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Mercruiser alpha one gen 2 service manual download. Mercruiser Service Manual 6 Outdrives R/MR/Alpha One/Alpha SS
DOWNLOAD MerCruiser Online Factory Service Repair Manuals PDF.Mercruiser Service Manual 6 Outdrives R/MR/Alpha One/Alpha SS | PDF | Paint | Nut (Hardware)
Guide U-joint shaft through gimbal bearing and into engine coupler while simultaneously guiding shift slide into drive shaft housing. Make sure shift slide remains upright and engaged with bell housing shift shaft lever. Do not force drive unit into position. If necessary, rotate propeller shaft counterclockwise slightly to help align U-joint shaft splines with engine coupler splines, then, slide drive unit all-the-way into bell housing.
Position drive unit shift shaft coupler so that is straight forward by turning coupler clockwise while simultaneously turning propeller shaft counterclockwise. Fasten drive unit to bell housing with hardware shown. Torque evenly, starting from center, to 50 lb. Install trim cylinders Aft End on drive shaft housing. Tighten locknuts until they bottom on anchor pin shoulder. If removed, install trim cylinders on gimbal ring. Tighten until locknuts bottom on anchor pin shoulder. Rubber Bushings 4 Washers 2 -Small I.
If equipped, reinstall remote oil reservoir hose. Refer to Section 1B for filling instructions. The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unexpectedly. The only difference with these models is that the remote control shift cable attaching hardware is slightly longer. Shift cable adjustment is the same as all other versions. NOTE: A difference exists between earlier and later model shift plates, in that the later models have a pin and cotter pin to secure the remote control shift cable to the shift lever, whereas the earlier models used a stud with washers and locknut.
However, adjustment procedures are the same. If equipped with shift assist assembly: Once brass barrel adjustment is correct, install end guide stop clip on threaded tube. Position as shown, with tang touching brass barrel. Installing Shift Cables 1. Push in on drive unit shift cable while simultaneously turning propeller shaft counterclockwise until shaft stops, to ensure drive unit is completely in gear.
Maintain pressure on propeller shaft with a suitable device elastic strap. Measure distance between center of hole in shift cable end guide and center of brass barrel. Measurement should be 6 in. Install drive unit shift cable as shown. Secure brass barrel in barrel retainer with cotter pin and spread both prongs.
Secure cable end guide with washers one on each side of end guide and locknut. Ensure shift lever adjustable stud is at bottom of slot. If necessary, loosen stud and move it to bottom of slot, then retighten stud. Be sure to refer to the appropriate procedure when performing the following steps.
Shift remote control as stated in a or b following: a. Place drive unit into gear by pushing in on drive unit shift cable, while simultaneously rotating propeller shaft counterclockwise until shaft stops, to ensure full clutch engagement.
Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel this removes all slack from the cable. Excessive force would be indicated by movement of the shift cutout switch. Lightly pull on remote control shift cable end guide to remove slack from remote control and cable and adjust brass barrel as necessary to align attaching points with shift lever clevis pin hole and stud. Be sure to maintain light pressure on drive unit shift cable.
Simultaneously rotate propeller shaft clockwise until shaft stops to ensure full clutch engagement. After remote control shift cable has been properly adjusted, reinstall cable and shift assist assembly if applicable and secure with hardware as shown. If shift assist assembly attaching points will not align, push in or pull out on end of shift assist assembly to install. Do not attempt to readjust shift cable. If roller is not centered: a. Ensure adjustable stud is at bottom of slot in shift lever.
Check remote control for proper shift cable output [3 in. Refer to Installation Requirements. If a and b are correct, ensure drive unit shift cable is not crushed or kinked.
If drive unit shift cable is binding, the shift cutout switch roller will move off center when shifting into and out of forward and reverse.
Washer Small I. NOTE: If shift cable was damaged during installation, install new shift cable assembly in accordance with instructions contained in sterndrive service manual, then repeat shift cable adjustment procedure. Clutch should engage and cause propeller shaft to lock. If clutch does not engage, loosen adjustable stud on shift lever and move it upward in slot until clutch engages with reverse gear.
Retighten stud. Shift remote control several times and stop in reverse to recheck shift cutout switch position. Roller must be centered. Locknut Washer Large I. Washers Small I.
If clutch does not engage, loosen adjustable stud on shift lever and move it upward in slot until clutch engages with forward gear. Shift remote control several times and stop in forward to recheck shift cutout switch position. Clutch should engage before shift lever comes to a stop. IMPORTANT: If an extra long remote control shift cable is used, or if there are a large number of bends in remote control shift cable, or remote control has inadequate output travel, an additional adjustment may be necessary.
