ALPHA ONE GENERATION II STERNDRIVE 2 - …

1 ALPHA ONE GENERATION II. STERNDRIVE . 2. 74243. INDEX. Table of Contents Page Page Installation Specifications .. 2 - 1 Standard Rotation Gear Housing Torque Specifications .. 2 - 1 Assembly Specifications .. 2 - 21. Lubricants, Sealers, and Adhesives .. 2 - 1 Pre-Disassembly Inspection .. 2 - 21. Special Tools .. 2 - 1 Pinion Gear Height .. 2 - 21. Transom Specifications .. 2 - 1 Shift Spool End Play .. 2 - 21. Installation Procedures .. 2 - 2 Forward Gear Backlash .. 2 - 22. Transom Assembly Installation .. 2 - 2 Reverse Gear Backlash .. 2 - 22. Power Steering Control Valve and Counter-Rotation Gear Housing Cable Installation .. 2 - 3 Specifications .. 2 - 23. Power Steering Hose Connections .. 2 - 4 Torque Specifications .. 2 - 23. Stern Drive Unit Installation .. 2 - 4 Shimming Specifications .. 2 - 23. Trim Cylinder Connection .. 2 - 4 Lubricants, Sealers, and Adhesives .. 2 - 23. Propeller Installation .. 2 - 5 Special Tools.

2 2 - 24. Drive Shaft Housing Specifications .. 2 - 6 Counter-Rotation Gear Housing Torque Specifications .. 2 - 6 Exploded Parts View .. 2 - 26. Upper Drive Shaft Bearing Preload .. 2 - 6 Drive Shaft Components .. 2 - 26. U-joint Bearing Preload .. 2 - 6 Propeller Shaft Components .. 2 - 28. Gear Shimming Specifications .. 2 - 6 Special Information For Lubricants, Sealers, and Adhesives .. 2 - 6 Counter-Rotation Gear Housing .. 2 - 30. Special Tools .. 2 - 6 Counter-Rotation Gear Housing Drive Shaft Housing Exploded Parts View .. 2 - 8 Assembly Specifications .. 2 - 32. U-Joint and Driven Gear Components .. 2 - 8 Pre-Disassembly Inspection .. 2 - 32. Drive Shaft Components .. 2 - 10 Forward and Reverse Gear Identification .. 2 - 32. Drive Shaft Housing Shimming .. 2 - 11. Pinion Gear Height .. 2 - 32. Gear Distance, Driven Gear .. 2 - 11. Shift Spool End Play .. 2 - 32. Gear Distance, Drive Gear .. 2 - 11. Forward Gear Backlash.

3 2 - 33. Drive Shaft Housing Special Information .. 2 - 12 Reverse Gear Backlash .. 2 - 33. Top Cover Bearing Cup .. 2 - 12 Transom Assembly Specifications .. 2 - 35. Top Cover Bearing Cup Drivers .. 2 - 12 Torque Specifications .. 2 - 35. Standard Rotation Gear Special Tools .. 2 - 35. Housing Specifications .. 2 - 13 Lubricants, Sealers, and Adhesives .. 2 - 35. Torque Specifications .. 2 - 13 ALPHA One Transom Assembly Shimming Specifications .. 2 - 13 Exploded View .. 2 - 36. Lubricants, Sealers, and Adhesives .. 2 - 13 Bell Housing Components .. 2 - 36. Special Tools .. 2 - 14 Gimbal Housing Components .. 2 - 38. Standard Rotation Gear Housing Inner Transom Plate Components .. 2 - 40. Exploded Parts View .. 2 - 16 Gimbal Ring and Steering Lever Drive Shaft Components .. 2 - 16 Components .. 2 - 41. Propeller Shaft Components .. 2 - 18. Special Information For Standard Rotation Gear Housing .. 2 - 20. 2 - 0 ALPHA One GENERATION II STERNDRIVE INDEX 90-806534970 1096.

