Brunswick bravo one Manual

OPERATION &
MAINTENANCE MANUAL
1996,BrunswickCorporation 90-806294962 196
5.7L/5.7LX/7.4L
Bravo
One/Two/Three

0
CA1 IDENTIFICATION RECORD
Please Record the Following Information
1. Engine Model and Horsepower
2. Engine Serial Number
3. Transom Assembly Serial Number
4. Stern Drive Unit Serial Number and Gear Ratio
5. Propeller Number
6. Propeller Pitch
7. Hull Identification Number (HIN) Purchase Date
8. Boat Manufacturer Boat Model Length
SERIAL NUMBERS
The serial numbers are the manufacturer’s keys to numerous engineering details
whichapplytoyourMerCruiserpowerpackage.WhencontactingyourAuthorized
MerCruiser Dealer about service, always specify model and serial numbers.
The description and specifications contained herein were in effect at the time this
guidewas approved for printing. Mercury Marine, whose policy is oneofcontinuous
improvement, reserves the right to discontinue models at any time, or to change
specifications or designs, without notice and without incurring obligation.
Mercury Marine, Fond du Lac, Wisconsin, U.S.A. Printed in U.S.A.
1996, Brunswick Corporation
The following are registered trademarks of Brunswick Corporation: Auto-
blend, Jet-Prop, Mariner, Merc, MerCathode, MerCruiser, Mercury, Mercury
Marine, Quicksilver, Ride-Guide, and Thruster.

1
CA310
74677
71352 71350
71360
ABC12345Z123
-19 48-12345
71345
5
6
712
2
3
4
4
1
23
456
7
COLOR CODE
MERCRUISER
Division of Mercury Marine
Stillwater, OK, U.S.A.
SPECIFICATIONS
MODEL MCM 5.7 LITRE LX. . . . . . .
DISPLACEMENT 350 CID. . . . . . . . .
IGNITION TIMING 10 BTDC. . . . . . .
CYL. FIRING ORDER 1-8-4-3-6-5-7-2
SPARK PLUGS AC-MR43T. . . . . . . .
ENGINE ROTATION LH. . . . . . . . . . .
MAX W.O.T. RPM 4400-4800. . . . . .
IDLE RPM IN NEUTRAL 650. . . . . . .
PLUG GAP .035’. . . . . . . . . . . . . . . . .
For Fuel and Oilrequirements refer to
Operations & Maintenance Manual
SERIAL NUMBERS

