Mercury Alpha - Repair Manual

90-12934--2 1097 iv Replacement Parts ! WARNING Electrical system components on gasolineengines and MerCruiser Stern Drives aredesigned and manufactured to comply with U.S.Coast Guard Rules and Regulations to minimizerisks of fire or explosion. Use of replacement electrical system compo-nents, which...

ImportantInformation Removal, Installation and Adjustments Sterndrive Unit Transom Assembly Power Trim Steering Systems Corrosion Protection 12345 6 7 90-12934--2 1097 v Service Manual Outline Section 1 - Important Information A - Important InformationB - MaintenanceC - Troubleshooting Section 2 - R...

GENERAL INFORMATION IMPORTANT INFORMATION A 1 23253

1A-0 - IMPORTANT INFORMATION 90-12934--2 1097 Table of Contents Page How To Use This Manual 1A-1 . . . . . . . . . . . . . . . . . . Page Numbering 1A-1 . . . . . . . . . . . . . . . . . . . . . . Introduction 1A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Product Informati...

IMPORTANT INFORMATION - 1A-1 90-12934--2 1097 How To Use This Manual This Manual is divided into sections which representmajor components and systems. Some sections are further divided into parts whichmore fully describe the component. Sections and parts are listed on page. Page Numbering Two number...

1A-2 - IMPORTANT INFORMATION 90-12934--2 1097 Serial Number Locations 23254 Transom Assembly Serial Number Location a - Transom Assembly Serial Number 23254 Sterndrive Unit Serial Number Location – Port Decal a - Sterndrive Unit Serial Numberb - Sterndrive Unit Gear Ratio Hi-Performance Boating Writ...

IMPORTANT INFORMATION - 1A-3 90-12934--2 1097 Painting Procedures Cleaning & Painting AluminumPropellers & Gear Housings ! WARNING Avoid serious injury from flying debris. Avoid se-rious injury from airborne particles. Use eye andbreathing protection with proper ventilation. PROPELLERS 1. Sa...

1A-4 - IMPORTANT INFORMATION 90-12934--2 1097 THIS PAGE IS INTENTIONALLY BLANK

A 2 22062 REMOVAL, INSTALLATIONAND ADJUSTMENTS ALL MODELS

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-1 Specifications Torque Specifications NOTE: Listed below are the torque specifications forthose fasteners which have a specific torque value.Tighten all other fasteners (not listed) securely. DESCRIPTION TORQUE DESCRIPTION lb. in. lb. ft. N ⋅...

2A-2 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 Checking TransomThickness Ensure transom surface thickness and flatness con-form to minimums specified in “Installation Require-ments” listed previously. 70004 a b a - Measuring Thicknessb - Measuring Flatness 75479 a a - Suitable Mandrel ...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-3 3. If installed, remove and cap remote oil reservoir hose. Remove adaptor fitting and plug drive unitvent hole. 23253 a - Oil Reservoir Hoseb - Adaptor Fitting 4. Remove locknuts and washers holding drive unit to bell housing. Keep ground pl...

2A-4 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 c. Bend tab on tab washer down. Loosen pivot bolts or remove pivot pins. Use a screw to re-move pivot pins. Remove power steeringunit. 23256 Power Steering Units Secured With Pivot Bolts 23256 Power Steering Units Secured With Pivot Pins a...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-5 c. Bend tab on tab washer down. Loosen pivot bolts or remove pivot pins. Use a screw to re-move pivot pins. Remove manual steeringring. 22945 Manual Steering Units Secured With Pivot Bolts 23256 Manual Steering Units Secured With Pivot Pins ...

2A-6 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 50483 Prestolite Power Trim Pump a - Sta-Strapb - Trim Limit Switch Wiresc - Hydraulic Hoses 7. If installed, remove exhaust pipe. 22054 In-line 4 Cylinder Models a - Exhaust Pipeb - Screws 22057 V6/V8 Models a - Exhaust Pipeb - Screws 8. ...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-7 9. Separate inner transom plate from transom gim- bal housing assembly. 22058 a - Short Screws With Lock Washersb - Flat Washers And Locknutsc - Long Screws, Lock Washers And Square Flat Washersd - Flat Washers And Locknuts (Securing Anode H...

2A-8 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 22028 a - Steering Leverb - Inner Transom Platec - Ground Wire IMPORTANT: Torque bolts and nuts evenly (start-ing from center and working out) to 20-25 lb. ft.(27-34 N·m). IMPORTANT: Be sure to pull all wires and cablescompletely through i...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-9 IMPORTANT: Exhaust pipe and gimbal housingmating surfaces must be clean and free of nicksand scratches and O-ring must be properlyseated in groove, or water and exhaust may leakinto boat. 22057 a - O-ringb - Mating Surface 2. If equipped, in...

2A-10 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 IMPORTANT: Make hydraulic hose connectionsas quickly as possible to prevent oil from leakingout of system. ! CAUTION DO NOT cross-thread or overtighten hose fit-tings when making hydraulic hose connectionsto power trim pump. 4. Connect po...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-11 6. Install engine (refer to appropriate Engine Ser- vice Manual). 7. If equipped, install power steering assembly on inner transom plate as follows: a. Lubricate swivel ring bushings with Special Lubricant 101. 22167 a - Special Lubricant 1...

2A-14 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 11. If equipped with manual steering, install steering cable as follows: a. Lubricate steering cable end with a liberal amount of Special Lubricant 101 and installcable end through guide tube. b. On single engine installations; connect st...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-15 Sterndrive Unit Installation 1. Install and align engine. (Refer to appropriate En- gine Service Manual). IMPORTANT: Rubber gasket must be properlypositioned in bell housing bore before installingdrive unit, or water may leak into boat. 2. ...

2A-16 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 IMPORTANT: Shift slide assembly is free to rotateon core wire, therefore, be careful that shift slide re-mains in upright position and is properly engagedwith shift shaft lever while installing drive unit. 50629 a - Shift Shaft Leverb - R...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-17 9. Fasten drive unit to bell housing with hardware shown. Torque evenly, starting from center, to 50lb. ft. (68 N·m). 22062 a - Locknuts And Flat Washersb - Locknut And Ground Plate (Do NOT Use Flat Washer) IMPORTANT: To aid in installing r...

2A-18 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 12. If equipped, reinstall remote oil reservoir hose. (Refer to Section 1B for filling instructions). 23253 a - Adaptor Fittingb - Hose Fittingc - Bracket Shift Cable Adjustment NOTE: Some models may be equipped with a shiftassist assembl...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-19 22265 Later Models (With Plastic Shift Lever) a - Remote Control Shift Cableb - Pin and Cotter Pin Installing Shift Cables 1. Push in on drive unit shift cable while simulta- neously turning propeller shaft counterclockwiseuntil shaft stops...

2A-20 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 5. Ensure shift lever adjustable stud is at bottom of slot. If necessary, loosen stud and move it to bot-tom of slot, then retighten stud. 50309 a - Adjustable Stud IMPORTANT: Shift cable adjustment for a righthand (RH) rotation drive uni...

90-12934--2 1097 REMOVAL, INSTALLATION AND ADJUSTMENT 2A-23 22910 Earlier Models (With Metal Shift Lever) WithoutShift Assist Assembly a - Washer (Same Size I.D.)b - Locknutc - Washer (Large I.D.)d - Washers (Small I.D.) (2)e - Cable End Guidef - Shift Lever 22266 Later Models (With Plastic Shift Le...

2A-24 –REMOVAL, INSTALLATION AND ADJUSTMENTS 90-12934--2 1097 50309 22058 a - Adjustable Studb - Shift Cutout Switch Roller 18. Place boat in water and start engine. Check the following: a. Shift into forward and reverse gear, making sure that clutch engages before engine be-gins to accelerate. b. A...

DRIVESHAFT HOUSING - 3A-1 90-12934--2 1097 Specifications Torque Specifications NOTE: Listed below are the torque specifications forthose fasteners which have a specific torque value.Tighten all other fasteners (not listed) securely. DESCRIPTION TORQUE DESCRIPTION lb. in. lb. ft. N ⋅ m Top Cover Scr...

3A-2 - DRIVESHAFT HOUSING 90-12934--2 1097 Overall Gear Ratios with 17/28 Lower Gears R/MR Models Model 1.32:1 (Drive/Driven) 20/16 1.50:1 22/20 1.65:1 24/24 1.84:1 17/19 1.98:1 20/24 2.40:1 20/24 120R S H 1 120MR S H 1 140R S H 1 140MR S H 1 170MR O S O 185R O S O 185MR O S O 190MR O S O 200MR O S ...

DRIVESHAFT HOUSING - 3A-3 90-12934--2 1097 Overall Gear Ratios When Serviced with 13/21 Lower Gears R/MR Models Model 1.29:1 (Drive/Driven) 20/16 1.47:1 22/20 1.62:1 24/24 1.81:1 17/19 1.94:1 20/24 2.40:1 20/24 120R S H 1 120MR S H 1 140R S H 1 140MR S H 1 170MR O S O 185R O S O 185MR O S O 190MR O ...

3A-4 - DRIVESHAFT HOUSING 90-12934--2 1097 Overall Gear Ratio with 17/28 Lower Gears Alpha One / Alpha One SS Models Model 1.32:1 (Drive/Driven) 20/16 1.50:1 22/20 1.65:1 24/24 1.84:1 17/19 1.98:1 20/24 2.40:1 20/24 120 Alpha One S H 1 140 Alpha One S H 1 165 Alpha One O S O 170 Alpha One O S O 175 ...

DRIVESHAFT HOUSING - 3A-5 90-12934--2 1097 Overall Gear Ratio When Serviced with 13/21 Lower Gears Alpha One / Alpha One SS Models Model 1.32:1 (Drive/Driven) 20/16 1.50:1 22/20 1.65:1 24/24 1.84:1 17/19 1.98:1 20/24 2.40:1 20/24 120 Alpha One S H 1 140 Alpha One S H 1 165 Alpha One O S O 170 Alpha ...

3A-6 - DRIVESHAFT HOUSING 90-12934--2 1097 Special Information C-Ring Kit To Eliminate U-JointKnocking If you encounter a MerCruiser I-R/I-MR sterndrivewith a U-joint knocking or vibrating problem whenturning or trimming, the problem may be caused byexcessive side-to-side play in the U-joint cross a...

DRIVESHAFT HOUSING - 3A-7 90-12934--2 1097 Torquing U-joint Bearing Retainer 1. Torque U-joint bearing retainer to 200 lb. ft. (271 N·m). Use the following procedure to allow torqu-ing retainer with a torque wrench. 22061 U-joint Bearing Retainer a - Retainer a. Use Bearing Retainer Wrench 91-17256....

3A-8 - DRIVESHAFT HOUSING 90-12934--2 1097 Use Of Older Model Sterndrive UnitsOn Mercruiser IR-IMR Models Mercury Marine does not recommend the use of old-er model sterndrive units on IR-lMR models, as theunits will not mate up satisfactorily with the transomassembly. In addition, the older in-line ...

3A-12 - DRIVESHAFT HOUSING 90-12934--2 1097 2. Mark position of trim tab with a piece of tape. Re- move trim tab. 23253 a - Trim Tabb - Plastic Plugc - 3/8 in. Hex Wrench 3. Remove gear housing from drive shaft housing. 23263 a - Hex Screw (Allen Screw)b - Locknuts 23261 c - Locknut (1)d - Locknut (...

DRIVESHAFT HOUSING - 3A-13 90-12934--2 1097 3. Remove U-joint Assembly by pulling straight out. 23268 a - U-joint Assembly 4. Remove and retain shims. 23266 a - Shims 5. Remove upper drive shaft and driven gear as- sembly. 23262 a - Upper Drive Shaft And Driven Gear Assembly 6. Remove water tube fro...

DRIVESHAFT HOUSING - 3A-15 90-12934--2 1097 12. Remove drive shaft housing lower oil seal. 23008 a - Oil Seal 13. Remove drive shaft housing upper oil seal. 23007 a - Oil Seal U-joint Assembly Servicing Pre-Disassembly Inspection 1. Inspect drive gear for pitting, chipped or broken teeth and excessi...

3A-16 - DRIVESHAFT HOUSING 90-12934--2 1097 Disassembly 1. Remove locknut and washer from U-joint shaft and remove drive gear and bearings. 23267 a - Drive Gear And Bearing Assemblyb - Locknutc - Flat Washer ! CAUTION When disassembling drive gear and bearing as-sembly, be careful not to switch tape...

DRIVESHAFT HOUSING - 3A-17 90-12934--2 1097 2. If seal is defective, remove U-joint seal from carri- er using a punch and hammer. 23009 a - Oil Sealb - Oil Seal Carrier IMPORTANT: If cross and bearings are to be re-used, liberally lubricate crosses with 2-4-CMarine Lubricant to help retain needle be...

