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Mercury Bravo Three manuals

Owner’s manuals and user’s guides for Motor vehicle accessories & components Mercury Bravo Three.
We providing 1 pdf manuals Mercury Bravo Three for download free by document types: Service Manual


Mercury Bravo Three Service Manual (596 pages)


Brand: Mercury | Category: Motor vehicle accessories & components | Size: 10.75 MB |

 

Table of contents

Number 28

1

90-863160

2

90-863160 MAY 2000 Page i

3

Engine Mechanical Components

4

Replacement Parts

4

Service Manual Outline

5

Page vi 90-863160 MAY 2000

8

POWER TRIM

10

STEERING SYSTEMS

11

CORROSION PROTECTION

12

ACCESSORIES

12

IMPORTANT INFORMATION

13

How To Use This Manual

14

How to Read a Parts Manual

15

Power Steering Pump Assembly

15

Introduction

16

Directional References

16

Propeller Rotation

16

Replacement Gears)

17

INDEXINDEX

18

Maintenance Schedules

21

Gas Sterndrive

21

Gas Sterndrive(Continued)

22

Torque Specification

23

Fluid Capacities

23

Lubrication

23

Steering System

24

Tie Bar Pivot Points

25

Changing Sterndrive Oil

28

MAINTENANCE

29

General Maintenance

30

Power Package Layup

31

Power Package Recommissioning

32

Troubleshooting

34

Drive Unit Shifts Hard

35

Gear Housing Noise

36

Drive Shaft Housing Noise

36

TROUBLESHOOTING

37

Power Shift

39

Performance Troubleshooting

40

Power Steering

42

Compact Hydraulic Steering

43

Power Trim Electrical System

44

IN/DOWN Direction

45

IN/DOWN SOLENOID CLICKS

46

OUT/UP SOLENOID CLICKS

46

TRAILER SWITCH OPERATES

47

TRIM OUT/UP SWITCH FUNCTIONS

47

Power Trim Hydraulic System

49

Movements

50

UNIT THUMPS WHEN SHIFTING

51

SOLENOIDS CLICK

54

SOLENOIDS DO NOT CLICK

55

AUTO MODE FUNCTIONS PROPERLY

57

DOWN SOLENOID DOES NOT CLICK

57

DOWN SOLENOID CLICKS

57

UP SOLENOID CLICKS

57

PROPERLY

58

TRIM UP/OUT SWITCH FUNCTIONS

59

Corrosion Protection

61

Protection

62

DRIVE CORRODING - CONTINUED

63

READINGS

65

CORROSION SYMPTOMS

65

Table of Contents

69

Transom Thickness and Surface

71

Sterndrive Unit Removal

74

Transom Assembly Removal

76

Transom Assembly Installation

80

Sterndrive Unit Installation

90

SERVICE MANUAL NUMBER 28

101

STERNDRIVE UNIT

103

Specifications

104

Bearing Preloads

105

Complete Housing

106

DRIVE SHAFT HOUSING

107

Exploded Parts View (Clutch)

108

Exploded Parts View (Shifter)

