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TP: 3979 Department of Homeland Security
(HM&E MANUAL) UNITED STATES

COAST GUARD
TECHNICAL MANUAL
CB-OTH
STERNDRIVE BRAVO MODELS
INSTALLATION MANUAL
DISTRIBUTION STATEMENT D. – Distribution authorized to Department of Homeland Security, DoD and their
contractors to protect publications required for official use or for administrative or operational purposes only;
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PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD
SWBS 583
SECTION A
Individual Manual Application Sheet
Technical Publications Number
3979
SWBS Number 583
SWBS Element BOATS, BOAT HANDLING AND STOWAGE
Title SYSTEMS
Section Identifier A
Equipment Functional CB-OTH - STERNDRIVE BRAVO

Description MODELS - INSTALLATION MANUAL
CI Functional
Description
ESWBS Code
Remarks
Section Applicability
Planset Hulls
378-
721
FRAM-E
378-
717, 719, 720, 722, 723, 724, 726
FRAM-W
618-
615, 616, 617, 618, 619
WMEC
627-
620, 621, 623, 624, 625, 626, 627, 629, 630
WMEC
901-
901, 902, 903, 904
WMEC
905-
905, 906, 907, 908, 909, 910, 911, 912, 913
WMEC
23-CB-
23126, 23128, 23129, 23130, 23131, 23132, 23133, 23134, 23135, 23136, 23138, 23139,
OTH-
23140, 23141, 23142, 23143, 23144, 23145, 23146, 23147, 23148, 23149, 23151, 23152
MKII
750-
INDEX
2003, Mercury Marine, The following are trademarks / service marks of Brunswick Corporation: Alpha, Bravo, Flo-Torq, Merc, MerCathode, Mercury, Mercury
Marine, Mercury MerCruiser, Mercury Precision Parts, Mercury Propellers, Mercury Product Protection, Quicksilver, RideGuide, SmartCraft and Zero Effort.
DIESEL STERNDRIVE BRAVO MODELS

INSTALLATION MANUAL
Models Covered
Bravo
Sterndrive Model Serial Number or Year
Bravo One X, Bravo Two X, and Bravo
0M750000-0M752024
Three X
NOTICE
After completing the installation, these instructions should be placed with the
product for the owner’s future use.
NOTICE
Predelivery preparation instructions must be performed before delivering the
boat to the product owner.
Page 1 of 80 Printed in U.S.A. -  2003, Mercury Marine CMD-4081868 / 90-861182032 SEPTEMBER 2003
INDEX
DIESEL STERNDRIVE BRAVO MODELS INSTALLATION MANUAL
Table of Contents
Models Covered . . . . . . . . . . . . . . . . . . . . . . . . . 1 Models Using Alternate Seawater
Bravo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
General Information . . . . . . . . . . . . . . . . . . . . . 3 Gear Lube Monitor . . . . . . . . . . . . . . . . . . . . 30
Notice to Boat Manufacturer / Installer . . . . 3 Gear Lube Monitor Hose . . . . . . . . . . . . . . 30
Sales and Technical Assistance . . . . . . . . . 5 Speedometer Pickup . . . . . . . . . . . . . . . . . . 32
Torque Specifications . . . . . . . . . . . . . . . . . . . 6 Steering System . . . . . . . . . . . . . . . . . . . . . . 33
Lubricants / Sealants / Adhesives . . . . . . . . 6 Power Trim Pump . . . . . . . . . . . . . . . . . . . . 36
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Shift Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Notice on Bravo Three Trim-In Limit Engine Installation . . . . . . . . . . . . . . . . . . . . . 37
Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Preparing The Transom . . . . . . . . . . . . . . . 37
Multiple Sterndrive Steering Tie Bar Installing The Engine . . . . . . . . . . . . . . . . . . 38
Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Aligning The Engine . . . . . . . . . . . . . . . . . . 38
Internal Power Steering With Internal Sterndrive Unit Connections . . . . . . . . . . . . 42
Tie Bar Only . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Continuity Circuit Wire . . . . . . . . . . . . . . . . . 42
Internal Power Steering With Internal Power Trim Pump . . . . . . . . . . . . . . . . . . . . 43
and External Tie Bar . . . . . . . . . . . . . . . . . . . 9 Trim Position Sender Connections . . . . . . 43
External Power Steering . . . . . . . . . . . . . . . . 9 MerCathode Connections . . . . . . . . . . . . . . 44
External Power Steering With Low Gear Lube Monitor . . . . . . . . . . . . . . . . . . . . 45
External Tie Bar . . . . . . . . . . . . . . . . . . . . . . . 9 Power Steering Hydraulic Hoses . . . . . . . . 48
Quicksilver Products - Accessories . . . . . 10 Shift Cable Installation and
Serial Number Decal Placement . . . . . . . . . 10 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Corrosion Protection . . . . . . . . . . . . . . . . . . . 10 Installing Sterndrive Unit Shift Cable . . . . 49
Antifouling Paint . . . . . . . . . . . . . . . . . . . . . . . 11 Troubleshooting Shift Problems . . . . . . . . . 54
Installation Requirements . . . . . . . . . . . . . . 12 Sterndrive Unit Installation . . . . . . . . . . . . . 56
Transom Thickness and Surface . . . . . . . . 12 Speedometer Connection . . . . . . . . . . . . . . . 63
Engine Bed . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Predelivery Preparation . . . . . . . . . . . . . . . . . 64
Power Trim Control . . . . . . . . . . . . . . . . . . . 13 Power Trim Pump . . . . . . . . . . . . . . . . . . . . 64
Power Trim Pump Location . . . . . . . . . . . . 13 Trim Position Sender Adjustment . . . . . . . 66
Throttle/Shift Remote Control and Propeller . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Propeller Rotation on Dual
Steering Helm and Cable . . . . . . . . . . . . . . 14 Installations . . . . . . . . . . . . . . . . . . . . . . . . . 67
Steering Cable Specifications . . . . . . . . . . 16 Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Transom Cutout . . . . . . . . . . . . . . . . . . . . . . . . 17 Propeller Installation . . . . . . . . . . . . . . . . . . 69
Finding The Crankshaft Vertical Bravo One and Two . . . . . . . . . . . . . . . . . . . 70
Centerline . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Bravo Three . . . . . . . . . . . . . . . . . . . . . . . . . 71
Single Engine . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine Operation Tests . . . . . . . . . . . . . . . . 72
Dual Engine . . . . . . . . . . . . . . . . . . . . . . . . . 17 Boat Out Of the Water . . . . . . . . . . . . . . . . . 72
Finding The Crankshaft Boat In the Water . . . . . . . . . . . . . . . . . . . . . 73
Horizontal Centerline (X-dimension) . . . . 18 Testing Preparation . . . . . . . . . . . . . . . . . . . 74
90 Degree Tool Method . . . . . . . . . . . . . . . . 19 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Tape Measure Method . . . . . . . . . . . . . . . . 20 Boat-ln-The-Water Tests . . . . . . . . . . . . . . . 77
Cutting Out The Transom . . . . . . . . . . . . . . 21 Wide-Open-Throttle Test . . . . . . . . . . . . . . . 77
Checking The Transom Thickness . . . . . . 23 Cold Weather or Extended Storage . . . . . 77
Gimbal Housing . . . . . . . . . . . . . . . . . . . . . . 23 Power Trim System Wiring Diagram . . . . . 78
Exhaust Block-Off Plate . . . . . . . . . . . . . . . 25 MerCathode System Wiring Diagram . . . . 79
Seawater System Routing . . . . . . . . . . . . . 26 Sterndrive Unit Predelivery Inspection . . . 80
Models Using Sterndrive Water Pickups . 26
Page 2 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

INDEX
General Information
Notice to Boat Manufacturer / Installer
Throughout this publication, Warnings and Cautions (accompanied by the International
Hazard Symbol ! ) are used to alert the manufacturer or installer 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
to these special instructions when performing the service, plus common sense operation,
are major accident prevention measures.
WARNING
Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
IMPORTANT: Indicates information or instructions that are necessary for proper

installation and/or operation.
CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 3 of 80

INDEX
NOTE: Refer to the appropriate Cummins MerCruiser Diesel Product Applications Manual
for application recommendations.
This installation manual has been written and published by Cummins MerCruiser Diesel to
aid the boat manufacturer (OEM) in the installation of the products described herein.
It is assumed that these personnel are familiar with marine product installation.
Furthermore, it is assumed that they are familiar with, if not trained in, the recommended
installation procedures of Cummins MerCruiser Diesel product.
We could not possibly know of or advise the marine trade of all conceivable installations and
of the possible hazards and/or results of each installation. Therefore, the OEM is
responsible for any installation that does not fulfill the requirements of this manual.
It is the responsibility of the boat manufacturer to select the appropriate
engine/transom/drive package (including the correct gear ratio and propeller) for a given
boat. Cummins MerCruiser Diesel recommends that any new or unique hull/power package
combination be thoroughly water tested prior to sale, to verify that the boat performs as
desired, and that the engine operates in the appropriate rpm range.
It is recommended that a Cummins MerCruiser Diesel product application engineer be
contacted for assistance.
All information, illustrations and specifications contained in this manual are based on the
latest product information available at time of publication. Cummins MerCruiser Diesel
reserves the right to make changes at any time without obligation. As required, revisions
to this manual will be made available. Any suggested improvements to this manual are
welcome and should be directed to:
Cummins MerCruiser Diesel

Attention: Technical Publication Department
4500 Leads Avenue, #301
Charleston, SC 29405 U.S.A.
or contact us at wavemaster@cummins.com

