Sonik Synth 2.1.

1 - Release Notes

Changes from version 2.1

fixed unexpected Digital ID changes (Authorization)
improved multiport MIDI interfaces compatibility
general maintenance update

IK Multimedia

License Agreement
Installation/Authorization
Manual

License Agreement
END-USER LICENSE AGREEMENT FOR IK Multimedia Product
Please read this document carefully before breaking the seal on the media package. This agreement
licenses the enclosed software to you and contains warranty and liability disclaimers.
By breaking the seal on the media envelope, you are confirming to have taken notice of terms and
conditions of this agreement and you acknowledge your acceptance of the software as well as your
acceptance of the terms of this agreement. If you do not wish to do so, do not break the seal. Instead,
promptly return the entire package, including the unopened media package, to the dealer from whom
you have obtained it, for a full refund.
1) DEFINITIONS
EULA means this end user license agreement
IK Multimedia Product means the software program included in the enclosed package, and all related
updates supplied by IK Multimedia.
IK Multimedia Product means the software program and hardware (if any) included in the enclosed
package, the related documentation, models, multimedia content (such as animation, sound and graphics) and all related updates supplied by IK Multimedia.
Not for resale (NFR) Version means a version of IK Multimedia Product, so identified, is intended for
review and evaluation purposes, only.
2) LICENSE
The IK Multimedia Product is protected by copyright laws and international copyright treaties, as well
as other intellectual property laws and treaties. The IK Multimedia Product is licensed, not sold. This
EULA grants you the rights as specified here below. All other actions and means of usage are reserved
to the written permission of the right holder IK Multimedia Production Srl:
Applications Software. The IK Multimedia Product may be used only by you. You may install and
use the IK Multimedia Product, or any prior version thereof for the same operating system, on up to
three (3) computers, provided that (a) each computer is owned by (or leased to) and under the exclusive
control of the licensee; (b) the program(s) shall NOT be used simultaneously on more than one machine,
and (c) any computer(s) with IK Multimedia software installed shall not be sold, rented, leased, loaned
or otherwise be removed from the licensees possession without first removing (uninstalling) the
licensed software, except as provided in Paragraph 4 (below) pertaining to Software Transfer.
Storage/Network use. You may also store or install a copy of the IK Multimedia Product on a storage
device, such as a network server, used only to install or run the IK Multimedia Product on your other
computers over an internal network; however, you must acquire and dedicate a distinct license for each
user of the IK Multimedia Product from the storage device. Any given license for the IK Multimedia
Product may not be shared or used concurrently or otherwise on different computers or by different
developers in a given organization.
3) AUTHORIZATION CODE
The IK Multimedia Product only functions when you are in the possession of an authorization code.
You will receive an authorization code upon completing the authorization code request procedure. Once
your authorization code is activated, you may use the product.
You agree to follow the authorization code request procedure and will provide true, accurate and complete information about yourself. If you provide any information that is untrue, inaccurate, not correct
or incomplete, or IK Multimedia has reasonable grounds to suspect that such information is untrue,
inaccurate, not correct or incomplete, IK Multimedia has the right to suspend or to revoke the license.
The termination of the license shall be without prejudice to any rights, whatsoever, of IK Multimedia.

4) DESCRIPTION OF OTHER RIGHTS AND LIMITATIONS

Limitations on Reverse Engineering, Decompilation, and Disassembly. You may not reverse engineer,
decompile, or disassemble the IK Multimedia Product, except and only to the extent that such activity is expressly permitted by applicable law notwithstanding this limitation of components. The IK
Multimedia Product is licensed as a single product. Its component parts may not be separated for use
on more than one computer.
Not for Resale Version. If the IK Multimedia Product is labeled Not for Resale or NFR or
Evaluation Copy, then, notwithstanding other sections of this EULA, you may not sell, or otherwise
transfer the IK Multimedia Product.
Rental. You may not rent, lease, or lend the IK Multimedia Product to any party.
Software Transfer. You may not transfer, license or sublicense your rights as Licensee of the software
or any IK Multimedia product, as licensed to you under this agreement without prior written consent
of the rights owner. The carrier on which the IK Multimedia product has been distributed may be transferred or otherwise made available to any third party only with the prior written consent of the rights
owner and provided that (a) the original media and license(s) accompany the carrier and (b) the party
transferring the media does not retain a copy of the media.
5) UPGRADES
If the IK Multimedia Product is labeled or otherwise identified by IK Multimedia as an upgrade, you
must be properly licensed to use a product identified by IK Multimedia as being eligible for the upgrade
in order to use the IK Multimedia Product.
An IK Multimedia Product labeled or otherwise identified by IK Multimedia as an upgrade replaces
and/or supplements the product that formed the basis for your eligibility for such upgrade. You may use
the resulting upgraded product only in accordance with the terms of this EULA. If the IK Multimedia
Product is an upgrade of a component of a package of software programs that you licensed as a single
product, the IK Multimedia Product may be used and transferred only as part of that single product
package and may not be separated for use on more than one computer.
6) DUAL-MEDIA SOFTWARE
You may receive the IK Multimedia Product in more than one medium. You may not loan, rent, lease,
or otherwise transfer the other medium to another user, except as part of the permanent transfer (as
provided above) of the IK Multimedia Product.
7) LIMITED WARRANTY
IK Multimedia warrants to the original purchaser of the computer software product, for a period of
ninety (90) days following the date of original purchase, that under normal use, the software program
and the user documentation are free from defects that will materially interfere with the operation of
the program as described in the enclosed user documentation.
8) WARRANTY CLAIMS
To make a warranty claim under the above limited warranty, please return the product to the point
of purchase, accompanied by proof of purchase, your name, your return address and a statement of
the defect, or send the CD(s) to us at the below address within ninety (90) days of purchase. Include
a copy of the dated purchase receipt, your name, your return address and a statement of the defect.
IK Multimedia or its authorized dealer will use reasonable commercial efforts to repair or replace the
product and return it to you (postage prepaid) or issue to you a credit equal to the purchase price, at
its option.
9) LIMITATIONS ON WARRANTY
IK Multimedia warrants only that the program will perform as described in the user documentation. No
other advertising, description or representation, whether made by a IK Multimedia dealer, distributor,
agent or employee, shall be binding upon IK Multimedia or shall change the terms of this warranty.

