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Discussion Starter #1
My Bravo 1 outdrive has two small stainless steel wires on the bottom of the gimball up close to the transom, that appear to be some sort of safety or limit device. One is frayed and broken. Does anyone know what these wires are for? Is it something most Mercruiser dealers would stock or a factory part?

Running a 496 MAG in a 25' Lightning. The wires do not seem to hamper performance, but I know they are there for a reason. I'd like to replace them both before I do any damage to the outdrive.

TIA
 

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Discussion Starter #4
After more research, I'm thinking the broken wire is a grounding cable. It is unshielded and not connected to the trim sensors. The picture below shows the broken wire probably better than I can explain it. It appears similar to two wires in the Mercruiser Continuity Kit. Anyone know if I'm getting closer?

 

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You are correct, They are for the grounding system of the continuity circuit kit.

Bonding System

The boats bonding system is basically a ?Daisy Chain? of wires and cables.
It links all major components together for a common ground and allows the zinc anodes and Mercathode to better protect? the drive system from galvanic corrosion.
The system is actually very detailed and is fully explained in Mercruisers? Manual Number 11 Corrosion Guide Part Number 90-17431?4.
To put it simply, the engine is connected to the inner gimbal,
the inner gimbal is connected to the outer gimbal and steering lever,
the steering lever is connected to the gimbal ring which is connected to the bellhousing.
The bellhousing is bonded to the drive unit and the props are grounded to the propshaft. In addition, the trim cylinders are bonded to the gimbal ring.
This Daisy Chain is accomplished through the use of wires, braided cables, bonding tabs and special washers.
If any part of this chain is broken the drive will not be fully protected.
Mercruiser does a great job of supplying the boat manufacturer with a pre-bonded unit.
It is the duty of the boat manufacturer to make sure that all of the bonding systems are properly hooked up during engine and drive installation.
We feel it is also the responsibility of the delivering dealership to make sure the bonding system was properly installed and that the system be explained to the buyer.
Servicing Dealers should be aware that elimination of any one of these components could result in accelerated galvanic corrosion damage. In short, one little cable left disconnected after servicing can cause severe damage.

http://www.sterndrives.com/bravo3_galvanic_corrosion.html

http://www.mercruiserparts.com/Show_Pictures3.asp?dnbr=880951002&ivar=images/COMMON/5065.png&inbr=11210&bnbr=40&bdesc=Continuity+Kit
 

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Discussion Starter #6
Boat Tech, You just saved me hours of wasted researching. With your confirmation of the broken part, I can have it replaced in no time at all. Thank you.
 
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