SERVICE MNUL NUMBER 28 Tble of Contents IMPORTNT INFORMTION Section 1B - Mintennce MINTENNCE 1 B Torque Specifictions................ 1B-2 Lubricnts / Selnts / dhesives..... 1B-2 pproved Hydrulic Steering Fluids.................... 1B-3 Fluid Cpcities...................... 1B-3 Specil Tools........................ 1B-4 Mintennce Schedules.............. 1B-5 Mintennce Intervls............... 1B-5 Gs Sterndrive....................... 1B-5 Routine Mintennce............... 1B-5 Scheduled Mintennce............ 1B-6 Corrosion........................... 1B-7 Mintining Ground Circuit Continuity.................... 1B-7 Mintining nodic Protection........ 1B-7 Checking Quicksilver MerCthode System................. 1B-8 Mintining Power Pckge Exterior Surfces.................... 1B-8 Bot Bottom Cre.................... 1B-8 nti-fouling Pint.................... 1B-9 Steering Hed nd Remote Control Mintennce................ 1B-10 Shift Cble........................ 1B-10 Sterndrive Wter Drin Holes........ 1B-11 Sterndrive Wter Pickups........... 1B-12 Flushing ttchments............ 1B-13 lterntive Wter Pickups........... 1B-16 Sterndrive Unit Oil.................. 1B-18 Checking......................... 1B-18 Filling............................ 1B-19 Chnging......................... 1B-20 Power Pckge Lyup............... 1B-22 Engine........................... 1B-22 Sterndrive........................ 1B-22 Power Pckge Recommissioning... 1B-28 Engine........................... 1B-28 Sterndrive........................ 1B-28 90-863160--1 JUNE 2003 Pge 1B-1
MINTENNCE SERVICE MNUL NUMBER 28 Torque Specifictions NOTE: Securely tighten ll fsteners not listed below. Description Nm lb-in. lb-ft Oil fill/drin plug 4.5 40 Oil vent plug 4.5 40 Lubricnts / Selnts / dhesives Description Where Used Prt Number Mercury Light Gry Primer 92-802878 52 Pinted surfces Mercury Phntom Blck 92-802878Q 1 Corrosion Gurd Pinted surfces 92-802878-55 Engine Oil Pivot points, guide contct surfces Obtin loclly Specil Lubricnt 101 Steering cble Propeller shft 92-8028651 SE 30W Engine Oil Tie br pivot points Steering system pivot points Obtin loclly U-joint nd Gimbl Bering Gimbl bering Grese Drive shft U-joints 92-8028701 Coupler Engine Coupler Spline Grese U-joint shft splines nd 92-8028691 O-rings High Performnce Ger Lube Ger lube monitor To fill sterndrive 92-8028541 Liquid Neoprene Clmps nd terminls 92-25711-3 2-4-C with Teflon Steering cble Propeller shft 92-8028591 nti-corrosion Grese Propeller shft 92-8028671 Pge 1B-2 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 pproved Hydrulic Steering Fluids MINTENNCE Fluid Cpcities Description Prt Number Hydrulic Helm Steering Fluid 92-8620141 SeStr Hydrulic Fluid H5430 Chevron vition Fluid Mobil ero HF Obtin loclly Shell ero 4 Hydrulic Fluid meeting MIL Specifiction H5606C NOTICE Unit Of Mesurement: Milliliters (Fluid Ounces) ll cpcities re pproximte fluid mesures. Model Brvo One Brvo Two Brvo Three 2602 ml. 3076 ml. 2839 ml. Sterndrive unit oil cpcity (88 fl oz) (104 fl oz) (96 fl oz) 90-863160--1 JUNE 2003 Pge 1B-3
MINTENNCE SERVICE MNUL NUMBER 28 Specil Tools Dul Wter Pick-Up Flush Ger Cse Sel Kit Use to block-off the front wter inlet holes on the dul wter inlet ger cses. 91-881150Q1 77977 Flushing Device ttches to the sterndrive unit wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine. 91-44357Q2 73440 Flushing Kit Use for flushing sterndrives with low wter inlet ger cses. 91-84996T1 78135 Reference Electrode Senses n electricl current in the wter when testing the MerCthode system. Use to check hull potentil. 