EXCEPT AS STATED ABOVE, IK MULTIMEDIA MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED,

REGARDING THIS PRODUCT. IK MULTIMEDIA DISCLAIMS ANY WARRANTY THAT THE SOFTWARE IS
FIT FOR A PARTICULAR PURPOSE, AND ANY IMPLIED WARRANTY OF MERCHANTABILITY SHALL BE
LIMITED TO A NINETY (90) DAY DURATION OF THIS LIMITED EXPRESS WARRANTY AND IS OTHERWISE
EXPRESSLY AND SPECIFICALLY DISCLAIMED. IK MULTIMEDIA SHALL NOT BE LIABLE FOR SPECIAL,
INCIDENTAL, CONSEQUENTIAL OR OTHER DAMAGES, EVEN IF IK MULTIMEDIA IS ADVISED OF OR
AWARE OF THE POSSIBILITY OF SUCH DAMAGES. THIS MEANS THAT IK MULTIMEDIA PRODUCTION SRL
SHALL NOT BE RESPONSIBLE OR LIABLE FOR THE LOSS OF PROFITS OR REVENUES, OR FOR DAMAGES
OR COSTS AS A RESULT OF LOSS OF TIME, DATA OR USE OF THE SOFTWARE, OR FROM ANY OTHER
CAUSE EXCEPT THE ACTUAL COST OF THE PRODUCT. IN NO EVENT SHALL IK MULTIMEDIA LIABILITY
EXCEED THE PURCHASE PRICE OF THIS PRODUCT.
10) CHOICE OF LAW
You agree that any and all claims, suits or other disputes arising from your use of the software shall be
determined in accordance with the laws of Italy, in the event IK Multimedia, is made a party thereto.
You agree to submit to the jurisdiction of the court in Modena, Italy for all actions, whether in contract
or in tort, arising from your use or purchase of the software.
11) GENERAL
This Agreement contains the complete agreement between the parties with respect to the subject matter hereof, and supersedes all prior or contemporaneous agreements or understandings, whether oral
or written. All questions concerning this Agreement shall be directed to:
IK Multimedia Production Srl
Via dellIndustria 46
41100 Modena
Italy
IK Multimedia. All rights reserved.

Chapter 1 - System Requirements

The following are the system requirements for using your IK Multimedia product.
Macintosh
- Power PC based Macintosh
Minimum: dual 1 GHz G4 processor, 1GB of RAM, Mac OS X 10.4 or later.
Suggested: dual 2 GHz G5 processor, 2 GB of RAM, Mac OS X 10.4 or later.
- Intel based Macintosh
Minimum: 1.5 GHz Intel processor, 1 GB of RAM, Mac OS X 10.4.4 or later.
Suggested: 2.3 GHz Intel Core Duo processor, 2 GB of RAM, Mac OS X 10.4.4 or later.
Windows
Minimum: Pentium 4 / Athlon XP processor, 1 GB of RAM, Windows XP / Vista or later.
Suggested: 2.33 GHz Intel Core Duo processor, 2 GB of RAM, Windows XP / Vista or later.

Chapter 2 - Installation
Macintosh
NOTE: in order to be able to install and uninstall IK Multimedia products in your Macintosh computer
(Power PC or Intel based) you must be a user with Administrator rights.
Double-click on the Install icon and follow the onscreen instructions.
The Standalone version is installed in your Applications folder.
Documentation is placed in:
Library / Documentation / IK Multimedia /
Uninstall
Double-click on the Uninstall icon and follow the onscreen instructions.
Windows
NOTE: in order to be able to install and uninstall IK Multimedia products in a computer equipped with
Windows Vista, you must be a user with Administrator rights.
Double-click on the Install icon and follow the onscreen instructions.
The installer asks you to confirm the destination folder. In the destination folder you will also find the documentation.
To launch the Standalone version go to:
Start menu, All Programs
The default destination folder is:
Program Files \ IK Multimedia \
Uninstall
In the Start menu, select Control Panel.
5

Double-click Add or Remove Programs. A list of the software installed in your system is displayed.
Select the IK Multimedia product you want to uninstall and click the Remove button. All the components will be removed from your system. If you added or changed files after the installation, it may be
that some files and folders are not removed. Delete them manually, from the destination folder you
selected during installation.

Chapter 3 - How the Authorization System works

Your IK Multimedia product must be authorized to work with unrestricted functionality. It will run with
full features for 10 days (grace period) which will start when launched for the first time, and revert to
demo mode after. You will need to authorize the product within this time frame to enable permanent
unrestricted functionality.
To authorize your IK Multimedia product youll need three numbers:
- Serial Number: this is written on the Registration Card (included with your IK boxed product,
inside the license envelope) or the one that has been delivered to you (e.g. Online purchase, such
as a Digital Delivery, or update).
- Digital ID: this will be shown during the authorization process and linked to the hardware where
you are running the software.
- Authorization Code: this will be generated online by registering and inserting the Serial Number
and Digital ID. If you are a registered IK Multimedia user, having your User Name and Password
on hand, will help speed up the authorization process.

Chapter 4 - Authorization
A built in software Wizard helps you in the authorization of your IK software. The first time the software is
launched the Wizard is displayed (Step 1. Wizard Introduction). Click Cancel to return to the software and
use the software within the 10 days grace period. Click Next to go to the Wizards next Step and authorize the
software.

Step 1. Wizard introduction

The next Step (Step 2. Enter Serial Number) is for inserting the Serial Number.

Step 2. Enter Serial Number

The Serial Number is written on the Registration Card (included with your IK boxed product, inside the license
envelope) or the one that has been delivered to you (e.g. Online purchase, such as a Digital Delivery, or update). Type
the Serial Number in the fields (using the TAB key to move from one field to the other). Once the Serial Number has
been properly inserted a green icon will display, showing that the number has been entered correctly. If a red icon
is displayed the Serial Number inserted is not correct and you will be asked to re-type it in the fields. Once the Serial
Number has been typed correctly, the Next button will enable you to move to the next Step of the Wizard.
Now the Wizard will ask you if you are requesting an Authorization Code for the first time, or if you intend
on reauthorizing your software with an Authorization Code previously received (Step 3. Authorization /
Reauthorization). For a new authorization click the first option. If you choose the second option because you
need to RE-AUTHORIZE your product, youll proceed directly to Step 7.

Step 3. Authorization/Reauthorization
7

In order to obtain the Authorization Code youll need to go online using an internet connection. In this
window, (Step 4. Connect to Internet) you are asked if you will connect to the internet using your current
computer or a separate one. Make your choice and click on the Next button (if you connect to the internet
using a different computer youll proceed directly to Step 6).

Step 4. Connect to the Internet

In this page of the Wizard (Step 5. User Name and Password) you should type your IK Multimedia User
Name and Password. If you have already registered any other IK Multimedia product you should use the
same User Name and Password that you used previously to access the IK Multimedia User Area (where
you can download updates and upgrades, requests new authorizations, manage your registration data,
etc...). If you have never registered any other IK Multimedia product or if you cant remember your previous
registration information click on the second option. Once you are done click Next.

Step 5. User Name and Password

At this point the Wizard presents you with a window where you can find your Serial Number and the
Digital ID required to register online (Step 6a. Online registration on the same computer). By clicking
Register On Line, your default browser will be opened and directed to the IK Multimedia Registration Page
(if the machine that you are installing on has an internet connection). Now simply fill out the mandatory
fields of the Registration Page with your data. Your Serial Number and Digital ID should have been pre
filled-in (otherwise COPY and PASTE them from your Wizard window to the Registration Page fields). If
you would have inserted your User Name and Password, as a previously registered IK Multimedia user, the
Registration Page will be pre-filled with your personal data making the authorization process faster.

