LPERCURY Racing STERNDRIVE PRODUCTS HP525 EFI BRAVO POWER PACKAGE INSTALLATION MANUAL Table of Contents Installation Information . ..3 Electrical Harness Installation 42 Notices to Installer and Owner. 3. Shift Cable/Throttle Adjustments....... 49 Hi-Performance Bravo Sterndrive Application Drive Unit Shift Cable Installation 49 Recommendations. 4 Troubleshooting Shift Problems. 55 Mercury Marine Precision Parts and Accessories Throttle Cable Installation and Adjustment... 86 ..7 Sterndrive Unit Installation se 57 Corrosion Protection . 7 Installing the Sterndrive Unit. 57 Warning System eon ..7 Attaching Speedometer Water Tube-Gimbal Anti-fouling Paint...10. seve 9 Housing to Sterndrive.... Serial Number Decals... 10 Predelivery Preparation ... General Engine Specifications 10 Battery Connection. Engine Operating Limitations. 10 Power Trim Pump Fuel Requirements... 14 Trim Position indicator. Torque Specifications... .12 Power Steering.. Fluid Capacities... 12 Drive Unit Gear Lube Monitor. Transom Assembly installation 13 Propellers... Special Notices To installer. -13 Test Running Engine. Gimbal Housing Installation 13. Starting Procedure for Dry EF! Engines Inner Transom Plate Installation 13 Priming Fuel System.. Exhaust Block-off Plate...... 14 Starting an Engine Without Priming the Fuel Water Pickup Connection 15 System. Th Installing Gear Lube Monitor, Hose, and Water Priming the Fuel System Before Starting the Inlet Fitting (Not on ITS)... 19 Engine..nn. 7 : 75 Power Trim Pump installation. 21 Boat in the Water Tests... 76 Speedometer Pick-up Tube Connection........22 Pre-delivery Inspection Checklist... 77 Engine Installation ..23 Trim Sender Diagnostics (If Supplied) 7 Engine Installation - General Information.......23 The Analog Trim Gauge Indicates Oft-Scalo High Engine Alignment. . 24 with No Self-Test Function........ pee TT Bilge Drain Plug and Oil Drain Hose Tether The Analog Trim Gauge Does Not indicate Installation... . Properly - Self-test Function Works . 78 ‘Seawater Connections. Wiring Diagrams .....02...cccccscesseuese 179 Engine Connections... MerCathode System. 79 Digital Trim Sender. ' Engine Starting. 80 SmartCraft Trim Gauge Connections Electrical Diagrams and Flow Diagrams veers 80 Exhaust System Installation 34 Wiring Diagrams 84 Engine Electrical Connections 38 Power Trim (Single Engine)... 81 MerCathode Connections. 39 Power Trim (Dual Engine) 82 Page 1/83 (© 2005 Mercury Marine ‘8000009 OCTOBER 2005HP525 EFI BRAVO POWER PACKAGE Lubricant, Sealant, Adhesives Tube RefNo. Description Where Used Part No. Loctite 271 Threadlocker Propeller shaft threads secon | @ Loctite 567 PST Pipe Sealant Fuel inlet ine fiting threads 92-809822 Perfect Seal Barbed fitting threads 92.34227-1 Battery torminale id Neo 28711 bea prone All MerCathode terminal connections Ce Special Lubricant 101 Propeller shaft - Fresh water use only | 92-802865A1 ana Gimbie housing studs, wjoint shaft | o> LUjoint ana Gimbal Bearing Grease] "Sines and ujomornngs | 920287041 [SAE Engine Oil 30W Shift cable pivot points lobtain Locally 8702 [high Performance Gear Lubricant Filling the gear lube monitor | 92-802854A1 Engine Coupler Spine Grease Coupler spines 92-802869A1 Exposed surfaces of propeller shaft [SE D2 |Anti-Corrosion Grease Te Stentor van | 92 20286741 if cable eye ends and sliding surfaces (O-ring seals -C Marin i 80% /2-4-C Marine Lubricant with Teflon ochre iresde 92-802859A1 Propeller shail - Fresh water use ont [LEE D> [Power Trim and Steering Fluid Power steering reservoir | $2-8028601 Special Tools [Tapered Insert Tool 91-43579 e Removes and installs the tapered inser retainer into the water inlet hose over [Alignment Tool Assembly 91-805475A 1 t — ao Aligns the engine and the sterndrive unit during installation. |} e189 [Shift Cable Adjustment Tool 91-12427 USF] Attaches over the shift cable, and aids in proper shit cable Tam adjustment atthe shit plate Flushing Device 91-4435702 Attaches to the water intakes; provides a fresh water [connection when flushing the cooling system or operating the engine Page 2/63 ‘awig000009HP525 EFI BRAVO POWER PACKAGE [Flushing Attachment 191-843122A01 Attaches to the water intakes; provides a fresh water [connection when flushing the cooling system or operating the| lengine. 14505, Dual Water Pick-up Flush Gearcase Seal Kit 91-881150K 1 Blocks off the front water inlet holes on the dual water inlet lgearcases. Installation Information Notices to Installer and Owner SAFETY ALERTS AND NOTICES APPROVED PRACTICES AND PROCEDURES. Throughout this publication, "Wamings" and "Cautions," accompanied by the international HAZARD symbol AM , are used to alert the technician to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe these safety alerts carefully These safety alerts alone can not eliminate the hazards they signal. Strict compliance to “! these special instructions when performing the service, and common sense operation are major accident prevention measures. WARNING - indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. TSA CAUTION 4 CAUTION - indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury or property damage. It may also be used to alert against unsafe practices. IMPORTANT: Indicates information or instructions that are necessary for a particular step or action. NOTE: Indicates information that helps in the understanding of a particular step or action. A CAUTION ‘Avoid personal injury or property damage. Personal safety is dependent upon using proper service procedures, the correct tools and appropriate parts. The procedures in this manual are safe and effective when performed properly. Some of the procedures require special tools, specifically designed for the purpose. If part replacement required, use only replacement parts that are manufactured or sold by Mercury Marine. Anyone who chooses to use procedures, tools or parts not recommended by Mercury Marine assumes