Owner's Guide

CMD-4081986 / 90-866839060 507
Declaration of Conformance—Cummins MerCruiser Diesel

This sterndrive or inboard engine when installed in accordance with Cummins MerCruiser Diesel instructions complies with
the requirements of the following directives by meeting the associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement Standards Applied

Handling characteristics (A.4) ISO 8665
Inboard engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO 10133
Applicable portions of: ISO 10592, ISO 8848 and ABYC
Steering system (A.5.4)
P‑17
Exhaust emission requirements (B.2) ISO 8178
Owner’s manual (B.4) ISO 8665
Noise emission levels (C.1) (sterndrive CE marked
*CMD-4081986,/,90-866839060*
ISO 14509
products only)
Cummins MerCruiser Diesel declares that our sterndrive or inboard engines without integral exhaust, when installed in a
recreational craft in accordance with the manufacturer's supplied instructions will meet the exhaust emissions requirements
of the directive mentioned above. This engine must not be put into service until the recreational craft in which it is to be
installed has been declared in conformity, if so required, with the relevant provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard EN 50081‑1

Generic immunity standard EN 50082‑1
Vehicles, boats and internal combustion engine driven
SAE J551 (CISPR 12)
devices—radio disturbance characteristics
Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
For specific information regarding exhaust or noise emissions and power declaration, please refer to the Declaration of
Conformity supplied with each Cummins MerCruiser Diesel engine.
This declaration is issued under the sole responsibility of Cummins MerCruiser Diesel.
Diesel Sterndrive—Bravo Models

Jim Kahlenbeck
Director of Engineering—Cummins MerCruiser Diesel, Charleston, South Carolina U.S.A.
Regulatory contact:
Engineering—Marine Emissions
Cummins MerCruiser Diesel
4500 Leeds Avenue
Charleston, South Carolina 29405
USA
(843) 745-1610
Identification Record
© 2009 Mercury Marine
Please record the following information:
Engine Model and Horsepower Engine Serial Number
Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number
Transmission Model (Inboard) Gear Ratio Transmission Serial Number
Propeller Number Pitch Diameter
Hull Identification Number (HIN) Purchase Date
Boat Manufacturer Boat Model Length
Exhaust Gas Emissions Certification Number
The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Cummins MerCruiser Diesel®
power package. When contacting Cummins MerCruiser Diesel (CMD®) about service, always specify model and serial
numbers.
Descriptions and specifications contained herein were in effect at the time this guide was approved for printing. Cummins
MerCruiser Diesel, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or
to change specifications or designs without notice and without incurring obligation.
Cummins MerCruiser Diesel, Charleston, South Carolina, U.S.A. Printed in U.S.A.
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Bravo Two, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode,
RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, VesselView, and SmartCraft logo are all
registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick
Corporation.
Welcome
You have selected one of the finest marine power packages available. It incorporates numerous design features to assure
operating ease and durability.
With proper care and maintenance, you will thoroughly enjoy using this product for many boating seasons. To ensure maximum
performance and carefree use, we ask that you thoroughly read this manual.
The Operation, Maintenance and Warranty Manual contains specific instructions for using and maintaining your product. We
suggest that this manual remain with the product for ready reference whenever you are on the water.
Thank you for purchasing one of our Cummins MerCruiser Diesel products. We sincerely hope your boating will be pleasant!
Cummins MerCruiser Diesel
Warranty Message
The product you have purchased comes with a limited warranty from Cummins MerCruiser Diesel; the terms of the warranty are
set forth in the Warranty Sections of this manual. The warranty statement contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages
and other related information. Please review this important information.
Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer for a demonstration of actual starting and
operating procedures.
Notice
Throughout this publication, and on your power package, dangers, warnings, cautions, and notices, accompanied by the
International Hazard Symbol ! , may be used to alert the installer and user to special instructions concerning a particular service
or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.
These Safety Alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while
performing the service, plus common sense operation, are major accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in engine or major component failure.
IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.
! WARNING
The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard and the safety of all
occupants aboard. We strongly recommend that the operator read this Operation, Maintenance and Warranty Manual and
thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.
! WARNING
The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other
reproductive harm.
TABLE OF CONTENTS
Section 1 - Warranty
Warranty Information................................................................. 2 Sterndrive Warranty Policy—High Output Diesel
Warranty Registration—United States and Canada........... 2 Recreational Use................................................................ 3
Warranty Registration—Outside the United States and Sterndrive Warranty Policy—Diesel Intermittent Rating..... 4
Canada...............................................................................2 Limited Warranty Against Corrosion (Worldwide)............... 6
Warranty Policies.......................................................................3 Transfer of Warranty........................................................... 7
Section 2 - Getting to Know Your Power Package

Indentification...........................................................................10 Features and Controls............................................................. 14
Bravo X Diesel and Bravo XR Models..............................10 Lanyard Stop Switch (If Equipped)...................................14
Bravo One Models........................................................10 Remote Controls...............................................................15
Bravo Two Models........................................................11 Panel Mount Features..................................................15
Bravo Three Models.....................................................11 Console Mount Features..............................................15
Bravo Sterndrive Serial Number and Identification...........12 Power Trim.......................................................................16
Bravo Transom Serial Number.........................................12 Single Engine Trim and Trailer.....................................17
Instrumentation........................................................................13 Dual Engine Trim and Trailer........................................17
Instruments—Sterndrive models...................................... 13 Electrical System Overload Protection............................. 17
Section 3 - On the Water

Safe Boating Suggestions........................................................20 Wave and Wake Jumping.................................................23
Be Alert to Carbon Monoxide Poisoning...........................21 Impact with Underwater Hazards......................................24
Good Ventilation...........................................................21 Sterndrive Impact Protection........................................24
Poor Ventilation ...........................................................21 Conditions Affecting Operation................................................24
Basic Boat Operation...............................................................21 Weight Distribution (Passengers and Gear) Inside the
Launching and Boat Operation.........................................21 Boat..................................................................................24
Starting the Engine After Stopped While in Gear............. 21 Bottom of Boat..................................................................25
Freezing Temperature Operation..................................... 22 Cavitation..........................................................................25
Drain Plug and Bilge Pump...............................................22 Ventilation.........................................................................25
Trailering the Boat............................................................ 22 Elevation and Climate.......................................................25
Protecting People In The Water...............................................22 Propeller Selection............................................................25
While You Are Cruising................................................ 22 Getting Started.........................................................................26
While Boat Is Stationary...............................................22 Sterndrive 10‑Hour Break‑In Period (New or With
High‑Speed and High‑Performance..................................22 Replacement Gears).........................................................26
Passenger Safety In Pontoon Boats And Deck Boats......22 End of First Season Checkup...........................................26
Boats Having An Open Front Deck.............................. 22
Boats With Front‑Mounted, Raised Pedestal Fishing
Seats............................................................................23
Section 4 - Specifications
Fluid Specifications..................................................................28 Approved Electro‑Hydraulic Power Steering Fluids......28
Bravo Sterndrive Fluid Specifications—Diesel................. 28 Approved Power Trim Fluids........................................28
Power Steering and Power Trim Fluids............................28 Approved Paints.......................................................................28
Approved Power Steering Fluids..................................28 Torque Specifications.............................................................. 29
Approved Compact Hydraulic Power Steering Fluids...28
CMD-4081986 / 90-866839060 MAY 2007 Page i

Section 5 - Maintenance
Product Responsibilities......................................................... 32 General Information......................................................... 46
Owner and Operator Responsibilities.............................. 32 Sterndrive Corrosion Protection Components................. 46
Dealer Responsibilities.................................................... 32 Anodes and MerCathode System Locations............... 47
Do‑It‑Yourself Maintenance Suggestions............................... 32 Continuity Circuit—Bravo Sterndrive............................... 48
Inspection......................................................................... 32 MerCathode.....................................................................50
Maintenance Intervals............................................................ 33 Boat Bottom Care............................................................ 51
Maintenance Schedule........................................................... 33 Painting Your Power Package......................................... 51
Routine Maintenance...................................................... 33 Sterndrive Surface Care.................................................. 52
Scheduled Maintenance.................................................. 34 Lubrication .............................................................................52
Maintenance Log............................................................. 35 Steering System.............................................................. 52
Sterndrive Gear Lube............................................................. 36 Shift Cable.......................................................................54
Checking......................................................................... 36 Transom Assembly.......................................................... 54
Filling...............................................................................36 Propeller Shaft................................................................. 54
Changing.........................................................................37 Engine Coupler................................................................ 55
Power Trim Fluid.................................................................... 40 Driveshaft Extension Models........................................... 56
Checking......................................................................... 40 Sterndrive, Bellows, and Engine Alignment.................... 56
Filling...............................................................................41 Maintaining Torques............................................................... 57
Changing.........................................................................42 Gimbal Ring U‑bolt Nuts.................................................. 57
Power‑Assisted Steering Fluid (If Equipped).......................... 42 Rear Engine Mount Torque............................................. 58
Electro‑Hydraulic Power‑Assisted Steering System (If Propeller................................................................................. 58
Equipped)............................................................................... 42 Bravo Diesel Sterndrive Propeller Removal.................... 58
Checking......................................................................... 42 Bravo One Models...................................................... 59
Filling...............................................................................42 Bravo Two Models...................................................... 60
Changing.........................................................................43 Bravo Three Models.................................................... 60
Sterndrive Water Passages.................................................... 43 Bravo Diesel Sterndrive Propeller Installation................. 62
Sterndrive Water Inlets Check......................................... 43 Bravo One Models...................................................... 62
Sterndrive Water Drain Check......................................... 43 Bravo Two Models...................................................... 63
Flushing the Sterndrive................................................... 43 Bravo Three................................................................ 64
Corrosion Protection............................................................... 46
Section 6 - Storage
Preparing the Power Package For Storage............................ 68 Power Package Recommissioning......................................... 68
Engine............................................................................. 68 Engine............................................................................. 68
Sterndrive Storage.......................................................... 68 Sterndrive........................................................................68
Section 7 - Troubleshooting
Remote Control Operates Hard, Binds, Has Excessive Power Trim does not Operate (Electric Motor Operates but
Free‑play, or Makes Unusual Sounds.................................... 70 Sterndrive does not Move)..................................................... 70
Steering Wheel Turns Hard or Jerky...................................... 70 Troubleshooting the Electro‑Hydraulic Power Steering System
Power Trim Does Not Operate (Electric Motor Does Not for Sterndrive Models (If Equipped)........................................ 70
Operate)................................................................................. 70
Section 8 - Customer Assistance Information

Owner Service Assistance...................................................... 74 Resolving a Problem......................................................... 74
Local Repair Service......................................................... 74
Service Away From Home................................................ 74
Stolen Power Package..................................................... 74
Attention Required After Submersion............................... 74
Replacement Service Parts.............................................. 74
Parts and Accessories Inquiries....................................... 74
Page ii CMD-4081986 / 90-866839060 MAY 2007

Customer Service Literature.................................................... 75 Andre språk........................................................................75
English Language.............................................................. 75 Outros Idiomas...................................................................76
Other Languages................................................................ 75 Otros idiomas.....................................................................76
Andre sprog........................................................................75 Andra språk........................................................................76
Andere talen.......................................................................75 Allej glþssej........................................................................76
Muut kielet..........................................................................75 Ordering Literature...................................................................76
Autres langues...................................................................75 United States and Canada................................................. 76
Andere Sprachen............................................................... 75 Outside the United States and Canada.............................. 76
Altre lingue.........................................................................75
CMD-4081986 / 90-866839060 MAY 2007 Page iii

Page iv CMD-4081986 / 90-866839060 MAY 2007
Section 1 - Warranty 1
Table of Contents
Warranty Information.............................................................. 2 Sterndrive Warranty Policy—Diesel Intermittent Rating
Warranty Registration—United States and Canada........ 2 .........................................................................................4
Warranty Registration—Outside the United States and Limited Warranty Against Corrosion (Worldwide)............ 6
Canada............................................................................2 Transfer of Warranty........................................................ 7
Warranty Policies.................................................................... 3
Sterndrive Warranty Policy—High Output Diesel
Recreational Use............................................................. 3
CMD-4081986 / 90-866839060 MAY 2007 Page 1

Warranty Information
Warranty Registration—United States and Canada
1. It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the factory immediately
upon sale of the new product.
2. It identifies the name and address of the original purchaser, product model and serial number(s), date of sale, type of use
and selling dealer's code, name, and address. The dealer also certifies that you are the original purchaser and user of the
product.
3. Upon receipt of the Warranty Registration Card at the factory, you will receive an owner resource guide that will include your
warranty registration confirmation.
4. A temporary Owner Warranty Registration Card will be presented to you when you purchase the product.
5. Because of your selling dealer's continuing personal interest in your satisfaction, the product should be returned to him for
warranty service.
6. If your owner resource guide is not received within 60 days from date of new product sale, please contact your selling dealer.
7. The product warranty is not effective until the product is registered at the factory.
NOTE: Registration lists must be maintained by the factory and dealer on marine products sold in the United States, should
a safety recall notification under the Federal Boat Safety Act be required.
8. You may change your address at any time, including at time of warranty claim, by calling Mercury MerCruiser or sending a
letter or fax with you name, old address, new address, and engine serial number to Mercury MerCruiser's warranty registration
department. Your dealer can also process this change of information.
United States customers or dealers may contact:
Mercury Marine
Attn: Warranty Registration Department
W6250 Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax 920-929-5893
Canadian customers or dealers may contact:
Mercury Marine Canada Limited
2395 Meadowpine Blvd.
Mississauga,
Canada, L5N 7W6
Fax 1-800-663-8334
Warranty Registration—Outside the United States and Canada

1. It is important that your selling dealer fills out the Warranty Registration Card completely and mails it to the distributor or
Marine Power Service Center responsible for administering the warranty registration and claim program for your area.
2. The Warranty Registration Card identifies your name and address, product model and serial numbers, date of sale, type of
use and the selling distributor's and dealer's code number, name and address. The distributor or dealer also certifies that you
are the original purchaser and user of the product.
3. A copy of the Warranty Registration Card, designated as the Purchaser's Copy, MUST be given to you immediately after the
card has been completely filled out by the selling distributor or dealer. This card represents your factory registration
identification, and should be retained by you for future use when required. Should you ever require warranty service on this
product, your dealer may ask you for the Warranty Registration Card to verify date of purchase and to use the information on
the card to prepare the warranty claim forms.
4. In some countries, the Marine Power Service Center will issue you a permanent (plastic) Warranty Registration Card within
30 days after receiving the Factory Copy of the Warranty Registration Card from your distributor or dealer. If you receive a
plastic Warranty Registration Card, you may discard the Purchaser's Copy that you received from the distributor or dealer
when you purchased the product. Ask your distributor or dealer if this plastic card program applies to you.
5. For further information concerning the Warranty Registration Card and its relationship to Warranty Claim processing, refer to
the International Warranty. See Table of Contents.
IMPORTANT: Registration lists must be maintained by the factory and dealer in some countries by law. It is our desire to have
ALL products registered at the factory should it ever be necessary to contact you. Make sure your Cummins MerCruiser Diesel
Distributor or Cummins MerCruiser Diesel Authorized Dealer fills out the warranty registration card immediately and sends the
factory copy to the Marine Power International Service Center for your area.
Page 2 CMD-4081986 / 90-866839060 MAY 2007

