ALPHA ONE GENERATION II STERNDRIVE 2 - Marine-J

1 274243 ALPHA ONE GENERATION IISTERNDRIVE2 - 0 ALPHA One GENERATION II Sterndrive90-806534970 1096 Table of ContentsPageInstallation Specifications2 - 1.. Torque Specifications2 - 1.. Lubricants, Sealers, and Adhesives2 - 1.. Special Tools2 - 1.. Transom Specifications2 - 1.. Installation Procedures2 - 2.. Transom Assembly Installation2 - 2.. Power Steering Control Valve and Cable Installation2 - 3.. Power Steering Hose Connections2 - 4.. Stern Drive Unit Installation2 - 4.. Trim Cylinder Connection2 - 4.. Propeller Installation2 - 5.. Drive Shaft Housing Specifications2 - 6.. Torque Specifications2 - 6.. Upper Drive Shaft Bearing Preload2 - 6.. U-joint Bearing Preload2 - 6.. Gear Shimming Specifications2 - 6.. Lubricants, Sealers, and Adhesives2 - 6.. Special Tools2 - 6.. Drive Shaft Housing Exploded Parts View2 - 8.. U-Joint and Driven Gear Components2 - 8.. Drive Shaft Components2 - 10.. Drive Shaft Housing Shimming2 - 11.. Gear Distance, Driven Gear2 - 11.

2 Gear Distance, Drive Gear2 - 11.. Drive Shaft HousingSpecial Information2 - 12.. Top Cover Bearing Cup2 - 12.. Top Cover Bearing Cup Drivers2 - 12.. Standard Rotation Gear Housing Specifications2 - 13.. Torque Specifications2 - 13.. Shimming Specifications2 - 13.. Lubricants, Sealers, and Adhesives2 - 13.. Special Tools2 - 14.. Standard Rotation Gear Housing Exploded Parts View2 - 16.. Drive Shaft Components2 - 16.. Propeller Shaft Components2 - 18.. Special Information For Standard Rotation Gear Housing2 - 20.. PageStandard Rotation Gear Housing Assembly Specifications2 - 21.. Pre-Disassembly Inspection2 - 21.. Pinion Gear Height2 - 21.. Shift Spool End Play2 - 21.. Forward Gear Backlash2 - 22.. Reverse Gear Backlash2 - 22.. Counter-Rotation Gear Housing Specifications2 - 23.. Torque Specifications2 - 23.. Shimming Specifications2 - 23.. Lubricants, Sealers, and Adhesives2 - 23.. Special Tools2 - 24.. Counter-Rotation Gear Housing Exploded Parts View2 - 26.

3 Drive Shaft Components2 - 26.. Propeller Shaft Components2 - 28.. Special Information For Counter-Rotation Gear Housing2 - 30.. Counter-Rotation Gear Housing Assembly Specifications2 - 32.. Pre-Disassembly Inspection2 - 32.. Forward and Reverse Gear Identification2 - 32.. Pinion Gear Height2 - 32.. Shift Spool End Play2 - 32.. Forward Gear Backlash2 - 33.. Reverse Gear Backlash2 - 33.. Transom Assembly Specifications2 - 35.. Torque Specifications2 - 35.. Special Tools2 - 35.. Lubricants, Sealers, and Adhesives2 - 35.. ALPHA One Transom Assembly Exploded View2 - 36.. Bell Housing Components2 - 36.. Gimbal Housing Components2 - 38.. Inner Transom Plate Components2 - 40.. Gimbal Ring and Steering Lever Components2 - 41.. ALPHA One GENERATION II STERNDRIVE 2 - 190-806534970 1096 Installation SpecificationsTorque SpecificationsNOTE: Securely tighten all fasteners not mExhaust Pipe to GimbalHousing Screws2331 Propeller Nut 15575 Steering Cable CouplerNutTighten Nut Until It Bottoms Out Against FlatWasher, then Loosen 1/2 TurnSteering Cable CouplerNut3548 Steering system Pivot Bolts5068 Transom Assembly Attaching Screws and Nuts2331 Power Steering HydraulicHFii2331gyHose Fittings2331 Stern Drive Unit to BellHousing Attaching Nuts50681: Amount specified is , Sealers, and AdhesivesDESCRIPTIONPART NUMBERQ uicksilver 2-4-C Marine Lubricantwith Teflon92 825407A3 Quicksilver Special Lubricant 10192-13872A1 Perfect Seal92-34227-1 Liquid Neoprene92-25711--2 Quicksilver Engine Coupler Spline Grease92-816391A4 Special ToolsDESCRIPTIONPART NUMBERA lignment Tool Assembly91-805475A1 Transom Specifications22170aecdabbfa - Transom Thickness-2-2 1/4 in.