full responsibility for the results, ‘818000009 Page 3/83HP525 EFI BRAVO POWER PACKAGE IMPORTANT: Use of procedures, tools, or parts not recommended by Mercury Marine may void the Mercury Marine Limited Warranty. This manual is written to aid our dealers and company service personnel in the proper installation or service of our products. Persons who are not familiar with these or similar products produced by Mercury Marine, and who have not been trained in the recommended servicing or installation procedures should have the work performed by an authorized Mercury Marine dealer technician. Improper installation or servicing of this product could result in damage to the product or personal injury. This document details safe service and diagnostic procedures. Mercury Marine cannot caution against all potentially hazardous service methods. For safety reasons, follow procedures as described in this document. Itis the responsibilty of the OEM to select the appropriate engine/transom/drive package (including the correct gear ratio and propeller) for a given boat. Making an appropriate selection requires knowledge of the boat (weight, length, hull design, intended use and duty cycle, desired speed, etc.) that is uniquely in the possession of the OEM. While Mercury employs people capable of assisting the OEM on such issues, the final decision rests with the OEM. Mercury recommends that any new or unique hull/power package combination be thoroughly water tested prior to sale to verify (among other things) that the boat performs as desired, and that the engine operates in the appropriate RPM range. Mercury Racing recommends that a Mercury Racing Product Integration manager be contacted for assistance if specific application or installation problems are encountered. All information, illustrations, and specifications contained in this manual are based on the latest product information available at time of publication. As required, revisions to this manual will be sent to all OEM boat companies. Hi-Performance Bravo Sterndrive Application Recommendations BRAVO III XR NOTICE: TRIM-IN LIMIT PIN INSERT NOTE: Bravo Ill XR Models are equipped with a Trim-in Limit Pin Insert. ‘Some boats (predominantly deep-Vee heavy boats) will oll 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 sterndrive 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 sterndrive 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 Pin Insert reduces stern-lift by preventing the sterndrive unit from reaching the last few degrees of full tm under. While this device should reduce the rolling tendency, it may not eliminate the tendency entirely. The need for this Trim-In Limit Pin, and its effectiveness, can. only be determined through boat testing and is ultimately the responsibility of the boat manufacturer. a Mercury Racing recommends that only qualified-personnel adjust the Trim-In Limit Insert. The 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 characteristic if the sterndrive unit is trimmed in at higher speeds. Increased Trim-In Tange may cause handling problems on some boats that could result in personal injury. Page 4/83 ‘88000009HP525 EFI BRAVO POWER PACKAGE TRIM POSITION INDICATORS BOAT TYPES. Some Hi-Performance Bravo Transom Assemblies do not have an electrical trim limit ‘switch or trim position sender, therefore, the following precautions must be observed. ee ARNG, ee ‘Avoid personal injury or damage to the stemdrive unit. Without trim limit protection, the drive unit can be trimmed up or out to a position where there is no drive unit side support from the gimbal ring. Mercury recommends that a mechanical (cable actuated) or electrical trim position indicator be used to provide drive unit trim angle information to the operator, and that the trim gauge be marked clearly to indicate the maximum up or out position (12°) where side support is still provided. The drive unit must not be trimmed to a position beyond the gimbal ring side support at engine speeds above 1200 RPM. Refer to the Power Package Installation Manual for the procedure to follow when "Marking" the mechanical (cable actuated) trim indicators. This Bravo engine package is recommended for use in most sport boat applications with the following exceptions: + When the application requires a surfacing propeller, we recommend using one of the Super Speedmaster drives from Mercury Racing that is designed specifically for surfaced propeller operation. + Applications requiring other than standard Quicksilver propellers to plane the boat or to keep the propeller from ventilating when the boat is on plane. + Some boats require the engine to be operated above 3200 RPM to keep them on plane. + Racing applications or other highly abusive applications where the boat and the drive unit will come out of the water frequently. These are applications where we recommend our Super Speedmaster drive unit. STEERING RECOMMENDATIONS. Mercury Racing recommends the use of hydraulic helm steering or external power steering systems. These steering systems give additional support for tight, firm steering control and are recommended for the following applications: * High speed single or twin engine applications and/or boats with unusual handling characteristics. It is virtually impossible to give a specific recommendation as to when external power steering should be used as this varies from boat design to boat design. Generally speaking, its recommended to use external power steering on boats which run in excess of 70 mph. However, there are boats which run 60 mph that would benefit from the use of external power steering. Because of the many variables involved, the final decision as to whether or not external power steering is required rests with the boat manufacturer and must be made after a thorough test and evaluation of each specific boat model, If there is any question whether or not external power steering is