Warranty Policies
Sterndrive Warranty Policy—High Output Diesel Recreational Use
WHAT IS COVERED
Cummins MerCruiser Diesel warrants its new products to be free of defects in material and workmanship
during the period described below.
Duration of Coverage
This Limited Warranty provides coverage for two (2) years from the date the product is first sold to a
recreational use retail purchaser, or the date on which the product is first put into service, whichever occurs
first. High Output Rating is for use in variable load applications where full power is limited to one (1) hour
out of every eight (8) hours of operation. Also, reduced power operations must be at or below 200 RPM of
the maximum rated RPM for engines rated at 3000 RPM or less, and at or below 400 RPM of the maximum
rated RPM for engines rated at greater than 3000 RPM. This rating is for pleasure (non‑revenue generating)
applications that operate 500 hours or less per year. Commercial use of the product voids the warranty.
Commercial use is defined as any work or employment related use of the product, or any use of the product
that generates income, for any part of the warranty period, even if the product is only occasionally used for
such purposes. The repair or replacement of parts, or the performance of service under this warranty, does
not extend the life of this warranty beyond its original expiration date. Unexpired warranty coverage can be
transferred from one recreational use customer to a subsequent recreational use customer upon proper
re‑registration of the product. Unexpired warranty coverage cannot be transferred either to or from a
commercial use customer.
Conditions That Must Be Met to Obtain Warranty Coverage
Warranty coverage is available only to retail customers that purchase from a Dealer authorized by Cummins
MerCruiser Diesel to distribute the product in the country in which the sale occurred, and then only after the
Cummins MerCruiser Diesel specified pre‑delivery inspection process is completed and documented.
Warranty coverage becomes available upon proper registration of the product by the authorized dealer.
Inaccurate warranty registration information regarding recreational use, or subsequent change of use from
recreational to commercial (unless properly re‑registered) may void the warranty at the sole discretion of
Cummins MerCruiser Diesel. Routine maintenance outlined in the Operation, Maintenance, & Warranty
Manual must be timely performed in order to obtain warranty coverage. Cummins MerCruiser Diesel
reserves the right to make any warranty coverage contingent upon proof of proper maintenance.
What Cummins MerCruiser Diesel Will Do
Cummins MerCruiser Diesel’s sole and exclusive obligation under this warranty is limited to, at our option,
repairing a defective part, replacing such part or parts with new or Mercury Marine certified re‑manufactured
parts, or refunding the purchase price of the Cummins MerCruiser Diesel product. Cummins MerCruiser
Diesel reserves the right to improve or modify products from time to time without assuming an obligation to
modify products previously manufactured.
How to Obtain Warranty Coverage
The customer must provide Cummins MerCruiser Diesel with a reasonable opportunity to repair, and
reasonable access to the product for warranty service. Warranty claims shall be made to a Cummins
MerCruiser Diesel Authorized Repair Facility to service the product. If purchaser cannot deliver the product
to such a dealer, written notice must be given to Cummins MerCruiser Diesel. We will then arrange for the
inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges
and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related
labor and material, and any other expenses associated with that service. Purchaser shall not, unless
requested by Cummins MerCruiser Diesel, ship the product or parts of the product directly to Cummins
MerCruiser Diesel. The warranty registration card is the only valid registration identification and must be
presented to the dealer at the time warranty service is requested in order to obtain coverage.
What Is Not Covered
CMD-4081986 / 90-866839060 MAY 2007 Page 3

This limited warranty does not cover the following:

• Routine maintenance items
• Minor adjustments or checks, including checking controls, and checking lubrication made in connection
with normal services
• Damage caused by abuse, abnormal use, neglect, accident, submersion, improper service, freezing
temperatures, alteration, or removal of parts
• Oils, lubricants, or fluids unless loss or contamination of the same is caused by product failure that
would be eligible for warranty consideration.
• Normal wear and tear
• Damage to the sterndrive lower unit or propeller caused by striking a marine hazard, such as a
submerged object
• Improper installation (proper installation specifications and techniques are set forth in the installation
instructions for the product)
• Additional service work requested by the customer other than that necessary to satisfy the warranty
obligation
• Damage to the Cummins MerCruiser Diesel product caused by the use of an accessory or part that
was not manufactured or sold by Cummins MerCruiser Diesel or Mercury Marine
• Operation with oils, lubricants, or fluids that are not suitable for use with the product (see the Operation,
Maintenance & Warranty Manual)
• Damage to the product from insufficient cooling water caused by blockage of the cooling system or
water inlets
• Damage caused by running the sterndrive out of water
• Damage resulting from mounting the power package too high on the transom
• Damage as a result of operating the boat with the engine over trimmed
• Labor performed by other than Cummins MerCruiser Diesel except when prior factory approval has
been given to have the work performed at that facility and when performed on an emergency basis,
providing there are no Authorized Repair Facilities in the area that can perform the work required or
have no facilities to haul out, tow, and so on
• Expenses related to haul‑out, launch, or towing
• Removal or replacement of boat partitions or other material in order to gain access to the product
• Expenses related to delivering the product to a Cummins MerCruiser Diesel Authorized Dealer when
reasonable access is not provided to the product for warranty service
• Expenses related to storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan
payments, loss of time, loss of income, or any other type of incidental or consequential damages
Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any
time, even by a previous owner of the product, voids the warranty.
No individual or entity, including Cummins MerCruiser Diesel authorized dealers, has been given authority
by Cummins MerCruiser Diesel to make any affirmation, representation, or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be enforceable against Cummins
MerCruiser Diesel.
DISCLAIMERS AND LIMITATIONS
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 Warranty Policy—Diesel Intermittent Rating

WHAT IS COVERED
Cummins MerCruiser Diesel warrants its new products to be free of defects in material and workmanship
during the period described below.
Page 4 CMD-4081986 / 90-866839060 MAY 2007

This Limited Warranty provides coverage for one (1) year or 400 hours (whichever occurs first) for
commercial applications from the date the product is first sold to a retail purchaser, or the date on which
the product is first put into service, whichever occurs first, and is intended for intermittent use in variable
load applications where full power is limited to two hours out of every eight hours of operation. Also, reduced
power operations must be at or below 200 RPM of the maximum rated RPM. This rating is an ISO 3046
fuel stop power rating and is intended for applications that operate less than 1,500 hours per year. The
repair or replacement of parts, or the performance of service under this warranty, does not extend the life
of this warranty beyond its original expiration date. Unexpired warranty coverage can be transferred from
one commercial use customer to a subsequent commercial use customer upon proper re‑registration of the
product. Unexpired warranty coverage cannot be transferred either to or from a recreational use customer.
This warranty coverage is available only for Bravo Two Sterndrives that are part of the QSB5.9 ES
230 propulsion package sold to retail customers in marine applications that purchase from Cummins
MerCruiser Diesel, Cummins MerCruiser Diesel Distributor, or Cummins MerCruiser Diesel Authorized
Dealer in the country in which the sale occurred, and then only after the Cummins MerCruiser Diesel
specified pre‑delivery inspection process is completed and documented. Warranty coverage becomes
available upon proper registration of the product by the authorized dealer. Inaccurate warranty registration
information or misapplication of the propulsion package may void the warranty at the sole discretion of
Cummins MerCruiser Diesel. Routine maintenance outlined in the Operation, Maintenance, & Warranty
Manual must be timely performed in order to obtain warranty coverage. Cummins MerCruiser Diesel
reserves the right to make any warranty coverage contingent upon proof of proper maintenance.
What Cummins MerCruiser Diesel Will Do
Cummins MerCruiser Diesel’s sole and exclusive obligation under this warranty is limited to, at our option,
repairing a defective part, replacing such part or parts with new or Mercury Marine certified re‑manufactured
parts, or refunding the purchase price of the Cummins MerCruiser Diesel product. Cummins MerCruiser
Diesel reserves the right to improve or modify products from time to time without assuming an obligation to
modify products previously manufactured.
The customer must provide Cummins MerCruiser Diesel with a reasonable opportunity to repair, and
reasonable access to the product for warranty service. Warranty claims shall be made to a Cummins
MerCruiser Diesel Authorized Repair Facility to service the product. If purchaser cannot deliver the product
to such a dealer, written notice must be given to Cummins MerCruiser Diesel. We will then arrange for the
inspection and any covered repair. Purchaser in that case shall pay for all related transportation charges
and/or travel time. If the service provided is not covered by this warranty, purchaser shall pay for all related
labor and material, and any other expenses associated with that service. Purchaser shall not, unless
requested by Cummins MerCruiser Diesel, ship the product or parts of the product directly to Cummins
MerCruiser Diesel. The warranty registration card is the only valid registration identification and must be
What Is Not Covered
CMD-4081986 / 90-866839060 MAY 2007 Page 5

This limited warranty does not cover the following:

• Routine maintenance items
• Minor adjustments or checks, including checking controls, and checking lubrication made in connection
with normal services
• Damage caused by abuse, abnormal use, neglect, accident, submersion, improper service, freezing
temperatures, alteration, or removal of parts
• Oils, lubricants, or fluids unless loss or contamination of the same is caused by product failure that
would be eligible for warranty consideration.
• Normal wear and tear
• Damage to the sterndrive lower unit or propeller caused by striking a marine hazard, such as a
submerged object
• Improper installation (proper installation specifications and techniques are set forth in the installation
instructions for the product)
• Additional service work requested by the customer other than that necessary to satisfy the warranty
obligation
• Damage to the Cummins MerCruiser Diesel product caused by the use of an accessory or part that
was not manufactured or sold by Cummins MerCruiser Diesel or Mercury Marine
• Operation with oils, lubricants, or fluids that are not suitable for use with the product (see the Operation,
Maintenance & Warranty Manual)
• Damage to the product from insufficient cooling water caused by blockage of the cooling system or
water inlets
• Damage caused by running the sterndrive out of water
• Damage resulting from mounting the power package too high on the transom
• Damage as a result of operating the boat with the engine over trimmed
• Labor performed by other than Cummins MerCruiser Diesel except when prior factory approval has
been given to have the work performed at that facility and when performed on an emergency basis,
providing there are no Authorized Repair Facilities in the area that can perform the work required or
have no facilities to haul out, tow, and so on
• Expenses related to haul‑out, launch, or towing
• Removal or replacement of boat partitions or other material in order to gain access to the product
• Expenses related to delivering the product to a Cummins MerCruiser Diesel Authorized Dealer when
reasonable access is not provided to the product for warranty service
• Expenses related to storage, telephone, rental, inconvenience, slip fees, insurance coverage, loan
payments, loss of time, loss of income, or any other type of incidental or consequential damages
Use of the product for racing or other competitive activity, or operating with a racing‑type lower unit at any
time, even by a previous owner of the product, voids the warranty.
No individual or entity, including Cummins MerCruiser Diesel authorized dealers, has been given authority
by Cummins MerCruiser Diesel to make any affirmation, representation, or warranty regarding the product,
other than those contained in this limited warranty, and if made, shall not be enforceable against Cummins
MerCruiser Diesel.
DISCLAIMERS AND LIMITATIONS
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 Warranty Against Corrosion (Worldwide)

What Is Covered
Cummins MerCruiser Diesel warrants that each new Alpha and Bravo sterndrive (Product) will not be
rendered inoperative as a direct result of corrosion for the period of time described below.
Page 6 CMD-4081986 / 90-866839060 MAY 2007

This limited corrosion warranty provides coverage for three (3) years from either the date the product is first
sold, or the date on which the product is first put into service, whichever occurs first. For sterndrive models
with SeaCore, the warranty coverage is four (4) years from either the date the product is first sold, or the
date on which the product is first put into service, whichever occurs first. The repair and replacement of
parts, or the performance of service under this warranty does not extend the life of this warranty beyond its
original expiration date. Unexpired warranty coverage can be transferred to subsequent purchaser upon
proper re‑registration of the product. Warranty coverage is terminated for used product repossessed from
a retail customer, purchased at auction, from a salvage yard, or from an insurance company that obtained
the product as a result of an insurance claim.
Warranty coverage is available only to retail customers that purchase from a dealer authorized by Cummins
MerCruiser Diesel to distribute the product in the country in which the sale occurred. Warranty coverage
becomes available upon proper registration of the product by the authorized dealer. Corrosion prevention
devices specified in the Operation, Maintenance, and Warranty manual must be in use on the boat, and
routine maintenance outlined in the Operation, Maintenance, and Warranty manual must be timely
performed (including without limitation the replacement of sacrificial anodes, use of specified lubricants,
and touch‑up of nicks and scratches) in order to maintain warranty coverage. Cummins MerCruiser Diesel
reserves the right to make warranty coverage contingent upon proof of proper maintenance.
What Mercury Will Do
Cummins MerCruiser Diesel's sole and exclusive obligation under this warranty is limited to, at our option,
repairing a corroded part, replacing such part or parts with new or Mercury Marine‑certified re‑manufactured
parts, or refunding the purchase price of the Mercury product. Mercury reserves the right to improve or
modify products from time to time without assuming an obligation to modify products previously
manufactured.
The customer must provide Cummins MerCruiser Diesel with reasonable access to the product for warranty
service and a reasonable opportunity to repair the product. Warranty claims shall be made by delivering the
product for inspection to a Cummins MerCruiser Diesel dealer authorized to service the product. If purchaser
cannot deliver the product to such a dealer, written notice must be given to Cummins MerCruiser Diesel.
We will then arrange for the inspection and any covered repair. If the service provided is not covered by
this warranty, purchaser shall pay for all related labor and material, and any other expenses associated with
that service. Purchaser shall not, unless requested by Cummins MerCruiser Diesel, ship the product or
parts of the product directly to Cummins MerCruiser Diesel. Proof of registered ownership must be
What Is Not Covered
This limited warranty does not cover electrical system corrosion; corrosion resulting from damage; corrosion
that causes purely cosmetic damage; abuse or improper service; corrosion to accessories, instruments, or
steering systems; corrosion to factory installed jet drive unit; damage due to marine growth; product sold
with less than a one year limited product warranty; replacement parts (parts purchased by the customer);
products used in a commercial application. Commercial use is defined as any work‑related or
employment‑related use of the product, or any use of the product that generates income, for any part of
warranty period, even if the product is only occasionally used for such purposes.
Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser, but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial applications.
To transfer the warranty to the subsequent owner, send or fax a copy of the bill of sale or purchase agreement, new owner’s name,
address and engine serial number to Mercury Marine’s Warranty Registration Department. In the United States and Canada, mail
to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
920-929-5054
Fax +1 920 929 5893
Upon processing the transfer of warranty, Mercury Marine will send registration verification to the new owner of the product by
mail.
There is no charge for this service.
CMD-4081986 / 90-866839060 MAY 2007 Page 7

