SERVICE MANUAL NUMBER 11 Tle of Contents GENERAL INFORMATION Section 1B - Mintennce MAINTENANCE 1 B Mintennce Schedules................ 1B-2 Mintennce Intervls............... 1B-2 Scheduled Mintennce Tht Cn Be Performed By Owner/Opertor....... 1B-2 Scheduled Mintennce Tht Cn Be Performed y Deler............... 1B-3 Specifictions......................... 1B-5 Torque Specifiction................ 1B-5 Quicksilver Mintennce Products.... 1B-5 Fluid Cpcities.................... 1B-5 Luricting Shift Cle Pivot Points...... 1B-6 Luricting Propeller Shft............. 1B-6 Luricting Steering System............ 1B-6 Luricting Tie Br Pivot Points......... 1B-7 Models With Control Vlve Mounted On Strord Trnsom Assemly....... 1B-7 Models With Control Vlve Mounted On Port Trnsom Assemly............. 1B-7 Luricting Trnsom Giml Housing Assemly Swivel Shft nd Giml Bering.............................. 1B-7 Checking nd Adding Sterndrive Oil..... 1B-8 Models Without Drive Unit Ger Lue Monitor........................... 1B-8 Models With Ger Lue Monitor...... 1B-9 Checking Luricnt for Wter........ 1B-10 Chnging Luricnt................ 1B-12 Generl Mintennce................. 1B-14 Mintining Power Pckge Exterior Surfces......................... 1B-14 Steering Hed nd Remote Control Mintennce..................... 1B-14 Checking Quicksilver MerCthode System.......................... 1B-14 Mintining Anodic Trim T or Plte. 1B-14 Checking Optionl Quicksilver Anti-Corrosion Anode Kit........... 1B-15 Bot Bottom Cre................. 1B-15 Antifouling Pint................... 1B-15 Mintining Ground Circuit Continuity 1B-15 Power Pckge Lyup (Out of Seson Storge)............................ 1B-16 Engine........................... 1B-16 Sterndrive........................ 1B-16 Power Pckge Recommissioning...... 1B-16 Engine........................... 1B-16 Sterndrive........................ 1B-16 90-17431--4 MARCH 1998 Pge 1B-1
MAINTENANCE SERVICE MANUAL NUMBER 11 Mintennce Schedules Mintennce Intervls Mintennce intervls nd the tsks to e performed, s shown in this current schedule, or s found in previously printed schedules, re generlly sed on n verge oting ppliction nd environment. However, individul operting hits nd personl mintennce preferences cn hve n impct on the suggested intervls. In considertion of these fctors, MerCruiser hs djusted some mintennce intervls nd corresponding tsks to e performed. In some cses, this my llow for more individul tsks to e performed in single visit to the serving deler, rther thn multiple visits. Therefore, it is very importnt tht the ot owner nd servicing deler discuss the current Mintennce Schedule nd develop pproprite mintennce intervls to coincide with the individul operting hits, environment, nd mintennce requirements. Scheduled Mintennce Tht Cn Be Performed By Owner/Opertor NOTE: Only perform mintennce which pplies to your prticulr power pckge. Tsk Engine Crnkcse Oil - Check level Closed Cooling Coolnt - Check level Power Steering Fluid - Check level Sterndrive Unit Oil - Check level Bttery - Check level nd inspect for dmge Fuel Pump Sight Tue (If Equipped) - Check tht no fuel is present Power Trim Pump Oil - Check level Anodes - Inspect for erosion Ger Housing Wter Pickups - Check for mrine growth or deris Drive Belt(s) - Inspect condition nd check tension Propeller Shft - Luricte Power Pckge - Exterior Surfces - Spry with rust preventtive Power Pckge Exterior Surfces - Clen nd pint