3A-18 - DRIVESHAFT HOUSING 90-12934--2 1097 Reassembly ! CAUTION Use only 2-4-C Marine Lubricant for lubricatingU-joint bearings. The use of any other lubricantwill decrease the life of the bearings. NOTE: When initially positioning crosses in yoke, besure that grease fittings are facing toward coup...

DRIVESHAFT HOUSING - 3A-19 90-12934--2 1097 6. Install components in order shown. 23010 a - Retainerb - Anti-galling Retainerc - O-ringd - Seal Carriere - Tapered Roller Bearingf - Bearing Cupg - Large Spacer h - Small Spacer (Note)i - Bearing Cupj - Tapered Roller Bearingk - Drive Gearl - Washerm -...

3A-20 - DRIVESHAFT HOUSING 90-12934--2 1097 2. While holding the bearings, rotate the pinion nut at least two full revolutions. Check preload by ro-tating the pinion nut very slowly a third time and,while rotating, take a reading of the preload. If thepreload is under the specification of 6-10 lb. i...

DRIVESHAFT HOUSING - 3A-21 90-12934--2 1097 3. Press on driven gear end until tapered roller bearing slides off. 23264 e - Universal Puller Platef - Driven Gearg - Tapered Roller Bearingh - Arbor Press 4. Remove (smaller) upper drive shaft tapered roller bearing. 23265 a - Upper Drive Shaft Bearing ...

3A-22 - DRIVESHAFT HOUSING 90-12934--2 1097 Cleaning 1. Clean all parts (except O-ring) with cleaning solvent. 2. Remove all foreign debris. ! CAUTION DO NOT spin bearings when drying componentsoff with compressed air, as damage to bearingscould occur. 3. Dry all parts with compressed air or a lint ...

DRIVESHAFT HOUSING - 3A-23 90-12934--2 1097 Water Pocket CoverServicing Disassembly 1. Remove rubber seal from water pocket cover. 50316 a - Rubber Sealb - Water Pocket Cover Cleaning and Inspection 1. Clean water pocket cover and rubber seal with a water and soap solution. 2. Dry parts completely w...

3A-24 - DRIVESHAFT HOUSING 90-12934--2 1097 Drive Shaft HousingReassembly and Shimming IMPORTANT: The shifter shaft bushing for the Al-pha One SS is made of plastic. Use care wheninstalling this bushing to avoid cracking it. 1. Install shifter shaft bushing using a suitable tool. 23261 a - Bushing (...

DRIVESHAFT HOUSING - 3A-25 90-12934--2 1097 3. Install water pocket cover and gasket(s). Apply Perfect Seal to screw threads and torque to30-40 lb. in. (3-4 N·m). 50316 a - Water Pocket Cover [Gasket(s) Beneath]b - Screws (4) ! CAUTION Alpha One SS has a shorter water tube than theAlpha One or MR dr...

3A-26 - DRIVESHAFT HOUSING 90-12934--2 1097 7. Install upper drive shaft and driven gear assembly. 23262 a - Upper Drive Shaft And Driver Gear Assembly 8. Place shims in top cover. NOTE: If using new shims, start with .015-.020 in.shim pack. 9. Install upper drive shaft bearing cup into top cov- er....

3A-32 - DRIVESHAFT HOUSING 90-12934--2 1097 21. Ensure U-joint retainer nut is torqued to 200 lb. ft. (217 N·m). 22. Install top cover and torque screws to 20 lb. ft. (27 N·m). 23261 a - Top Coverb - Screws Gear Housing Installation ALPHA I AND MC I DRIVE SHAFT CHANGES The service drive shaft for th...

A 4 23152 TRANSOM ASSEMBLY SERVICE PROCEDURES REQUIRINGMINOR DISASSEMBLY

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-1 Specifications Torque Specifications DESCRIPTION TORQUE DESCRIPTION lb. in. lb. ft. N ⋅ m Shift Cable Core Wire An-chor Screws 20 2.3 Bellows Clamps 35 4 Lubricants/Sealers/Adhesives Description Part No. 3M Adhesive 92-86166-1 2-4-C Marine Lubricant 92-825407...

4A-2 - TRANSOM ASSEMBLY 90-12934--2 1097 New Trim Position Sender The newer style trim position sender has a newsealing system for improved water resistance anddurability. The sender leads are connected internallyon the newer style sender to help ensure goodelectrical integrity. NOTE: Insulator used...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-5 2. Install trim position sender. Ensure insulator slot aligns with slot in sender. 22091 a - Trim Position Senderb - Screws (2)c - Retainer (2) Trim Position Sender andTrim Limit SwitchReplacement ! WARNING Disconnect both battery cables before installingnew ...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-7 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. ! WARNING Be sure to read and follow package label direc-tions when using bellows adhesive. b. Apply ...

4A-10 - TRANSOM ASSEMBLY 90-12934--2 1097 Trim Position Sender Installation 1. Install trim position sender as follows: a. Place sterndrive unit in the full DOWN/IN position. b. Turn center rotor of trim position sender to align index mark with index mark on senderbody. 71218 a - Index Marks 2. Inst...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-11 Trim Limit Switch Installation 1. Align index marks on switch. 71218 a - Index Marks 2. Install trim limit switch. 71221 a - Screws, Washers And Retainers Trim Limit Switch Adjustment ! WARNING When adjusting trim limit switch, use extremecare that engine is...

4A-12 - TRANSOM ASSEMBLY 90-12934--2 1097 4. Slowly turn trim limit switch counterclockwise un- til trim cylinders extend to dimension shown. 71221 a - Rotate Counterclockwise To Adjust 50464 b - 21-3/4 in. 1/4 in. (554 mm 6 mm) Gimbal Bearing IMPORTANT: Gimbal bearing and carrier are amatched set a...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-13 23152 a - Driver Rod (91-37323)*b - Plate (91-29310)*c - Driver Head (91-32325)*d - Mandrel (91-30366-1)*e - Gimbal Bearing Assembly * From Bearing Removal And Installation Tool 91-31229A7 2. Remove tolerance ring. 22159 a - Gimbal Bearing Carrierb - Toleran...

4A-14 - TRANSOM ASSEMBLY 90-12934--2 1097 2. Install and position new tolerance ring as shown. Align opening in tolerance ring with grease holein carrier. 22159 a - Carrierb - Carrier Grease Holec - Tolerance Ringd - Opening In Tolerance Ring IMPORTANT: Ensure that notched edge of bear-ing carrier f...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-15 5. Remove set screw from shift slide. 23153 a - Safety Wire - Cutb - Set Screwc - Shift Slide 6. Remove inner core wire and shift slide. 23262 a - Inner Core Wireb - Shift Slidec - Shift Cable 7. Remove and discard shift cable bellows crimp clamp. NOTE: On u...

4A-16 - TRANSOM ASSEMBLY 90-12934--2 1097 9. Pull shift cable through shift cable bellows. 75793 a - Shift Cableb - Shift Cable Bellows 10. Using shift cable removal and installation tool (91-12037), completely loosen shift cable retain-ing nut. 23156 New Style Shift Cable a - Shift Cable Retaining ...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-17 INSTALLATION IMPORTANT: This shift cable (which attaches tobell housing from aft end) can be used on modelswith old style shift cable (attached on front sideof bell housing). To do this, the threaded hole inbell housing must be tapped all the way through,usi...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-19 7. Install set screw into shift slide. Tighten until con- tact with core wire. Then back off 1/8 turn max.Safety wire set screw to shift slide using a “figure8” pattern. Twist until tight and cut off excesslength of safety wire. 23153 a - Set Screwb - Shift ...

4A-20 - TRANSOM ASSEMBLY 90-12934--2 1097 13. Push in on drive unit shift cable while simulta- neously turning propeller shaft counterclockwiseuntil shaft stops, to ensure drive unit is complete-ly in forward gear. Maintain pressure on propellershaft with a suitable device (elastic strap). 14. Measu...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-21 INSTALLATION ! WARNING Bellows adhesive contains toluol and petroleumdistillates which are harmful or fatal if swallowed.Avoid prolonged contact with skin or breathingof vapors. If swallowed, do not induce vomiting.Call physician immediately. Keep out of rea...

4A-22 - TRANSOM ASSEMBLY 90-12934--2 1097 d. Reposition tool into third bellows convolution. e. Pull bellows onto bell housing flange. f. Tighten hose clamp. 23158 a - Exhaust Bellowsb - Bell Housing Flangec - Hose Clamp Exhaust Tube (If Equipped) REMOVAL NOTE: It is not necessary to remove drive un...

90-12934--2 1097 TRANSOM ASSEMBLY - 4A-23 ! CAUTION Exhaust tube hose clamp may corrode if ground-ing clip is not installed. 1. Position grounding clip on exhaust tube as shown. 22184 a - Exhaust Tubeb - Grounding Clip 2. Install exhaust tube on gimbal housing as fol- lows:a. Position tube so that “...

A 5 22163 POWER TRIM OILDYNE POWER TRIM PUMP(WITH PLASTIC RESERVOIR)

OILDYNE POWER TRIM PUMP - 5A-1 90-12934--2 1097 Specifications Valve Pressure Specifications Valve Pressure Up Circuit 2200-2600 psi (15173-17932 kPa) Down Circuit 400-600 P.S.l. (2759-4138 kPa) Electrical Specification Pump Amperage Draw 115 Amps at 2200-2600 P.S.l. (15173-17932 kPa) Torque Specifi...

90-12934--2 1097 5A-2 - OILDYNE POWER TRIM PUMP 1. Remove fill cap, then raise and lower drive unit 6 to 10 times to purge air from system. Check oillevel visually (b). 22031 a - If There Is A Vent Screw, It Must Be Backed Out 2 Full Turns; If There Is No Vent Screw, The Fill Cap Is Vented If“Caplug...

OILDYNE POWER TRIM PUMP - 5A-3 90-12934--2 1097 Bleeding IN/DOWN Trim Circuit 1. Ensure pump reservoir is filled to proper level. 2. Disconnect IN/DOWN hose from rear connection on gimbal housing hydraulic connector. If bothcylinders were rebuilt, disconnect hoses fromboth sides of hydraulic connect...

90-12934--2 1097 5A-4 - OILDYNE POWER TRIM PUMP 50390 a - Hydraulic Test Gauge (91-52915A6)b - Gimbal Housing Hydraulic Connector 50391 c - Capsd - Plugs Supplied with Gauge Gauge Connect to Hydraulic Connector 4. Open Valve “A” and “B” and run pump UP and DOWN several times (to purge air). Internal...

OILDYNE POWER TRIM PUMP - 5A-5 90-12934--2 1097 IN/DOWN Pressure Test 1. Close Valve “A” and open Valve “B”. 2. Run pump IN/DOWN while observing gauge. Reading should be 400-600 psi (2759-4138kPa). • Gauge reading within specifications, proceedto step 3. • Gauge reading NOT within specifications,per...

90-12934--2 1097 5A-6 - OILDYNE POWER TRIM PUMP Trim Pump Hydraulic System 73552 1 - Shuttle 2 - Pump Adaptor 3 - UP/OUT Pressure Relief Valve 4 - Thermal Relief Valve 5 - Fitting 6 - IN/DOWN Pressure Relief Valve

90-12934--2 1097 5A-8 - OILDYNE POWER TRIM PUMP 50390 Gauge Connected to Hydraulic Connector a - Test Gaugeb - Coupling (Supplied With Gauge)c - Front Hydraulic Connector Port 3. Open Valve “A” and “B” and run pump OUT/UP and IN/DOWN several times (to purge air). 4. Run pump OUT/UP until trim cylind...

OILDYNE POWER TRIM PUMP - 5A-9 90-12934--2 1097 Motor and Electrical BenchTests Trim Pump Motor Test (In Boat) ! WARNING DO NOT perform this test near flammables (or ex-plosives), as a spark may occur when makingconnections. ! WARNING Remain clear of drive unit when performing pow-er trim pump motor...

OILDYNE POWER TRIM PUMP - 5A-11 90-12934--2 1097 2. IN/DOWN Solenoid. a. Connect a jumper wire between positive (+) solenoid terminal and GREEN/WHITE har-ness wire terminal. b. Motor should run. 22494 a - IN/DOWN Solenoidb - Positive (+) Solenoid Terminalc - GREEN/WHITE Harness Wire Terminald - Jump...

90-12934--2 1097 5A-12 - OILDYNE POWER TRIM PUMP 5. IN/DOWN Solenoid. a. Connect 12 volt positive (+) supply lead to GREEN/WHITE harness wire terminal. b. Connect negative (-) supply lead to solenoid ground terminal. c. Connect ohmmeter leads to large terminals on solenoid. 22494 a - IN/DOWN Solenoi...