For products purchased outside the United States and Canada, contact the distributor in your country, or the Marine Power Service
Center closest to you.
Page 8 CMD-4081986 / 90-866839060 MAY 2007


Table of Contents
Indentification....................................................................... 10
Bravo X Diesel and Bravo XR Models........................... 10
Features and Controls.......................................................... 14
Lanyard Stop Switch (If Equipped)................................ 14
2
Bravo One Models ................................................. 10 Remote Controls............................................................ 15
Bravo Two Models ................................................. 11 Panel Mount Features ........................................... 15
Bravo Three Models .............................................. 11 Console Mount Features ....................................... 15
Bravo Sterndrive Serial Number and Identification........ 12 Power Trim....................................................................16
Bravo Transom Serial Number...................................... 12 Single Engine Trim and Trailer .............................. 17
Instrumentation..................................................................... 13 Dual Engine Trim and Trailer ................................ 17
Instruments—Sterndrive models................................... 13 Electrical System Overload Protection.......................... 17
CMD-4081986 / 90-866839060 MAY 2007 Page 9

Indentification
Bravo X Diesel and Bravo XR Models
Bravo One Models
18203
Bravo One X Diesel
18204
Bravo One XR
Page 10 CMD-4081986 / 90-866839060 MAY 2007

Bravo Two Models
18207
Bravo Two X Diesel
Bravo Three Models
18210
Bravo Three X Diesel
18211
Bravo Three XR
CMD-4081986 / 90-866839060 MAY 2007 Page 11

Bravo Sterndrive Serial Number and Identification

The sterndrive serial number, gear ratio, model number, and bar code is embedded in the ground plate located on the port side
of the Bravo sterndrive.
a b c
a- Bar code
b- Gear ratio
d c- Serial Number
d- Model number
25906
The serial number is also stamped on the sterndrive casting inside the back cover. This is used as a permanent reference for
Cummins MerCruiser Diesel Authorized Repair Facilities.
Bravo sterndrive serial number

a stamping
a - Serial number stamping
25907
Bravo Transom Serial Number

The Bravo transom serial number is stamped in the U‑bolt plate of the Bravo transom assembly.
Bravo transom assembly U-bolt plate

a - Transom assembly serial number
25904
Page 12 CMD-4081986 / 90-866839060 MAY 2007

The serial number is also stamped on the gimbal housing. This is used as a permanent reference for Cummins MerCruiser Diesel
Authorized Repair Facilities.
Gimbal housing with serial

number stamping
a - Transom assembly serial
number
25905
Instrumentation
Instruments—Sterndrive models
The following briefly explains the instrumentation typically found on some boats. The owner and operator should be familiar with
all the instruments and their functions on the boat. Because of the large variety of instrumentation and manufacturers, have your
boat dealer explain the gauges and normal readings that will appear on your boat.
The following types of gauges may be included with your power package.
a b c
d e 26019
Typical gauges
Reference Gauge Function

a Oil pressure gauge Indicates engine oil pressure.
b Battery meter Indicates battery voltage.
c Coolant temperature gauge Indicates engine operating temperature.
d Fuel gauge Indicates quantity of fuel in tank.
e Power trim gauge Indicates sterndrive angle (trim up [out] and down [in]).
CMD-4081986 / 90-866839060 MAY 2007 Page 13

Features and Controls

Lanyard Stop Switch (If Equipped)
The purpose of a lanyard stop switch is to turn off the engine when the operator moves outside the operator's position (as in
accidental ejection from the operator's position).
RUN a a - Stop switch

b b - Lanyard
c - Clips to the operator
c
74608
Accidental ejections, such as falling overboard, are more likely to occur in:
• low‑sided sport boats
• bass boats
• high‑performance boats
Accidental ejections can also occur from:
• poor operating practices
• sitting on the seat or gunwale at planing speeds
• standing at planing speeds
• operating at planing speeds in shallow or obstacle infested waters
• releasing your grip on the steering wheel that is pulling in one direction
• consuming alcohol or drugs
• high‑speed boating maneuvers
Some remote control units are equipped with a lanyard stop switch, if your remote control is not equipped with a lanyard stop
switch one can be installed on the dashboard or side adjacent to the operator's position. The lanyard is a cord usually between
122 and 152 cm (4 and 5 feet) in length when stretched out, with an element on one end made to be inserted into the switch and
a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest condition as short as possible to
minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the likelihood
of accidental activation should the operator choose to move around in an area close to the normal operator's position. If it is desired
to have a shorter lanyard, wrap the lanyard around the operator's wrist or leg, or tie a knot in the lanyard.
Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance
depending upon the velocity and degree of any turn at shut down. However, the boat will not complete a full circle. While the boat
is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.
We strongly recommend that other occupants be instructed on proper starting and operating procedures should they be required
to operate the engine in an emergency (e.g. if the operator is accidentally ejected).
! WARNING
If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being
struck by the boat. Always properly connect the operator to the stop switch using a lanyard.
Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the
following potentially hazardous situations:
• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front
of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.
• Loss of power and directional control in heavy seas, strong current or high winds.
• Loss of control when docking.
! WARNING
Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat
operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.
Page 14 CMD-4081986 / 90-866839060 MAY 2007

Remote Controls
Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features
shown. Consult your dealer for a description and/or demonstration of your remote control.
Panel Mount Features

a e
a- Neutral lock button
b- Throttle‑only button
f c- Lanyard stop switch
d- Control handle tension adjustment screw
e- Control handle
b f- Trim and tilt button
c
d
mc77019-1
Neutral lock button. Prevents accidental shift and throttle engagement. The neutral lock button must be pushed into move the
control handle out of neutral.
Throttle-only button. Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle‑only button can be depressed only when the remote control handle is in the
neutral position, and should only be used to assist in starting the engine.
Lanyard stop switch. Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from
the operator's position to activate the switch. See Lanyard Stop Switch for information on the use of this switch.
Control handle. The shift and throttle are controlled by the movement of the control handle. Push the control handle forward from
neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control
handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.
Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote
control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.
Trim (tilt) button. See Power Trim.
Console Mount Features
b a- Throttle‑only button
b b- Control handle
d c c- Power trim switch
d- Trailer switch
a d
a c mc79503-1
Throttle-only button. Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift
mechanism from the control handle. The throttle‑only button can be depressed only when the remote control handle is in the
neutral position.
CMD-4081986 / 90-866839060 MAY 2007 Page 15

Control handles. The shift and throttle are controlled by the movement of the control handle. Push the control handle forward
from neutral with a quick, firm motion to the first detent for forward gear and continue pushing forward to increase speed. Pull the
control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase
speed.
Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote
control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.
Power trim switch. See the Power Trim section for detailed power trim operating procedures.
Trailer switch. Used to raise the sterndrive for trailering, launching, beaching, or shallow water operation. See Power Trim for
detailed trailer switch operation.
Power Trim
Power trim allows the operator to adjust the sterndrive angle while underway to provide the ideal boat angle for varying load and
water conditions. The trailer switch allows the operator to raise and lower the sterndrive for trailering, beaching, launching,
low‑speed (below 1200 RPM engine speed), and shallow water operation.
! WARNING
Excessive trim can cause serious injury or death at high speeds, and single‑ram trim systems do not provide a trim‑out limiting
device or trim indicator. Use caution when trimming with a single‑ram trim system and never trim out beyond the unit's side
support flanges while the boat is underway or at engine speeds above 1200 RPM.
For best performance, trim the sterndrive so that the boat bottom is at a 3–5° angle to the water.
3-5
mc79528
Trimming the sterndrive up (out) has the following effects:

• Generally increases top speed.
• Increases clearance over submerged objects or a shallow bottom.
• Causes the boat to accelerate and reach plane more slowly.
• Causes porpoising (bouncing) or propeller ventilation if trimmed excessively.
• Causes engine overheating if trimmed to a point where any cooling water intake holes are above the water line.
mc78529
Trimming the sterndrive down (in) has the following effects:

• Helps the boat accelerate and reach plane more quickly.
• Generally improves the ride in choppy water.
• Generally reduces boat speed.
Page 16 CMD-4081986 / 90-866839060 MAY 2007

• If in excess, lower the bow of some boats to a point at which they begin to plow with their bow in the water while on plane.
This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a
significant wave is encountered.
mc79530
Single Engine Trim and Trailer

Single engine applications have a button to trim the sterndrive up (out) or down (in).
To raise the sterndrive for trailering, beaching, launching, low‑speed (below 1200 RPM), and shallow water operation, push the
trim button to raise the sterndrive to the full up (out) position.
Some controls have a trailer button that trims the sterndrives to a position suitable only for hauling the boat by trailer.
Dual Engine Trim and Trailer
NOTICE
If using external tie bars, raising or lowering the drives independently of each other can damage the drive and steering systems.
If using an external tie bar, raise and lower all drives together as a unit.
Dual‑engine applications may have a single integral button to operate both sterndrives simultaneously or separate button for each
sterndrive.
Some controls have a trailer button that trims the sterndrives to a position suitable only for hauling the boat by trailer.
Electrical System Overload Protection

If an electrical overload on the electrical system occurs, a fuse will burn out (blow). Find and correct the cause before replacing
the fuse.
NOTE: In an emergency, when the engine must be operated and the cause for the electrical overload, or excessive current draw,
cannot be located and corrected, turn OFF or disconnect all accessories connected to the engine and instrumentation wiring.
Replace the fuse. If the fuse burns out, the electrical overload has not been eliminated. Further checks must be made on the
electrical system. Contact your authorized Cummins MerCruiser Diesel repair facility.
1. The Power Trim System is protected from overload by a 110‑amp fuse and a 20‑amp in‑line fuse on the power trim pump.
a - 20‑amp holder
b - 110‑amp fuse
b 9208
CMD-4081986 / 90-866839060 MAY 2007 Page 17

2. The Quicksilver Three‑Button Power Trim Control Panel is protected from overload by a 20‑amp in‑line fuse.
a - 20‑amp in‑line fuse
3. The Quicksilver MerCathode System has a 20‑amp in‑line fuse in the wire that connects to the positive (+) terminal on the
controller. If the fuse is burned out (blown), the system will not operate resulting in a loss of corrosion protection.
a a - 20‑amp in‑line fuse
19834
4. The Electro‑Hydraulic Power Steering System, if equipped, is protected from overload by a 90‑amp fuse on the steering pump
positive lead at the battery positive connection.
90-amp fuse for the electro-hydraulic power steering pump

a a a - Power steering pump positive lead
b - Fuse eyelet for the positive battery post
c - 90‑amp fuse
c
c
b 20516
Page 18 CMD-4081986 / 90-866839060 MAY 2007


Table of Contents
Safe Boating Suggestions.................................................... 20 Boats With Front‑Mounted, Raised Pedestal Fishing
Be Alert to Carbon Monoxide Poisoning........................ 21 Seats ..................................................................... 23
Good Ventilation .................................................... 21 Wave and Wake Jumping.............................................. 23
Poor Ventilation .................................................... 21 Impact with Underwater Hazards................................... 24
Basic Boat Operation............................................................ 21
Launching and Boat Operation...................................... 21
Starting the Engine After Stopped While in Gear.......... 21
Sterndrive Impact Protection ................................. 24
Conditions Affecting Operation............................................. 24
Weight Distribution (Passengers and Gear) Inside the Boat
3
Freezing Temperature Operation.................................. 22 .......................................................................................24
Drain Plug and Bilge Pump............................................ 22 Bottom of Boat............................................................... 25
Trailering the Boat......................................................... 22 Cavitation.......................................................................25
Protecting People In The Water........................................... 22 Ventilation......................................................................25
While You Are Cruising ......................................... 22 Elevation and Climate.................................................... 25
While Boat Is Stationary ........................................ 22 Propeller Selection......................................................... 25
High‑Speed and High‑Performance............................... 22 Getting Started..................................................................... 26
Passenger Safety In Pontoon Boats And Deck Boats Sterndrive 10‑Hour Break‑In Period (New or With
.......................................................................................22 Replacement Gears)...................................................... 26
Boats Having An Open Front Deck ....................... 22 End of First Season Checkup........................................ 26
CMD-4081986 / 90-866839060 MAY 2007 Page 19

Safe Boating Suggestions

In order to safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions,
and also consider the following suggestions.
• Know and obey all nautical rules and laws of the waterways.
Cummins MerCruiser Diesel strongly recommends that all powerboat operators complete a boating safety course. Courses are
offered in the U.S.A. by the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating
law enforcement agency. Inquiries may be made to the Boating Hotline at 1‑800‑368‑5647 or the Boat U.S. Foundation at
1‑800‑336‑BOAT.
• Perform safety checks and required maintenance. Follow a regular schedule and ensure that all repairs are properly made.
• Check safety equipment on board. Here are some suggestions of the types of safety equipment to carry when boating:
Approved fire extinguishers
Paddle or oar
Signal devices: flashlight, rockets or flares, flag, and whistle or horn
Transistor radio
Tools necessary for minor repairs
First aid kit and instructions
Anchor and extra anchor line
Waterproof storage containers
Manual bilge pump and extra drain plugs
Spare operating equipment, batteries, bulbs, and fuses
Drinking water
Compass and map or chart of the area
• Watch for signs of weather change and avoid foul weather and rough-sea boating.
• Tell someone where you are going and when you expect to return.
• Passenger boarding. Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the
boat. Shifting the drive unit into neutral is not sufficient.
• Use personal flotation devices. Federal law requires that there be a U. S. Coast Guard–approved, wearable‑type life jacket
(personal flotation device), correctly sized and readily accessible for every person aboard, plus a throwable cushion or ring.
We strongly advise that everyone wear a life jacket at all times while in the boat.
• Prepare other boat operators. Instruct at least one person aboard in the basics of starting and operating the engine and
handling the boat in case the driver becomes disabled or falls overboard.
• Do not overload your boat. Most boats are rated and certified for maximum load (weight) capacities (refer to your boat
capacity plate). Know your boat’s operating and loading limitations. Know if your boat will float if full of water. When in doubt,
contact your authorized Cummins MerCruiser Diesel dealer/distributor or the boat manufacturer.
• Ensure that everyone in the boat is properly seated. Do not allow anyone to sit or ride on any part of the boat that was
not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any
rotating fishing seat; anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control or
sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a
proper seat and are in it before any boat movement.
• Never be under the influence of alcohol or drugs while boating (it is the law). Alcohol or drugs impairs your judgment
and greatly reduce your ability to react quickly.
• Know your boating area and avoid hazardous locations.
• Be alert. The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must
have an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view
when operating the boat above idle or planing transition speed. Watch out for others, keep your eyes on the the water, and
be aware of your wake.
• Never drive your boat directly behind a water skier in case the skier falls. As an example, your boat traveling at 40 km/h
(25 MPH) will overtake a fallen skier who was 61 m (200 ft.) in front of you in five seconds.
• Watch fallen skiers. When using your boat for water skiing or similar activities, always keep a fallen or down skier on the
operator’s side of the boat while returning to attend to the skier. The operator should always have the down skier in sight and
never back up to the skier or anyone in the water.
Page 20 CMD-4081986 / 90-866839060 MAY 2007