Step 6a. Online registration on the same computer

If you are authorizing your software from a separate computer, the Wizard will display a page (Step
6b. Online Registration on a separate computer) where you are asked to access the IK Multimedia
Registration Page, online at www.ikmultimedia.com/registration and register your software to obtain
the Authorization Code.

Step 6b. Online Registration on a separate computer

9

In this case, please carefully type your Serial Number and Digital ID in the corresponding field of the Registration
Page. Be sure to fill out all the mandatory fields as well. Once your registration process has been completed, an
Authorization Code will be displayed in the check out page of your IK Multimedia online registration (as well as
sent to you by email). Copy the Authorization Code and click Next on the Wizard. You will now be prompted to paste
the Authorization Code in the new Wizard window (Step7. Paste Authorization Code). Point the cursor in the first
field of the Authorization Code in the Wizard and click on the Paste button. All the separated fields will be filled and
a green icon will display, showing the Authorization Code has been entered correctly. If a red icon is displayed, the
Serial Number inserted is not correct and you will be asked to re-type it in the fields (if you typed it manually).

Step 7. Paste Authorization Code

Once the green icon is displayed, click Next and the last page of the Wizard will appear (Step 8.
Authorization Completed) listing your Serial Number, Digital ID and Authorization Code as a reference.
Click Finish to start using your IK Multimedia product with unrestricted functionality.

Step 8. Authorization Completed

10

If you have no access to the Internet, in the software CD youll find a PDF file called Authorization Request
Form.
Europe, Africa, Asia and Australia
Open the file (with Acrobat Reader), print the form, fill the required fields and fax everything to +39-0592861671 to receive your Authorization Code within 24 hours of your fax (standard European business hours).
Please write clearly: if we cant decipher the codes, we wont be able to generate a working Authorization Code.
If you dont have access to a fax machine fill the aforementioned Authorization Code Request Form and mail it
to the following address:
IK Multimedia Production srl
Via DellIndustria 46
41100 Modena
Italy
North and South America
Open the file (with Acrobat Reader), print the form, fill the required fields and fax everything to 954846-9077 to receive your Authorization Code within 24 hours of your fax (10am-6pm EST). Please write
clearly: if we cant decipher the codes, we wont be able to generate a working Authorization Code. If you
dont have access to a fax machine fill the aforementioned Authorization Code Request Form and mail it
to the following address:
IK Multimedia US LLC
1153 Sawgrass Corporate Parkway
Sunrise, FL 33323
USA
Youll be given your Authorization Code by return mail within 15 working days.
For any question you may have, please refer to the FAQ at:
www.ikmultimedia.com/faq
where youll find answers to the most common questions.
To submit a Technical Support Form, go to:
www.ikmultimedia.com/Support.php
For other requests such as Product, Sales, Web info or License Transfer, please go to:
www.ikmultimedia.com/ContactIKForm.php

11

Chapter 5 - Troubleshooting
Where can I find my IK product Serial Number?
The Serial Number is written in the Registration Card (included with your IK product, inside the
license envelope). In the snapshot, please check its exact location.
1) Here you can find your SERIAL NUMBER

2) At the bottom of the registration card a legend helps you identify the
characters in your SERIAL NUMBER
For a clear characters identification, please analyze the legend.
IMPORTANT: the number zero can easily be identified in your Serial Number because it is crossed
by a line.
Why is the Wizard rejecting my Serial Number?
Probably because it found a typo, so please analyze the common errors:
* Typing a 0 (zero number) instead of an O (o letter)
* Typing 1 (one number) instead of an I (i letter)
* Typing 2 (two number) instead of an Z (z letter)
* Typing 5 (five number) instead of an S (s letter)
* Typing 8 (eight number) instead of an B (b letter)
* Typing a . (point) instead of a - (minus)
Suggestions:
- When is possible, please copy and paste the information.
- Cut off all the leading and trailing spaces.
- Please type all codes UPPERCASE during the installation and registration process.
- Check that the Serial number that you are entering is in correlation with the product
installed.

12

During the Product Registration process I received this message: The Serial Number is already
registered...
Remember that you are able to register your product only once. So, if you are trying to get a new
Authorization Code, please read the related FAQ.
Where can I find my Digital ID?
The Digital ID is displayed in the Authorization window of your IK product.

Why is my Digital ID being rejected during the Online Registration process?

There probably is a typo on it. Remember that the Digital ID has NO letter I and O, only the
numbers 1 (one) and 0 (zero). In order to prevent any further mistakes, please Copy the Digital
ID from the Authorization Form to the Registration Form.
Where can I find my Serial Number, Digital ID and the Authorization Code of a registered IK
Product?
In your IK product interface, locate the Authorization button and click on it. If your product version has no Authorization button, you can also log in into the User Area and click on Request a
new Authorization Code. You will be able to check all the main information about your registered
products.
How can I get a new Authorization Code?
Please log in into the User Area at
www.ikmultimedia.com/userarea
Click on the "Authorizations" link: a list of the products which you have registered will be displayed. Locate the product for which you require a new Authorization Code and click on the corresponding "View/Request" button: a new page will appear. Insert the Digital ID of your computer,
then click on the "Request New Authorization" button.

13

Ive already registered my product online, but I didnt get an Authorization Code.
Usually, this happens because the Digital ID was not submitted during the registration process.
In order to get a new Authorization Code, please read the How can I get a new Authorization
Code? FAQ.
I need to log in into the User Area but I forgot my User Name and Password. What should I do?
Please go to the User Area and enter your registered email address (in the proper empty box). You
will receive an email with the necessary information to Log in.
I have already installed, registered and authorized my IK product in my main computer. What do I
have to do to use my IK product in other computers?
You need to install the program and get a new Authorization Code. To learn how to get a new
Authorization Code, please refer to How can I get a new Authorization Code paragraph in this
chapter.
I just bought an IK software. What should I do to register and authorize my new product?
In the Support area of our website www.ikmultimedia.com click on the Product Registration link,
or click on the Tech Support Page link and click on option 1 (Register your product).
In the Serial Number field of the Product Registration Form, please insert the Serial Number
written on the Registration Card (included with your IK boxed product, inside the license envelope) or the one that has been delivered to you (e.g. Online purchase, such as a Digital Delivery,
or update).
Complete the Registration Form and click Submit.
Regarding the Authorization process, if you already typed your Digital ID while filling the Product
Registration Form, you will receive an email from us with your Authorization Code. If not, after
you launch the program the Product Authorization Wizard will appear. Please read and follow the
instructions provided in each of the wizards windows and get an Authorization Code.

14

IK Multimedia Production, Via dellIndustria 46, 41100, Modena, Italy.

Phone: +39-059-285496 - Fax: +39-059-2861671
IK Multimedia US LLC, 1153 Sawgrass Corporate Pkwy. Sunrise, FL 33323
Phone: (954) 846-9101 - Fax: (954) 846-9077
www.ikmultimedia.com

All specifications are subject to change without further notice.

2007-2009 IK Multimedia Production srl.
Mac and the Mac logo are trademarks of Apple Computer, Inc.,
registered in the U.S. and other countries.
Windows Vista and the Windows logo are trademarks or registered trademarks
of Microsoft Corporation in the United States and/or other countries.
15

PN: MNI-IK-0004

MAIN MENU

SERVICE
MANUAL
Number 11

Bravo Sterndrives

Printed in U.S.A.

