REMOVAL AND INSTALLATION 2 B MCM MODELS - BRAVO DRIVES

Transcription

1 REMOVAL AND INSTALLATION 2 B MCM MODELS - BRAVO DRIVES

2 Tle of Contents Pge Torque Speifitions B-1 Tools/Lurints/Ahesives/Selnts B-1 Removl B-2 Engine Removl B-2 Instlltion B-3 Engine Instlltion/Alignment B-3 Engine Connetions B-6 Throttle Connetions B-7 2B-0 - INSTALLATION - BRAVO DRIVES

3 Torque Speifitions Fstener Lotion L. In. L. Ft. N m Drive Unit Cle Brrel Spre Cotter Key Shift Cle Cle En Guie See Note Hose Clmps Seurely Rer Engine Mounts Power Steering Flui Hose Fitting Erlier Style Lrge Smll Lter Style Rer Engine Mounts Remote Control Cle Brrel Seurely Shift Cles Cle En Guie See Note Remote Control Cle Brrel Seurely Throttle Cle Cle En Guie See Note Note: Tighten, then k nut off one hlf turn. Tools/Lurints/Ahesives/Selnts DESCRIPTION PART NUMBER Engine Alignment Tool A1 Engine Coupler Spline Grese A4 Liqui Neoprene Lotite Pipe Selnt With Teflon Otin Lolly CAUTION DO NOT use n lignment tool from nother mnufturer. Alignment tools other thn Quiksilver Alignment Tools ( A1 or properly moifie A3) my use improper lignment n mge to giml ering n/or engine oupler. e f! - Mteril To Be Remove (She Are) - Mesurement in. (29.21 mm) - Mesurement in. (69.85 mm) - Mesurement in. (55.88 mm) e - Rius (1.5 mm) f - Chmfer in. (1.5 mm) x 45 egree To Alph or Brvo Coupling Quiksilver Engine Alignment Tool ( A3) Moifition 2B-1 - INSTALLATION - BRAVO DRIVES INSTALLATION - BRAVO DRIVES - 2B-1

4 Removl IMPORTANT: Stern rive unit must e remove prior to engine removl. Refer to Stern Drive Servie Mnul. Engine Removl 1. Disonnet ttery les from ttery. 2. Remove instrument hrness onnetor plug from engine hrness reeptle fter loosening lmp.! WARNING DO NOT llow lifting sling to hook or ompress engine omponents or mge will our. Multi-Port engines MUST e lifte with lifting rm or mge to engine omponents will our. 12. Support engine with suitle sling through lifting eyes on engine n remove front n rer engine mounting olts. Retin hrwre. Be reful when working on fuel system. Gsoline is extremely flmmle n highly explosive uner ertin onitions. Do not smoke or llow sprk or open flme in re. Wipe up ny spille fuel immeitely. 3. Using wrenh to stilize rss filter nut t fuel inlet, loosen fuel line fitting, isonnet n suitly plug fuel line to prevent fuel in tnk from leking into ilge Disonnet throttle le from ruretor, or throttle oy on Fuel Injetion moels, n retin loknuts n hrwre. 5. Disonnet ullet onnetors of trim sener wires (oming from trnsom ssemly) from engine hrness. NOTE: After wires re isonnete e sure to loosen them from lmps or st-strps retining them to engine or hoses. 6. Disonnet MerCthoe wires from MerCthoe ontroller if mounte on engine (some moels). 7. Disonnet sewter inlet hose from giml housing Disonnet exhust elow hoses (ellows). 9. Remove oth shift les from shift plte. Retin loknuts n hrwre. 10. Disonnet ny grouning wires n essories tht re onnete to engine. 11. Disonnet (n suitly plug) flui hoses from power steering ontrol vlve on trnsom Suitle Sling - Engine Lifting Eyes Center lifting eye (lote on top of thermostt housing) is use for engine lignment only. DO NOT use to lift entire engine. 13. Crefully remove engine. DO NOT hit power steering ontrol vlve. 2B-2 - INSTALLATION - BRAVO DRIVES