INDEX
Sales and Technical Assistance

Cummins MerCruiser Diesel (CMD) employs a staff of highly trained specialists to assist you
with any sales or technical issues. This includes a group of Application Engineers who
specialize in the application of our product and are recognized throughout the industry for
their expertise.
If you have an issue with the application of our product that cannot be resolved over the
telephone, an application engineer can be scheduled to assist you at your facility. All
requests for assistance should be directed to your local distributor of Cummins MerCruiser
Diesel products.
The distributor for your area can be found by using the service locator on the Cummins
website (www.Cummins.com) or by contacting CMD sales or service.
Cummins MerCruiser Diesel

Attention: Sales or Service
4500 Leads Avenue, #301
Charleston, SC 29405 U.S.A.
1-800-DIESELS
(1-800-343-7357)
or contact us at wavemaster@cummins.com

INDEX
Torque Specifications
Description Nm lb-in. lb-ft
Transom assembly locknut 31 23
Exhaust block-off plate bolt 31 23
Seawater inlet block-off plate bolt 5 45
Speedometer pickup barb fitting 1.5 13
Steering system pivot bolt 34 25
Steering cable coupler nut 47 35
Power trim pump hose fitting 14 125
Rear engine mount bolt 47 35
Power steering hydraulic hose fitting 31 23
Sterndrive unit fastener 68 50
Power trim pump hose fitting 9 80
Propeller nut (Bravo One and Two) 1 75 55
Front 136 100
Propeller locknut (Bravo Three) 1
Rear 81 60
1 Amount specified is MINIMUM.
Lubricants / Sealants / Adhesives

Description Where Used Part Number
Engine Coupler Spline Grease Coupler splines 92-802869A1
Bell housing studs, anchor pins,
2-4-C with Teflon o-ring seals, shift cable end, 92-802859Q1
propeller shaft splines
U-Joint and Gimbal Bearing
Gimbal bearing 92-802870A1
Grease
Exxon Unirex EP 2 Grease
U-joints Obtain Locally
(Bravo X U-joint)
Pivot bolts, power steering
bushings, clevis pin, steering
Special Lubricant 101 92-802865A1
cable end, propeller shaft
splines
Liquid Neoprene MerCathode connections 92-25711-3
Power steering pump, power
Power Trim and Steering Fluid 92-802880A1
trim pump
Dexron III - Automatic
Power steering pump Obtain Locally
Transmission Fluid
Speedometer barb fitting
Loctite 565 PST Obtain locally
(standard connection)
High Performance Gear Lube Gear lube monitor 92-802854A1

INDEX
Special Tools
Alignment Tool Assembly
Aligns the engine and the

sterndrive unit during 91-805475A1
installation.
73699
Shift Cable Adjustment Tool

Attaches over the shift cable.
Use for proper Bravo
91-12427
sterndrive unit shift cable
73479 adjustment at the shift plate.
Tapered Insert Tool
Installs the tapered insert

retainer into the water inlet
91-43579
hose on all the Bravo
sterndrive units.
73456
Transom Cutout and Drill Fixture
Use when cutting and drilling

the boat transom for 91-43693A2
sterndrive installation.
22056

INDEX
Notice on Bravo Three Trim-In Limit Insert

NOTE: Bravo One, Two and Three Models are equipped with a Trim-In Limit Insert.
It has been brought to our attention that some boats (predominantly deep-V heavy boats)
will roll up on their side under certain, specific, operating conditions. The roll can be either
to port or starboard and may be experienced while moving straight ahead, or while making
a turn. The roll occurs most frequently at or near maximum speed, with the drive unit
trimmed at or near full trim-in. While the boat will not roll completely over, the roll may be
sufficient to unseat the operator or passengers, and thereby create an unsafe situation.
The roll is caused by stern-lift created from excessive drive unit trim-in. Under these extreme
stern-lift / bow-down conditions instability can be created which may cause the boat to roll.
Weight distribution to the stern can reduce stern-lift and, in some circumstances, help to
control the condition. Weight distribution in the bow, port or starboard, may worsen the
condition.
The Trim-In Limit Insert reduces stern-lift by preventing the drive unit from reaching the last
few degrees of full trim-in. While this device should reduce the rolling tendency, it may not
eliminate the tendency entirely. The need for this Trim-In Limit Insert, and its effectiveness,
can only be determined through boat testing and is ultimately the responsibility of the boat
manufacturer.
WARNING
It is recommended that only qualified personnel adjust the Trim-In Limit Insert. Boat
must be water tested after adjusting the device to ensure that the modified trim-in
range does not cause the boat to exhibit an undesirable boat handling characteris-
tic if the drive unit is trimmed In at higher speeds. Increased trim-in range may
cause handling problems on some boats which could result in personal injury.

INDEX
Multiple Sterndrive Steering Tie Bar Arrangements

With multiple sterndrives you must select one of several possible steering systems.
CAUTION
Failure to observe the recommended Tie Bar Arrangements as presented in this
section could result in serious damage to the steering and/or trim system
components. This damage could adversely affect control of the boat.
Internal Power Steering With Internal Tie Bar Only
At the lower end of the performance spectrum, boats not capable of speeds in excess of 60
mph (97 km/h), the basic internal tie bar is recommended. It connects the slave sterndrive
to the sterndrive that is directly connected to the factory power steering output. This internal
tie bar is available in a variety of lengths from the sterndrive manufacturer.
Internal Power Steering With Internal and External Tie Bar
As a boat moves into the moderate performance range of 60-70 mph (97-113 km/h)or for
a reduction in steering backlash, an external tie bar should be added. External tie bars are
usually designed to attach at the aft power trim cylinder bosses. This location is an excellent
choice because of its proximity to the propeller. HOWEVER, because of the potential
overstress that can occur if one drive is trimmed much differently than the other, a dual trim
control kit (Part Number 90362A3) should be installed to limit this potential tilt differential to
about 20 degrees.
IMPORTANT: Cummins MerCruiser Diesel does not recommend the use of an
external tie bar ONLY with no internal tie bar when using the internal power steering
system. This can cause excessive loads on the steering components on the drive
connected to the internal power steering system. These increased loads can damage
the steering components, resulting in increased play in the steering of the boat.
External Power Steering
When boat speeds move past 70 mph (113 km/h) or if additional steering backlash reduction
is desired, external power steering is recommended. This normally will include an external
tie bar mounted at the same general location as the power steering cylinders, which are
generally attached at the top of the sterndrive’s drive shaft housing. With this steering
system, no internal tie bar should be used. These steering cylinders can be attached either
inboard (between) or outboard of the sterndrives.
External Power Steering With Low External Tie Bar
For the fastest boats, over 80 mph (129 km/h), or for the ultimate in steering backlash
reduction, use external power steering, BUT (where mechanically possible) with the
external tie bar mounted at the trim cylinder boss location (as previously described in
Internal Power Steering with Internal and External Tie Bar statements). Again, this system
does NOT use an internal tie bar.

INDEX
Quicksilver Products - Accessories

Quicksilver remote controls, steering systems, propellers and other accessories are
available for this product. Refer to Mercury Precision Parts / Quicksilver Accessories Guide
for complete listing.
This Guide is available from:

Attn: Parts Department
Mercury Marine
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI
54936-1939
Outside of U.S.A., order through Distribution Center, or Distributor.
Serial Number Decal Placement

There are three sets of serial number decal strips provided with each sterndrive package.
One set should be used for each of the following:
• Engine Identification Decal
• Warranty Registration Card
• Operation and Maintenance Manual Identification page.
Corrosion Protection
Cummins MerCruiser Diesel sterndrives are equipped with anodes and a MerCathode
System, to help protect them from galvanic corrosion. A MerCathode Monitor also is
available to allow the operator to check the operation of the MerCathode System with the
push of a button. (Refer to Quicksilver Accessories Guide for part numbers.)
Boats which are connected to AC shore power, require additional protection to prevent
destructive low voltage galvanic currents from passing through the shore power ground
wire. A Quicksilver Galvanic Isolator can be installed to block the passage of these currents
while still providing a path to ground for dangerous fault (shock) currents. (Refer to
Quicksilver Accessories Guide for part number.)
IMPORTANT: If AC shore power is not isolated from the boat ground, the MerCathode
System and anodes may be unable to handle the increased galvanic corrosion
potential.

INDEX
Antifouling Paint
IMPORTANT: Corrosion damage that results from the improper application of
anti-fouling paint will not be covered by the limited warranty.
Painting Boat Hull or Boat Transom: Anti-fouling paint may be applied to boat hull and
boat transom but you must observe the following precautions:
IMPORTANT: Do not paint anodes or MerCathode System reference electrode and
anode, as this will render them ineffective as galvanic corrosion inhibitors.
IMPORTANT: If anti-fouling protection is required for boat hull or boat transom,
copper base paint, if not prohibited by law, can be used. If using copper based
anti-fouling paint, observe the following:
• Avoid an electrical interconnection between the Mercury MerCruiser Product,
Anodic Blocks, or MerCathode System and the paint by allowing a minimum of
40 mm (1-1/2 in.) UNPAINTED area on transom of the boat around these items.
b 71176
a - Painted boat transom

b - Minimum 40 mm (1-1/2 in.) unpainted area around transom assembly
NOTE: Sterndrive unit and transom assembly can be painted with a good quality marine
paint or an anti-fouling paint that DOES NOT contain copper or any other material that could
conduct electrical current. Do not paint drain holes, anodes, MerCathode system or items
specified by boat manufacturer.
NOTE: Do not wash the sterndrive unit with a power washer as this can damage the coating
on the reference wire and increase corrosion.