1998, Mercury Marine

90-17431--4 MARCH 1998

90-17431--4 MARCH 1998

90-17431--4

MerCruiser #11 Bravo Sterndrives

90-17431--4

Page 0

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

MerCruiser #11 Bravo Sterndrives

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

Notice
Throughout this publication 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.

WARNING
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.

CAUTION
CAUTION - Hazards or unsafe practices which could result in minor personal injury
or product or property damage.
IMPORTANT: Indicates information or instructions that are necessary for proper
operation and/or maintenance.

Notice To Users of This Manual

This service manual has been written and published by the service department of the
manufacturer to aid our dealers mechanics and company service personnel when servicing
the product described herein. It is assumed that these personnel are familiar with the servicing procedures of this product, or like or similar products. That they have been trained in the
recommended servicing procedures of these products which includes the use of mechanics common hand tools from other suppliers.
We could not possibly know of and advise the service trade of all conceivable procedures
by which a service might be performed and of all possible hazards and/or results of each
method. We have not undertaken any such wide evaluation. Therefore, anyone who uses
a service procedure and/or tool which is not recommended by the manufacturer, first must
completely satisfy himself that neither his nor the products safety will be endangered by the
service procedure selected.
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 dealers contracted by us to sell and/or
service these products.

90-17431--4 MARCH 1998

Page i

BRAVO STERNDRIVES

SERVICE MANUAL NUMBER 11

Replacement Parts

WARNING
Electrical system components on gasoline engines and MerCruiser Sterndrives are
designed and manufactured to comply with U.S. Coast Guard Rules and Regulations to minimize risks of fire or explosion.
Use of replacement electrical systems components, which do not comply to these
rules and regulations, could result in a fire or explosion hazard and should be avoided.
When servicing electrical systems, it is extremely important that all components
are properly installed and tightened. If not, any electrical component opening
would permit sparks to ignite fuel vapors from fuel system leaks, if they exist or develop.

WARNING
Electrical system components on diesel engines are not external ignition protected. DO NOT STORE OR UTILIZE GASOLINE ON BOATS EQUIPPED WITH THESE
ENGINES, UNLESS PROVISIONS HAVE BEEN MADE TO EXCLUDE GASOLINE VAPORS FROM ENGINE COMPARTMENT (ref: 33 CFR). Failure to comply could result
in fire, explosion and/or severe personal injury.

Models Covered in This Manual

MODEL

SERIAL NUMBER

Bravo One Sterndrive Unit

B664190 and Above

Bravo Two Sterndrive Unit

B892613 and Above

Bravo Three Sterndrive Unit

D763691 and Above

Bravo Transom Assembly (Standard) *

B673048 and Above

Bravo Transom Assembly (High Performance)

D796083 and Above

Bravo Transom Assembly (Magnum)

K104738 and Above

* Some Standard Bravo Transom Assemblies could have been converted to High Performance Transom Assemblies by use of a High Performance Gimbal Ring Kit (822374A2). Refer to Transom Assembly sections of
this manual for identification information.

NOTICE
Refer to appropriate engine service manual for engine repair.

Page ii

90-17431--4 MARCH 1998

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

Service Manual Outline

Section 1 - General Information
A - Important Information
B - Maintenance
C - Troubleshooting
Section 2 - Removal, Installation and Adjustments
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 - All Models
Section 7 - Corrosion Protection
A - All Models
Section 8 - Accessories
A - All Models

Important
Information

Removal, Installation
and Adjustment

Sterndrive Unit

Transom Assembly

Power Trim

Steering Systems

Corrosion Protection

Accessories

90-17431--4 MARCH 1998

1
2
3
4
5
6
7
8

Page iii

BRAVO STERNDRIVES

SERVICE MANUAL NUMBER 11

Table of Contents

GENERAL INFORMATION
Section 1A - Important Information
How To Use This Manual . . . . . . . . . . . . . . .
How To Read Parts Manual . . . . . . . . . . . .
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . .
Directional References . . . . . . . . . . . . . . . . .
Propeller Rotation . . . . . . . . . . . . . . . . . . . . .

1A-2
1A-3
1A-4
1A-4
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
Maintenance Schedules . . . . . . . . . . . . . . .
Maintenance Intervals . . . . . . . . . . . . . . .
Scheduled Maintenance That Can Be
Performed By Owner/Operator . . . . . . .
Scheduled Maintenance That Can Be
Performed by Dealer . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specification . . . . . . . . . . . . . . . .
Quicksilver Maintenance Products . . . .
Fluid Capacities . . . . . . . . . . . . . . . . . . . .
Lubricating Shift Cable Pivot Points . . . . .
Lubricating Propeller Shaft . . . . . . . . . . . . .
Lubricating Steering System . . . . . . . . . . . .
Lubricating Tie Bar Pivot Points . . . . . . . . .
Models With Control Valve Mounted On
Starboard Transom Assembly . . . . . . .
Models With Control Valve Mounted On
Port Transom Assembly . . . . . . . . . . . .
Lubricating Transom Gimbal Housing
Assembly Swivel Shaft and Gimbal
Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and Adding Sterndrive Oil . . . . .
Models Without Drive Unit Gear Lube
Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . .

1B-2
1B-2
1B-2
1B-3
1B-5
1B-5
1B-5
1B-5
1B-6
1B-6
1B-6
1B-7
1B-7
1B-7
1B-7
1B-8

Models With Gear Lube Monitor . . . . . . 1B-9

Checking Lubricant for Water . . . . . . . 1B-10
Changing Lubricant . . . . . . . . . . . . . . . . 1B-12
General Maintenance . . . . . . . . . . . . . . . . . 1B-14
Maintaining Power Package Exterior
Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Steering Head and Remote Control
Maintenance . . . . . . . . . . . . . . . . . . . . . 1B-14
Checking Quicksilver MerCathode
System . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-14
Maintaining Anodic Trim Tab or Plate . 1B-14
Checking Optional Quicksilver
Anti-Corrosion Anode Kit . . . . . . . . . . . 1B-15
Boat Bottom Care . . . . . . . . . . . . . . . . . 1B-15
Antifouling Paint . . . . . . . . . . . . . . . . . . . 1B-15
Maintaining Ground Circuit Continuity 1B-15
Power Package Layup (Out of Season
Storage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
Power Package Recommissioning . . . . . 1B-16
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-16
Sterndrive . . . . . . . . . . . . . . . . . . . . . . . . 1B-16

1B-8

Section 1C - Troubleshooting
Sterndrive Unit Troubleshooting . . . . . . . . .
Sterndrive Unit Will Not Slide Into Bell
Housing . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Does Not Shift Into Gear;
Remote Control Shift Handle Moves . .
Drive Unit Does Not Shift Into Gear;
Remote Control Shift Handle Does
Not Move . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Shifts Hard . . . . . . . . . . . . . . .
Drive Unit In Gear, Will Not Shift Out
Of Gear . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing Noise . . . . . . . . . . . . . . . .
Drive Shaft Housing Noise . . . . . . . . . . .
Bravo Power Shift . . . . . . . . . . . . . . . . . . . . .
System Does Not React . . . . . . . . . . . . .
System Binds . . . . . . . . . . . . . . . . . . . . . .
Performance Troubleshooting . . . . . . . . . . .
Low Full-Throttle Engine RPM . . . . . . . .
High Full-Throttle Engine RPM . . . . . . .