4 (51-57mm)b - Transom Surfaces-Parallel to within 1/8 in. ( mm)c - Area Covered by Inner Transom Plate - Flat towithin 1/8 in. ( mm)d - Area Covered by Gimbal Housing Assembly - Flat to within1/16 in. ( mm)e - Transom Angle-10 to 16 f - Keel (if Equipped) - Remove 4 ft. ( m) forwardof transom2 - 2 ALPHA One GENERATION II Sterndrive90-806534970 1096 Installation ProceduresTransom Assembly Installation!CAUTIONS teering lever ground wire MUST be positionedas shown or wire may - Speedometer Tube Pick-up Connection2 - Locknuts and Flat Washers3 - Screw4 - Steering Lever Continuity Wire5 - Trim System Wires6 - Shift Cable7 - Trim Hoses (and MerCathode Wires, if so equipped)8 - Gear Lube Hose FittingTorque Specificationa23 lb. ft. (31 N m)b70-90 (8-10 N m) ALPHA One GENERATION II STERNDRIVE 2 - 390-806534970 1096 Power Steering Control Valve and Cable Installation71901719037190656874a123b107 390195A1 - Steering Cable2 - Grease Fitting3 - Cable Coupler Nut4 - Cable Guide Tube5 - Cable End6 - Clevis7 - Clevis Pin8 - Cotter Pin9 - Flats on Guide Tube MUST Be Vertical10- Pivot BoltLubricants, Sealers, and AdhesivesA- Quicksilver Special Lubricant 10192-13872A1.

5 Torque Specificationa35 lb. ft. (47 N m)b50 lb. ft. (68 N m)2 - 4 ALPHA One GENERATION II Sterndrive90-806534970 1096 Power Steering Hose Connections73786aTypical Hose Routinga - Hose Fittings - Torque Both Fittings to 23 lb. ft. (31 N m).Stern Drive Unit InstallationUSING THE ALIGNMENT TOOL!CAUTIONF orcing the alignment tool into position maydamage the Gimbal Bearing or Engine not attempt to force the alignment tool!Raise or lower the engine as necessary until align-ment tool moves - Alignment Toolb - Gimbal Bearingc - Engine CouplerSTERN DRIVE TO BELL HOUSING CONNECTIONab22062a - Locknut and Flat Washers - Torque to 50 lb. ft. (68 N m)b - Locknut and Continuity Circuit Washer - Torque to50 lb. ft. (68 N m)Trim Cylinder Connectionabcde70027a - Aft Anchor Pinb - Bushingsc - Flat Washers (2)d - E-ring Clips (2)e - Plastic Caps (2) ALPHA One GENERATION II STERNDRIVE 2 - 590-806534970 1096 Propeller InstallationabcefgdTypical Propellera - Propeller Shaftb - Forward Thrust Hubc - Propellerd - Continuity Washere - Spline Washerf - Tab Washerg - Propeller Nut-Torque to 55 lb.