INDEX
Installation Requirements
For additional information refer to the Cummins MerCruiser Diesel Applications Manual,
SECTION 3.
Transom Thickness and Surface
IMPORTANT: Transom thickness and surface plane (flatness) must be controlled
where the sterndrive unit mounts.
Transom thickness and surface must conform to the following:
Transom Specifications
Thickness Between 51 - 57 mm (2 - 2-1/4 in.)
Parallelism 1 Inner and outer surfaces must be parallel within 3 mm (1/8 in.)
Flatness 1 Transom surfaces in the area where the transom assembly will be
mounted (includes vertical as well as horizontal dimensions):
Inner Surface – Flat within 3 mm (1/8 in.)
Outer Surface – Flat within 2 mm (1/16 in.)
Angle 10-16 Degrees (13 - 16 degrees ideal)
2 In transom assembly mounting area.
a e
b d d
72700
22170
a - Transom thickness
b - Inner surface
c - Outer surface
d - Transom plate coverage
e - Transom angle

INDEX
Engine Bed
The engine bed design must allow for the distance between mounts and position the engine
so that a minimum of up and down adjustment still exists on mounts after performing final
engine alignment. This is necessary to allow for realigning engine in the future.
Description Specification
Mount adjustment up and down (minimum) 6 mm (1/4 in.)
NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure
that the front and rear mount locations in the vessel are in parallel planes. This may be
checked by tying a string from the left front mount location to the right rear mount location
and another from right front to left rear. The strings should touch where they cross.
Power Trim Control
Any of the Quicksilver panel or in-handle type trim controls (that are specified for use with
Cummins MerCruiser Diesel sterndrives) can be used with this Power Trim system. Install
trim control in accordance with instructions that accompany it.
Power Trim Pump Location
Select an appropriate mounting location for the trim pump that meets the following
requirements:
• Within limits of black and gray hydraulic hoses (coming from gimbal housing assembly).
• Close to the battery so that trim pump battery leads can be connected.
• Allow easy access to trim pump oil fill and vent locations.
• Area where pump will not be exposed to water.
• Trim pump must be mounted so that when steering wheel is turned in either direction
(right or left), the power steering booster cylinder does not come in contact with trim
pump.

INDEX
Throttle/Shift Remote Control and Cables

To ensure proper shift and throttle operation, we recommend the use of a Quicksilver remote
control and cables. Refer to Mercury Precision Parts / Quicksilver Accessories Guide for
selection. However, if a control other than Quicksilver is to be used, control must provide
the following:
Shift Cable Travel Shift Cable Load

(At shift plate end.) (Applied to the cable end guide.)
73 mm (2-7/8 in.) to 80 mm (3-1/8 in.) 6.8-9 kg (15-20 lb.)
Steering Helm and Cable

Transom assembly is shipped with the steering cable guide tube preset for cables with end
dimensions that comply with ABYC standards as outlined in the NMMA certification
handbook. The steering cable coupler nut must also have a means of locking it to the guide
tube, as specified in ABYC requirements.
WARNING
Failure to use a steering cable locking device could cause loss of steering, which
could cause damage to the boat and/or injury.
All current production Quicksilver RideGuide steering cables have a self-locking coupler nut
and do not require an external locking device. Other cable manufacturers also make cables
with self-locking coupler nut.
22060
a - Quicksilver RideGuide steering cable self-locking coupler nut (identified by
groove)

INDEX
IMPORTANT: If using a steering cable that does not have a self-locking coupler nut,
an external locking device must be used.
a
b
Example of a typical external locking device
a - Steering cable
b - Locking device sleeve
CAUTION
POWER STEERING EQUIPPED UNITS ONLY: If steering cable with improper
dimensions is installed, severe damage to transom assembly and/or steering
system may result.
Ensure the following are observed:
• Steering cable must be the correct length, particularly when installed in larger boats.
• Avoid sharp bends, kinks or loops in cable.
• Fully extended steering cable end dimension must be as shown in Steering Cable
Specifications.

INDEX
Steering Cable Specifications

IMPORTANT: Power steering pump lugging (squealing) in a hard right turn (against
lock) may mean a steering cable has been installed that does not have the correct
dimensions.
a c
b d
e
g
f CL
k j h
l i
21435
a - Coupler nut - 7/8 - 14 UNF - 28 thread

b - 298 mm (11-3/4 in.) min.
c - Interface point
d - 12.7 mm (1/2 in.) max.
e - 10.7 mm (27/64 in.) min. flat
f - 3.1 mm (7/64 in.) min. radius
g - 15.9 mm (5/8 in.) max. diameter end fitting
h - 9.5 mm (3/8 in.)
i - 9.8 mm (3/8 in.) diameter through hole (chamfered each side)
j - 34.9 mm (1-3/8 in.) max.
k - 15.9 mm (5/8 in.) diameter tube
l - Cable Travel:
- Mid-travel position - 429 mm. (16-7/8 in)
- Total travel to be 203 mm (8 in.) min. to 228 mm (9 in.) max.
- Travel each side of mid-travel position - 102 mm (4 in.) min. to
114 mm. (4-1/2 in) max.
a b
21436
a - Steering cable mounting flange

b - Center of hole in steering cable end
c - 543 mm (21-3/8 in.) max.

INDEX
Transom Cutout
Finding The Crankshaft Vertical Centerline
SINGLE ENGINE
1. Locate and mark the vertical centerline on the transom, if known. This is also the
crankshaft vertical centerline.
2. If unknown, a compass can be used to locate the vertical centerline:
a. Mark identical locations on each side of the boat 294 mm (12 in.) from the bottom
of the hull.
b. Position the fixed end of a compass at the marks and draw arcs on the transom.
c. Draw the crankshaft vertical centerline through the intersection points of the 2 arcs.
b e
a c b
d e
71620
Single engine installation

a - 305 mm (12 in.)
b - Identical side marks
c - Compass arc
d - Arc intersection points
e - Crankshaft vertical centerline
DUAL ENGINE
1. Locate and mark the vertical centerline on the transom. Refer to Single Engine
procedure.
NOTE: Refer to engine manufacturer’s minimum distance between crankshaft vertical
centerlines for dual side-by-side applications.
2. Make a set of marks equal to 1/2 the minimum distance between crankshaft vertical
centerlines on either side of the vertical centerline.
3. Draw the 2 crankshaft vertical centerlines through the intersection of the marks.
b
c c
b
a 22033
Dual installation
a - Vertical centerline
b - 1/2 minimum distance between crankshaft centerline marks
c - Crankshaft vertical centerlines

INDEX
Finding The Crankshaft Horizontal Centerline (X-dimension)

After finding and marking the crankshaft vertical centerline, either the 90 Degree Tool
Method or Tape Measure Method can be used to locate the crankshaft horizontal centerline
(X-dimension).
IMPORTANT: The following instructions will provide a sterndrive unit mounting
location that is suitable for most boats. The best mounting location for a particular
boat, however, can be determined only by testing.
1. Below 40 km/h (25 mph): Subtract 13 mm (1/2 in.) from X-dimension.
2. Heavy duty applications: Subtract 25 mm (1 in.) from X-dimension.
3. Above 40 km/h (25 mph): Use X-dimension shown.
4. Above 80 km/h (50 mph): The X-dimension can be increased to improve performance
in some applications. However, pulling power for skiing will decrease. During testing, the
X-dimension should be increased 13 mm (1/2 in.) at a time until the desired performance
is achieved but in no case should it ever be increased by more than:
Maximum Increase In X-dimension

Bravo One and Three 76 mm (3 in.)
Bravo Two 25 mm (1 in.)
Extreme care should be taken when raising drive unit to ensure that water supply does not
become aerated. Use clear water inlet hose to monitor incoming water and monitor engine
temperature gauge to ensure that the engine does not overheat.
IMPORTANT: Damage to Cummins MerCruiser Diesel products caused by too high
of an installed height will not be covered by Mercury MerCruiser warranty.

INDEX
90 DEGREE TOOL METHOD

1. Construct the 90 degree tool.
a 90°
b 71621
a - 345 mm (13-9/16 in.)

b - 1.2 m (4 ft)
IMPORTANT: The 345 mm (13-9/16 in.) dimension should only be raised or lowered
after proper testing.
To lower drive unit - Subtract from dimension “a”.
To raise drive unit - Add to dimension “a”.
2. Place the 90 degree tool along the boat bottom at the vertical centerline.
3. Locate the point at which top of tool contacts transom on vertical centerline. This is the
crankshaft horizontal centerline or X-dimension.
4. Draw a line perpendicular to the vertical centerline at crankshaft horizontal centerline.
b c b
a 71623
71622 a
Single engine Dual engine

a - 90 degree tool along boat bottom at vertical centerline
b - Contact point
c - Crankshaft horizontal centerline

INDEX
TAPE MEASURE METHOD

1. Determine the X-dimension from the following chart.
IMPORTANT: This dimension should only be raised or lowered after proper testing.
Transom Angle
X-dimension
(degrees)
16 364 mm (14-5/16 in.)
15 362 mm (14-1/4 in.)
14 360 mm (14-3/16 in.)
13 359 mm (14-1/8 in.)
12 357 mm (14-1/16 in.)
11 356 mm (14 in.)
10 354 mm (13-15/16 in.)
2. On the vertical crankshaft centerline, measure up from the bottom of the transom to the
X-dimension selected previously. This is the crankshaft horizontal centerline.
3. Draw a line perpendicular to the vertical centerline at the crankshaft horizontal
centerline.
a
a
c c
b b
71622 71623
Single engine Dual engine

a - Vertical centerline
b - X-dimension that corresponds to transom angle
c - Crankshaft horizontal centerline

INDEX
Cutting Out The Transom

1. Cut out transom using the Template or the Transom Drilling Fixture Kit (purchased
separately).
90-79135--5
50017 22056
Transom cutout template Transom drilling fixture kit
2. Follow instructions indicated on template or provided with drilling fixture.

3. Ensure that centerlines on either the template or transom drilling fixture align with lines
previously marked on transom.