Refer to step 15 or 16 as applicable. Propeller Installation! WARNING Place a block of wood between the anti-ventilation plate and propeller to protect hands from propeller blades and to prevent propeller from turning. To aid in future propeller removal, liberally coat the propeller shaft splines with one of the following lubricants.
Install propeller as shown. Place boat in water and start engine. Check the following: a. Shift into forward and reverse gear, making sure that clutch engages before engine begins to accelerate. Accelerate engine in forward and reverse gear to ensure engine does not shut down. Check that shift cutout switch roller is centered in notch of shift cutout lever, with drive unit in forward and reverse gear.
Shifting from in gear position to neutral, ensure drive unit is in neutral before remote control shift lever comes to neutral detent position. Tighten propeller nut until a torque of 55 lb. Bend tabs into spline washer. Ratio Changed in Gear Housing must be changed by dealer-not a factory option Use 1. Replace standard cross and bearing assembly C-rings with C-ring Kit A1. Kit contains 8 C-rings, which is enough for 1 drive unit. C-rings are curved at the ends and must be installed with the curve toward the yoke or center socket.
Be sure C-rings are seated in grooves. C-rings cannot be used with service replacement Spicer cross and bearing assembly as grooves in bearing caps are too narrow.
C-ring Kit A1. Should it be necessary to convert one of these units to a different gear ratio, be sure to mark the decal with the appropriate ratio. The customer also should be advised as to what gear ratio his unit is equipped with. Torquing U-joint Bearing Retainer 1. Torque U-joint bearing retainer to lb. Use the following procedure to allow torquing retainer with a torque wrench. Torque wrench reading will be less than actual torque being applied to retainer, due to torque reading being taken through retainer wrench.
Use the following chart to determine torque wrench reading required to properly torque retainer. Use Bearing Retainer Wrench Measure length of torque wrench as follows: On beam-type torque wrenches, measure from square drive to fulcrum pivot point of handle.
On click-stop or dial type torque wrenches, measure from square drive to reference mark on handle 2 bands, etc. In addition, the older in-line model sterndrive units are equipped with U-joint coupling end yoke A1. This yoke is shorter than yoke A1 used on the IR-IMR sterndrive units and therefore, will not fully engage the engine coupler splines.
Drive Unit Gear Ratio Identification All drive unit gear ratios are identified on each drive in two places. It is important to note the ratio of the drive unit before proceeding with any repairs. The first place to look is on the decal on the port side of the drive housing. It will have a number such as 1. The second place to look will be on the universal joint splined yoke. It will be identified with a letter such as F. This method is explained in the following chart. This will be true for new drive units or drive units that have not been serviced.
A drive unit could have had the gear ratio changed for high altitude or had the lower unit gears changed to a more recent version, which would void out any application of the above chart. The gear ratio would then have to be determined by counting the teeth on the drive gear and the driven gear in the drive shaft housing and using the following chart for reference. Torque Specifications a b c d e f 25 lb. Allow drive unit to drain completely. Remove intermediate shift shaft bushing with a suitable mandrel earlier models only.
Discard the bushing on Alpha l, SS model drive units. Inspect drive gear for pitting, chipped or broken teeth and excessive or uneven wear. If any of these conditions exist, it will be necessary to replace complete drive gear and bearing assembly. Rotate bearings by hand; rough, uneven movement, or a loose condition indicates need for replacement. If drive gear is in good condition, then it will be necessary to replace bearings only.
Check splines on coupling end yoke for twisting or cracks. If U-joint knocking is suspected, inspect for evidence of bearing caps hitting center socket. Check cross and bearings for roughness and excessive side-to-side play. This kit contains 8 curved Crings. These C-rings are used as standard equipment on later production units.
Disassembly 1. Remove locknut and washer from U-joint shaft and remove drive gear and bearings. Bearings must be matched with its original bearing cup. Be sure to note order of components for reassembly. If bearings are to be replaced, replace both bearings and small and large spacers as an assembly, to ensure correct amount of preload when reassembling. Remove loose bearing. If inspection determines that U-joint cross and bearings should be replaced proceed as follows: 3.
Drive off C-rings with punch and hammer. Turn U-joint assembly degrees and press on cross until second bearing is pressed out into adaptor. Remove each pair of bearings in this manner. Remove both O-rings from coupling end of Ujoint shaft. Discard the O-rings. Dry all parts with air or a lint free cloth.