OILDYNE POWER TRIM PUMP - 5A-13 90-12934--2 1097 110 Amp Fuse Test (Pump Out ofBoat) 1. Connect ohmmeter leads between terminals on fuse. Zero Ohms Reading (Full Continuity)-Fuse OK High Ohms Reading (No Continuity)-Replace fuse 22493 a - 110 Amp Fuseb - Ohmmeter Leads 20 Amp Fuse Test 1. Remove fus...

90-12934--2 1097 5A-14 - OILDYNE POWER TRIM PUMP Hydraulic Repair Disassembly 1. Disconnect trim motor wires. 22497 a - Blue/White Motor Wireb - Green/White Motor Wirec - Black Ground Wire 2. Remove mounting bolts and remove trim pump from floor bracket. 22548 a - Trim Pumpb - Floor Bracketc - Mount...

OILDYNE POWER TRIM PUMP - 5A-15 90-12934--2 1097 Filter Replacement 1. Remove filter by twisting while pulling upward. 22547 a - Filter 2. Install new filter. 22547 a - Filterb - 5/8 in. Socket UP Pressure Relief ValveReplacement NOTE: UP pressure relief valve in kit is color codedblue for easy iden...

90-12934--2 1097 5A-16 - OILDYNE POWER TRIM PUMP 1. Replace UP pressure relief valve. Loosen jam nut on original pressure valve. Do NOT loosenjam nut on replacement valves. Remove spring,eyelet and check ball and discard. Ensure thatthreaded hole is free of dirt. Lubricate O-ring atbase of new valve...

OILDYNE POWER TRIM PUMP - 5A-17 90-12934--2 1097 1. Replace DOWN pressure relief valve. Loosen jam nut on original pressure valve. Do NOT loos-en jam nut on replacement valves. Removespring, eyelet and check ball and discard. Ensurethat threaded hole is free of dirt. Lubricate O-ringat base of new v...

90-12934--2 1097 5A-18 - OILDYNE POWER TRIM PUMP 2. Remove O-rings from old pump and install on new pump. 3. Lubricate lip of adaptor seal with light weight oil. 22545 a - O-ringsb - Adaptor Seal 4. Install pump and torque screws to 70 lb. in. (7.9 N·m). 70870 a - Screws Adaptor Replacement 1. Remov...

OILDYNE POWER TRIM PUMP - 5A-19 90-12934--2 1097 3. Remove and discard (motor to adaptor) O-ring. 4. Remove vent screw (dipstick) from old adaptor. 5. Install vent screw (dipstick) and new motor to adaptor O-ring. 6. Ensure coupling is installed so that shallow slot is toward reservoir. Lubricate co...

OILDYNE POWER TRIM PUMP - 5A-21 90-12934--2 1097 12. Thread hex plug retainers into adaptor by hand until retainer contacts check valve body. 70871 a - Spring (2)b - O-ring (2)c - Hex Plug Retainer (2) ! CAUTION Hex plug retainers MUST BE turned into adaptorexactly as outlined or damage to check val...

90-12934--2 1097 5A-22 - OILDYNE POWER TRIM PUMP 6. Lubricate lip of seal with light weight oil. Replace O-rings if necessary. 22545 a - Oil Seal-Lip Toward Pumpb - O-rings 7. Install pump and torque screws to 75 lb. in. (8 N·m) using a hex lobular socket or a standard3/16 inch socket. 70870 a - Scr...

OILDYNE POWER TRIM PUMP - 5A-25 90-12934--2 1097 9. Remove field assembly from motor housing. 22501 a - Field Assemblyb - Motor Housing 10. Remove motor housing O-ring. 22645 a - O-ringb - Motor Housing Armature Tests CONTINUITY TEST 1. Check armature for continuity. Set ohmmeter on Rx1 scale. Place...

90-12934--2 1097 5A-26 - OILDYNE POWER TRIM PUMP Field Tests TEST FOR OPEN CIRCUIT 1. Connect ohmmeter between field brush lead and BLUE/WHITE lead. Zero Ohms Indicated (full continuity)-Field OK. Zero Ohms Not Indicated (no continuity)-Replacefield assembly. 22644 a - Ohmmeter Lead-Connected To Bru...

OILDYNE POWER TRIM PUMP - 5A-27 90-12934--2 1097 2. Insert an insulator (piece of paper) between contact points on ohmmeter between spadeconnector and brush lead. Zero Ohms Indicated (full continuity)-Replace ther-mal switch. Zero Ohms Not Indicated (no continuity)-Thermalswitch OK. 22649 a - Therma...

90-12934--2 1097 5A-32 - OILDYNE POWER TRIM PUMP 10. Align motor shaft with coupler and install trim motor on adaptor. Torque screws to 25 lb. in. (2.8N·m). 22496 22548 a - Trim Motorb - Adaptorc - Screws (2) (Opposite Corners)d - Couplere - Motor Shaft 11. Install trim pump on floor bracket. Tighte...

OILDYNE POWER TRIM PUMP - 5A-33 90-12934--2 1097 Trim Pump Installation 1. Secure pump and mounting bracket to boat using lag bolts and washers. 2. Reconnect trim hoses to pump. Black hose to left connection; gray hose to right connection. DONOT cross-thread or overtighten hose fittings.Torque to 70...

90-12934--2 1097 5A-34 - OILDYNE POWER TRIM PUMP POWER TRIM WIRING DIAGRAM 22252 BLK BLack BLU BLUE BRN BROWN GRY GRAY GRN GREEN ORN ORANGE PNK PINK PUR PURPLE RED RED TAN TAN WHT WHITE YEL YELLOW LIT LIGHT DRK DARK

STEERING SYSTEM - 6A-1 90-12934--2 1097 Specifications Torque Specification DESCRIPTION TORQUE DESCRIPTION lb. in. lb. ft. N ⋅ m Coupler Nut 35 48 Pivot Bolts 25 35 Power Steering Hose(Large Fitting) 20-25 27-34 Power Steering Hose(Small Fitting) 96-108 11-12 Steering Tube Nut 15-20 20-27 Control Va...

22213 6A-2 - STEERING SYSTEM 90-12934--2 1097 Power Steering System (VIEWING FROM INSIDE OF BOAT LOOKING ATTRANSOM)

STEERING SYSTEM - 6A-5 90-12934--2 1097 Steering Helm and Cable Transom assembly is shipped with the steering cableguide tube preset for cables with end dimensions thatcomply with ABYC standards as outlined in theNMMA certification handbook. The steering cablecoupler nut must also have a means of lo...

6A-6 - STEERING SYSTEM 90-12934--2 1097 Filling and Air BleedingPower Steering System IMPORTANT: Power Steering system MUST BEfilled exactly as explained, following, to be surethat all air is bled from the system. All air must beremoved, or fluid in pump may foam during op-eration and be discharged ...

STEERING SYSTEM - 6A-7 90-12934--2 1097 Balancing Power SteeringControl Valve IMPORTANT: Control valve is balanced by themanufacturer and should not require further ad-justment. However, if drive unit tends to creep inone direction or the other (with engine running,drive unit in neutral, and hands o...

STEERING SYSTEM - 6A-9 90-12934--2 1097 12. Place 2-4-C Marine Lubricant in adjustment nut cavity and reinstall dust cover. 22023 a - Adjustment Nut Cavity 13. Restart engine and observe drive unit. If drive unit still creeps in one direction or the other, anexternal tension may exist on steering ca...

6A-10 - STEERING SYSTEM 90-12934--2 1097 Removal 1. Remove steering cable. 22023 a - Steering Cableb - Cable Coupler Nutc - Lock Plated - Screw And Washere - Cotter Pinf - Clevis Pin Installation ! WARNING Steering cable outer casing MUST BE free tomove back-and-forth for steering to functionproperl...

STEERING SYSTEM - 6A-13 90-12934--2 1097 2. Assemble and install test gauge. 3. Open valve on gauge completely. 22146 a - Pump Pressure Hoseb - Gauge Fittingc - Gauge Valve Hosed - Control Valve 4. Connect a flush test device to drive unit. Partially open water tap (approximately 1/2 max.) and al-lo...

6A-14 - STEERING SYSTEM 90-12934--2 1097 If pressure is above 1000 psi (6897 kPa): sys-tem pressure is good. If pressure is below 1000 psi (6897 kPa): con-duct “Pump Pressure Test”, see “Index”. 22023 a - Control Valve Adaptor Block Pump Pressure Test ! CAUTION In performing the following test, DO N...

6A-16 - STEERING SYSTEM 90-12934--2 1097 Power Steering ComponentRepair Power Steering Unit REMOVAL 1. Remove steering cable and Power Steering pump fluid hoses. Plug power steering pumphoses. 22023 22023 a - Cotter Pin (Hidden)b - Clevis Pinc - Power Steering Pump Fluid Hosesd - Coupler Unit Locke ...

6A-18 - STEERING SYSTEM 90-12934--2 1097 Cable Guide Tube REMOVAL 1. Remove power steering pump hoses from con- trol valve. Cap hoses and plug holes in controlvalve. 22023 a - Control Valveb - Pump Hoses 2. Remove steering cable from power steering con- trol valve. 22023 a - Clevis Pinb - Cotter Pin...

6A-20 - STEERING SYSTEM 90-12934--2 1097 Control Valve NOTE: If accessibility to control valve area is limited,remove Power Steering unit from transom assembly,to gain easier access to control valve. REMOVAL 1. Remove steering cable and Power Steering pump fluid hoses. Plug Power Steering pumpfluid ...

6A-22 - STEERING SYSTEM 90-12934--2 1097 REASSEMBLY 1. Install lower ball seat into sleeve bearing. 22140 a - Lower Ball Seatb - Sleeve Bearing 2. Install sleeve bearing. Pull ball stud up into rub- ber boot. 22140 a - Sleeve Bearingb - Ball Studc - Adaptor Housing 3. Position ball stud in sleeve be...

6A-26 - STEERING SYSTEM 90-12934--2 1097 8. Connect power steering pump hoses to their re- spective fittings on control valve. Torque large fit-ting to 20-25 lb. ft. (27-34 N·m). Torque small fit-ting 96-108 lb. in. (11-12 N·m). 22023 a - Hose (Large Fitting)b - Hose (Small Fitting) Booster Cylinder...

STEERING SYSTEM - 6A-29 90-12934--2 1097 Power Steering Pump REMOVAL 1. Disconnect hoses at pump. Cap hose and fit- tings. 2. Loosen pump bolts at engine to remove pump belt. 3. Remove bracket from pump. FLOW CONTROL VALVE SERVICING 1. Drain fluid from pump. 2. Remove components shown. 22149 a - Fit...

STEERING SYSTEM - 6A-31 90-12934--2 1097 DISASSEMBLY 1. Drain fluid from pump. 2. Remove pump pulley. 22149 a - Kent Moore Pulley Removal Tool (J-25034) 3. Remove fitting assembly, control valve assembly, flow control spring, o-ring and studs. Discard o-ring. 4. Remove reservoir by tapping from pump...

6A-32 - STEERING SYSTEM 90-12934--2 1097 8. Remove and discard O-rings from housing. 22155 a - O-rings-Discard 9. Remove retaining ring, rotor and thrust plate. 22155 a - Retaining Ringb - Rotorc - Thrust Plated - Pump Shaft 10. Remove magnet. 22154 a - Magnet CLEANING AND INSPECTION 1. Clean and in...

STEERING SYSTEM - 6A-35 90-12934--2 1097 12. Secure reservoir to pump housing. Torque studs to 35 lb. ft. (47 N·m). 22153 a - Reservoirb - Pump Housingc - Studs 13. Install flow control spring, control valve assem- bly, o-rings and fitting assembly into reservoir.Torque fitting assembly to 35 lb. ft...

STEERING SYSTEM - 6A-37 90-12934--2 1097 Installation DUAL INSTALLATIONS WITH STEERINGCABLE ATTACHED TO STARBOARD POWERPACKAGE 1. Install tie bar. a. Attach fixed bar end (a) to steering lever (b), using clevis pin (c) and cotter pin (d). Spreadcotter pin ends. 22079 22211 b. Position drive units as...

CORROSION PROTECTION - 7A-1 90-12934--2 1097 Continuity Circuit Transom assembly and sterndrive unit are equippedwith a continuity circuit, to ensure good electrical con-tinuity between engine, transom assembly and stern-drive components. Good continuity is essential forthe zinc trim tab and MerCath...

CORROSION PROTECTION - 7A-3 90-12934--2 1097 Anodic Block Replacement ! CAUTION DO NOT paint new anodic block, as this will ren-der it ineffective as a galvanic corrosion inhibi-tor. 1. Remove screws, ground washers and gasket from anodic block. Remove anodic block to hy-draulic manifold gasket and ...

7A-4 - CORROSION PROTECTION 90-12934--2 1097 5. Install screws and washers into block as shown. 73891 a - Screws (2)b - Anodic Blockc - Continuity Washers ! CAUTION To be effective, new anodic block MUST makegood continuity contact with gimbal housing. 6. Be sure new gasket is in proper position bet...