Page iv

1C-2
1C-2
1C-2
1C-3
1C-3
1C-3
1C-4
1C-4
1C-7
1C-7
1C-7
1C-8
1C-8
1C-8

Propeller Ventilating/Cavitating . . . . . . . 1C-8

Poor Boat Performance And/Or Poor
Maneuverability-Bow Too Low . . . . . . . 1C-9
Poor Boat Performance And/Or Poor
Maneuverability-Bow Too High . . . . . . . 1C-9
Power Steering . . . . . . . . . . . . . . . . . . . . . . 1C-10
Hard Steering - RideGuide Steering
System . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10
Hard Steering (Engine Running) Power Steering System . . . . . . . . . . . . 1C-10
Power Steering System External Fluid
Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-10
Power Trim Electrical System . . . . . . . . . . 1C-11
Power Trim System Wiring Diagram . . . . 1C-15
Power Trim Hydraulic System . . . . . . . . . . 1C-16
Power Trim Hydraulic Schematic . . . . . . . 1C-19
Auto Trim Electrical System . . . . . . . . . . . 1C-20
Auto Trim II System Wiring Diagram . . . . 1C-26
Corrosion Protection . . . . . . . . . . . . . . . . . . 1C-27

90-17431--4 MARCH 1998

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

REMOVAL, INSTALLATION AND ADJUSTMENTS

Section 2A - All Models
Installation Specifications . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . .
Lubricants/Sealers/Adhesives . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . .
Transom Specifications . . . . . . . . . . . . . .
Checking Transom Thickness . . . . . . . .
Special Information . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim-In Limit
Blocks or Limit Spacer . . . . . . . . . . . . . .

2A-2
2A-2
2A-2
2A-2
2A-3
2A-3
2A-4

Sterndrive Unit Removal . . . . . . . . . . . . . . . 2A-6

Transom Assembly Removal . . . . . . . . . . . 2A-8
Transom Assembly Installation . . . . . . . . . 2A-15
Sterndrive Unit Installation . . . . . . . . . . . . 2A-27
Shift Cable Installation and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . 2A-34
Troubleshooting Shift Problems . . . . . 2A-38

2A-4

STERNDRIVE UNIT
Section 3A - Drive Shaft Housing
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
Torque Specifications . . . . . . . . . . . . . . . 3A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3A-2
Bearing Preloads . . . . . . . . . . . . . . . . . . . 3A-2
Lubricants/Sealers/Adhesives . . . . . . . . 3A-3
Drive Shaft Housing Exploded View . . . . . 3A-4
Complete Housing . . . . . . . . . . . . . . . . . . 3A-4
Exploded Parts View (Clutch) . . . . . . . . . . . 3A-6
Exploded Parts View (Shifter) . . . . . . . . . . . 3A-7
U-Joint Assembly . . . . . . . . . . . . . . . . . . . 3A-8
Drive Shaft Housing and Gear Case
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9
Drive Unit Gear Ratio Identification . . . 3A-9
Bravo One . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9
U-Joint Identification . . . . . . . . . . . . . . 3A-9
Number Of Teeth Per Gear Drive Shaft Housing . . . . . . . . . . . . . 3A-9
Bravo Two . . . . . . . . . . . . . . . . . . . . . . . . . 3A-9
U-Joint Identification . . . . . . . . . . . . . . 3A-9
Number Of Teeth Per Gear Drive Shaft Housing . . . . . . . . . . . . 3A-10
Bravo Three . . . . . . . . . . . . . . . . . . . . . . 3A-10
U-Joint Identification . . . . . . . . . . . . . 3A-10
Number Of Teeth Per Gear Drive Shaft Housing . . . . . . . . . . . . 3A-10
Bravo Drive/Unit Housing Comparison
and Identification . . . . . . . . . . . . . . . . . . 3A-10
Changes . . . . . . . . . . . . . . . . . . . . . . . 3A-10
Identification . . . . . . . . . . . . . . . . . . . 3A-11
Drive Shaft Housing . . . . . . . . . . . . . 3A-11
Gear Housing . . . . . . . . . . . . . . . . . . 3A-11
Separate Housings . . . . . . . . . . . . . . . . 3A-17
Special Information - Latest Changes to
Gear Assembly, Cone Clutch and Shifter
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-20

90-17431--4 MARCH 1998

Gear, Clutch and Shifter Kits . . . . . . . .

Cone Clutch and Cam Kit . . . . . . . . . . .
Yoke and Cam Kit . . . . . . . . . . . . . . . . .
Drive Shaft Housing Disassembly . . . . . .
Shifter Repair . . . . . . . . . . . . . . . . . . . . . . . .
Shifter Inspection . . . . . . . . . . . . . . . . . . . .
Shifter Reassembly . . . . . . . . . . . . . . . . . . .
U-Joint and Pinion Gear Inspection,
Disassembly and Reassembly . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . .
Clutch Disassembly, Inspection and
Reassembly . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Housing and Top Cover Bearings and Bearing Sleeves . . . . . . . .
Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Sleeve Removal (Top Cover)
Bearing Sleeve Removal (Drive Shaft
Housing) . . . . . . . . . . . . . . . . . . . . . . . . .
Roller Bearing Removal . . . . . . . . . . . .
Bearing Sleeve Installation . . . . . . . . .
Roller Bearing Installation . . . . . . . . . .
Drive Shaft Housing Reassembly . . . . . .
Torque Conversion Chart For
U-joint Retainer . . . . . . . . . . . . . . . .
Torquing Bravo U-joint Bearing
Retainer Nut . . . . . . . . . . . . . . . . . . .

