Mercury MerCruiser Bravo Sterndrive Service Manual 2000–2005 (P/N 90-863160-1)

Mercury Marine Service Manual No. 28 (P/N 90-863160-1), issued in June 2003, covers Bravo sterndrives from serial 0M100000 and Sport Master models from serial 0M052945. The drive sections distinguish Bravo One, Two, and Three, Bravo X, XZ, and XR, Diesel Bravo One X, Two X, and Three X, and Super SportMaster components.

Searchable Text, Bookmarks, and Diagram Detail

Finding procedures and reading diagrams: Search the PDF text or expand the bookmarks to jump to a subsection. Zoom in to read the smallest wire-color codes and terminal numbers on the power trim diagrams.

The download contains one printable English PDF with 688 pages, including nine notes pages within the manual.

Sterndrive Overhaul, Transom Service, and Trim Diagnosis

These selected topics show the range of workshop procedures in the manual. Other sections cover Power Shift vacuum troubleshooting and compact hydraulic steering installations with through-transom exhaust.

• Drive and gearcase repair: Covers sterndrive removal and installation, drive shaft housing and gearcase separation, clutch and shifter repair, U-joint and pinion service, and model-specific gearcase reassembly.

• Transom assembly service: Covers minor and major disassembly of standard and high-performance assemblies, including gimbal bearings, bell housings, gimbal rings, swivel shafts, shift cables, and bellows.

• Power trim diagnosis and repair: Covers the Oildyne pump, trim cylinders, and dual controls, with bleeding, pressure and internal leak tests, motor bench tests, and relay, diode, solenoid, and fuse checks.

• Steering system service: Covers helm and cable installation, power steering assembly and pump service, flow-control valve work, pressure testing, single- and twin-station bleeding, and multiple-drive tie-bar setups.

• Maintenance and corrosion protection: Covers water-pickup flushing, layup and recommissioning, anode maintenance, ground continuity, Integral MerCathode systems, galvanic isolators, hull-potential testing, and corrosion troubleshooting.

• Exploded views and schematics: Includes drive shaft housing, Super SportMaster gear housing, and Bravo transom assembly views, plus trim hydraulics, dual trim harness, and standard and quick-connect MerCathode diagrams.

Mercury Marine wrote the manual for dealer mechanics and company service personnel trained in the recommended procedures and familiar with the specified shop tools.

Drive Identification and Overhaul

Gear-ratio decals, U-joint shaft markings, and gear tooth-count tables help identify the installed gearing before selecting parts or a repair procedure. If the gearing has been changed, the tooth-count tables help verify the ratio. The manual also identifies Permalube U-joints by ratio and serial number and distinguishes dual-water-pickup gearcases.

The Bravo One, Two, and Three gearcase sections cover bearing and gear inspection, propeller shafts and bearing carriers, shimming, backlash, and end play. The drive shaft housing chapter explains how clutch-gear timing marks align with the housing index marks and warns that incorrect timing can damage the gears and U-joint pinion gear.

Transom and Trim Configurations

The transom chapters cover trim-position-sender and trim-limit-switch wiring, gear-lube-monitor components, and the Bravo access-plug drilling template. They distinguish high-performance transom assemblies without an electrical sender or limit switch. For internal engine work or engine removal and installation during transom service, use the applicable Mercury MerCruiser engine service manual.

The trim chapters distinguish early and later Oildyne pump construction and cover relief-valve service, armature and field checks, and the Bravo Three trim-in limit insert. The pump test section warns that crossing the IN/DOWN and OUT/UP hoses can damage the sterndrive housing.

Maintenance and Special Tools

The maintenance chapter specifies a 10-hour break-in period for new sterndrives or replacement gears and covers service schedules, oil checks and changes, fluid capacities, and approved lubricants. The electrical service precautions call for disconnecting the battery cables when terminals could be grounded or touched.

Specified tools include the shift cable adjustment tool (91-12427), drive shaft pinion gear shimming tool (91-42840T), trim pump test gauge kit (91-52915A6), power steering test gauge kit (91-38053A4), and reference electrode (91-76675T1) for MerCathode hull-potential checks.

Gear Backlash and Trim Pressure Examples

The Bravo One gear housing chapter specifies gear backlash of 0.30–0.38 mm (0.012–0.015 in.) for the gearcase check.

The Oildyne pump specifications give a valve pressure range of 2,200–2,600 psi for the UP circuit and 400–600 psi for the DOWN circuit, with separate ranges for diagnosing each direction.