necessary, Mercury Racing recommends that it be installed. + Any Hi-Performance sport boat powered by three or more engines. + Offshore boats or other applications where the boat and drive units will come out of the water occasionally. ‘818000009 Page 5/83HP525 EFI BRAVO POWER PACKAGE MULTIPLE STERNDRIVE STEERING TIE BAR ARRANGEMENTS With multiple sterndrives, it is important to consider which of several possible steering systems should be selected. il 2 A CAUTION E Failure to observe the recommended Tie Bar Arrangements could result in serious damage to the steering and/or trim system components. This damage could adversely affect control of the boat. Observe the recommended Tie Bar Arrangements as presented in this section: Internal Tie Bar Only At the lower end of the performance spectrum (boats not capable of speeds in excess of 60 mph), the basic internal tie bar is recommended. It connects the slave sterndrive to the stemndrive that is directly connected to the factory power steering output. This intemal tie bar is available in a variety of lengths from the sterndrive manufacturer. Internal and External Tie Bar As a boat moves into a moderate performance range (60-70 mph) 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 which is an excellent location 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, care must be taken by the operator to avoid trimming one drive more than 20° differently than the other. Extemal Power Steering When boat speeds move past 70 mph, 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 of 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. Extemal Power Steering With. Low External Tie Bar For the fastest boats (over 80 mph), 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 and External Tie Bar" statements). Again this system does not use an internal tie bar. Mercury Racing does not recommend the use of an external tie bar only (no internal tie bar) when using the intemal 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. Sterndrive Multi-Engine Toe-In/Toe-Out Adjustments The units should be checked for steering play between the units when the boat is at rest. If any play exists, the units should be adjusted with some toe-in or toe-out at rest so that at maximum speed the side forces (e.g., paddle wheel effect) will pull the units into a Parallel position taking up the inevitable play in the steering system. As one or more tie bars are added to the steering system and/or external power steering is installed, the units should be adjusted to be parallel’at rest as all of the play in the steering can be adjusted to zero. Page 6/83 ‘@M8000009HP525 EFI BRAVO POWER PACKAGE Mercury Marine Precision Parts and Accessories Mercury Marine Precision Parts and Accessories gauges, remote controls, steering systems, propellers, etc., are available for this product. Refer to the Mercury Accessories Guide for complete listing This Guide is available from: Parts Department Mercury Marine WE250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1839 oR- Outside of U.S.A, order through Distribution Center or Distributor. Corrosion Protection The power package is equipped with zinc anodes to help protectit from galvanic corrosion under moderate conditions. However, for severe conditions, or if using a stainless stee! propeller, it is recommended that a Quicksilver Anti-Corrosion Anode Kit andlor a MerCathode System (included with all Bravo models) be installed. ‘A MerCathode Monitor is also available to check operation of the MerCathode System with the push of a button (refer to Mercury Accessories Guide for part number). 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 Mercury Accessories Guide for part number.) IMPORTANT: If AC shore power is not isolated from boat ground, the MerCathode System and zinc anodes may be unable to handle the increased galvanic corrosion potential. Warning System The engine's warning system includes an audible alert consisting of a hom located in the helm harness, and the Engine Guardian system. Do not attempt to alter or disable the warning system in any way. A CAUTION ‘Avoid engine damage. Do not operate the engine after a continous horn is heard, EXCEPT TO AVOID A HAZARDOUS SITUATION. ENGINE GUARDIAN SYSTEM The Engine Guardian system monitors sensors on the engine for any early indications of problems. If a sensor indicates a fault, the system responds to the problem by emitting a continuous or intermittent horn and, depending on the type of fault, may reduce engine power to provide engine protection. If the boat is equipped with System View, a message will be given on the display screen in conjunction with the horn. Refer to the System View manual for details. When the key switch is turned "ON", the warning system's horn beeps ‘once to verify horn operation. FAULT TYPE AND RELATED WARNING SIGNAL + Critical - Steady horn + Severe - § beeps, each 3 seconds long ‘@v8000009 Page 7/83HP525 EF BRAVO POWER PACKAGE + Warning - 3 beeps, each 1.5 seconds long + Caution - 2 beeps, each 1 second long + To stop an activated hom warning, turn off the engine. If the horn continues to sound on restart, the system detected a fault again. See your Mercury Marine dealer to correct the problem as soon as possible. + If on restart the beeping stops, the problem does not need immediate attention but will require you to see your authorized Mercury Marine dealer to diagnose and clear the fault, If the Propulsion Control Module (PCM) detects a fault signal from an engine sensor, it records a fault code. A Digital Diagnostic Terminal (DDT) or Computer Diagnostic System (CDS) is required to extract specific problem codes from the PCM. WARNING SYSTEM TABLE The following table is divided into four columns. The Possible Cause column lists items that could be initiating the fault. The Horn column lists the type of audible alert that will be given ifa faults detected. Ifthe boat is equipped