Ensure all cleaning solvent has been removed. The use of any other lubricant will decrease the life of the bearings. NOTE: When initially positioning crosses in yoke, be sure that grease fittings are facing toward coupler yoke longer yoke. Place U-joint bearing cups in yoke and start them onto cross members.
Press oil seal into oil seal carrier with lip of seal facing away from stepped side of carrier. Each bearing must be matched with its original bearing cup. If using old bearings, be sure to use original small and large spacers. If new bearings are being used, be sure to use new spacers. This will ensure proper bearing preload. Reassembly without Small Spacer: 1. Insert a suitable tool, such as a screwdriver, between the U-joint yokes as shown in the next figure, to prevent the U-joint from rotating when tightening down the pinion nut.
Tighten the pinion nut down until the preload on the bearings starts to go up just slightly and remove the hose clamp. Bearings and gears must be Iubricated to obtain accurate preload readings. Reassembly with Small Spacer: 1. Install a hose clamp around large spacer between Bearing Cups.
While holding the bearings, rotate the pinion nut at least two full revolutions. Check preload by rotating the pinion nut very slowly a third time and, while rotating, take a reading of the preload. If the preload is under the specification of lb. Continue this sequence until the proper preload is achieved. Press on plate until it bottoms. Failure to follow these instructions will cause premature failure of the unit.
Cleaning 1. Clean all parts except O-ring with cleaning solvent. Remove all foreign debris. Dry all parts with compressed air or a lint free cloth. Ensure all solvent has been removed. Water Pocket Cover Servicing Disassembly 1. Remove rubber seal from water pocket cover. Reassembly 1. Install rubber seal into water pocket cover. Ensure that embossment on seal fits into hole in water pocket cover.
Cleaning and Inspection 1. Clean water pocket cover and rubber seal with a water and soap solution. Dry parts completely with compressed air or a lint free cloth. Inspect parts for signs of overheating melting, warping or cracks. Use care when installing this bushing to avoid cracking it. Install shifter shaft bushing using a suitable tool. This restrictor plate must be installed with the side marked G. Install water pocket cover and gasket s. Apply Perfect Seal to screw threads and torque to lb.
Bearings and gears must be lubricated to obtain accurate preload readings, following. Place shims in drive shaft housing. NOTE: If installing the upper driven gear bearing cup for the first time use the same thickness of shims that were removed or a. Install driven gear tapered roller bearing cup.
Be careful not to install a short tube Alpha One SS in an Alpha One or MR drive unit, as this would substantially reduce water flow to the engine, causing engine to overheat. Install water tube copper into water pocket cover. Install top cover. Torque screws to 20 lb. NOTE: If using new shims, start with. Install upper drive shaft bearing cup into top cover.
Install O-ring. Check upper drive shaft bearing preload and shim as follows: a. Invert upper drive shaft housing. Insert gear housing drive shaft with pinion gear nut installed into upper drive shaft splines. Make sure bearings and gear have been lubricated.
Turn drive shaft clockwise several times to seat bearings. Using lb. Insert shimming tool into drive shaft housing with appropriate opening toward gear. Position gear so that at least two full teeth are centered on gauging surface. One full tooth must be on each side of gauging surface center-line. Insert a. Rotate shimming tool until gauging surface contacts feeler gauge and a slight drag on feeler gauge is felt. Re-shim as necessary: If reading is too high; remove shims from beneath bearing cup in top cover.
If reading is too low; add shims beneath bearing cup in top cover. If reading is within specifications; reinstall top cover and torque screws to 20 lb. Recheck bearing preload and adjust shim thickness until specified preload is attained. Without moving shimming tool, remove feeler gauge and insert gauge between other tooth and gauging surface. Check upper drive shaft driven gear height and shim as follows: IMPORTANT: Upper drive shaft bearing preload must be correct and top cover must be properly torqued before checking driven gear height.
If feeler gauge can be inserted with only a slight drag, shimming is correct. Proceed in reassembly with step If feeler gauge inserts with no drag, gear is too low. Repeat steps c and d with progressively thicker feeler gauges until the same clearance is obtained between both gear teeth and gauging surface.
Calculate the thickness of shims to add under driven gear bearing cup as shown following. Clearance Between Gear-. Apply Loctite or Type A to outside diameter of drive shaft housing upper oil seal and install oil seal with lips facing up.
Shims equal to the resulting difference must be added beneath driven gear bearing cup. If feeler gauge cannot be inserted without moving shimming tool, gear is too high. Repeat steps c and d with progressively thinner feeler gauges until the same clearance is obtained between both gear teeth and gauging surface. Calculate the thickness of shims to be removed from under driven gear bearing cup as follows:.