INDEX
4. Drill two 6 mm (1/4 in.) pilot holes at a 60 degree angle for hole saw guides.
5. Using a hole saw cut the two 51 mm (2 in.) holes for the steering lever cutout. If the hole
saw cutout is made incorrectly, drive unit steering lever may contact transom causing
limited steering travel.
6. Cut the transom on the cut line at a 90 degree angle. If the transom cutout is made
incorrectly the gimbal housing or exhaust system may improperly contact the boat
transom causing transom mounting problems.
7. Seal inside edge of transom cutout opening with a suitable sealant to prevent water
absorption and deterioration of transom.
a
d
c
f e 79157
a - 51 mm (2 in.) hole saw holes (steering lever cutout)

b - 60 degrees versus transom angle
c - Cut line
d - 90 degrees to transom
e - Exhaust pipe area
f - Mounting holes perpendicular to transom (8)

INDEX
Checking The Transom Thickness

1. Ensure transom thickness and surface conform to specifications listed previously in
Transom Thickness and Surface.
70004 75479
a - Measuring thickness
b - Measuring flatness
c - Suitable mandrel to check for uniform transom thickness
Installing The Transom Assembly

Gimbal Housing
1. Carefully remove transom assembly from shipping carton.
2. Remove and read all tags which are attached to transom assembly.
3. Remove cardboard protector from gimbal housing.
4. Insert wires, hoses and shift cable through appropriate openings in inner transom plate.
5. Position gimbal housing on transom and hold in place.

INDEX
NOTE: When tightening transom assembly fasteners in the following step, start in the
center, and using a circular pattern, move outward. Tighten in small increments and go
around the pattern several times until the proper torque is achieved.
6. Secure the transom assembly with flat washers and locknuts as shown. Torque the
locknuts.
IMPORTANT: Steering lever continuity circuit wire must be positioned as shown to
avoid stressing the wire when the steering lever moves.
b
d
c
71626 71628
70005 a
71629
72043
5 7
3 2
1 4
8 6
e
a - Locknuts and flat washers (8)

b - Bolt
c - Steering lever continuity wire
d - Transom plate continuity wire
e - Torque sequence

Transom assembly locknut 31 23

INDEX
Exhaust Block-Off Plate

NOTE: It is necessary to install through the transom or through the hull exhaust when using
the exhaust block-off plate.
IMPORTANT: The exhaust block-off plate and gimbal housing mating surfaces must
be clean and free of nicks and scratches and O-ring must be properly seated in
groove, or water and exhaust may leak into boat.
1. Ensure the block-off plate and gimbal housing mating surfaces are clean and free of
nicks and scratches.
2. Ensure the O-ring is properly seated in the groove.
22069
a - Gimbal housing mating surface

b - O-ring
3. Install the block off plate as shown, using the four bolts and lockwashers. Torque the
bolts.
76638
a - Block-off plate
b - Bolt and lockwasher

Exhaust block-off plate bolt 34 25

INDEX
Seawater System Routing

MODELS USING STERNDRIVE WATER PICKUPS
1. Install the water inlet fitting gasket.
2. Install the water inlet fitting.
3. Install the star washers and bolts.
4. Torque the bolts.
b c
50663
a - Water inlet fitting gasket (not visible)

b - Water fitting
c - Bolt and star washer

Water inlet fitting bolt 5 45
IMPORTANT: Hose must not come in contact with steering system components,
engine coupler, U-joint shaft or drive shaft.

INDEX
MODELS USING ALTERNATE SEAWATER PICKUP

Seawater for engine cooling can be supplied through an alternate (separate) seawater
pickup, not through the sterndrive unit. When using a separate seawater pickup, it is
necessary to block the sterndrive unit seawater passage and to cut the water hose that is
located between the bell housing and the gimbal housing. This allows water to continue to
circulate through the sterndrive unit for cooling.
NOTICE
Installation of a water inlet block-off plate will make it necessary to provide an
alternate seawater pickup and related hardware. Depending upon application and
boat configuration a through the hull or through the transom seawater pickup must
be used.
CAUTION
Avoid overheating the sterndrive. The sterndrive water inlet holes must be allowed
to flow water without being obstructed, or overheating damage to sterndrive may
result. Do not dead-end water hose from bell housing. Hose must be cut as
recommended.
1. Remove the tapered insert in the gimbal housing using the Tapered Insert Tool
(91-43579). Discard the insert.
c
a
22101
b
22080
a - Tapered insert
b - Tapered Insert Tool
c - Gimbal housing cross-section
Tapered Insert Tool
Removes and installs the
tapered insert retainer into
91-43579
the water inlet hose on all the
73456 Bravo sterndrive units.

INDEX
2. Install the seawater inlet block-off plate with the new gasket. Secure with bolts and
lockwashers. Torque the bolts.
a
d
c
75314
75313
a - Block-off plate
b - Gasket
c - Screw
d - Lockwasher

Seawater inlet block-off plate bolt 5 45
CAUTION
Avoid sterndrive damage. Damage to the sterndrive may result from inadequate
water flow through the drive. Do not block or restrict the water flow from the bell
housing. Provide an exit for sterndrive water flow.
3. Move the trim limit switch wires and speedometer hose aside. Reach between the
gimbal housing and the bell housing and detach the water hose from the gimbal housing
where the tapered insert was located in Step 1.
a
d
e
b 71184 22101
a - Trim limit switch wires

b - Speedometer hose
c - Gimbal housing
d - Water hose
e - Tapered insert location

INDEX
WARNING
Avoid water leakage into boat. Damage to U-joint bellows could result in water
entering the boat. Do not damage the U-joint bellows when removing a section of
the water hose attached between the gimbal housing and bell housing.
NOTE: Move the trim limit switch wires and speedometer hose to avoid damaging them
when cutting the water hose. The existing tie strap and clip can be reused if they are moved
and repositioned after the hose is cut.
4. Cut completely through the inlet water hose 127 mm (5 in.) in front of the aft end of the
hose where it is fitted into the bell housing. Do not damage the U-joint bellows. Discard
loose hose piece.
5. Secure the trim limit switch wires and speedometer hose to the remaining section of
water hose using the existing tie strap and clip.
c
a
f
e
d
22101 71184
a - Water hose
b - Measurement: 127 mm (5 in.)
c - Trim limit wires
d - Speedometer hose
e - Tie strap
f - Clip

INDEX
Gear Lube Monitor

IMPORTANT: A bracket is included to allow gear lube monitor to be located on the
transom. The mounting location specified must be above the steering lever on the
transom assembly. Hose must be positioned to avoid moving parts (steering system,
engine coupler).
1. Install the gear lube monitor bracket in the specified location and secure with lag screws
and flat washers.
2. Install the gear lube monitor in the bracket. Secure the monitor with the retaining strap.
a
c
b 79149
a - Bracket
b - Lag screw and flat washer
c - Gear lube monitor and cap
d - Retaining strap
Gear Lube Monitor Hose

1. Connect the quick release 90 degree fitting of the gimbal housing hose assembly to the
gimbal housing fitting.
d c
a
b
79146
a - Gimbal housing hose assembly
b - Quick release 90 degree fitting
c - Gimbal housing fitting
d - Female quick release connector
CAUTION
AVOID STERNDRIVE UNIT DAMAGE. Quick release button on gear lube monitor 90
degree hose fitting may not lock on gimbal housing if touching or depressed by
water inlet fitting, or block-off plate if equipped. Ensure quick release button does
not contact block-off plate, or water inlet fitting if equipped. Failure to do so could
result in a loose 90 degree fitting causing a loss of gear lube and damage to
sterndrive unit.

INDEX
2. Position quick release button on 90 degree hose fitting away from water inlet fitting, or
block-off plate if equipped. Release button must not contact water fitting, or block-off
plate if equipped.
b
d
e c
c
71998
Block-off plate installation shown, similar with water inlet fitting

a - Block-off plate
b - 90 degree hose fitting
c - Quick release button
d - ACCEPTABLE positions
e - NOT ACCEPTABLE position
IMPORTANT: Hose must not come in contact with steering system components,
engine coupler, U-joint shaft or drive shaft.
3. Secure the gear lube monitor gimbal housing hose assembly with the J-clip on the
transom plate.
79385
a - J-clip
4. Temporarily position the hose out of the way until final connection after engine
installation.

INDEX
Speedometer Pickup
CAUTION
Excess water in bilge can damage engine or cause boat to sink. Do not remove plug
from speedometer pickup tube fitting unless connection is to be utilized.
1. Remove the protective cap from the male quick connect.
2. Connect a 4 mm (5/32 in.) hose (not provided) from the speedometer to the barb fitting
on the female quick connect. Secure the hose to the fitting with a tie strap.
a
b
c
c
e
d
79399
79287
a - Male quick connect

b - Female quick connect
c - Barbed fitting
d - Hose
e - Tie strap
3. Connect the male and female quick connects.
CAUTION
AVOID WATER LEAKING INTO BOAT. Speedometer hose is filled with water,
especially during boat operation. Hose contact with moving or rotating engine
parts could cause damage to the hose resulting in water leaking into boat. Do not
let speedometer hose contact steering system components, engine coupler or
drive shaft.
4. Secure the hose to the transom with the hose clip and screw that are provided in the
parts bag. Ensure that the hose does not contact the steering system components or
the engine coupler and drive shaft.

INDEX
Steering System
NOTE: For Dual Installations, Power steering unit can be mounted on port or starboard
transom assembly. Measure exact distance between power package centerlines. Select a
tie bar from Mercury Precision Parts/Quicksilver Accessories Guide. Refer to tie bar
installation instructions before proceeding.
1. Inspect power steering bushings for debris. Apply lubricant to the bushings.
a A
73898
a - Bushings

A Special Lubricant 101 Power steering bushings 92-802865A1
2. Remove upper and lower pivot bolts and ensure threads are well lubricated with
specified lubricant.