• Report accidents. Boat operators are required by law to file a Boating Accident Report with their state boating law
enforcement agency when their boat is involved in certain boating accidents. A boating accident must be reported if 1) there
is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage
to boats or other property where the damage value exceeds US $500.00 or 4) there is complete loss of the boat. Seek further
assistance from local law enforcement.
Be Alert to Carbon Monoxide Poisoning

Carbon monoxide is present in the exhaust fumes of all internal combustion engines including the outboards, sterndrives and
inboard engines that propel boats, as well as the generators that power various boat accessories. Carbon monoxide is a deadly
gas that is odorless, colorless and tasteless.
Early symptoms of carbon monoxide poisoning, which should not be confused with seasickness or intoxication, include headache,
dizziness, drowsiness and nausea.
! WARNING
Carbon monoxide poisoning can lead to unconsciousness, brain damage, or death. Keep the boat well ventilated while at rest
or underway and avoid prolonged exposure to carbon monoxide.
Good Ventilation
Ventilate the passenger area, open the side curtains or forward hatches to remove fumes.
1. Example of desired air flow through the boat.
mc79553-1
Poor Ventilation
Under certain conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in
carbon monoxide. Install one or more carbon monoxide detectors in your boat.
Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains
or is near an operating engine may be exposed to a hazardous level of carbon monoxide.
1. Examples of poor ventilation while a boat is stationary:
a - Operating the engine when

the boat is moored in a
confined space
a b mc79554-1 b - Mooring close to another boat
with its engine operating
2. Examples of poor ventilation while a boat is moving:
a - Operating the boat with the trim

angle of the bow too high
mc79556-1 b - Operating the boat with no
a b forward hatches open (station
wagon effect)
Basic Boat Operation

Launching and Boat Operation
IMPORTANT: Install bilge drain plug prior to launching boat.
Starting the Engine After Stopped While in Gear

IMPORTANT: Avoid stopping the engine if the sterndrive is in gear. If the engine does stop with the sterndrive in gear, see the
following procedure:
1. Push and pull repeatedly on the remote control handle until the handle returns to the neutral detent position. This may take
several tries if the power package was operating above idle RPM when the engine stopped.
CMD-4081986 / 90-866839060 MAY 2007 Page 21

2. After the handle returns to the neutral detent position, resume normal starting procedures.
Freezing Temperature Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freeze damage to the
power package. Damage caused by freezing is not covered by the Cummins MerCruiser Diesel Limited Warranty.
Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a
drain plug or a bilge pump. It is very important to check these items on a regular basis to ensure that the water level does not
come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by
submersion is not covered by the Mercury MerCruiser or Cummins MerCruiser Diesel Limited Warranty.
Trailering the Boat

Your boat can be trailered with the sterndrive in the up (out) or down (in) position. Adequate clearance is required between the
road and sterndrive when transporting.
If adequate road clearance is a problem, place the sterndrive in full trailer position and support it with an optional trailer kit, which
is available from your Cummins MerCruiser Diesel Authorized Repair Facility.
Protecting People In The Water

While You Are Cruising
It is very difficult for a person in the water to take quick action to avoid a boat heading in their direction, even at slow speeds.
21604
Always slow down and exercise extreme caution any time you are boating in an area where there might be people in the water.
Whenever a boat is moving (even coasting) and the gear shift is in neutral, there is sufficient force by the water on the propeller
to cause the propeller to rotate. This neutral propeller rotation can cause serious injury.
While Boat Is Stationary
! WARNING
A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers.
Stop the engine immediately whenever anyone in the water is near your boat.
Shift into neutral and shut off the engine before allowing people to swim or be in the water near your boat.
High‑Speed and High‑Performance

If your boat is considered a high‑speed or high‑performance boat with which you are unfamiliar, we recommend that you never
operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an
operator experienced with your boat. For additional information, refer to the Hi-Performance Boat Operation booklet
(90‑849250‑R03) from your Cummins MerCruiser Diesel Authorized Repair Facility.
Passenger Safety In Pontoon Boats And Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other
than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave
or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat. Falling over the
front of the boat between the two pontoons will position them to be run over.
Boats Having An Open Front Deck

No one should ever be on the deck in front of the rail while the boat is in motion. Keep all passengers behind the front rail or
enclosure.
Page 22 CMD-4081986 / 90-866839060 MAY 2007

Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs
caught by a wave and pulled into the water.
mc79555-1
! WARNING
Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death.
Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.
Boats With Front-Mounted, Raised Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats
designated for traveling at faster speeds.
Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.
mc79557-1
Wave and Wake Jumping

! WARNING
Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or
wake jumping whenever possible.
mc79680-1
Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough
speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat re‑enters the
water.
The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the boat
to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats
or out of the boat.
There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat
pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant.
This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer sharply
to one side.
CMD-4081986 / 90-866839060 MAY 2007 Page 23

Impact with Underwater Hazards

Reduce speed and proceed with caution whenever you're driving a boat in shallow water or in areas where the waters are
suspected of having underwater obstacles that could be struck by the underwater drive components, rudder, or the boat bottom.
mc79679-1
IMPORTANT: The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater
object is control the boat speed. Under these conditions, boat speed should be kept to a maximum speed of 24 to 40 km/h
(15 to 25 MPH).
The following demonstrate some, but not all, examples of what can happen if the boat strikes an object:
• The boat could move suddenly in a new direction. Such a sharp change in direction or turn can throw occupants out of their
seats or out of the boat.
• A rapid reduction in speed. This will cause occupants to be thrown forward, even out of the boat.
• Impact damage to the underwater drive components, rudder, or boat.
Keep in mind that one of the most important things you can do to help reduce injury or impact damage in these situations is control
the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater
obstacles.
After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts.
If damage is present or suspected, the power package should be taken to an authorized Cummins MerCruiser Diesel repair facility
for a thorough inspection and any necessary repair.
The boat should be checked for hull fractures, transom fractures, and water leaks.
Operating with damaged underwater drive components, rudder, or boat bottom could cause additional damage to other parts of
the power package, or could affect control of the boat. If continued operation is necessary, do so at greatly reduced speeds.
! WARNING
Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences
any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.
Sterndrive Impact Protection

The power trim hydraulic system is designed to provide impact protection for the sterndrive. If a submerged object is struck while
the boat is moving forward, the hydraulic system will cushion the kickup of the sterndrive as it clears the object, reducing damage
to the sterndrive. After the sterndrive has cleared the object, the hydraulic system allows the sterndrive to return to its original
operating position, preventing loss of steering control and engine overspeed.
Use extreme caution when operating in shallow water or where underwater objects are known to be present. No impact protection
is provided in reverse; use extreme care to prevent striking submerged objects while operating in reverse.
IMPORTANT: Impact protection system cannot be designed to ensure total protection from impact damage under all conditions.
Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat
Shifting weight to rear (stern):
• Generally increases speed and engine RPM
• Causes bow to bounce in choppy water
• Increases danger of following wave splashing into the boat when coming off plane
• At extremes, can cause the boat to porpoise
Shifting weight to front (bow):
• Improves ease of planing
• Improves rough water ride
Page 24 CMD-4081986 / 90-866839060 MAY 2007

• At extremes, can cause the boat to veer back and forth (bow steer)
Bottom of Boat
To maintain maximum speed, ensure that the boat bottom is:
• Clean, free of barnacles and marine growth.
• Free of distortion, nearly flat where it contacts water.
• Straight and smooth, fore and aft.
Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog water
inlets and cause the engine to overheat.
Cavitation
Cavitation occurs when water flow cannot follow the contour of a fast‑moving underwater object, such as a gear housing or a
propeller. Cavitation increases propeller speed while reducing boat speed. Cavitation can seriously erode the surface of the gear
housing or the propeller. Common causes of cavitation are:
• Weeds or other debris snagged on the propeller
• Bent propeller blade
• Raised burrs or sharp edges on the propeller
Ventilation
Ventilation is caused by surface air or exhaust gases that are introduced around the propeller resulting in propeller speed‑up and
a reduction in boat speed. Air bubbles strike the propeller blade and cause erosion of the blade surface. If allowed to continue,
eventual blade failure (breakage) will occur. Excessive ventilation is usually caused by:
• Drive unit trimmed out too far
• A missing propeller diffuser ring
• A damaged propeller or gear housing, which allows exhaust gases to escape between propeller and gear housing
• Drive unit installed too high on transom
Elevation and Climate

NOTE: Engines equipped with an Engine Control Module (ECM) reduce the effects of changes in elevation and climate by
automatically adjusting fuel flow for weather conditions and elevation. ECM controlled engines, however, do not compensate for
increased loading or hull conditions.
Elevation and climate changes affect the performance of your power package. Loss of performance can be caused by:
• High elevations
• High temperatures
• Low barometric pressures
• High humidity
For optimum engine performance under changing weather conditions and high elevation, use a propeller that allows the engine
to operate at rated RPM at wide open throttle (WOT) with a maximum boat load during your normal boating.
In most cases, the rated RPM at WOT can be achieved by changing to a lower pitch propeller.
Propeller Selection
NOTICE
Operating the engine with the wrong propeller installed can limit power, increase fuel consumption, overheat the engine, or
cause internal powerhead damage. Choose a propeller that allows the engine to operate at the specified wide open throttle
RPM.
The boat manufacturer and the selling dealer are responsible to equip the power package with the correct propeller. Refer to the
Diesel Parts And Accessories Guide and read Everything You Need To Know About Propellers. Refer to the engine
manufacturer or manufacturer's operation manual for the specified engine rated RPM.
Select a propeller that allows the engine power package to operate at the engine rated RPM with a full load. Do not consider high
RPM caused by excessive trim angle in selecting the correct propeller.
NOTE: Use an accurate service tachometer to verify RPM.
If WOT is below the engine rated RPM, change the propeller to prevent loss of performance and possible engine damage.
Operating the engine above the engine rated RPM will cause higher than normal wear or damage.
After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:
CMD-4081986 / 90-866839060 MAY 2007 Page 25

• RPM loss caused by warmer weather and greater humidity (not as significant on these models).
• RPM loss caused by operating in a higher elevation (not as significant on these models).
• RPM loss caused by operating with a damaged propeller or dirty boat bottom.
• Loss of speed caused by operating with increased load (additional passengers, pulling skiers).
Because many design variables affect a boats performance, test the boat to determine the best propeller for a particular application.
Refer to Diesel Sterndrive Bravo Models Installation Manual, and complete Boat in the Water—Wide Open Throttle Test.
Getting Started
Sterndrive 10‑Hour Break‑In Period (New or With Replacement Gears)
It is important that the following procedure be used on new sterndrives and rebuilt sterndrives with new replacement gears. This
break‑in procedure allows the proper seating of the sterndrive gears and related components, which greatly reduces the likelihood
of problems.
• Avoid full throttle starts.
• Do not operate at any one constant speed for extended periods of time.
• Do not exceed 75% of full throttle during the first 5 hours. During the next 5 hours, operate at intermittent full throttle.
• The sterndrive should be shifted into forward gear a minimum of 10 times during break‑in, with run‑in time at moderate RPM
after each shift.
End of First Season Checkup

At the end of the first season of operation, contact a Cummins MerCruiser Diesel Authorized Repair Facility to discuss or perform
scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact
your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.
Page 26 CMD-4081986 / 90-866839060 MAY 2007

Table of Contents
Fluid Specifications............................................................... 28 Approved Electro‑Hydraulic Power Steering Fluids
Bravo Sterndrive Fluid Specifications—Diesel.............. 28 .............................................................................. 28
Power Steering and Power Trim Fluids......................... 28 Approved Power Trim Fluids ................................. 28
Approved Power Steering Fluids ........................... 28 Approved Paints................................................................... 28
Approved Compact Hydraulic Power Steering Fluids Torque Specifications........................................................... 29
.............................................................................. 28
CMD-4081986 / 90-866839060 MAY 2007 Page 27

Fluid Specifications
IMPORTANT: All capacities are approximate fluid measures.
Bravo Sterndrive Fluid Specifications—Diesel

Fluid Capacity includes the
Sterndrive Model Sterndrive and the Fluid Type Fluid Part Number
Gearlube Monitor
Bravo One X Diesel
2736 ml (92‑1/2 oz.)
Bravo One XR
High Performance Gear
Bravo Two X Diesel 3209 ml (108‑1/2 oz.) 92‑858064K01
Lubricant
2972 ml (100‑1/2 oz.)
Bravo Three XR
Power Steering and Power Trim Fluids

Approved Power Steering Fluids
Description Part Number
Power Trim and Steering Fluid 92‑858074K01
Dexron III Automatic Transmission Fluid Obtain Locally
Approved Compact Hydraulic Power Steering Fluids

Hydraulic Helm Steering Fluid 92‑858078Q01
SeaStar® Hydraulic Fluid HA5430
Chevron® Aviation Fluid
Mobil® Aero HFA Obtain locally
Shell® Aero 4
Hydraulic Fluid meeting MIL Specification H5606C
Approved Electro-Hydraulic Power Steering Fluids

Synthetic Power Steering Fluid SAE 10W‑30 92‑858077K01
Approved Power Trim Fluids

Power Trim and Steering Fluid 92‑858074K01
SAE Engine Oil 10W‑30 Obtain locally
SAE Engine Oil 10W‑40 Obtain locally
Approved Paints
Mercury Light Gray Primer 92‑802878 52
Mercury Phantom Black 92‑802878Q 1
Page 28 CMD-4081986 / 90-866839060 MAY 2007

Torque Specifications
Description Nm lb. in. lb. ft.
Rear engine mount bolt 47 35
Gimbal ring locknuts 7/16 in. U‑bolt 95 70
75 55
Bravo One propeller nut
Then align tabs with grooves
81 60
Bravo Two propeller nut
Then align tabs with groves
Bravo Three front propeller nut 136 100
Bravo Three rear propeller nut 81 60
Propeller shaft anode screw 19 168
CMD-4081986 / 90-866839060 MAY 2007 Page 29

