2001-2011 Mercury MerCruiser Bravo Outdrives Sterndrives Marine Engines Service Manual Number 28

SERVICE MANUAL
Number 28
BRAVO STERNDRIVES
MerCruiser #28 Bravo Sterndrives 90-863160

Notice

Throughout this publication, “Dangers,” “Warnings” and “Cautions” (accompanied by the International HAZARD Symbol ) are used to alert the mechanic 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.

1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 and 2011

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Service Manual Outline

Section 1 – Important Information
A – General Information
B – Maintenance
C – Troubleshooting

Section 2 – Removal, Installation and Adjustment A – All Models
Section 3 – Sterndrive Unit
A – Drive Shaft Housing
B – Gear Housing – Bravo One
C – Gear Housing – Bravo Two
D – Gear Housing – Bravo Three
Section 4 – Transom Assembly
A – Service Procedures Requiring Minor Disassembly B – Service Procedures Requiring Major Disassembly
Section 5 – Power Trim
A – Oildyne Power Trim Pump
B – Trim Cylinders
C – Dual Power Trim Control
D – Auto Trim II
Section 6 – Steering Systems
A – Power Steering
B – Compact Hydraulic Steering
Section 7 – Corrosion Protection
A – All Models
Section 8 – Drives
A – All Models

Important Information 1

Removal, Installation and
Adjustment 2
Sterndrive Unit 3
Transom Assembly 4
Power Trim 5
Steering Systems 6
Corrosion Protection 7
Drives 8

90-863160 MAY 2000 Page iii
Table of Contents IMPORTANT INFORMATION
Section 1A – General Information

How To Use This Manual . . . . . . . . . . . . . . . 1A-2
Page Numbering . . . . . . . . . . . . . . . . . . . 1A-2
How to Read a Parts Manual . . . . . . . . . . . 1A-3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-4
Directional References . . . . . . . . . . . . . . . . . 1A-4
Propeller Rotation . . . . . . . . . . . . . . . . . . . . . 1A-4 Sterndrive Unit 10-Hour Break-In Period (New or With Replacement Gears) . . . . . . 1A-5 Serial Number Locations and Engine
Designation Decal . . . . . . . . . . . . . . . . . . . . 1A-5
Section 1B – Maintenance

Lubricants / Sealants / Adhesives . . . . . . . 1B-2
Maintenance Schedules . . . . . . . . . . . . . . . . 1B-3
Maintenance Intervals . . . . . . . . . . . . . . . 1B-3
Gas Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 1B-3
Routine Maintenance * . . . . . . . . . . . . . . 1B-3
Gas Sterndrive(Continued) . . . . . . . . . . . . . 1B-4
Scheduled Maintenance * . . . . . . . . . . . . 1B-4
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Torque Specification . . . . . . . . . . . . . . . . . . . 1B-5
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Shift Cable Pivot Points . . . . . . . . . . . . . . 1B-5
Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 1B-6
Steering System . . . . . . . . . . . . . . . . . . . . 1B-6
Tie Bar Pivot Points . . . . . . . . . . . . . . . . . 1B-7
Transom Gimbal Housing Assembly Swivel Shaft and Gimbal Bearing . . . . . . . . . . . . 1B-7
Checking and Adding Sterndrive Oil . . . . . 1B-8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1B-9
Changing Sterndrive Oil . . . . . . . . . . . . . . . 1B-10 General Maintenance . . . . . . . . . . . . . . . . . 1B-12 Maintaining Power Package Exterior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Steering Head and Remote Control Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-12 Checking Quicksilver MerCathode System . . 1B-12
Maintaining Anodic Plate . . . . . . . . . . . 1B-12 Boat Bottom Care . . . . . . . . . . . . . . . . . 1B-12 Anti-fouling Paint . . . . . . . . . . . . . . . . . . 1B-12 Maintaining Ground Circuit Continuity 1B-13 Power Package Layup . . . . . . . . . . . . . . . . 1B-13 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 1B-13 Power Package Recommissioning . . . . . . 1B-14 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14 Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Section 1C – Troubleshooting

Source: maxumownersclub.com