Mercury Racing HP525 EFI Bravo Sterndrive Series Installation guide

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Thank You
for your purchase of one of the finest marine power
packages available. It incorporates numerous design
features to ensure 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, Maintenance & Warranty 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.
Again, thank you for purchasing one of our Mercury Marine
products. We sincerely hope your boating will be pleasant!
Mercury Racing,
N7480 County Road "UU"
Fond du Lac, WI 54935-9585
7406
Warranty Message
! 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, Maintenance and
Warranty Manual and thoroughly understand the
operational instructions for the power package and all
related accessories before the boat is used.
© 2013 Mercury Marine HP525 EFI Bravo Sterndrive Models 90-8M0079397 513

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The product you have purchased comes with a limited warranty
from Mercury Marine; the terms of the warranty are set forth in
the Warranty Information section of this manual. The warranty
statement contains a description of what is covered, what is not
covered, the duration of coverage, how to best obtain warranty
coverage, important disclaimers and limitations of damages, and
other related information. Please review this important
information.
Safety Alerts and Notices
Throughout this publication, dangers, warnings, cautions, and
notices, accompanied by the international HAZARD symbol !,
are used to alert the boat operator and technician to special
instructions concerning a particular service or operation that may
be hazardous if performed incorrectly or carelessly. Observe
these safety alerts carefully.
These safety alerts alone can not eliminate the hazards they
signal. Strict compliance to these special instructions when
performing the service, and common sense operation are major
accident prevention measures.
! DANGER
Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
! WARNING
Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
! CAUTION
Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE
Indicates a situation which, if not avoided, could result in
engine or major component failure.

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IMPORTANT: Identifies information essential to the successful
completion of the task.
NOTE: Indicates information that helps in the understanding of a
particular step or action.
Copyright and Trademark Information
© 2013 Mercury Marine, Fond du Lac, Wisconsin, USA. Printed
in USA.
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser,
Mercury Racing, Mercury Precision Parts, Mercury Propellers,
Mariner, Quicksilver, #1 On The Water, Alpha, Bravo One, Bravo
Two, Bravo Three, OptiMax, Sport‑Jet, K‑Planes, MerCathode,
SmartCraft, Zero Effort, VesselView, Zeus, Axius, Circle M with
Waves logo, Mercury with Waves logo, and SmartCraft logo are
all trademarks or registered trademarks of Brunswick
Corporation. Mercury Product Protection logo is a registered
service mark of Brunswick Corporation.
! WARNING
The engine exhaust from this product contains chemicals
known to the state of California to cause cancer, birth defects
or other reproductive harm.

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Warranty Information
Warranty Registration United States and Canada....................... 1
Transfer of Warranty.................................................................... 2
Mercury Racing Division One‑Year Limited Warranty................. 3
Products Sold to Government Agencies...................................... 6
Three‑Year Limited Warranty Against Corrosion......................... 7
Warranty Coverage and Exclusions for Mercury Racing
Sterndrive Products................................................................... 10
E.P.A. Emission Controls...........................................................11
General Information
Before Operating Your Boat...................................................... 14
Boat Horsepower Capacity........................................................ 14
High‑Speed and High‑Performance Boat Operation................. 15
Paddle Wheel and Water Temperature Sensors....................... 15
Lanyard Stop Switch.................................................................. 16
Trailering the Boat..................................................................... 17
Protecting People in the Water.................................................. 17
Exhaust Emissions.................................................................... 18
Wave and Wake Jumping.......................................................... 20
Impact With Underwater Hazards.............................................. 21
Operating in Shallow Water....................................................... 22
Safe Boating Suggestions......................................................... 24
Stolen Power Package.............................................................. 27

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Specifications
Engine Identification.................................................................. 28
Fuel Requirements.................................................................... 29
Low Permeation Fuel Hose Requirement ................................. 31
Crankcase Oil............................................................................ 31
Capacities.................................................................................. 33
General Engine Specifications...................................................33
Engine Operating Limitations.....................................................34
Engine Break‑in......................................................................... 35
After Break‑In Period................................................................. 35
Operation
Instrumentation.......................................................................... 36
Warning System........................................................................ 36
Electrical System Overload Protection...................................... 39
Remote Controls........................................................................ 43
Remote Controls (Console Mounted Zero Effort)...................... 46
Power Trim................................................................................ 47
Starting, Shifting and Stopping.................................................. 52
Operation Chart......................................................................... 54
Freezing Temperature Operation.............................................. 55
Drain Plug and Bilge Pump........................................................56
Launching And Boat Operation Care......................................... 56
Conditions Affecting Operation
Weight Distribution.....................................................................57
Bottom Of Boat.......................................................................... 57
Cavitation................................................................................... 57
Ventilation.................................................................................. 58
Propeller Selection.....................................................................58
Conditions That Lower Engine Performance............................. 59