CORROSION PROTECTION - 7A-5 90-12934--2 1097 Anodic Trim Tab Replacement ! CAUTION DO NOT paint new trim tab, as this will render itineffective as a galvanic corrosion inhibitor. 1. Remove plug from drive shaft housing to gain ac- cess to trim tab attaching screws. 22093 a - Plug 2. Use an allen wre...

7A-6 - CORROSION PROTECTION 90-12934--2 1097 Integral MerCathode System Removing Electrode Assembly 1. Disconnect electrode assembly wires from MerCathode Controller. 22231 a - Electrode Assembly Wire (Orange)b - Electrode Assembly Wire (Brown) 2. Remove two screws, flat washers and lock wash- ers; ...

CORROSION PROTECTION - 7A-11 90-12934--2 1097 Quicksilver Isolator Boats, which are connected to A.C. shore power,require additional protection, to prevent destructivelow voltage galvanic currents from passing throughthe shore power ground wire. A Quicksilver GalvanicIsolator can be installed to blo...

7A-14 - CORROSION PROTECTION 90-12934--2 1097 Low Reading Possible Cause Remedy 1. Loss of continuity between drive unit components and negative (–) battery terminal. 1. Check that continuity devices are not missing or damaged and that connections are cleanand tight. If unit is equipped with continu...

CORROSION PROTECTION - 7A-15 90-12934--2 1097 Possible Cause Remedy 13. *Faulty MerCathode Controller. 13. With anode and reference electrode leads connected to controller, connect a jumper wirebetween “R” and “–” terminals on controller. Connect positive (+) lead of volt meter (set on 0-20 scale) t...

7A-16 - CORROSION PROTECTION 90-12934--2 1097 Normal Reading But Corrosion Is Evident Problem Possible Cause Remedy Corrosion on Entire DriveDrive Unit Drive unit raised so far thatsacrificial trim tab is out of the water. Drive unit must be left “In” (“Down”)position when boat is moored fortrim tab...

MAINTENANCE - 1B-1 90-12934--2 1097 Maintenance Schedules Maintenance Intervals Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a pre-viously printed schedules, are generally based on an average boating application and environment. However,indiv...

1B-2 - MAINTENANCE 90-12934--2 1097 Scheduled Maintenance That Can Be Performed by Dealer NOTE: Only perform maintenance which applies to your particular power package. Task Interval Seawater Pickup Pump - Disassemble and inspect. Whenever insufficient seawater flow is suspected.(If operating temper...

MAINTENANCE - 1B-3 90-12934--2 1097 Scheduled Maintenance That Can Be Performed by Dealer (Continued) NOTE: Only perform maintenance which applies to your particular power package. Task Interval Steering Head and Remote Control - Inspect andlubricate. End of first boating season and thereafter, ever...

1B-4 - MAINTENANCE 90-12934--2 1097 Lubricating Shift Cable Pivot Points 1. Lubricate with SAE 20 or SAE 30 Oil. 22911 Early Models 22265 Later Models 50308 Models With Shift Assist Assembly a - Lubrication Points Lubricating Propeller Shaft 1. Lubricate with Special Lubricant 101, 2-4-C Ma- rine Lu...

MAINTENANCE - 1B-5 90-12934--2 1097 Lubricating Steering System ! WARNING Transom end of steering cable MUST BE fully re-tracted into cable housing when lubricatingcable. If cable is lubricated while extended, hy-draulic lock of cable could occur. Power Steering Models 1. Lubricate following points ...

1B-6 - MAINTENANCE 90-12934--2 1097 22079 Port Engine a - Pivot Points Lubricating Tie Bar Pivot Points CONTROL VALVE MOUNTED ON PORT TRANSOM 1. Lubricate pivot points with SAE 20 or SAE 30 oil. 22079 Port Engine 22079 Starboard Engine a - Pivot Points Lubricating Transom GimbalHousing Assembly Swiv...

MAINTENANCE - 1B-7 90-12934--2 1097 Checking and AddingSterndrive Oil Units Without Gear Lube Monitor 1. Position sterndrive unit so that anti-ventilation plate is level. 2. Remove oil vent plug from drive shaft housing. 3. Check oil level - Oil should be even with bottom edge of oil vent hole. If o...

1B-8 - MAINTENANCE 90-12934--2 1097 Models With Gear Lube Monitor IMPORTANT: DO NOT check oil level with driveunit hot from operation, as hot, expanded oil mayprovide a false reading at reservoir. Allow driveunit to cool prior to checking oil level. ! CAUTION If color of oil appears milky, or if con...

MAINTENANCE - 1B-9 90-12934--2 1097 Models With Gear Lube Monitor Check for water at bottom of monitor. If oil appearsdiscolored, a water leak is indicated somewhere inthe drive unit and the drive unit must be resealed. ! CAUTION If more than 2 fl. oz. (59 mL) of Quicksilver GearLube is required to ...

1B-10 - MAINTENANCE 90-12934--2 1097 8. Remove lubricant pump and quickly reinstall fill/ drain screw and sealing washer. Torque to 30 - 50lb. in. (3.4-5.7 N·m). 9. Recheck oil level after first use. 23266 a - Oil Fill/Drain Plugb - Sealing Washer Units With Gear Lube Monitor 1. Raise drive unit to ...

1B-12 - MAINTENANCE 90-12934--2 1097 General Maintenance Maintaining Power Package ExteriorSurfaces Entire Power Package should be sprayed at recom-mended intervals with Quicksilver Corrosion andRust Preventive Type II. Follow instructions on canfor proper application. At least once each year, entir...

MAINTENANCE - 1B-13 90-12934--2 1097 Maintaining Continuity Circuit Transom assembly and sterndrive unit may beequipped with a continuity circuit to ensure goodelectrical continuity between engine, transom as-sembly and sterndrive components. Good continuityis essential for the anodes and MerCathode...

MAINTENANCE - 1B-15 90-12934--2 1097 7. Using a piece of wire, check water drain holes in sterndrive unit to ensure that they are open. 23253 Sterndrive Unit Water Drain Holes a - Drive Shaft Housing Water Drain Holes (Two Each Side)b - Gear Housing Water Drain Hole 8. Inspect sterndrive for damage....

MR/ALPHA ONE/ALPHA ONE SS - 3B-1 90-12934--2 1097 Identification Early MerCruiser MR gear housings can be visuallyidentified by the letter “A” stamped on the end of thepropeller shaft. This mark was removed on later MRand Alpha One models. The gear housing can nowbe identified by the absence of a pr...

3B-2 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 Special Tools (continued) Description Part Number Shift Shaft Bushing Tool 91-31107 Slide Hammer Puller 91-34569 A1 Torque Wrench - Lb. In. 91-66274 Universal BearingRemoval andInstallation Tool 91-31229 A7 Bearing Adaptor 91-37263 Bearing Driver 91-...

MR/ALPHA ONE/ALPHA ONE SS - 3B-3 90-12934--2 1097 Forward Gear Bearing Bore The later style forward gear bearing bore is smaller(3.2635 - 3.2650 in.) than the earlier style (3.4985 to3.5000 in.) This slightly smaller bearing bore for theforward gear bearing adaptor is approximately 1/4 in.(6 mm) sma...

Torque Specifications 60-80 lb. ft. (81-108 N·m) 30-lb. in. (3-5 N·m) 60-80 lb. in. (6.8-9 N·m) 28 lb. ft. (38 N·m) 35 lb. ft. (47 N·m) 23 lb. ft. (31 N·m) 50 lb. ft. (68 N·m) 210 lb. ft. (285 N·m) 30-50 lb. in. (3.39-5.65 N·m) 100 lb. ft. (130 N·m) a b c d e Lubricants/Sealers/Adhesives Quicksilver...

3B-14 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 Gear Housing Disassembly NOTE: If O-ring remains lodged between upper driveshaft seals (in drive shaft housing), be sure to removeO-ring or reassembly will be impaired. 1. Remove components shown. 23266 a - O-ringb - Water Tubec - Rubber Centrifugal...

MR/ALPHA ONE/ALPHA ONE SS - 3B-15 90-12934--2 1097 5. Straighten tabs on bearing carrier tab washer. 50312 a - Tab On Tab Washer 6. Remove bearing carrier retainer following Step a or b as follows: a. Remove bearing carrier retainer using bearing carrier retainer wrench (P/N91-61069). 23347 a - Bear...

3B-16 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 7. Remove bearing carrier following step “a or b” as follows: ! CAUTION On Earlier Style Units - DO NOT pull on the bear-ing carrier outer ring, as damage to the carrierwill result. a. On Earlier Style Units - Pull the bearing carrier from the gear ...

MR/ALPHA ONE/ALPHA ONE SS - 3B-19 90-12934--2 1097 13. Remove shift shaft metal washer and rubber washer. 23354 a - Metal Washer And Rubber Washer (Under Metal Washer) 14. Loosen shift shaft bushing. 23354 a - Shift Shaft Bushing Tool (91-31107) 15. Lift shift shaft assembly and shift shaft bushing ...

3B-20 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 WATER PUMP DISASSEMBLY 1. Remove water pump base O-ring and gasket. 23348 a - O-ringb - Gasket 2. Remove water pump base oil seals. 23347 a - Water Pump Baseb - Screw Driverc - Oil Seals (2)-Drive Out One At A Time 3. If water pump insert required r...

MR/ALPHA ONE/ALPHA ONE SS - 3B-21 90-12934--2 1097 WATER PUMP REASSEMBLY 1. Press smaller diameter oil seal into water pump base from bottom, with lip of seal facing top ofwater pump base using oil seal driver. 23139 a - Oil Sealb - Oil Seal Driver (91-44110)c - Water Pump Base 2. Press larger diame...

3B-26 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 7. Perform step “a or b” as necessary. a. If Replacing Propeller Shaft Needle Bearing and Seals: Remove needlebearing and seals with tools as shown. 23140 a - Needle Bearingb - Oil Sealsc - Puller Head (91-36569)d - Bearing Driver Rod (91-37323) b. ...

MR/ALPHA ONE/ALPHA ONE SS - 3B-29 90-12934--2 1097 SHIFT SPOOL ASSEMBLY INSPECTION NOTE: The later style shift spool assembly has alarger gap than the earlier style. This later style shiftspool is sold as a whole assembly and can be usedwhen replacing the earlier style (Prior to S/NOK041000). The en...

3B-30 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 PROPELLER SHAFT, FORWARD GEAR ANDBEARING AND SHIFT SPOOL ASSEMBLY INSPECTION AND CLEANING 1. Inspect forward gear for pitting, chipped or broken teeth, fracturing and excessive or unevenwear. 2. Check forward gear clutch jaws for damage. Jaws must n...

3B-32 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 SHIFT SHAFT DISASSEMBLY 1. Remove shift shaft components as shown. 23354 a - Shift Shaft Bushingb - O-ringc - Washerd - Clipe - Shift Shaft SHIFT SHAFT INSPECTION AND CLEANING 1. Inspect shift shaft bushing for corrosion. 23349 a - Shift Shaft Bushi...

MR/ALPHA ONE/ALPHA ONE SS - 3B-35 90-12934--2 1097 4. Install bearing cup and retainer. 23352 a - Bearing Cupb - Retainer 5. Torque retainer using Drive Shaft Bearing Retainer Tool (91-43506) to 100 lb. ft. (130 N·m). 23348 a - Drive Shaft Bearing Retainer Tool (91-43506)b - Retainer 6. Partially in...

3B-36 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 2. Pull up on the drive shaft and tighten the two (2) allen screws in the top nut of the bearing preloadtool. 75733 a - Allen Screws 3. Screw the bottom nut of the bearing preload tool down until it is one inch further down the threadedrod than it w...

3B-38 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 ! CAUTION Before loosening collar set screw, tighten bear-ing preload tool nuts until they bottom onspacers. 7. Remove bearing preload tool as follows: a. Tighten 3 nuts until they bottom on spacers. b. Loosen collar set screw and remove collar. c. ...

MR/ALPHA ONE/ALPHA ONE SS - 3B-43 90-12934--2 1097 CHECKING FORWARD GEAR BACKLASH Current Style Preload Tool Installation 1. Install the components from the Bearing Preload Tool Kit (91-14311A1), over the drive shaft in theorder show 73885 a - Top Nut With Threaded Pipeb - Nutc - Springd - Thrust Wa...

3B-44 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 Early Style Preload Tool Installation 1. Install the following components from Bearing Preload Tool (91-44307A1) over driveshaft inorder shown. 23144 a - Springb - Platec - Washerd - Bearinge - Washerf - Spacers (3) 2. Install and tighten nuts until...

3B-46 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 c. To ensure reliability of results, take 3 more backlash readings, turning drive shaft 90degrees at a time. Be sure to loosen backlashindicator rod and realign Dial IndicatorPointer with mark “I” on rod. 23146 a - Drive Shaftb - Dial Indicatorc - I...

