opertor red this Opertion, Mintennce nd Wrrnty Mnul nd thoroughly understnd the opertionl instructions for the power pckge nd ll relted ccessories efore the ot is used.! WARNING The engine exhust from this product contins chemicls known to the stte of Cliforni to cuse cncer, irth defects or other reproductive hrm.

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5 TABLE OF CONTENTS Section 1 - Wrrnty Wrrnty Informtion...2 Wrrnty Registrtion United Sttes nd Cnd...2 Wrrnty Registrtion Outside the United Sttes nd Cnd...2 Wrrnty Policies...3 Sterndrive Wrrnty Policy High Output Diesel Recretionl Use...3 Sterndrive Wrrnty Policy Diesel Intermittent Rting...4 Limited Wrrnty Aginst Corrosion (Worldwide)...6 Trnsfer of Wrrnty...7 Section 2 - Getting to Know Your Power Pckge Indentifiction...10 Brvo X Diesel nd Brvo XR Models...10 Brvo One Models...10 Brvo Two Models...11 Brvo Three Models...11 Brvo Sterndrive Seril Numer nd Identifiction...12 Brvo Trnsom Seril Numer...12 Instrumenttion...13 Instruments Sterndrive models...13 Fetures nd Controls...14 Lnyrd Stop Switch (If Equipped)...14 Remote Controls...15 Pnel Mount Fetures...15 Console Mount Fetures...15 Power Trim...16 Single Engine Trim nd Triler...17 Dul Engine Trim nd Triler...17 Electricl System Overlod Protection...17 Section 3 - On the Wter Sfe Boting Suggestions...20 Be Alert to Cron Monoxide Poisoning...21 Good Ventiltion...21 Poor Ventiltion...21 Bsic Bot Opertion...21 Lunching nd Bot Opertion...21 Strting the Engine After Stopped While in Ger...21 Freezing Temperture Opertion...22 Drin Plug nd Bilge Pump...22 Trilering the Bot...22 Protecting People In The Wter...22 While You Are Cruising...22 While Bot Is Sttionry...22 High Speed nd High Performnce...22 Pssenger Sfety In Pontoon Bots And Deck Bots...22 Bots Hving An Open Front Deck...22 Bots With Front Mounted, Rised Pedestl Fishing Sets...23 Wve nd Wke Jumping...23 Impct with Underwter Hzrds...24 Sterndrive Impct Protection...24 Conditions Affecting Opertion...24 Weight Distriution (Pssengers nd Ger) Inside the Bot...24 Bottom of Bot...25 Cvittion...25 Ventiltion...25 Elevtion nd Climte...25 Propeller Selection...25 Getting Strted...26 Sterndrive 10 Hour Brek In Period (New or With Replcement Gers)...26 End of First Seson Checkup...26 Section 4 - Specifictions Fluid Specifictions...28 Brvo Sterndrive Fluid Specifictions Diesel...28 Power Steering nd Power Trim Fluids...28 Approved Power Steering Fluids...28 Approved Compct Hydrulic Power Steering Fluids...28 Approved Electro Hydrulic Power Steering Fluids...28 Approved Power Trim Fluids...28 Approved Pints...28 Torque Specifictions...29 CMD / MAY 2007 Pge i

6 Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities...32 Deler Responsiilities...32 Do It Yourself Mintennce Suggestions...32 Inspection Mintennce Intervls Mintennce Schedule...33 Routine Mintennce Scheduled Mintennce...34 Mintennce Log...35 Sterndrive Ger Lue Checking Filling...36 Chnging...37 Power Trim Fluid Checking Filling...41 Chnging...42 Power Assisted Steering Fluid (If Equipped)...42 Electro Hydrulic Power Assisted Steering System (If Equipped) Checking Filling...42 Chnging...43 Sterndrive Wter Pssges...43 Sterndrive Wter Inlets Check...43 Sterndrive Wter Drin Check...43 Flushing the Sterndrive Corrosion Protection...46 Generl Informtion...46 Sterndrive Corrosion Protection Components...46 Anodes nd MerCthode System Loctions...47 Continuity Circuit Brvo Sterndrive...48 MerCthode...50 Bot Bottom Cre...51 Pinting Your Power Pckge Sterndrive Surfce Cre...52 Luriction...52 Steering System...52 Shift Cle...54 Trnsom Assemly...54 Propeller Shft...54 Engine Coupler...55 Driveshft Extension Models...56 Sterndrive, Bellows, nd Engine Alignment Mintining Torques...57 Giml Ring U olt Nuts...57 Rer Engine Mount Torque...58 Propeller Brvo Diesel Sterndrive Propeller Removl...58 Brvo One Models Brvo Two Models Brvo Three Models...60 Brvo Diesel Sterndrive Propeller Instlltion...62 Brvo One Models Brvo Two Models Brvo Three Section 6 - Storge Prepring the Power Pckge For Storge...68 Engine Sterndrive Storge Power Pckge Recommissioning...68 Engine Sterndrive...68 Section 7 - Trouleshooting Remote Control Opertes Hrd, Binds, Hs Excessive Free ply, or Mkes Unusul Sounds Steering Wheel Turns Hrd or Jerky Power Trim Does Not Operte (Electric Motor Does Not Operte) Power Trim does not Operte (Electric Motor Opertes ut Sterndrive does not Move) Trouleshooting the Electro Hydrulic Power Steering System for Sterndrive Models (If Equipped)...70 Section 8 - Customer Assistnce Informtion Owner Service Assistnce...74 Locl Repir Service...74 Service Awy From Home...74 Stolen Power Pckge Attention Required After Sumersion Replcement Service Prts Prts nd Accessories Inquiries Resolving Prolem...74 Pge ii CMD / MAY 2007

7 Customer Service Literture...75 English Lnguge...75 Other Lnguges...75 Andre sprog...75 Andere tlen...75 Muut kielet...75 Autres lngues...75 Andere Sprchen...75 Altre lingue...75 Andre språk...75 Outros Idioms...76 Otros idioms...76 Andr språk...76 Allej glþssej...76 Ordering Literture...76 United Sttes nd Cnd...76 Outside the United Sttes nd Cnd...76 CMD / MAY 2007 Pge iii

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9 Tle of Contents Section 1 - Wrrnty Section 1 - Wrrnty 1 Wrrnty Informtion... 2 Wrrnty Registrtion United Sttes nd Cnd...2 Wrrnty Registrtion Outside the United Sttes nd Cnd...2 Wrrnty Policies... 3 Sterndrive Wrrnty Policy High Output Diesel Recretionl Use...3 Sterndrive Wrrnty Policy Diesel Intermittent Rting...4 Limited Wrrnty Aginst Corrosion (Worldwide)...6 Trnsfer of Wrrnty...7 CMD / MAY 2007 Pge 1

10 Section 1 - Wrrnty Wrrnty Informtion Wrrnty Registrtion United Sttes nd Cnd 1. It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the fctory immeditely upon sle of the new product. 2. It identifies the nme nd ddress of the originl purchser, product model nd seril numer(s), dte of sle, type of use nd selling deler's code, nme, nd ddress. The deler lso certifies tht you re the originl purchser nd user of the product. 3. Upon receipt of the Wrrnty Registrtion Crd t the fctory, you will receive n owner resource guide tht will include your wrrnty registrtion confirmtion. 4. A temporry Owner Wrrnty Registrtion Crd will e presented to you when you purchse the product. 5. Becuse of your selling deler's continuing personl interest in your stisfction, the product should e returned to him for wrrnty service. 6. If your owner resource guide is not received within 60 dys from dte of new product sle, plese contct your selling deler. 7. The product wrrnty is not effective until the product is registered t the fctory. NOTE: Registrtion lists must e mintined y the fctory nd deler on mrine products sold in the United Sttes, should sfety recll notifiction under the Federl Bot Sfety Act e required. 8. You my chnge your ddress t ny time, including t time of wrrnty clim, y clling Mercury MerCruiser or sending letter or fx with you nme, old ddress, new ddress, nd engine seril numer to Mercury MerCruiser's wrrnty registrtion deprtment. Your deler cn lso process this chnge of informtion. United Sttes customers or delers my contct: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Cndin customers or delers my contct: Mercury Mrine Cnd Limited 2395 Medowpine Blvd. Mississug, Cnd, L5N 7W6 Fx Wrrnty Registrtion Outside the United Sttes nd Cnd 1. It is importnt tht your selling deler fills out the Wrrnty Registrtion Crd completely nd mils it to the distriutor or Mrine Power Service Center responsile for dministering the wrrnty registrtion nd clim progrm for your re. 2. The Wrrnty Registrtion Crd identifies your nme nd ddress, product model nd seril numers, dte of sle, type of use nd the selling distriutor's nd deler's code numer, nme nd ddress. The distriutor or deler lso certifies tht you re the originl purchser nd user of the product. 3. A copy of the Wrrnty Registrtion Crd, designted s the Purchser's Copy, MUST e given to you immeditely fter the crd hs een completely filled out y the selling distriutor or deler. This crd represents your fctory registrtion identifiction, nd should e retined y you for future use when required. Should you ever require wrrnty service on this product, your deler my sk you for the Wrrnty Registrtion Crd to verify dte of purchse nd to use the informtion on the crd to prepre the wrrnty clim forms. 4. In some countries, the Mrine Power Service Center will issue you permnent (plstic) Wrrnty Registrtion Crd within 30 dys fter receiving the Fctory Copy of the Wrrnty Registrtion Crd from your distriutor or deler. If you receive plstic Wrrnty Registrtion Crd, you my discrd the Purchser's Copy tht you received from the distriutor or deler when you purchsed the product. Ask your distriutor or deler if this plstic crd progrm pplies to you. 5. For further informtion concerning the Wrrnty Registrtion Crd nd its reltionship to Wrrnty Clim processing, refer to the Interntionl Wrrnty. See Tle of Contents. IMPORTANT: Registrtion lists must e mintined y the fctory nd deler in some countries y lw. It is our desire to hve ALL products registered t the fctory should it ever e necessry to contct you. Mke sure your Cummins MerCruiser Diesel Distriutor or Cummins MerCruiser Diesel Authorized Deler fills out the wrrnty registrtion crd immeditely nd sends the fctory copy to the Mrine Power Interntionl Service Center for your re. Pge 2 CMD / MAY 2007

11 Section 1 - Wrrnty Wrrnty Policies Sterndrive Wrrnty Policy High Output Diesel Recretionl Use WHAT IS COVERED Durtion of Coverge Cummins MerCruiser Diesel wrrnts its new products to e free of defects in mteril nd workmnship during the period descried elow. This Limited Wrrnty provides coverge for two (2) yers from the dte the product is first sold to recretionl use retil purchser, or the dte on which the product is first put into service, whichever occurs first. High Output Rting is for use in vrile lod pplictions where full power is limited to one (1) hour out of every eight (8) hours of opertion. Also, reduced power opertions must e t or elow 200 RPM of the mximum rted RPM for engines rted t 3000 RPM or less, nd t or elow 400 RPM of the mximum rted RPM for engines rted t greter thn 3000 RPM. This rting is for plesure (non revenue generting) pplictions tht operte 500 hours or less per yer. Commercil use of the product voids the wrrnty. Commercil use is defined s ny work or employment relted use of the product, or ny use of the product tht genertes income, for ny prt of the wrrnty period, even if the product is only occsionlly used for such purposes. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one recretionl use customer to susequent recretionl use customer upon proper re registrtion of the product. Unexpired wrrnty coverge cnnot e trnsferred either to or from commercil use customer. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wht Cummins MerCruiser Diesel Will Do How to Otin Wrrnty Coverge Wht Is Not Covered Wrrnty coverge is ville only to retil customers tht purchse from Deler uthorized y Cummins MerCruiser Diesel to distriute the product in the country in which the sle occurred, nd then only fter the Cummins MerCruiser Diesel specified pre delivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion regrding recretionl use, or susequent chnge of use from recretionl to commercil (unless properly re registered) my void the wrrnty t the sole discretion of Cummins MerCruiser Diesel. Routine mintennce outlined in the Opertion, Mintennce, & Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Cummins MerCruiser Diesel reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Cummins MerCruiser Diesel s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Cummins MerCruiser Diesel product. Cummins MerCruiser Diesel reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. The customer must provide Cummins MerCruiser Diesel with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde to Cummins MerCruiser Diesel Authorized Repir Fcility to service the product. If purchser cnnot deliver the product to such deler, written notice must e given to Cummins MerCruiser Diesel. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Cummins MerCruiser Diesel, ship the product or prts of the product directly to Cummins MerCruiser Diesel. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must e presented to the deler t the time wrrnty service is requested in order to otin coverge. CMD / MAY 2007 Pge 3