3A-20
3A-22
3A-23
3A-25
3A-29
3A-31
3A-32
3A-36
3A-36
3A-37
3A-39
3A-43
3A-43
3A-46
3A-46
3A-49
3A-49
3A-49
3A-50
3A-51
3A-52
3A-53
3A-54
3A-57
3A-57

Page v

BRAVO STERNDRIVES

SERVICE MANUAL NUMBER 11

Section 3B - Bravo One Gear Housing

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2
Torque Specifications . . . . . . . . . . . . . . . 3B-2
Preloads . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2
Lubricants/Sealers/Adhesives . . . . . . . . 3B-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3B-3
Gear Ratio - Teeth per Gear (Gear
Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-3
Bravo One Gear Housing Exploded View 3B-4
Drive Shaft Components . . . . . . . . . . . . 3B-4
Propeller Shaft Components . . . . . . . . . 3B-6
Pre-Disassembly Inspection . . . . . . . . . . . . 3B-8
Drive Shaft Housing and Gear Housing
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-8
Gear Housing Disassembly . . . . . . . . . . . . 3B-10
Component Servicing . . . . . . . . . . . . . . . . . 3B-15
Drive Shaft and Pinion Bearing
Inspection and Cleaning . . . . . . . . . . . 3B-15
Drive Shaft Disassembly . . . . . . . . . . . . 3B-15
Pinion Bearing Removal . . . . . . . . . . . . 3B-16
Pinion Bearing Installation . . . . . . . . . . 3B-17
Drive Shaft Reassembly . . . . . . . . . . . . 3B-18

Bearing Carrier Inspection . . . . . . . . . . 3B-19

Bearing Carrier Servicing . . . . . . . . . . . 3B-19
Propeller Shaft Inspection . . . . . . . . . . 3B-21
Propeller Shaft Bearing Removal . . . . 3B-21
Propeller Shaft Bearing Installation . . 3B-22
Driven Gear Bearing Removal and
Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3B-22
Driven Gear Bearing Removal . . . . . . . 3B-22
Driven Gear Bearing Installation . . . . . 3B-23
Driven Gear Bearing Cup Removal
and Inspection . . . . . . . . . . . . . . . . . . . . 3B-23
Driven Gear Bearing Cup Installation . 3B-24
Speedometer Water Tube Pickup
Inspection and Cleaning . . . . . . . . . . . 3B-24
Speedometer Water Tube Seal
Replacement . . . . . . . . . . . . . . . . . . . . . 3B-25
Gear Housing Reassembly and Shimming . 3B-26
Driven Gear Shimming for Models with
Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-32
Driven Gear Shimming for Models with
Load Ring . . . . . . . . . . . . . . . . . . . . . . . . 3B-37

Section 3C - Bravo Two Gear Housing

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2
Torque Specifications . . . . . . . . . . . . . . . 3C-2
Preloads . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2
Lubricants/Sealers/Adhesives . . . . . . . . 3C-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3C-3
Gear Ratio - Teeth per Gear
(Gear Housing) . . . . . . . . . . . . . . . . . . . . 3C-3
Bravo Two Gear Housing Exploded View . . 3C-4
Drive Shaft and Propeller Shaft
Components . . . . . . . . . . . . . . . . . . . . . . 3C-4
Pre-Disassembly Inspection . . . . . . . . . . . . 3C-6
Drive Shaft Housing and Gear Housing
Separation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Gear Housing Disassembly . . . . . . . . . . . . . 3C-8
Component Servicing . . . . . . . . . . . . . . . . . 3C-13
Drive Shaft and Pinion Bearing
Inspection and Cleaning . . . . . . . . . . . 3C-13
Drive Shaft Disassembly . . . . . . . . . . . . 3C-13
Pinion Bearing Removal . . . . . . . . . . . . 3C-14

Page vi

Pinion Bearing Installation . . . . . . . . . .

Drive Shaft Reassembly . . . . . . . . . . . .
Bearing Carrier Inspection . . . . . . . . . .
Bearing Carrier Servicing . . . . . . . . . . .
Propeller Shaft Inspection . . . . . . . . . .
Propeller Shaft Bearing Removal . . . .
Propeller Shaft Bearing Installation . .
Driven Gear Bearing Removal and
Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Driven Gear Bearing Installation . . . . .
Driven Gear Bearing Cup Removal
and Inspection . . . . . . . . . . . . . . . . . . . .
Driven Gear Bearing Cup Installation . .
Speedometer Water Tube Pickup
Inspection and Cleaning . . . . . . . . . . .
Speedometer Water Tube Seal
Replacement . . . . . . . . . . . . . . . . . . . . .
Gear Housing Reassembly and
Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . .

3C-15
3C-16
3C-17
3C-18
3C-20
3C-21
3C-22
3C-22
3C-23
3C-23
3C-24
3C-24
3C-25
3C-25

90-17431--4 MARCH 1998

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

Section 3D - Bravo Three Gear Housing

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 3D-2
Torque Specifications . . . . . . . . . . . . . . . 3D-2
Lubricants/Sealers/Adhesives . . . . . . . . 3D-2
Bearing Preloads . . . . . . . . . . . . . . . . . . . 3D-2
Gear Ratio - Teeth per Gear
(Gear Housing) . . . . . . . . . . . . . . . . . . . . 3D-3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Torquing Outer Prop Shaft Bearing
Retainer and Bearing Carrier . . . . . . . . 3D-5
Bravo Three Gear Housing Exploded View 3D-6
Drive Shaft and Propeller Shaft
Components . . . . . . . . . . . . . . . . . . . . . . 3D-6
Pre-Disassembly Inspection . . . . . . . . . . . . 3D-8
Gear Housing Disassembly . . . . . . . . . . . . . 3D-9
Component Servicing . . . . . . . . . . . . . . . . . 3D-13
Drive Shaft and Pinion Bearing
Inspection and Cleaning . . . . . . . . . . . 3D-13
Drive Shaft Disassembly . . . . . . . . . . . . 3D-14
Pinion Bearing Removal . . . . . . . . . . . . 3D-14
Pinion Bearing Installation . . . . . . . . . . 3D-15
Drive Shaft Reassembly . . . . . . . . . . . . 3D-16
Propeller Shaft Disassembly . . . . . . . . 3D-17

Bearing Carrier Inspection . . . . . . . . . . 3D-18

Bearing Carrier Servicing . . . . . . . . . . . 3D-18
Propeller Shaft Inspection . . . . . . . . . . 3D-19
Outer Propeller Shaft Servicing . . . . . . 3D-19
Front and Rear Driven Gear and
Bearing Inspection . . . . . . . . . . . . . . . . 3D-20
Front and Rear Driven Gear Bearing
Replacement . . . . . . . . . . . . . . . . . . . . . 3D-21
Front Driven Gear Bearing Cup
Removal and Inspection . . . . . . . . . . . 3D-21
Propeller Shaft Spline Lash Check . . . 3D-22
Front Driven Gear Bearing Cup
Installation . . . . . . . . . . . . . . . . . . . . . . . 3D-23
Speedometer Water Tube Pickup
Inspection and Cleaning . . . . . . . . . . . 3D-23
Speedometer Water Tube Seal
Replacement . . . . . . . . . . . . . . . . . . . . . 3D-24
Gear Housing Reassembly and Shimming . 3D-24
Checking Backlash . . . . . . . . . . . . . . . . 3D-31
Installing Gear Housing On Drive Shaft
Housing . . . . . . . . . . . . . . . . . . . . . . . . . 3D-36
Propeller Installation . . . . . . . . . . . . . . . . . . 3D-38

TRANSOM ASSEMBLY
Section 4A - Service Procedures Requiring Minor Disassembly
Bravo Transom Assembly Specifications . 4A-2
Torque Specifications . . . . . . . . . . . . . . . 4A-2
Lubricants/Sealers/Adhesives . . . . . . . . 4A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 4A-2
Bravo Transom Assembly Exploded
Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-3
Inner Transom Plate Components . . . . 4A-3
Bell Housing Components . . . . . . . . . . . 4A-4
Gimbal Ring Components . . . . . . . . . . . 4A-5
Gimbal Housing Components . . . . . . . . 4A-7
Special Information . . . . . . . . . . . . . . . . . . . . 4A-9
Trim Limit Switch . . . . . . . . . . . . . . . . . . . 4A-9
Trim Position Sender . . . . . . . . . . . . . . . . 4A-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4A-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . 4A-12
Trim Limit Switch Adjustment . . . . . . . . 4A-16
High Performance Transom Assembly Without Electrical Trim Sender and
Trim Limit Switch . . . . . . . . . . . . . . . . . . 4A-17
Gimbal Bearing . . . . . . . . . . . . . . . . . . . . . . 4A-17

90-17431--4 MARCH 1998

Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Cable Installation . . . . . . . . . . . . .
Replacing Earlier Model Shift Cables
with Later Model Shift Cables . . . . . . .
Exhaust Bellows (If Equipped) . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Tube (If Equipped) . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Water Hose and Water Fitting . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .