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Maintenance
Service Responsibilities............................................................. 60
Replacement Service Parts....................................................... 61
Do‑It‑Yourself Maintenance Suggestions.................................. 61
Servicing High‑Horsepower Engines......................................... 63
Engine Maintenance Charts...................................................... 63
Bravo Drive Maintenance Charts............................................... 65
Checking Fluid Levels................................................................67
Changing Fluids......................................................................... 74
Lubrication................................................................................. 85
Propellers...................................................................................88
Flushing the Power Package..................................................... 96
Seawater Pump Impeller Inspection........................................ 100
Cleaning Seawater (Raw Water) Section of Oil Cooler........... 101
Changing Positive Crankcase Ventilation Valve...................... 102
Serpentine Drive Belt............................................................... 103
Changing Fuel Filters...............................................................105
Corrosion and Corrosion Protection........................................ 108
Battery..................................................................................... 115
Bottom of Boat......................................................................... 116
Inspection and Maintenance.................................................... 116
Attention Required After Submersion...................................... 116
Cold Weather or Extended Storage
Power Package Lay‑up............................................................117
Draining Instructions................................................................ 119
Battery Winter Storage............................................................ 122
Power Package Recommissioning.......................................... 122

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Troubleshooting
Engine Will Not Crank..............................................................126
Engine Cranks But Will Not Start............................................. 126
Engine Hard to Start, Runs Rough, Misses, and/or Backfires. 127
Low Engine Coolant (Closed Cooling) Temperature............... 127
Poor Performance....................................................................128
Insufficient Engine Temperature.............................................. 128
High Engine Temperature........................................................129
Low Engine Oil Pressure......................................................... 129
Battery Will Not Come Up On Charge..................................... 130
Power Trim Does Not Operate (Motor Doesn't Run)............... 130
Power Trim Does Not Operate (Motor Runs But Drive Unit Does
Not Move)................................................................................ 130
Electrical Analog Trim Gauge Malfunction...............................131
Remote Control Operates Hard, Binds, Has Excessive Free‑Play
or Makes Unusual Sounds.......................................................131
Steering Wheel Turns Hard or Jerky....................................... 131
Seawater Pressure Is Below Specification.............................. 132
Seawater Pressure Is Above Specification.............................. 132
Owner Service Assistance
Local Repair Service................................................................133
Service Away from Home........................................................ 133
Parts and Accessories Inquiries.............................................. 133
Service Assistance.................................................................. 133
Mercury Mercruiser Service Offices.........................................134
Ordering Literature
United States and Canada.......................................................136
Outside The United States and Canada.................................. 136

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Maintenance Log
Maintenance Log..................................................................... 137

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WARRANTY INFORMATION
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Warranty Registration United States and Canada
Outside United States and Canada–Check with your local
distributor.
1. You may change your registered address at any time,
including at time of warranty claim, by calling Mercury
Marine or sending a letter or fax with your name, old
address, new address, and engine serial number to Mercury
Marine’s warranty registration department. Your dealer can
also process this change of information.
Mercury Marine
Attn.: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
NOTE: Registration lists must be maintained by Mercury Marine
and any dealer on marine products sold in the United States,
should a safety recall notification under the Federal Safety Act
be required.
2. At the time of sale, the dealer should complete the warranty
registration and immediately submit it to Mercury Marine via
MercNET, E‑mail, or mail. Upon receipt of this warranty
registration, Mercury Marine will record the registration.
IMPORTANT: Your warranty coverage begins at the time of
sale, but warranty claims cannot be processed until the product
is registered with Mercury Marine.
3. Upon processing the warranty registration, Mercury Marine
will send the purchaser a Mercury Owner Resource Guide.
The back page of this guide contains your warranty
registration information and should be saved. If this
registration verification is not received within 30 days,
please contact your selling dealer immediately.