Special Lubricant 101 Pivot bolts 92-802865A1
3. Install steering assembly as follows:

a. Position steering assembly so that pivot bolts will enter bushings in pivot block.
b. Install upper and lower pivot bolts along with tab washers. Ensure that tab washer
tangs straddle the ridge on inner transom plate.
c. Turn pivot bolts all-the-way in by hand to ensure proper alignment.
d. Check to ensure steering assembly pivots freely.
e. Torque the pivot bolts. Bend washer tabs against corresponding flats on bolt heads.
c
a
b
a
73899
c
73900
a - Tab washers
b - Ridge
c - Pivot bolt

Steering system pivot bolt 34 25

INDEX
CAUTION
MOVING THE CONTROL VALVE RAM with the hoses disconnected will expel fluid
from the ports. Wear eye protection.
4. The cylinder ram may be stiff and difficult to move when you attempt to pull it out or push
it in for installation. First move the spool assembly in the directions shown below.
a
74145
a
74144
a - Ports
5. Connect clevis to steering lever. Apply lubricant to the clevis pin. Be sure to spread both
ends of the cotter pin.
c
b
a
71904
a - Clevis
b - Steering lever
c - Clevis pin
d - Cotter pin

Special Lubricant 101 Clevis pin 92-802865A1

INDEX
6. Connect steering cable as follows:

a. Remove shipping cap from both ends of steering cable guide tube.
b. Apply lubricant to the steering cable end.

Special Lubricant 101 Steering cable end 92-802865A1
c. Install steering cable and secure with hardware as shown.
h
71906
e d
f
73901
c
a b
71901
d 71903
a - Steering cable
b - Grease fitting
c - Cable coupler nut
d - Cable guide tube
e - Steering cable end
f - Clevis
g - Clevis pin
h - Cotter pin
d. Using a suitable wrench hold the flat surfaces on the cable guide tube in the vertical
position. Torque the coupler nut. Be certain the flat surfaces are still aligned
vertically after torque is applied to coupler nut.

Steering cable coupler nut 47 35
CAUTION
Steering cable outer casing must be free to move back and forth for steering system
to function properly. Do not fasten any items to steering cable.

INDEX
Power Trim Pump

1. Mount pump in desired location.
IMPORTANT: Make hydraulic connections as quickly as possible to prevent oil from
leaking out of system. Be careful not to cross-thread or overtighten hose fittings.
2. Connect the power trim pump hoses to the trim pump. Torque the hose fittings.

Power trim pump hose fittings 9 80
3. Connect power trim pump control harness to trim pump. Secure with tie strap.
4. Connect trim limit switch wires and secure with wire retainer and tie strap.
c
75126
76631
f
g
a
e 50632
79738
Typical
a - Black hose (UP circuit)
b - Gray hose (DOWN circuit)
c - Harness connector
d - Tie strap
e - Trim Limit switch wire to BLUE/WHITE harness wire
f - Trim Limit switch wire to PURPLE/WHITE harness wire
g - Wire retainer and cable tie

INDEX
Shift Plate
IMPORTANT: Shift plate and bracket assembly must be mounted within the limits of
the sterndrive unit shift cable. Be sure that the mounting location will not cause
interference with other moving components and will not cause any sharp bends
and/or kinks.
1. Use appropriate fasteners (depending on mounting surface) to install mounting bracket
in desired location.
79733
Typical
a - Shift plate
b - Lag bolt location
Engine Installation
Preparing The Transom
1. Position rear engine mount attaching hardware on inner transom plate mounts as
shown.
b
a
50628
a - Fiber washers
b - Double-wound lockwasher
c - Locknuts

INDEX
Installing The Engine

1. Attach a suitable sling to the lifting eyes on the engine and adjust so that the engine is
level when suspended.
2. Lift the engine into position in the boat using an overhead hoist.
3. Align rear engine mounts with inner transom plate mounts.
4. Install both rear engine mounting bolts and torque. Do not relieve hoist tension.
a d
f
h
b
g
c
22032
a - Engine flywheel housing
b - Rear engine mount
c - Inner transom plate mount
d - Bolt
e - Washer
f - Spacer
g - Fiber washer
h - Double-wound lockwasher

Rear engine mount bolt 47 35
Aligning The Engine

1. Ensure that the dust cover is removed or folded back out of the way.
22027
a - Dust cover

INDEX
CAUTION
Do not use an alignment tool from another manufacturer. Alignment tools other
than Quicksilver Alignment Tool may cause improper alignment and damage to
gimbal bearing and/or engine coupler.
2. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into
the engine coupler splines.
CAUTION
To avoid damage to gimbal bearing, engine coupler, or alignment tool do not raise
or lower engine with alignment tool inserted (or partially inserted) in gimbal bearing
or engine coupler.
3. If the Alignment Tool does not fit, remove it and carefully raise or lower the front end of
the engine using the center alignment eye and attempt to insert the Alignment Tool.
NOTE: It may be necessary to hit the Alignment Tool with a synthane hammer to set the
gimbal bearing to the coupler.
4. If necessary lightly tap the sides of the Alignment Tool at 90 degree increments to help
align the gimbal bearing.
78506
Typical
a - Alignment Tool (use only recommended Alignment Tool)
b - Insert this end of Alignment Tool through gimbal housing assembly
c - 90 degree increments

INDEX
5. Repeat step 3. and 4. until the Alignment Tool installs easily (SLIDES FREELY WITH
TWO FINGERS) all the way into and out of engine coupler splines. Do not check by
turning.
22029
a - Quicksilver Alignment Tool (use only recommended Alignment Tool)
b - Insert this end of Alignment Tool through gimbal housing assembly
c
b
73345 73794
a - Quicksilver Alignment Tool

b - Gimbal bearing
c - Engine coupler
6. Remove the alignment tool.

INDEX
IMPORTANT: The finished boat stringer must position the front engine mount so that
a minimum of 6 mm (1/4 in.) up or down adjustment exists after the mount is adjusted
to contact the stringer. This allows for future engine alignment or adjustments. Make
proper alterations to the boat stringer (structure) height to obtain the 6 mm (1/4 in.)
dimension.
7. Adjust front engine mounts until they rest on boat stringers.
8. Relieve hoist tension entirely and fasten both front mounts to boat stringer using
appropriate hardware (lag bolts, through bolts, and so on).
NOTE: When appropriate, attach mounts to stringers using 9 mm (3/8 in.) lag bolts
minimum.
9. Attempt to insert the Alignment Tool.
IMPORTANT: Turn both front engine mount adjustment nuts an equal amount in
direction required to align engine.
10. If the Alignment Tool does not fit, remove it and carefully adjust engine mounts as
necessary.
11. Repeat steps 9. through 10., until the Alignment Tool installs easily (SLIDES FREELY
WITH TWO FINGERS) all the way into and out of the engine coupler splines. Do not
check by turning the Alignment Tool.
12. When alignment is correct, tighten engine mount locking device as appropriate for the
specific installation.
13. Recheck alignment with the Alignment Tool.
NOTE: Bend tab down on adjusting nut if locking device is a tab washer.
a
b e
c
d
71649
Typical
a - Nut and lockwasher
b - Adjustment nut
c - Turn adjustment nut in this direction (counterclockwise) to raise front of engine
d - Slotted hole toward front of engine.
e - Tab washer (if equipped)
14. Remove the alignment tool and fold bell housing dust cover flap back into place and tape
shut for boat shipment.

INDEX
Sterndrive Unit Connections

Continuity Circuit Wire
IMPORTANT: When routing all wire harnesses and hoses, be sure they are routed and
secured to avoid coming in contact with hot spots on engine and avoid contact with
moving parts.
1. Connect continuity circuit wire from transom plate to a good engine ground (–) point.
IMPORTANT: Do not attach any accessory ground (–) wires to transom plate ground
point. Accessory ground wires can only be attached to ground (–) on battery or with
proper fusing to engine.
a
b
71651
Typical
a - Engine ground stud
b - Continuity circuit wire
c - Inner transom plate grounding bolt

INDEX
Power Trim Pump

1. Connect the power trim pump wires to the battery.
76631
Typical
a - Positive (+) battery lead
b - Negative (–) battery lead
Trim Position Sender Connections

1. Connect the trim position sender wires (from the transom assembly) to the instrument
harness.
a b
BRN/WHT BLK
BLK BLK
74029
a - Wires to instrument harness (typical colors shown)

b - Wires from transom assembly

INDEX
MerCathode Connections
1. Connect the wires to the MerCathode controller assembly.
IMPORTANT: Opposite end of RED/PURPLE wire and BLACK wire must be connected
directly to battery terminals. Do not connect them to a switched circuit. The
MerCathode system must function continuously for proper corrosion protection.
a b c d 22232
Typical
a - ORANGE Wire - from anode on transom assembly
b - RED/PURPLE Wire - connect (other end) to positive (+) battery terminal
c - BLACK Wire - from engine harness
d - BROWN Wire - from electrode on transom assembly
2. Apply a thin coat of sealant to all wire connections.

Liquid Neoprene Electrical connections 92-25711-3

INDEX
Gear Lube Monitor

CAUTION
Avoid sterndrive unit damage. Ensure the gear lube monitor hose is not kinked
during installation. If hose is kinked, the gear lube monitor will not function properly
and damage to the sterndrive could occur.
1. Locate the white gear lube monitor quick connect at the rear of the engine.
2. Ensure the gimbal housing hose assembly hose is mounted in the J-clip on the transom.
3. Fasten the quick connect fitting between the gimbal housing hose assembly and the
gear lube monitor hose assembly.
a
b c 79147
a - Gimbal housing hose assembly

b - Gear lube monitor hose assembly
c - Quick connect fitting

INDEX
IMPORTANT: Avoid using excessive hose when routing to the gear lube monitor.
Hose should be routed directly to the oil reservoir in as straight a line as possible to
avoid low spots (traps) in the system.
4. Route the gear lube monitor hose, or hose assemblies if equipped with quick connect,
to the gear lube monitor.
5. If necessary, cut the gear lube monitor hose to the correct length at the gear lube
monitor.
6. Connect and securely clamp the gear lube monitor hose to the gear lube monitor fitting.
c
b
a
d e
79148
Typical
a - Quick connect, if equipped
b - Gear lube monitor hose
c - Gear lube monitor
d - Clamp
e - Fitting
IMPORTANT: The gear lube monitor hose must not come in contact with the steering
system components, engine coupler, or drive shaft.
7. Secure the gear lube monitor hose with cable ties.