5 Instlltion Engine Instlltion/Alignment 1. Follow instrutions - e :. Be ertin fier wshers (emente in ple) on inner trnsom plte re present. Inspet fier wshers. Reple if worn or mge.. Instll oule woun lokwshers onto inner trnsom plte insie fier wsher.. Be ertin rer engine mount loknuts re in position s shown.. Lurite exhust ellows with sop n wter to ese instlltion. e. Lurite engine oupler splines with Quiksilver Engine Coupler Spline Grese. 3. Lift engine into position (in ot), using n overhe hoist. 4. Align rer engine mounts with inner trnsom plte mounts while simultneously ligning exhust tues with exhust pipe hoses (ellows). IMPORTANT: Engine tthing hrwre must e instlle in sequene shown. 5. Instll oth rer engine mounting olts n hrwre s shown. Torque to l. ft. (47-54 N m). e g h f Doule Woun Lokwsher - Fier Woun Lokwsher (Cemente In Ple) - Inner Trnsom Plte Mount (Engine Support) - Loknuts (Engine Mounting Bolts) Bolt, Rer Engine Mounting - Wsher, Lrge Steel - Metl Sper - Rer Engine Mount e - Doule Woun Lokwsher f - Fier Wsher g - Inner Trnsom Plte Mounts h - Loknut (Hien In This View) Center lifting eye (lote on top of thermostt housing) is use for engine lignment only. DO NOT use to lift entire engine. When lowering engine into position DO NOT set engine on shift le. Shift le outer sing n e rushe using iffiult or improper shifting. DO NOT llow lifting sling to hook or ompress engine omponents or mge will our. 2. Atth suitle sling to lifting eyes on engine n just so tht engine is level when suspene. (Refer to Removl setion for lotion of lifting eyes.) 2B-3 - INSTALLATION - BRAVO DRIVES INSTALLATION - BRAVO DRIVES - 2B-3

6 6. Set engine own on stringers n relieve hoist tension. Disonnet sling from engine lifting eyes n swith sling to enter lifting eye. Avoi mge to exhust system. Engines with single peie mnifols, stress n e ple on the lower exhust pipe if front of engine is rise too high while performing engine lignment proeure. Ensure tht engine is not rise higher thn the top of engine mount justing stu Center Lifting Eye DO NOT use n lignment tool from nother mnufturer. Alignment tools other thn Quiksilver Alignment Tool A1, my use improper lignment n mge to giml ering n/ or engine oupler. To voi mge to giml ering, engine oupler, or lignment tool: DO NOT ttempt to fore lignment tool! DO NOT rise or lower engine with lignment tool inserte (or prtilly inserte) in giml ering or engine oupler Align engine s follows:. Attempt to insert soli en of Quiksilver Alignment Tool through giml ering n into engine oupler splines. If it will not insert esily proee to following.. If the tool oes not fit, remove it n refully rise or lower the from en of the engine, s neessry, n ttempt to insert the lignment tool. 2B-4 - INSTALLATION - BRAVO DRIVES

7 . Repet step until the lignment tool instlls esily (SLIDES FREELY) ll the wy into n out of engine oupler splines. IMPORTANT: Turn oth front engine mount justment nuts n equl mount in iretion require to lign engine.. Ajust front engine mounts until they rest on ot stringers. e. Relieve hoist tension entirely n fsten oth front mounts to ot stringer using pproprite hrwre (lg olts or thru-olts, et.). f. Rehek lignment with lignment tool. Tool must enter oupler splines freely. If not, rejust front mounts. g. When lignment is orret, tighten loknut or nut with lokwsher on eh mount seurely. h. Ben t wsher own ginst flt on justing nut Alignment Tool (Use Only Quiksilver Alignment Tool ( A1) - Insert This En of Alignment Tool through Giml Housing Assemly e - Alignment Tool - Giml Bering - Engine Coupler Loknut - Ajustment Nut - Turn Ajustment Nut In This Diretion (Counterlokwise) To Rise Front Of Engine - Slotte Hole To Front Of Engine e - T Wsher i. Remove lignment tool if not lrey remove. 8. Tighten ll exhust system hose lmps seurely s follows (use two hose lmps on eh onnetion): 2B-5 - INSTALLATION - BRAVO DRIVES INSTALLATION - BRAVO DRIVES - 2B-5