91-76675T1 73446 Pge 1B-4 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 Mintennce Schedules MINTENNCE Mintennce Intervls Gs Sterndrive Mintennce intervls nd the corresponding tsks to be performed, s shown in this current schedule or s found in previously printed schedule, re generlly bsed on n verge boting ppliction nd environment. However, individul operting hbits nd personl mintennce preferences cn hve n impct on the suggested intervls. In considertion of these fctors, Mercury MerCruiser hs djusted some mintennce intervls nd the corresponding tsks to be performed. In some cses, this my llow for more individul tsks in single visit to the servicing deler. Therefore, it is very importnt tht the bot owner nd the servicing deler discuss the current Mintennce Schedule nd develop pproprite mintennce intervls to coincide with the individul operting hbits, the environment nd the mintennce requirements. CUTION lwys disconnect bttery cbles from bttery BEFORE working round electricl systems components to prevent injury to yourself nd dmge to electricl system should wire be ccidentlly shorted. Routine Mintennce * Check sterndrive unit oil level, trim pump oil level nd steering fluid level. Check wter pickups for debris or mrine growth. Check wter striner nd clen. Check coolnt level. Inspect sterndrive unit nodes nd replce if 50 percent eroded. Lubricte propeller shft nd the retorque nut (if operting in only freshwter, this mintennce my be extended to every four months). Ech Dy Strt Ech Dy End Weekly Every Two Months * Only perform mintennce tht pplies to your prticulr power pckge Stndrd models Horizon models 90-863160--1 JUNE 2003 Pge 1B-5
MINTENNCE SERVICE MNUL NUMBER 28 Gs Sterndrive (continued) Scheduled Mintennce * Touch-up power pckge pint nd spry with Corrosion Gurd. Chnge sterndrive unit oil nd retorque connection of gimbl ring to steering shft. Check steering system nd remote control for loose, missing or dmged prts. Lubricte cbles nd linkges. Inspect U-joints, splines nd bellows. Check clmps. Check engine lignment. Lubricte U-joints splines. Lubricte gimbl bering nd engine coupler. Check continuity circuit for loose or dmged connections. Test MerCthode unit output on Brvo Models. nnully Every 100 hours or nnully Every 200 hours or 3 yers Every 300 hours or 3 yers Every 2 yers Every 5 yers * Only perform mintennce tht pplies to your prticulr power pckge Stndrd models Horizon models Lubricte engine coupler every 50 hours if operted t idle for prolonged periods of time or if used in hevy bot pplictions. Lter stndrd-models cn be serviced every 200 hours or 3 yers. Pge 1B-6 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 Corrosion MINTENNCE Refer to the Mercury Precision Prts / Mrine Corrosion Protection Guide (90-881813003). Mintining Ground Circuit Continuity The trnsom ssembly nd sterndrive unit re equipped with ground wire circuit to ensure good electricl continuity between engine, trnsom ssembly nd sterndrive components. Good continuity is essentil for the MerCthode System to function effectively. Refer to Section 7. Mintining nodic Protection Ech sterndrive unit is equipped with scrificil nodic plte to help protect underwter metl prts from glvnic corrosion. Becuse of its self-scrificing nture, nodic plte MUST BE replced if eroded 50% or more. Refer to Section 7. IMPORTNT: Replce scrificil nodes if eroded 50 percent or more. 73919 70578 71966 72032 Common scrificil nodes nd MerCthode system 1 -Universl nodic plte 2 -nodic plte 3 -MerCthode system 4 -node kit (if equipped) 5 -Trim cylinder nodes 6 -Bering crrier node (Brvo One) Universl nodic Plte - serves s scrificil node. nodic Plte - serves s scrificil node. MerCthode System - stndrd on Brvo. node Kit (if equipped) - mounted to bot trnsom. cts s scrificil node. Trim Cylinder nodes - mounted on ech trim cylinder. Bering Crrier node (Brvo One) - locted in front of the propeller, between the front side of the propeller nd the ger housing. 90-863160--1 JUNE 2003 Pge 1B-7