2
CB538 TABLE OF CONTENTS Page
Welcome! 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read This Manual Thoroughly 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Lanyard Stop Switch 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Boating Suggestions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting People In The Water 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
High-speed And High-performance Boat Operation 11. . . . . . . . . .
Conditions Affecting Operation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Elevation And Climate Affect Performance 15. . . . . . . . . .
Important Information 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation And Maintenance 16. . . . . . . . . . . . . . . . . . . . . . . . . . .
Freezing Temperature Operation 17. . . . . . . . . . . . . . . . . . . . . . .
Drive Unit Impact Protection 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions Information 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attention Required After Submersion 18. . . . . . . . . . . . . . . . . . . .
Trailering Boat 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Launching And Boat Operation Care 19. . . . . . . . . . . . . . . . . . . .
Stolen Power Package 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Service Parts 20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Do-It-Yourself Maintenance Suggestions 21. . . . . . . . . . . . . . . . .
20-Hour Break-In Period 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After Break-In Period 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-Hour Checkup 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrumentation 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System Overload Protection 29. . . . . . . . . . . . . . . . . . .
Models With Mercathode System 29. . . . . . . . . . . . . . . . . . . . . . .
Remote Controls (Panel Mounted) 31. . . . . . . . . . . . . . . . . . . . . .
Remote Controls (Console Mounted) 33. . . . . . . . . . . . . . . . . . . .
Remote Controls (Two Lever) 35. . . . . . . . . . . . . . . . . . . . . . . . . .
Power Trim 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting, Shifting And Stopping 44. . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Recommendations 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Crankcase Oil 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tune-Up 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
Page
Maintenance 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Aids 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Chart 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Fluid Levels 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Fluids 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Cooling System 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Pump Impeller Inspection 79. . . . . . . . . . . . . . . . . . . . .
Cleaning Seawater (Raw Water) Section Of Heat
Exchangers - Closed Cooling Models Only 81. . . . . . . . . . . . . .
Drive Belts 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Separating Fuel Filter 85. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Sight Tube Inspection 85. . . . . . . . . . . . . . . . . . . . . . .
Corrosion And Corrosion Protection 87. . . . . . . . . . . . . . . . . . . . .
Emissions 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Positive Crankcase Ventilation (PCV) Valve 93. . .
Emissions Testing 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of Test Probes 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous Maintenance 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather Or Extended Storage 98. . . . . . . . . . . . . . . . . . . . . . .
Power Package Lay Up 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining Instructions 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Winter Storage 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Package Recommissioning 112. . . . . . . . . . . . . . . . . . . . .
Troubleshooting 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty Information 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Owner Warranty Registration 120. . . . . . . . . . . . . . . . . . . . . . . . .
International Owner Registration 121. . . . . . . . . . . . . . . . . . . . . .
Warranty Policies 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mercruiser Limited Warranty - Gasoline Engines 122. . . . . . . .
Mercruiser International Warranty - Gasoline Engines 124. . .
3 Year Limited Warranty Against Corrosion Failure 126. . . . . . . . .
Warranty Coverage 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transferable Warranty 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Q-Guard Product Protection Plan 132. . . . . . . . . . . . . . . . . . . . . . . .
Owner Service Assistance 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Centers 136. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Service Literature 140. . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Maintenance Parts 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Literature Order Form 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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CA165 WELCOME!
You have selected one of the finest marine power packages available. It
incorporates numerous design features to assure operating ease and
durability.
With proper care and maintenance, you will thoroughly enjoy using this
product for many boating seasons. To ensure maximum performance and
carefree use, we ask that you thoroughly read this manual.
The Operation and Maintenance Manual contains specific instructions for
using and maintaining your product. We suggest that this manual remain
with the product for ready reference whenever you are on the water.
Thank you for purchasing one of our MerCruiser products. We sincerely
hope your boating will be pleasant!
Consumer Affairs Department

5
CA166 Read This Manual Thoroughly
IF YOU DON’T UNDERSTAND ANY PORTION, CONTACT YOUR
DEALER FOR A DEMONSTRATION OF ACTUAL STARTING
AND OPERATING PROCEDURES.
NOTICE
Throughout this publication, and on your power package,
WARNINGS and CAUTIONS, accompanied by the International
Hazard Symbol !, may be used to alert the installer/user 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 with these special instructions while
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-Hazardsorunsafepracticeswhich couldresultinmi-
nor personal injury or product or property damage.
IMPORTANT: - Indicates information or instructions that are
necessary for proper operation and /or maintenance.
!WARNING
The operator (driver) is responsible for the correct and safe
operation of the boat, the equipment aboard and the safety of
all occupants aboard. We strongly recommend that the
operator read this Operation and Maintenance Manual and
thoroughly understand the operational instructions for the
power package and all related accessories before the boat is
used.

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CA280 Lanyard Stop Switch
74608
21
1Someboatscome equipped with alanyardstop switch. A lanyard
stopswitchcanalsobeinstalledasanaccessory.Thepurposeofthis
switch is to turn off the engine ignition whenever the operator (when
attached to the lanyard) moves far enough away from the operator’s
position to activate the switch.
2Thelanyardisacordusuallybetween4and5feet(1220and1524
mm) in length when stretched out with an element on one end made
to be inserted into the switch and a metal snap on the other end for
attaching to the operator. It is coiled to make its at rest condition as
short as possible so as to minimize the likelihood of lanyard
entanglement with nearby objects. It is made as long as it is in its
stretchedconditiontominimizethelikelihoodofaccidentalactivation
should the operator choose to move around in an area close to the
normal operator’s position. If for any reason it is desired to have a
shorter functional lanyard, this may be accomplished by using up
length in the way the lanyard and clip are attached to the operator
(such as wrapping the lanyard around the operator’s wrist or leg) or
by tying a simple knot in the lanyard.
Read the Safety Warning on this page and the following page
before electing to install, use, or not to use such a switch.
!WARNING
The following advantages and disadvantages of a lanyard stop
switch should be considered before electing to use, or not to
use, such a switch.