with System View, the Monitor Display column indicates whether or not a message will be given on the screen. The Guardian Activated and Engine Power Reduced column indicates if the PCM will reduce engine power or force the engine into an idle based on the severity of the problem. The table lists only the possible problem areas and not specific error codes or messages recorded by the PCM, Guardian Activated and Posse Case rom | montarispay] Engine Powe Reus POM Eror Sindy Hom ves Forced le Guan vores Saad Horm ves No Engine Overpoed Steady Horn ves No Tow SeavaterPresaze | Seaty Hom ves Yes Seawater Pressure Sensor | aeeps.1.5 Sec Long] Yes No Gacan Ovrheat Seedy Hom Yer Yer Gooiant Temperate Sensor Ts Beeps. Sec Lone] Yes No Tov Ol Pressure Seedy Horm Ye 7 i Presswe Sensor Faure [9 Bees-15sec. tong Yes Yes Oi Tenperatre Hoh steady Hom es Wo i Temptaure Sensor Fare [3 Beop-15 se. tonal Ves Wo Charge Teroeratwe ign | Steady Hom Yes Wo Charge Tenpsatze Soo” [spears 1.6 econo) Yes Ne Sie Grankanat Paton Sensor Sea4y tom ves ves WAP Sensor Ear | 6 Beeps 3 Sec Long | Ves we Col Pack Faure | 8 boone 3See-tong | Yes Wo Fuel njecorFatuo [6 boop See tong | Yoo ne Fuel Purp Faure | 8 Boape'3 Sec.torg | You Wo Fuel Pressure Senor Faure [3 Beeps 1.8 See. Lond] Ves No ie Ar Convl Faire | 6 Beep-8 Se. Long | Yes No Cam Sensor Raonato [3 Beeps 1.8 See. Lond] Ves ne Tirole Position Sensor ature [3 Beeps 15 See tonal Vos ves Page 8788 anreonGo08HP525 EFI BRAVO POWER PACKAGE (Guardian Activated and Possible Cause Horn |Monitor Display] _ Engine Power Reduced Tow Battery Votage [2 Beepe-15 Sec.Lonal Yes No Bator Range high orlow [2 Beape-t.5 See. Long] Yes Yes tow Drive Lube or Transmission | peeps Sec.tong | Yes No Lanyard Swich acvaled | 2Beaps-1 Sec tong | ves Wo Anti-fouling 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: If anti-fouling protection is required for boat hull or boat transom, copper or tin base paints, if not prohibited by law, can be used. If using copper or tin based anti-fouling paints, observe the following: Do not paint anodes or MerCathode System reference electrode and anode as this will render them ineffective as galvanic corrosion inhibitors. ‘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.) of an unpainted area on the transom of the boat around these items, a - Painted boat transom b- Unpainted area NOTE: Drive unit and transom assembly can 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 the drain holes, anodes, MerCathode system, and items specified by the boat manufacturer. ‘8000009 Page 9/83:HP525 EFI BRAVO POWER PACKAGE Serial Number Decals Place the serial number decals for the engine, drive and transom in the space provided ‘on the decal that is located on the front of the Model Displacement Max WOT RPM: ‘Spark Plugs: Spark Plug Gap: Spark Timing: Fuel Octane: 1HP525 EFI 502 C.LD. ‘4800 - 5200 NGK BPR6ES 0.035 Inch “non-adjustable 87 (ReM)/2 oF 92 RON International “Quicksilver 25040 Dex:Cool © Engine Oil: Engine Coolant: “see owner's manual General Engine Specifications heat exchanger. SERIAL NUMBERS ENGINE DRIVE TRANSOM 7163 Horsepower: 525 HP (391 KW) Displacement Ja.2t (602 ci) [Cylinder arrangement v8 Bore 114mm (4.47 in.) Stroke 102 mm (4.00 in.) [Compression ratio fe75:1 [Alternator [65 amp / 917 watt Battery requirements [750 CCA.950 MCA Ignition type PCM 03 Distributoriess ‘Spark plug type INGK BPREES ‘Spark plug gap [0.889 mm (0.035 in.) Fuel system [Sequential Fue! injection [Weight [544 kg / 1200 lbs Approximately Engine Operating Limitations [Maximum wide open throttle (W.0.7.) RPM [4800 - 5200 RPM Rev limit [5300 RPM (Horn) $400 RPM Limit idle RPM in gear [700 RPM idle RPM out of gear 750 RPM Maximum fuel system flow rate [241 Linr (56 gals/hr) at §200 RPM Fuel pressure at idle [276 kPa (40 psi) Fuel pressure at 5200 RPM [262 to 483 kPa (38 psi) Coolant thermostat intially opens at temperature Je2" c (143° F) Coolant thermostat is at maximum open at temperature| [74° C (160° F) Minimum water pressure supplied to the engine 138 kPa (20 psi) at 5200 RPM (from oll cooler |sensor) Maxinium water pressure supplied to the engine 1414 kPa (60 psi) at 5200 RPM (rom oil cooler [sensor) Minimum oil pressure at idle (Hot) 138 kPa (20 psi) [Minimum oil pressure at 5200 RPM (Hat) [241 kPa (35 psi) [Maxiumum oll temperature {93° C (200° F) Page 10/83 ‘88000009HP525 EFI BRAVO POWER PACKAGE Fuel Requirements Use a major brand of unleaded gasoline, preferably without alcohol. Mercury Marine recommends fuels that contain fuel injector cleaner for added internal cleanliness. Mime = ae FIRE AND EXPLOSION HAZARD: Fuel leakage from any par of the fuel system can be a fire and explosion hazard which can cause serious bodily injury or death. Careful periodic inspection of entire fuel system is mandatory, particularly after storage. All fuel components should be inspected for leakage, softening, hardening, swelling or corrosion. Any sign of leakage or deterioration requires replacement before further engine operation. A CAUTION Use of improper fuel can seriously damage your engine. Engine damage resulting from use of improper fuel is considered misuse of the engine and damage caused thereby will not be covered under the Mercury Racing limited warranty. OCTANE REQUIREMENTS (U.S./CANADA) FUEL TYPE, MINIMUM POSTED OCTANE Premium Unleaded (eM) + 2= 67 or RON = 68" NOTE: ‘Research Octane Number OCTANE REQUIREMENTS (OUTSIDE THE U.S./CANADA) FUEL TYPE MINIMUM POSTED OCTANE Premium Unleaded" (R+M) + 2=87 or RON = 96" NOTE: ‘Research Octane Number USING REFORMULATED (OXYGENATED) FUELS (USA ONLY) This type of fuel is required in certain areas of the U.S. The two types of oxygenates used in these fuels are alcohol (Ethanol) or Ether (MTBE or ETBE). If Ethanol is the oxygenate that is used in the gasoline in your area, refer to the Fuel Containing Alcohol section. These reformulated fuels are acceptable for use in your