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Sonik Synth 2.1.1 - Release Notes: Changes From Version 2.1
Sonik Synth 2.1.1 - Release Notes: Changes From Version 2.1
1 - Release Notes
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.
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 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.
The next Step (Step 2. Enter Serial Number) is for inserting the Serial Number.
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).
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.
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).
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.
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
PN: MNI-IK-0004
MAIN MENU
SERVICE
MANUAL
Number 11
Bravo Sterndrives
Printed in U.S.A.
90-17431--4
90-17431--4
Page 0
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.
Page i
BRAVO STERNDRIVES
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.
SERIAL NUMBER
* 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
BRAVO STERNDRIVES
Important
Information
Removal, Installation
and Adjustment
Sterndrive Unit
Transom Assembly
Power Trim
Steering Systems
Corrosion Protection
Accessories
1
2
3
4
5
6
7
8
Page iii
BRAVO STERNDRIVES
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
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
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
BRAVO STERNDRIVES
2A-2
2A-2
2A-2
2A-2
2A-3
2A-3
2A-4
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
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
Page vi
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
BRAVO STERNDRIVES
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
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
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
BRAVO STERNDRIVES
5B-2
5B-2
5B-2
5B-2
5B-3
5B-3
5B-4
5B-5
5B-6
5B-6
5C-2
5C-2
5C-2
5C-3
5C-4
5C-4
5C-4
5C-5
5D-2
5D-2
5D-2
5D-3
5D-4
5D-6
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BRAVO STERNDRIVES
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
7A-15
7A-16
7A-16
7A-17
7A-18
7A-18
7A-21
7A-22
7A-23
7A-24
7A-25
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 . . . . . . . . . . . . . . . . . . . . . . .
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
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BRAVO STERNDRIVES
Page xii