MINTENNCE SERVICE MNUL NUMBER 28 Checking Quicksilver MerCthode System The MerCthode system should be tested to ensure dequte output. The test should be performed where bot is moored, using the Reference Electrode nd Test Meter. Refer to Section 7. Reference Electrode Senses n electricl current in the wter when testing the MerCthode system. Use to check hull potentil. 91-76675T1 73446 Mintining Power Pckge Exterior Surfces Bot Bottom Cre 1. Spry entire power pckge t recommended intervls with Corrosion Gurd. Follow instructions on cn for proper ppliction. Description Where Used Prt Number Corrosion Gurd Pinted surfces 92-802878-55 2. Clen entire power pckge. Externl surfces tht hve become bre should be repinted with Primer nd Spry Pint t recommended intervls. Description Where Used Prt Number Mercury Light Gry Primer 92-802878 52 Pinted surfces Mercury Phntom Blck 92-802878Q 1 To chieve mximum performnce nd fuel economy, bot bottom MUST BE kept clen. ccumultion of mrine growth or other foreign mtter cn gretly reduce bot speed nd increse fuel consumption. To ensure best performnce nd efficiency, periodiclly clen bot bottom in ccordnce with mnufcturer s recommendtions. In some res, it my be dvisble to pint the bottom to help prevent mrine growth. Refer to the following informtion for specil notes bout the use of nti-fouling pints. Pge 1B-8 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 nti-fouling Pint MINTENNCE IMPORTNT: Corrosion dmge tht results from the improper ppliction of nti-fouling pint will not be covered by the limited wrrnty. Pinting Bot Hull or Bot Trnsom: nti-fouling pint my be pplied to bot hull nd bot trnsom but you must observe the following precutions: IMPORTNT: Do not pint nodes or MerCthode System reference electrode nd node, s this will render them ineffective s glvnic corrosion inhibitors. IMPORTNT: If nti-fouling protection is required for bot hull or bot trnsom, copper bse pints, if not prohibited by lw, cn be used. If using copper bsed nti-fouling pints, observe the following: void n electricl interconnection between the Mercury MerCruiser product, nodic blocks, or MerCthode system nd the pint by llowing minimum of 40 mm (1-1/2 in.) UNPINTED re on trnsom of the bot round these items. b -Pinted bot trnsom b-minimum 40 mm (1-1/2 in.) UNPINTED re round trnsom ssembly 71176 NOTE: Sterndrive unit nd trnsom ssembly cn be pinted with good qulity mrine pint or n nti-fouling pint tht does not contin copper or ny other mteril tht could conduct electricl current. Do not pint drin holes, nodes, MerCthode system, nd items specified by bot mnufcturer. 90-863160--1 JUNE 2003 Pge 1B-9
MINTENNCE SERVICE MNUL NUMBER 28 Steering Hed nd Remote Control Mintennce 1. Lubricte steering hed nd remote control t recommended intervls. Inspect steering hed nd remote control for ese of opertion. Shift Cble Description Where Used Prt Number Engine Oil Pivot points, guide contct surfces Obtin loclly 1. Lubricte the pivot points nd the guide contct surfces. b b 79178 Typicl -Pivot points b-guide contct surfces Description Where Used Prt Number Engine Oil Pivot points, guide contct surfces Obtin loclly Pge 1B-10 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 Sterndrive Wter Drin Holes MINTENNCE 1. Using piece of wire, check wter drin holes in sterndrive unit to ensure tht they re open. b d c e 70134 78525 Sterndrive unit wter drin holes -Speedometer pitot tube b-node cvity vent hole c -node cvity drin pssge d-ger housing wter drin hole (1 ech - port nd strbord) e -Ger housing cvity vent hole (Brvo II only) 90-863160--1 JUNE 2003 Pge 1B-11