8 . On Engines with Thru-Prop Exhust: NOTE: In the following view the engine is not in position, for visul lrity in this step Hose Clmps - Tighten Seurely - Exhust Tue - Long Tue, Port Sie - Short Tue, Str or Sie - Wter Inlet Tue - Hose Clmp (Tighten Seurely) - Sewter Inlet 2. Connet instrument hrness to engine hrness with hose lmp. Tighten lmp seurely. CORRECT INCORRECT Engine Connetions IMPORTANT: When routing ll wire hrnesses n hoses, e sure they re route n seure to voi oming in ontt with hot spots on engine n voi ontt with moving prts. 1. Connet sewter hose to wter tue t giml housing with hose lmp. Tighten lmp seurely. - Engine Wiring Hrness Reeptle Brket - Instrumenttion Wiring Hrness Plug - Hose Clmp - Tighten Seurely 2B-6 - INSTALLATION - BRAVO DRIVES

9 3. Connet trim position sener les from giml housing to les from engine hrness. Mke ertin onnetions re seure. Chek for leks. 5. Connet throttle le using hrwre retine n just following instrutions or : Throttle Connetions 2 BARREL CARBURETOR BROWN/WHITE (From Engine Hrness) - BLACK (From Engine Hrness) - BLACK (From Trnsom) - BLACK (From Trnsom Assemly)! WARNING Be reful when working on fuel system. Gsoline is extremely flmmle n highly explosive uner ertin onitions. Do not smoke or llow sprk or open flme in re. Wipe up ny spille fuel immeitely. FUEL SUPPLY CONNECTIONS! WARNING Avoi gsoline fire or explosion. Improper instlltion of rss fittings or plugs into fuel pump or fuel filter se n rk sting n/or use fuel lek. Apply #592 Lotite Pipe Selnt with Teflon to thres of rss fitting or plug. DO NOT USE TEFLON TAPE. Thre rss fitting or plug into fuel pump or fuel filter se until finger tight. Tighten fitting or plug n itionl 1-3/4 to 2-1/4 turns using wrenh. DO NOT OVER-TIGHTEN. Instll fuel line. To prevent over-tightening, hol rss fitting with suitle wrenh n tighten fuel line onnetors seurely. Chek for fuel leks. 4. Connet fuel line from fuel tnk(s) to engine. - Cle En Guie - Atthing Hrwre - Cle Brrel - Anhor Stus WEBER 4 BARREL CARBURETOR - Cle En Guie - Atthing Hrwre (DO NOT Over-Tighten) - Cle Brrel - Anhor Stus B-7 - INSTALLATION - BRAVO DRIVES INSTALLATION - BRAVO DRIVES - 2B-7

10 1. Ple remote ontrol hnle(s) in neutrl, ile position. IMPORTANT: Be sure tht le is route in suh wy s to voi shrp ens n/or ontt with moving prts. DO NOT fsten ny items to throttle le. Outer le must e free to move when le is tute. 2. Instll le en guie on throttle lever, then push le rrel lightly towr throttle lever en. (This will ple slight prelo on le to voi slk in le when moving remote ontrol lever.) Ajust rrel on throttle le to lign with nhor stu. 3. Seure throttle le with hrwre (retine) s shown. Tighten le en guie nut until it ottoms out n then k off one full turn. Tighten le rrel seurely. DO NOT OVER-TIGHT- EN, s le must pivot freely. Wie-Open-Throttle Position - Throttle Shft Lever Contts () At W.O.T. Position - Cruretor Boy Csting Ple remote ontrol throttle lever in the wie-open-throttle (W.O.T.) position. Chek to ensure tht throttle shutters (vlves) re ompletely open n throttle shft lever ontts ruretor oy sting. 5. Return remote ontrol throttle lever to ile position n hek to ensure tht throttle lever ontts ile spee justment srew Ile Position - Throttle Lever Contts () In ile Position - Ile Spee Ajustment Srew 2B-8 - INSTALLATION - BRAVO DRIVES