Mercury engine FUEL CONTAINING ALCOHOL Ifthe fuel in your area contains either methanol (methyl alcohol) or ethanol (ethyl alcohol), you should be aware of certain adverse effects that can occur. These adverse effects are more severe with methanol. Increasing the percentage of alcohol in the fuel can also worsen these adverse effects. Some of these adverse effects are caused because the alcohol in the fuel can absorb moisture from the air, resulting in a separation of the water/alcohol from the gasoline in the fuel tank. The fuel system components on your Mercury engine will withstand up to 10% alcohol content in the gasoline. We do not know what percentage your boat's fuel system will withstand. Contact your boat manufacturer for specific recommendations on the boats fuel system components (fuel tanks, fuel lines, and fittings). Fuel containing alcohol may increase: + Corrosion of metal parts. + Deterioration of rubber or plastic parts. 1. Mercury Racing does not recommend using leaded gasoline, Leaded gasoline is acceptable in areas where unleaded gasoline is not available; however, lead particles may build up in the exhaust passages and/or the combustion chambers. ‘a1g000009 Page 11/83HP525 EFI BRAVO POWER-PACKAGE + Fuel permeation through rubber fuel lines. + Starting and operating difficulties. ; 7A CAUTIONS When operating a Mercury engine with fuel containing alcohol, avoid storing the fuel in the fuel tank for long periods of time. Long storage periods, common to boats, create unique problems. In cars, alcohol-blend fuels are normally consumed before they can absorb enough moisture to cause trouble. However, boats offen sit idle long enough for phase separation to take place. In addition, internal corrosion may take place during storage if alcohol has washed protective oil films from internal components. IMPORTANT: Because of possible adverse effects of alcohol in gasoline, it is recommended that only alcohol-free fuel be used where possible. If only fue! containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnormalities is required. Torque Specifications NOTE: Fasteners not listed should be tightened securely. TRANSOM ASSEMBLIES [Description Nm 1b. in. Ibf [Drive Unit Gear Lube Monitor - 90° Hose Barb Fitting 2 80 | Speedometer Pickup Barb Fitting 15 13. Exhaust Pipe or Block-off Plate 31 23 [Power Trim Pump Hose Fittings 3 110 Transom Assembly Fasteners 31 23 [Seawater Pickup Fiting Tos «6 STERNDRIVE [Description Nm ib.in 1b. ft [Sterdrive Unit Fasteners 68 50 [Propeller Nut (Bravo Two, XR) (Min. Torque) 75 55 [Propeller Nut (FRONT) (Bravo Il! XR) (Min. Torque) 135, 400 Propeller Nut (REAR) (Bravo i XR) (Min, Torque) at 60 Power Trim Gylinder to Drive Unit Tighten unti nuts bottom out ENGINE Description Nm Ib. in. Ib. ft. Exhaust Tailpipe to Exhaust Header 14 120 Exhaust Header to Engine Cylinder Head a 30 Rear Engine Mounts to inner Transom Plate a7 35 Fuel Line Inlet Fitting ‘See Fuel Line Connections directions Fluid Capacities ENGINE [Crankcase Oil With Fier (Always use dipstick to determine exact quantity of ol or uid require.) mena [Closed Cooling Systamn [132% ters (125 ats) Page 12/83 ‘eMe000009,STERNDRIVE HP525 EF! BRAVO POWER PACKAGE Model Bravo One XRIXR | — Bravo One XR SportMasterxZ__| SportMaster (Short) Greve til XR Drive Unit OW Capacity (with pee one wenn 265 liters (2841s) | 26 liters (275ats) | 2.8 liters (ats) Transom Assembly Installation Special Notices To Installer IMPORTANT: The following procedures start with the installation of the drive unit's transom assembly. Refer to the Requirements Manual for procedures on cutting the opening in the transom in preparation for the drive unit's transom assembly. The Requirements Manual will also provide information about required special tools and drilling fixtures. IMPORTANT: The following procedures are for Bravo drive unit installations without a Mercury Racing Intergrated Transom System (ITS). For ITS installation procedures, refer to the Installation Manual included with the ITS. IMPORTANT: The following procedures are for Bravo drive unit installations without a Driveline Extension Kit. When a forward mounted power package is ordered, a special flywheel housing, sterndrive inner transom plate, and driveline extension kit are required. Refer to the Installation Manual included with driveline extension kit for installation procedures. Gimbal Housing Installation 1. Carefully remove the transom assembly from the shipping carton and remove the sealing ring protectors from the outer transom assembly. 2. Remove and read all tags which are attached to the transom assembly. a - Sealing ring protectors Inner Transom Plate Installation 4. Place the inner transom plate against the boat's inner transom. 2. Route the wires, hoses and shift cable through the transom and the appropriate openings in the inner transom plate. 3. Position the outer gimbal housing onto the transom and hold in place. 4, Install the bolts and nuts to secure the inner and outer transom assemblies together. ‘8118000009 Page 13/83HP525 EFI BRAVO POWER PACKAGE 5. Tighten the nuts in small increments, going around the pattern several times until the proper torque is achieved. The tightening sequence is numbered in the following the illustration. 6. Verify all fasteners are torqued to Specifications IMPORTANT: The steering lever continuity circuit wire must be positioned as shown to avoid stress on the wire when the steering lever moves. 