Cooling System - Flush sewter section Intervl Weekly Every 100 hours of opertion or 120 dys. whichever occurs first. Sltwter Use: Every 50 hours of opertion or 60 dys, whichever occurs first. Freshwter Use: Every 100 hours of opertion or 120 dys, whichever occurs first. Once yer Sltwter Use: After every use. Pge 1B-2 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 MAINTENANCE Scheduled Mintennce Tht Cn Be Performed y Deler NOTE: Only perform mintennce which pplies to your prticulr power pckge. Tsk Sewter Pickup Pump - Disssemle nd inspect Crnkcse Oil nd Filter - Chnge Ignition system - Clen nd inspect condition Flme Arrestor nd Crnkcse Ventiltion Hose - Clen nd inspect Positive Crnkcse Ventiltion (PCV) Vlve (If Equipped) - Chnge Sterndrive Unit Oil - Chnge Giml Ring Clmping Screws - Retorque to 40 ft. l. (54 N m) Rer Engine Mounts - Ensure torque is 30-40 ft. l. (47-54 N m) Giml Bering - Luricte Cooling System - Clen nd inspect Engine Alignment - Check Engine Coupling Universl Joint Shft Splines - Luricte Steering System - Luricte nd inspect for loose, dmged or missing prts Electricl System - Check for loose or dmged wiring Cooling System Hoses nd Clmps - Inspect for dmge nd deteriortion. Check clmps for tightness. Closed Cooling System Pressure Cp - Clen, inspect nd test Continuity Circuit - Check components for loose connections, roken or fryed wires Shift nd Throttle Cle nd Linkge - Luricte nd inspect for loose, dmged or missing prts Intervl Whenever insufficient sewter flow is suspected. (If operting temperture exceeds norml rnge.) End of first oting seson nd therefter, every 100 hours of opertion or once yerly, whichever occurs first. 90-17431--4 MARCH 1998 Pge 1B-3
MAINTENANCE SERVICE MANUAL NUMBER 11 Scheduled Mintennce Tht Cn Be Performed y Deler (Continued) NOTE: Only perform mintennce which pplies to your prticulr power pckge. Tsk Engine Exhust System - Inspect externlly for dmge, deteriortion nd restrictions. Check for tightness. Ignition System - Check timing nd djust s needed Steering Hed nd Remote Control - Inspect nd luricte Cruretor (If Equipped) - Inspect nd djust Throttle Body (EFI Models) - Inspect Fuel Filters - Replce Quicksilver Mercthode System - Test output Closed Cooling Coolnt - Test for Alklinity Het Exchnger - Clen sewter section Drive Unit Bellows nd Clmps - Inspect Universl Joint Cross Berings- Inspect nd grese Closed Cooling Coolnt - Replce Intervl End of first oting seson nd therefter, every 100 hours of opertion or once yerly, whichever occurs first. Once Yer End of first oting seson nd therefter, every 200 hours of opertion or once yerly, whichever occurs first. Every Five Yers or 1,000 hours of opertion 1 1 Only if Extended Life 5/100 Ethylene Glycol Antifreeze/Coolnt is used. If ny non-comptile coolnt is dded to this coolnt, coolnt must e chnged every 2 yers or 400 hours, whichever occurs first. All coolnts other thn Extended Life 5/100 Ethylene Glycol Antifreeze/Coolnt must e chnged every 2 yers or 400 hours, whichever occurs first. Pge 1B-4 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 Specifictions MAINTENANCE Torque Specifiction Drive Unit Fill/Drin Plug Drive Unit Vent Plug 30-50 l. in. (3.39-5.56 N m) 30-50 l. in. (3.39-5.56 N m) Quicksilver Mintennce Products We recommend the use of Quicksilver Mintennce Products where specified. Fluid Cpcities NOTICE UNIT OF MEASUREMENT: U.S. Fluid Ounces (Milliliters) All cpcities re pproximte fluid mesures. MODEL BRAVO ONE BRAVO TWO Drive Unit Oil Cpcity (With Squre Ger Lue Monitor) Drive Unit Oil Cpcity (With Round Ger Lue Monitor) BRAVO THREE 88 (2603) 104 (3076) 96 (2839) 96 (2840) 112 (3313) 104 (3076) 90-17431--4 MARCH 1998 Pge 1B-5