6 Ft. (75 N m)70134abcefdgPropeller With Flo-Torque Huba - Propeller Shaftb - Forward Thrust Hubc - Drive Sleeved - Propellere - Drive Sleeve Adapterf - Tab Washerg - Propeller Nut-Torque to 55 lb. ft. (75 N m)2 - 6 ALPHA One GENERATION II Sterndrive90-806534970 1096 Drive Shaft HousingSpecificationsTorque SpecificationsNOTE: Securely tighten all fasteners not listed mTop Cover Screws17-2323-31U-joint Retainer Nut200271 Oil Vent Drive Shaft Bearing PreloadDESCRIPTIONTORQUEDESCRIPTIONlb. mNew Bearings* *Bearings are considered used if spun under load Bearing PreloadDESCRIPTIONTORQUEDESCRIPTIONlb. mNew Bearings* *Bearings are considered used if spun under load Shimming SpecificationsDESCRIPTIONGEAR LOCATIONDESCRIPTION inchesmillimetersDrive , Sealers, and AdhesivesDESCRIPTIONPART NUMBERQ uicksilver 2-4-C Marine Lubricantwith Teflon92-825407A3 Quicksilver U-Jointand Gimbal BearingGrease92-828052A23M Brand Adhesive92-25234-1 Quicksilver BellowsAdhesive92-86166 Quicksilver NeedleBearing Assembly Lubricant92-825265A1 Quicksilver Perfect Seal92-34227-1 Permatex Ultra Blue Silicone SealantObtain LocallyQuicksilver Special Lubricant 10192-13872A1 Quicksilver High Performance GearLube92-816026A4 Special ToolsDESCRIPTIONPART NUMBERA daptor91-38756 Bearing Cup Driver91-38918 Bearing Driver Cup91-33493 Driver Cup91-36577 Driver Rod91-37323 Driver Tool91-90774 Oil Seal Driver91-817570 Shimming Tool(Driven Gear)91-60526 Shimming Tool(Drive Gear)91-60523 Slide Hammer Puller91-34569A1 Torque Wrench (lb.)

7 In.)91-66274U-joint BearingRetainer Wrench91-17256 Universal Puller Plate91-37241 ALPHA One GENERATION II STERNDRIVE 2 - 790-806534970 1096 TORQUE CONVERSION CHARTUse the following table to torque the u-joint retainerto 200 lb. ft. (271 N m).Torque WrenchLengthin Inches (cm)Torque Wrench Readingin lb. ft. (N m) toAchieve 200 lb. ft.(271 N m) of Torque15 (38)16 (41)17 (43)18 (46)19 (48)20 (51)21 (53)22 (56)23 (58)24 (61)25 (64)26 (66)27 (69)28 (71)29 (74)30 (76)31 (79)32 (81)33 (84)34 (86)35 (89)36 (91)111 (151)114 (155)117 (159)120 (163)123 (167)125 (170)127 (172)129 (175)131 (178)133 (180)135 (183)136 (184)138 (187)140 (190)141 (191)143 (194)144 (195)145 (197)147 (200)148 (201)149 (202)150 (203)a26363aa - Torque Wrench Length7069012345678910111112131415161718 19202119222325262324272829baDACBBD2 - 8 ALPHA One GENERATION II Sterndrive90-806534970 1096 Drive Shaft Housing Exploded Parts ViewU-Joint and Driven Gear ComponentsAlpha One GENERATION II STERNDRIVE 2 - 990-806534970 10961 - Drive Shaft Housing2 - Screw3 - O-ring4 - Spring Assembly5 - Oil Seal6 - Wear Pad7 - Plug8 - Universal Joint9 - Yoke, Universal Joint - Gear End10- Socket, Center - Universal Joint11- Cross and Bearing12- Yoke Assembly, Universal Joint - Coupling End13- O-ring14- Retainer15- Ring16- O-ring17- Carrier Assembly18- Oil Seal19- Roller Bearing and Cups20- Cup Spacer21- Shim22- Shim23- Drive Gear Assembly24- Roller Bearing and Cup25- Washer26- Nut27- Shims28- Ground Plate29- ScrewLubricants, Sealers, and AdhesivesA- 2-4-C Marine Lubricantwith Teflon92-825407A12.