Shims equal to the resulting difference must be removed from beneath driven gear bearing cup. Recheck bearing preload and proceed with reassembly, Step Remove top cover and upper drive shaft and driven gear assembly.
Apply Loctite or Type A to outside diameter of drive shaft housing lower oil seal and install oil seal with lips facing up toward top of housing.
A variation in feeler gauge used for checking drive gear depth is needed for checking gears stamped with date code G NOTE: Newer 1. For these units, refer to the next step on the following page. Align index marks on drive gear with index mark on driven gear. Reinstall upper drive shaft and driven gear assembly. Do not install top cover at this time. Place drive gear shims in drive shaft housing. Push U-joint assembly straight into drive shaft housing so that index marked teeth properly mesh.
All Units without 1. Push U-joint assembly straight into drive shaft housing so that gear teeth mesh. Check drive gear U-joint assembly depth and shim as follows: a. Proceed with reassembly Step If feeler gauge inserts with no drag, gear is too far away from tool. Repeat Steps c and d with progressively thicker feeler gauges until the same clearance is obtained between both gear teeth and gauging surface.
Calculate shim thickness to be removed from between U-joint assembly bearing cup and drive shaft housing shoulder, as shown following. NOTE: Be sure to substitute. Clearance Between-. One full tooth must be on each side of gauging surface centerline. Rotate shimming tool until gauging surface contacts feeler gauge and a slight drag is felt while holding shimming tool down on housing.
Shims equal to the resulting difference must be removed from between U-joint assembly bearing cup and drive shaft housing shoulder. If feeler gauge cannot be inserted without moving shimming tool, gear is too close to tool. Repeat Steps c and d with progressively thinner feeler gauges until some clearance is obtained between both gear teeth and gauging surface. Calculate shim thickness to be added between U-joint assembly bearing cup and drive shaft housing shoulder, as shown following. Shims equal to the resulting difference must be added between U-joint assembly bearing cup and drive shaft housing shoulder.
Ensure U-joint retainer nut is torqued to lb. Install top cover and torque screws to 20 lb. All present production units contain the New Style shaft without an O-ring groove also.
Install trim tab allen screw. Check that alignment pins, centrifugal slinger and drive shaft O-ring is in place. Move gear housing shift shaft clockwise to shift gear housing into forward gear. NOTE: Gear housing may be held in forward gear by applying light pressure to propeller shaft in counterclockwise direction. NOTE: If propeller shaft is rotated in a clockwise direction before shift shafts are coupled, gear housing must be shifted back into forward gear and held in position.
Align water tube with tube guide and drive shaft and shift shaft splines with upper drive shaft and shift shaft splines and install gear housing. NOTE: Rotate propeller shaft counterclockwise only after shift shaft splines have engaged. This will help engage drive shaft splines. Secure gear housing to drive shaft housing as shown.
Torque locknuts to 35 lb. Torque allen screw to 38 lb. Install trim tab and position according to marks made before disassembly. Torque to 23 lb. Reinstall plastic plug. Trim Limit Switch Adjustment. Gimbal Bearing. Shift Cable. Exhaust Bellows.
Cleaning And Inspection. Exhaust Tube If Equipped. The newer style trim limit switch has a new sealing system for improved water resistance and durability. The trim limit switch leads are connected internally on the newer style switch to help ensure good electrical integrity. New Trim Position Sender The newer style trim position sender has a new sealing system for improved water resistance and durability.
The sender leads are connected internally on the newer style sender to help ensure good electrical integrity. Shift Cable Transom assembly serial number and above. A new style drive unit shift cable attaches to the bell housing from the aft end rather than the front end as did the old style cable for easier removal and installation. With the exception of the cable attaching method, the installation and adjustment procedure is the same as the old style cable.
NOTE: Insulator used on older style sender is not required when using newer style sender. Trim position sender leads are provided with the newer sender and are pre-connected at the factory. Transom assembly serial number 0C and above. A new style drive unit shift cable is being used. Following is a list of the major differences from the earlier cable. DO NOT mix parts between old and new style. Inspect switch for cracks or other signs of damage. Inspect wires for chafing, cuts and cracks in insulation.
Inspect quad ring seals on rotor assembly for twisting and damage. Remove trim position sender. This style cannot be repaired, but must be replaced as a single unit. Remove sterndrive unit. Remove trim limit switch. Remove bell housing as follows: a.