7240 a - Locknuts and flat washers (8) d - Steering lever continuity wire b- Transom plate continuity wire e - Digital Trim Sender Connection c- Bolt Desciption ee Frensom assembly ocknuts at 23 Exhaust Block-off Plate In most Mercury Racing power package installations, the engine exhaust will be routed through the transom with tailpipes rather than through the propeller shaft housing of the drive unit. In this case the exhaust port in the gimbal housing will be covered with a block-off plate 1. Ensure that the gimbal housing exhaust block-off plate surface is clean and free of nicks and scratches and that the O-ring is properly seated in the groove. Page 14783 ‘818000009HP525 EFI BRAVO POWER PACKAGE 2. Install the gimbal housing exhaust block-off plate and torque lockwashers to specifications. a- Gimbal housing mating surface - Block-off plate b- O-ring d- Bolts and lockwashers (4) Description Nm 1b. in, bf [Gimbal housing block-off plate bolts and lockwashers 3t 3 Water Pickup Connection The engine uses both a closed and external cooling system. The external cooling system @ has water supplied to the engine from sea water outside the boat. This can be done by either lower, side, or both (called “dual") water pick-up holes in the Bravo drive unit or by an alternative external water pick-up device. Determine if the external water supply to the engine will be provided by the Bravo drive unit or by an external water pick-up device, then follow the installation instructions for the appropriate method. 4029 b- Lower pick-up (optional) a- Side pick-up c- Alternative external pick-up ‘ d- Transom water inlet ‘818000009 Page 15/83HP525 EFI BRAVO POWER PACKAGE BRAVO DRIVE UNIT WATER PICK-UP CONNECTION When using the water supplied by the water pick-up holes in the Bravo drive unit, a water inlet fitting willbe installed to the inner transom. In applications using a MerCruiser engine, the quick release type fitting supplied in the parts bag should be used. In applications using a Mercury Racing engine, the barb type fitting supplied in the parts bag should be used NOTE: Mercury Racing engines use the barb type fitting supplied in the parts bag for the water inlet fitting. 1. Clean the water inlet mounting surface on the inner transom. 2. Determine if a J-clip will be needed to route the gear lube monitor hose. Refer to Installing Gear Lube Monitor. 3. Install gasket and water inlet fiting with bolts and washers. 4. Torque to Specifications. 12009 a- Water inlet fiting d= J-clip b- Mounting surface @ - Bolts and washers c- Gasket [Description Nm ib. in. bf [Sorew, water fiting 5 5 ALTERNATIVE WATER PICK-UPS If the Bravo drive unit water pickup will not be used to supply water to the engine and an alternative extemal water pick-up in the hull or transom of the boat will be used, then a water block-off plate will be installed to the water inlet of the inner transom of the drive unit. Refer to the Mercury Marine Precision Parts and Accessories Guide for the water block-off plate part number. . When installing the block-off plate, it is necessary 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. Page 16/83 ‘88000009‘N48000009 HP525 EFI BRAVO POWER PACKAGE A CAUTION ‘Avoid overheating the stemdrive. The seawater inlet holes must be allowed to flow water without being obstructed or damage to the sterndrive will result. Do not dead-end the seawater hose from bell housing. Cut hose as recommended in procedures. 1. If previously installed, remove the water inlet fitting and gasket. Discard the screws and washers. Remove and discard the tapered plastic hose expander insert in the gimbal housing using the tapered insert tool. This will release the hose from inside the housing. a- Tapered insert b- Tapered insert tool ¢- Gimbal housing cross-sectional view 91-43579 [Tapered Insert Tool Install the new gasket and block-off plate. Secure with screws and lockwashers. 3. Torque the screws to Specifications. re02 a Block-off plate c- Screw b- Gasket d- Lockwasher Description Nm bin | bn Screw, water fiting 5 45 Page 17/83HP525 EFI BRAVO POWER PACKAGE 4. Move aside the trim limit sender wires and speedometer hose. Reach between the gimbal housing and the bell housing and detach the water hose from the gimbal housing where the tapered plastic hose expander insert was removed in step two. 7285 a- Trim limit sender wires d- Water hose b- Speedometer hose e- Tapered insert ¢- Gimbal housing poe ee SR WARNING Ee e ‘Avoid water leakage into the boat. Ifthe U-joint bellows is damaged, water will enter the boat. Be careful not to damage the U-joint bellows when removing the section of the water hose attached between the gimbal housing and the bell housing. NOTE: Move the trim limit sender wires and speedometer hose to avoid damaging them when cutting the water hose. The existing tie strap and clip can be re-used if they are moved and re-positioned after the hose is cut. 5. Cut completely through the water hose 127 mm (5 in.) in front of the aft end of the hose where it is fitted into the bell housing in the area shown. Do not damage the U-joint bellows. Discard the hose piece. 6. Secure the trim limit sender wires and speedometer hose to the remaining section of the water hose using the existing tie strap and clip. rr a-Tie strap d- Speedometer hose b- Clip e- Trim limit wire harness - Water inlet hose f- Cutting area Page 18/83 ‘@M8000009HP525 EFI BRAVO POWER PACKAGE Installing Gear Lube Monitor, Hose, and Water Inlet Fitting (Not on ITS) 1. Connect the gimbal housing hose assembly with the quick release 90 degree fitting to the gimbal housing fitting a~- Gimbal housing hose assembly —_¢ - Gimbal housing fitting b- Quick release 90 degree fitting d- Female quick release connector A CAUTION Avoid damaging the stemndrive unit. The quick release button on the 90 degree hose fitting may not lock on the gimbal housing if it is touching or if it is depressed by the water inlet fitting or the block-off plate. Ensure that the quick release button does not contact the block-off plate or the water inlet fiting. Failure to do so could resultin a loose 90 degree fitting that could cause a loss of gear lube, and damage to the sterndrive unit. 2. Position the quick release button on the 90 degree fitting away from water inlet fitting or block-off plate. The quick release button must not contact the water inlet fitting or e the