8 B- Quicksilver High PerformanceGear Lube92-816025A4.. C- Quicksilver Special Lubricant 10192-13872A1.. D- Quicksilver Engine Coupler Spline Grease92-816391A4.. Torque Specificationa200 lb. ft. (271 N m) - See Chart on Page 7 Rolling PreloadbTighten in Small Increments Until6-10 lb. in. (. N m) of Rolling Preload2 - 10 ALPHA One GENERATION II Sterndrive90-806534970 1096 Drive Shaft Components74243abbAB51234891011121314161 517181 - Cover, top2 - Bearing and Cup3 - Shim4 - O-ring5 - Screw8 - Drive Shaft, upper9 - Filler Wall10- Washer11 - Nut12- Anodic Plate13- Screw14- Lockwasher15- Screw16- Seal17- Water Tube18- Stuffer PlugLubricants, Sealers, and AdhesivesA- Quicksilver 2-4-C MarineLubricant with Teflon 92-825407A12.. B- Quicksilver High Performance Gear Lube92-816026A4. Torque Specificationsa20 lb. ft. (27 N m)b35 lb. ft. ( N m) ALPHA One GENERATION II STERNDRIVE 2 - 1190-806534970 1096 Drive Shaft HousingShimmingGear Distance, Driven GearSHIMMING TOOL 91-60526 Overall DriveUnit Gear ( )a - Feeler Gauge.

9 025 in. ( )Gear Distance, Drive ( )a23012 SHIMMING TOOL 91-60523 Overall DriveUnit Gear :1a - Feeler Gauge - .025 in. ( )2 - 12 ALPHA One GENERATION II Sterndrive90-806534970 1096 Drive Shaft HousingSpecial InformationTop Cover Bearing CupThe later style bearing cup is thinner than the earlierstyle - Earlier Style Bearing Cup in. Diameter(Prior to S/N OF680000)b - Later Style Bearing Cup in. Diameter(S/N OF680000 and Above)Top Cover Bearing Cup DriversUse the appropriate driver for installation of the bear-ing - Shimsb - Bearing Cupc - Bearing Cup Driver (91-38918) used with 31-61100 A1 Bearing OR Bearing Cup Driver (91-808053) used with31-32575 A1 Bearingd - Driver Rod (91-37323)e - Top CoverAlpha One GENERATION II STERNDRIVE 2 - 1390-806534970 1096 Standard Rotation GearHousing SpecificationsTorque SpecificationsNOTE: Securely tighten all fasteners not listed mWater Pump Gear Nut7095 Gear Housing to DriveShaft Housing Screws2838 Gear Housing to DriveShaft Housing Nuts3547 Trim Tab Screw2331 Shift Shaft Shaft Retainer100136 Bear Carrier Retainer210285 Oil Fill/Drain Nut 155751.

10 Amount specified is SpecificationsDESCRIPTIONGEAR LOCATIONDESCRIPTION inchesmillimetersPinion Gear Gear Gear , Sealers, and AdhesivesDESCRIPTIONPART NUMBERQ uicksilver 2-4-C Marine Lubricant with Teflon92-825407A33M Brand Adhesive92-25234-1 Quicksilver BellowsAdhesive92-86166 Quicksilver Needle BearingAssembly Lubricant92-825265A1 Quicksilver Perfect Seal92-34227-1 Permatex Ultra BlueSilicone SealantObtain LocallyQuicksilver SpecialLubricant 10192-13872A1 Loctite 883192-823089-1 Quicksilver HighPerformance Gear Lube92-816026A42 - 14 ALPHA One GENERATION II Sterndrive90-806534970 1096 Special ToolsDESCRIPTIONPARTNUMBERB acklash Indicator Rod91-53459 Bearing Carrier RetainerWrench91-61069 Bearing Preload Tool91-14311A2 Belleville Washer12-54048 Dial Indicator91-58222A1 Dial Indicator Holding Tool91-89897 Drive Shaft Nut Wrench91-56775 Cup Driver91-36577 Drive Shaft Bearing Wrench91-43506 Needle Bearing Driver91-15755 Needle Bearing Driver91-33491 Oil Seal Driver91-31108 Oil Seal Driver91-817569 Pinion Gear Shimming Tool91-56048 Pinion Nut