Number 6 - boatfix.com

1 Number 6 Printed in 1097 1997, Mercury MarineSterndrive UnitsR MR Alpha One Alpha One SSS U 90-12934--2 1097090-12934--290-12934--290-12934--2 1097iModels Covered in This Manual transom AssembliesModelSerial NumberMC 120R/140B/185R/488R/898R/228R/260R621668 7 6849289MC 120MR/140MR/170MR/185MR/190MR/200MR/230M R/260MR/300 Tempest MR6849290 0A471374MC Alpha One/Alpha One SS0A471375 and AboveSterndrive UnitsMC 120R-260 ROriginal RatioRatio If Serviced With 13:21 GearsSerial :16231571-6663947MC 120 MR - 300 TEMPEST MROriginal RatioRatio If Serviced With 13:28 GearsSerial :16847030-0A479506MC ALPHA ONE / ALPHA ONE SSOriginal RatioRatio If Serviced With13:28 Serial Serial :10A476747 and Above0C881740 and :10A470165 and Above0C884040 and :10A475787 and Above0C881790 and :10A479507 and Above0C852908 and :10A613927 and AboveAlpha One :1 :10A545004 and Above90-12934--2 1097iiSea Ray Sterndrive Units and transom assembly (Oyster White)Original RatioRatio If Serviced With 13:21 GearsSerial.

2 10B804807-0C340030 transom Assembly0B815811-0C340333 When making repairs to Sea Ray (Oyster White) sterndrives, follow procedures as outlined for correspondingMerCruiser models as shown in the cross-reference chart Alpha Alpha Alpha Alpha OneSRX Magnum Alpha OneSRX Magnum Alpha One90-12934--2 1097iiiNoticeThroughout this publication, Warnings and Cau-tions (accompanied by the International HAZARD symbol ! ) are used to alert the mechanic to specialinstructions concerning a particular service or opera-tion that may be hazardous if performed incorrectlyor carelessly.

3 OBSERVE THEM CAREFULLY!These Safety Alerts alone cannot eliminate thehazards that they signal. Strict compliance to thesespecial instructions when performing the service,plus common sense operation, are major accidentprevention !DANGER - Immediate hazards which will result insevere personal injury or death.!WARNINGWARNING - Hazards or unsafe practices whichCOULD result in severe personal injury or death.!CAUTIONCAUTION - Hazards or unsafe practices whichcould result in minor personal injury or productor property : Indicates information or instruc-tions that are necessary for proper operationand/or To Users of This ManualThis service manual has been written and publishedby the service department of the manufacturer to aidour dealers mechanics and company service per-sonnel when servicing the product described is assumed that these personnel are familiar withthe servicing procedures of this product, or like orsimilar products.

4 That they have been trained in therecommended servicing procedures of these prod-ucts which includes the use of mechanics commonhand tools from other could not possibly know of and advise the servicetrade of all conceivable procedures by which aservice might be performed and of all possiblehazards and/or result of each method. We have notundertaken any such wise evaluation. Therefore,anyone who uses a service procedure and/or toolwhich is not recommended by the manufacturer, firstmust completely satisfy himself that neither his northe product s safety will be endangered by theservice procedure information, illustrations, and specifications con-tained in this manual are based on the latest productinformation available at time of required, revisions to this manual will be sent toall dealers contracted by us to sell and/or servicethese 1097ivReplacement Parts!

5 WARNINGE lectrical system components on gasolineengines and MerCruiser Stern Drives aredesigned and manufactured to comply with Guard Rules and Regulations to minimizerisks of fire or of replacement electrical system compo-nents, which do not comply to these rules andregulations, could result in a fire or explosionhazard and should be servicing electrical systems, it is extremelyimportant that all components are properly installedand tightened. If not, any electrical componentopening would permit sparks to ignite fuel vaporsfrom fuel system leaks, if they exist or develop.

6 !WARNINGE lectrical system components on diesel enginesare not external ignition protected. DO NOTSTORE OR UTILIZE GASOLINE ON BOATSEQUIPPED WITH THESE ENGINES, UNLESSPROVISIONS HAVE BEEN MADE TO EXCLUDEGASOLINE VAPORS FROM ENGINE COMPART-MENT (ref: 33 CFR). Failure to comply could resultin fire, explosion and/or severe personal , Installation and AdjustmentsSterndrive UnitTransom AssemblyPower TrimSteering SystemsCorrosion Protection123456790-12934--2 1097vService Manual OutlineSection 1 - Important InformationA - Important InformationB - MaintenanceC - TroubleshootingSection 2 - Removal.

7 Installation and AdjustmentsA - All ModelsSection 3 - Sterndrive UnitA - Drive Shaft HousingB - Gear Housing - MR/Alpha One/Alpha One SSC - Gear Housing - I-RD - Gear Housing - Alpha One Counter RotationSection 4 - transom AssemblyA - Service Procedures Requiring Minor DisassemblyB - Service Procedures Requiring Major DisassemblySection 5 - Power TrimA - Oildyne Power Trim Pump (Plastic Reservoir)B - Oildyne Power Trim Pump (Aluminum Reservoir)C - Prestolite Power Trim PumpD - Trim CylindersE - Dual Power Trim ControlF - Auto Trim IISection 6 - Steering SystemsA - Power SteeringB - Manual SteeringSection 7 - Corrosion ProtectionA - All Models