block-off plate. O10 Zea 7 O 78 Block-off plate installation shown, models with water inlet fitting similar e a- Acceptable positions d- Quick release 90 degree fitting b - Non-acceptable position @ - Block-off plate (or water inlet fitting ¢~ Quick release button if equipped) ‘88000009 Page 19/83HP525 EFI BRAVO POWER PACKAGE 3. Install water inlet fitting with gasket. Torque bolts and star washers to Specifications. IMPORTANT: If the gear lube monitor bottle is mounted on the port (left) side of the transom, it will be necessary to install a hose clip ("c" - shown below) behind the top bolt on water inlet fitting. Hose must be routed directly to the gear lube monitor, avoiding low @ spots (traps) in the system. d- J-clip a- Water inlet fitting @ - Quick release button b- Bolts and star washers ¢- Gear lube monitor hose Description Nm. ‘b. in. ib. f e 5 Bolts 4. Connect the gear lube monitor hose assemblies. 5h og a - Gear lube monitor hose assembly from transom b- Gear lube monitor hose assembly from gear lube monitor c+ Quick connect fitting » = ACAUTION Be sure that the gear lube monitor hose does not become kinked when it is connected. Ifthe hose is kinked, the monitor will not function properly and damage to the drive unit could occur. IMPORTANT: Hose assemblies must not come in. contact with steering system components, engine coupler, u-joint shaft, or driveshaft. NOTE: The quick release button on hose fitting must be positioned away from water inlet fitting or any other object that might cause the connection to release. 5. Secure gear lube bottle bracket to innef transom with lag screws and flat washers as shown, Page 20/83 ‘@m18000008HP525 EFI BRAVO POWER PACKAGE 6. Position the gear lube monitor bottle in the bracket and secure it with a rubber tie strap. a- Bracket b- Gear lube monitor c- Rubber tie strap 7. Route the hose to the monitor and cut the hose to length. Connect the hose to the monitor and secure it with a hose clamp. 8. Connect the audio warning system wires, located above the oil cooler on the rear starboard side of the engine, (BLU/TAN and BLK) to the gear lube monitor (BLK and BLK). Use the extension harness from this kit or the extension harness from the drive shaft extension kit (if applicable). Wire polarity does not matter. @ 9. Use extra hose clips to secure the hose to the transom. a~ Gear lube monitor d= Audio waming system wires b- Hose clamp e- Hose clip c- Hose Power Trim Pump Installation Some Hi-Performance Bravo Transom Assemblies do not have an electrical trim limit switch or trim position sender. ‘ag000009 Page 21/83HP525 EFI BRAVO POWER PACKAGE. Avoid personal injury or damage to the stemdrive unit. Without trim limit protection, the drive unit can be trimmed up or out to a position where there is no drive unit side support from the gimbal ring. Mercury recommends that a mechanical (cable actuated) or electrical trim position indicator be used to provide drive unit trim angle information to the operator, and that the trim gauge be marked clearly to indicate the maximum up or out position (12°) where side support is stil provided. The drive unit must not be trimmed to a position beyond the gimbal ring side support at engine speeds above 1200 RPM. 1. Mount the pump in the desired location and discard the disposable shipping cap and plug. 2. Connect the hydraulic hoses to the trim pump. 3. Connect the trim pump control harness to the trim pump up and down solenoids, and secure the harness with a clamp. If necessary see Wiring Diagrams. a - Battery negative cable (-) f~ Shipping plug (discard) b - Battery positive cable (+) g- Black hose (trim up) c- Up solenoid connection h- Reservoir cap d- Down solenoid connection i+ Gray hose (trim down) - Shipping cap (discard) Speedometer Pick-up Tube Connection IMPORTANT: Do not remove the plug at the transom plate speedometer fitting if you are not installing a speedometer or if an alternate speedometer pickup will be used. 1. Remove the plug from the speedometer pickup tube fitting. Page 22/83 ‘eMg000008HP525 EFI BRAVO POWER PACKAGE 2. Apply Perfect Seal to the barb fitting threads and install the fitting. Torque fitting to specifications. a - Fitting plug b- Speedometer pickup tube fitting ¢- Barbed fitting Descipton Nn | bin | ba Barbed ting [ras 3 | ‘Tube Ref No. Description Where Used Part No. Perfect Seal Barbed fiting threads 62-34007-1 3. Connect hose from speedometer to barb fitting. Secure hose with tie strap. 4. Mount speedometer hose to transom with hose clip and screw. Hose must not come in contact with any moving or hot components. @ Engine Installation Engine Installation - General Information 1. Remove all hardware that secures engine to shipping container. A CAUTION ‘When installing battery, connect the positive (+) battery cable to the positive (+) battery terminal first, and the negative (-) battery cable to the negative (-) battery terminal last. If battery cables are reversed, or connection order is reversed, electrical system damage will result. IMPORTANT: There is a fuse located at the starter solenoid. Do not remove this fuse. | The positive battery cable must be connected to the base of the fuse, current for starting must not pass through the fuse. 2. Make sure that the grounding stud and the starter solenoid terminals are clean. 3. Connect the battery cables to the engine, positive (+) cable first. 4. Apply a thin coat of Liquid Neoprene to the terminals. “Tube Ref No Description Where Used [PartNo [D> [Liquid Neoprene Battery terminals [__szasrat-s 5. Slide the rubber boot over the positive (+) terminal. e 6. Drape the battery cables over the top of the engine during the installation. ‘818000009 Page 23/83HP525 EFI BRAVO POWER PACKAGE NOTE: Do not remove 90 amp fuse. soe a- Positive (+) battery cable c- Starter b- 90 amp fuse d- Negative (-) battery cable 7. Remove the shipping plug from the coupler and lubricate the splines with Quicksilver Engine Coupler Spline Grease. a - Shipping plug/coupler Tube Ret No Desaipon Where Used Patna Eine Cale Spine Geos] Coun spres | s0- —_[specelLuricant sor | Povelerstan-Fresnwatr | o2 enzeesas Ex) |Anti-Corrosion Grease Propeller shaft - Saltwater use 92-802867A1 “app 2S Marine Labrcantwin | Propeler sof Fresh water ep Pao ae 20286081 3. Align splines and place the propeller on the propeller shaft. 