MR/ALPHA ONE/ALPHA ONE SS - 3B-47 90-12934--2 1097 CHECKING REVERSE GEAR BACKLASH Install the components from the Bearing Preload ToolKit (91-14311A1), over the drive shaft in the ordershown. 73885 Current Style Preload Tool Installation a - Top Nut With Threaded Pipeb - Nutc - Springd - Thrust Wash...

3B-50 – MR/ALPHA ONE/ALPHA ONE SS 90-12934--2 1097 NOTE: By adding .001 in. (0.025 mm) shim, thebacklash will change approximately .001 in. (0.025mm). 10. Remove pinion nut adaptor tool from propeller shaft. 11. Remove dial indicator and associated tools. ! CAUTION Before loosening collar set screw,...

MR/ALPHA ONE/ALPHA ONE SS - 3B-51 90-12934--2 1097 WATER PUMP INSTALLATION 1. If O-ring is present, cover drive shaft O-ring groove with a piece of tape. 50312 2. Lubricate water pump base oil seal lips with 2-4-C Marine Lubricant with Teflon and installwater pump base with gasket over drive shaft. ...

TRANSOM ASSEMBLY - 4B-1 90-12934--2 1097 Specifications Torque Specifications Fastener Location Torque Hinge Pins - Gimbal Ring toBell Housing 105 - 115 lb. ft.(141 - 155 N·m) Screws - Gimbal Ring 50 - 55 lb. ft.(67 - 74 N·m) Screw and Nut - SteeringLever 75 lb. ft. (101 N·m) Screws, Nut - TransomAs...

4B-4 – TRANSOM ASSEMBLY 90-12934--2 1097 Gimbal Housing Water Tube Transom assembly serial number 6665169 andabove will be equipped with a 3/4 in. (19 mm) I.D.gimbal housing water tube and hose for increasedcooling capacity. Older sterndrives were fitted with a5/8 in. (16 mm) water tube and hose. Ne...

TRANSOM ASSEMBLY - 4B-5 90-12934--2 1097 Upper Swivel Shaft Transom assembly serial number 6666130 andabove. A new square swivel shaft steering lever provides asquare connection at both the steering lever and gim-bal ring for improved durability. In the past, a splinedconnection was used between the...

4B-6 – TRANSOM ASSEMBLY 90-12934--2 1097 The new trim cylinders will be used as a servicereplacement for older MerCruiser 120R through260R and MR models. A new trim cylinder can beintermixed with an old trim cylinder on the same unit.If the additional 3 of trim “IN” is desired, both new trim cylinde...

TRANSOM ASSEMBLY - 4B-7 90-12934--2 1097 Component Disassembly Bell Housing Removal 1. Remove sterndrive unit (Refer to Section 2A). 2. Remove trim position sender. 22091 a - Trim Position Senderb - Screws (2)c - Retainer (2) 3. Remove trim limit switch. 22091 a - Trim Limit Switchb - Screws (2)c - ...

4B-8 – TRANSOM ASSEMBLY 90-12934--2 1097 8. Remove inner core wire and shift slide. 23262 a - Inner Core Wireb - Shift Slidec - Shift Cable NOTE: On units with old style shift cable, pull bellowsaway from bell housing after crimp clamp is loos-ened. 9. Remove and discard shift cable bellows crimp cl...

4B-10 – TRANSOM ASSEMBLY 90-12934--2 1097 b. Loosen U-joint bellows front hose clamp. c. Loosen exhaust bellows rear hose clamp. d. Pull bell housing away from gimbal housing. e. Pull shift cable through shift cable bellows. 23158 a - U-joint Bellows Front Hose Clampb - Exhaust Bellows Rear Hose Cla...

TRANSOM ASSEMBLY - 4B-11 90-12934--2 1097 ! CAUTION Be sure to drill holes and tap threads perpendicu-lar to gimbal housing surfaces in the followingsteps. 4. Drill pilot holes (port and starboard) using a drill that is the same size as pilot rod being used withhole saw. (Approximately 1/4 in.). 505...

4B-12 – TRANSOM ASSEMBLY 90-12934--2 1097 Gimbal Ring, Swivel Shaft andSteering Lever Removal 1. Loosen (not necessary to remove) screws and nuts. 23254 a - Screws (2) Washers (4)Nuts (2) b - Gimbal Ring 2. Remove cotter pin, lower swivel pin and washer. Disconnect continuity wire. 22461 a - Cotter ...

TRANSOM ASSEMBLY - 4B-13 90-12934--2 1097 4. Unthread nut from top of upper swivel shaft. 50541 With Engine and Transom Assembly Installed a - Nutb - Pin Punch (Through Access Hole) 50541 With Engine and Transom Assembly Removed a - Nut 5. Remove upper swivel shaft, steering lever and hardware shown...

4B-14 – TRANSOM ASSEMBLY 90-12934--2 1097 Component Servicing Bell Housing U-JOINT BELLOWS 1. Loosen hose clamp and remove U-joint bellows from bell housing. 50543 a - Bell Housingb - U-joint Bellowsc - Hose Clamp 2. Remove old adhesive from U-joint bellows mounting surface, using lacquer thinner. 2...

TRANSOM ASSEMBLY - 4B-15 90-12934--2 1097 4. Apply bellows adhesive to U-joint bellows mount- ing surface. Allow to dry (approximately 10 min-utes) until no longer tacky. 23364 a - U-joint Bellowsb - Mounting Surface 5. Position ground clips on U-joint bellows as shown. Then, position hose clamp on ...

4B-16 – TRANSOM ASSEMBLY 90-12934--2 1097 2. Loosen hose clamp and remove water tube from water hose. 23294 a - Water Hoseb - Water Tubec - Hose Clamp 3. Remove water hose connector from bell housing. 50543 a - Bell Housingb - Water Hose Connector 4. Apply Perfect Seal to threads of water hose conne...

TRANSOM ASSEMBLY - 4B-17 90-12934--2 1097 6. Connect water hose to connector on bell housing. Position hose and clamp as shown.Tighten securely. 23361 a - Water Hoseb - Hose Clamp SHIFT CABLE 1. Loosen shift cable retaining nut using shift cable removal and installation tool and remove shiftcable. 2...

4B-18 – TRANSOM ASSEMBLY 90-12934--2 1097 2. Apply Perfect Seal to threads of shift cable retainer and install shift cable. Tighten retainersecurely using shift cable removal and installationtool (until no more than two threads of retainer areshowing). 23156 Newer Style Shift Cable a - Shift Cableb ...

4B-20 – TRANSOM ASSEMBLY 90-12934--2 1097 6. Install upper shift shaft lever and shift shaft. Apply Loctite 27131 to screw threads. Tighten securely. 70141 a - Upper Shift Shaft Lever Screwb - Upper Shift Shaft Leverc - Washer (Beneath Lever)d - Upper Shift Shaft GASKET AND O-RING 1. Remove U-joint ...

4B-22 – TRANSOM ASSEMBLY 90-12934--2 1097 b. Install bushing in gimbal ring by tapping in place with a hammer. 22454 a - Bushingb - Bearing And Seal Driver (91-43578) SYNTHANE WASHERS 1. If synthane washers are worn, remove and replace using Epoxy (92-65150-1). 22454 a - Gimbal Ringb - Synthane Wash...

4B-24 – TRANSOM ASSEMBLY 90-12934--2 1097 5. Install large bearing or bushing and oil seal, using Driver (91-33491). 73988 Transom Assembly with Spline-Square UpperSwivel Shaft a - Large Bearingb - Oil Seal 26370 Transom Assembly with Square-Upper SwivelShaft a - Large Bushingb - Oil Seal IMPORTANT:...

TRANSOM ASSEMBLY - 4B-25 90-12934--2 1097 4. Clean exhaust bellows mounting flange with a wire brush or sandpaper. Wipe clean with lacquerthinner. 5. Install exhaust bellows on gimbal housing and position hose clamp as shown. Tighten securely. 22081 a - Exhaust Bellowsb - Hose Clamp SHIFT CABLE BELL...

4B-26 – TRANSOM ASSEMBLY 90-12934--2 1097 TRIM POSITION SENDER AND TRIM LIMITSWITCH WIRE REPLACEMENT 1. Remove trim limit switch wires and trim position sender wires. 70197 a - Screwb - Trim Harness Clamp - Removec - Trim Limit Switch Wiresd - Trim Position Sender Wires 2. Install trim limit switch ...

TRANSOM ASSEMBLY - 4B-27 90-12934--2 1097 2. Coat upper swivel shaft with Special Lubricant 101. Check that upper swivel shaft fits all the wayinto gimbal ring. Shoulder on shaft must bottomout against ring. If necessary, clean up matingsurfaces with a file. 23361 a - Gimbal Ringb - Swivel Shaft 3. ...

4B-28 – TRANSOM ASSEMBLY 90-12934--2 1097 6. If removed, install clamping screw and nut on steering lever. 23293 a - Screwb - Nut 7. Thread new, grooved nut all the way onto swivel shaft (to cut threads). Remove nut. 23293 a - Nutb - Swivel Shaft 8. Place steering lever, new nut and washers in posit...

TRANSOM ASSEMBLY - 4B-29 90-12934--2 1097 50541 Engine and Transom Assembly Removed a - Nutb - Wrench (1-1/16 in.) 22445 22461 a - Feeler Gauge - .002-.010 in. (0.05-0.25 mm)b - Washerc - Gimbal Housing Mountd - Gimbal Ring 11. Strike down on gimbal ring flanges using a rawhide mallet. Recheck clear...

4B-30 – TRANSOM ASSEMBLY 90-12934--2 1097 50541 Engine and Transom Assembly Removed a - Wrenchb - Wrench 14. Lubricate upper swivel shaft (through grease fit- ting) with 2-4-C Marine Lubricant on modelsequipped with grease fitting. 23254 a - Grease Fitting (Not Present On Later Models) 15. Install s...

4B-34 – TRANSOM ASSEMBLY 90-12934--2 1097 8. Install water tube through gimbal housing and install rubber grommet over tube. Push grommetinto cavity. 50544 a - Water Tubeb - Rubber Grommet 9. Install water tube cover and tighten screws securely. 23364 a - Water Tube Coverb - Screws 10. Install core ...

4B-36 – TRANSOM ASSEMBLY 90-12934--2 1097 20. Push in on drive unit shift cable while simulta- neously turning propeller shaft counterclockwiseuntil shaft stops, to ensure drive unit is complete-ly in forward gear. Maintain pressure on propellershaft with a suitable device (elastic strap). 21. Measu...

TRANSOM ASSEMBLY - 4B-37 90-12934--2 1097 26. Install trim position sender as follows: a. Models with older style sender, install insulator. b. Align index marks. 22160 Older Style Sender a - Index Marksb - Insulator 22092 Newer Style Sender a - Index Marks c. Install trim position sender. Ensure in...

OILDYNE POWER TRIM PUMP - 5B-1 90-12934--2 1097 Identification All MerCruiser 120R-MR through 260R-MR Stern-drives are equipped with either the Oildyne or Presto-lite Power Trim pump. The Oildyne Power Trim pumpis covered in this section. Refer to “Part B” for Presto-lite pump information. (See “Ind...

5B-2 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 Description The Oildyne Power Trim Pump has internal valvingthat eliminates the need for an external reverse lock,as was required in the past. The pump generates ahigher volume of fluid, but at lower pressure than pre-vious pumps. This, in conjunction ...

OILDYNE POWER TRIM PUMP - 5B-3 90-12934--2 1097 New Adaptor And Reservoir Later production Oildyne pumps are equipped with anew adaptor. Accompanying this change, analuminum (instead of stamped steel) oil reservoirwas utilized. 50472 New Adaptor Identification a - Adaptorb - Date Code Letter (Follow...

5B-4 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 Maintaining Power TrimPump Oil Level ! CAUTION Fill/Vent screw MUST BE backed out one (1) fullturn (after bottoming out) to vent pump reservoir.FAILURE TO BACK SCREW OUT COULDRESULT IN DAMAGE TO PUMP. IMPORTANT: Check oil level wIth sterndrive unitin t...

OILDYNE POWER TRIM PUMP - 5B-7 90-12934--2 1097 3. Run pump OUT/UP until gauge reading reaches 2200 - 2600 psi (15173 - 17932 kPa). Stop pump-ing UP. Pressure should not fall below 1900 psi(13104 kPa). • Gauge Reading NOT Below 1900 PSI(13104 kPa), UP Pressure Test completed. • Gauge Reading Below 1...

5B-10 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 Trim Cylinder Shock PistonTest If trim system checks out good, but drive unit will nottrim IN/DOWN, problem may be due to a leaky trimcylinder shock piston. Use the following test to checkfor this condition. Test gauge is not required. 1. Run pump in ...