4A-17
4A-18
4A-19
4A-20
4A-20
4A-22
4A-26
4A-28
4A-28
4A-29
4A-29
4A-31
4A-31
4A-31
4A-32
4A-33
4A-33
4A-34

Page vii

BRAVO STERNDRIVES

SERVICE MANUAL NUMBER 11

Section 4B - Service Procedures Requiring Major Disassembly

Bravo Transom Assembly Specifications . 4B-2
Torque Specifications . . . . . . . . . . . . . . . 4B-2
Lubricants/Sealers/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-15
Gimbal Ring, Swivel Shaft and Steering
Lever Removal . . . . . . . . . . . . . . . . . . . 4B-17
Gimbal Ring Servicing . . . . . . . . . . . . . . 4B-20

Gimbal Housing Servicing . . . . . . . . . . . . .

U-joint Bellows Replacement . . . . . . . .
Shift Cable Bellows Replacement . . . .
Exhaust Bellows Replacement . . . . . .
Speedometer Hose Replacement . . . .
Gear Lube Monitor System
Components . . . . . . . . . . . . . . . . . . . .
Trim Position Sender and Trim Limit
Switch Wire Replacement . . . . . . . . . .
Gimbal Ring/Swivel Shaft/and Steering
Lever Installation . . . . . . . . . . . . . . . . . . . .
Bell Housing Installation . . . . . . . . . . . . . .
Shift Cable Installation . . . . . . . . . . . . . . . .
Bravo Access Plug Drilling Template . . . .

4B-26
4B-26
4B-28
4B-32
4B-34
4B-36
4B-39
4B-40
4B-46
4B-52
4B-56

POWER TRIM
Section 5A - Oildyne Trim Pump
Trim Pump Specifications . . . . . . . . . . . . . . 5A-2
Valve Pressure Specifications . . . . . . . . 5A-2
Electrical Specification . . . . . . . . . . . . . . 5A-2
Torque Specification . . . . . . . . . . . . . . . . 5A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 5A-2
Lubricants/Adhesives/Sealers . . . . . . . . 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-6
Testing Power Trim Pump . . . . . . . . . . . . . . 5A-7
Test Gauge . . . . . . . . . . . . . . . . . . . . . . . . 5A-7
Internal Restriction Test . . . . . . . . . . . . . 5A-8
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-14
Motor and Electrical Bench Tests . . . . . . . 5A-15
Trim Pump Motor Test (In Boat) . . . . . 5A-15
Trim Pump Motor Test (Out of Boat) . . 5A-16
Solenoid Test (Pump In Boat) . . . . . . . 5A-17
Solenoid Test (Pump Out of Boat) . . . 5A-18
110 Amp Fuse Test (Pump in Boat) . . 5A-20
110 Amp Fuse Test
(Pump Out of Boat) . . . . . . . . . . . . . . . 5A-21
20 Amp Fuse Test . . . . . . . . . . . . . . . . . 5A-21
Trim Pump Removal . . . . . . . . . . . . . . . . . . 5A-22

Page viii

Hydraulic Repair . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . .
Filter Replacement . . . . . . . . . . . . . . . . .
UP Pressure Relief Valve
Replacement . . . . . . . . . . . . . . . . . . . . .
DOWN Pressure Relief Valve
Replacement . . . . . . . . . . . . . . . . . . . . .
Thermal Relief Valve Replacement . .
Pump Replacement . . . . . . . . . . . . . . . .
Adapter Replacement . . . . . . . . . . . . . .
Adapter Repair . . . . . . . . . . . . . . . . . . . .
Pump Shaft Oil Seal Replacement . . .
Motor Repair . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . .
Armature Tests . . . . . . . . . . . . . . . . . . . . . .
Continuity Test . . . . . . . . . . . . . . . . . . . .
Test for Shorts . . . . . . . . . . . . . . . . . . . .
Cleaning Commutator . . . . . . . . . . . . . .
Field Tests . . . . . . . . . . . . . . . . . . . . . . . . . .
Test for Open Circuit . . . . . . . . . . . . . . .
Test for Short in Field . . . . . . . . . . . . . .
Thermal Switch Continuity Test . . . . . .
Brush Replacement . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Pump Installation . . . . . . . . . . . . . . . .
Trim Pump Wiring Diagrams . . . . . . . . . . .
Model With Three-Button Trim/Trailer
Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model With Trim In Handle and Trailer
Switch Separate . . . . . . . . . . . . . . . . . .

5A-23
5A-23
5A-24
5A-25
5A-26
5A-27
5A-28
5A-29
5A-30
5A-33
5A-35
5A-35
5A-38
5A-38
5A-39
5A-39
5A-39
5A-39
5A-40
5A-41
5A-42
5A-44
5A-50
5A-51
5A-51
5A-52

90-17431--4 MARCH 1998

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

Section 5B - Trim Cylinders

Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . .
Lubricants/Sealers/Adhesives . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . .
Trim Cylinder Exploded Views . . . . . . . . . .
Bravo Trim Cylinders . . . . . . . . . . . . . . . .
Bravo Trim System Components . . . . .
Power Trim Hydraulic Schematic . . . . . . . .
Special Information . . . . . . . . . . . . . . . . . . . .
Bravo Three Notice: Trim In Limit
Blocks or Limit Pin . . . . . . . . . . . . . . . . .