INDEX
NOTE: The gear lube monitor switch is in the NORMALLY OPEN position when the monitor
is full. The circuit closes to ground (–) when the monitor is empty.
8. Connect the audio warning system harness wires (if equipped) to the gear lube monitor
audio warning wires.
b
79123
Typical
a - Gear lube monitor
b - Audio warning wires

INDEX
Power Steering Hydraulic Hoses

CAUTION
Avoid injury or property damage. Extreme heat will lower burst pressure or melt
steering system hydraulic hoses. Stress on hose fittings or kinks in the hoses may
cause hose failure. In any case, a loss of steering control may occur. Route the
hydraulic hoses to avoid extreme heat, stress on hose fittings and hose kinks.
IMPORTANT: Make hydraulic connections as quickly as possible to prevent fluid
leakage.
IMPORTANT: Be careful not to cross-thread or over-tighten fittings.
1. Route power steering hydraulic hoses to control valve as shown. Secure hoses to avoid
contact with moving components.
2. Connect power steering hydraulic hose fittings to control valve. Torque hose fittings.
74248
a - Rear fitting (pressure hose)

b - Front fitting (return hose)

Power steering hydraulic hose fitting 31 23

INDEX
Shift Cable Installation and Adjustment

Installing Sterndrive Unit Shift Cable
NOTE: Shift Cable Adjustment Tool (91-12427) allows the shift cables to be installed and
adjusted, with or without the sterndrive attached.
IMPORTANT: The direction of propeller rotation (RH or LH) for this drive unit is
determined by the following method.
1. Determine desired propeller rotation according to a., b., or c.:
a. Bravo One / Two - If shift cable end guide moves in direction “A” when control lever
is placed in FORWARD, remote control is setup for RIGHT HAND (RH) propeller
rotation.
b. Bravo One / Two - If shift cable end guide moves in direction “B” when control lever
is placed in FORWARD, remote control is setup for LEFT HAND (LH) propeller
rotation.
B 71656
Bravo One / Two

c. Bravo Three - Front propeller on drive unit is always LH Rotation and rear propeller
is always RH Rotation. Shift cable end guide must move in direction “A,” when
control lever is placed in FORWARD gear position.
A
71656
Bravo Three
IMPORTANT: When installing shift cables, be sure that cables are routed in such a
way as to avoid sharp bends and/or contact with moving parts. DO NOT fasten any
items to shift cables.
2. Install the shift cable into the remote control. Refer to the appropriate remote control
instructions.
3. Loosen the stud and move it to the dimension, as shown. Retighten the stud.
a
79295
a - Stud
b - 76 mm (3 in.) - center of pivot bolt to center of stud

INDEX
4. Remove the Adjustment Tool.
79709
5. Install the sterndrive unit shift cable.

6. Insert the cotter pins from the top. Spread the ends of the cotter pins fully.
d
79728 b
a - Sterndrive unit shift cable

b - Washers (2)
c - Long cotter pin
d - Short cotter pin
7. Place the Adjustment Tool over the sterndrive unit shift cable, as shown. Hold the tool
in place, using a piece of tape over the barrel retainer.
79729

INDEX
8. Locate the center of the remote control and control cable play (backlash).
a. Shift the remote control to NEUTRAL.
b. Push in on the control cable end with enough pressure to remove play, and mark
position “a” on tube.
c. Pull out on the control cable end with enough pressure to remove play and mark
position “b” on tube.
d. Measure the distance between marks “a” and “b” and mark position “c” half-way
between marks “a” and “b”.
c
a
b 71656
IMPORTANT: Be sure to keep center mark “c” aligned with control cable end guide
edge when making the following adjustment.
9. Adjust control cable as follows:
a. Temporarily install control cable end guide into shift lever, and insert clevis pin.
b. Adjust control cable barrel so that hole in barrel centers with vertical centerline of
stud. Ensure that backlash center mark is aligned with edge of control cable end
guide.
CAUTION
Do not attempt to install or remove control cable barrel from stud without first
removing end guide clevis pin from shift lever and removing cable. Attempting to
bend control cable to install or remove barrel will place undue stress on cable end
guide and shift lever and damage to both could occur.
c. Remove the control cable end guide from the shift lever, by removing the clevis pin.
d
c a
79298
b
a - Control cable end guide
b - Clevis pin
c - Backlash center
d - Control cable barrel
e - Stud

INDEX
10. Install the control cable.

11. Install the washer and cotter pin to secure the barrel. Spread the ends of the cotter pin
fully.
12. Install the clevis pin.
13. Install the cotter pin into the clevis pin. Spread the ends of the cotter pin fully.
c
b a
79730
d
a - Cotter pin
b - Washers - both sides of barrel
c - Clevis pin
d - Cotter pin (partially shown)

15. Shift the remote control lever into the full FORWARD position. Place the end of the
Adjustment Tool in the barrel retainer.
RH ROTATION BRAVO ONE, TWO, AND THREE MODEL: Rear slot in tool should fit over
shift lever stud.
LH ROTATION BRAVO ONE AND TWO: Forward slot in tool should fit over shift lever stud.
16. If the slot does not fit over the stud, loosen the shift lever stud and slide the stud up or
down, until the slot in tool fits over the stud. When adjustment is correct, retighten the
stud.
c
c
b
b
a
a
d 79732 e 79731
RH Rotation Bravo One, Two, Three LH Rotation Bravo One and Two
a - Adjustment Tool
b - Barrel retainer hairpin
c - Shift lever stud
d - Shift lever Adjustment Tool rear slot
e - Shift lever Adjustment Tool forward slot

INDEX

18. Shift the remote control into REVERSE and repeat the adjustment process.
LH ROTATION BRAVO ONE AND TWO: Rear slot in tool should fit over shift lever stud.
RH ROTATION BRAVO ONE, TWO, AND THREE MODEL: Forward slot in tool should fit
over shift lever stud.
19. If the slot does not fit over the stud, loosen the shift lever stud and slide the stud up or
down, until the slot in tool fits over the stud. When adjustment is correct, retighten the
stud.
c
c
b
b
a
a
d 79732 e 79731
LH Rotation Bravo One and Two RH Rotation Bravo One, Two, Three
a - Adjustment Tool
b - Barrel retainer hairpin
c - Shift lever stud
d - Shift lever adjustment slot

21. Ensure that all cotter pins are secure and that the ends of the cotter pins are spread to
between 90 degrees and 180 degrees.
22. Lubricate the shift cable pivot points.

30W engine oil Shift cable pivot points Obtain Locally

INDEX
Troubleshooting Shift Problems

NOTE: The following information is provided to assist an installer in troubleshooting, if hard
shifting or chucking/racheting is encountered when shifting into forward gear.
1. When installing the control box in the side panel of the boat, make sure that the cables
have enough clearance to operate. This is necessary because the cables move up and
down when the shift handle is moved. If the control box is mounted too far back towards
any fiberglass structure, the cables will be interfered with, this will cause very hard
shifting.
NOTE: The control box housing can be rotated in 30 degree increments to improve cable
routing.
74689
74688
Proper cable bend Improper cable bend
2. Make sure that when the shift cable from the control box is lead through the side gunnel
of the hull, that it does not have any extremely sharp bends in it as this will cause the
stiff shifting.

INDEX
3. Before installing the shift cable into the control box, extend the stainless rod eye end of
the cable and apply lubricant. Move it back and forth to allow even distribution of the
grease.
A A
A A
22005

A 2-4-C with Teflon Shift cable end 92-802859Q1
4. Do not strap or clamp the control cables to any other cables or rigid structure within 914
mm (3 ft) of the control box.
5. Be sure the cable is not permanently kinked.
6. Make sure there is proper clearance for cable movement when the control box is
installed in the side panel. The cables must have room to move up and down when the
control handle is shifted into either forward or reverse.
7. Check to make sure that the engine was not set down on the intermediate shift cable
during installation, as this will crush the inner cable tubing and cause improper and / or
stiff shifting.
8. Do not fasten the shift cable with straps or clamps to any other cable within 1524 mm
(5 ft.) of the shift plate.
9. Do not fasten the shift cable to the transom with any type of plastic clips or fasteners
within 1524 mm (5 ft.) of the shift plate.
10. Do not over tighten the throttle or shift cable attaching nuts at the engine end. Barrel and
cable end must be free to rotate on the mounting stud.
11. Check the intermediate shift cable routing from the transom assembly to the shift plate.
The cable should not have any sharp bends or kinks.

INDEX
Sterndrive Unit Installation

1. Remove trim cylinder support and dust cover from bell housing studs. Retain elastic stop
nuts and flat washers.
2. Remove gear lube monitor cap and fill gear lube monitor with lubricant.
79123
Typical
a - Gear lube monitor cap

High Performance Gear Lube Gear lube monitor 92-802854A1
3. Push dribble valve stem in until gear lube appears.
72471
a - Dribble valve
4. Once gear lube appears, release the dribble valve stem.

5. Fill the monitor to the “OPERATING RANGE” (full) mark.
6. Install the gear lube monitor cap. Ensure that the rubber gasket is inside the monitor cap.
Do not overtighten the cap.
7. Recheck the oil level after first use.

