Section 4B - Service Procedures Requiring Major Disassembly
Bravo Transom Assembly Specifications . 4B-2
Torque Specifications . . . . . . . . . . . . . . . 4B-2
Lubricants / Sealants / Adhesives . . . . . 4B-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 4B-2
Bravo Transom Assembly
Exploded Views . . . . . . . . . . . . . . . . . . . . . . 4B-4
Inner Transom Plate Components . . . . 4B-4
Bell Housing Components . . . . . . . . . . . 4B-5
Gimbal Ring Components . . . . . . . . . . . . 4B-6
Gimbal Housing Components . . . . . . . . 4B-8
Bell Housing Removal . . . . . . . . . . . . . . . . 4B-10
Access Plug Kit Installation . . . . . . . . . . . . 4B-14
Gimbal Ring, Swivel Shaft and
Shift Cable Bellows Replacement . . . . 4B-29
Exhaust Bellows Replacement . . . . . . 4B-32
Speedometer Hose Replacement . . . . 4B-34
Gear Lube Monitor System
Components . . . . . . . . . . . . . . . . . . . . . . 4B-35
Trim Position Sender and Trim Limit
Switch Wire Replacement . . . . . . . . . . 4B-38
Gimbal Ring / Swivel Shaft and
Steering Lever Installation . . . . . . . . . . . . 4B-39
Bell Housing Installation . . . . . . . . . . . . . . . 4B-45
Standard Transom Assembly . . . . . . . . 4B-45
High Performance Transom Assembly 4B-46
Standard And High Performance
Steering Lever Removal . . . . . . . . . . . 4B-16
Gimbal Ring Servicing . . . . . . . . . . . . . . 4B-20
Gimbal Housing Servicing . . . . . . . . . . . . . 4B-26
U-joint Bellows Replacement . . . . . . . . 4B-26
Transom Assemblies . . . . . . . . . . . . . . 4B-47
Shift Cable Installation . . . . . . . . . . . . . . . . 4B-51
Bravo Access Plug Drilling Template . . . . 4B-55
Crimp Clamp Tool . . . . . . . . . . . . . . . . . . . . 4B-57
POWER TRIM
Section 5A - Oildyne Power Trim Pump
Trim Pump Specifications . . . . . . . . . . . . . . 5A-2
Hydraulic Repair . . . . . . . . . . . . . . . . . . . . . 5A-25
Disassembly . . . . . . . . . . . . . . . . . . . . . . 5A-25
Filter Replacement . . . . . . . . . . . . . . . . . 5A-27
UP Pressure Relief
Valve Pressure Specifications . . . . . . . . 5A-2
Electrical Specification . . . . . . . . . . . . . . 5A-2
Torque Specification . . . . . . . . . . . . . . . . 5A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Lubricants / Sealants / Adhesives . . . . . 5A-2
Trim Pump Exploded View . . . . . . . . . . . . . . 5A-3
Oildyne Trim Pump . . . . . . . . . . . . . . . . . 5A-3
Maintaining Power Trim Pump Oil Level . . 5A-4
Air Bleeding Power Trim System . . . . . . . . 5A-5
Bleeding OUT/UP Trim Circuit . . . . . . . . 5A-5
Bleeding IN/DOWN Trim Circuit . . . . . . 5A-5
Testing Power Trim Pump . . . . . . . . . . . . . . 5A-6
Test Gauge . . . . . . . . . . . . . . . . . . . . . . . . 5A-6
Internal Restriction Test . . . . . . . . . . . . . 5A-7
OUT/UP Pressure Test . . . . . . . . . . . . . . 5A-8
IN/DOWN Pressure Test . . . . . . . . . . . . 5A-10
Trim Pump Hydraulic System . . . . . . . . 5A-11
Trim Cylinder Internal Leak Test . . . . . . . . 5A-12
Trim Cylinder Shock Piston Test . . . . . 5A-15
Motor and Electrical Bench Tests . . . . . . . 5A-16
Trim Pump Motor Test (In Boat) . . . . . 5A-16
Trim Pump Motor Test (Out of Boat) . . 5A-18
Solenoid Test (Pump In Boat) . . . . . . . 5A-19
Solenoid Test (Pump Out of Boat) . . . . 5A-20
Valve Replacement . . . . . . . . . . . . . . . . 5A-28
DOWN Pressure Relief
Valve Replacement . . . . . . . . . . . . . . . . 5A-29
Thermal Relief Valve Replacement . . . 5A-30
Pump Replacement . . . . . . . . . . . . . . . . 5A-30
Adapter Replacement . . . . . . . . . . . . . . 5A-31
Adapter Repair . . . . . . . . . . . . . . . . . . . . 5A-33
Pump Shaft Oil Seal Replacement . . . 5A-37
Motor Repair . . . . . . . . . . . . . . . . . . . . . . . . 5A-39
Disassembly . . . . . . . . . . . . . . . . . . . . . . 5A-39
Armature Tests . . . . . . . . . . . . . . . . . . . . . . . 5A-42
Continuity Test . . . . . . . . . . . . . . . . . . . . 5A-42
Test for Shorts . . . . . . . . . . . . . . . . . . . . 5A-43
Cleaning Commutator . . . . . . . . . . . . . . 5A-43
Field Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-43
Test for Open Circuit . . . . . . . . . . . . . . . 5A-43
Test for Short in Field . . . . . . . . . . . . . . 5A-44
Thermal Switch Continuity Test . . . . . . 5A-45
Brush Replacement . . . . . . . . . . . . . . . . 5A-46
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 5A-49
Trim Pump Installation . . . . . . . . . . . . . . . . 5A-55
Trim Pump Wiring Diagrams . . . . . . . . . . . 5A-56
Model With Three-Button
110
110
Amp Fuse Test (Pump in Boat) . . 5A-22
Amp Fuse Test (Pump
Out of Boat) . . . . . . . . . . . . . . . . . . . . . . 5A-22
Trim/Trailer Panel . . . . . . . . . . . . . . . . . 5A-56
Model With Trim In Handle and
Trailer Switch Separate . . . . . . . . . . . . 5A-57
20
Amp Fuse Test . . . . . . . . . . . . . . . . . 5A-23
Trim Pump Removal . . . . . . . . . . . . . . . . . . 5A-23
Page viii
90-863160 MAY 2000
| Categories | Mercury MerCruiser Manuals |
|---|---|
| Tags | MerCruiser Sterndrives 90-863160 |
| Model Year | 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011 |
| Download File |
|
| Document File Type | |
| Copyright | Attribution Non-commercial |
(1 votes, average: 3 out of 3)
Marine readers have rated Mercury MerCruiser Bravo Outdrives Sterndrives Marine Engines Service Manual Number 28 3.0 out of 3.0 based on 1 product reviews. I could not find any mention of the seawater pump assembly.
Maybe I have the wrong unit