OILDYNE POWER TRIM PUMP - 5B-17 90-12934--2 1097 Manual Release Valve Replacement(If Equipped) NOTE: Refer to “Special Information.” NOTE: Replacement of manual release valve can becompleted without removing the trim pump fromboat. O-ring damage may result from the following: • Operation of the Powe...

5B-18 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 UP Pressure Relief ValveReplacement NOTE: UP pressure relief valve in kit is color codedblue for easy identification. NEW ADAPTOR OLD ADAPTOR 50474 a - O-ringb - UP Pressure Relief Valve IMPORTANT: When installing a replacementpressure relief valve, D...

OILDYNE POWER TRIM PUMP - 5B-19 90-12934--2 1097 IMPORTANT: When installing a replacementpressure relief valve, DO NOT loosen nor attemptto remove hex “jam” nut. This valve is preset atthe factory for proper DOWN pressure relief. NOTE: Original factory installed pressure reliefvalves will be a natur...

5B-20 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 Replacement Plug - Trail-Out Valve NOTE: Refer to “Special Information” (See “Index”). 1. Remove and discard trail out valve assembly. 2. Install replacement plug with O-ring. Be sure that threaded valve hole is clean and free of foreignmaterial. 3. T...

OILDYNE POWER TRIM PUMP - 5B-23 90-12934--2 1097 6. Clean hex plug retainers and spool. 70867 a - O-ringsb - Hex Plug Retainersc - Springsd - Poppet Valvese - Check Valve Bodiesf - Spool 7. Lubricate check valve body O-rings with power trim and steering fluid, or with 10W-30 or 10W-40motor oil. ! CA...

OILDYNE POWER TRIM PUMP - 5B-25 90-12934--2 1097 4. Remove and replace O-rings on pump base. 5. Install new seal with lips toward pump. Oil seal can be pressed in by hand. 6. Lubricate lip of seal with light weight oil. 50474 a - Oil Seal - Lip Toward Pumpb - O-ringsc - Pump 7. Install pump and torq...

5B-26 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 3. Remove motor assembly. Remove O-ring from motor base. 50476 a - Locknuts (Studs May Turn Out)b - DO NOT Loosen 4. Disassemble motor as follows: a. Remove end frame caps. b. Remove thrust washer (if equipped). c. Remove armature from field and frame...

OILDYNE POWER TRIM PUMP - 5B-27 90-12934--2 1097 TEST FOR SHORTS 1. Check armature on a growler (follow growler manufacturers instructions). Indication of a shortrequires replacement. CLEANING COMMUTATOR NOTE: If commutator is worn it can be turned downon a lathe or an armature conditioner tool. 1. ...

5B-28 – OILDYNE POWER TRIM PUMP 90-12934--2 1097 2. Connect ohmmeter between field brush lead and GREEN/WHITE lead. Zero Ohms Indicated (Full Continuity): Field OK.Zero Ohms Not Indicated (No Continuity): Re-place field assembly. 50510 a - Ohmmeter Lead - Connected to Brush Leadb - Ohmmeter Lead - C...

OILDYNE POWER TRIM PUMP - 5B-31 90-12934--2 1097 9. Install studs, coupling and new O-ring. 10. Install coupling with shallow slot toward oil reservoir. 11. Liberally lubricate coupling with 2-4-C Marine Lubricant. 50471 a - Coupling (Shallow Slot Toward Oil Reservoir)b - O-ring 12. Install motor as...

OILDYNE POWER TRIM PUMP - 5B-33 90-12934--2 1097 Wiring Diagram 26351

6B-2 – STEERING SYSTEM 90-12934--2 1097 Steering Cable Selection,Removal, and Installation Selection Steering system has the steering cable guide tubeset for cables with end dimensions which comply withthe BIA Certification Handbook. ! CAUTION If cables with improper dimensions are installed,severe ...

STEERING SYSTEM - 6B-3 90-12934--2 1097 Removal 1. Remove cotter pin, clevis pin and locking sleeve. Unthread the cable coupler nut and removesteering cable. 22055 a - Cotter Pinb - Clevis Pinc - Locking Sleeved - Cable Coupler Nute - Steering Cable Installation 1. Liberally coat steering cable end ...

6B-4 – STEERING SYSTEM 90-12934--2 1097 Manual Steering Swivel RingComponent Repair Removal 1. Remove steering cable. 22055 a - Cotter Pinsb - Clevis Pinc - Locking Sleeved - Cable Coupler Nut 2. Remove manual steering swivel ring. Be sure to bend tab on tab washer away from pivot bolt be-fore remov...

6B-6 – STEERING SYSTEM 90-12934--2 1097 3. HAND THREAD pivot bolts all the way into inner transom plate and swivel ring. DO NOT use awrench. Straddle tab washer tangs on inner tran-som plate ridge. 22944 a - Pivot Boltsb - Tab Washerc - Swivel Ring 4. Torque bolts to 25 lb. ft. (35 N·m). Bend washer...

TROUBLESHOOTING - 1C-1 90-12934--2 1097 Troubleshooting This section is a guide for performance and producttroubleshooting. Referrals to specific sections of thismanual are made where special tests or repair proce-dures are to be performed. Because of the relationship between Power Packagecomponents...

1C-2 - TROUBLESHOOTING 90-12934--2 1097 Drive Unit Does Not Shift Into Gear; Remote Control Shift Handle Does NotMove Cause Remedy 1. Control box not properly assembled. 1. Properly reassemble control box. 2. Broken or damaged linkage in control box. 2. Repair linkage. 3. Controls improperly adjuste...

TROUBLESHOOTING - 1C-3 90-12934--2 1097 Drive Unit In Gear, Will Not Shift Out Of Gear Cause Remedy 1. Shift cable broken. 1. Replace cable and adjust. 2. Cable end not connected in drive unit. 2. Remove and reinstall drive unit. 3. Remote control damaged. 3. Repair or replace remote control. 4. Int...

1C-4 - TROUBLESHOOTING 90-12934--2 1097 Drive Shaft Housing Noise Cause Remedy 1. Steering lever contacting transom cutout opening in turns. 1. Modify transom cutout. 2. Engine flywheel housing contacting inner transom plate or exhaust pipe. 2. Determine cause for interference (loose engine mounts, ...

TROUBLESHOOTING - 1C-7 90-12934--2 1097 Performance Troubleshooting Low Full-Throttle Engine RPM Cause Remedy 1. Improper drive unit trim angle. 1. Properly adjust drive unit trim angle. 2. Damaged propeller. 2. Repair or replace. 3. Improper propeller pitch. 3. Water test boat using a lower pitch p...

1C-8 - TROUBLESHOOTING 90-12934--2 1097 Poor Boat Performance And/Or Poor Maneuverability-Bow Too Low Cause Remedy 1. Improper drive unit trim angle. 1. Properly adjust drive unit trim angle. 2. Boat is bow heavy. 2. Redistribute boat load to stern. If bow over weigh is caused by permanently install...

TROUBLESHOOTING - 1C-9 90-12934--2 1097 Steering SystemTroubleshooting If Power Package is equipped with Power Steering,first determine if problem is caused by the PowerSteering System or Ride Guide portion of the steer-ing system. Proceed as follows: 1. Remove clevis pin which attaches steering cab...

1C-10 - TROUBLESHOOTING 90-12934--2 1097 Power Steering System External Fluid Leaks Cause Remedy 1. Pump reservoir leaking at fill cap (reservoir too full). 1. Remove fluid to bring to proper level. 2. Pump reservoir leaking at fill cap (air or water in fluid). 2. Locate source of air or water and c...

TROUBLESHOOTING - 1C-11 90-12934--2 1097 Power Trim Electrical System Power Trim Pump Motor Will Not Run In The Out/Up Or In/Down Direction(Solenoids Do Not Click) IMPORTANT: Refer to wiring diagram at end of this section for assistance in electrical system trouble-shooting. Cause Remedy 1. Thermal ...

1C-14 - TROUBLESHOOTING 90-12934--2 1097 Trim Control Out/Up Switch Inoperative (Trailer Switch Operates) Cause Remedy 1. Trim limit switch lead bullet connectors loose or corroded. 1. Clean and/or tighten connections “14,” “15,” “16”and “17” (in wiring diagram), as necessary. 2. Trim limit switch o...

TROUBLESHOOTING - 1C-15 90-12934--2 1097 Power Trim 22252 BLK = BLACKBLU = BLUE BRN = BROWN GRY = GRAY GRN = GREENORN = ORANGE PNK = PINKPUR = PURPLERED = RED TAN = TAN WHT = WHITE YEL = YELLOW LIT = LIGHT DRK = DARK Wiring Diagram (With 3-Button Trim Control)

1C-18 - TROUBLESHOOTING 90-12934--2 1097 Auto Trim Electrical System NOTE: Refer to wiring diagram, following, for assistance in electrical system troubleshooting. Pump Motor Will Not Run Up Or Down In Either Manual Or Auto Mode(Solenoids Click) Cause Remedy 1. Pump positive battery cable connection...

1C-20 - TROUBLESHOOTING 90-12934--2 1097 Pump Motor Will Run Up, But Not Down In Both Manual And Auto Modes(Down Solenoid Clicks) Cause Remedy 1. Loose or dirty solenoid connections. 1. Check connections “10” and “11.” 2. Faulty solenoid. 2. Check for voltage at terminal “11” while trimmingDOWN (in ...

TROUBLESHOOTING - 1C-21 90-12934--2 1097 Pump Motor Will Not Stop Running Down In Auto Mode (Trim Out/Up SwitchAnd Trailer Switch Inoperative In Manual Mode) NOTE: An internal timer in the control module stops the pump motor 50 seconds after this condition occurs. Cause Remedy 1. Loose or dirty sole...

TROUBLESHOOTING - 1C-25 90-12934--2 1097 Auto Trim II System Wiring Diagram 22178 41 42 40 39 44 45 43 36 37 35 32 33 34 38 26 25 46 4 6 5 10 11 24 21 22 23 17 31 30 19 16 15 29 18 14 1 2 7 8 47 13 12 9 BLK = BLACKBLU = BLUE BRN = BROWN GRY = GRAY GRN = GREENORN = ORANGE PNK = PINKPUR = PURPLERED = ...

TROUBLESHOOTING - 1C-29 90-12934--2 1097 Oil Foams Out Of Pump Fill/Vent Screw Cause Remedy 1. Contaminated oil. 1. Flush system with clean oil refill pump and bleedtrim system. 2. Oil level low. 2. Check for cause of low oil level and correct. Add oil to pump and bleed system. The Trim Pump Motor R...

73552 9 1 2 5 7 8 5 3 4 6 10 11 1C-30 - TROUBLESHOOTING 90-12934--2 1097 Power Trim Hydraulic Schematic 1 - Shuttle2 - Pump Adaptor3 - Out/Up PressureRelief Valve 4 - Thermal Relief Valve 5 - Trim Cylinder6 - IN/DOWN Pressure ReliefValve 7 - Out/Up Hose 8 - IN/DOWN Hose 9 - Pilot Check Valves 10 Gim...

TROUBLESHOOTING - 1C-31 90-12934--2 1097 Power Trim System Troubleshooting - Hydraulic System onPrestolite Trim Pump Drive Unit Cannot Be Trimmed OUT/UP Or Trims Slowly Or with JerkyMovements (Numbers refer to callouts on the Oildyne Trim System Diagram P. 1C-21) Cause Remedy 1. Power trim pump oil ...

1C-32 - TROUBLESHOOTING 90-12934--2 1097 Drive Unit Will Not Stay In Full OUT/UP Position For Extended Periods Cause Remedy 1. External leakage. 1. Check for cause and correct. Add oil to pump (1)and bleed trim system. 2. Pump OUT/UP circuit (3) (4) (5) leaking internally. 2. Test as explained follo...

TROUBLESHOOTING - 1C-33 90-12934--2 1097 Prestolite Trim System Diagram

1C-34 - TROUBLESHOOTING 90-12934--2 1097 Corrosion Protection Corrosion Of Underwater Parts, Without Mercathode Or Current Protection Cause Remedy 1. Sacrificial anode(s) consumed. 1. Replace anode(s) when 50% consumed. 2. Stainless steel propeller installed. 2. Add Mercathode (impressed current pro...

TROUBLESHOOTING - 1C-37 90-12934--2 1097 Corrosion Troubleshooting Procedures 1. Unplug shore power (if equipped). 2. Measure hull potential with silver/silver chloride reference electrode and digital volt/ohm meter. READINGS Potential Diagnosis1 Below 850 millivolts Drive is corroding, see (DRIVE C...

1C-38 - TROUBLESHOOTING 90-12934--2 1097 Shift SystemTroubleshooting NOTE: Some models may be equipped with a shiftassist assembly. The only difference with these mod-els is that the remote control shift cable attachinghardware is slightly longer. Shift cable adjustment isthe same as all other versi...

TROUBLESHOOTING - 1C-39 90-12934--2 1097 IMPORTANT: When pushing or pulling on driveunit shift cable in the following steps, applyenough pressure so that shift cutout switch roll-er starts to move off center of notch, then ease upslightly. Use a fine tip marking device to markthreaded tube to obtain...