Notes:
Page 30 CMD-4081986 / 90-866839060 MAY 2007

Table of Contents
Product Responsibilities....................................................... 32 General Information....................................................... 46
Owner and Operator Responsibilities............................ 32 Sterndrive Corrosion Protection Components............... 46
Dealer Responsibilities.................................................. 32 Anodes and MerCathode System Locations ......... 47
Do‑It‑Yourself Maintenance Suggestions............................. 32 Continuity Circuit—Bravo Sterndrive............................. 48
Inspection ..................................................................... 32 MerCathode...................................................................50
Maintenance Intervals.......................................................... 33 Boat Bottom Care.......................................................... 51
Maintenance Schedule......................................................... 33 Painting Your Power Package....................................... 51
Routine Maintenance..................................................... 33 Sterndrive Surface Care................................................ 52
Scheduled Maintenance................................................ 34 Lubrication ........................................................................... 52
Maintenance Log........................................................... 35 Steering System............................................................ 52
Sterndrive Gear Lube........................................................... 36 Shift Cable.....................................................................54
Checking........................................................................36 Transom Assembly........................................................ 54
Filling.............................................................................36 Propeller Shaft............................................................... 54
Changing.......................................................................37
Power Trim Fluid.................................................................. 40
Checking........................................................................40
Engine Coupler.............................................................. 55
Driveshaft Extension Models......................................... 56
Sterndrive, Bellows, and Engine Alignment................... 56
5
Filling.............................................................................41 Maintaining Torques............................................................. 57
Changing.......................................................................42 Gimbal Ring U‑bolt Nuts................................................ 57
Power‑Assisted Steering Fluid (If Equipped)........................ 42 Rear Engine Mount Torque........................................... 58
Electro‑Hydraulic Power‑Assisted Steering System (If Propeller............................................................................... 58
Equipped)............................................................................. 42 Bravo Diesel Sterndrive Propeller Removal.................. 58
Checking........................................................................42 Bravo One Models ................................................. 59
Filling.............................................................................42 Bravo Two Models ................................................. 60
Changing.......................................................................43 Bravo Three Models .............................................. 60
Sterndrive Water Passages.................................................. 43 Bravo Diesel Sterndrive Propeller Installation............... 62
Sterndrive Water Inlets Check....................................... 43 Bravo One Models ................................................. 62
Sterndrive Water Drain Check....................................... 43 Bravo Two Models ................................................. 63
Flushing the Sterndrive.................................................. 43 Bravo Three ........................................................... 64
Corrosion Protection............................................................. 46
CMD-4081986 / 90-866839060 MAY 2007 Page 31

Product Responsibilities
Owner and Operator Responsibilities
It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are
complied with for safe operation, and to return the unit to a Cummins MerCruiser Diesel Authorized Repair Facility for a periodic
checkup.
Normal maintenance service and replacement parts are the responsibility of the owner or operator and as such, are not considered
defects in workmanship or material within the terms of the warranty. Individual operating habits and usage contribute to the need
for maintenance service.
Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your
overall operating expenses at a minimum. See your Cummins MerCruiser Diesel Authorized Repair Facility for service aids.
Dealer Responsibilities
In general, a dealer's responsibilities to the customer include predelivery inspection and preparation such as:
• Make certain that the power package and other equipment are in proper operating condition before delivery.
• Make all necessary adjustments for maximum efficiency.
• Explain and demonstrate the operation of the power package and boat.
• Provide you with a copy of a Predelivery Inspection Checklist.
• Fill out the Warranty Registration Card completely and mail it to the factory immediately upon sale of the new product. All
power packages must be registered for warranty purposes.
Do‑It‑Yourself Maintenance Suggestions

Present day marine equipment, such as your Cummins MerCruiser Dieael power package, are highly technical pieces of
machinery. Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for
the untrained mechanic.
If you like to do it yourself, here are some suggestions for you.
• Do not attempt any repairs unless you are aware of the cautions, warnings, and procedures required. Your safety is our
concern.
• If you attempt to service the product yourself, we suggest you order the service manual for that model. The service manual
outlines the correct procedures to follow. It is written for the trained mechanic, so there may be procedures you don't
understand. Do not attempt repairs if you do not understand the procedures.
• There are special tools and equipment that are required to perform some repairs. Do not attempt these repairs unless you
have these special tools or equipment. You can cause damage to the product in excess of the cost a dealer would charge
you.
• Also, if you partially disassemble an engine or drive assembly and are unable to repair it, the dealer's mechanic must
reassemble the components and test to determine the problem. This will cost you more than taking it to the dealer immediately
upon having a problem. It may be a very simple adjustment to correct the problem.
• Do not telephone the dealer, service office, or the factory to attempt for them to diagnose a problem or to request the repair
procedure. It is difficult for them to diagnose a problem over the telephone.
Your Authorized Cummins MerCruiser Diesel repair facility is there to service your power package. They have qualified factory
trained mechanics.
It is recommended you have the local Authorized Cummins MerCruiser Diesel repair facility do periodic maintenance checks on
your power package. Have them winterize it in the fall and service it before the boating season. This will reduce the possibility of
any problems occurring during your boating season when you want trouble free boating pleasure.
Inspection
Inspect your power package often and at regular intervals to help maintain its top operating performance and correct potential
problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.
• Check for loose, damaged, or missing parts, hoses, and clamps; tighten or replace as necessary.
• Check electrical connections and leads for damage.
• Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your Authorized Cummins MerCruiser Diesel
repair facility.
Page 32 CMD-4081986 / 90-866839060 MAY 2007

• Repair nicks and corrosion damage on the power package exterior finish. Contact your Authorized Cummins MerCruiser
Diesel repair facility.
a
Bravo One X Diesel Shown
a - Transom assembly
b - Sterndrive
b c - Anode plate
d - Propeller
e - Speedometer pitot tube
f - MerCathode electrode
g - Power trim cylinder
f
g
e c
d
19927
Maintenance Intervals
Maintenance intervals and the corresponding tasks to be performed are based on an average boating application and environment.
However, individual operating habits and personal preferences can have an impact on the suggested intervals. We have adjusted
some maintenance intervals and their corresponding tasks to allow for these differences. In some cases these changes allow for
more individual tasks in a single visit to the servicing dealer. Therefore, it is very important that the boat owner and the servicing
dealer discuss the current maintenance schedule and develop appropriate maintenance intervals to coincide with individual
operating habits, the environment, and maintenance preferences.
! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death
due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery
before maintaining, servicing, installing, or removing engine or drive components.
Maintenance Schedule
NOTE: Perform only the maintenance tasks that apply to your power package.
Routine Maintenance
Task Interval Maintenance Tasks
• Check the sterndrive propeller blades for damage.
• Check the tie bar fasteners (dual engine installations) for proper tightness.
• Check the sterndrive gear lube level.
Before each • Check the trim pump oil level.
use
• Check the power‑assisted steering pump fluid level, if equipped.
• Check the steering system for binding or loose components.
• Check the hydraulic steering fittings and hoses for leaks or signs of damage.
• If operating in saltwater, brackish water, or polluted water, flush the sterndrive after each use if it is
After each use removed from the water.
CMD-4081986 / 90-866839060 MAY 2007 Page 33


• Check the water inlets for debris or marine growth.
Weekly • Inspect the sterndrive anodes and replace if 50% eroded.
Every two • Lubricate the propeller shaft and retorque the nut. If operating in freshwater only, this interval may be
months extended to every four months.
Scheduled Maintenance
• Touch up the paint on the power package.
• Change the sterndrive gear lube.
• Retorque the gimbal ring U‑bolt nuts.
• Retorque the rear engine mount bolts.
Every 100 hours or • Models with driveshaft extensions: lubricate the driveshaft U‑joints and the tailstock input and output
annually bearings.
(whichever occurs
first) • Check the steering system and the remote control for loose, missing, or damaged parts. Lubricate
the cables and the linkages.
• Check the continuity circuit for loose or damaged connections. If equipped with a MerCathode unit,
test the output.
• If equipped with electro‑hydraulic power steering, check the fluid level.
• Check the engine alignment.

Every 200 hours or 3 • Inspect the U‑joints, the splines, the bellows, and check the clamps.
years • Lubricate the U‑joint splines and cross bearing.
(whichever occurs
first) • Lubricate the gimbal bearing and the engine coupler. Lubricate the engine coupler every 50 hours
if operated at idle for prolonged periods or if used in heavy boat applications.
Page 34 CMD-4081986 / 90-866839060 MAY 2007

Maintenance Log
Record all maintenance performed on your power package here. Save all work orders and receipts.
Date Maintenance Performed Engine Hours
CMD-4081986 / 90-866839060 MAY 2007 Page 35

Sterndrive Gear Lube

NOTICE
Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant,
or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal
or recycling of waste, and contain and dispose of fluids as required.
Checking
NOTE: The gear lube level will fluctuate during operation. The gear lube level should be checked with the engine cold, before
starting.
1. Check the gear lube monitor to determine the gear lube level. Keep the gear lube level within the recommended operating
range. See Filling.
Gear lube level shown is at the correct operating range

a - "ADD" mark
b b - "OPERATING RANGE" mark
19948
IMPORTANT: If any water is visible at the bottom of the gear lube monitor or appears at the fill and drain plug hole, or if the
gear lube appears discolored, contact your Cummins MerCruiser Diesel Authorized Repair Facility immediately. Both
conditions may indicate a water leak in the sterndrive.
Filling
IMPORTANT: If more than 59 ml (2 fl. oz.) of High Performance Gear Lube is required to fill the gear lube monitor, a seal may be
leaking. Damage to the sterndrive may occur due to lack of lubrication. Contact your Cummins MerCruiser Diesel Authorized
Repair Facility .
1. Remove the gear lube monitor cap.
2. Fill the gear lube monitor with the specified gear lube so that the gear lube level is in the operating range. Do not overfill.
c Gear lube monitor

a - Gear lube level at the "ADD" mark
b b - Gear lube level at the "OPERATING RANGE" mark
c - Gear lube monitor cap
19947
Tube Ref No. Description Where Used Part No.

87 Gear lube monitor 92-858064K01
Lube
Page 36 CMD-4081986 / 90-866839060 MAY 2007

3. Ensure that the rubber gasket is inside the gear lube monitor cap and install the cap. Do not overtighten.
a
a - Gear lube monitor cap
19962
NOTE: When filling the entire sterndrive, see Changing.
Changing
1. Remove the gear lube monitor from the bracket.
a a - Gear lube monitor bracket

b - Gear lube monitor and cap
b
c - Retaining strap
5500
2. Empty the contents of the gear lube monitor into a suitable container.
3. Install the gear lube monitor in the bracket.
4. Remove the propeller. See Propellers.
5. Bravo One Models:
a. Lower the sterndrive to the full down (in) position.
b. Remove the gear lube fill and drain plug and sealing washer.
c. Drain the gear lube into a suitable container
a - Fill and drain plug

b - Sealing washer
mc79506-1
b
6. Bravo Two models and Bravo Three models:
a. Place the sterndrive in full trim limit out (up) position.
b. Remove the fill and drain plug and sealing washer.
CMD-4081986 / 90-866839060 MAY 2007 Page 37

c. Drain the gear lube into a suitable container.
b b
a a
14621 19777
Bravo Two Bravo Three

b - Sealing washer
7. Remove the vent plug and sealing washer. Allow the gear lube to drain completely.
a - Vent plug
b - Sealing washer
a b
19066
IMPORTANT: If any water drains from the fill and drain plug hole, or if the gear lube appears milky, the sterndrive is leaking
and should be checked immediately by your Cummins MerCruiser Diesel Authorized Repair Facility.
8. Lower the sterndrive so that the propeller shaft is level.
9. Fill the sterndrive through the fill and drain plug hole with the specified gear lube until an air‑free stream of lube flows from
the vent plug hole.

87 Sterndrive unit 92-858064K01
Lube
IMPORTANT: Use only Mercury/Quicksilver High Performance Gear Lube in the sterndrive.
10. Install the vent plug and sealing washer.
11. Continue to pump gear lube into the drive through the fill and drain plug hole until the gear lube appears in the gear lube
monitor.
Page 38 CMD-4081986 / 90-866839060 MAY 2007

12. Fill the gear lube monitor so that the gear lube level is in the operating range. Do not overfill.
c Gear lube monitor

a - Gear lube level at the "ADD" mark
b b - Gear lube level at the "OPERATING RANGE" mark
c - Gear lube monitor cap
19947
Fluid Capacity includes the

Sterndrive Model Sterndrive and the Gear Fluid Type Fluid Part Number
lube Monitor
Bravo One X Diesel
2736 ml (92‑1/2 oz.)
Bravo One XR
Bravo Two X Diesel 3209 ml (108‑1/2 oz.) 92‑802854A1
Lube
2972 ml (100‑1/2 oz.)
Bravo Three XR
13. Ensure that the rubber gasket is inside the gear lube monitor cap and install. Do not overtighten.
a
a - Gear lube monitor cap
19962
14. Remove the pump from the sterndrive fill and drain plug hole.
CMD-4081986 / 90-866839060 MAY 2007 Page 39

15. Quickly install the sealing washer and the fill and drain plug. Torque to the following specifications.
b
a
mc79506-1
b 14621
All Bravo Models Shown

b - Sealing washer
b
a
19777

Fill and drain plug 6.8 60
16. Install the sterndrive propeller. See Propellers.
17. Recheck the gear lube level at the gear lube monitor after the first use. See Checking.
IMPORTANT: The gear lube level in the gear lube monitor will rise and fall during sterndrive operation; always check the gear
lube level when the sterndrive is cool and 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. Place the sterndrive in full down (in) position.
Page 40 CMD-4081986 / 90-866839060 MAY 2007

2. Observe the fluid level. The fluid level must be between the "MIN" and "MAX" lines on the reservoir.
a b
7876
a - Reservoir
b - "MIN" and "MAX" lines
3. Fill as necessary with the specified fluid. See Filling.