5B-2
5B-2
5B-2
5B-2
5B-3
5B-3
5B-4
5B-5
5B-6

Trim In Limit Blocks - Removal,

Installation or Adjustment . . . . . . . . . . . 5B-7
Trim Cylinder Internal Leak Test . . . . . . . . . 5B-9
Trim Cylinder Shock Piston Test . . . . . . . . . 5B-9
Trim Cylinder Repair . . . . . . . . . . . . . . . . . . . 5B-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 5B-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . 5B-10
Reassembly . . . . . . . . . . . . . . . . . . . . . . 5B-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . 5B-19

5B-6

Section 5C - Dual Power Trim System

Important Information . . . . . . . . . . . . . . . . . .
Testing Dual Power Trim System . . . . . . . .
Relay Test . . . . . . . . . . . . . . . . . . . . . . . . .
Diode Module Test . . . . . . . . . . . . . . . . . .
Trailer Switch Test . . . . . . . . . . . . . . . . . .
Starboard Trim Switch Test . . . . . . . . . .
Port Trim Switch Test . . . . . . . . . . . . . . . .
Dual Power Trim System Component
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5C-2
5C-2
5C-2
5C-3
5C-4
5C-4
5C-4

Important Information . . . . . . . . . . . . . . . 5C-5

Relay Replacement . . . . . . . . . . . . . . . . . 5C-5
Diode Module Replacement . . . . . . . . . . . . 5C-7
Trim Control Panel Switch(es)
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5C-8
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . 5C-9
Dual Trim Harnesses . . . . . . . . . . . . . . . . 5C-9
Electrical Box Wiring . . . . . . . . . . . . . . . 5C-10

5C-5

Section 5D - Auto Trim II

Auto Trim II System . . . . . . . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . .
Auto Trim II Operation . . . . . . . . . . . . . . . . .
Auto Mode Operation . . . . . . . . . . . . . . .
Manual Mode Operation . . . . . . . . . . .
Electrical System Overload Protection . . .

90-17431--4 MARCH 1998

5D-2
5D-2
5D-2
5D-3
5D-4
5D-6

Auto Trim Limit Adjustment . . . . . . . . . . . . . 5D-6

Adjusting Drive Unit Trim Angle . . . . . . . 5D-7
Control Module Adjustment . . . . . . . . . . . . . 5D-9
Trim Position Indicator Adjustment . . . . . 5D-10
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 5D-11

Page ix

BRAVO STERNDRIVES

SERVICE MANUAL NUMBER 11

STEERING SYSTEMS
Section 6A - Power Steering
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Lubricants/Adhesives/Sealers . . . . . . . . 6A-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-2
Earlier Style Control Valve . . . . . . . . . . . 6A-3
Later Style Control Valve . . . . . . . . . . . . 6A-3
Earlier Model Power Steering System . . . . 6A-4
Right Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-4
Earlier Model Power Steering System . . . . 6A-5
Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-5
Earlier Model Power Steering System . . . . 6A-6
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-6
Later Model Power Steering System . . . . . 6A-7
Right Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-7
Later Model Power Steering System . . . . . 6A-8
Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-8
Later Model Power Steering System . . . . . 6A-9
NeutraL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-9
Steering Helm and Cable . . . . . . . . . . . . . 6A-10
Steering Cable Specifications . . . . . . . 6A-11
Filling and Air Bleeding Power Steering
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-12
Balancing Power Steering Control Valve 6A-13
Steering Cable Selection, Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 6A-17

Selection . . . . . . . . . . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .
Power Steering Pump Lugging Test . .
Power Steering System Pressure Test .
Pump Pressure Test . . . . . . . . . . . . . . .
Booster Cylinder Test . . . . . . . . . . . . . .
Power Steering Component Repair . . . . .
Power Steering Unit . . . . . . . . . . . . . . .
Cable Guide Tube (Early Style Only) .
Control Valve (Early Style Only) . . . . .
Booster Cylinder (Early Style Only) . .
Power Steering Pump . . . . . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Valve Servicing . . . . . . . .
Pump Shaft Oil Seal Replacement . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . .
Cleaning And Inspection . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . .
Multiple Sterndrive Steering Tie Bar
Arrangements . . . . . . . . . . . . . . . . . . . .
Determining Tie Bar Length . . . . . . . . .
Selection . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . .

6A-17
6A-17
6A-17
6A-19
6A-20
6A-22
6A-24
6A-25
6A-27
6A-27
6A-30
6A-34
6A-46
6A-50
6A-50
6A-50
6A-51
6A-54
6A-56
6A-56
6A-62
6A-63
6A-64
6A-64

CORROSION PROTECTION
Section 7A - All Models
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 7A-2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . 7A-2
Lubricants/Sealers/Adhesives . . . . . . . . 7A-2
Continuity Circuit . . . . . . . . . . . . . . . . . . . . . . 7A-2
Anodic Block . . . . . . . . . . . . . . . . . . . . . . . . . 7A-5
Trim Cylinder Anodes . . . . . . . . . . . . . . . . . . 7A-8
Anodic Trim Tab or Plate . . . . . . . . . . . . . . . 7A-9
Bravo One Drive Units . . . . . . . . . . . . . . 7A-9
Bravo Two Drive Units . . . . . . . . . . . . . . 7A-11
Bravo Three Drive Units . . . . . . . . . . . . 7A-11
Integral MerCathode System . . . . . . . . . . 7A-12
Removing Electrode Assembly . . . . . . 7A-12
Installing Electrode Assembly . . . . . . . . . . 7A-13

Page x

Connect Electrical Leads to Controller

Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . .
MerCathode Monitor . . . . . . . . . . . . . . .
Mercathode Controller . . . . . . . . . . . . .
Quicksilver Isolator . . . . . . . . . . . . . . . . . . .
Corrosion Protection Testing and
Troubleshooting . . . . . . . . . . . . . . . . . . . . .
Test Equipment Set-Up . . . . . . . . . . . . .
Low Readings . . . . . . . . . . . . . . . . . . . . .
Low Readings (continued) . . . . . . . . . .
High Reading . . . . . . . . . . . . . . . . . . . . .
Normal Reading But Corrosion is
Evident . . . . . . . . . . . . . . . . . . . . . . . . . .

7A-15
7A-16
7A-16
7A-17
7A-18
7A-18
7A-21
7A-22
7A-23
7A-24
7A-25

90-17431--4 MARCH 1998

SERVICE MANUAL NUMBER 11

BRAVO STERNDRIVES

ACCESSORIES
Section 8A - All Models
Specifications . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . .
Lubricants/Sealers/Adhesives . . . . . . . .
Power Shift (P/N 38638A4) . . . . . . . . . . . . .
Description . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . .
Checking Vacuum Drop-Off . . . . . . . . . .
Power Shift Cylinder Repair . . . . . . . . . . . .
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly . . . . . . . . . . . . . . . . . . . . . . .

90-17431--4 MARCH 1998

8A-2
8A-2
8A-2
8A-2
8A-2
8A-3
8A-5
8A-6
8A-6
8A-6

Reassembly . . . . . . . . . . . . . . . . . . . . . . . 8A-9
Shift Cable Replacement and
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 8A-13
Installation Preparation . . . . . . . . . . . . . 8A-13
Shift Cable Barrel Adjustment . . . . . . . 8A-13
Installing Input Cable . . . . . . . . . . . . . . . 8A-14
Installing Output Cable . . . . . . . . . . . . . 8A-14
Attach Dust Cover . . . . . . . . . . . . . . . . . 8A-15
Mounting Power Shift Cylinder . . . . . . 8A-15
Connecting Vacuum Hose to Engine . 8A-15

Page xi

BRAVO STERNDRIVES

SERVICE MANUAL NUMBER 11

THIS PAGE IS INTENTIONALLY BLANK

Page xii

90-17431--4 MARCH 1998