12 Section 1 - Wrrnty DISCLAIMERS AND LIMITATIONS This limited wrrnty does not cover the following: Routine mintennce items Minor djustments or checks, including checking controls, nd checking luriction mde in connection with norml services Dmge cused y use, norml use, neglect, ccident, sumersion, improper service, freezing tempertures, ltertion, or removl of prts Oils, luricnts, or fluids unless loss or contmintion of the sme is cused y product filure tht would e eligile for wrrnty considertion. Norml wer nd ter Dmge to the sterndrive lower unit or propeller cused y striking mrine hzrd, such s sumerged oject Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Additionl service work requested y the customer other thn tht necessry to stisfy the wrrnty oligtion Dmge to the Cummins MerCruiser Diesel product cused y the use of n ccessory or prt tht ws not mnufctured or sold y Cummins MerCruiser Diesel or Mercury Mrine Opertion with oils, luricnts, or fluids tht re not suitle for use with the product (see the Opertion, Mintennce & Wrrnty Mnul) Dmge to the product from insufficient cooling wter cused y lockge of the cooling system or wter inlets Dmge cused y running the sterndrive out of wter Dmge resulting from mounting the power pckge too high on the trnsom Dmge s result of operting the ot with the engine over trimmed Lor performed y other thn Cummins MerCruiser Diesel except when prior fctory pprovl hs een given to hve the work performed t tht fcility nd when performed on n emergency sis, providing there re no Authorized Repir Fcilities in the re tht cn perform the work required or hve no fcilities to hul out, tow, nd so on Expenses relted to hul out, lunch, or towing Removl or replcement of ot prtitions or other mteril in order to gin ccess to the product Expenses relted to delivering the product to Cummins MerCruiser Diesel Authorized Deler when resonle ccess is not provided to the product for wrrnty service Expenses relted to storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny time, even y previous owner of the product, voids the wrrnty. No individul or entity, including Cummins MerCruiser Diesel uthorized delers, hs een given uthority y Cummins MerCruiser Diesel to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not e enforcele ginst Cummins MerCruiser Diesel. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Sterndrive Wrrnty Policy Diesel Intermittent Rting WHAT IS COVERED Durtion of Coverge Cummins MerCruiser Diesel wrrnts its new products to e free of defects in mteril nd workmnship during the period descried elow. Pge 4 CMD / MAY 2007

13 Section 1 - Wrrnty This Limited Wrrnty provides coverge for one (1) yer or 400 hours (whichever occurs first) for commercil pplictions from the dte the product is first sold to retil purchser, or the dte on which the product is first put into service, whichever occurs first, nd is intended for intermittent use in vrile lod pplictions where full power is limited to two hours out of every eight hours of opertion. Also, reduced power opertions must e t or elow 200 RPM of the mximum rted RPM. This rting is n ISO 3046 fuel stop power rting nd is intended for pplictions tht operte less thn 1,500 hours per yer. The repir or replcement of prts, or the performnce of service under this wrrnty, does not extend the life of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred from one commercil use customer to susequent commercil use customer upon proper re registrtion of the product. Unexpired wrrnty coverge cnnot e trnsferred either to or from recretionl use customer. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wht Cummins MerCruiser Diesel Will Do How to Otin Wrrnty Coverge Wht Is Not Covered This wrrnty coverge is ville only for Brvo Two Sterndrives tht re prt of the QSB5.9 ES 230 propulsion pckge sold to retil customers in mrine pplictions tht purchse from Cummins MerCruiser Diesel, Cummins MerCruiser Diesel Distriutor, or Cummins MerCruiser Diesel Authorized Deler in the country in which the sle occurred, nd then only fter the Cummins MerCruiser Diesel specified pre delivery inspection process is completed nd documented. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Inccurte wrrnty registrtion informtion or misppliction of the propulsion pckge my void the wrrnty t the sole discretion of Cummins MerCruiser Diesel. Routine mintennce outlined in the Opertion, Mintennce, & Wrrnty Mnul must e timely performed in order to otin wrrnty coverge. Cummins MerCruiser Diesel reserves the right to mke ny wrrnty coverge contingent upon proof of proper mintennce. Cummins MerCruiser Diesel s sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring defective prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Cummins MerCruiser Diesel product. Cummins MerCruiser Diesel reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. The customer must provide Cummins MerCruiser Diesel with resonle opportunity to repir, nd resonle ccess to the product for wrrnty service. Wrrnty clims shll e mde to Cummins MerCruiser Diesel Authorized Repir Fcility to service the product. If purchser cnnot deliver the product to such deler, written notice must e given to Cummins MerCruiser Diesel. We will then rrnge for the inspection nd ny covered repir. Purchser in tht cse shll py for ll relted trnsporttion chrges nd/or trvel time. If the service provided is not covered y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Cummins MerCruiser Diesel, ship the product or prts of the product directly to Cummins MerCruiser Diesel. The wrrnty registrtion crd is the only vlid registrtion identifiction nd must e presented to the deler t the time wrrnty service is requested in order to otin coverge. CMD / MAY 2007 Pge 5

14 Section 1 - Wrrnty DISCLAIMERS AND LIMITATIONS This limited wrrnty does not cover the following: Routine mintennce items Minor djustments or checks, including checking controls, nd checking luriction mde in connection with norml services Dmge cused y use, norml use, neglect, ccident, sumersion, improper service, freezing tempertures, ltertion, or removl of prts Oils, luricnts, or fluids unless loss or contmintion of the sme is cused y product filure tht would e eligile for wrrnty considertion. Norml wer nd ter Dmge to the sterndrive lower unit or propeller cused y striking mrine hzrd, such s sumerged oject Improper instlltion (proper instlltion specifictions nd techniques re set forth in the instlltion instructions for the product) Additionl service work requested y the customer other thn tht necessry to stisfy the wrrnty oligtion Dmge to the Cummins MerCruiser Diesel product cused y the use of n ccessory or prt tht ws not mnufctured or sold y Cummins MerCruiser Diesel or Mercury Mrine Opertion with oils, luricnts, or fluids tht re not suitle for use with the product (see the Opertion, Mintennce & Wrrnty Mnul) Dmge to the product from insufficient cooling wter cused y lockge of the cooling system or wter inlets Dmge cused y running the sterndrive out of wter Dmge resulting from mounting the power pckge too high on the trnsom Dmge s result of operting the ot with the engine over trimmed Lor performed y other thn Cummins MerCruiser Diesel except when prior fctory pprovl hs een given to hve the work performed t tht fcility nd when performed on n emergency sis, providing there re no Authorized Repir Fcilities in the re tht cn perform the work required or hve no fcilities to hul out, tow, nd so on Expenses relted to hul out, lunch, or towing Removl or replcement of ot prtitions or other mteril in order to gin ccess to the product Expenses relted to delivering the product to Cummins MerCruiser Diesel Authorized Deler when resonle ccess is not provided to the product for wrrnty service Expenses relted to storge, telephone, rentl, inconvenience, slip fees, insurnce coverge, lon pyments, loss of time, loss of income, or ny other type of incidentl or consequentil dmges Use of the product for rcing or other competitive ctivity, or operting with rcing type lower unit t ny time, even y previous owner of the product, voids the wrrnty. No individul or entity, including Cummins MerCruiser Diesel uthorized delers, hs een given uthority y Cummins MerCruiser Diesel to mke ny ffirmtion, representtion, or wrrnty regrding the product, other thn those contined in this limited wrrnty, nd if mde, shll not e enforcele ginst Cummins MerCruiser Diesel. THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS, LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE. AS A RESULT, THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO COUNTRY. Limited Wrrnty Aginst Corrosion (Worldwide) Wht Is Covered Durtion of Coverge Cummins MerCruiser Diesel wrrnts tht ech new Alph nd Brvo sterndrive (Product) will not e rendered inopertive s direct result of corrosion for the period of time descried elow. Pge 6 CMD / MAY 2007

15 Section 1 - Wrrnty This limited corrosion wrrnty provides coverge for three (3) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. For sterndrive models with SeCore, the wrrnty coverge is four (4) yers from either the dte the product is first sold, or the dte on which the product is first put into service, whichever occurs first. The repir nd replcement of prts, or the performnce of service under this wrrnty does not extend the life of this wrrnty eyond its originl expirtion dte. Unexpired wrrnty coverge cn e trnsferred to susequent purchser upon proper re registrtion of the product. Wrrnty coverge is terminted for used product repossessed from retil customer, purchsed t uction, from slvge yrd, or from n insurnce compny tht otined the product s result of n insurnce clim. Conditions Tht Must Be Met to Otin Wrrnty Coverge Wht Mercury Will Do How to Otin Wrrnty Coverge Wht Is Not Covered Trnsfer of Wrrnty Wrrnty coverge is ville only to retil customers tht purchse from deler uthorized y Cummins MerCruiser Diesel to distriute the product in the country in which the sle occurred. Wrrnty coverge ecomes ville upon proper registrtion of the product y the uthorized deler. Corrosion prevention devices specified in the Opertion, Mintennce, nd Wrrnty mnul must e in use on the ot, nd routine mintennce outlined in the Opertion, Mintennce, nd Wrrnty mnul must e timely performed (including without limittion the replcement of scrificil nodes, use of specified luricnts, nd touch up of nicks nd scrtches) in order to mintin wrrnty coverge. Cummins MerCruiser Diesel reserves the right to mke wrrnty coverge contingent upon proof of proper mintennce. Cummins MerCruiser Diesel's sole nd exclusive oligtion under this wrrnty is limited to, t our option, repiring corroded prt, replcing such prt or prts with new or Mercury Mrine certified re mnufctured prts, or refunding the purchse price of the Mercury product. Mercury reserves the right to improve or modify products from time to time without ssuming n oligtion to modify products previously mnufctured. The customer must provide Cummins MerCruiser Diesel with resonle ccess to the product for wrrnty service nd resonle opportunity to repir the product. Wrrnty clims shll e mde y delivering the product for inspection to Cummins MerCruiser Diesel deler uthorized to service the product. If purchser cnnot deliver the product to such deler, written notice must e given to Cummins MerCruiser Diesel. We will then rrnge for the inspection nd ny covered repir. If the service provided is not covered y this wrrnty, purchser shll py for ll relted lor nd mteril, nd ny other expenses ssocited with tht service. Purchser shll not, unless requested y Cummins MerCruiser Diesel, ship the product or prts of the product directly to Cummins MerCruiser Diesel. Proof of registered ownership must e presented to the deler t the time wrrnty service is requested in order to otin coverge. This limited wrrnty does not cover electricl system corrosion; corrosion resulting from dmge; corrosion tht cuses purely cosmetic dmge; use or improper service; corrosion to ccessories, instruments, or steering systems; corrosion to fctory instlled jet drive unit; dmge due to mrine growth; product sold with less thn one yer limited product wrrnty; replcement prts (prts purchsed y the customer); products used in commercil ppliction. Commercil use is defined s ny work relted or employment relted use of the product, or ny use of the product tht genertes income, for ny prt of wrrnty period, even if the product is only occsionlly used for such purposes. The limited wrrnty is trnsferle to susequent purchser, ut only for the reminder of the unused portion of the limited wrrnty. This will not pply to products used for commercil pplictions. To trnsfer the wrrnty to the susequent owner, send or fx copy of the ill of sle or purchse greement, new owner s nme, ddress nd engine seril numer to Mercury Mrine s Wrrnty Registrtion Deprtment. In the United Sttes nd Cnd, mil to: Mercury Mrine Attn: Wrrnty Registrtion Deprtment W6250 W. Pioneer Rod P.O. Box 1939 Fond du Lc, WI Fx Upon processing the trnsfer of wrrnty, Mercury Mrine will send registrtion verifiction to the new owner of the product y mil. There is no chrge for this service. CMD / MAY 2007 Pge 7