MAINTENANCE SERVICE MANUAL NUMBER 11 Luricting Shift Cle Pivot Points - Luricte with SAE 20 or 30 Engine Oil Luricting Propeller Shft 22245 BRAVO ONE DRIVE BRAVO THREE DRIVE BRAVO TWO DRIVE 72239 24727 - Propeller Shft - Luricte with Specil Luricnt 101, Anti-Corrosion Grese, 2-4-C Mrine Luricnt with Teflon (Listed in Order of Effectiveness). Luricting Steering System WARNING Trnsom end of steering cle MUST BE fully retrcted into cle housing when luricting cle. If cle is luricted while extended, hydrulic lock of cle could occur. d d c c e e 22023 Erlier Style Control Vlve Lter Style Control Vlve - Steering Cle Grese Fitting - 2-4-C Mrine Luricnt with Teflon (See Wrning Aove) - Control Vlve Grese Fitting - 2-4-C Mrine Luricnt with Teflon c - Steering Cle End - Specil Luricnt 101 d - Pivot Point - SAE 20 or 30 Engine Oil e - Pivot Bolts - Specil Luricnt 101 71901 Pge 1B-6 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 Luricting Tie Br Pivot Points MAINTENANCE Models With Control Vlve Mounted On Strord Trnsom Assemly 22079 22079 Strord Engine Port Engine - SAE 20 or 30 Engine Oil Models With Control Vlve Mounted On Port Trnsom Assemly 22079 22079 Port Engine - SAE 20 or 30 Engine Oil Strord Engine Luricting Trnsom Giml Housing Assemly Swivel Shft nd Giml Bering 50072 - Swivel Shft Grese Fitting - 2-4-C Mrine Luricnt with Teflon (On Erlier Models) - Giml Bering Grese Fitting - Quicksilver U-Joint nd Giml Bering Grese 90-17431--4 MARCH 1998 Pge 1B-7
MAINTENANCE SERVICE MANUAL NUMBER 11 Checking nd Adding Sterndrive Oil IMPORTANT: Position sterndrive unit in DOWN/IN position so tht nti-ventiltion plte is level. Models Without Drive Unit Ger Lue Monitor 1. Check oil level - oil should come up to line on dipstick. If oil is t proper level, reinstll oil dipstick nd seling wsher. If oil is low, proceed to Step 2. - Oil Dipstick - Seling Wsher (on Threds) CAUTION 22098 DO NOT ttempt to fill drive unit through oil vent hole, s ir will e trpped in drive unit nd unit will e dmged from lck of luriction. CAUTION If more thn 2 fl. oz. (59 ml) of oil is required to fill drive unit, n oil lek my exist. Find nd correct cuse of lek efore unit is plced in opertion. 2. If oil level is low, reinstll dipstick; then, remove oil fill/drin plug nd insert luricnt pump into oil fill/drin hole. 3. Remove oil vent plug; then, fill drive unit (through oil fill/drin unit hole) with oil until n ir-free strem of oil flows out of oil vent hole. 22095 22103 c d - Oil Vent Plug - Seling Wsher or O-ring c - Oil Fill/Drin Plug d - Seling Wsher or O-ring 22101 22101 Pge 1B-8 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 MAINTENANCE 4. Without removing luricnt pump from fill/drin hole, reinstll vent plug nd seling wsher (or O-ring if equipped). Torque to 30-50 l. in. (3.39-5.56 N m). 5. Remove luricnt pump nd quickly reinstll fill/drin plug nd seling wsher (or O-ring if so equipped). Torque to 30-50 l. in. (3.39-5.56 N m). 