INDEX
8. Apply lubricant to the bell housing studs.
72471
a - Studs (6)

2-4-C with Teflon Bell housing studs 92-802859Q1
IMPORTANT: Cummins MerCruiser Diesel recommends applying engine coupler

spline grease to the sterndrive unit pilot to help prevent corrosion.
9. Coat the sterndrive unit pilot, U-joint O-rings and drive shaft splines with grease. A
grease packet for this procedure is provided with the sterndrive packaging.
A a
b A
b A
c A
70114
a - Sterndrive unit pilot

b - O-rings
c - Splines
Drive unit pilot
A Engine
g Coupler
p Spline
p Grease U-Joint O-rings 92-802869A1
Drive shaft splines

INDEX
10. Ensure that the driveshaft U-joint bellows are clean and free of debris.
72472
a - Driveshaft bellows
11. Apply lubricant to the O-ring seals.
a
72183
a - O-ring seals

2-4-C with Teflon O-ring seals 92-802859Q1
12. Pull out shift linkage as far as it moves. Jaws will open, as shown.
72460
a - Shift linkage

INDEX
IMPORTANT: As sterndrive is inserted into bell housing, entry of the shift cable must
be closely checked to make sure cable enters the jaws of shift linkage assembly in
the sterndrive.
13. Place Remote Control in neutral position.
NOTE: As Bell Housing shift cable enters the shift linkage assembly, it pushes the assembly
back into the sterndrive housing, and the jaw closes, securing the cable, as shown in steps
“A”, “B”, and “C”.
C 72467
IMPORTANT: If the Bell Housing Shift Cable “b” does not line up to properly enter the
jaws of the shift linkage assembly “a”, the cable will have to be aligned manually.
72457
a - Shift linkage assembly

b - Shift cable

INDEX
14. Place the drive shaft housing in position on the bell housing and install the sterndrive
unit, as follows:
a. Position the trim cylinders so they point straight backwards.
b. Position the drive unit so that the U-joint shaft aligns with the bell housing bore.
c. Guide the U-joint shaft through the bearing in the gimbal housing and into the engine
coupler. Make sure that the shift linkage jaws engage the bell housing shift cable
assembly.
d. If necessary, rotate the propeller shaft counterclockwise slightly (using a propeller)
to align the U-joint shaft splines with the splines in the engine coupling, then slide
the drive unit all-the-way into the bell housing.
15. Secure the drive unit to the bell housing with 5 flat washers and 6 locknuts. Torque the
sterndrive unit fasteners.
b
b
71244
a - Locknut only
b - Locknut and flat washer

Sterndrive unit fasteners 68 50

INDEX
IMPORTANT: The Trim-In Limit Insert must be properly positioned before installing
the trim cylinder anchor pin in the following steps.
16. Ensure that the Trim-In-Limit Insert is positioned as shown for the appropriate Bravo
model.
75157
Bravo One and Two (Insert positioned forward)
75158
Bravo Three (Insert positioned aft)

a - Trim-In Limit Insert
IMPORTANT: The position of the Trim-In Limit Insert on the Bravo Three sterndrive
unit should only be changed after the boat has been properly tested. Refer to Notice
On Bravo Three Trim-In Limit Insert statement at the front of this manual.

INDEX
17. Apply lubricant to all components except plastic caps upon installation.
18. Install the trim cylinders on the aft end of the sterndrive unit with hardware as shown.
19. Tighten the locknuts until the washer and nut contact the shoulder on the anchor pin.
20. Install the plastic caps and tighten hand tight only.
A
b
c c
a d e
c
f
71668 71669
a - Aft anchor pin

b - Large inner diameter flat washer (2)
c - Rubber bushing (4)
d - Small inner diameter flat washer (2)
e - Locknut (2)
f - Plastic cap (2)

A 2-4-C with Teflon Anchor pin threads 92-802859Q1
21. Place sterndrive unit serial number decal as described in Serial Number Decal
Placement.

INDEX
Speedometer Connection
1. Raise the drive to gain access to the area between the gimbal housing and the
sterndrive, immediately atop the transom end of the anti-ventilation plate.
2. Insert speedometer tube fitting into the opening on the topside of the anti-ventilation
plate, in position shown.
22025
a - Tube fitting
b - Opening
3. With the fitting fully seated, turn the handle to the left to a tightly seated position, as
shown.
22025
a - Handle

INDEX
Predelivery Preparation
NOTICE
Before starting Predelivery read General Information and Installation
Requirements completely.
Once the power package installation is complete, the following final steps should be taken
to prepare power package for delivery to the customer. It is the boat manufacturer’s respon-
sibility to perform these procedures, or to make arrangement with the dealer to have these
procedures completed.
Power Trim Pump

NOTE: See 90-863152 for mounting hole template.
IMPORTANT: Use only Quicksilver Power Trim and Steering Fluid, SAE 10W-30, or
10W-40 engine oil in power trim system.
NOTE: Fill cap assembly with Mercury M logo on top: New design of fill cap does not
require cap plug removal. The cap plug and fill cap are assembled and should not be
separated.
1. Remove the fill cap assembly from the reservoir.
79699
79701
79701
a - Fill cap assembly (top and underneath side views)
b - Reservoir fill neck

INDEX
IMPORTANT: Check the oil level with sterndrive unit in the full DOWN/IN position only.
2. Raise and lower the sterndrive unit (to the full UP/OUT position) 6 - 10 times to purge
air from system. Check the oil level visually with the sterndrive unit in the full DOWN/IN
position. Oil level should be maintained within the MINIMUM and MAXIMUM lines on
the reservoir.
79734
Typical
a - Oil level marks

Power Trim and Steering Fluid Power trim pump 92-802880A1
3. Check the power trim pump hose fittings for leaks. If fluid is visible at the fittings, torque
the fittings.

Power trim pump hose fittings 9 80

INDEX
Trim Position Sender Adjustment

1. Loosen the trim position sender retaining screws.
b
a
78537
a - Retaining screws
b - Trim position sender
CAUTION
Do not start engine in the following step or damage to sterndrive and engine could
result from lack of cooling water.
2. Turn the ignition key to the RUN position.
3. Trim the sterndrive to the full DOWN/IN position.
4. Rotate the trim position sender as required to show full DOWN/IN position on the
dashboard instrument as shown.
a
71671
a - Trim gauge needle
5. Tighten the retaining screws and turn the ignition key to the OFF position.
b
a
78537
a - Retaining screws
b - Trim position sender

INDEX
Propeller
PROPELLER ROTATION ON DUAL INSTALLATIONS
The best all-around performance usually is obtained by installing the engines so that the
propellers turn outboard (looking at the stern).
b a
79203
Outboard propeller rotation

a - RH rotation
b - LH rotation

INDEX
SELECTION
IMPORTANT: Installed propeller must allow engine to operate at the Engine Rated
revolutions per minute (rpm). Use an accurate service tachometer to verify engine
operating rpm.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power
package with the correct propeller.
Select a propeller that will allow the engine power package to operate at or near the Engine
Rated rpm with a normal load. High rpm, caused by an excessive trim angle, should not be
used in determining correct propeller selection.
If full throttle operation is below the Engine Rated rpm, the propeller must be changed to
prevent loss of performance and possible engine damage. On the other hand, operating an
engine above the Engine Rated rpm will cause higher than normal wear and/or damage.
After initial propeller selection, the following common problems may require that the
propeller be changed to a lower pitch:
• Warmer weather and greater humidity cause an rpm loss.
• Operating in a higher elevation causes an rpm loss.
• Operating with increased load (additional passengers, pulling skiers, etc.)
For better acceleration, such as is needed for water skiing, use the next lower pitch
propeller. However, do not operate at full throttle when using the lower pitch propeller but
not pulling skiers.
Because of the many variables of boat design, only testing will determine the best propeller
for a particular application. Available propellers are listed in the Mercury Precision Parts /
Quicksilver Accessories Guide.
See BOAT IN THE WATER TESTS, Maximum RPM Test in the power package Installation
Manual.

INDEX
Propeller Installation
IMPORTANT: Correct rotation propeller MUST match direction of rotation of propeller
shaft.
WARNING
Avoid Injury: Be sure that remote control is in neutral position and ignition key is
removed from switch prior to installing propeller.
WARNING
Avoid Injury: Place a block of wood between the anti-ventilation plate and propeller
to protect hands from propeller blades and to prevent propeller from turning when
tightening propeller nut.
1. Place a block of wood between the anti-ventilation plate and the propeller when
tightening the propeller nut.
71560
2. To aid in future removal of the propeller, liberally coat propeller the shaft splines with
lubricant.

Special Lubricant 101 Propeller shaft splines 92-802865A1
IMPORTANT: Installation is correct when at least 2 threads of propeller shaft are

exposed through propeller locknut after torquing it.

INDEX
BRAVO ONE AND TWO

1. Install the propeller with the attaching hardware.
2. Apply lubricant on splines of propeller shaft.

Special Lubricant 101 Propeller shaft splines 92-802865A1
3. Torque the locknut to the specified minimum, then continue to tighten until 3 tabs on the
tab washer align with grooves on spline washer. Bend the 3 tabs down into grooves.
e
f
g
a
b
c
76910
Bravo One
a - Propeller shaft e - Drive sleeve adapter

b - Forward thrust hub f - Tab washer
c - Flo-Torque drive hub g - Locknut
d - Propeller
b
c d e f 70561
Bravo Two
a - Propeller shaft d - Continuity/spline washer

b - Forward thrust hub e - Tab washer
c - Propeller f - Locknut

Propeller nut (Bravo One and Two) 1 75 55
1: Amount specified is MINIMUM.

INDEX
BRAVO THREE
1. Slide forward thrust hub onto propeller shaft, with tapered side toward propeller hub.
2. Align splines and place front propeller on propeller shaft.
3. Install front propeller locknut and torque.

Front dual propeller nut1 136 100
3 Amount specified is MINIMUM.
4. Slide aft thrust hub onto propeller shaft with tapered side toward propeller hub.
5. Align splines and install aft propeller.
6. Install propeller nut and torque.