16 Section 1 - Wrrnty For products purchsed outside the United Sttes nd Cnd, contct the distriutor in your country, or the Mrine Power Service Center closest to you. Pge 8 CMD / MAY 2007

17 Section 2 - Getting to Know Your Power Pckge Section 2 - Getting to Know Your Power Pckge Tle of Contents Indentifiction Brvo X Diesel nd Brvo XR Models...10 Brvo One Models Brvo Two Models Brvo Three Models Brvo Sterndrive Seril Numer nd Identifiction...12 Brvo Trnsom Seril Numer...12 Instrumenttion Instruments Sterndrive models...13 Fetures nd Controls Lnyrd Stop Switch (If Equipped)...14 Remote Controls...15 Pnel Mount Fetures Console Mount Fetures Power Trim...16 Single Engine Trim nd Triler Dul Engine Trim nd Triler Electricl System Overlod Protection CMD / MAY 2007 Pge 9

18 Section 2 - Getting to Know Your Power Pckge Indentifiction Brvo X Diesel nd Brvo XR Models Brvo One Models Brvo One X Diesel Brvo One XR Pge 10 CMD / MAY 2007

19 Section 2 - Getting to Know Your Power Pckge Brvo Two Models Brvo Two X Diesel Brvo Three Models Brvo Three X Diesel Brvo Three XR CMD / MAY 2007 Pge 11

20 Section 2 - Getting to Know Your Power Pckge Brvo Sterndrive Seril Numer nd Identifiction The sterndrive seril numer, ger rtio, model numer, nd r code is emedded in the ground plte locted on the port side of the Brvo sterndrive. c d - Br code - Ger rtio c - Seril Numer d - Model numer The seril numer is lso stmped on the sterndrive csting inside the ck cover. This is used s permnent reference for Cummins MerCruiser Diesel Authorized Repir Fcilities Brvo sterndrive seril numer stmping - Seril numer stmping Brvo Trnsom Seril Numer The Brvo trnsom seril numer is stmped in the U olt plte of the Brvo trnsom ssemly. Brvo trnsom ssemly U-olt plte - Trnsom ssemly seril numer Pge 12 CMD / MAY 2007

21 Section 2 - Getting to Know Your Power Pckge The seril numer is lso stmped on the giml housing. This is used s permnent reference for Cummins MerCruiser Diesel Authorized Repir Fcilities. Giml housing with seril numer stmping - Trnsom ssemly seril numer Instrumenttion Instruments Sterndrive models The following riefly explins the instrumenttion typiclly found on some ots. The owner nd opertor should e fmilir with ll the instruments nd their functions on the ot. Becuse of the lrge vriety of instrumenttion nd mnufcturers, hve your ot deler explin the guges nd norml redings tht will pper on your ot. The following types of guges my e included with your power pckge. c d e Typicl guges Reference Guge Function Oil pressure guge Indictes engine oil pressure. Bttery meter Indictes ttery voltge. c Coolnt temperture guge Indictes engine operting temperture. d Fuel guge Indictes quntity of fuel in tnk. e Power trim guge Indictes sterndrive ngle (trim up [out] nd down [in]). CMD / MAY 2007 Pge 13

22 Section 2 - Getting to Know Your Power Pckge Fetures nd Controls Lnyrd Stop Switch (If Equipped) The purpose of lnyrd stop switch is to turn off the engine when the opertor moves outside the opertor's position (s in ccidentl ejection from the opertor's position). c RUN - Stop switch - Lnyrd c - Clips to the opertor Accidentl ejections, such s flling overord, re more likely to occur in: low sided sport ots ss ots high performnce ots Accidentl ejections cn lso occur from: poor operting prctices sitting on the set or gunwle t plning speeds stnding t plning speeds operting t plning speeds in shllow or ostcle infested wters relesing your grip on the steering wheel tht is pulling in one direction consuming lcohol or drugs high speed oting mneuvers Some remote control units re equipped with lnyrd stop switch, if your remote control is not equipped with lnyrd stop switch one cn e instlled on the dshord or side djcent to the opertor's position. The lnyrd is cord usully etween 122 nd 152 cm (4 nd 5 feet) in length when stretched out, with n element on one end mde to e inserted into the switch nd snp on the other end for ttching to the opertor. The lnyrd is coiled to mke its t rest condition s short s possile to minimize the likelihood of lnyrd entnglement with nery ojects. Its stretched out length is mde to minimize the likelihood of ccidentl ctivtion should the opertor choose to move round in n re close to the norml opertor's position. If it is desired to hve shorter lnyrd, wrp the lnyrd round the opertor's wrist or leg, or tie knot in the lnyrd. Activtion of the lnyrd stop switch will stop the engine immeditely, ut the ot will continue to cost for some distnce depending upon the velocity nd degree of ny turn t shut down. However, the ot will not complete full circle. While the ot is costing, it cn cuse injury to nyone in the ot's pth s seriously s the ot would when under power. We strongly recommend tht other occupnts e instructed on proper strting nd operting procedures should they e required to operte the engine in n emergency (e.g. if the opertor is ccidentlly ejected).! WARNING If the opertor flls out of the ot, stop the engine immeditely to reduce the possiility of serious injury or deth from eing struck y the ot. Alwys properly connect the opertor to the stop switch using lnyrd. Accidentl or unintended ctivtion of the switch during norml opertion is lso possiility. This could cuse ny, or ll, of the following potentilly hzrdous situtions: Occupnts could e thrown forwrd due to unexpected loss of forwrd motion, prticulr concern for pssengers in the front of the ot who could e ejected over the ow nd possily struck y the propulsion or steering components. Loss of power nd directionl control in hevy ses, strong current or high winds. Loss of control when docking.! WARNING Avoid serious injury or deth from decelertion forces resulting from ccidentl or unintended stop switch ctivtion. The ot opertor should never leve the opertor's sttion without first disconnecting the stop switch lnyrd from the opertor Pge 14 CMD / MAY 2007

23 Remote Controls Section 2 - Getting to Know Your Power Pckge Your ot my e equipped with Mercury Precision Prts or Quicksilver remote controls. All controls my not hve ll fetures shown. Consult your deler for description nd/or demonstrtion of your remote control. Pnel Mount Fetures f e - Neutrl lock utton - Throttle only utton c - Lnyrd stop switch d - Control hndle tension djustment screw e - Control hndle f - Trim nd tilt utton c d mc Neutrl lock utton. Prevents ccidentl shift nd throttle enggement. The neutrl lock utton must e pushed into move the control hndle out of neutrl. Throttle-only utton. Allows engine throttle dvncement without shifting the engine. This is done y disengging the shift mechnism from the control hndle. The throttle only utton cn e depressed only when the remote control hndle is in the neutrl position, nd should only e used to ssist in strting the engine. Lnyrd stop switch. Turns the ignition off whenever the opertor (when ttched to the lnyrd) moves fr enough wy from the opertor's position to ctivte the switch. See Lnyrd Stop Switch for informtion on the use of this switch. Control hndle. The shift nd throttle re controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger. Continue pushing forwrd to increse speed. Pull the control hndle ck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing ck to increse speed. Control hndle tension djustment screw (not visile). This screw is used to djust the effort required to move the remote control hndle. Refer to the instructions provided with the remote control for complete djustment instructions. Trim (tilt) utton. See Power Trim. Console Mount Fetures d c - Throttle only utton - Control hndle c - Power trim switch d - Triler switch c d mc Throttle-only utton. Allows engine throttle dvncement without shifting the engine. This is done y disengging the shift mechnism from the control hndle. The throttle only utton cn e depressed only when the remote control hndle is in the neutrl position. CMD / MAY 2007 Pge 15

24 Section 2 - Getting to Know Your Power Pckge Control hndles. The shift nd throttle re controlled y the movement of the control hndle. Push the control hndle forwrd from neutrl with quick, firm motion to the first detent for forwrd ger nd continue pushing forwrd to increse speed. Pull the control hndle ck from neutrl with quick, firm motion to the first detent for reverse ger nd continue pushing ck to increse speed. Control hndle tension djustment screw (not visile). This screw is used to djust the effort required to move the remote control hndle. Refer to the instructions provided with the remote control for complete djustment instructions. Power trim switch. See the Power Trim section for detiled power trim operting procedures. Triler switch. Used to rise the sterndrive for trilering, lunching, eching, or shllow wter opertion. See Power Trim for detiled triler switch opertion. Power Trim Power trim llows the opertor to djust the sterndrive ngle while underwy to provide the idel ot ngle for vrying lod nd wter conditions. The triler switch llows the opertor to rise nd lower the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM engine speed), nd shllow wter opertion.! WARNING Excessive trim cn cuse serious injury or deth t high speeds, nd single rm trim systems do not provide trim out limiting device or trim indictor. Use cution when trimming with single rm trim system nd never trim out eyond the unit's side support flnges while the ot is underwy or t engine speeds ove 1200 RPM. For est performnce, trim the sterndrive so tht the ot ottom is t 3 5 ngle to the wter. 3-5 mc79528 Trimming the sterndrive up (out) hs the following effects: Generlly increses top speed. Increses clernce over sumerged ojects or shllow ottom. Cuses the ot to ccelerte nd rech plne more slowly. Cuses porpoising (ouncing) or propeller ventiltion if trimmed excessively. Cuses engine overheting if trimmed to point where ny cooling wter intke holes re ove the wter line. mc78529 Trimming the sterndrive down (in) hs the following effects: Helps the ot ccelerte nd rech plne more quickly. Generlly improves the ride in choppy wter. Generlly reduces ot speed. Pge 16 CMD / MAY 2007

25 Section 2 - Getting to Know Your Power Pckge If in excess, lower the ow of some ots to point t which they egin to plow with their ow in the wter while on plne. This cn result in n unexpected turn in either direction clled ow steering or over steering if ny turn is ttempted or if significnt wve is encountered. mc79530 Single Engine Trim nd Triler Single engine pplictions hve utton to trim the sterndrive up (out) or down (in). To rise the sterndrive for trilering, eching, lunching, low speed (elow 1200 RPM), nd shllow wter opertion, push the trim utton to rise the sterndrive to the full up (out) position. Some controls hve triler utton tht trims the sterndrives to position suitle only for huling the ot y triler. Dul Engine Trim nd Triler NOTICE If using externl tie rs, rising or lowering the drives independently of ech other cn dmge the drive nd steering systems. If using n externl tie r, rise nd lower ll drives together s unit. Dul engine pplictions my hve single integrl utton to operte oth sterndrives simultneously or seprte utton for ech sterndrive. Some controls hve triler utton tht trims the sterndrives to position suitle only for huling the ot y triler. Electricl System Overlod Protection If n electricl overlod on the electricl system occurs, fuse will urn out (low). Find nd correct the cuse efore replcing the fuse. NOTE: In n emergency, when the engine must e operted nd the cuse for the electricl overlod, or excessive current drw, cnnot e locted nd corrected, turn OFF or disconnect ll ccessories connected to the engine nd instrumenttion wiring. Replce the fuse. If the fuse urns out, the electricl overlod hs not een eliminted. Further checks must e mde on the electricl system. Contct your uthorized Cummins MerCruiser Diesel repir fcility. 1. The Power Trim System is protected from overlod y 110 mp fuse nd 20 mp in line fuse on the power trim pump mp holder mp fuse 9208 CMD / MAY 2007 Pge 17

26 Section 2 - Getting to Know Your Power Pckge 2. The Quicksilver Three Button Power Trim Control Pnel is protected from overlod y 20 mp in line fuse mp in line fuse 3. The Quicksilver MerCthode System hs 20 mp in line fuse in the wire tht connects to the positive (+) terminl on the controller. If the fuse is urned out (lown), the system will not operte resulting in loss of corrosion protection mp in line fuse The Electro Hydrulic Power Steering System, if equipped, is protected from overlod y 90 mp fuse on the steering pump positive led t the ttery positive connection. c 90-mp fuse for the electro-hydrulic power steering pump - Power steering pump positive led - Fuse eyelet for the positive ttery post c - 90 mp fuse c Pge 18 CMD / MAY 2007