Power Trim and Steering
114 Power trim pump 92-858074K01
Fluid
Filling
1. If the fluid level is below the "MIN" line, the specified fluid must be added.
2. Remove the fill cap from the reservoir.
NOTE: The fill cap is vented.
a b Power trim pump reservoir shows

the fluid level is below "MIN" line
a - Fill cap assembly
b - Fill cap installed
7701
CMD-4081986 / 90-866839060 MAY 2007 Page 41

3. Add the specified fluid to bring the fluid level to within the "MIN" and "MAX" lines on the reservoir.
a b
7876
a - Reservoir
b - "MIN" and "MAX" lines

Power Trim and Steering
114 Power trim pump 92-858074K01
Fluid
4. Install the fill cap.
Changing
Power trim fluid does not require changing unless it becomes contaminated with water or debris. Contact your Cummins MerCruiser
Diesel Authorized Repair Facility.
Power‑Assisted Steering Fluid (If Equipped)

Refer to the OEM for information on checking, filling, and changing the power‑assisted steering fluid.
Electro‑Hydraulic Power‑Assisted Steering System (If Equipped)

IMPORTANT: Running the pump dry will damage the pump. Always check steering fluid levels before operating the boat.
Checking
1. Remove the cover and the fill cap to check the fluid level.
2. The fluid level should be slightly below the bottom of the fill opening.
b
a - Cover
a b - Fill cap
c c - Fill level (below the bottom of the fill opening)
29315
3. If the fluid level is low, add the specified fluid. See Filling.
4. Install the cover.
Filling
1. Remove the fill cap
2. Add the specified fluid to bring the fluid level slightly below the bottom of the fill opening.
Page 42 CMD-4081986 / 90-866839060 MAY 2007


Synthetic Power Steering
138 Power-assisted steering system 92-858076K01
Fluid SAE 10W-30
3. Install the fill cap.
4. Install the cover.
Changing
Power‑assisted steering fluid does not require changing unless it becomes contaminated. See your Cummins MerCruiser Diesel
Authorized Repair Facility.
Sterndrive Water Passages

Sterndrive Water Inlets Check
1. Obtain a piece of wire the appropriate size to insert into the water inlets holes.
2. Insert the wire in and out of the sterndrive water inlets to ensure that they are open and to remove debris or marine growth.
Do not scrape the sterndrive paint.
3. Remove the wire from the sterndrive and retain for periodic water inlet checks.
a - Dual water pickup water inlets

b - Side pickup water inlets
a b
22495
Sterndrive Water Drain Check

1. Obtain a piece of wire the approprite size to insert into the water drain holes.
2. Insert the wire in and out of the sterndrive water drain holes to ensure that they are open and to remove debris or marine
growth. Do not scrape the sterndrive paint.
3. Remove the wire from the sterndrive and retain for periodic water drain checks.
Sterndrive water drain holes

a - Speedometer pitot tube
b - Anode cavity vent hole
c - Anode cavity drain passage
b d - Gear housing water drain hole (1 each ‑ port
and starboard)
d c e - Gear housing cavity vent hole (Bravo II only)
e a
14627
Flushing the Sterndrive

IMPORTANT: This service should be preformed by a Cummins MerCruiser Diesel Authorized Repair Facility. Damage caused by
incorrectly flushing the sterndrive is not covered by the Cummins MerCruiser Diesel Limited Warranty.
NOTE: Refer to the engine OEM operation, maintenance and warranty manual for operating specifications, fluid capacities, and
flushing instructions.
CMD-4081986 / 90-866839060 MAY 2007 Page 43

NOTE: Flushing the sterndrive if it has been operated in salty, brackish, mineral‑laden or polluted water. For best results flush
after each outing and before cold weather storage and extended storage.
If you plan to perform this procedure, seek guidance from a Cummins MerCruiser Diesel Authorized Repair Facility.
This procedure requires sufficient water supply to the engine and sterndrive.
1. Flush the sterndrive with the boat out of water.
2. Lower the sterndrive to the full down (in) position. Do not allow the sterndrive skeg to contact the ground.
! WARNING
Rotating propellers can cause serious injury or death. Never operate the boat out of the water with a propeller installed. Before
installing or removing a propeller, place the drive unit in neutral and engage the lanyard stop switch to prevent the engine from
starting. Place a block of wood between the propeller blade and the anti‑ventilation plate.
3. Remove the propeller. See Propellers.
4. Connect a flushing hose to the water source.
5. On models with dual water pickups:
a. Install the dual water pickup flush gearcase seal kit.
b. Install the flushing device.
c. Attach the flushing hose to the flushing device.
a
Flushing attachments for the sterndrive with dual water pickup
a - Flushing device
b - Hose attachment
c - Dual water pickup flush gearcase seal kit
b
c
21514
Dual Water Pick‑up Flush Gearcase Seal Kit 91‑881150K 1
Blocks off the front water inlet holes on the dual water inlet gearcases.
9194
Flushing Device 91‑44357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing
the cooling system or operating the engine.
9192
6. On Models with side water pickups:
a. Install the flushing device.
Page 44 CMD-4081986 / 90-866839060 MAY 2007

b. Attach the flushing hose to the flushing device.
a
Flushing attachment for the sterndrive with side water pickups
a - Flushing device
b - Hose attachment
21515
Flushing Device 91‑44357Q 2
Attaches to the water intakes; provides a fresh water connection when flushing
the cooling system or operating the engine.
9192
NOTICE
Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide
a sufficient supply of water to the water inlets during operation.
IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal housing and using a through‑hull or
through‑transom water inlet need a supply of cooling water available to both the sterndrive and to the engine during operation.
IMPORTANT: Prevent air from entering the water chamber of the engine. If applicable, block additional seawater inlets or
engine seawater openings that are not needed to cool the engine while flushing the sterndrive. Refer to the appropriate engine
service manual.
7. Place remote control handle in neutral.
8. Partially open the water source to about 1/2 maximum. Do not use full water pressure.
NOTICE
Operating the engine out of the water at high speeds creates suction, which can collapse the water supply hose and overheat
the engine. Do not operate the engine above 1400 RPM out of the water and without sufficient cooling water supply.
9. Start the engine.
10. Provide a sufficient supply of water to the sterndrive water inlet holes and the through‑hull water inlet holes.
11. Observe the water temperature gauge to ensure that the engine is operating in the normal range.
12. Operate the engine at idle speed in neutral for about ten minutes or until the discharge water is clear.
13. Stop the engine.
14. Shut off the supply water and remove the flushing attachment.
15. Install the propeller. See Propellers.
16. Prepare the engine and sterndrive for normal operation.
CMD-4081986 / 90-866839060 MAY 2007 Page 45

Corrosion Protection
General Information
Whenever two or more dissimilar metals (such as those found on this power package) are submerged in a conductive solution
such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current
to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This erosion
is known as galvanic corrosion and, if it is not controlled, it will eventually cause the need for replacement of power package
components exposed to water.
To help control the effects of galvanic corrosion, Cummins MerCruiser Diesel power packages come with several sacrificial anodes
and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the
Marine Corrosion Protection Guide (90‑88181301).
IMPORTANT: Replace sacrificial anodes if eroded 50% or more. Cummins MerCruiser Diesel strongly recommends avoiding the
use of anodes from another manufacturer. Refer to your Cummins MerCruiser Diesel Authorized Repair Facility for additional
information.
Sterndrive Corrosion Protection Components

To help control the effects of galvanic corrosion, Cummins MerCruiser Diesel sterndrives come with several sacrificial anodes and
other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection, refer to the
Marine Corrosion Protection Guide (90‑88181301).
1- Gearcase anodic plate

2- Anode plate
3- MerCathode System
4- Anode kit
5- Trim cylinder anodes
6- Bearing carrier anodes
2 7- Propeller shaft Anode (Bravo III standard)
5
1
4 3 6
7 20337
NOTICE
Washing the MerCathode assembly can damage components and lead to rapid corrosion. Do not use any cleaning equipment
such as brushes or high‑pressure washers to clean the MerCathode assembly.
Do not pressure‑wash the MerCathode assembly. Doing so will damage the coating on the reference electrode wire and decrease
the corrosion protection.
c a MerCathode mounted to the underside of

the gimbal housing
a - MerCathode reference electrode
b - Do not paint
c - Do not pressure wash
b
6211
Page 46 CMD-4081986 / 90-866839060 MAY 2007

Anodes and MerCathode System Locations

IMPORTANT: Replace sacrificial anodes if eroded 50 percent or more.
The sacrificial anodes in the following table are installed at different locations on your power package. These anodes help protect
against galvanic corrosion by sacrificing their metal to be slowly eroded instead of the metal components on the power package.
MerCathode System. The electrode assembly replaces the anode block. The system should be tested to ensure adequate output.
Perform the test when the boat is moored using a Quicksilver Reference Electrode and Test Meter. Contact your Cummins
MerCruiser Diesel Authorized Repair Facility.
Anodes and MerCathode System Locations

Description Location Figure
Mounted on the underside of the lower

Gearcase anode plate
gearcase.
20336
Ventilation plate anode Mounted on the front of the gearcase.

20338
The MerCathode electrode is mounted

to the underside of the gimbal housing.
The MerCathode controller is mounted
MerCathode System
on the engine or on the boat transom.
The controller harness connects to the
electrode harness. 20340
Anode kit (if equipped) Mounted to the boat transom.
20341
Trim cylinder anodes Mounted on each of the trim cylinders.
20342
Located in front of the propeller,

Bearing carrier anode (Bravo One) between the front side of the propeller
and the gear housing.
20343
Propeller shaft anode (Bravo Three) Located behind the aft propeller.
20344
CMD-4081986 / 90-866839060 MAY 2007 Page 47

In addition to the corrosion protection devices, take the following steps to inhibit corrosion:
1. Paint the power package. See Painting Your Power Package.
2. Annually spray the power package components on the inside of the boat with Corrosion Guard to protect the finish from dulling
and corrosion. You may also spray external power package components.
3. Keep all lubrication points, especially the steering system, shift, and throttle linkages, well lubricated.
4. Flush the cooling system periodically, preferably after each use.
Continuity Circuit—Bravo Sterndrive

The transom assembly and sterndrive have ground‑circuit wires to ensure good electrical continuity between the engine, transom
assembly, and sterndrive components. Good continuity to a ground is essential for the anode and MerCathode system to function
effectively.
1. Inspect the steering lever ground wire for loose connections, broken connectors, or frayed wiring.
2. Inspect the inner transom plate ground wire for loose connections, broken connectors, or frayed wiring.
a
a
27282
27283
Steering lever continuity wire Transom plate continuity wires

a - Continuity wire
3. Inspect the flywheel housing grounding stud and ground wire, and the inner transom plate grounding screw for loose
connections, broken connectors, or frayed wiring.
Typical
a - Flywheel housing screw or grounding stud
b - Continuity circuit (ground) wire
c c - Inner transom plate grounding screw
a
b
7782
Page 48 CMD-4081986 / 90-866839060 MAY 2007

4. Inspect the driveshaft housing–to–gear housing ground plate inside the anode cavity for a loose or faulty connection.
Sterndrive anodic plate cavity

a a - Ground plate (inside anode cavity)
27285
5. Inspect the gimbal housing ground wires for loose connections, broken connectors, or frayed wiring.
a - Gimbal housing–to–gimbal ring ground wire

b - Gimbal housing–to–trim cylinder ground wires
b
7006
6. Inspect the gimbal ring ground wire for loose connections, broken connectors, or frayed wiring.
a - Gimbal ring‑to‑bell housing ground wire
27263
CMD-4081986 / 90-866839060 MAY 2007 Page 49

7. Inspect the sterndrive ground plate for loose or broken connections.
a - Sterndrive‑to‑bell housing ground plate
27264
8. Inspect the continuity washers under the hydraulic manifold block fasteners for a loose or faulty connection .
a - Continuity washers
a
9957
9. Inspect the sterndrive U‑joint bellows ground clips and exhaust tube ground clip for loose or faulty connections.
a
Exhaust tube ground clip shown, U-joint bellows ground clips similar
a - Exhaust tube ground clip
19627
MerCathode
If the boat is equipped with a Quicksilver MerCathode system, the system should be tested to ensure that it is providing adequate
output to protect the underwater metal parts on the boat. The test should be made where the boat is moored, using a Quicksilver
Reference Electrode and Test Meter.
Reference Electrode 91‑76675T 1
Senses and electrical current in the water when testing the MerCathode system.
Use to check hull potential.
9188
Refer to the appropriate Mercury MerCruiser Sterndrive Service Manual for testing procedures.
Page 50 CMD-4081986 / 90-866839060 MAY 2007

Boat Bottom Care

To achieve maximum performance and fuel economy, the boat bottom must be kept clean. Accumulation of marine growth or
other foreign matter can greatly reduce boat speed and increase fuel consumption. To ensure best performance and efficiency,
periodically clean the boat bottom in accordance with manufacturer's recommendations.
In some areas, it may be advisable to paint the bottom to help prevent marine growth. Refer to the following information for special
notes about the use of anti‑fouling paints.
Painting Your Power Package

IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint will not be covered by the limited
warranty.
1. Painting the boat hull or transom: you may apply anti‑fouling paint to the boat hull and transom. However, observe the
following:
IMPORTANT: Do not paint anodes or MerCathode System reference electrode and anode. Paint will render them ineffective
as inhibitors of galvanic corrosion.
IMPORTANT: If anti‑fouling protection is required for the boat hull or transom, you can use copper‑based or tin‑based paints
where not prohibited by law. If using copper‑based or tin‑based anti‑fouling paints, observe the following:
• Avoid any electrical interconnection between the paint and the Mercury MerCruiser product, anodic blocks, or
MerCathode system by allowing a minimum of 40 mm (1‑1/2 in.) unpainted area on the transom of the boat around these
items.
a - Painted boat transom

b - Unpainted Area on Transom
b
5578
2. Painting the sterndrive unit or transom assembly: The sterndrive unit and transom assembly should be painted with a
good‑quality marine paint or an anti‑fouling paint that does not contain copper, tin, or any other material that could conduct
electrical current. Do not paint drain holes, anodes, MerCathode system, or items specified by the boat manufacturer.
CMD-4081986 / 90-866839060 MAY 2007 Page 51

Sterndrive Surface Care

c
Standard Bravo sterndrive
a - Sacrificial trim cylinder anode
d b - Sacrificial anodic plate
c - Steering lever ground wire
a d - Ground wire between the gimbal ring and bell housing
e - Stainless steel hoses
e f - Ground wire between the gimbal housing and trim cylinder
g - Ground wire between the gimbal ring and gimbal housing
f
g
b
21083
We recommend the following maintenance items to help keep your sterndrive corrosion‑free:
• Maintain a complete paint covering on the sterndrive.
• Check the finish regularly. Prime and paint nicks and scratches using Mercury enamel paint and touch up paint. Use only tin–
based anti–fouling paint or its equivalent on or near aluminum surfaces below the waterline.
• If bare metal is showing, apply 2 coats paint.
Description Where used Part number

Mercury Phantom Black Bare metal 92‑ 802878‑1
• Spray all electrical connections with sealant.

