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.

2 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 - 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.

3 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 .. 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.

4 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. Installation Specifications Transom Specifications a Torque Specifications NOTE: Securely tighten all fasteners not listed below.

5 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.

6 F - Keel (if Equipped) - Remove 4 ft. ( 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.

7 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). 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.

8 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). 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).

9 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. 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.

10 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.