6. Recheck oil level, using dipstick. Models With Ger Lue Monitor IMPORTANT: Position drive unit in DOWN/IN position so tht nti-ventiltion plte is level. NOTE: Drive unit oil level is checked t ger lue monitor. Ger Lue Monitor decl 50323 IMPORTANT: Oil level in ger lue monitor will rise nd fll during drive opertion; lwys check oil level when drive is cool nd engine is shut down. - Round Ger Lue Monitor - Squre Ger Lue Monitor 50028 71990 1. Fill ger lue monitor to FULL line on decl. Luricte O-ring sel on ger lue monitor neck with sterndrive oil, to ensure ese of instlling nd removing cp, nd instll ger lue monitor cp. Do not overtighten cp - 1/4 turn, fter cp contcts sel, is sufficient. CAUTION On models with Ger Lue Monitor, tht hve dipstick in driveshft housing cover: DO NOT REMOVE DIPSTICK - DO NOT CHECK OIL LEVEL WITH DIPSTICK. Removl of dipstick results in oil level rising/overfill condition, which cn cuse oil sel dmge; if left open, drive unit will overflow. 2. Check oil level in ger lue monitor. 90-17431--4 MARCH 1998 Pge 1B-9
MAINTENANCE SERVICE MANUAL NUMBER 11 Checking Luricnt for Wter Periodiclly inspect luricnt for wter, to ensure tht drive unit sels re not leking. MODELS WITHOUT DRIVE UNIT GEAR LUBE MONITOR 1. Trim drive unit to the full trim UP/OUT position. Remove fill/drin plug to tke smple of luricnt. If wter is oserved or if luricnt ppers discolored, drive unit is leking nd must e reseled. 22103 - Fill/Drin Plug - Seling Wsher or O-ring 22101 2. Reinstll fill/drin plug. Torque to 30-50 l. in. (3.39-5.56 N m). Pge 1B-10 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 MODELS WITH GEAR LUBE MONITOR MAINTENANCE Check for wter t ottom of ger lue monitor, nd/or if oil ppers discolored, wter lek is indicted somewhere in the drive unit, nd drive unit must e reseled. CAUTION If more thn 2 fl. oz. (59ml) of Quicksilver High Performnce Ger Lue is required to fill ger lue monitor, sel my e leking. Find nd correct cuse of lek efore unit is plced in opertion. IMPORTANT: If drive unit hs set overnight or longer, check for wter in drive unit, s follows: 1. Trim drive unit to full UP/OUT position if drin plug is locted in nose of ger housing. 22103 22101 - Oil Fill/Drin Plug - Seling Wsher or O-ring 2. Trim drive unit to full DOWN/IN position, if drin plug is locted in ering crrier. 70023 - Oil Fill/Drin Plug - Seling Wsher or O-ring 3. Remove fill/drin plug to smple luricnt. If wter runs out, nd/or if luricnt ppers discolored, drive unit is leking nd must e reseled. 4. Reinstll fill/drin plug. Torque to 30-50 l. in. (3.39-5.56 N m). 90-17431--4 MARCH 1998 Pge 1B-11
MAINTENANCE SERVICE MANUAL NUMBER 11 Chnging Luricnt CAUTION If ny wter drins from fill/drin hole, or if oil color ppers discolored, lek in drive unit my exist. Find nd correct cuse of lek efore plcing unit ck in opertion. CAUTION DO NOT ttempt to fill drive unit through oil vent holes, s ir will e trpped in drive unit nd unit will e dmged from lck of luriction. 1. Trim drive unit to full UP/OUT position if drin plug is locted in nose of ger housing. 22103 - Oil Fill/Drin Plug - Seling Wsher or O-ring 22101 2. Trim drive unit to full DOWN/IN position, if drin plug is locted in ering crrier. - Oil Fill/Drin Plug - Seling Wsher or O-ring 70023 Pge 1B-12 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 MAINTENANCE 3. Models with drive unit Ger Lue Monitor, only: remove drive unit ger lue monitor from rcket, remove cp, empty contents of ger lue monitor into suitle continer nd discrd. Clen ger lue monitor thoroughly, nd return ger lue monitor to rcket. Do not refill t this time. Check condition of hose nd hose connections - replce s necessry. - Round Ger Lue Monitor - Squre Ger Lue Monitor 50028 71990 4. All models: remove drive unit vent plug, nd fill/drin plug; llow luricnt to drin completely. 