Rear propeller nut 81 60
7. Install propeller shaft anode screw with washers. Torque the screw.
e f
b c d
a
g
h
79361
Bravo Three
a - Rear propeller nut
b - Rear propeller
c - Rear propeller thrust hub
d - Front propeller nut
e - Front propeller
f - Front propeller thrust hub
g - Propeller shaft anode
h - Propeller shaft anode screw and washers

Propeller shaft anode screw 19 168

INDEX
Engine Operation Tests

WARNING
Avoid Injury: If engine is to be tested with the boat out of the water, the propeller
must be removed to avoid injury.
CAUTION
Overheating from insufficient cooling water will cause engine and drive damage.
Ensure that there is sufficient water always available at the water inlet holes during
operation.
BOAT OUT OF THE WATER
For engine operation tests with the boat out of the water:
IMPORTANT: If using a flushing attachment (sometimes referred to as a flush test
device) over the water inlet holes and a water hose as shown, do not use full water
source pressure.
1. Install a flushing attachment over the sterndrive water inlet holes.
2. Connect a hose between the flushing attachment and a water source.
3. Open the water source about 1/2 maximum. Do not use full water pressure.
70564
Typical
a - Flushing attachment
b - Water hose
IMPORTANT: Engines with the sterndrive water inlet blocked off at the gimbal
housing and using a through the hull water inlet, need a supply of cooling water
available to both the sterndrive unit and to the engine during operation.
4. On Engines With Through The Hull Water Inlet: Supply sufficient cooling water to the
engine. Refer to the engine manufacturer’s instructions.
5. Proceed to Testing Preparation.

INDEX
BOAT IN THE WATER

For engine operation tests with the boat in the water:
IMPORTANT: If using a test tank the water level must be above the water inlet holes
on the sterndrive unit or the through the hull pickup.
1. Ensure that the water level is above the water inlet holes on the sterndrive or the through
the hull pickup.
a
b
70099
Sterndrive Water Inlet (Through The Hull Similar)

a - Minimum water level
b - Water inlet holes
2. Proceed to Testing Preparation.

INDEX
TESTING PREPARATION
IMPORTANT: During operation ensure that the engine seawater pump suction does
not collapse the hose to the water source causing the engine water supply to stop.
1. Ensure that there is a sufficient supply of cooling water to the sterndrive water inlet holes
and the through hull water inlet holes.
2. If using a flushing attachment ensure that the correct device is used for the type of water
pickup found on the sterndrive unit.
CAUTION
If using flush test device (flushing attachment), install over water intake holes and
connect a water hose. Do not use full water tap pressure. Also, do not operate en-
gine above 1500 rpm, as suction created could cause water hose to collapse caus-
ing water supply to be cut off.
77899
Dual water pickup Side pickup

INDEX
Dual Water Pick-Up Flush Gear

91-881150Q1
Case Seal Kit
Description: Use to block-off the front

water inlet holes on the dual water inlet gear
cases.
77977
Flushing Device 91-44357Q2
Description: Attaches to the drive unit

water intakes, provides a fresh water
connection when flushing the cooling
system or operating the engine.
73440
3. Check all engine related items as specified by the engine manufacturer. Refer to the
engine manufacturer’s instructions.
NOTE: Refer to the Operation, Maintenance and Warranty Manual provided with the
product for operating specifications and fluid capacities.
IMPORTANT: The sterndrive unit oil level in the gear lube monitor will rise and fall
during sterndrive operation. Always check the oil level in the monitor when the
sterndrive is cool and the engine is shut down.
4. Check the sterndrive unit oil level.
5. Test the audio warning system, if equipped.

INDEX
TESTING
WARNING
Do not leave the helm unattended when performing tests with the boat in the water.
CAUTION
Avoid engine damage. Instruments can warn of engine problems. Watch the
temperature gauge on the dash to ensure that the engine does not overheat.
1. Refer to engine manufacturer’s Operation Manual and start the engine. Operate at IDLE
rpm until it reaches normal operating temperature.
2. Turn the steering wheel to starboard, then to port, and ensure that the drive unit turns
the correct way.
3. Check the power steering system for lugging condition (engine rpm drops and/or power
steering pump tone changes):
a. Turn the steering wheel LEFT / PORT until it stops, and continue to apply pressure.
If the pump lugs, check the following.
(1.) Check for an obstruction between the gimbal ring and the gimbal housing, and
all moving steering components.
(2.) Ensure that the steering lever is not contacting cutout in transom. If there is
contact, modify the cutout.
b. Turn the steering wheel RIGHT / STARBOARD until it stops and continue to apply
pressure. If the pump lugs , check the following.
(1.) Check for an obstruction between gimbal ring and gimbal housing, and all
moving steering components.
(2.) Ensure that the steering lever is not contacting cutout in transom. If there is
contact, modify the cutout.
(3.) Check steering cable end dimension with cable fully extended. Refer to
Installation Requirements for proper steering cable dimensions.
4. Turn the engine OFF.
5. Restart the engine and observe the sterndrive unit. If sterndrive unit creeps, an external
tension may exist on steering cable. Ensure that there is nothing attached to steering
cable casing. Cable must be free to move when actuated.
6. Check the power steering pump fluid level:
a. Center the sterndrive unit. Turn the engine OFF.
b. Check the fluid level and add as necessary.

INDEX
Boat-ln-The-Water Tests
Wide-Open-Throttle Test
IMPORTANT: To operate the engine at full throttle before the break-in period is
complete, follow engine manufacturers recommendations.
To test if the correct propeller has been installed, operate the boat with normal load on board
at WOT and check rpm with an accurate tachometer. Engine rpm should be near top of the
specified range so that, under a heavy load, engine speed will not fall below specifications.
If engine speed is too high, replace propeller with a higher pitch propeller.
Cold Weather or Extended Storage
CAUTION
The sterndrive unit should be stored in the FULL DOWN / IN position. The universal
joint bellows may develop a set if the unit is stored in the raised position and may
fail when the unit is returned to service.
CAUTION
If the Power Package will not be used for an extended period of time, or will be
exposed to freezing temperatures, drain the water from the seawater circuit of the
cooling system. Water MUST BE drained to prevent corrosion and freeze damage
to the engine and/or the sterndrive unit.

INDEX
Power Trim System Wiring Diagram
b
a
c
f e
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
h GRN
ORN
=
=
GREEN
ORANGE
PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
LIT = LIGHT
DRK = DARK
73962
a - 20 Ampere fuse
b - Ground bolt (floor mount)
c - UP solenoid
d - 110 Ampere fuse
e - DOWN solenoid
f - Trailer switch
g - Neutral switch to instrument wiring harness
h - Trim limit switch

INDEX
MerCathode System Wiring Diagram
d
b
BLK = BLACK
BLU = BLUE
BRN = BROWN
GRY = GRAY
GRN = GREEN
ORN = ORANGE
c PNK = PINK
PUR = PURPLE
RED = RED
TAN = TAN
WHT = WHITE
YEL = YELLOW
73596 LT OR LIT = LIGHT
DRK = DARK
a - Controller
b - 20 Ampere fuse
c - Electrode
d - BLACK wire - with engine harness or separate

INDEX
Sterndrive Unit Predelivery Inspection

Does Not Check/
Apply Adjust
CHECK BEFORE RUNNING
Engine mounts tight
Engine alignment
Drive unit fasteners torqued
Power trim cylinders fasteners tight
All electrical connections tight
Correct rotation propeller (Installed and torqued)
Steering and shift system fasteners tightened properly
Power trim oil level
Sterndrive unit oil level
Audio warning system operation
Does Not Check/

Apply Adjust
ON THE WATER TEST
Starter neutral safety switch operation
Instrument operation
Forward - Neutral - Reverse gear operation
Steering operation throughout range
WOT rpm within specification (in forward gear)
Power trim operation
Boat handling
Does Not Check/

Apply Adjust
AFTER ON THE WATER TEST
Propeller nut, torque
Fluid leaks

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TP: 3979 Department of Homeland Security

(HM&E MANUAL) UNITED STATES

PUBLISHED UNDER AUTHORITY OF THE U.S. COAST GUARD

Technical Publications Number

Equipment Functional CB-OTH - STERNDRIVE BRAVO

DIESEL STERNDRIVE BRAVO MODELS

Page 2 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

IMPORTANT: Indicates information or instructions that are necessary for proper

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 3 of 80

Cummins MerCruiser Diesel

Page 4 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

Sales and Technical Assistance

Cummins MerCruiser Diesel

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 5 of 80

Lubricants / Sealants / Adhesives

Page 6 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

Aligns the engine and the

Shift Cable Adjustment Tool

Tapered Insert Tool

Installs the tapered insert

Transom Cutout and Drill Fixture

Use when cutting and drilling

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 7 of 80

Notice on Bravo Three Trim-In Limit Insert

Page 8 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

Multiple Sterndrive Steering Tie Bar Arrangements

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 9 of 80

Quicksilver Products - Accessories

This Guide is available from:

Outside of U.S.A., order through Distribution Center, or Distributor.

Serial Number Decal Placement

Page 10 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

a - Painted boat transom

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 11 of 80

Page 12 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 13 of 80

Throttle/Shift Remote Control and Cables

Shift Cable Travel Shift Cable Load

Steering Helm and Cable

Page 14 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 15 of 80

Steering Cable Specifications

a - Coupler nut - 7/8 - 14 UNF - 28 thread

a - Steering cable mounting flange

Page 16 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

Single engine installation

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 17 of 80

Finding The Crankshaft Horizontal Centerline (X-dimension)

Maximum Increase In X-dimension

Page 18 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

90 DEGREE TOOL METHOD

a - 345 mm (13-9/16 in.)

Single engine Dual engine

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 19 of 80

TAPE MEASURE METHOD

Single engine Dual engine

Page 20 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003

Cutting Out The Transom

Transom cutout template Transom drilling fixture kit

2. Follow instructions indicated on template or provided with drilling fixture.

CMD-4081868 / 90-861182032 SEPTEMBER 2003 Page 21 of 80

a - 51 mm (2 in.) hole saw holes (steering lever cutout)

Page 22 of 80 CMD-4081868 / 90-861182032 SEPTEMBER 2003