27 Tle of Contents Section 3 - On the Wter Section 3 - On the Wter Sfe Boting Suggestions Be Alert to Cron Monoxide Poisoning...21 Good Ventiltion Poor Ventiltion Bsic Bot Opertion Lunching nd Bot Opertion...21 Strting the Engine After Stopped While in Ger...21 Freezing Temperture Opertion...22 Drin Plug nd Bilge Pump...22 Trilering the Bot...22 Protecting People In The Wter While You Are Cruising While Bot Is Sttionry High Speed nd High Performnce...22 Pssenger Sfety In Pontoon Bots And Deck Bots...22 Bots Hving An Open Front Deck Bots With Front Mounted, Rised Pedestl Fishing Sets Wve nd Wke Jumping...23 Impct with Underwter Hzrds...24 Sterndrive Impct Protection Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot...24 Bottom of Bot...25 Cvittion...25 Ventiltion...25 Elevtion nd Climte...25 Propeller Selection...25 Getting Strted Sterndrive 10 Hour Brek In Period (New or With Replcement Gers)...26 End of First Seson Checkup CMD / MAY 2007 Pge 19

28 Section 3 - On the Wter Sfe Boting Suggestions In order to sfely enjoy the wterwys, fmilirize yourself with locl nd ll other governmentl oting regultions nd restrictions, nd lso consider the following suggestions. Know nd oey ll nuticl rules nd lws of the wterwys. Cummins MerCruiser Diesel strongly recommends tht ll powerot opertors complete oting sfety course. Courses re offered in the U.S.A. y the U.S. Cost Gurd Auxiliry, the Power Squdron, the Red Cross, nd your stte or provincil oting lw enforcement gency. Inquiries my e mde to the Boting Hotline t or the Bot U.S. Foundtion t BOAT. Perform sfety checks nd required mintennce. Follow regulr schedule nd ensure tht ll repirs re properly mde. Check sfety equipment on ord. Here re some suggestions of the types of sfety equipment to crry when oting: Approved fire extinguishers Pddle or or Signl devices: flshlight, rockets or flres, flg, nd whistle or horn Trnsistor rdio Tools necessry for minor repirs First id kit nd instructions Anchor nd extr nchor line Wterproof storge continers Mnul ilge pump nd extr drin plugs Spre operting equipment, tteries, uls, nd fuses Drinking wter Compss nd mp or chrt of the re Wtch for signs of wether chnge nd void foul wether nd rough-se oting. Tell someone where you re going nd when you expect to return. Pssenger ording. Stop the engine whenever pssengers re ording, unloding, or re ner the ck (stern) of the ot. Shifting the drive unit into neutrl is not sufficient. Use personl flottion devices. Federl lw requires tht there e U. S. Cost Gurd pproved, werle type life jcket (personl flottion device), correctly sized nd redily ccessile for every person ord, plus throwle cushion or ring. We strongly dvise tht everyone wer life jcket t ll times while in the ot. Prepre other ot opertors. Instruct t lest one person ord in the sics of strting nd operting the engine nd hndling the ot in cse the driver ecomes disled or flls overord. Do not overlod your ot. Most ots re rted nd certified for mximum lod (weight) cpcities (refer to your ot cpcity plte). Know your ot s operting nd loding limittions. Know if your ot will flot if full of wter. When in dout, contct your uthorized Cummins MerCruiser Diesel deler/distriutor or the ot mnufcturer. Ensure tht everyone in the ot is properly seted. Do not llow nyone to sit or ride on ny prt of the ot tht ws not intended for such use. This includes the cks of sets, gunwles, trnsom, ow, decks, rised fishing sets, nd ny rotting fishing set; nywhere tht sudden unexpected ccelertion, sudden stopping, unexpected loss of ot control or sudden ot movement could cuse person to e thrown overord or into the ot. Ensure tht ll pssengers hve proper set nd re in it efore ny ot movement. Never e under the influence of lcohol or drugs while oting (it is the lw). Alcohol or drugs impirs your judgment nd gretly reduce your ility to rect quickly. Know your oting re nd void hzrdous loctions. Be lert. The opertor of the ot is responsile y lw to mintin proper lookout y sight nd hering. The opertor must hve n unostructed view prticulrly to the front. No pssengers, lod, or fishing sets should lock the opertor's view when operting the ot ove idle or plning trnsition speed. Wtch out for others, keep your eyes on the the wter, nd e wre of your wke. Never drive your ot directly ehind wter skier in cse the skier flls. As n exmple, your ot trveling t 40 km/h (25 MPH) will overtke fllen skier who ws 61 m (200 ft.) in front of you in five seconds. Wtch fllen skiers. When using your ot for wter skiing or similr ctivities, lwys keep fllen or down skier on the opertor s side of the ot while returning to ttend to the skier. The opertor should lwys hve the down skier in sight nd never ck up to the skier or nyone in the wter. Pge 20 CMD / MAY 2007

29 Section 3 - On the Wter Report ccidents. Bot opertors re required y lw to file Boting Accident Report with their stte oting lw enforcement gency when their ot is involved in certin oting ccidents. A oting ccident must e reported if 1) there is loss of life or prole loss of life, 2) there is personl injury requiring medicl tretment eyond first id, 3) there is dmge to ots or other property where the dmge vlue exceeds US $ or 4) there is complete loss of the ot. Seek further ssistnce from locl lw enforcement. Be Alert to Cron Monoxide Poisoning Cron monoxide is present in the exhust fumes of ll internl comustion engines including the outords, sterndrives nd inord engines tht propel ots, s well s the genertors tht power vrious ot ccessories. Cron monoxide is dedly gs tht is odorless, colorless nd tsteless. Erly symptoms of cron monoxide poisoning, which should not e confused with sesickness or intoxiction, include hedche, dizziness, drowsiness nd nuse.! WARNING Cron monoxide poisoning cn led to unconsciousness, rin dmge, or deth. Keep the ot well ventilted while t rest or underwy nd void prolonged exposure to cron monoxide. Good Ventiltion Ventilte the pssenger re, open the side curtins or forwrd htches to remove fumes. 1. Exmple of desired ir flow through the ot. mc Poor Ventiltion Under certin conditions, permnently enclosed or cnvs enclosed cins or cockpits with insufficient ventiltion my drw in cron monoxide. Instll one or more cron monoxide detectors in your ot. Although the occurrence is rre, on very clm dy, swimmers nd pssengers in n open re of sttionry ot tht contins or is ner n operting engine my e exposed to hzrdous level of cron monoxide. 1. Exmples of poor ventiltion while ot is sttionry: mc Operting the engine when the ot is moored in confined spce - Mooring close to nother ot with its engine operting 2. Exmples of poor ventiltion while ot is moving: mc Operting the ot with the trim ngle of the ow too high - Operting the ot with no forwrd htches open (sttion wgon effect) Bsic Bot Opertion Lunching nd Bot Opertion IMPORTANT: Instll ilge drin plug prior to lunching ot. Strting the Engine After Stopped While in Ger IMPORTANT: Avoid stopping the engine if the sterndrive is in ger. If the engine does stop with the sterndrive in ger, see the following procedure: 1. Push nd pull repetedly on the remote control hndle until the hndle returns to the neutrl detent position. This my tke severl tries if the power pckge ws operting ove idle RPM when the engine stopped. CMD / MAY 2007 Pge 21

30 Section 3 - On the Wter 2. After the hndle returns to the neutrl detent position, resume norml strting procedures. Freezing Temperture Opertion IMPORTANT: If the ot is operted during periods of freezing temperture, tke precutions to prevent freeze dmge to the power pckge. Dmge cused y freezing is not covered y the Cummins MerCruiser Diesel Limited Wrrnty. Drin Plug nd Bilge Pump The engine comprtment in your ot is nturl plce for wter to collect. For this reson, ots re normlly equipped with drin plug or ilge pump. It is very importnt to check these items on regulr sis to ensure tht the wter level does not come into contct with your power pckge. Components on your engine will e dmged if sumerged. Dmge cused y sumersion is not covered y the Mercury MerCruiser or Cummins MerCruiser Diesel Limited Wrrnty. Trilering the Bot Your ot cn e trilered with the sterndrive in the up (out) or down (in) position. Adequte clernce is required etween the rod nd sterndrive when trnsporting. If dequte rod clernce is prolem, plce the sterndrive in full triler position nd support it with n optionl triler kit, which is ville from your Cummins MerCruiser Diesel Authorized Repir Fcility. Protecting People In The Wter While You Are Cruising It is very difficult for person in the wter to tke quick ction to void ot heding in their direction, even t slow speeds Alwys slow down nd exercise extreme cution ny time you re oting in n re where there might e people in the wter. Whenever ot is moving (even costing) nd the ger shift is in neutrl, there is sufficient force y the wter on the propeller to cuse the propeller to rotte. This neutrl propeller rottion cn cuse serious injury. While Bot Is Sttionry! WARNING A spinning propeller, moving ot, or ny solid device ttched to the ot cn cuse serious injury or deth to swimmers. Stop the engine immeditely whenever nyone in the wter is ner your ot. Shift into neutrl nd shut off the engine efore llowing people to swim or e in the wter ner your ot. High Speed nd High Performnce If your ot is considered high speed or high performnce ot with which you re unfmilir, we recommend tht you never operte it t its high speed cpility without first requesting n initil orienttion nd demonstrtion ride with your deler or n opertor experienced with your ot. For dditionl informtion, refer to the Hi-Performnce Bot Opertion ooklet ( R03) from your Cummins MerCruiser Diesel Authorized Repir Fcility. Pssenger Sfety In Pontoon Bots And Deck Bots Whenever the ot is in motion, oserve the loction of ll pssengers. Do not llow ny pssengers to stnd or use sets other thn those designted for trveling fster thn idle speed. A sudden reduction in ot speed, such s plunging into lrge wve or wke, sudden throttle reduction, or shrp chnge of ot direction, could throw them over the front of ot. Flling over the front of the ot etween the two pontoons will position them to e run over. Bots Hving An Open Front Deck No one should ever e on the deck in front of the ril while the ot is in motion. Keep ll pssengers ehind the front ril or enclosure. Pge 22 CMD / MAY 2007

31 Section 3 - On the Wter Persons on the front deck could esily e thrown overord or persons dngling their feet over the front edge could get their legs cught y wve nd pulled into the wter. mc ! WARNING Sitting or stnding in n re of the ot not designed for pssengers t speeds ove idle cn cuse serious injury or deth. Sty ck from the front end of deck ots or rised pltforms nd remin seted while the ot is in motion. Bots With Front-Mounted, Rised Pedestl Fishing Sets Elevted fishing sets re not intended for use when the ot is trveling fster thn idle or trolling speed. Sit only in sets designted for trveling t fster speeds. Any unexpected, sudden reduction in ot speed could result in the elevted pssenger flling over the front of the ot. mc Wve nd Wke Jumping! WARNING Wve or wke jumping cn cuse serious injury or deth from occupnts eing thrown within or out of the ot. Avoid wve or wke jumping whenever possile. mc Operting recretionl ots over wves nd wkes is nturl prt of oting. However, when this ctivity is done with enough speed to force the ot hull prtilly or completely out of the wter, certin hzrds rise, prticulrly when the ot re enters the wter. The primry concern is the ot chnging direction while in the midst of the jump. In such cses the lnding my cuse the ot to violently veer in new direction. Such shrp chnge in direction or turn cn cuse occupnts to e thrown out of their sets or out of the ot. There is nother less common hzrdous result from llowing your ot to lunch off of wve or wke. If the ow of your ot pitches down fr enough while irorne, upon wter contct it my penetrte under the wter surfce nd sumrine for n instnt. This will ring the ot nerly to stop in n instnt nd cn send the occupnts flying forwrd. The ot my lso veer shrply to one side. CMD / MAY 2007 Pge 23