Loosen U-joint bellows front hose clamp. Loosen exhaust bellows rear hose clamp. Pull bell housing away from gimbal housing. Pull shift cable through shift cable bellows. Apply Perfect Seal to threads of screw and install trim harness clamp and screw. Remove trim harness clamp.
Remove trim limit switch wires and trim position sender wires. Bell Housing Installation 1. Install U-joint bellows on bell housing as follows: a.
Clean mounting flange with sandpaper and wipe clean with lacquer thinner. Install bell housing between gimbal ring. Push on bell housing and guide U-joint bellows onto gimbal housing mounting flange.
Apply bellows adhesive to mounting surface on inside of bellows. Position grounding clip clamp over bellows on bell housing end. Install U-joint bellows on bell housing flange and tighten clamp.
Install exhaust bellows on gimbal housing as follows: a. Position grounding clip on bellows. Place both clamps over bellows end. Tighten clamp on gimbal housing end. Leave remaining clamp loose on bellows. Apply Locquic Primer T to internal bell housing threads and external hinge pin threads and allow to dry. Apply Loctite to bell housing threads and install hinge pins.
Torque hinge pins to 95 lb. Install exhaust bellows on bell housing as follows: a. Place Expander Tool A1 into first bellows convolution. Pull tool until tool touches the mounting flange on bell housing bellows starts to slip onto flange. Release tool. Reposition tool into the third bellows convolution. Pull bellows onto bell housing flange. Crimp clamp must be compressed evenly around bellows and shift cable to prevent water leakage. Insert shift cable through shift cable bellows and compress crimp clamp.
Install upper shift shaft lever and shift shaft. Apply Loctite to screw threads. Tighten securely. Trim Position Sender Installation 1. Install trim position sender as follows: a. Turn center rotor of trim position sender to align index mark with index mark on sender body. Loosen trim position sender screws. Turn ignition key to the RUN position. Rotate sender until needle is at bottom of arc. Trim Limit Switch Adjustment! Use care to prevent placing hands in an area where injury could occur because of drive unit movement.
If switch is adjusted incorrectly, drive unit could move out beyond the gimbal ring support flanges and cause damage to sterndrive unit. Do not use trailer switch. Slowly turn trim limit switch counterclockwise until trim cylinders extend to dimension shown. Tolerance ring must be replaced anytime gimbal bearing is removed. Remove sterndrive unit Refer to Section 2A. Reach through bell housing and rotate gimbal bearing to check for rough spots.
Push and pull on inner race to check for side wear. Any excessive movement or roughness is cause for replacement. Do not remove gimbal bearing unless replacement is necessary, as damage to bearing may result during removal. Remove gimbal bearing assembly using tools as shown. Install and position new tolerance ring as shown.
Avoid serious injury from airborneparticles. Use eye and breathing protection with proper ventilation. Feather edges of all broken paint edges. Try not to sand through the primer. If bare metal has been exposed, use Quicksilvers Light Gray Primer.
Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish. This procedure willprovide the most durable paint system available in the field. The materials recommendedare of high quality and approximate marine requirements. The following procedure willprovide a repaint job that compares with a properly applied factory paint finish.
It isrecommended that the listed materials be purchased from a local Ditzler Automotive FinishSupply Outlet. The minimum package quantity of each material shown is sufficient torefinish several gear housings. Wash gear housing with a muriatic acid base cleaner to remove any type of marine. Wash gear housing with soap and water, then rinse.
Feather edge all broken paint edges. Clean gear housing thoroughly with DX wax and grease remover. Spot repair surfaces where bare metal is exposed with DX alodine treatment. IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properlyadhere to the surface nor will the coating be sufficiently thick to resist future paintblistering. Mix epoxy chromate primer DP with equal part catalyst DP per.
Cut out a cardboard plug for trim pump pocket to keep paint off of mating surface to. Allow a minimum of one hour drying time and no more than one week before top coatingassemblies. Catalyze the colors with Ditzler DU5 catalyst mixed ratio.
Reduce with solvents perDitzler label. Using a spray gun, apply one half to one mil even thickness. Let dry, flash off forfive minutes and apply another even coat of one half to one mil film thickness. Thisurethane paint will dry to the touch in a matter of hours, but will remain sensitiveto scratches and abrasions for a few days.