5. If drive unit is drining in full DOWN/IN position, trim to full UP/OUT position fter drining, to further drin ny remining oil from internl driveshft housing ledges. 6. Trim drive unit to full DOWN/IN position (with nti-ventiltion plte level) to complete drining process. d c 50072 - Oil Vent Plug - Seling Wsher or O-ring c - Vent Hole d - Dipstick (if present, DO NOT OPEN or remove on oil Ger Lue Monitor models) 7. Using luricnt pump, fill drive unit through fill/drin hole with luricnt until oil is even with ottom edge of vent hole. 8. Without removing luricnt pump from fill/drin hole, reinstll oil vent plug nd seling wsher. Non-Ger Lue Monitor models: torque oil vent plug to 30-50 l. in. (3.39-5.56 N m). Ger Lue Monitor Models: tighten oil vent plug snugly; do not torque t this time. 9. All models: remove luricnt pump nd quickly reinstll fill/drin plug nd seling wsher. Torque to 30-50 l. in. (3.39-5.56 N m). 90-17431--4 MARCH 1998 Pge 1B-13
MAINTENANCE SERVICE MANUAL NUMBER 11 Models with Ger Lue Monitor, (steps 10-12): 10. Remove oil vent plug nd seling wsher (with drive unit in full DOWN/IN position). 11. Fill ger lue monitor ottle with Quicksilver High-Performnce Ger Lue. When oil strts to run out the vent hole (ger lue hose etween drive unit nd ger lue ottle ecomes filled), reinsert vent plug. Torque to 30-50 l. in. (3.39-5.56 N m). 12. Fill ger lue monitor to FULL line on decl. Luricte O-ring sel on ger lue monitor neck with sterndrive oil, to ensure ese of instlling nd removing cp. Instll ger lue monitor cp. Do not overtighten. 13. All models: recheck oil level fter first use. - Vent Hole Generl Mintennce 50072 Mintining Power Pckge Exterior Surfces Entire Power Pckge should e spryed t recommended intervls with Quicksilver Corrosion Gurd. Follow instructions on cn for proper ppliction. At lest once ech yer, entire Power Pckge should e clened nd externl surfces tht hve ecome re should e repinted with Quicksilver Primer nd Spry Pint. Steering Hed nd Remote Control Mintennce Luricte steering hed nd remote control with 2-4-C Mrine Luricnt with Teflon. Inspect steering hed nd remote control for ese of opertion. Checking Quicksilver MerCthode System If ot is equipped with Quicksilver MerCthode System, system should e tested to ensure tht it is providing dequte output to protect underwter metl prts on ot. Test should e mde where ot is moored, using Quicksilver Reference Electrode nd Test Meter. Refer to Section 7. Mintining Anodic Trim T or Plte Ech sterndrive unit is equipped with scrificil nodic trim t (or plte on lter models) to help protect underwter metl prts from glvnic corrosion. Becuse of its self-scrificing nture, trim t (or plte) MUST BE replced if eroded 50% or more. An nodic plte is the new service replcement for the nodic trim t. Instll the nodic plte in plce of the nodic trim t. Refer to Section 7. Pge 1B-14 90-17431--4 MARCH 1998