32 Section 3 - On the Wter Impct with Underwter Hzrds Reduce speed nd proceed with cution whenever you're driving ot in shllow wter or in res where the wters re suspected of hving underwter ostcles tht could e struck y the underwter drive components, rudder, or the ot ottom. mc IMPORTANT: The most importnt thing you cn do to help reduce injury or impct dmge from striking floting or underwter oject is control the ot speed. Under these conditions, ot speed should e kept to mximum speed of 24 to 40 km/h (15 to 25 MPH). The following demonstrte some, ut not ll, exmples of wht cn hppen if the ot strikes n oject: The ot could move suddenly in new direction. Such shrp chnge in direction or turn cn throw occupnts out of their sets or out of the ot. A rpid reduction in speed. This will cuse occupnts to e thrown forwrd, even out of the ot. Impct dmge to the underwter drive components, rudder, or ot. Keep in mind tht one of the most importnt things you cn do to help reduce injury or impct dmge in these situtions is control the ot speed. Bot speed should e kept to minimum plning speed when driving in wters known to hve underwter ostcles. After striking sumerged oject, stop the engine s soon s possile nd inspect the drive system for ny roken or loose prts. If dmge is present or suspected, the power pckge should e tken to n uthorized Cummins MerCruiser Diesel repir fcility for thorough inspection nd ny necessry repir. The ot should e checked for hull frctures, trnsom frctures, nd wter leks. Operting with dmged underwter drive components, rudder, or ot ottom could cuse dditionl dmge to other prts of the power pckge, or could ffect control of the ot. If continued opertion is necessry, do so t gretly reduced speeds.! WARNING Operting ot or engine with impct dmge cn result in product dmge, serious injury, or deth. If the vessel experiences ny form of impct, hve n uthorized Mercury Mrine deler inspect nd repir the vessel or power pckge. Sterndrive Impct Protection The power trim hydrulic system is designed to provide impct protection for the sterndrive. If sumerged oject is struck while the ot is moving forwrd, the hydrulic system will cushion the kickup of the sterndrive s it clers the oject, reducing dmge to the sterndrive. After the sterndrive hs clered the oject, the hydrulic system llows the sterndrive to return to its originl operting position, preventing loss of steering control nd engine overspeed. Use extreme cution when operting in shllow wter or where underwter ojects re known to e present. No impct protection is provided in reverse; use extreme cre to prevent striking sumerged ojects while operting in reverse. IMPORTANT: Impct protection system cnnot e designed to ensure totl protection from impct dmge under ll conditions. Conditions Affecting Opertion Weight Distriution (Pssengers nd Ger) Inside the Bot Shifting weight to rer (stern): Generlly increses speed nd engine RPM Cuses ow to ounce in choppy wter Increses dnger of following wve splshing into the ot when coming off plne At extremes, cn cuse the ot to porpoise Shifting weight to front (ow): Improves ese of plning Improves rough wter ride Pge 24 CMD / MAY 2007

33 At extremes, cn cuse the ot to veer ck nd forth (ow steer) Bottom of Bot To mintin mximum speed, ensure tht the ot ottom is: Clen, free of rncles nd mrine growth. Free of distortion, nerly flt where it contcts wter. Stright nd smooth, fore nd ft. Section 3 - On the Wter Mrine vegettion my ccumulte when the ot is docked. This growth must e removed efore opertion; it my clog wter inlets nd cuse the engine to overhet. Cvittion Cvittion occurs when wter flow cnnot follow the contour of fst moving underwter oject, such s ger housing or propeller. Cvittion increses propeller speed while reducing ot speed. Cvittion cn seriously erode the surfce of the ger housing or the propeller. Common cuses of cvittion re: Weeds or other deris sngged on the propeller Bent propeller lde Rised urrs or shrp edges on the propeller Ventiltion Ventiltion is cused y surfce ir or exhust gses tht re introduced round the propeller resulting in propeller speed up nd reduction in ot speed. Air ules strike the propeller lde nd cuse erosion of the lde surfce. If llowed to continue, eventul lde filure (rekge) will occur. Excessive ventiltion is usully cused y: Drive unit trimmed out too fr A missing propeller diffuser ring A dmged propeller or ger housing, which llows exhust gses to escpe etween propeller nd ger housing Drive unit instlled too high on trnsom Elevtion nd Climte NOTE: Engines equipped with n Engine Control Module (ECM) reduce the effects of chnges in elevtion nd climte y utomticlly djusting fuel flow for wether conditions nd elevtion. ECM controlled engines, however, do not compenste for incresed loding or hull conditions. Elevtion nd climte chnges ffect the performnce of your power pckge. Loss of performnce cn e cused y: High elevtions High tempertures Low rometric pressures High humidity For optimum engine performnce under chnging wether conditions nd high elevtion, use propeller tht llows the engine to operte t rted RPM t wide open throttle (WOT) with mximum ot lod during your norml oting. In most cses, the rted RPM t WOT cn e chieved y chnging to lower pitch propeller. Propeller Selection NOTICE Operting the engine with the wrong propeller instlled cn limit power, increse fuel consumption, overhet the engine, or cuse internl powerhed dmge. Choose propeller tht llows the engine to operte t the specified wide open throttle RPM. The ot mnufcturer nd the selling deler re responsile to equip the power pckge with the correct propeller. Refer to the Diesel Prts And Accessories Guide nd red Everything You Need To Know Aout Propellers. Refer to the engine mnufcturer or mnufcturer's opertion mnul for the specified engine rted RPM. Select propeller tht llows the engine power pckge to operte t the engine rted RPM with full lod. Do not consider high RPM cused y excessive trim ngle in selecting the correct propeller. NOTE: Use n ccurte service tchometer to verify RPM. If WOT is elow the engine rted RPM, chnge the propeller to prevent loss of performnce nd possile engine dmge. Operting the engine ove the engine rted RPM will cuse higher thn norml wer or dmge. After initil propeller selection, the following common prolems my require tht the propeller e chnged to lower pitch: CMD / MAY 2007 Pge 25

34 Section 3 - On the Wter RPM loss cused y wrmer wether nd greter humidity (not s significnt on these models). RPM loss cused y operting in higher elevtion (not s significnt on these models). RPM loss cused y operting with dmged propeller or dirty ot ottom. Loss of speed cused y operting with incresed lod (dditionl pssengers, pulling skiers). Becuse mny design vriles ffect ots performnce, test the ot to determine the est propeller for prticulr ppliction. Refer to Diesel Sterndrive Brvo Models Instlltion Mnul, nd complete Bot in the Wter Wide Open Throttle Test. Getting Strted Sterndrive 10 Hour Brek In Period (New or With Replcement Gers) It is importnt tht the following procedure e used on new sterndrives nd reuilt sterndrives with new replcement gers. This rek in procedure llows the proper seting of the sterndrive gers nd relted components, which gretly reduces the likelihood of prolems. Avoid full throttle strts. Do not operte t ny one constnt speed for extended periods of time. Do not exceed 75% of full throttle during the first 5 hours. During the next 5 hours, operte t intermittent full throttle. The sterndrive should e shifted into forwrd ger minimum of 10 times during rek in, with run in time t moderte RPM fter ech shift. End of First Seson Checkup At the end of the first seson of opertion, contct Cummins MerCruiser Diesel Authorized Repir Fcility to discuss or perform scheduled mintennce items. If you re in n re where the product is operted continuously, yer round, you should contct your deler t the end of the first 100 hours of opertion or once yerly, whichever occurs first. Pge 26 CMD / MAY 2007

35 Tle of Contents Section 4 - Specifictions Section 4 - Specifictions Fluid Specifictions Brvo Sterndrive Fluid Specifictions Diesel...28 Power Steering nd Power Trim Fluids...28 Approved Power Steering Fluids Approved Compct Hydrulic Power Steering Fluids Approved Electro Hydrulic Power Steering Fluids Approved Power Trim Fluids Approved Pints Torque Specifictions CMD / MAY 2007 Pge 27

36 Section 4 - Specifictions Fluid Specifictions IMPORTANT: All cpcities re pproximte fluid mesures. Brvo Sterndrive Fluid Specifictions Diesel Sterndrive Model Fluid Cpcity includes the Sterndrive nd the Gerlue Monitor Fluid Type Fluid Prt Numer Brvo One X Diesel Brvo One XR Brvo Two X Diesel Brvo Three X Diesel Brvo Three XR 2736 ml (92 1/2 oz.) 3209 ml (108 1/2 oz.) 2972 ml (100 1/2 oz.) High Performnce Ger Luricnt K01 Power Steering nd Power Trim Fluids Approved Power Steering Fluids Description Prt Numer Power Trim nd Steering Fluid K01 Dexron III Automtic Trnsmission Fluid Otin Loclly Approved Compct Hydrulic Power Steering Fluids Description Prt Numer Hydrulic Helm Steering Fluid Q01 SeStr Hydrulic Fluid HA5430 Chevron Avition Fluid Moil Aero HFA Otin loclly Shell Aero 4 Hydrulic Fluid meeting MIL Specifiction H5606C Approved Electro-Hydrulic Power Steering Fluids Description Prt Numer Synthetic Power Steering Fluid SAE 10W K01 Approved Power Trim Fluids Description Prt Numer Power Trim nd Steering Fluid K01 SAE Engine Oil 10W 30 Otin loclly SAE Engine Oil 10W 40 Otin loclly Approved Pints Description Prt Numer Mercury Light Gry Primer Mercury Phntom Blck Q 1 Pge 28 CMD / MAY 2007

37 Torque Specifictions Section 4 - Specifictions Description Nm l. in. l. ft. Rer engine mount olt Giml ring locknuts 7/16 in. U olt Brvo One propeller nut Then lign ts with grooves Brvo Two propeller nut Then lign ts with groves Brvo Three front propeller nut Brvo Three rer propeller nut Propeller shft node screw CMD / MAY 2007 Pge 29

38 Section 4 - Specifictions Notes: Pge 30 CMD / MAY 2007

39 Tle of Contents Section 5 - Mintennce Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities...32 Deler Responsiilities...32 Do It Yourself Mintennce Suggestions Inspection Mintennce Intervls Mintennce Schedule Routine Mintennce...33 Scheduled Mintennce...34 Mintennce Log...35 Sterndrive Ger Lue Checking...36 Filling...36 Chnging...37 Power Trim Fluid Checking...40 Filling...41 Chnging...42 Power Assisted Steering Fluid (If Equipped) Electro Hydrulic Power Assisted Steering System (If Equipped) Checking...42 Filling...42 Chnging...43 Sterndrive Wter Pssges Sterndrive Wter Inlets Check...43 Sterndrive Wter Drin Check...43 Flushing the Sterndrive...43 Corrosion Protection Generl Informtion...46 Sterndrive Corrosion Protection Components...46 Anodes nd MerCthode System Loctions Continuity Circuit Brvo Sterndrive...48 MerCthode...50 Bot Bottom Cre...51 Pinting Your Power Pckge...51 Sterndrive Surfce Cre...52 Luriction Steering System...52 Shift Cle...54 Trnsom Assemly...54 Propeller Shft...54 Engine Coupler...55 Driveshft Extension Models...56 Sterndrive, Bellows, nd Engine Alignment...56 Mintining Torques Giml Ring U olt Nuts...57 Rer Engine Mount Torque...58 Propeller Brvo Diesel Sterndrive Propeller Removl...58 Brvo One Models Brvo Two Models Brvo Three Models Brvo Diesel Sterndrive Propeller Instlltion...62 Brvo One Models Brvo Two Models Brvo Three CMD / MAY 2007 Pge 31