Trim Pump Specifications 5A Valve Pressure Specifications 5A Maintenance Schedules 1B Maintenance Intervals 1B Gas Sterndrive 1B Quicksilver Maintenance Products 1B Lubricating Propeller Shaft 1B Lubricating Steering System 1B Power Steering Models 1B Manual Steering Models 1B Checking Lubricant for Water 1B Changing Lubricant 1B General Maintenance 1B Boat Bottom Care 1B Antifouling Paint 1B Maintaining Ground Circuit Continuity 1B Engine 1B Sterndrive 1B Power Package Recommissioning 1B Maintenance intervals and the tasks to be performed, as shown in this current schedule, oras found in a previously printed schedules, are generally based on an average boatingapplication and environment.
However, individual operating habits and personalmaintenance preferences can have an impact on the suggested intervals. In considerationof these factors, Mercury MerCruiser has adjusted some maintenance intervals andcorresponding tasks to be performed.
In some cases, this may allow for more individualtasks to be performed in a single visit to the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner and servicing dealer discuss the currentMaintenance Schedule and develop appropriate maintenance intervals to coincide with theindividual operating habits, environment, and maintenance requirements. Check water pickups for debris or marine growth.
Check water strainer and clean. Check coolant level. Lubricate propeller shaft and the retorque nut if operating in only freshwater, this maintenance may beextended to every four months. Check steering system and remote control for loose, missing or damaged parts. Lubricate cables andlinkages. Inspect U-joints, splines and bellows. Check clamps. Check engine alignment. Lubricate U-joint splines.
Check continuity circuit for loose or damaged connections. Test MerCathode unit output on Bravo mod-els. Check cooling system and exhaust system hose clamps for tightness. Inspect both systems for damageor leaks. Whichever occurs first. Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.
Interval will be reduced if not using extended life coolant. If cable is lubricated while extended, hydraulic lock of cable couldoccur. Check oil level - oil should come up to line on dipstick. If oil is at proper level, reinstall oildipstick and sealing washer.
If oil is low, proceed to Step 2. Find and correct cause of leak before unit is placed in operation. Torque to 40 lb-in. NOTE: Drive unit oil level is checked at gear lube monitor. Fill gear lube monitor to FULL line on decal. Lubricate O-ring seal on gear lube monitorneck with sterndrive oil, to ensure ease of installing and removing cap, and install gearlube monitor cap. Checking Lubricant for WaterPeriodically inspect lubricant for water to ensure that drive unit seals are not leaking.
If water is observed or if lubricant. Find and correct cause of leak beforeunit is placed in operation. Find and correct cause of leak before placing unit back inoperatIon. Models with drive unit Gear Lube Monitor, only: remove drive unit gear lube monitorfrom bracket, remove cap, empty contents of gear lube monitor into suitable containerand discard.
Clean gear lube monitor thoroughly, and return gear lube monitor tobracket. Do not refill at this time. Check condition of hose and hose connections - replaceas necessary. Non-Gear Lube Monitor Models: torque oil vent plug to 40 lb-in.
Gear Lube Monitor Models: tighten oil vent plug snugly; do not torque at this time. Models with Gear Lube Monitor When oil. Lubricate O-ring seal on gear lube monitorneck with sterndrive oil, to ensure ease of installing and removing cap. Install gear lubemonitor cap. Do not overtighten. Follow instructions on can for proper application. At least once each year, entire Power Package should be cleaned and external surfaces thathave become bare should be repainted with Quicksilver Primer and Spray Paint.
Inspectsteering head and remote control for ease of operation. Checking Quicksilver MerCathode SystemIf boat is equipped with a Quicksilver MerCathode System, system should be tested toensure that it is providing adequate output to protect underwater metal parts on boat. Refer to section 7. Maintaining Anodic Trim Tab or PlateEach sterndrive unit is equipped with a sacrificial anodic trim tab or plate on later models to help protect underwater metal parts from galvanic corrosion.
Ananodic plate is the new service replacement for the anodic trim tab. Install the anodic platein place of the anodic trim tab. Refer to Section 7. Carefully follow installation instructions, thataccompany new Anode Kit, to ensure proper installation.
Accumulation of marine growth or other foreign matter can greatly reduce boat speed andincrease fuel consumption. To ensure best performance and efficiency, periodically cleanboat bottom in accordance with manufacturers recommendations. In some areas, it may be advisable to paint the bottom to help prevent marine growth.
Referto the following information for special notes about the use of antifouling paints. If using copper or tinbased antifouling paints, observe the following:. NOTE: Drive unit and transom assembly can be painted with a good quality marine paintor an antifouling paint that DOES NOT contain copper, tin, or any other material that couldconduct electrical current.