SERVICE MANUAL NUMBER 11 Checking Optionl Quicksilver Anti-Corrosion Anode Kit Bot Bottom Cre Antifouling Pint MAINTENANCE If ot is equipped with Quicksilver Anti-Corrosion Anode Kit, inspect node nd replce if eroded to less thn 50% of its originl size. Crefully follow instlltion instructions, tht ccompny new Anode Kit, to ensure proper instlltion. To chieve mximum performnce nd fuel economy, ot ottom MUST BE 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 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 ntifouling pints. IMPORTANT: Corrosion dmge tht results from the improper ppliction of ntifouling pint will not e covered y the limited wrrnty. Pinting Bot Hull or Bot Trnsom: Antifouling pint my e pplied to ot hull nd ot trnsom ut you must oserve the following precutions: IMPORTANT: DO NOT pint nodes or MerCthode System reference electrode nd node, s this will render them ineffective s glvnic corrosion inhiitors. IMPORTANT: If ntifouling protection is required for ot hull or ot trnsom, copper or tin se pints, if not prohiited y lw, cn e used. If using copper or tin sed ntifouling pints, oserve the following: Avoid n electricl interconnection etween the MerCruiser Product, Anodic Blocks, or MerCthode System nd the pint y llowing minimum of 1-1/2 in. (40mm) UN- PAINTED re on trnsom of the ot round these items. 71176 - Pinted Bot Trnsom - Minimum 1-1/2 in (40mm) UNPAINTED Are Around Trnsom Assemly NOTE: Drive unit nd trnsom ssemly cn e pinted with good qulity mrine pint or n ntifouling pint tht DOES NOT contin copper, tin, or ny other mteril tht could conduct electricl current. Do not pint drin holes, nodes, MerCthode system, nd items specified y ot mnufcturer. Mintining Ground Circuit Continuity The trnsom ssemly nd sterndrive unit re equipped with ground wire circuit, to ensure good electricl continuity etween engine, trnsom ssemly nd sterndrive components. Good continuity is essentil for the MerCthode System to function effectively. Refer to Section 7. 90-17431--4 MARCH 1998 Pge 1B-15
MAINTENANCE SERVICE MANUAL NUMBER 11 Power Pckge Lyup (Out of Seson Storge) Engine Sterndrive Refer to pproprite Engine Service Mnul. 1. Luricte steering system. Refer to Section 6. 2. Luricte trnsom giml housing ssemly swivel shft, giml ering, nd propeller shft. Refer to Section 4 nd Section 1-B. 3. Luricte sterndrive unit U-joint shft splines nd cross erings. Refer to Section 3-A. 4. Inspect U-joint ellows for crcks or other signs of deteriortion. Check ellows clmps for tightness. Refer to Section 4. 5. Check engine lignment. Refer to Engine Service Mnul. 6. Chnge sterndrive unit oil. Refer to Section 1-B. 7. Inspect sterndrive for dmge. Repir or replce dmged components. 8. Clen sterndrive exterior surfces nd repint ny re metl surfces with Quicksilver Primer nd Spry Pint. Refer to Section 1-B. 9. After pint hs dried spry entire sterndrive with Quicksilver Corrosion Gurd. Refer to Section 1-B. CAUTION Store sterndrive unit in the full trim DOWN/IN position. U-joint ellows my develop set if unit is stored in rised position nd my fil when unit is returned to service. 10. If not lredy done, plce sterndrive unit in the full trim DOWN/IN position. 11. Store ttery. Refer to ttery mnufcturer s instructions. Power Pckge Recommissioning Engine Sterndrive Refer to pproprite Engine Service Mnul. 1. Perform ALL mintennce specified for completion At Lest Once Ech Yer in Mintennce Chrt (Refer to Section 1-B), except items which were performed t the time of sterndrive lyup. 2. Instll fully-chrged ttery. Clen ttery cle clmps nd terminls nd reconnect cles. Be sure to tighten clmps securely. Apply thin cot of petroleum sed grese to clmps nd terminls to help retrd corrosion. 3. After recommissioning nd strting engine, check steering system nd shift control for proper opertion. Pge 1B-16 90-17431--4 MARCH 1998