40 Section 5 - Mintennce Product Responsiilities Owner nd Opertor Responsiilities It is the opertor's responsiility to perform ll sfety checks, to ensure tht ll luriction nd mintennce instructions re complied with for sfe opertion, nd to return the unit to Cummins MerCruiser Diesel Authorized Repir Fcility for periodic checkup. Norml mintennce service nd replcement prts re the responsiility of the owner or opertor nd s such, re not considered defects in workmnship or mteril within the terms of the wrrnty. Individul operting hits nd usge contriute to the need for mintennce service. Proper mintennce nd cre of your power pckge will ensure optimum performnce nd dependility nd will keep your overll operting expenses t minimum. See your Cummins MerCruiser Diesel Authorized Repir Fcility for service ids. Deler Responsiilities In generl, deler's responsiilities to the customer include predelivery inspection nd preprtion such s: Mke certin tht the power pckge nd other equipment re in proper operting condition efore delivery. Mke ll necessry djustments for mximum efficiency. Explin nd demonstrte the opertion of the power pckge nd ot. Provide you with copy of Predelivery Inspection Checklist. Fill out the Wrrnty Registrtion Crd completely nd mil it to the fctory immeditely upon sle of the new product. All power pckges must e registered for wrrnty purposes. Do It Yourself Mintennce Suggestions Present dy mrine equipment, such s your Cummins MerCruiser Dieel power pckge, re highly technicl pieces of mchinery. Electronic ignition nd specil fuel delivery systems provide greter fuel economies, ut lso re more complex for the untrined mechnic. If you like to do it yourself, here re some suggestions for you. Do not ttempt ny repirs unless you re wre of the cutions, wrnings, nd procedures required. Your sfety is our concern. If you ttempt to service the product yourself, we suggest you order the service mnul for tht model. The service mnul outlines the correct procedures to follow. It is written for the trined mechnic, so there my e procedures you don't understnd. Do not ttempt repirs if you do not understnd the procedures. There re specil tools nd equipment tht re required to perform some repirs. Do not ttempt these repirs unless you hve these specil tools or equipment. You cn cuse dmge to the product in excess of the cost deler would chrge you. Also, if you prtilly disssemle n engine or drive ssemly nd re unle to repir it, the deler's mechnic must ressemle the components nd test to determine the prolem. This will cost you more thn tking it to the deler immeditely upon hving prolem. It my e very simple djustment to correct the prolem. Do not telephone the deler, service office, or the fctory to ttempt for them to dignose prolem or to request the repir procedure. It is difficult for them to dignose prolem over the telephone. Your Authorized Cummins MerCruiser Diesel repir fcility is there to service your power pckge. They hve qulified fctory trined mechnics. It is recommended you hve the locl Authorized Cummins MerCruiser Diesel repir fcility do periodic mintennce checks on your power pckge. Hve them winterize it in the fll nd service it efore the oting seson. This will reduce the possiility of ny prolems occurring during your oting seson when you wnt troule free oting plesure. Inspection Inspect your power pckge often nd t regulr intervls to help mintin its top operting performnce nd correct potentil prolems efore they occur. The entire power pckge should e checked crefully, including ll ccessile engine prts. Check for loose, dmged, or missing prts, hoses, nd clmps; tighten or replce s necessry. Check electricl connections nd leds for dmge. Remove nd inspect the propeller. If dly nicked, ent, or crcked, contct your Authorized Cummins MerCruiser Diesel repir fcility. Pge 32 CMD / MAY 2007

41 Section 5 - Mintennce Repir nicks nd corrosion dmge on the power pckge exterior finish. Contct your Authorized Cummins MerCruiser Diesel repir fcility. Brvo One X Diesel Shown - Trnsom ssemly - Sterndrive c - Anode plte d - Propeller e - Speedometer pitot tue f - MerCthode electrode g - Power trim cylinder e f g c d Mintennce Intervls Mintennce intervls nd the corresponding tsks to e performed re sed on n verge oting ppliction nd environment. However, individul operting hits nd personl preferences cn hve n impct on the suggested intervls. We hve djusted some mintennce intervls nd their corresponding tsks to llow for these differences. In some cses these chnges llow for more individul tsks in single visit to the servicing deler. Therefore, it is very importnt tht the ot owner nd the servicing deler discuss the current mintennce schedule nd develop pproprite mintennce intervls to coincide with individul operting hits, the environment, nd mintennce preferences.! WARNING Performing service or mintennce without first disconnecting the ttery cn cuse product dmge, personl injury, or deth due to fire, explosion, electricl shock, or unexpected engine strting. Alwys disconnect the ttery cles from the ttery efore mintining, servicing, instlling, or removing engine or drive components. Mintennce Schedule NOTE: Perform only the mintennce tsks tht pply to your power pckge. Routine Mintennce Tsk Intervl Before ech use After ech use Mintennce Tsks Check the sterndrive propeller ldes for dmge. Check the tie r fsteners (dul engine instlltions) for proper tightness. Check the sterndrive ger lue level. Check the trim pump oil level. Check the power ssisted steering pump fluid level, if equipped. Check the steering system for inding or loose components. Check the hydrulic steering fittings nd hoses for leks or signs of dmge. If operting in sltwter, rckish wter, or polluted wter, flush the sterndrive fter ech use if it is removed from the wter. CMD / MAY 2007 Pge 33

42 Section 5 - Mintennce Tsk Intervl Weekly Every two months Mintennce Tsks Check the wter inlets for deris or mrine growth. Inspect the sterndrive nodes nd replce if 50% eroded. Luricte the propeller shft nd retorque the nut. If operting in freshwter only, this intervl my e extended to every four months. Scheduled Mintennce Tsk Intervl Every 100 hours or nnully (whichever occurs first) Every 200 hours or 3 yers (whichever occurs first) Touch up the pint on the power pckge. Chnge the sterndrive ger lue. Retorque the giml ring U olt nuts. Retorque the rer engine mount olts. Mintennce Tsks Models with driveshft extensions: luricte the driveshft U joints nd the tilstock input nd output erings. Check the steering system nd the remote control for loose, missing, or dmged prts. Luricte the cles nd the linkges. Check the continuity circuit for loose or dmged connections. If equipped with MerCthode unit, test the output. If equipped with electro hydrulic power steering, check the fluid level. Check the engine lignment. Inspect the U joints, the splines, the ellows, nd check the clmps. Luricte the U joint splines nd cross ering. Luricte the giml ering nd the engine coupler. Luricte the engine coupler every 50 hours if operted t idle for prolonged periods or if used in hevy ot pplictions. Pge 34 CMD / MAY 2007

43 Section 5 - Mintennce Mintennce Log Record ll mintennce performed on your power pckge here. Sve ll work orders nd receipts. Dte Mintennce Performed Engine Hours CMD / MAY 2007 Pge 35

44 Section 5 - Mintennce Sterndrive Ger Lue NOTICE Dischrge of oil, coolnt, or other engine/drive fluids into the environment is restricted y lw. Use cution not to spill oil, coolnt, or other fluids into the environment when using or servicing your ot. Be wre of the locl restrictions governing the disposl or recycling of wste, nd contin nd dispose of fluids s required. Checking NOTE: The ger lue level will fluctute during opertion. The ger lue level should e checked with the engine cold, efore strting. 1. Check the ger lue monitor to determine the ger lue level. Keep the ger lue level within the recommended operting rnge. See Filling. Ger lue level shown is t the correct operting rnge - "ADD" mrk - "OPERATING RANGE" mrk Filling IMPORTANT: If ny wter is visile t the ottom of the ger lue monitor or ppers t the fill nd drin plug hole, or if the ger lue ppers discolored, contct your Cummins MerCruiser Diesel Authorized Repir Fcility immeditely. Both conditions my indicte wter lek in the sterndrive. IMPORTANT: If more thn 59 ml (2 fl. oz.) of High Performnce Ger Lue is required to fill the ger lue monitor, sel my e leking. Dmge to the sterndrive my occur due to lck of luriction. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. 1. Remove the ger lue monitor cp. 2. Fill the ger lue monitor with the specified ger lue so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Ger lue monitor K01 Pge 36 CMD / MAY 2007

45 Section 5 - Mintennce 3. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll the cp. Do not overtighten. - Ger lue monitor cp NOTE: When filling the entire sterndrive, see Chnging. Chnging 1. Remove the ger lue monitor from the rcket. - Ger lue monitor rcket - Ger lue monitor nd cp c - Retining strp c Empty the contents of the ger lue monitor into suitle continer. 3. Instll the ger lue monitor in the rcket. 4. Remove the propeller. See Propellers. 5. Brvo One Models:. Lower the sterndrive to the full down (in) position.. Remove the ger lue fill nd drin plug nd seling wsher. c. Drin the ger lue into suitle continer - Fill nd drin plug - Seling wsher mc Brvo Two models nd Brvo Three models:. Plce the sterndrive in full trim limit out (up) position.. Remove the fill nd drin plug nd seling wsher. CMD / MAY 2007 Pge 37

46 Section 5 - Mintennce c. Drin the ger lue into suitle continer Brvo Two - Fill nd drin plug - Seling wsher Brvo Three 7. Remove the vent plug nd seling wsher. Allow the ger lue to drin completely. - Vent plug - Seling wsher IMPORTANT: If ny wter drins from the fill nd drin plug hole, or if the ger lue ppers milky, the sterndrive is leking nd should e checked immeditely y your Cummins MerCruiser Diesel Authorized Repir Fcility. 8. Lower the sterndrive so tht the propeller shft is level. 9. Fill the sterndrive through the fill nd drin plug hole with the specified ger lue until n ir free strem of lue flows from the vent plug hole. Tue Ref No. Description Where Used Prt No. 87 High Performnce Ger Lue Sterndrive unit K01 IMPORTANT: Use only Mercury/Quicksilver High Performnce Ger Lue in the sterndrive. 10. Instll the vent plug nd seling wsher. 11. Continue to pump ger lue into the drive through the fill nd drin plug hole until the ger lue ppers in the ger lue monitor. Pge 38 CMD / MAY 2007

47 Section 5 - Mintennce 12. Fill the ger lue monitor so tht the ger lue level is in the operting rnge. Do not overfill. c Ger lue monitor - Ger lue level t the "ADD" mrk - Ger lue level t the "OPERATING RANGE" mrk c - Ger lue monitor cp Sterndrive Model Brvo One X Diesel Brvo One XR Brvo Two X Diesel Brvo Three X Diesel Brvo Three XR Fluid Cpcity includes the Sterndrive nd the Ger lue Monitor 2736 ml (92 1/2 oz.) 3209 ml (108 1/2 oz.) 2972 ml (100 1/2 oz.) Fluid Type High Performnce Ger Lue 13. Ensure tht the ruer gsket is inside the ger lue monitor cp nd instll. Do not overtighten. - Ger lue monitor cp Fluid Prt Numer A Remove the pump from the sterndrive fill nd drin plug hole. CMD / MAY 2007 Pge 39

48 Section 5 - Mintennce 15. Quickly instll the seling wsher nd the fill nd drin plug. Torque to the following specifictions. mc All Brvo Models Shown - Fill nd drin plug - Seling wsher Description Nm l. in. l. ft. Fill nd drin plug Instll the sterndrive propeller. See Propellers. 17. Recheck the ger lue level t the ger lue monitor fter the first use. See Checking. IMPORTANT: The ger lue level in the ger lue monitor will rise nd fll during sterndrive opertion; lwys check the ger lue level when the sterndrive is cool nd the engine is shut down. Power Trim Fluid Checking IMPORTANT: Check the fluid level with the sterndrive in the full down (in) position only. 1. Plce the sterndrive in full down (in) position. Pge 40 CMD / MAY 2007

49 2. Oserve the fluid level. The fluid level must e etween the "MIN" nd "MAX" lines on the reservoir. Section 5 - Mintennce Reservoir - "MIN" nd "MAX" lines 3. Fill s necessry with the specified fluid. See Filling. Tue Ref No. Description Where Used Prt No. 114 Power Trim nd Steering Fluid Power trim pump K01 Filling 1. If the fluid level is elow the "MIN" line, the specified fluid must e dded. 2. Remove the fill cp from the reservoir. NOTE: The fill cp is vented. Power trim pump reservoir shows the fluid level is elow "MIN" line - Fill cp ssemly - Fill cp instlled 7701 CMD / MAY 2007 Pge 41

50 Section 5 - Mintennce 3. Add the specified fluid to ring the fluid level to within the "MIN" nd "MAX" lines on the reservoir Reservoir - "MIN" nd "MAX" lines Tue Ref No. Description Where Used Prt No Instll the fill cp. Chnging Power Trim nd Steering Fluid Power trim pump K01 Power trim fluid does not require chnging unless it ecomes contminted with wter or deris. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. Power Assisted Steering Fluid (If Equipped) Refer to the OEM for informtion on checking, filling, nd chnging the power ssisted steering fluid. Electro Hydrulic Power Assisted Steering System (If Equipped) IMPORTANT: Running the pump dry will dmge the pump. Alwys check steering fluid levels efore operting the ot. Checking 1. Remove the cover nd the fill cp to check the fluid level. 2. The fluid level should e slightly elow the ottom of the fill opening. c - Cover - Fill cp c - Fill level (elow the ottom of the fill opening) 3. If the fluid level is low, dd the specified fluid. See Filling. 4. Instll the cover. Filling Remove the fill cp 2. Add the specified fluid to ring the fluid level slightly elow the ottom of the fill opening. Pge 42 CMD / MAY 2007