MINTENNCE SERVICE MNUL NUMBER 28 Sterndrive Wter Pickups IMPORTNT: Brvo models equipped with closed cooling require dul wter pickups nd must be equipped with through the hull or through the trnsom pickup in ddition to the sterndrive wter inlets. There re 3 types of wter pickups vilble on Mercury MerCruiser sterndrives: low wter, dul wter, nd side pickups. Dul wter pickups require the Flushing Device (92-44357Q2) nd the Dul Wter Pick-Up Flush Ger Cse Sel Kit (92-881150Q1), low wter pickups require the Flushing Kit (92-849996T1), nd side pickups require the Flushing Device (92-44357Q2). 77899 Dul wter pickup Low wter pickup Side pickup Pge 1B-12 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 FLUSHING TTCHMENTS MINTENNCE Dul Wter Pick-Up Flush Ger Cse Sel Kit Use to block-off the front wter inlet holes on the dul wter inlet ger cses. 91-881150Q1 77977 Flushing Device ttches to the sterndrive unit wter intkes; provides fresh wter connection when flushing the cooling system or operting the engine. 91-44357Q2 73440 Flushing Kit Use for flushing sterndrives with low wter inlet ger cses. 91-84996T1 78135 90-863160--1 JUNE 2003 Pge 1B-13
MINTENNCE SERVICE MNUL NUMBER 28 0194.2 NOTE: Flushing is needed only for slty, brckish, minerl lden or polluted wter pplictions. Flushing is recommended fter ech outing for best results. CUTION If flushing with the bot in the wter, sewter cn flow into the engine cusing engine dmge. Wter inlet must be closed when flushing the engine. 1. Drin the sewter section of the cooling system. 2. Sewter cooled Models: Proceed to Step 4. or Step 5. 3. Closed Cooled models could require through the hull or through the trnsom wter inlet nd sterndrive wter inlets. Verify your model s follows:. If you hve Brvo sterndrive unit nd closed cooling (equipped with het exchnger on the front of the engine), verify tht hose is connected between the trnsom nd the y-fitting nd between the se striner nd the y-fitting. b. If there is hose running to the trnsom, shut the secock locted in the hose between the se striner nd the y-fitting. Proceed to Step 4. or Step 5. c. If there is not hose running to the trnsom, refer to lterntive Wter Pickups. 4. If flushing the cooling system with bot in wter:. Rise sterndrive unit to TRILER position. b. Instll pproprite flushing ttchments over wter intke openings in the ger housing. c. Lower sterndrive unit to full DOWN/IN position. 5. If flushing cooling system with bot out of wter:. Lower sterndrive unit to full DOWN/IN position. WRNING Contct with moving drive components nd the propeller cn cuse personl injury or deth. To void possible injury, remove the propeller nd ensure tht no people or nimls re in the re of the drive unit while flushing. b. Remove propeller. c. Instll pproprite flushing ttchments over wter intlets in ger housing. 6. Connect hose between flushing ttchment nd wter source. 7. With sterndrive unit in norml operting position, prtilly open wter source (bout 1/2 mximum). Pge 1B-14 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 8. Plce sterndrive in NEUTRL, idle speed position nd strt engine. MINTENNCE CUTION Suction creted by the sewter pickup pump my collpse the flushing wter hose cusing the engine to overhet. void engine dmge from overheting, Do NOT operte the engine bove 1500 rpm. 9. Slowly dvnce throttle until engine reches 1300 rpm (+/ 100 rpm). CUTION Engine overheting cn cuse engine dmge. To void, observe the wter temperture guge nd ensure tht the engine is operting in the norml rnge. 10. Observe the wter temperture guge to ensure tht the engine is operting in the norml rnge. 11. Operte engine with sterndrive in NEUTRL for bout 10 minutes or until dischrge wter is cler. 12. Slowly return throttle to idle speed position. 13. Stop engine. 14. Shut off wter nd remove flushing ttchment. 15. Remove the sewter inlet hose from the sewter pump nd plug the hose to prevent wter from siphoning into the engine. 16. Tg the ignition switch with n pproprite tg requiring the sewter inlet hose to be reconnected prior to operting engine. 90-863160--1 JUNE 2003 Pge 1B-15