11 THROTTLE BODY INJECTION 1. Instll le en guie on throttle lever, then push le rrel en lightly towr throttle lever en. (This will ple slight prelo on shift le to voi slk in le when moving remote ontrol lever). Ajust rrel on throttle le to lign with hole in nhor plte. 2. Seure throttle le with hrwre s shown n tighten seurely. 3. Ple remote ontrol throttle level in the wie open throttle (W.O.T.) position. Chek to ensure tht throttle pltes re ompletely open. 4. Return remote ontrol throttle lever to ile position. 6. Moels with MerCthoe: Connet wires to MerCthoe ontroller ssemly s shown. Apply thin ot of Quiksilver Liqui Neoprene to ll onnetions ORANGE Wire - From Eletroe On Trnsom Assemly - RED/PURPLE Wire - Connet (Other En) to Positive (+) Bttery Terminl - BLACK Wire - From Engine Hrness - BROWN Wire - From Eletroe on Trnsom Assemly IMPORTANT: Ajust shift les s outline in pproprite Stern Drive Servie Mnul. 7. Refer to pproprite Stern Drive Servie Mnul n instll n just rive unit n remote ontrol shift les, using hrwre retine. - Cle En Guie - Flt Wsher n Loknut - Tighten Until Bottoms Out, Then Bk Off One Hlf Turn - Cle Brrel - Flt Wsher n Loknut IMPORTANT: Do not tth ny essory groun ( ) wires to trnsom plte groun point. Aessory groun wires shoul only e tthe to groun stu on engine. 5. Connet ny grouning wires or essories tht my hve een isonnete. IMPORTANT: After flui hose instlltion in the following, lee power steering system s outline in SECTION 1B - Mintenne of this mnul, or refer to the pproprite Stern Drive Servie Mnul. Route hoses extly s shown elow. This will help voi stress on the hose fittings n will help voi kinks in the hose. IMPORTANT: Mke hyruli onnetions s quikly s possile to prevent flui lekge. IMPORTANT: Be reful not to ross-thre or over- tighten fittings. 2B-9 - INSTALLATION - BRAVO DRIVES INSTALLATION - BRAVO DRIVES - 2B-9

12 8. Connet oth hyruli hose fittings.. Erlier Style Control Vlves: Torque the lrge fitting to 23 l. ft. (31 N m). Torque the smll fitting to 100 l. in. (11 N m) Smll Fitting - Lrge Fitting. Lter Style Control Vlve: Torque oth fittings to 23 l. ft. (31 N m). Route hoses s shown for eh moel - Hose Fittings Connet ttery les to ttery y FIRST onneting positive (+) ttery le (usully RED) to positive (+) ttery terminl. Tighten lmp seurely. Then, onnet negtive ( ) ttery le (usully BLACK) to negtive ( ) ttery terminl. Tighten lmp seurely. NOTE: Spry terminls with ttery onnetion selnt to help retr orrosion. 2B-10 - INSTALLATION - BRAVO DRIVES

13 THIS PAGE IS INTENTIONALLY BLANK TO ALLOW FOR CORRECTIONS OR ADDITIONS AT A LATER DATE 2B-11 - INSTALLATION - BRAVO DRIVES INSTALLATION - BRAVO DRIVES - 2B-11