51 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No Instll the fill cp. 4. Instll the cover. Chnging Synthetic Power Steering Fluid SAE 10W-30 Power-ssisted steering system K01 Power ssisted steering fluid does not require chnging unless it ecomes contminted. See your Cummins MerCruiser Diesel Authorized Repir Fcility. Sterndrive Wter Pssges Sterndrive Wter Inlets Check 1. Otin piece of wire the pproprite size to insert into the wter inlets holes. 2. Insert the wire in nd out of the sterndrive wter inlets to ensure tht they re open nd to remove deris or mrine growth. Do not scrpe the sterndrive pint. 3. Remove the wire from the sterndrive nd retin for periodic wter inlet checks. - Dul wter pickup wter inlets - Side pickup wter inlets Sterndrive Wter Drin Check 1. Otin piece of wire the pproprite size to insert into the wter drin holes. 2. Insert the wire in nd out of the sterndrive wter drin holes to ensure tht they re open nd to remove deris or mrine growth. Do not scrpe the sterndrive pint. 3. Remove the wire from the sterndrive nd retin for periodic wter drin checks d c Sterndrive wter drin holes - Speedometer pitot tue - Anode cvity vent hole c - Anode cvity drin pssge d - Ger housing wter drin hole (1 ech port nd strord) e - Ger housing cvity vent hole (Brvo II only) e Flushing the Sterndrive IMPORTANT: This service should e preformed y Cummins MerCruiser Diesel Authorized Repir Fcility. Dmge cused y incorrectly flushing the sterndrive is not covered y the Cummins MerCruiser Diesel Limited Wrrnty. NOTE: Refer to the engine OEM opertion, mintennce nd wrrnty mnul for operting specifictions, fluid cpcities, nd flushing instructions CMD / MAY 2007 Pge 43

52 Section 5 - Mintennce NOTE: Flushing the sterndrive if it hs een operted in slty, rckish, minerl lden or polluted wter. For est results flush fter ech outing nd efore cold wether storge nd extended storge. If you pln to perform this procedure, seek guidnce from Cummins MerCruiser Diesel Authorized Repir Fcility. This procedure requires sufficient wter supply to the engine nd sterndrive. 1. Flush the sterndrive with the ot out of wter. 2. Lower the sterndrive to the full down (in) position. Do not llow the sterndrive skeg to contct the ground.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. 3. Remove the propeller. See Propellers. 4. Connect flushing hose to the wter source. 5. On models with dul wter pickups:. Instll the dul wter pickup flush gercse sel kit.. Instll the flushing device. c. Attch the flushing hose to the flushing device. Flushing ttchments for the sterndrive with dul wter pickup - Flushing device - Hose ttchment c - Dul wter pickup flush gercse sel kit c Dul Wter Pick up Flush Gercse Sel Kit K 1 Blocks off the front wter inlet holes on the dul wter inlet gercses Flushing Device Q 2 Attches to the wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine On Models with side wter pickups:. Instll the flushing device. Pge 44 CMD / MAY 2007

53 Section 5 - Mintennce. Attch the flushing hose to the flushing device. Flushing ttchment for the sterndrive with side wter pickups - Flushing device - Hose ttchment Flushing Device Q 2 Attches to the wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine NOTICE Without sufficient cooling wter, the engine, the wter pump, nd other components will overhet nd suffer dmge. Provide sufficient supply of wter to the wter inlets during opertion. IMPORTANT: Engines with the sterndrive wter inlet locked off t the giml housing nd using through hull or through trnsom wter inlet need supply of cooling wter ville to oth the sterndrive nd to the engine during opertion. IMPORTANT: Prevent ir from entering the wter chmer of the engine. If pplicle, lock dditionl sewter inlets or engine sewter openings tht re not needed to cool the engine while flushing the sterndrive. Refer to the pproprite engine service mnul. 7. Plce remote control hndle in neutrl. 8. Prtilly open the wter source to out 1/2 mximum. Do not use full wter pressure. NOTICE Operting the engine out of the wter t high speeds cretes suction, which cn collpse the wter supply hose nd overhet the engine. Do not operte the engine ove 1400 RPM out of the wter nd without sufficient cooling wter supply. 9. Strt the engine. 10. Provide sufficient supply of wter to the sterndrive wter inlet holes nd the through hull wter inlet holes. 11. Oserve the wter temperture guge to ensure tht the engine is operting in the norml rnge. 12. Operte the engine t idle speed in neutrl for out ten minutes or until the dischrge wter is cler. 13. Stop the engine. 14. Shut off the supply wter nd remove the flushing ttchment. 15. Instll the propeller. See Propellers. 16. Prepre the engine nd sterndrive for norml opertion. CMD / MAY 2007 Pge 45

54 Section 5 - Mintennce Corrosion Protection Generl Informtion Whenever two or more dissimilr metls (such s those found on this power pckge) re sumerged in conductive solution such s sltwter, polluted wter, or wter with high minerl content, chemicl rection tkes plce cusing electricl current to flow etween metls. The electricl current flow cuses the metl tht is most chemiclly ctive, or nodic, to erode. This erosion is known s glvnic corrosion nd, if it is not controlled, it will eventully cuse the need for replcement of power pckge components exposed to wter. To help control the effects of glvnic corrosion, Cummins MerCruiser Diesel power pckges come with severl scrificil nodes nd other corrosion protection devices. For more comprehensive explntion of corrosion nd corrosion protection refer to the Mrine Corrosion Protection Guide ( ). IMPORTANT: Replce scrificil nodes if eroded 50% or more. Cummins MerCruiser Diesel strongly recommends voiding the use of nodes from nother mnufcturer. Refer to your Cummins MerCruiser Diesel Authorized Repir Fcility for dditionl informtion. Sterndrive Corrosion Protection Components To help control the effects of glvnic corrosion, Cummins MerCruiser Diesel sterndrives come with severl scrificil nodes nd other corrosion protection devices. For more comprehensive explntion of corrosion nd corrosion protection, refer to the Mrine Corrosion Protection Guide ( ) Gercse nodic plte 2 - Anode plte 3 - MerCthode System 4 - Anode kit 5 - Trim cylinder nodes 6 - Bering crrier nodes 7 - Propeller shft Anode (Brvo III stndrd) NOTICE Wshing the MerCthode ssemly cn dmge components nd led to rpid corrosion. Do not use ny clening equipment such s rushes or high pressure wshers to clen the MerCthode ssemly. Do not pressure wsh the MerCthode ssemly. Doing so will dmge the coting on the reference electrode wire nd decrese the corrosion protection. c MerCthode mounted to the underside of the giml housing - MerCthode reference electrode - Do not pint c - Do not pressure wsh 6211 Pge 46 CMD / MAY 2007

55 Anodes nd MerCthode System Loctions IMPORTANT: Replce scrificil nodes if eroded 50 percent or more. Section 5 - Mintennce The scrificil nodes in the following tle re instlled t different loctions on your power pckge. These nodes help protect ginst glvnic corrosion y scrificing their metl to e slowly eroded insted of the metl components on the power pckge. MerCthode System. The electrode ssemly replces the node lock. The system should e tested to ensure dequte output. Perform the test when the ot is moored using Quicksilver Reference Electrode nd Test Meter. Contct your Cummins MerCruiser Diesel Authorized Repir Fcility. Anodes nd MerCthode System Loctions Description Loction Figure Gercse node plte Mounted on the underside of the lower gercse Ventiltion plte node Mounted on the front of the gercse MerCthode System The MerCthode electrode is mounted to the underside of the giml housing. The MerCthode controller is mounted on the engine or on the ot trnsom. The controller hrness connects to the electrode hrness Anode kit (if equipped) Mounted to the ot trnsom Trim cylinder nodes Mounted on ech of the trim cylinders Bering crrier node (Brvo One) Locted in front of the propeller, etween the front side of the propeller nd the ger housing Propeller shft node (Brvo Three) Locted ehind the ft propeller CMD / MAY 2007 Pge 47

56 Section 5 - Mintennce In ddition to the corrosion protection devices, tke the following steps to inhiit corrosion: 1. Pint the power pckge. See Pinting Your Power Pckge. 2. Annully spry the power pckge components on the inside of the ot with Corrosion Gurd to protect the finish from dulling nd corrosion. You my lso spry externl power pckge components. 3. Keep ll luriction points, especilly the steering system, shift, nd throttle linkges, well luricted. 4. Flush the cooling system periodiclly, preferly fter ech use. Continuity Circuit Brvo Sterndrive The trnsom ssemly nd sterndrive hve ground circuit wires to ensure good electricl continuity etween the engine, trnsom ssemly, nd sterndrive components. Good continuity to ground is essentil for the node nd MerCthode system to function effectively. 1. Inspect the steering lever ground wire for loose connections, roken connectors, or fryed wiring. 2. Inspect the inner trnsom plte ground wire for loose connections, roken connectors, or fryed wiring Steering lever continuity wire - Continuity wire Trnsom plte continuity wires 3. Inspect the flywheel housing grounding stud nd ground wire, nd the inner trnsom plte grounding screw for loose connections, roken connectors, or fryed wiring. c Typicl - Flywheel housing screw or grounding stud - Continuity circuit (ground) wire c - Inner trnsom plte grounding screw 7782 Pge 48 CMD / MAY 2007

57 Section 5 - Mintennce 4. Inspect the driveshft housing to ger housing ground plte inside the node cvity for loose or fulty connection. Sterndrive nodic plte cvity - Ground plte (inside node cvity) Inspect the giml housing ground wires for loose connections, roken connectors, or fryed wiring. - Giml housing to giml ring ground wire - Giml housing to trim cylinder ground wires 6. Inspect the giml ring ground wire for loose connections, roken connectors, or fryed wiring Giml ring to ell housing ground wire CMD / MAY 2007 Pge 49

58 Section 5 - Mintennce 7. Inspect the sterndrive ground plte for loose or roken connections. - Sterndrive to ell housing ground plte Inspect the continuity wshers under the hydrulic mnifold lock fsteners for loose or fulty connection. - Continuity wshers Inspect the sterndrive U joint ellows ground clips nd exhust tue ground clip for loose or fulty connections. Exhust tue ground clip shown, U-joint ellows ground clips similr - Exhust tue ground clip MerCthode If the ot is equipped with Quicksilver MerCthode system, the system should e tested to ensure tht it is providing dequte output to protect the underwter metl prts on the ot. The test should e mde where the ot is moored, using Quicksilver Reference Electrode nd Test Meter. Reference Electrode T 1 Senses nd electricl current in the wter when testing the MerCthode system. Use to check hull potentil Refer to the pproprite Mercury MerCruiser Sterndrive Service Mnul for testing procedures. Pge 50 CMD / MAY 2007

59 Bot Bottom Cre Section 5 - Mintennce To chieve mximum performnce nd fuel economy, the ot ottom must e kept clen. Accumultion of mrine growth or other foreign mtter cn gretly reduce ot speed nd increse fuel consumption. To ensure est performnce nd efficiency, periodiclly clen the ot ottom in ccordnce with mnufcturer's recommendtions. In some res, it my e dvisle to pint the ottom to help prevent mrine growth. Refer to the following informtion for specil notes out the use of nti fouling pints. Pinting Your Power Pckge IMPORTANT: Corrosion dmge tht results from the improper ppliction of nti fouling pint will not e covered y the limited wrrnty. 1. Pinting the ot hull or trnsom: you my pply nti fouling pint to the ot hull nd trnsom. However, oserve the following: IMPORTANT: Do not pint nodes or MerCthode System reference electrode nd node. Pint will render them ineffective s inhiitors of glvnic corrosion. IMPORTANT: If nti fouling protection is required for the ot hull or trnsom, you cn use copper sed or tin sed pints where not prohiited y lw. If using copper sed or tin sed nti fouling pints, oserve the following: Avoid ny electricl interconnection etween the pint nd the Mercury MerCruiser product, nodic locks, or MerCthode system y llowing minimum of 40 mm (1 1/2 in.) unpinted re on the trnsom of the ot round these items. - Pinted ot trnsom - Unpinted Are on Trnsom Pinting the sterndrive unit or trnsom ssemly: The sterndrive unit nd trnsom ssemly should e pinted with good qulity mrine pint or n nti fouling pint tht does not contin copper, tin, or ny other mteril tht could conduct electricl current. Do not pint drin holes, nodes, MerCthode system, or items specified y the ot mnufcturer. CMD / MAY 2007 Pge 51