MINTENNCE SERVICE MNUL NUMBER 28 0195.2 lterntive Wter Pickups IMPORTNT: Two wter sources re needed for this procedure. NOTE: Flushing is needed only for slty, brckish, minerl lden or polluted wter pplictions. Flushing is recommended fter ech outing for best results. 1. Drin the sewter section of the cooling system. IMPORTNT: Engines with the sterndrive wter inlet blocked off t the gimbl housing nd using through the hull wter inlet need supply of cooling wter vilble to both the sterndrive unit nd to the engine during opertion. 2. If flushing cooling system with bot in wter:. Rise sterndrive unit to TRILER position. b. Instll pproprite flushing ttchment over the wter intke openings in the ger housing. c. Lower sterndrive unit to full DOWN/IN position. d. Proceed to Step 4. 3. If flushing cooling system with bot out of wter:. Lower sterndrive unit to full DOWN/IN position. WRNING Contct with moving drive components nd the propeller cn cuse personl injury or deth. To void possible injury, remove the propeller nd ensure tht no people or nimls re in the re of the drive unit while flushing. b. Remove propeller. c. Instll pproprite flushing ttchments over wter inlets ger housing. 4. Connect hose between flushing ttchment nd wter source. 5. Disconnect the wter inlet hose (upper hose) from the ft side of the sewter pump. 77945 6. Plug the sewter inlet hose or close the secock to prevent wter from siphoning into the bot. Pge 1B-16 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 MINTENNCE 7. Using suitble dpter, connect the flushing hose from the wter source to the wter inlet of the sewter pump. CUTION Overheting from insufficient cooling wter will cuse engine nd drive system dmge. Ensure tht there is sufficient wter lwys vilble t wter inlet holes during opertion. 8. With sterndrive unit in norml operting position, prtilly open the 2 wter sources (bout 1/2 mximum). 9. Plce sterndrive in NEUTRL, idle speed position nd strt engine. CUTION Suction creted by the sewter pickup pump my collpse the flushing wter hose cusing the engine to overhet. void engine dmge from overheting, Do NOT operte the engine bove 1500 rpm. 10. Slowly dvnce throttle until engine reches 1300 rpm (+/ 100 rpm). CUTION Engine overheting cn cuse engine dmge. To void, observe the wter temperture guge nd ensure tht the engine is operting in the norml rnge. 11. Observe the wter temperture guge to ensure tht the engine is operting in the norml rnge. 12. Operte engine with sterndrive in NEUTRL for bout 10 minutes or until dischrge wter is cler. 13. Slowly return throttle to idle speed position. 14. Stop engine. 15. Shut off wter nd remove flushing ttchments. 16. If the bot is out of the wter: Instll the wter inlet hose to the ft side of the sewter pump. Tighten the hose clmp securely. 17. If the bot is in the wter: Tg the ignition switch with n pproprite tg requiring the sewter inlet hose to be reconnected prior to operting engine. 90-863160--1 JUNE 2003 Pge 1B-17
MINTENNCE SERVICE MNUL NUMBER 28 Sterndrive Unit Oil Checking 1. Periodiclly inspect oil for wter to ensure tht sterndrive unit sels re not leking. 2. Check for wter t bottom of ger lube monitor. If wter lek is indicted, the sterndrive unit must be reseled. IMPORTNT: If sterndrive unit hs set overnight or longer, check for wter in sterndrive unit.. Brvo I: Trim sterndrive unit to full DOWN/IN position. b -Oil fill/drin plug b-seling wsher 70023 b. Brvo II nd III: Trim sterndrive unit to full UP/OUT position. 22103 b -Oil fill/drin plug b-seling wsher 22101 c. Remove fill/drin plug. If wter runs out, sterndrive unit is leking nd must be reseled. d. Reinstll fill/drin plug nd torque. Description Nm lb-in. lb-ft Fill/drin plug 4.5 40 Pge 1B-18 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 Filling MINTENNCE IMPORTNT: Position sterndrive unit in DOWN/IN position so tht nti-ventiltion plte is level. CUTION If more thn 59 ml (2 fl oz) of oil is required to fill sterndrive unit, n oil lek my exist. Find nd correct cuse of lek before unit is plced in opertion. NOTE: Sterndrive unit oil level is checked t ger lube monitor. IMPORTNT: Oil level in ger lube monitor will rise nd fll during sterndrive opertion; lwys check oil level when sterndrive is cool nd engine is shut down. NOTE: Oil will purge from ger lube monitor if rubber gsket is not in cp. 77813 -Ger lube monitor full line / operting rnge 1. Fill ger lube monitor to FULL line / OPERTING rnge 2. Ensure tht rubber gsket is instlled in ger lube monitor cp. 3. Instll ger lube monitor cp. Tighten cp 1/4 turn fter monitor contcts gsket. IMPORTNT: Do not overtighten cp. 4. Check oil level in ger lube monitor. 90-863160--1 JUNE 2003 Pge 1B-19