25 Liquid Neoprene All electrical connections 92- 25711 3
• Inspect the sacrificial trim tab or anode plate if equipped, at regular intervals and replace it before it is half gone. If a stainless
steel propeller is installed, additional anodes or a MerCathode System will be required.
• Inspect the propeller shaft for fishing line, which can cause corrosion on a stainless steel shaft.
• Remove the propeller at least every 60 days and lubricate the propeller shaft.
• Do not use lubricants containing graphite on or near the aluminum in saltwater.
• Do not paint trim tabs or the mounting surface.
Lubrication
Steering System
! WARNING
Incorrect cable lubrication can cause hydraulic lock, leading to serious injury or death from loss of boat control. Completely
retract the end of the steering cable before applying lubricant.
NOTE: If the steering cable does not have a grease fitting, the inner wire of the cable cannot be greased.
1. If the steering cable has grease fittings, turn the steering wheel until the steering cable is fully retracted into the cable
housing.
Page 52 CMD-4081986 / 90-866839060 MAY 2007

2. Apply approximately three pumps of grease from a typical hand‑operated grease gun.
a - Steering cable grease fitting
6221

34 Special Lubricant 101 Steering cable grease fitting 92-802865Q02
3. Turn the steering wheel until the steering cable is fully extended.
4. Lightly lubricate the exposed part of the cable.
a - Extended steering cable

a
6222

34 Special Lubricant 101 Steering cable 92-802865Q02
5. Lubricate the steering pin.
a - Steering pin
mc71904-1

80 SAE Engine Oil 30W Steering pin Obtain Locally
6. On dual engine boats, lubricate the tie bar pivot points.
CMD-4081986 / 90-866839060 MAY 2007 Page 53


80 SAE Engine Oil 30W Tie bar pivot points Obtain Locally
7. Upon first starting the engine, turn the steering wheel several times to starboard and then port to ensure that the steering
system operates properly before getting underway.
Shift Cable
1. Lubricate the pivot points and guide contact surfaces.
a
a
20261
Typical sterndrive model shift cable

a - Pivot points
b - Guide contact surface

80 SAE Engine Oil 30W Shift cable pivot points and guide contact surfaces Obtain Locally
Transom Assembly
1. Lubricate the gimbal bearing by applying approximately 8‑10 pumps of grease from a typical hand‑operated grease gun.
a - Gimbal bearing grease insert
19979

U-joint and Gimbal
42 Gimbal bearing grease insert 92-802870A1
Bearing Grease
Propeller Shaft
NOTE: See Propeller Removal.
Page 54 CMD-4081986 / 90-866839060 MAY 2007

1. Liberally coat the propeller shaft with one of the following lubricants.
a
a
20335
a - Propeller shaft

34 Special Lubricant 101 Propeller shaft 92-802865Q02
94 Anti-Corrosion Grease Propeller shaft 92-802867Q 1
2-4-C Marine Lubricant

95 Propeller shaft 92-802859A 1
with Teflon
NOTE: Anti‑corrosion grease is for saltwater applications only.
Engine Coupler
1. Lubricate engine coupler splines through grease fittings on coupler by applying approximately 8‑10 pumps of grease from a
typical hand‑operated grease gun.
NOTE: If equipped with a sealed engine coupler, the sealed coupler and shaft splines can be lubricated without removing the
sterndrive. Apply lubricant from a typical hand‑operated grease gun.
NOTE: If the boat is operated at idle for prolonged periods of time or if used in heavy boat applications, Bravo model aluminum
coupler should be lubricated every 50 hours.
a a
14535
Sealed steel coupler Steel coupler

a - Engine coupler grease fitting

Engine Coupler Spline
91 Coupler 92-802869A 1
Grease
CMD-4081986 / 90-866839060 MAY 2007 Page 55

Driveshaft Extension Models

1. Lubricate the transom end grease fitting and engine end grease fitting by applying approximately 10 ‑ 12 pumps of grease
from a typical hand‑operated grease gun.
2. Lubricate the driveshaft grease fittings by applying approximately 3 ‑ 4 pumps of grease from a typical hand‑operated grease
gun.
a a 17014
a - Driveshaft grease fittings

b - Transom end grease fitting
c - Engine end grease fitting

U-joint and Gimbal Transom end grease fitting, engine end grease fitting,
42 92-802870A1
Bearing Grease driveshaft grease fittings
Sterndrive, Bellows, and Engine Alignment

NOTE: Have your Cummins MerCruiser Diesel Authorized Repair Facility perform the maintenance procedures listed, or refer to
the appropriate Mercury MerCruiser Bravo Sterndrive Service Manual.
1. Lubricate the U‑joint shaft splines and the O‑rings.
a - U‑joint shaft splines

b b - U‑joint shaft O‑rings
19867

Engine Coupler Spline
91 U-joint shaft splines and O-rings 92-802869A 1
Grease
2. Inspect the U‑joint bellows for cracks or other signs of deterioration. Ensure that the bellows clamps are tight.
Page 56 CMD-4081986 / 90-866839060 MAY 2007

3. Rotate the bell housing in the upward and side‑to‑side directions to inspect the exhaust tube, shift cable bellows, and clamps.
e
a- U‑joint bellow
b- Exhaust tube
c- Bell housing
a d- Gimbal ring
c e- Gimbal housing
f- Shift cable bellows
f
b
d 22189
4. Check the engine alignment.
d
b c
a
7936
a- Alignment tool
b- End of alignment tool to insert through gimbal housing assembly
c- Gimbal bearing
d- Engine coupler
Maintaining Torques
Gimbal Ring U‑bolt Nuts
NOTE: The gimbal ring is a component of the transom assembly.
CMD-4081986 / 90-866839060 MAY 2007 Page 57

1. Torque the gimbal ring U‑bolt nuts.
a - Transom assembly
b - Gimbal ring U‑bolt nuts
b
a
19624

Gimbal ring U‑bolt nuts for 3/8 in. U‑bolt 72 53
Gimbal ring U‑bolt nuts for 7/16 in. U‑bolt 95 70
Rear Engine Mount Torque

NOTE: Not required on some engine models. Refer to the engine manufacturer for engine mount torque maintenance.
1. Torque the engine mount bolts at the transom plate mount.

Rear engine mount bolt 47 35
Propeller
Bravo Diesel Sterndrive Propeller Removal
! WARNING
! WARNING
Page 58 CMD-4081986 / 90-866839060 MAY 2007

Bravo One Models

1. Straighten the bent tabs of the tab washer on the propeller shaft.
a b c
a- Prop
b- Tab washer
d c- Drive sleeve adapter
d- Tab bent down
e- Propeller nut
e
4750
2. Place a block of wood between the propeller blade and the sterndrive's anti‑ventilation plate.
a - Wood block
b - Propeller
c - Propeller nut under socket
a
b
4826
3. Turn the propeller shaft nut counterclockwise and remove the nut.
4. Slide the propeller and the attaching hardware from the propeller shaft.
d Bravo One models

a - Propeller shaft splines
b - Forward thrust hub
c - Flo‑Torque II drive hub
e d - Propeller
f
a e - Drive sleeve adapter
b f - Tab washer
c g - Propeller nut
g 5301
CMD-4081986 / 90-866839060 MAY 2007 Page 59

Bravo Two Models

1. Straighten the bent tabs of the tab washer on the propeller shaft.
a b c
a- Prop
b- Tab washer
d- Tab bent down
e- Propeller nut
e
4750
a - Wood block
b - Propeller
a
b
4826
3. Turn the propeller shaft nut counterclockwise to remove the nut.

4. Slide the propeller and attaching hardware from the propeller shaft.
c Bravo Two
d b - Forward thrust hub
f c - Propeller
a d - Spline washer
e - Tab washer
b f - Propeller nut
8566
e
Bravo Three Models
2. Remove the bolt and washers securing the propeller shaft anode.
Page 60 CMD-4081986 / 90-866839060 MAY 2007

3. Remove the propeller shaft anode.
a- Propeller
b- Propeller shaft nut
c- Propeller shaft anode
d- Propeller shaft anode screw
e- Flat washer
a f- Star washer
b
c
d
f
e 19058
4. Turn the aft propeller shaft nut counterclockwise to remove the nut.
5. Slide the propeller and thrust hub off of the propeller shaft.
6. Using the Propeller Nut Tool, turn the front propeller shaft nut counterclockwise and remove the nut.
Propeller Nut Tool 91‑805457T 1
Aids in the removal and installation of the front propeller nut.
10677
7. Slide the propeller and the thrust hub off the propeller shaft.
e Bravo Three
a - Aft propeller nut
f b - Aft propeller
b c - Aft propeller thrust hub
d d - Front propeller nut
c
e - Front propeller
a f - Front propeller thrust hub
i g - Propeller shaft anode screw
j h - Flat washer
g h i - Star washer
j - Propeller shaft anode
5304
CMD-4081986 / 90-866839060 MAY 2007 Page 61

Bravo Diesel Sterndrive Propeller Installation

! WARNING
! WARNING
a - Wood block
b - Propeller
a
b
4826
Bravo One Models

IMPORTANT: Use a propeller with the correct rotation. The propeller rotation must match the direction of rotation of the propeller
shaft.
1. Liberally coat the propeller shaft spline with one of the following Quicksilver lubricants.

34 Special Lubricant 101 Propeller shaft splines 92-802865Q02
94 Anti-Corrosion Grease Propeller shaft splines 92-802867Q 1

95 Propeller shaft splines 92-802859A 1
with Teflon

2. Install the propeller with the attaching hardware as shown.
3. Torque the propeller nut.
d Typical Bravo One model

b - Forward thrust hub
c - Flo‑Torque II drive hub
e d - Propeller
f
a e - Drive sleeve adapter
b f - Tab washer
c g - Propeller nut
g 5301
NOTE: The propeller torque stated is a minimum torque value.
Page 62 CMD-4081986 / 90-866839060 MAY 2007

Description Nm lb. ft.

75 55
Bravo One propeller nut Then align tabs with
grooves
4. Models equipped with the tab washer: Continue to tighten the propeller nut until the three tabs on the tab washer align with
the grooves on the spline washer.
5. Bend the three tabs down into the grooves.
a b c
a- Prop
b- Tab washer
d- Tab bent down
e- Propeller nut
e
4750
Bravo Two Models

IMPORTANT: Use a propeller with the correct rotation. The propeller rotation must match the direction of rotation of the propeller
shaft.


with Teflon

2. Install the propeller with the attaching hardware as shown.
3. Torque the propeller nut.
c Bravo Two
d b - Forward thrust hub
f c - Propeller
a d - Spline washer
e - Tab washer
b f - Propeller nut
8566
e
NOTE: The propeller torque stated is a minimum torque value.

81 60
Bravo Two propeller nut Then align tabs with
groves
CMD-4081986 / 90-866839060 MAY 2007 Page 63

4. Continue to tighten the propeller nut until the three tabs on the tab washer align with the grooves on the spline washer.
5. Bend the three tabs down into the grooves.
a b c
a- Prop
b- Tab washer
d- Tab bent down
e- Propeller nut
e
4750
Bravo Three


with Teflon

2. Slide the forward thrust hub onto the propeller shaft with the tapered side toward the propeller hub.
3. Align the splines and place the front propeller on the propeller shaft.
4. Install the front propeller locknut and torque using the Propeller Nut Tool.
Propeller Nut Tool 91‑805457T 1
For removal and installation of the front propeller nut.
10677

Bravo Three front propeller nut 136 100
5. Slide the rear thrust hub onto the propeller shaft with the tapered side toward the propeller hub.
6. Align the splines and install the rear propeller.
7. Install the propeller nut and torque.

Bravo Three rear propeller nut 81 60
Page 64 CMD-4081986 / 90-866839060 MAY 2007

8. Install the propeller shaft anode and screw and torque.
e Bravo Three
a - Rear propeller nut
f b - Rear propeller
b c - Rear propeller thrust hub
d d - Front propeller nut
c
e - Front propeller
a f - Front propeller thrust hub
i g - Propeller shaft anode screw
j h - Flat washer
g h i - Star washer
j - Propeller shaft anode
5304
Description Nm lb. in.

Propeller shaft anode screw 19 168
CMD-4081986 / 90-866839060 MAY 2007 Page 65

Notes:
Page 66 CMD-4081986 / 90-866839060 MAY 2007

Section 6 - Storage
Section 6 - Storage
Table of Contents
Preparing the Power Package For Storage.......................... 68 Power Package Recommissioning....................................... 68
Engine............................................................................ 68 Engine............................................................................ 68
Sterndrive Storage......................................................... 68 Sterndrive......................................................................68
CMD-4081986 / 90-866839060 MAY 2007 Page 67

Section 6 - Storage
Preparing the Power Package For Storage

Engine
Refer to the appropriate engine owners or service manual.
Sterndrive Storage
IMPORTANT: Cummins MerCruiser Diesel strongly recommends that this service is preformed by an Cummins MerCruiser Diesel
Authorized Repair Facility. Damage caused by freezing is not covered by the Cummins MerCruiser Diesel Limited Warranty.
1. Perform all procedures listed. See the Maintenance section for procedure instructions.
Sterndrive Gear Lube—Changing
Sterndrive Water Drain Check
Sterndrive Water Inlet Check
Steering System
Shift Cable
Transom Assembly
Propeller Shaft
Engine Coupler
Driveshaft Extension Models
Sterndrive, Bellows, and Engine Alignment
Gimbal Ring U‑Bolt Nuts
Rear Engine Mount (if applicable)
Flushing the Sterndrive
NOTICE
The universal joint bellows may develop a set when stored in a raised or up position, causing the bellows to fail when returned
to service and allowing water to enter the boat. Store the sterndrive in the full down position.
2. Store the sterndrive in the full down (in) position.
Power Package Recommissioning

Engine
Refer to the appropriate engine owners or service manual.
Sterndrive
1. Perform all annual maintenance specified in the Maintenance Schedule, except items that were performed at the time of
sterndrive layup.
2. Apply a thin coat of petroleum‑based grease to clamps and terminals to help retard corrosion.