WARRANTY INFORMATION
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Transfer of Warranty
The limited warranty is transferable to a subsequent purchaser,
but only for the remainder of the unused portion of the limited
warranty. This will not apply to products used for commercial
applications.
To transfer the warranty to the subsequent owner, send or fax a
copy of the bill of sale or purchase agreement, new owner’s
name, address and engine serial number to Mercury Marine’s
Warranty Registration Department. In the United States and
Canada, mail to:
Mercury Marine
Attn: Warranty Registration Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
920-929-5054
Fax [phone]
Upon processing the transfer of warranty, Mercury Marine will
send registration verification to the new owner of the product by
mail.
There is no charge for this service.
For products purchased outside the United States and Canada,
contact the distributor in your country, or the Marine Power
Service Center closest to you.

WARRANTY INFORMATION
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Mercury Racing Division One‑Year Limited
Warranty
WHAT IS COVERED
Mercury Marine warrants its new products (and remanufactured
products sold under the trade name "Pacemaker") to be free of
defects in material and workmanship during the period described
below.
DURATION OF COVERAGE
This Limited Warranty provides coverage for one (1) year from
either the date the product is first sold to a recreational use retail
purchaser, or the date on which the product is first put into
service, whichever occurs first. The repair or replacement of
parts, or the performance of service under this warranty, does
not extend the life of this warranty beyond its original expiration
date. Unexpired warranty coverage can be transferred to a
subsequent purchaser upon proper re‑registration of the product.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN
WARRANTY COVERAGE
Warranty coverage is available only to retail customers that
purchase from a dealer authorized by Mercury Marine to
distribute the product in the country in which the sale occurred,
and then only after the Mercury Marine‑specified pre‑delivery
inspection process is completed and documented. Warranty
coverage becomes available upon proper registration of the
product by the authorized dealer. Inaccurate warranty
registration information regarding recreational use, or
subsequent change of use from recreational to commercial may
void the warranty at the sole discretion of Mercury Marine.
Routine maintenance outlined in the Operation and Maintenance
Manual must be timely performed in order to maintain warranty
coverage. Mercury Marine reserves the right to make warranty
coverage contingent upon proof of proper maintenance.

WARRANTY INFORMATION
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WHAT MERCURY WILL DO
Mercury’s sole and exclusive obligation under this warranty is
limited to, at our option, repairing a defective part, replacing such
part or parts with new or Mercury Marine‑certified
re‑manufactured parts, or refunding the purchase price of the
Mercury product. Mercury reserves the right to improve or modify
products from time to time without assuming an obligation to
modify products previously manufactured.
HOW TO OBTAIN WARRANTY COVERAGE
The customer must provide Mercury with a reasonable
opportunity to repair and reasonable access to the product for
warranty service. Warranty claims shall be made by delivering
the product for inspection to a Mercury dealer authorized to
service the product. If purchaser cannot deliver the product to
such a dealer, written notice must be given to Mercury. We will
then arrange for the inspection and any covered repair.
Purchaser in that case shall pay for all related transportation
charges and/or travel time. If the service provided is not covered
by this warranty, purchaser shall pay for all related labor and
material, and any other expenses associated with that service.
Purchaser shall not, unless requested by Mercury, ship the
product or parts of the product directly to Mercury. Proof of
registered ownership must be presented to the dealer at the time
warranty service is requested in order to obtain coverage.

WARRANTY INFORMATION
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WHAT IS NOT COVERED
This limited warranty does not cover routine maintenance items,
tune ups, adjustments, normal wear and tear, damage caused by
abuse, abnormal use, use of a propeller or gear ratio that does
not allow the engine to run in its recommended
wide‑open‑throttle RPM range, operation of the product in a
manner inconsistent with the recommended operation/duty cycle
section of the Warranty, Operation, and Maintenance Manual,
neglect, accident, submersion, improper installation (proper
installation specifications and techniques are set forth in the
installation instructions for the product), improper service, use of
an accessory or part not manufactured or sold by us, operation
with fuels, oils or lubricants which are not suitable for use with
the product, alteration or removal of parts, water entering the
engine through the fuel intake, air intake or exhaust system, or
damage to the product from insufficient cooling water caused by
blockage of the cooling system by a foreign body, running the
engine out of water, mounting the engine too high on the
transom, or running the boat with the engine trimmed out too far.
The commercial use of the product, defined as any work or
employment related use of the product, or any income
generating use of the product, even if such use is only
occasional, will void the warranty. Use of the product for racing
or other competitive activity, at any point, even by a prior owner
of the product, voids the warranty. Expenses related to haul‑out,
launch, towing, storage, telephone, rental, inconvenience, slip
fees, insurance coverage, loan payments, loss of time, loss of
income, tournament fees, club fees, prize money or any other
type of incidental or consequential damages are not covered by
this warranty. Also, expenses associated with the removal and/or
replacement of boat partitions or material caused by boat design
for access to the product are not covered by this warranty.