109

Bravo One

112

Bravo Two

112

Bravo Three

113

Bravo XZ

113

Bravo XR

114

Diesel Bravo One X

114

Diesel Bravo Two X

114

Diesel Bravo Three X

115

Separate Housings

116

Shifter Repair

124

Shifter Inspection

127

Shifter Reassembly

128

U-Joint and Pinion Gear

132

Reassembly

136

Disassembly

144

Inspection

146

Roller Bearing Removal

151

Steel Bearing Adaptor Removal

153

Bearing Sleeve Installation

155

Roller Bearing Installation

156

BRAVO ONE GEAR HOUSING

175

Drive Shaft Components

176

Pre-Disassembly Inspection

182

Gear Housing Disassembly

185

Inspection and Cleaning

191

Drive Shaft Disassembly

191

Pinion Bearing Removal

192

Pinion Bearing Installation

193

Drive Shaft Reassembly

194

Bearing Carrier Inspection

195

Bearing Carrier Disassembly

195

Bearing Carrier Reassembly

196

Propeller Shaft

197

Driven Gear Bearing

198

Driven Gear Bearing Removal

199

Speedometer Water Passage

201

Installing Bearing Carrier

217

BRAVO TWO GEAR HOUSING

223

Bearing Carrier

239

BRAVO THREE GEAR HOUSING

265

Lubricants/Sealants/Adhesives

266

Driveshaft And Pinion Bearing

278

Pinion Bearing

280

Front Driven Gear And Bearing

286

Bearing Cup Removal

287

Bearing Cup Installation

287

Installation

288

Seal Removal

290

Seal Installation

290

Checking Backlash

298

Propeller Installation

305

TRANSOM ASSEMBLY

307

Torque Specifications

308

Bell Housing Components

311

Gimbal Ring Components

312

Gimbal Housing Components

314

Special Information

316

Trim Limit Switch Adjustment

322

Trim Limit Switch

324

Gimbal Bearing

325

Shift Cable

328

Shift Cable Installation

329

Exhaust Bellows (If Equipped)

333

Exhaust Tube (If Equipped)

336

Water Hose and Water Fitting

338

Crimp Clamp Tool

341

Special Tools

344

Bell Housing Removal

352

Access Plug Kit Installation

356

Gimbal Ring Servicing

362

Gimbal Housing Servicing

368

Exhaust Bellows Replacement

374

Speedometer Hose Replacement

376

Bell Housing Installation

387

Trim Pump Specifications

402

Trim Pump Exploded View

403

Bleeding OUT/UP Trim Circuit

405

Bleeding IN/DOWN Trim Circuit

405

Testing Power Trim Pump

406

Internal Restriction Test

407

OUT/UP Pressure Test

408

IN/DOWN Pressure Test

410

Trim Pump Hydraulic System

411

OILDYNE TRIM PUMP

413

Reading OK

414

Reading NOT OK

414

Solenoid Test (Pump In Boat)

419

20 Amp Fuse Test

423

Trim Pump Removal

424

Hydraulic Repair

425

Filter Replacement

427

Pump Replacement

430

Adapter Replacement

431

Adapter Repair

433

76891 76892

435

Motor Repair

439

Armature Tests

442

Field Tests

443

Test for Short in Field

444

Brush Replacement

446

Trim Pump Installation

455

Trim Pump Wiring Diagrams

456

Trim Cylinder Exploded Views

461

Bravo Trim System Components

462

TRIM CYLINDERS

463

Trim Cylinder Repair

465

Important Information

482

Diode Module Test

483

Trailer Switch Test

484

Starboard Trim Switch Test

484

Port Trim Switch Test

484

Relay Replacement

485

Diode Module Replacement

487

Wiring Diagrams

490

Electrical Box Wiring

491

Auto Trim II System

494

Auto Trim II Operation

494

Auto Mode Operation

495

“Manual” Mode Operation

496

AUTO TRIM II

497

Auto Trim Limit Adjustment

498

Control Module Adjustment

501

Wiring Diagram

503

Description

507

Power Steering System

508

RIGHT TURN

508

LEFT TURN

509

Steering Helm and Cable

511

Steering Cable Specifications

512

Checking Fluid Level

513

Engine Warm

513

Engine Cold

513

Filling and Bleeding

514

Power Steering Assembly

515

POWER STEERING

517

Pump Pressure Test

521

Power Steering Pump

523

Flow Control Valve Servicing

524

Cleaning And Inspection

530

EXTERNAL POWER STEERING

537

Determining Tie Bar Length

538

Selection

539

Page 6B-390-863160 MAY 2000

545

90-863160 MAY 2000Page 6B-4

546

Page 6B-590-863160 MAY 2000

547

90-863160 MAY 2000Page 6B-6

548

Page 6B-790-863160 MAY 2000

549

90-863160 MAY 2000Page 6B-8

550

Page 6B-990-863160 MAY 2000

551

Connecting The Clevis

552

Hydraulic Fluid Level

553

Continuity Circuit

556

Trim Cylinder Anodes

559

Anodic Plate

560

Bravo Two Sterndrive Units

562

Bravo Three Sterndrive Units

562

Integral MerCathode System

563

Installing Electrode Assembly

564

MerCathode Controller

568

Quicksilver Isolator

569

Test Equipment Set-Up

572

Low Readings

573

Low Readings (continued)

574

High Reading

575

Power Shift (P/N 38638A4)

580

General Information

581

Checking Vacuum Drop-Off

583

Power Shift Cylinder Repair

584

ACCESSORIES - ALL MODELS

585

Installation Preparation

592

Shift Cable Barrel Adjustment

592

Installing Input Cable

593

Installing Output Cable

594

Attach Dust Cover

594

Mounting Power Shift Cylinder

595




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