25 Liquid Neoprene Clamps and terminals 92- 25711 3
3. After recommissioning and starting the engine, check the steering system and shift control for proper operation.
4. Check all fluid levels before and after first use.
Page 68 CMD-4081986 / 90-866839060 MAY 2007

Table of Contents
Remote Control Operates Hard, Binds, Has Excessive Power Trim does not Operate (Electric Motor Operates but
Free‑play, or Makes Unusual Sounds.................................. 70 Sterndrive does not Move)................................................... 70
Steering Wheel Turns Hard or Jerky.................................... 70 Troubleshooting the Electro‑Hydraulic Power Steering System
Power Trim Does Not Operate (Electric Motor Does Not for Sterndrive Models (If Equipped)...................................... 70
Operate)............................................................................... 70
CMD-4081986 / 90-866839060 MAY 2007 Page 69

Remote Control Operates Hard, Binds, Has Excessive Free‑play, or Makes

Unusual Sounds
Possible Cause Remedy
Insufficient lubrication on shift and throttle linkage
Lubricate.
fasteners.
Obstruction in the shift or throttle linkages. Remove the obstruction.
Check all throttle linkages. If any are loose or missing, see a Cummins
Loose or missing shift and throttle linkages.
MerCruiser Diesel Authorized Repair Facility immediately.
Straighten cable or have a Cummins MerCruiser Diesel Authorized Repair
Shift or throttle cable kinked.
Facility replace cable if damaged beyond repair.
Have adjustment checked by a Cummins MerCruiser Diesel Authorized
Improper shift cable adjustment.
Repair Facility.
Steering Wheel Turns Hard or Jerky

Low power steering pump fluid level. Check for leak. Refill the system with fluid.
Drive belt loose or in poor condition. Replace or adjust.
Insufficient lubrication on the steering components. Lubricate.
Check all parts and fasteners; if any are loose or missing, see a Cummins
Loose or missing steering fasteners or parts.
MerCruiser Diesel Authorized Repair Facility immediately.
Contaminated power steering fluid. See a Cummins MerCruiser Diesel Authorized Repair Facility.
Power Trim Does Not Operate (Electric Motor Does Not Operate)
Blown fuse. Replace the fuse.
Loose or dirty electrical connections or Check all the associated electrical connections and the wires (especially the battery
damaged wiring. cables). Clean and tighten the faulty connection. Repair or replace the wiring.
Power Trim does not Operate (Electric Motor Operates but Sterndrive does not
Move)
The trim pump oil level is low. Fill the trim pump with oil.
Check for obstruction. See a Cummins MerCruiser Diesel Authorized Repair
The drive unit is binding in the gimbal ring.
Facility.
Troubleshooting the Electro‑Hydraulic Power Steering System for Sterndrive

Models (If Equipped)
Problem Possible Cause Remedy
Power steering system operates (pump runs), Check the pressure and the tank hoses for correct
Hoses connections.
but the sterndrive does not steer. connections at the helm.
Power steering system operates (pump runs),
Bleed the power steering system. Contact your
but the sterndrive does not steer, steers slowly, Air in system.
Authorized Cummins MerCruiser Diesel repair facility
or is erratic. Hose connections are correct.
Page 70 CMD-4081986 / 90-866839060 MAY 2007

Problem Possible Cause Remedy

1. Check the fuse at the power steering pump positive
Power steering pump does not operate (pump lead at the battery positive connection. Replace if
Blown fuse. blown.
does not run).
2. Check the battery connection.
90-amp fuse for the electro-hydraulic power steering pump

a a a - Power steering pump positive lead
b - Fuse eyelet for the positive battery post
c - 90‑amp fuse
c
c
b 20516
CMD-4081986 / 90-866839060 MAY 2007 Page 71

Notes:
Page 72 CMD-4081986 / 90-866839060 MAY 2007


Table of Contents
Owner Service Assistance.................................................... 74 Muut kielet .................................................................... 75
Local Repair Service .................................................... 74 Autres langues .............................................................. 75
Service Away From Home ............................................ 74 Andere Sprachen .......................................................... 75
Stolen Power Package ................................................. 74 Altre lingue .................................................................... 75
Attention Required After Submersion ........................... 74 Andre språk .................................................................. 75
Replacement Service Parts .......................................... 74 Outros Idiomas ............................................................. 76
Parts and Accessories Inquiries ................................... 74 Otros idiomas ............................................................... 76
Resolving a Problem .................................................... 74 Andra språk .................................................................. 76
Customer Service Literature................................................. 75 Allej glþssej ................................................................... 76
English Language ......................................................... 75 Ordering Literature............................................................... 76
Other Languages .......................................................... 75 United States and Canada ........................................... 76
Andre sprog .................................................................. 75 Outside the United States and Canada ........................ 76
Andere talen ................................................................. 75
CMD-4081986 / 90-866839060 MAY 2007 Page 73

Owner Service Assistance

Local Repair Service
Always return your Cummins MerCruiser Diesel (CMD) powered boat to your authorized dealer should the need for service arise.
Only he has the factory trained mechanics, knowledge, special tools and equipment, and the genuine Quicksilver parts and
accessories to properly service your engine should the need occur. He knows your engine best. Contact 1‑800‑DIESELS to locate
your closest distributor.
Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest Cummins MerCruiser Diesel authorized
dealer. Refer to the Yellow Pages of the telephone directory or by using the service locator on the Cummins MerCruiser Diesel
website (www.cmdmarine.com). If, for any reason, you cannot obtain service, contact the nearest Regional Service Center.
Outside the United States and Canada, contact the nearest Marine Power International Service Center.
Stolen Power Package

If your power package is stolen, immediately advise the local authorities and Cummins MerCruiser Diesel of the model and serial
number(s) and to whom the recovery is to be reported. This information about the stolen motor is placed into a file at Cummins
MerCruiser Diesel to aid authorities and dealers and distributors in the recovery of stolen motors.
Attention Required After Submersion

1. Before recovery, contact an Cummins MerCruiser Diesel Authorized Repair Facility.
2. After recovery, immediate service by an Cummins MerCruiser Diesel Authorized Repair Facility is required to prevent serious
damage to power package.
Replacement Service Parts

! WARNING
Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Cummins MerCruiser Diesel products comply
with U.S. Coast Guard rules to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components
that do not comply with these rules. When servicing the electrical and fuel systems, properly install and tighten all components.
Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both fresh
and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine engine parts,
as specifications are quite different from those of the standard automotive engine.
Since marine engines must be capable of running at or near maximum RPM much of the time, special pistons, camshafts, and
other heavy‑duty moving parts are required for long life and peak performance.
These are but a few of the many special modifications that are required in Cummins MerCruiser Diesel marine engines to provide
long life and dependable performance.
Parts and Accessories Inquiries

All inquiries concerning Quicksilver replacement parts and accessories should be directed to your local authorized dealer. The
dealer has the necessary information to order parts and accessories for you if he does not have them in stock. Only authorized
dealers can purchase genuine Quicksilver parts and accessories from the factory. Cummins MerCruiser Diesel does not sell to
unauthorized dealers or retail customers. When inquiring on parts and accessories, the dealer requires the engine model and
serial numbers to order the correct parts.
Resolving a Problem
Satisfaction with your Cummins MerCruiser Diesel product is very important to your dealer and to us. If you ever have a problem,
question, or concern about your power package, contact your Cummins MerCruiser Diesel Authorized Repair Facility. If additional
assistance is required, take these steps:
1. Talk with the dealership’s sales manager or service manager. If this has already been done, then contact the owner of the
dealership.
2. If you have a question, concern, or problem that cannot be resolved by your dealership, please contact your local distributor
of Cummins MerCruiser Diesel products for assistance. The distributor will work with you and your dealership to resolve all
problems.
The service office will need the following information:
• Your name and address
• Daytime telephone number
Page 74 CMD-4081986 / 90-866839060 MAY 2007

• Model and serial numbers for your power package

• The name and address of your dealership
• The nature of the problem
To find the distributor for your area, use the service locator on the Cummins MerCruiser Diesel website (www.cmdmarine.com)
or contact CMD sales or service listed in the yellow pages of the telephone directory. Contact 1‑800‑DIESELS to locate your
closest distributor.
Customer Service Literature

English Language
English language publications are available from:
Mercury Marine
Attn: Publications Department
W6250 West Pioneer Road
P.O. Box 1939
Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for
further information.
When ordering be sure to:
• List your product, model, year and serial numbers.
• Check the literature and quantities you want.
• Enclose full remittance in check or money order (NO COD).
Other Languages
To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine
Power International Service Center for information. A list of part numbers for other languages is provided with your power package.
Andre sprog
Kontakt det nærmeste Mercury Marine eller Marine Power International servicecenter for oplysninger om hvordan du kan anskaffe
en Betjenings‑ og vedligeholdelsesmanual på et andet sprog. En liste med reservedelsnumre for andre sprog leveres sammen
med din power‑pakke.
Andere talen
Voor het verkrijgen van een Handleiding voor gebruik en onderhoud in andere talen dient u contact op te nemen met het
dichtstbijzijnde internationale servicecentrum van Mercury Marine of Marine Power voor informatie hierover. Een lijst met
onderdeelnummers voor andere talen wordt bij uw motorinstallatie geleverd.
Muut kielet
Saadaksesi Käyttö‑ ja huolto‑ohjekirjoja muilla kielillä, ota yhteys lähimpään Mercury Marine tai Marine Power International
huoltokeskukseen, josta saat lähempiä tietoja. Moottorisi mukana seuraa monikielinen varaosanumeroluettelo.
Autres langues
Pour obtenir un Manuel d'utilisation et d'entretien dans une autre langue, contactez le centre de service après‑vente international
Mercury Marine ou Marine Power le plus proche pour toute information. Une liste des numéros de pièces en d'autres langues
accompagne votre bloc‑moteur.
Andere Sprachen
Um eine Betriebs‑ und Wartungsanleitung in einer anderen Sprache zu erhalten, wenden Sie sich an das nächste Mercury Marine
oder Marine Power International Service Center. Eine Liste mit Teilenummern für Fremdsprachen ist im Lieferumfang Ihres Motors
enthalten.
Altre lingue
Per ottenere il manuale di funzionamento e manutenzione in altra lingua, contattate il centro assistenza internazionale Mercury
Marine o Marine Power più vicino. In dotazione con il gruppo motore, viene fornito l'elenco dei codici prodotto dei componenti
venduti all'estero.
Andre språk
Ytterligere informasjon om bruks‑ og vedlikeholdshåndbok på andre språk kan fås ved henvendelse til nærmeste internasjonale
servicecenter for Mercury Marine eller Marine Power. En liste over delenumre for andre språk følger med aggregatet.
CMD-4081986 / 90-866839060 MAY 2007 Page 75

Outros Idiomas
Para obter um Manual de Operação e Manutenção em outro idioma, contate o Centro de Serviço Internacional de Marine Power"
(Potência Marinha) ou a Mercury Marine mais próxima para obter informações. Uma lista de números de referência para outros
idiomas é fornecida com o seu pacote de propulsão.
Otros idiomas
Para obtener un Manual de operación y mantenimiento en otro idioma, póngase en contacto con el centro de servicio más cercano
de Mercury Marine o Marine Power International para recibir información. Con su conjunto motriz se entrega una lista de los
números de pieza para los otros idiomas.
Andra språk
För att få Instruktions‑ och underhållsböcker på andra språk, kontakta närmaste Mercury Marine eller Marine Power International
servicecenter, som kan ge ytterligare information. En förteckning över artikelnummer på andra språk medföljer ditt kraftpaket.
Allej glþssej
Gia na apoktÞsete Ýna Egxeirßdio Leitourgßaj kai SuntÞrhshj se Üllh glþssa, epikoinwnÞste me to plhsiÝstero DieqnÝj KÝntro
SÝrbij thj Mercury Marine Þ thj Marine Power gia plhroforßej. To pakÝto isxýoj saj sunodeýetai apü Ýnan katÜlogo ariqmþn
paraggelßaj gia Üllej glþssej.
Ordering Literature
Before ordering literature, please have the following information about your power package available:
Serial
Model
Number
Horsepower Year
United States and Canada

For additional literature about for your particular Cummins MerCruiser Diesel power package, contact your nearest Cummins
MerCruiser Diesel dealer/distributor or contact:
Mercury Marine
Telephone Fax Mail
Mercury Marine
(920) 929–5110 (920) 929‑4894 Attn: Publications Department
(USA Only) (USA Only) P.O. Box 1939
Outside the United States and Canada

Contact your nearest authorized Cummins MerCruiser Diesel dealer/distributor or Marine Power Service Center to order additional
literature that is available for your particular Cummins MerCruiser Diesel power package.
Mercury Marine
Please submit the Attn: Publications Department
following order form with W6250 West Pioneer Road
payment to: P.O. Box 1939
Ship To: (Please copy this form and print or type–This is your shipping label)
Name
Address
City, State, Province
ZIP or postal code
Country
Quantity Item Stock Number Price Total

. .
Page 76 CMD-4081986 / 90-866839060 MAY 2007

Quantity Item Stock Number Price Total

. .
. .
. .
. .
Total Due . .
CMD-4081986 / 90-866839060 MAY 2007 Page 77

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CMD-4081986 / 90-866839060 507

Declaration of Conformance—Cummins MerCruiser Diesel

Applicable Requirement Standards Applied

Generic emission standard EN 50081‑1

Diesel Sterndrive—Bravo Models

Director of Engineering—Cummins MerCruiser Diesel, Charleston, South Carolina U.S.A.

Please record the following information:

Engine Model and Horsepower Engine Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number

Read This Manual Thoroughly

IMPORTANT: Identifies information essential to the successful completion of the task.

Section 2 - Getting to Know Your Power Package

Section 3 - On the Water

CMD-4081986 / 90-866839060 MAY 2007 Page i

Section 8 - Customer Assistance Information

Page ii CMD-4081986 / 90-866839060 MAY 2007

CMD-4081986 / 90-866839060 MAY 2007 Page iii

CMD-4081986 / 90-866839060 MAY 2007 Page 1

Warranty Registration—Outside the United States and Canada

Page 2 CMD-4081986 / 90-866839060 MAY 2007

CMD-4081986 / 90-866839060 MAY 2007 Page 3

This limited warranty does not cover the following:

Sterndrive Warranty Policy—Diesel Intermittent Rating

Page 4 CMD-4081986 / 90-866839060 MAY 2007

CMD-4081986 / 90-866839060 MAY 2007 Page 5

This limited warranty does not cover the following:

Limited Warranty Against Corrosion (Worldwide)

Page 6 CMD-4081986 / 90-866839060 MAY 2007

CMD-4081986 / 90-866839060 MAY 2007 Page 7

Page 8 CMD-4081986 / 90-866839060 MAY 2007

Section 2 - Getting to Know Your Power Package

CMD-4081986 / 90-866839060 MAY 2007 Page 9

Bravo One X Diesel

Page 10 CMD-4081986 / 90-866839060 MAY 2007

Bravo Two Models

Bravo Two X Diesel

Bravo Three Models

Bravo Three X Diesel

CMD-4081986 / 90-866839060 MAY 2007 Page 11

Bravo Sterndrive Serial Number and Identification

Bravo sterndrive serial number

Bravo Transom Serial Number

Bravo transom assembly U-bolt plate

Page 12 CMD-4081986 / 90-866839060 MAY 2007

Gimbal housing with serial

Reference Gauge Function

CMD-4081986 / 90-866839060 MAY 2007 Page 13

Features and Controls

RUN a a - Stop switch

Page 14 CMD-4081986 / 90-866839060 MAY 2007

Panel Mount Features

Console Mount Features

CMD-4081986 / 90-866839060 MAY 2007 Page 15

Trimming the sterndrive up (out) has the following effects:

Trimming the sterndrive down (in) has the following effects:

Page 16 CMD-4081986 / 90-866839060 MAY 2007

Single Engine Trim and Trailer

Dual Engine Trim and Trailer

Electrical System Overload Protection

CMD-4081986 / 90-866839060 MAY 2007 Page 17