4 Installation Specifications Transom Specifications a Torque Specifications NOTE: Securely tighten all fasteners not listed below. e c TORQUE. ITEM a lb. in. lb. ft. N m d Exhaust Pipe to Gimbal 23 31 b Housing Screws Propeller Nut 1 55 75. Tighten Nut Until It Steering Cable Coupler Bottoms Out Against Flat Nut Washer, then Loosen 1/2. Turn Steering Cable Coupler b 35 48. Nut Steering system Pivot Bolts 50 68. Transom Assembly f 22170. 23 31. Attaching Screws and Nuts a - Transom Thickness-2-2 1/4 in. (51-57mm). Power Steeringg Hydraulic y b - Transom Surfaces-Parallel to within 1/8 in. ( mm). 23 31. H. Hose Fi i Fittings c - Area Covered by Inner Transom Plate - Flat to within 1/8 in. ( mm). Stern Drive Unit to Bell d - Area Covered by Gimbal Housing Assembly - Flat to within 50 68. Housing Attaching Nuts 1/16 in. ( mm). e - Transom Angle-10 to 16 . 1: Amount specified is MINIMUM. f - Keel (if Equipped) - Remove 4 ft.

5 ( m) forward of transom Lubricants, Sealers, and Adhesives DESCRIPTION PART NUMBER. Quicksilver 2-4-C. Marine Lubricant 92 825407A3. with Teflon Quicksilver Special 92-13872A1. Lubricant 101. Perfect Seal 92-34227-1. Liquid Neoprene 92-25711--2. Quicksilver Engine 92-816391A4. Coupler Spline Grease Special Tools DESCRIPTION PART NUMBER. Alignment Tool 91-805475A1. Assembly 90-806534970 1096 INDEX ALPHA One GENERATION II STERNDRIVE 2 - 1. Installation Procedures ! CAUTION. Steering lever ground wire MUST be positioned as shown or wire may fatigue. Transom Assembly Installation 2 a 4. 1. 70011. 5. 70015. a 2. 3. b 8. 70006. 50632. a 7 2. 2 6. a 50632. 70012. 70005. 7. 1 - Speedometer Tube Pick-up Connection Torque Specification 2 - Locknuts and Flat Washers 3 - Screw a 23 lb. ft. (31 N m). 4 - Steering Lever Continuity Wire 5 - Trim System Wires b 70-90 (8-10 N m). 6 - Shift Cable 7 - Trim Hoses (and MerCathode Wires, if so equipped).

6 8 - Gear Lube Hose Fitting 2 - 2 ALPHA One GENERATION II STERNDRIVE INDEX 90-806534970 1096. Power Steering Control Valve and Cable Installation 7. 5 6 9. 8. 5. 73901. 71906. A. a b 10 3. 2. 1. 4 71903. 71901. 1 - Steering Cable Lubricants, Sealers, and Adhesives 2 - Grease Fitting 3 - Cable Coupler Nut A - Quicksilver Special 4 - Cable Guide Tube Lubricant 101 .. 92-13872A1. 5 - Cable End 6 - Clevis 7 - Clevis Pin Torque Specification 8 - Cotter Pin 9 - Flats on Guide Tube MUST Be Vertical a 35 lb. ft. (47 N m). 10- Pivot Bolt b 50 lb. ft. (68 N m). 90-806534970 1096 INDEX ALPHA One GENERATION II STERNDRIVE 2 - 3. Power Steering Hose Connections STERN DRIVE TO BELL HOUSING CONNECTION. a 73786. a b Typical Hose Routing a - Hose Fittings - Torque Both Fittings to 23 lb. ft. (31 N m). Stern Drive Unit Installation USING THE ALIGNMENT TOOL. 22062. ! CAUTION a - Locknut and Flat Washers - Torque to 50 lb. ft. (68 N m).

7 B - Locknut and Continuity Circuit Washer - Torque to Forcing the alignment tool into position may 50 lb. ft. (68 N m). damage the Gimbal Bearing or Engine Coupler. Do not attempt to force the alignment tool! Trim Cylinder Connection Raise or lower the engine as necessary until align- ment tool moves freely. c e b c a a d a 71463. 70027. a - Alignment Tool a - Aft Anchor Pin b - Gimbal Bearing b - Bushings c - Engine Coupler c - Flat Washers (2). d - E-ring Clips (2). e - Plastic Caps (2). 2 - 4 ALPHA One GENERATION II STERNDRIVE INDEX 90-806534970 1096. Propeller Installation e f a b c d g Typical Propeller a - Propeller Shaft b - Forward Thrust Hub c - Propeller d - Continuity Washer e - Spline Washer f - Tab Washer g - Propeller Nut-Torque to 55 lb. ft. (75 N m). e f a b c d g 70134. Propeller With Flo-Torque Hub a - Propeller Shaft b - Forward Thrust Hub c - Drive Sleeve d - Propeller e - Drive Sleeve Adapter f - Tab Washer g - Propeller Nut-Torque to 55 lb.