60 Section 5 - Mintennce Sterndrive Surfce Cre c d e Stndrd Brvo sterndrive - Scrificil trim cylinder node - Scrificil nodic plte c - Steering lever ground wire d - Ground wire etween the giml ring nd ell housing e - Stinless steel hoses f - Ground wire etween the giml housing nd trim cylinder g - Ground wire etween the giml ring nd giml housing f g We recommend the following mintennce items to help keep your sterndrive corrosion free: Mintin complete pint covering on the sterndrive. Check the finish regulrly. Prime nd pint nicks nd scrtches using Mercury enmel pint nd touch up pint. Use only tin sed nti fouling pint or its equivlent on or ner luminum surfces elow the wterline. If re metl is showing, pply 2 cots pint. Description Where used Prt numer Mercury Phntom Blck Bre metl Spry ll electricl connections with selnt. Tue Ref No. Description Where Used Prt No. 25 Liquid Neoprene All electricl connections Inspect the scrificil trim t or node plte if equipped, t regulr intervls nd replce it efore it is hlf gone. If stinless steel propeller is instlled, dditionl nodes or MerCthode System will e required. Inspect the propeller shft for fishing line, which cn cuse corrosion on stinless steel shft. Remove the propeller t lest every 60 dys nd luricte the propeller shft. Do not use luricnts contining grphite on or ner the luminum in sltwter. Do not pint trim ts or the mounting surfce. Luriction Steering System 21083! WARNING Incorrect cle luriction cn cuse hydrulic lock, leding to serious injury or deth from loss of ot control. Completely retrct the end of the steering cle efore pplying luricnt. NOTE: If the steering cle does not hve grese fitting, the inner wire of the cle cnnot e gresed. 1. If the steering cle hs grese fittings, turn the steering wheel until the steering cle is fully retrcted into the cle housing. Pge 52 CMD / MAY 2007

61 Section 5 - Mintennce 2. Apply pproximtely three pumps of grese from typicl hnd operted grese gun. - Steering cle grese fitting 6221 Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Steering cle grese fitting Q02 3. Turn the steering wheel until the steering cle is fully extended. 4. Lightly luricte the exposed prt of the cle. - Extended steering cle 6222 Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Steering cle Q02 5. Luricte the steering pin. - Steering pin mc Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Steering pin Otin Loclly 6. On dul engine ots, luricte the tie r pivot points. CMD / MAY 2007 Pge 53

62 Section 5 - Mintennce Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Tie r pivot points Otin Loclly 7. Upon first strting the engine, turn the steering wheel severl times to strord nd then port to ensure tht the steering system opertes properly efore getting underwy. Shift Cle 1. Luricte the pivot points nd guide contct surfces Typicl sterndrive model shift cle - Pivot points - Guide contct surfce Tue Ref No. Description Where Used Prt No. 80 SAE Engine Oil 30W Shift cle pivot points nd guide contct surfces Otin Loclly Trnsom Assemly 1. Luricte the giml ering y pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun. - Giml ering grese insert Tue Ref No. Description Where Used Prt No. 42 U-joint nd Giml Bering Grese Giml ering grese insert A1 Propeller Shft NOTE: See Propeller Removl. Pge 54 CMD / MAY 2007

63 Section 5 - Mintennce 1. Lierlly cot the propeller shft with one of the following luricnts Propeller shft Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Propeller shft Q02 94 Anti-Corrosion Grese Propeller shft Q C Mrine Luricnt with Teflon Propeller shft A 1 NOTE: Anti corrosion grese is for sltwter pplictions only. Engine Coupler 1. Luricte engine coupler splines through grese fittings on coupler y pplying pproximtely 8 10 pumps of grese from typicl hnd operted grese gun. NOTE: If equipped with seled engine coupler, the seled coupler nd shft splines cn e luricted without removing the sterndrive. Apply luricnt from typicl hnd operted grese gun. NOTE: If the ot is operted t idle for prolonged periods of time or if used in hevy ot pplictions, Brvo model luminum coupler should e luricted every 50 hours. Seled steel coupler - Engine coupler grese fitting Steel coupler Tue Ref No. Description Where Used Prt No. 91 Engine Coupler Spline Grese Coupler A 1 CMD / MAY 2007 Pge 55

64 Section 5 - Mintennce Driveshft Extension Models 1. Luricte the trnsom end grese fitting nd engine end grese fitting y pplying pproximtely pumps of grese from typicl hnd operted grese gun. 2. Luricte the driveshft grese fittings y pplying pproximtely 3 4 pumps of grese from typicl hnd operted grese gun. c Driveshft grese fittings - Trnsom end grese fitting c - Engine end grese fitting Tue Ref No. Description Where Used Prt No. 42 U-joint nd Giml Bering Grese Sterndrive, Bellows, nd Engine Alignment Trnsom end grese fitting, engine end grese fitting, driveshft grese fittings A1 NOTE: Hve your Cummins MerCruiser Diesel Authorized Repir Fcility perform the mintennce procedures listed, or refer to the pproprite Mercury MerCruiser Brvo Sterndrive Service Mnul. 1. Luricte the U joint shft splines nd the O rings. - U joint shft splines - U joint shft O rings Tue Ref No. Description Where Used Prt No. 91 Engine Coupler Spline Grese U-joint shft splines nd O-rings A 1 2. Inspect the U joint ellows for crcks or other signs of deteriortion. Ensure tht the ellows clmps re tight. Pge 56 CMD / MAY 2007

65 Section 5 - Mintennce 3. Rotte the ell housing in the upwrd nd side to side directions to inspect the exhust tue, shift cle ellows, nd clmps. c e f - U joint ellow - Exhust tue c - Bell housing d - Giml ring e - Giml housing f - Shift cle ellows d Check the engine lignment. c d Alignment tool - End of lignment tool to insert through giml housing ssemly c - Giml ering d - Engine coupler Mintining Torques Giml Ring U olt Nuts NOTE: The giml ring is component of the trnsom ssemly. CMD / MAY 2007 Pge 57

66 Section 5 - Mintennce 1. Torque the giml ring U olt nuts. - Trnsom ssemly - Giml ring U olt nuts Description Nm l. in. l. ft. Giml ring U olt nuts for 3/8 in. U olt Giml ring U olt nuts for 7/16 in. U olt Rer Engine Mount Torque NOTE: Not required on some engine models. Refer to the engine mnufcturer for engine mount torque mintennce. 1. Torque the engine mount olts t the trnsom plte mount. Propeller Description Nm l. in. l. ft. Rer engine mount olt Brvo Diesel Sterndrive Propeller Removl! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. Pge 58 CMD / MAY 2007

67 Section 5 - Mintennce Brvo One Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Prop - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket c Turn the propeller shft nut counterclockwise nd remove the nut. 4. Slide the propeller nd the ttching hrdwre from the propeller shft. c d e f Brvo One models - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut g 5301 CMD / MAY 2007 Pge 59

68 Section 5 - Mintennce Brvo Two Models 1. Strighten the ent ts of the t wsher on the propeller shft. c d e - Prop - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket c Turn the propeller shft nut counterclockwise to remove the nut. 4. Slide the propeller nd ttching hrdwre from the propeller shft. c e d 8566 f Brvo Two - Propeller shft splines - Forwrd thrust hu c - Propeller d - Spline wsher e - T wsher f - Propeller nut Brvo Three Models 1. Plce lock of wood etween the propeller lde nd the sterndrive's nti ventiltion plte. 2. Remove the olt nd wshers securing the propeller shft node. Pge 60 CMD / MAY 2007

69 Section 5 - Mintennce 3. Remove the propeller shft node. c - Propeller - Propeller shft nut c - Propeller shft node d - Propeller shft node screw e - Flt wsher f - Str wsher d f e Turn the ft propeller shft nut counterclockwise to remove the nut. 5. Slide the propeller nd thrust hu off of the propeller shft. 6. Using the Propeller Nut Tool, turn the front propeller shft nut counterclockwise nd remove the nut. Propeller Nut Tool T 1 Aids in the removl nd instlltion of the front propeller nut Slide the propeller nd the thrust hu off the propeller shft. g i h j c d e f 5304 Brvo Three - Aft propeller nut - Aft propeller c - Aft propeller thrust hu d - Front propeller nut e - Front propeller f - Front propeller thrust hu g - Propeller shft node screw h - Flt wsher i - Str wsher j - Propeller shft node CMD / MAY 2007 Pge 61

70 Section 5 - Mintennce Brvo Diesel Sterndrive Propeller Instlltion! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte.! WARNING Rotting propellers cn cuse serious injury or deth. Never operte the ot out of the wter with propeller instlled. Before instlling or removing propeller, plce the drive unit in neutrl nd engge the lnyrd stop switch to prevent the engine from strting. Plce lock of wood etween the propeller lde nd the nti ventiltion plte. - Wood lock - Propeller c - Propeller nut under socket c Brvo One Models 4826 IMPORTANT: Use propeller with the correct rottion. The propeller rottion must mtch the direction of rottion of the propeller shft. 1. Lierlly cot the propeller shft spline with one of the following Quicksilver luricnts. Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Propeller shft splines Q02 94 Anti-Corrosion Grese Propeller shft splines Q C Mrine Luricnt with Teflon Propeller shft splines A 1 NOTE: Anti corrosion grese is for sltwter pplictions only. 2. Instll the propeller with the ttching hrdwre s shown. 3. Torque the propeller nut. c d e f Typicl Brvo One model - Propeller shft splines - Forwrd thrust hu c - Flo Torque II drive hu d - Propeller e - Drive sleeve dpter f - T wsher g - Propeller nut g 5301 NOTE: The propeller torque stted is minimum torque vlue. Pge 62 CMD / MAY 2007

71 Section 5 - Mintennce Description Nm l. ft. Brvo One propeller nut Then lign ts with grooves 4. Models equipped with the t wsher: Continue to tighten the propeller nut until the three ts on the t wsher lign with the grooves on the spline wsher. 5. Bend the three ts down into the grooves. c d e - Prop - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut Brvo Two Models 4750 IMPORTANT: Use propeller with the correct rottion. The propeller rottion must mtch the direction of rottion of the propeller shft. 1. Lierlly cot the propeller shft spline with one of the following Quicksilver luricnts. Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Propeller shft splines Q02 94 Anti-Corrosion Grese Propeller shft splines Q C Mrine Luricnt with Teflon Propeller shft splines A 1 NOTE: Anti corrosion grese is for sltwter pplictions only. 2. Instll the propeller with the ttching hrdwre s shown. 3. Torque the propeller nut. NOTE: The propeller torque stted is minimum torque vlue. Brvo Two - Propeller shft splines - Forwrd thrust hu c - Propeller d - Spline wsher e - T wsher f - Propeller nut Description Nm l. ft. Brvo Two propeller nut c e d 8566 f Then lign ts with groves CMD / MAY 2007 Pge 63

72 Section 5 - Mintennce 4. Continue to tighten the propeller nut until the three ts on the t wsher lign with the grooves on the spline wsher. 5. Bend the three ts down into the grooves. c d e - Prop - T wsher c - Drive sleeve dpter d - T ent down e - Propeller nut 4750 Brvo Three 1. Lierlly cot the propeller shft spline with one of the following Quicksilver luricnts. Tue Ref No. Description Where Used Prt No. 34 Specil Luricnt 101 Propeller shft splines Q02 94 Anti-Corrosion Grese Propeller shft splines Q C Mrine Luricnt with Teflon Propeller shft splines A 1 NOTE: Anti corrosion grese is for sltwter pplictions only. 2. Slide the forwrd thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 3. Align the splines nd plce the front propeller on the propeller shft. 4. Instll the front propeller locknut nd torque using the Propeller Nut Tool. Propeller Nut Tool T 1 For removl nd instlltion of the front propeller nut Description Nm l. ft. Brvo Three front propeller nut Slide the rer thrust hu onto the propeller shft with the tpered side towrd the propeller hu. 6. Align the splines nd instll the rer propeller. 7. Instll the propeller nut nd torque. Description Nm l. ft. Brvo Three rer propeller nut Pge 64 CMD / MAY 2007