1C-40 - TROUBLESHOOTING 90-12934--2 1097 Boat In Water (Engine Running) ! WARNING • At least two people will be needed for the fol-lowing procedure, one person to check theadjustment and one person to stay at the con-trol station of the boat. • Ensure boat is secured to dock and precau-tions have be...

TROUBLESHOOTING - 1C-41 90-12934--2 1097 4. Check for excessive play in drive unit shift system as follows: a. Push in on drive unit shift cable. b. Place a mark on shift cable threaded tube, against cable end guide. 50499 a - Drive Unit Shaft Cableb - Threaded Tube c. Lightly pull on drive unit shi...

1C-42 - TROUBLESHOOTING 90-12934--2 1097 b. Rotate shift shaft coupler clockwise while si- multaneously turning propeller shaft counter-clockwise until clutch locks into gear. Makenote of pointer location on scale. 50498 a - Shift Shaft Couplerb - Pointerc - Scale c. While maintaining pressure on pr...

TROUBLESHOOTING - 1C-43 90-12934--2 1097 2. Place remote control into the opposite gear from that established in step 1. Measure the distancebetween the edge of the shift cable end guide andthe mark in step 1. Total shift cable output mustnot be less than 2-7/8 in. (73 mm) or more than3-1/8 (80 mm)....

1C-44 - TROUBLESHOOTING 90-12934--2 1097 Checking Cutout Switch Timing 1. Disconnect cutout switch white/green wire from terminal block. 2. Connect ohmmeter positive (+) lead to cutout switch white/green wire and ohmmeter negative(-) lead to cutout switch black wire at terminalblock. 3. Set ohmmeter...

TROUBLESHOOTING - 1C-45 90-12934--2 1097 While shifting, rotate propeller shaft clockwise.Clutch should engage and cause propeller shaft tolock. If clutch does not engage, loosen adjustablestud on shift lever and move it upward in slot untilclutch engages with gear. Retighten stud. Shift re-mote con...

3C-12 - IR GEAR HOUSING 90-12934--2 1097 Gear Housing Disassembly NOTE: If O-ring remains lodged between upper driveshaft seals (in drive shaft housing), be sure to removeO-ring or reassembly will be impaired. 1. Remove components shown. 23266 a - O-ring (On Units With O-ring Groove)b - Water Tubec ...

IR GEAR HOUSING - 3C-13 90-12934--2 1097 5. Straighten tabs on bearing carrier tab washer. 50312 a - Tab On Tab Washer 6. Remove bearing carrier retainer following step “a” or “b” as follows: a. Remove bearing carrier retainer using bear- ing carrier retainer wrench (P/N 91-61069). 23347 a - Bearing...

3C-14 - IR GEAR HOUSING 90-12934--2 1097 FOR CURRENT STYLE UNITS: d. Pull the bearing carrier from the gear housing by pulling on the outer ring of the bearingcarrier. NOTE: If the bearing carrier is seized in the gearhousing, it may be necessary to use heat to loosenthe carrier. 70492 Current Style...

IR GEAR HOUSING - 3C-15 90-12934--2 1097 e. If Drive Shaft is Broken: Place pinion nut adaptor over propeller shaft and onto pinionnut. Shift gear housing into forward gear.Turn propeller shaft counterclockwise to turngears, thus removing pinion nut. NOTE: Propeller Shaft Tool 91-61077 is includedwi...

IR GEAR HOUSING - 3C-17 90-12934--2 1097 WATER PUMP DISASSEMBLY 1. Remove water pump base O-ring and gasket. 23348 a - O-ringb - Gasket 2. Remove water pump base oil seals using a screw driver to pry each one out individually. 23347 a - Water Pump Baseb - Screw Driverc - Oil Seals (2) 3. If water pu...

3C-22 - IR GEAR HOUSING 90-12934--2 1097 ! CAUTION Clamp on reinforcing rib of bearing carrier ONLY,or damage to carrier may result. 2. Place bearing carrier in vise, clamping on carrier reinforcing rib. 3. Using Slide Hammer Puller 91-34569A1, remove, as an assembly, reverse gear, thrust ringand be...

IR GEAR HOUSING - 3C-23 90-12934--2 1097 7. Perform step “a” or “b” as necessary. a. If Replacing Propeller Shaft Needle Bear- ing and Seals: Remove needle bearing andseals with tools as shown. 23140 a - Needle Bearingb - Oil Sealsc - Puller Head (91-36569)d - Bearing Driver Rod (91-37323) b. If Rep...

IR GEAR HOUSING - 3C-27 90-12934--2 1097 PROPELLER SHAFT, FORWARD GEAR ANDBEARING AND SHIFT SPOOL ASSEMBLYINSPECTION AND CLEANING 1. Inspect forward gear for pitting, chipped or bro- ken teeth, fracturing and excessive or unevenwear. 2. Check forward gear clutch jaws for damage. Jaws must not be chi...

IR GEAR HOUSING - 3C-31 90-12934--2 1097 4. Install rubber washer and then stainless steel washer onto shift shaft. 23354 a - Stainless Steel Washer (Rubber Washer Beneath) DRIVE SHAFT AND PINION GEARINSTALLATION (Without Propeller Shaft inPlace) IMPORTANT: If unit does not require reshimming(no par...

3C-32 - IR GEAR HOUSING 90-12934--2 1097 4. Place pinion gear in gear housing. 5. Insert drive shaft in bore. Rotate drive shaft to en- gage splines in drive shaft. Install pinion nut withthe machined shoulder against the pinion gear. Ifboth sides of the nut have a machined shoulder,then either shou...

IR GEAR HOUSING - 3C-37 90-12934--2 1097 6. Install bearing carrier retainer. Torque to 200 lb. ft. (285 N·m). 23355 a - Bearing Carrier Retainer Wrench (91-61069) IMPORTANT: Do not secure bearing carrier re-tainer by bending tab on tab washer until forwardand reverse gear backlash have been checked...

3C-38 - IR GEAR HOUSING 90-12934--2 1097 NOTE: Take the following backlash readings at 4locations, rotating drive shaft 90 at a time. 5. Lightly turn drive shaft back-and-forth, so as to feel backlash between gears (no movementshould be noticed at propeller shaft). Dial indicator MUST register .020-...

3C-40 - IR GEAR HOUSING 90-12934--2 1097 WATER PUMP INSTALLATION 1. If O-ring groove is present, cover drive shaft O-ring groove with a piece of tape. 50456 a - Tape On O-ring Groove (If O-ring Groove is Present) 2. Lubricate water pump base oil seal lips with 2-4-C Marine Lubricant and install wate...

PRESTOLITE POWER TRIM PUMP - 5C-1 90-12934--2 1097 Identification Some MerCruiser Sterndrives will be equipped witha Prestolite Power Trim pump. This pump was usedinterchangeably with the Oildyne pump for a periodof time. 50524 Prestolite Power Trim Pump Specifications Valve Pressure Specifications ...

5C-2 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 Description The Prestolite Power Trim Pump has internal valvingthat eliminates the need for an external reverse lock,as was required in the past. The pump generates ahigher volume of fluid, but at a lower pressure thanprevious Prestolite pumps. This...

5C-4 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 Testing Power Trim Pump Connecting Test Gauge 1. Check trim pump oil level. Fill if necessary. 2. Place drive unit in the full IN/DOWN position. 3. Connect test gauge at the most convenient loca- tion (at pump or hydraulic connector). 26344 Gauge Co...

5C-6 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 2. Connect gauge at most convenient location. 26345 Gauge Connected at Pump a - Hydraulic Test Gauge 91-52915A3b - Fitting (22-77366)c - Fittings (Supplied with Gauge)d - Black Hydraulic Hose (From Gimbal Housing)e - Gray Hydraulic Hose (From Gimbal...

PRESTOLITE POWER TRIM PUMP - 5C-11 90-12934--2 1097 5. IN/DOWN Solenoid: a. Connect 12 volt positive (+) supply lead to GREEN/WHITE harness wire terminal. b. Connect negative (-) supply lead to solenoid ground terminal. c. Connect ohmmeter leads to large terminals on solenoid. 50521 a - IN/DOWN Sole...

PRESTOLITE POWER TRIM PUMP - 5C-13 90-12934--2 1097 Trim Pump Removal 1. Disconnect trim pump battery leads from battery (negative lead first). 2. Disconnect trim harness connector (3 pronged) from trim pump. 3. Remove hydraulic hoses from trim pump. Cap end of hoses. 4. Remove lag bolts and washers...

5C-14 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 2. Remove mounting bolts and remove trim pump from floor bracket. 50522 50522 a - Trim Pumpb - Floor Bracketc - Mounting Bolts 3. Remove solenoids (if replacement is necessary). 50520 a - UP Solenoidb - DOWN Solenoidc - Mounting Bolts (2 On Each So...

5C-16 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 2. Remove solenoid plate and connector and harness. 50459 a - Solenoid Plateb - Nutc - Screwsd - Solenoidse - Spacerf - Connector and Harness 3. Remove valve body and gear assembly. 50460 a - Screws (8)b - Valve Body And Gear Assemblyc - Seal (Not ...

PRESTOLITE POWER TRIM PUMP - 5C-17 90-12934--2 1097 Armature Tests CONTINUITY TEST 1. Check armature for continuity. Set ohmmeter on Rx1 scale. Connect leads as shown. Continuity Indicated: Armature is grounded (re-place armature). Continuity Not Indicated: Armature is OK. 50461 a - Ohmmeterb - Mete...

5C-18 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 TEST FOR SHORT IN FIELD 1. Set ohmmeter on Rx1 scale. Connect ohmmeter between field brush lead and field frame. Zero Ohms Indicated (full continuity) - Shortindicated (Replace field assembly). Zero Ohms Not Indicated (no continuity) - Field OK. 50...

PRESTOLITE POWER TRIM PUMP - 5C-19 90-12934--2 1097 Brush Replacement Inspect brushes and replace if: • Pitted • Chipped • Brush is less than 1/4 in. (6mm) long • Leads are fraying BRUSH REPLACEMENT 1. Cut brush leads off as close to brush holders as possible. 2. Using 70-30 tin-lead alloy rosin cor...

5C-20 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 Reassembly 1. Install armature and washers. 26506 a - Large Washerb - Small Washer(s)c - Armatured - Reservoire - Long Studf - Sleeve (1)g - Small Studh - Connector And Harness Holder 2. Install field and frame assembly. Align index mark on field a...

5C-22 – PRESTOLITE POWER TRIM PUMP 90-12934--2 1097 9. Install trim pump on floor bracket. Tighten securely. 50522 50522 a - Trim Pumpb - Floor Bracketc - Screws and Lock Washers Trim Pump Installation 1. Secure pump and mounting bracket to boat using lag bolts and washers. 2. Reconnect trim hoses t...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-1 90-12934--2 1097 Identification The Alpha One counter rotating gear housing can beidentified by the letter “L” stamped at the end of thepropeller shaft. Specifications Torque Specifications DESCRIPTION TORQUE DESCRIPTION lb. in. lb. ft. N ⋅ m Nuts-Water...

3D-4 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 The following is a supersession list to use when ordering the Gear Housing Only for replacement of the originallower unit. ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Gear Housing Only Supersession List ÁÁÁÁÁ Á...

3D-6 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 Exploded View - Alpha One Counter Rotating Gear Case 23135 17 18 17 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 19 20 21 22 23 24 25 26 29 30 31 32 33 34 35 36 37 27 28 40 41 42 43 44 45 46 47 48 38 39 51 52 49 50

3D-10 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 Separate Drive ShaftHousing From Gear Housing 1. Tilt drive unit at a 45 degree angle, remove fill/ drain screw; then remove oil vent screw. Allowdrive unit to drain completely. 23263 23266 a - Fill/Drive Screwb - Vent Screw 2. Remove ...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-11 90-12934--2 1097 b. Remove locknut from front side of drive shaft housing. c. Loosen locknuts (one on each side of gear housing). DO NOT attempt to remove one nutbefore opposite side is loosened sufficientlyor drive shaft housing could be damaged. d. P...

3D-14 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 9. Remove rear thrust bearing. 50786 a - Thrust Bearing 10. Remove rear thrust collar. 50787 a - Thrust Collar 11. Lift up on propeller shaft and push down on front thrust collar to remove two keepers. 50778 50826 a - Thrust Collarb - ...

3D-16 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 NOTE: The thrust race that must be removed in thefollowing step has a tight fit in the gear housing bore.Use Special Tool (91-815850) to attempt to removethrust race and forward gear together. If this attemptfails, form a small hook on...