Do not paint drain holes, anodes, MerCathode system, and itemsspecified by boat manufacturer. Maintaining Ground Circuit ContinuityThe transom assembly and sterndrive unit are equipped with a ground wire circuit, to ensuregood electrical continuity between engine, transom assembly and sterndrive components.
Good continuity is essential for the MerCathode System to function effectively. Refer toSection 7. Lubricate steering system.
Refer to Section 6. Lubricate transom gimbal housing assembly swivel shaft, gimbal bearing, and propeller. Refer to Section 4 and Section 1-B. Lubricate sterndrive unit U-joint shaft splines and cross bearings. Refer to Section 3-A. Inspect U-joint bellows for cracks or other signs of deterioration. Check bellows clamps. Refer to Section 4. Refer to Engine Service Manual. Change sterndrive unit oil. Refer to Section 1-B. Using a piece of wire, check water drain holes in sterndrive unit to ensure that they areopen.
Inspect sterndrive for damage. Repair or replace damaged components. Clean sterndrive exterior surfaces and repaint any bare metal surfaces with Quicksilver. Primer and Spray Paint. After paint has dried spray entire sterndrive with Quicksilver Corrosion Guard. Refer to. U-joint bellows may developa set if unit is stored in raised position and may fail when unit is returned to ser-vice. Store battery. Refer to battery manufacturers instructions. Install fully-charged battery. Clean battery cable clamps and terminals and reconnectcables.
Be sure to tighten clamps securely. Apply a thin coat of petroleum based greaseto clamps and terminals to help retard corrosion.
After recommissioning and starting engine, check steering system and shift control forproper operation. Troubleshooting 1C Sterndrive Unit Troubleshooting 1C Drive Unit Shifts Hard 1C Gear Housing Noise 1C Drive Shaft Housing Noise 1C Performance Troubleshooting 1C Power Steering 1C Compact Hydraulic Steering 1C Important Information 1C System Difficult To Fill 1C Steering Hard To Turn 1C Power Trim Electrical System 1C Corrosion Protection 1C Testing Procedure for Corrosion Protection 1C MerCathode Controller 1C Shift System Troubleshooting 1C Troubleshooting Shift Problems 1C Checking for Excessive Play 1C Isolating Excessive Play 1C Checking Operation 1C TroubleshootingThis section is a guide for performance and product troubleshooting.
Referrals to specificsections of this manual are made where special tests or repair procedures are to beperformed. Because of the relationship between Power Package components engine and sterndrive ,it will be necessary in some cases to simultaneously refer to the appropriate Engine ServiceManual for further troubleshooting information.
Allowing adequate time for testing and analysis. Utilizing these charts as a guide - a starting point. Gimbal bearing not properly installed. Check engine alignment to determine ifgimbal bearing is cocked or improperlyinstalled in gimbal housing. Cause Special InstructionsShift cables improperly adjusted. Adjust shift cables. Shift cables not connected. Install and adjust shift cables. Inner core wire broken or loose.
Reconnect or replace inner core wire. Cause Special InstructionsControl box not properly assembled. Properly reassemble control box. Broken or damaged linkage in control box. Repair linkage. Controls improperly adjusted-cable endguide hitting brass barrel. Damaged remote control or drive unit shiftcable. Replace cable s and adjust. Shift cable too short sharp bends or toolong loops and long bends.
Select and install proper length cable. Corroded shift cables. Replace, adjust and check for waterleakage. Internal wear in remote control box. Repair as needed. Shift cable attaching nuts too tight endcannot pivot. Properly install nuts. Shift cable pivot ends are corroded or notlubricated. Clean and lubricate. Cause Special InstructionsShift cable broken. Replace cable and adjust.
Cable end not connected in drive unit. Remove and reinstall drive unit. Remote control damaged. Repair or replace remote control. Internal shift mechanism damage.
Repair or replace as necessary. Metal particles in drive unit lubricant. Disassemble, clean and inspect andreplace necessary components. Incorrect gear shimming. Check gear housing backlash and piniongear height. Determine cause for interference looseengine mounts, transom too thin, etc. Make sure that proper thickness retainingrings are used and that rings are fullyseated in U-joint bearing cap grooves. Excessive side-to-side play in U-jointcross and bearing assemblies.
Replace cross and bearing assembly. Make sure proper cross and bearingassemblies are used. U-joint cross and bearings rough. Replace assemblies. Signs of scoring,galling or roughness are the result of lackof lubricant.