WARRANTY INFORMATION
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No individual or entity, including Mercury Marine‑authorized
dealers, has been given authority by Mercury Marine to make
any affirmation, representation or warranty regarding the
product, other than those contained in this limited warranty, and
if made, shall not be enforceable against Mercury Marine. For
additional information regarding events and circumstances
covered by this warranty, and those that are not, see the
Warranty Coverage section of this manual, incorporated by
reference into this warranty.
Disclaimers and limitations the implied warranties of
merchantability and fitness for a particular pupose are expressly
disclaimed. to the extent that they cannot be disclaimed, the
implied warranties are limited in duration to the life of the express
warranty. Incidental and consequential damages are excluded
from coverage under this warranty. Some states and countries
do not allow for the disclaimers, limitations, and exclusions
identifies above, as a result, they may not apply to you. This
warranty gives you specific legal rights, and you may also have
other legal rights which vary from state‑to‑state and
country‑to‑country.
Products Sold to Government Agencies
Contact the Mercury Racing Sales Department for a copy of the
Government Agencies Warranty Packet Kit which explains the
conditions required for government agencies to receive warranty
when purchasing Mercury Racing Outboard or Sterndrive
product.
Mercury Racing Sales Department
N7840 County Road UU
Fond du Lac, WI 54935
920-921-5330
Fax [phone]

WARRANTY INFORMATION
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Three‑Year Limited Warranty Against Corrosion
WHAT IS COVERED: Mercury Marine warrants that each new
Mercury, Mariner, Mercury Racing Outboard, Sport Jet, M2 Jet
Drive, Tracker by Mercury Marine Outboard, Mercury MerCruiser
inboard or sterndrive engine, Mercury Racing Bravo‑style
sterndrive engine (Product) will not be rendered inoperative as a
direct result of corrosion for the period of time described below.
DURATION OF COVERAGE: This limited corrosion warranty
provides coverage for three (3) years from either the date the
product is first sold, or the date on which the product is first put
into service, whichever occurs first. The repair or replacement of
parts, or the performance of service under this warranty does not
extend the life of this warranty beyond its original expiration date.
Unexpired warranty coverage can be transferred to subsequent
(non‑commercial use) purchaser upon proper re‑registration of
the product.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN
WARRANTY COVERAGE: Warranty coverage is available only
to retail customers that purchase from a dealer authorized by
Mercury Marine to distribute the product in the country in which
the sale occurred, and then only after the Mercury Marine
specified pre‑delivery inspection process is completed and
documented. Warranty coverage becomes available upon proper
registration of the product by the authorized dealer. Corrosion
prevention devices specified in the Operation and Maintenance
Manual must be in use on the boat, and routine maintenance
outlined in the Operation and Maintenance Manual must be
timely performed (including without limitation the replacement of
sacrificial anodes, use of specified lubricants, and touch‑up of
nicks and scratches) in order to maintain warranty coverage.
Mercury Marine reserves the right to make warranty coverage
contingent upon proof of proper maintenance.

WARRANTY INFORMATION
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WHAT MERCURY WILL DO: Mercury's sole and exclusive
obligation under this warranty is limited to, at our option,
repairing a corroded part, replacing such part or parts with new
or Mercury Marine‑certified re‑manufactured parts, or refunding
the purchase price of the Mercury product. Mercury reserves the
right to improve or modify products from time to time without
assuming an obligation to modify products previously
manufactured.
HOW TO OBTAIN WARRANTY COVERAGE: The customer
must provide Mercury with a reasonable opportunity to repair,
and reasonable access to the product for warranty service.
Warranty claims shall be made by delivering the product for
inspection to a Mercury dealer authorized to service the product.
If purchaser cannot deliver the product to such a dealer, written
notice must be given to Mercury. We will then arrange for the
inspection and any covered repair. Purchaser in that case shall
pay for all related transportation charges and/or travel time. If the
service provided is not covered by this warranty, purchaser shall
pay for all related labor and material, and any other expenses
associated with that service. Purchaser shall not, unless
requested by Mercury, ship the product or parts of the product
directly to Mercury. Proof of registered ownership must be
presented to the dealer at the time warranty service is requested
in order to obtain coverage.
WHAT IS NOT COVERED: This limited warranty does not cover
electrical system corrosion; corrosion resulting from damage,
corrosion which causes purely cosmetic damage, abuse or
improper service; corrosion to accessories, instruments, steering
systems; corrosion to factory installed jet drive unit; damage due
to marine growth; replacement parts (parts purchased by
customer); products used in a commercial application.
Commercial use is defined as any work or employment related
use of the product, or any use of the product which generates
income, for any part of the warranty period, even if the product is
only occasionally used for such purposes.