7
ADVANTAGES: The purpose of a lanyard stop switch is to stop
theengineignitionwhenevertheoperator(whenattachedtothe
lanyard)movesfarenoughawayfrom theoperator’spositionto
activate the switch. This would occur if the operator falls or
moves within the boat a sufficient distance from the operator’s
position. This type of accident is most likely in certain types of
boats such as low-sided boats, and high-performance boats,
It is also likely as a result of poor operating practices such as
sitting on the back of the seat at planing speeds, standing at
planing speeds, operating at high speeds in shallow or
obstacle-infested waters, releasing your grip on a steering
wheel that is pulling in one direction, drinking and driving, or
daring, high-speed boat maneuvers.
DISADVANTAGES: Inadvertent activation of the switch is also
a possibility. This could cause any, or all, of the following
potentially hazardous situations:
1. Loss of balance and falling forward of unstable boat
passengers - a particular concern in bow rider type boats.
2. Loss of power and directional control in heavy seas, strong
current or high winds.
3. Loss of control when docking.
While activation of the lanyard stop switch will result in
immediate power shut-down, a boat can continue to coast for
some distance depending upon the velocity and degree of any
turn at shut-down. However, the boat will not complete a full
circle. While the boat is coasting, it can cause injury to anyone
in the boat’s path as seriously as the boat would when under
power.
As we cannot possibly know of and advise the boating public
of all conceivable boat/motor types and/or poor operating
practices, the final decision of whether to use a lanyard stop
switch rests with you, the owner/driver.
We strongly recommend that other occupants be instructed on
proper starting and operating procedures should they be
required to operate the engine and boat in an emergency.

8
CA281 Safe Boating Suggestions
In order to safely enjoy the waterways, familiarize yourself with local
and other governmental boating regulations and restrictions, and
consider the following suggestions.
•Know and obey all nautical rules and laws of the waterways.
Boatoperatorsshouldcompleteaboatingsafetycourse.Courses
are offered in the U.S.A. by (1) The U.S. Coast Guard Auxiliary,
(2) The Power Squadron, (3) The Red Cross and (4) your state
or provincial boating law enforcement agency. Inquiries may be
made to the Boating Hotline, 1-800-368-5647 or the Boat U.S.
Foundation information number 1-800-336-BOAT.
We strongly recommend that all powerboat operators attend one of
these courses.
YoushouldalsoreviewtheNMMA SourcesofWaterwayInformation
booklet. It lists regional sources of safety, cruising and local
navigation and is available at no charge by writing to:
Sources of Waterway Information
National Marine Manufacturers Association
410 N. Michigan Avenue
Chicago, IL 60611 U.S.A.
•Perform safety checks and required maintenance. Follow a
regular schedule and ensure that all repairs are properly made.
•Check safety equipment on board. Herearesuggestionsofthe
types of safety equipment to carry when boating:
(1) Approved fire extinguisher(s); paddle or oar.
(2) Signal devices: flashlight, rockets or flares, flag and whistle or
horn.
(3) Spare propeller, thrust hubs and an appropriate wrench.
(4) Tools for necessary minor repairs; first aid kit and book.
(5) Anchor and extra anchor line; water-proof storage containers.
(6) Manual bilge pump and extra drain plugs; compass and map or
chart of area.
(7) Spare operating equipment; batteries, bulbs, fuses, etc.
(8) Transistor radio
(9) Drinking water