O-rings missing or flattened out on U-jointshaft causing shaft to rattle against ID ofgimbal bearing. Remove U-joint coupling end yoke andinsert into gimbal bearing and enginecoupling. Rotate shaft back and forth. Adjust alignment. Ensure that alignmenttool moves in and out of coupler freely. If proper alignment is no longerobserved, coupler is crooked and must bereplaced.
Replace gimbal bearing. Failure todo this may result in a loose bearing fit incarrier. Reinstall bearing assembly using a newtolerance ring if carrier is loose in gimbalhousing. If bearing is loose in carrier,bearing assembly must be replaced. Excessive clearance between gimbal ringand gimbal housing.
This could causemisalignment between bell housing andgimbal housing and also may allow gimbalring to vibrate up and down. Improperly installed or failed rear enginemounts. This will affect engine alignment,but usually is not detectable with enginealignment tool.
Check for uneven mount height, or looseor soft mounts. Make sure there isclearance between flywheel housing andfiber washer.
If no clearance exists,mounts have probably sagged. Installmounts correctly or replace, as necessary. Boat transom thickness uneven. This couldaffect engine to transom assemblyalignment and is usually not detectable withalignment tool.
Bell housing contacting gimbal ring. Thiswould cause knocking in the fully trimmedIN position only. Check for soft or split trim cylinderbushings and loose or worn hinge pin bushings. Stringer height uneven or transomassembly installed cocked on boattransom. This will affect engine alignment,but is usually not detectable withalignment tool. Measure the distance between the engineflywheel housing and the inner transomplate on both sides. If distances areuneven, the problem may be due touneven stringer height or a cockedtransom assembly.
Adjust the stringerheight or relocate the transom cutout asrequired. Weak boat transom or boat bottom thatflexes under power and causes enginemisalignment - this condition will usuallycause engine coupler failure. Hello I am looking to download a digital pdf MerCruiser manual 44 Appreciate your assistance! Greg B. Thursday, 29 September Looking for Manual for Power Steering Pump replacement.
Jesper Lundberg Thursday, 15 September Adrian Wednesday, 14 September Craig Monday, 12 September Tom Wednesday, 31 August Kevin Morrison Tuesday, 16 August I'm in a really bad need for a very complete service and repair shop manual for a mercruiser lll dual stern drive hp ci. For my boatel Islander 47 foot houseboat. I'm stranded in a drying up lake in Texas and need to get this thing running and cooling correctly so I can move it where I can have more than about 18 inchs of water underneath it asap.
Ron Munroe Friday, 12 August Looking foe owners operating manual for 3. Michal Tuesday, 09 August I've been looking for the Installation and Service Manual for the 4. Jay P Wenstrup Friday, 05 August Manh Sunday, 31 July Denise Saturday, 16 July Chris Smith Tuesday, 12 July Is there a full service Manual for a 3.
Sonny Thursday, 23 June How do I adjust the idle speed. Qamar Al-Hafidh Friday, 10 June Chris knowles Monday, 06 June Need someone to help with a manual to correctly assist with connecting my dashboard guages to a bravo one mercruiser engine. Greg brooks Friday, 27 May Mercruse hp inboard inline six outdrive. Can anyone help me with a manual for a MerCruiser horsepower. Ed Burie Thursday, 28 April Donald Riggs Tuesday, 26 April I'm looking to download a repair manual for my 50hp Mercury Tracker pro series outboard motor model AN and serial number is 0T I was told the repair manual part number is 8m?
Thank You Donald Riggs. I have a Mercruiser 4. Having ignition circuit problems. Was hoping to download ignition troubleshooting and ignition wiring diagram.
Thanks in advance. Nickhisaw gmail. Ser 1A Henry Lokate Monday, 21 March I have twin mercruiser magnums Looking for the service manual to download motor number 0F thnx. Any chance of a Mercruiser 3. I would like to get the repair manual of MCM 4. Mr E Cranfield Friday, 14 January John van Aert Sunday, 02 January Beste, Wij hebben een oude mercruiser V8 HP motor welke we willen herstellen en monteren.
Wij zijn op zoek naar handleidingen en schema's van deze motor met aandrijving. Roger Gean Wednesday, 20 October I have a glastron with mercruiser hp straight 6 cylinder motor and I really need a manual.
Can you set me in the right direction? Tim hunter Friday, 27 August I have a Bayliner with an engine Mercriser V8 7. Victor T. Martinez Thursday, 26 August Alan Wednesday, 28 July Jason Friday, 23 July Looking for a manual for a Sea Ray Sundancer sport Cruiser 3. Daniel Sarrubbo Wednesday, 21 July I am looking to get a hardcopy of a manual for a Mercruiser 5.
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