WARRANTY INFORMATION
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Corrosion damage caused by stray electrical currents (on‑shore
power connections, nearby boats, submerged metal) is not
covered by this corrosion warranty and should be protected
against by the use of a corrosion protection system, such as the
Mercury Precision Parts or Quicksilver MerCathode system
and/or galvanic Isolator. Corrosion damage caused by improper
application of copper base anti‑fouling paints is also not covered
by this limited warranty. If anti‑fouling protection is required,
tri‑butyl‑tin‑adipate (TBTA) base anti‑fouling paints are
recommended on outboard and MerCruiser boating applications.
In areas where TBTA base paints are prohibited by law, copper
base paints can be used on the hull and transom. Do not apply
paint to the outboard or MerCruiser product. In addition, care
must be taken to avoid an electrical interconnection between the
warranted product and the paint. For MerCruiser product, an
unpainted gap of at least 38 mm (1.5 in.) should be left around
the transom assembly. Refer to the Operation and
Maintenance Manual for additional details.
For additional information regarding events and circumstances
covered by this warranty, and those that are not, see the
Warranty Coverage section of the Operation and Maintenance
Manual, incorporated by reference into this warranty.
DISCLAIMERS AND LIMITATIONS:
THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
A PARTICULAR PURPOSE ARE EXPRESSLY DISCLAIMED. TO THE
EXTENT THAT THEY CANNOT BE DISCLAIMED, THE IMPLIED
WARRANTIES ARE LIMITED IN DURATION TO THE LIFE OF THE
EXPRESS WARRANTY. INCIDENTAL AND CONSEQUENTIAL DAMAGES
ARE EXCLUDED FROM COVERAGE UNDER THIS WARRANTY. SOME
STATES/COUNTRIES DO NOT ALLOW FOR THE DISCLAIMERS,
LIMITATIONS AND EXCLUSIONS IDENTIFIED ABOVE, AS A RESULT,
THEY MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU
SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER LEGAL
RIGHTS WHICH VARY FROM STATE TO STATE AND COUNTRY TO
COUNTRY.

WARRANTY INFORMATION
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Warranty Coverage and Exclusions for Mercury
Racing Sterndrive Products
The purpose of this section is to help eliminate some of the more
common misunderstandings regarding warranty coverage. The
following information explains some of the types of services that
are not covered by warranty. The provisions set forth following
have been incorporated by reference into the Mercury Racing
Division Three‑Year Limited Warranty Against Corrosion Failure,
the Mercury Racing Division 90‑Day, Six‑Month and One‑Year
Limited Warranties.
Keep in mind that warranty covers repairs that are needed within
the warranty period because of defects in material and
workmanship. Installation errors, accidents, normal wear, and a
variety of other causes that affect the product are not covered.
Warranty is limited to defects in material or workmanship, but
only to retail customers that purchase from a dealer authorized
by Mercury Marine to distribute the product in the country in
which the sale occurred, and then only after the Mercury Marine
specified pre‑delivery inspection process is completed and
documented.
Should you have any questions concerning warranty coverage,
contact your authorized dealer. They will be pleased to answer
any questions that you may have.
GENERAL EXCLUSIONS FROM WARRANTY
1. Minor adjustments and tune‑ups, including checking,
cleaning or adjusting spark plugs, ignition components,
carburetor or EFI settings, filters, belts, controls, and
checking lubrication made in connection with normal
services.
2. Damage caused by lack of maintenance.
3. Haul‑out, launch, towing charges, and all related
transportation charges and/or travel time, etc.
4. Additional service work requested by customer other than
that necessary to satisfy the warranty obligation.