4. Install and tighten the propeller nut to the specified torque. Check the propeller at least every 20 hours of operation and retighten as needed. Description Nm. tb. in ib. ft Forward propeller nut 136 100 5. Slide the aft thrust hub onto the propeller shaft with the tapered side toward the propeller hub (toward the end of the shaft). 6. Align splines and place the propeller on the propeller shaft. 7. Install and tighten the propeller nut to the specified torque. Check propeller at least every 20 hours of operation and retighten as needed. [Description Nm bin bf [Aft propeller nut 81 60 8. Install the propeller shaft anode over the propeller shaft nut. ‘818000009 Page 71/83HPS525 EFI BRAVO POWER PACKAGE 9. Place the flat washer onto the propeller shaft anode screw. 10. Place the star washer onto the propeller shaft anode screw. 11. Ifa propeller shaft anode is reinstalled, apply Loctite Threadiocker 271 to the threads of the propeller shaft anode screw. a= Propeller d- Propeller shaft anode screw b- Propeller shaft nut e- Flat washer ¢- Propeller shaft anode f+ Star washer Tube Ref No. Description | ‘Where Used Part No. osie 271 Treadodor | Provera woass [e-em 42. Secure the propeller shaft anode to the propeller shaft using the propeller shaft anode screw and washers. Tighten the screw to the specified torque. Description Nm tb. in. lb. ft. Propeller shaft anode screw 38 mm (0.3125-18 x 1.5 in.) long 27 20 NOTE: Some damaged propellers can be repaired. See your Mercury Marine dealer. Test Running Engine If the engine is to be tested with boat out of the water, the propeller must be removed to avoid injury. USING A TEST TANK IMPORTANT: intake holes. a test tank is to be used, ensure that the water level is above the water 7389 a- Minimum water level c- Low water single inlet gearcase b- Dual water inlet gearcase d- Water intake holes Page 72/83 '8§18000009HPS525 EFI BRAVO POWER PACKAGE USING A FLUSH TEST DEVICE IMPORTANT: If using a flush test device, install the appropriate flushing attachment over the water intake holes and connect a water hose as shown. See the /Installation Products section for part numbers. On dual water inlet drives, you must also use a Dual Pick-Up Flush Seal Kit. Do not use full water tap pressure. Do not operate the engine above 1500 RPM, as the suction created could cause the water hose to collapse, cutting off the water supply. 761 a - Bravo One SportMaster/Low d- Fresh water source water inlet gearcase e- Flushing attachment over water b - Dual water inlet gearcase intake holes: cc - Low water inlet flushing f- Dual water flushing attachment attachment TESTING me J SA WARNINGES a a Do not leave the helm unattended when performing tests with the boat in the water. 1. Follow the instructions in the Using a Test Tank and Using a Flush Test Kit sections, above. 2. Perform the following checks:HPS525 EFI BRAVO POWER PACKAGE 1 Ensure that the cooling system drain plugs, petcocks, and hoses are installed and tight. NOTE: Refer to the Operation, Maintenance and Warranty Manual for operating specifications. Refer.to the appropriate Mercury Racing Sterndrive Service Manual for fluid capacity information. (1 Check the crankcase oil level. (1 Check the transmission oil level (if applicable) (1 Check the stemndrive unit oil level (1 Check the drive belt tension. 3. Test the audio warning system: a. Turn the key switch to the "RUN" position. The horn should sound immediately. b. Start the engine as described in the Starting Procedure for "Dry" EF! Engines section, following. The horn should stop as soon as the engine is running. 4. Start the engine and operate at idle RPM until water temperature is normal. 5. Watch all gauges for normal readings. 6. Tur the steering wheel starboard, then port, and check to ensure that the drive unit turns the correct way. 7. Inspect the engine compartment for water, oil, fuel, and exhaust leaks 8. Shut off the engine and check all fluid levels. Starting Procedure for Dry EFI Engines Priming Fuel System This procedure is for EFI engines that are new or being started after a lengthy period of non-use and EFI engines started after a water separating fuel fiter replacement. IMPORTANT: The throttle must not be advanced until the engine idles and operates smoothly and the water temperature has reached a minimum of 54°C (130 °F). Advancing the throttle prematurely while the PCM is in its rich running mode will result in poor engine starting and performance. The throttle should not be advanced during starting even if the system is primed. However, with a primed system, the engine does not need to warm up before the boat can be operated. Starting an Engine Without Priming the Fuel System. a 7 A CAUTION Apply Loctite 567 PST Pipe Sealant with Teflon to threads of the fuel inlet connector. Do not use Teflon tape. To prevent cracking the casting and/or fuel leaks, tum the inlet connector in by hand until finger-tight, then tighten to 1-3/4 to 2-1/4 turns with wrench. Do not overtighten. Inspect for fuel leaks. 4. Connect the main permanent fuel line to the engine. 2, Donotadvance the throttle until the engine idles and operates smoothly and the water temperature has reached a minimum of 54 °C (130 °F). 3. Crank the engine over for a period of 10 seconds at a time and stop. 4, Repeat the cranking procedure until the engine starts and operates smoothly. This may take three to five attempts. Allow the engine to idle until the water temperature reaches 54 °C (130 °F). Page 74/83 ‘@M8000009