MINTENNCE SERVICE MNUL NUMBER 28 Chnging 1. Remove the ger lube monitor from the brcket. 77813 -Ger lube monitor 2. Empty the contents into suitble continer. 3. Instll the monitor in the brcket. 4. Brvo One Models: Remove the propeller, plce the sterndrive unit in full trim limit IN position, remove the oil fill/drin screw nd seling wsher nd drin the oil. 70568 b -Oil fill/drin b-seling wsher 5. ll Other Models: Plce the sterndrive unit in full trim limit OUT position, remove the oil fill/drin screw nd seling wsher nd drin the oil. b 72522 -Oil fill/drin b-seling wsher Pge 1B-20 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 MINTENNCE 6. Remove the oil vent screw nd seling wsher. llow the oil to drin completely. b 77106 -Oil vent screw b-seling wsher IMPORTNT: If ny wter drined from the oil fill/drin hole, or if the oil ppers milky, the sterndrive unit is leking nd should be checked immeditely by your uthorized Mercury MerCruiser deler. 7. Lower the sterndrive unit so tht the propeller shft is level. Fill the sterndrive unit through the oil fill/drin hole, with specified ger lube until n ir-free strem of lubricnt flows from oil vent hole. Description Where Used Prt Number High Performnce Ger Lube Ger lube monitor 92-8028541 IMPORTNT: Use only High Performnce Ger Lube in sterndrive unit. 8. Instll the oil vent screw nd seling wsher. 9. Continue to pump ger lube into the ger lube monitor circuit until the ger lube ppers in the ger lube monitor. 10. Fill the monitor so tht the oil level is in the operting rnge. Do not overfill. Ensure tht the rubber gsket is inside the cp nd instll. Do not overtighten. Description Where Used Prt Number High Performnce Ger Lube Ger lube monitor 92-8028541 11. Remove the pump from the oil fill/drin hole. Quickly instll the seling wsher nd oil fill/drin screw. Tighten securely. 12. Reinstll the propeller. 13. Recheck the oil level fter the first use. IMPORTNT: Oil level in the ger lube monitor will rise nd fll during sterndrive opertion; lwys check the oil level when the sterndrive is cool nd the engine is shut down. 90-863160--1 JUNE 2003 Pge 1B-21
MINTENNCE SERVICE MNUL NUMBER 28 Power Pckge Lyup Engine Sterndrive Refer to pproprite Mercury MerCruiser Engine Service Mnul. 1. Lubricte the steering system. WRNING Do not grese steering cble while extended. Hydrulic lock could occur nd cuse loss of steering control.. If steering cble hs grese fittings: Turn steering wheel until steering cble is fully retrcted into cble housing. pply pproximtely 3 pumps of grese from typicl hnd-operted grese gun. NOTE: If steering cble does not hve grese fitting, inner wire of cble cnnot be gresed. 71903 -Steering cble grese fitting Description Where Used Prt Number Specil Lubricnt 101 Steering cble 92-8028651 b. Turn steering wheel until steering cble is fully extended. Lightly lubricte the exposed prt of cble. 71901 -Extended steering cble Description Where Used Prt Number Specil Lubricnt 101 Steering cble 92-8028651 Pge 1B-22 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 c. Lubricte the steering system pivot points. MINTENNCE 71904 -Steering system pivot points Description Where Used Prt Number SE 30W Engine Oil Steering system pivot points Obtin loclly d. On dul engine bots: Lubricte the tie br pivot points. Description Where Used Prt Number SE 30W Engine Oil Tie br pivot points Obtin loclly e. Upon first strting engine, turn steering wheel severl times to strbord nd then port to ensure tht the steering system opertes properly before getting underwy. 2. Lubricte the gimbl bering nd the sterndrive propeller shft.. Lubricte gimbl bering by pplying pproximtely 8-10 pumps of grese from typicl hnd-operted grese gun. 77068 -Gimbl bering grese fitting Description Where Used Prt Number U-joint nd Gimbl Bering Grese Gimbl bering 92-8028701 90-863160--1 JUNE 2003 Pge 1B-23