8 Ft. (75 N m). 90-806534970 1096 INDEX ALPHA One GENERATION II STERNDRIVE 2 - 5. Drive Shaft Housing Lubricants, Sealers, and Adhesives Specifications DESCRIPTION PART NUMBER. Quicksilver 2-4-C. Marine Lubricant 92-825407A3. Torque Specifications with Teflon NOTE: Securely tighten all fasteners not listed be- Quicksilver U-Joint low. and Gimbal Bearing 92-828052A2. Grease TORQUE 3M Brand Adhesive 92-25234-1. DESCRIPTION. lb. in. lb. ft. N m Quicksilver Bellows 92-86166. Top Cover Screws 17-23 23-31 Adhesive U-joint Retainer Nut 200 271 Quicksilver Needle Bearing Assembly 92-825265A1. Lubricant Oil Vent Screw 30-50. Quicksilver Perfect Seal 92-34227-1. Permatex Ultra Blue Obtain Locally Upper Drive Shaft Bearing Preload Silicone Sealant Quicksilver Special 92-13872A1. TORQUE Lubricant 101. DESCRIPTION Quicksilver High lb. in. N m Performance Gear 92-816026A4. Lube New Bearings 6-15. Used Bearings* Special Tools *Bearings are considered used if spun under load once.

9 DESCRIPTION PART NUMBER. Adaptor 91-38756. U-joint Bearing Preload Bearing Cup Driver 91-38918. TORQUE Bearing Driver Cup 91-33493. DESCRIPTION. lb. in. N m Driver Cup 91-36577. Driver Rod 91-37323. New Bearings 6-10. Driver Tool 91-90774. Oil Seal Driver 91-817570. Used Bearings* Shimming Tool 91-60526. *Bearings are considered used if spun under load once. (Driven Gear). Shimming Tool 91-60523. (Drive Gear). Gear Shimming Specifications Slide Hammer Puller 91-34569A1. GEAR LOCATION Torque Wrench (lb. in.) 91-66274. DESCRIPTION. inches millimeters U-joint Bearing 91-17256. Retainer Wrench Drive Gear .025 Universal Puller Plate 91-37241. Driven Gear .025 2 - 6 ALPHA One GENERATION II STERNDRIVE INDEX 90-806534970 1096. TORQUE CONVERSION CHART. Use the following table to torque the u-joint retainer to 200 lb. ft. (271 N m). Torque Wrench Torque Wrench Reading Length in lb. ft. (N m) to in Inches (cm) Achieve 200 lb.

10 Ft. a (271 N m) of Torque 15 (38) 111 (151). 16 (41) 114 (155). 17 (43) 117 (159). 18 (46) 120 (163). 19 (48) 123 (167). 20 (51) 125 (170). 21 (53) 127 (172). 22 (56) 129 (175). 23 (58) 131 (178). 24 (61) 133 (180). 25 (64) 135 (183). 26 (66) 136 (184). 27 (69) 138 (187). 28 (71) 140 (190). 29 (74) 141 (191). 30 (76) 143 (194). 31 (79) 144 (195). 32 (81) 145 (197). 33 (84) 147 (200). 34 (86) 148 (201). 35 (89) 149 (202). 36 (91) 150 (203). a 26363. a - Torque Wrench Length 90-806534970 1096 INDEX ALPHA One GENERATION II STERNDRIVE 2 - 7. Drive Shaft Housing Exploded Parts View U-Joint and Driven Gear Components D. 13. 12. 8. 11 D. 10. 11. 9. C. 14 a 23. 15. 16. B. 17. 24 19. 18 20. 27 A. 19. 21 4. B 22. 5. 23. 25. 2 26. 3 b 1. 7. 6. 29 28. 70690. 2 - 8 ALPHA One GENERATION II STERNDRIVE INDEX 90-806534970 1096. 1 - Drive Shaft Housing Lubricants, Sealers, and Adhesives 2 - Screw 3 - O-ring A - 2-4-C Marine Lubricant 4 - Spring Assembly with Teflon.