3D-20 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 c. Locate and retain thrust race and thrust bearing which could be on top of reverse gear(If not, they may be stuck to reverse gearbearing adaptor). 50887 b - Thrust Bearing And Race 24. Remove reverse gear bearing adaptor and shims us...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-21 90-12934--2 1097 26. Loosen shift shaft bushing. 23354 a - Shift Shaft Bushing Tool (91-31107) 27. Lift shift shaft assembly and shift shaft bushing from gear housing. Remove shift crank from gearhousing. 23355 a - Shift Shaft Assemblyb - Shift Shaft B...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-23 90-12934--2 1097 Water Pump Reassembly 1. Coat O.D. of small seal with Loctite 27131. Press seal into water pump base from bottom, with lipof seal facing water pump base, using Oil SealDriver (91-44110). 23139 a - Oil Sealb - Oil Seal Driver (P/N 91-44...

3D-24 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 5. Install water tube seal. Lubricate inside diameter with 2-4-C Marine Lubricant. 23351 a - Water Tube Seal Drive Shaft and Pinion BearingInspection and Cleaning 1. The condition of the drive shaft bearing cup is an indication of the ...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-25 90-12934--2 1097 Pinion Bearing Installation 1. If needle bearings have fallen over in casing, install needles using Needle Bearing AssemblyLubricant (92-825265A1) to help hold needles inplace. If new bearing is being installed, leavecardboard shipping...

3D-26 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 2. Check bearing carrier for signs of corrosion, es- pecially in area where bearing carrier mates withgear housing. If corrosion is excessive, replacecarrier. 50818 a - Bearing Carrierb - Mating Surfaces 3. Inspect bearing carrier reta...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-27 90-12934--2 1097 Bearing Carrier Reassembly 1. Press needle bearing into bearing carrier until tool bottoms on bearing carrier. Ensure num-bered side of needle bearing faces seal end ofcarrier. 50788 a - Needle Bearingb - Bearing Carrierc - Bearing Dri...

3D-28 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 Forward Gear Bearing AdaptorDisassembly and Inspection 1. Inspect bearing and race for pitting and scoring and any other visible signs of damage. Replaceif damaged. 2. Inspect bearing adaptor for damage. Ensure thrust bearing race cont...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-29 90-12934--2 1097 Propeller Shaft, Reverse Gear andShift Spool Disassembly 1. Remove spring from clutch. 50885 a - Springb - Clutch 2. Remove pin from clutch, slide spool assembly out of propeller shaft, remove reverse gear andslide clutch off of propel...

3D-32 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 Propeller Shaft, Reverse Gear andShift Spool Reassembly IMPORTANT: The appearance of the forward andreverse gear is almost identical. There are twoways to distinguish between reverse and forwardgears. Reverse gear has a shorter hub and...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-33 90-12934--2 1097 Shift Shaft Disassembly 1. Remove shift shaft components as shown. 23354 a - Shift Shaft Bushingb - O-ringc - Washerd - Clipe - Shift Shaft Shift Shaft Inspection and Cleaning NOTE: If oil seal in shift shaft bushing is found to bedefe...

3D-34 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 Reverse Gear Bearing Adaptor RollerBearing Replacement 1. Press needle bearing from bearing adaptor using a suitable mandrel. 2. Inspect bearing and adaptor for damage and replace if necessary. 3. Apply a light coat of Special Lubrican...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-35 90-12934--2 1097 3. Coat threads of bushing with Perfect Seal and thread shift shaft bushing into gear housing.Torque to 50 lb. ft. (68 N·m) using shift shaftbushing tool. 50317 a - Shift Shaft Bushing Tool (91-31107) ! WARNING Failure to install the s...

3D-36 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 4. Press bearing adaptor into gear housing using Installation Tool (91-18605A2) as follows: IMPORTANT: Be sure that bearing adaptor ispositioned as straight as possible to avoid cock-ing it in bore while pressing it in. a. Lubricate th...

3D-38 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 CHECKING PINION GEAR HEIGHT Current Style Preload Tool Installation 1. Install the components from the Bearing Preload Tool Kit (91-14311A1), over the drive shaft in theorder shown. 75750 a - Top Nut With Threaded Pipeb - Nutc - Spring...

3D-40 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 6. Measure pinion height as follows: a. Place pinion gear shimming tool in gear housing. NOTE: Take the following measurements at 3locations, rotating drive shaft and pinion gear 120degrees at a time. b. Insert a .025 in. (0.64 mm) fee...

3D-42 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 7. Place Installation Tool (91-815850) through for- ward gear as shown. 50880 a - Installation Tool 8. Lower forward gear with thrust bearing and race down over propeller shaft. Ensure thrust race isseated against shim by tapping it do...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-43 90-12934--2 1097 11. Begin lowering bearing carrier down over propel- ler shaft. Once carrier is over end of shaft, hold upon propeller shaft until bearing carrier is fullyseated. 50888 a - Bearing Carrier 12. Install tab washer and bearing carrier ret...

3D-46 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 22. Remove drive shaft retainer and lift out drive shaft. Insert cardboard sleeve into pinion bearingto keep rollers from falling out. 23352 a - Retainer Checking Reverse Gear Backlash 1. Ensure bearing adaptor race surface is clean. C...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-47 90-12934--2 1097 4. Place shim(s) in drive shaft housing bore. 23351 a - Shim(s) NOTE: For ease of installation, glue washer to piniongear, using 3M Adhesive (92-86166-1) or equivalent. 5. Place pinion gear and washer in gear housing. 6. Insert drive s...

3D-48 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 10. Partially install bearing carrier retainer nut (to protect threads) and torque pinion nut to 60-80 lb.ft. (81-108 N·m). 50890 a - Drive Shaft Nut Wrench (91-56775)b - Torque Wrenchc - Socketd - Breaker Bare - Bearing Carrier Retain...

3D-52 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 24. Remove drive shaft retainer and lift out drive shaft. 23352 a - Retainer 25. Remove reverse gear. Thrust bearing and thrust race should be left in gear housing. 50884 a - Reverse Gear Gear Housing Reassembly 1. Position shift crank...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-53 90-12934--2 1097 3. With propeller shaft tilted to the left (port) side of gear housing, continue to lower propeller shaftassembly until reverse gear hub comes in con-tact with the reverse gear bearing adaptor andthe propeller shaft is fully inserted i...

3D-54 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 b. Apply Loctite 27131 or Type “A” to pinion nut threads. c. Place pinion nut on pinion nut adaptor. NOTE: To aid in installation, glue the pinion nut wash-er to the pinion gear. d. Install drive shaft and pinion gear. Rotate drive sha...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-55 90-12934--2 1097 h. Torque retainer to 100 lb. ft. (130 N·m). 23343 a - Drive Shaft Bearing Retainer Tool (P/N 91-43506) i. Torque pinion nut by turning drive shaft usingpinion nut wrench and torque wrench withappropriate socket, to 60-80 lb. ft. (81-1...

3D-56 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 9. Use Forward Gear Installation Tool (91-815850) to install forward gear down over propeller shaft.Ensure thrust race seats evenly on shim. Tapdown lightly using a soft punch. 50783 a - Forward Gear Installation Toolb - Forward Gear 1...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-57 90-12934--2 1097 13. Install thrust collar with stepped side down. Seat collar in bearing. 50784 a - Thrust Collar 14. Pull up lightly on propeller shaft to expose groove for keepers. Install two keepers in groove andlower propeller shaft to hold them ...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-59 90-12934--2 1097 20. Install tab washer as shown. 50779 a - Tab Washer 21. Apply Special Lubricant 101 to threads of bearing carrier retainer and install in gear housing. 50790 a - Bearing Carrier Retainer 22. Torque bearing carrier retainer to 210 lb....

3D-60 - ALPHA ONE COUNTER ROTATION GEAR HOUSING 90-12934--2 1097 WATER PUMP INSTALLATION 1. On units with O-ring and O-ring groove, cover drive shaft O-ring groove with a piece of tape. 50312 2. Lubricate water pump base, O-ring and oil seal lips with 2-4-C Marine Lubricant. Install waterpump base a...

ALPHA ONE COUNTER ROTATION GEAR HOUSING - 3D-63 90-12934--2 1097 NOTE: If propeller shaft is rotated in a clockwisedirection before shift shafts are coupled, gear hous-ing must be shifted back into reverse gear and heldin position. 7. Align water tube with tube guide and drive shaft and shift shaft ...

TRIM CYLINDERS - 5D-1 90-12934--2 1097 Specifications Torque Specifications DESCRIPTION TORQUE DESCRIPTION lb. in. lb. ft. N ⋅ m Piston Rod Bolt 15-20 20-27 Trim Cylinder Anchor PinBolts Tighten Until Nuts Bottom On Anchor Pin Shoulder End Cap 40-50 55-68 Lubricants/Sealers/Adhesives NOTE: Prior to ...

5D-2 - TRIM CYLINDERS 90-12934--2 1097 3. Remove front and rear power trim cylinder mounting hardware. 22133 a - Front Anchor Pinb - Large I.D. Washers (Port And Starboard)c - Rubber Bushings (2) (Port And Starboard)d - Small I.D. Washers (Port And Starboard)e - Locknuts (Port And Starboard)f - Plas...

TRIM CYLINDERS - 5D-5 90-12934--2 1097 Reassembly IMPORTANT: Later model Alpha One drive unitsuse a trim cylinder that is 3 / 4 in. (19mm) longer, to achieve 6 additional tilt. Earlier model R, MR and Alpha One, as well as Bravo drive units, use theshorter trim cylinder. DO NOT attempt to substi-tut...

TRIM CYLINDERS - 5D-7 90-12934--2 1097 ! CAUTION Ensure work area and all components are cleanbefore reassembling trim cylinders. Power Trimcomponents can become damaged if dirt getsinto system. NOTE: Before reassembly, lubricate all internal partswith Quicksilver Power Trim and Steering Fluid orSAE...

DUAL POWER TRIM CONTROL - 5E-1 90-12934--2 1097 Important information When testing this Dual Power Trim system, take spe-cial note of the following: 1. Control box harness connectors must be discon- nected and key switch must be “OFF.” 2. Make certain that the jumper lead used between terminal 3 and...

5E-2 - DUAL POWER TRIM CONTROL 90-12934--2 1097 Trailer Switch Test ! CAUTION Remove fuse from red/purple harness lead be-fore proceeding with test. 1. Set ohmmeter on Rx1 scale. 2. Push down on “TRAILER” switch and check for continuity between terminals 10 and 3. • Continuity Indicated: proceed to ...

DUAL POWER TRIM CONTROL - 5E-3 90-12934--2 1097 4. Install new relay. IMPORTANT: Use 63/67 (Tin/Lead) alloy solder.DO NOT use acid core solder as damage to relaycan result. Coat terminal connections withQuicksilver Liquid Neoprene (92-25711). 5. Resolder wires from terminal block to relay as shown. ...

5E-6 - DUAL POWER TRIM CONTROL 90-12934--2 1097 22129 CONTROL BOX WIRING

22178 POWER TRIM BLK Black BLU Blue BRN Brown GRY Gray GRN Green ORN Orange PNK Pink PUR Purple RED Red TAN Tan WHT White YEL Yellow LIT Light DRK Dark AUTO TRIM II SYSTEM WIRING DIAGRAM AUTO TRIM AND AUTO TRIM II - 5F-1 90-12934--2 1097 Auto Trim System Description NOTE: The only difference between...

5F-2 - AUTO TRIM AND AUTO TRIM II 90-12934--2 1097 Auto Trim Operation The Auto Trim system is designed to allow either au-tomatic or manual trimming of the boat while under-way – in addition to allowing drive unit to be raised fortrailering, beaching, launching or shallow water op-eration. A 2-posi...

AUTO TRIM AND AUTO TRIM II - 5F-3 90-12934--2 1097 22212 Quicksilver “Commander” Panel Trim Control a - “Trailer” Switch – Press Until Drive Unit Reaches Desired Height or End of Upward Travel NOTE: Some Power Trim pump motors are protectedfrom overheating by an internal circuit breaker. Iftrailerin...

5F-4 - AUTO TRIM AND AUTO TRIM II 90-12934--2 1097 ! CAUTION NEVER trim the drive unit “Out” using the “Trail-er” switch(es) while boat is underway. Severedamage to drive unit may result if the unit israised beyond the gimbal ring support flanges atengine speeds above idle RPM. 3. TRIMMING DRIVE UNI...

AUTO TRIM AND AUTO TRIM II - 5F-5 90-12934--2 1097 Adjusting the drive unit “In” from normal position willforce the bow of the boat down, thus increasing thewetted surface of the hull and, in some cases,improving boat ride in rough water (at partial throttle).However, this will reduce boat speed in ...

AUTO TRIM AND AUTO TRIM II - 5F-7 90-12934--2 1097 ! CAUTION While performing this adjustment, use extremecare that engine is not accidentally started andkeep clear area near propeller. 1. Turn ignition key to “RUN” position. 2. Loosen trim position sender retaining screws. 3. Rotate sender, as requ...