MINTENNCE SERVICE MNUL NUMBER 28 b. pply liberl cot of one of the following lubricnts to the propeller shft. 77046 72239 -Propeller shft Description Where Used Prt Number nti-corrosion Grese 92-8028671 Specil Lubricnt 101 Propeller shft 92-8028651 2-4-C with Teflon 92-8028591 3. Lubricte engine coupler splines through grese fittings on coupler by pplying pproximtely 8-10 pumps of grese from typicl hnd-operted grese gun. NOTE: If equipped with seled engine coupler, the seled coupler nd shft splines cn be lubricted without removing the sterndrive unit. pply lubricnt from typicl hnd-operted grese gun. NOTE: If the bot is operted t idle for prolonged periods of time or if used in hevy bot pplictions, Brvo model luminum coupler should be lubricted every 50 hours. 79177 Steel Coupler -Engine coupler grese fitting luminum Coupler Description Where Used Prt Number Engine Coupler Spline Grese Coupler 92-8028691 Pge 1B-24 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 MINTENNCE. Drive shft extension models: Lubricte the drive shft grese fittings t trnsom end by pplying pproximtely 10-12 pumps of grese from typicl hnd-operted grese gun. 71346 -Grese fitting loctions Description Where Used Prt Number U-joint nd Gimbl Bering Grese Drive shft U-joints 92-8028701 b. Lubricte drive shft grese fittings t engine end by pplying pproximtely 3-4 pumps of grese from typicl hnd-operted grese gun. 71347 -Grese fitting loctions Description Where Used Prt Number U-joint nd Gimbl Bering Grese Drive shft U-joints 92-8028701 90-863160--1 JUNE 2003 Pge 1B-25
MINTENNCE SERVICE MNUL NUMBER 28 4. Lubricte the sterndrive U-joint cross berings by pplying pproximtely 3-6 pumps of grese from typicl hnd-operted grese gun. NOTE: The crosses nd berings on the sterndrive U-joint will need to be lubricted through the grese fittings. pply lubricnt from typicl hnd-operted grese gun until smll mount of grese begins to push out. The sterndrive unit must be removed to grese these fittings. 5. Lubricte the U-joint shft splines nd the O-rings. d b c c -U-joint shft splines b-u-joint shft O-rings c -Cross berings grese insert d-cross berings ssemblies 22026 76832 Description Where Used Prt Number U-joint shft splines nd Engine Coupler Spline Grese O-rings 92-8028691 Cross berings grese insert Pge 1B-26 90-863160--1 JUNE 2003
SERVICE MNUL NUMBER 28 MINTENNCE 6. Inspect U-joint bellows for crcks or other signs of deteriortion. Check bellows clmps for tightness.. Rotte the bell housing in the upwrd nd side to side directions to inspect bellows nd hose clmps. e c b d 76620 -U-joint bellow b-exhust bellow c -Bell housing d-gimbl ring e -Gimbl housing 7. Check engine lignment. Refer to pproprite Mercury MerCruiser Engine Service Mnul. 90-863160--1 JUNE 2003 Pge 1B-27
MINTENNCE SERVICE MNUL NUMBER 28 Power Pckge Recommissioning Engine Sterndrive Refer to pproprite Mercury MerCruiser Engine Service Mnul. 1. Perform LL mintennce specified for completion nnully in Mintennce Chrt except items which were performed t the time of sterndrive lyup. 2. pply thin cot of petroleum bsed grese to clmps nd terminls to help retrd corrosion. Description Where Used Prt Number Liquid Neoprene Clmps nd terminls 92-25711-3 3. fter recommissioning nd strting engine, check steering system nd shift control for proper opertion. 4. Check ll fluid levels before nd fter first use. Pge 1B-28 90-863160--1 JUNE 2003