Mercury MerCruiser Bravo Sterndrives Service Manual #28 (P/N 90-863160, 2000 edition)

• Official Mercury Marine publication P/N 90-863160 (May 2000 edition) spanning 596 pages
• Covers Mercury Bravo One, Bravo Two, Bravo Three, Bravo X, Bravo XZ, and Bravo XR sterndrive units, including Diesel Bravo X variants
• Features detailed technical diagrams for gear housings, trim systems, steering mechanisms, and shift cable linkage
• Provides factory-authorized procedures outlining the exact specifications used for the 2000-era marine engine lineup

System Documentation Overview

This service publication outlines the factory-mandated protocols for overhauling, maintaining, and installing Bravo sterndrive propulsion systems. You will find complete disassembly and reassembly sequences for gear housings. The breakdown includes critical measurements like bearing preloads, gear lash settings, and gear ratio identification necessary for precise bench work. Beyond the drives themselves, the manual details the transom assembly, power trim pump, and steering setups. Professional mechanics and seasoned do-it-yourselfers can rely on the provided hydraulic schematic layouts and wiring diagrams to trace faults efficiently in the shop.

Specification Highlights and Reference Data

Having the correct torque specs and fluid levels on hand prevents costly rework. This manual includes extensive reference tables for hardware identification and exact torque values, such as securing the propeller nut at 55 lb-ft and sterndrive unit attachment hardware at 50 lb-ft. It lists specific sterndrive unit oil capacities for Bravo One, Two, and Three models (88, 104, and 96 US quarts respectively). The text also outlines the strict 10-hour break-in period for new or replacement gears alongside electrical system voltage checks for MerCathode controllers. Additional reference data establishes corrosion protection testing thresholds for both salt and freshwater environments.

Working on marine propulsion systems involves significant weight, moving parts, and pressurized fluids. Always verify your work against these factory standards, ensure the vessel is properly supported before removing the sterndrive, and wear appropriate protective gear when handling hydraulic components.