ALPHA STERN DRIVE

2 A

50309

INSTALLATION AND ADJUSTMENTS

INDEX

Table of Contents
Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A -1 Torque Specifications . . . . . . . . . . . . . . . . . . . . . 2A -1 Lubricants, Sealers, and Adhesives . . . . . . . . . 2A -1 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A -1 Transom Specifications . . . . . . . . . . . . . . . . . . . 2A -1 Installation Procedures . . . . . . . . . . . . . . . . . . . . . . . 2A -2 Transom Assembly Installation . . . . . . . . . . . . . 2A -2 Steering Cable Installation . . . . . . . . . . . . . . . . . 2A -3 Stern Drive Unit Installation . . . . . . . . . . . . . . . . 2A -5 Remote Control Shift Cable Adjustment, Drive Unit Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A -6 Propeller Installation . . . . . . . . . . . . . . . . . . . . . . 2A -11 Check Cutout Switch Timing . . . . . . . . . . . . . . . 2A -12

INDEX
2A - ALPHA INSTALLATION AND ADJUSTMENT 2A -0 - INSTALLATION AND ADJUSTMENT 90-806534940

Specifications
Torque Specifications
Description Exhaust Pipe To Gimbal Housing Screws Propeller Nut Shift Cable End Guide Attaching Nuts Torque 23 lb. ft. (31 NSm) 55 lb. ft. (75 NSm) MINIMUM Tighten Nut Until It bottoms Out Against Flat Washer; then loosen 1/2 turn 35 lb. ft. (48 NSm) 50 lb. ft. (68 NSm) 23 lb. ft. (31 NSm) 20-25 lb. ft. (27-34 NSm) 100 lb. in. (135 NSm) 20-25 lb. ft. (27-34 NSm) 50 lb. ft. (68 NSm)

Special Tools
Description Alignment Tool Assembly Part Number 91-805475A1

Transom Specifications
a

e a d

Steering Cable Coupler Nut Steering System Pivot Bolts Transom Assembly Attaching Screws and Nuts Earlier Style Power Steering Hydraulic Hose Fitting (Large) Earlier Style Power Steering Hydraulic Hose Fitting (Small) Later Style Power Steering Hydraulic Hose (Both Fittings) Stern Drive Unit to Bell Housing Attaching Nuts

22170

a - Transom Thickness-2-2 1/4 in. (51mm-57mm) b - Transom Surfaces-Parallel to within 1/8 in. (3.2 mm) c - Area Covered by Inner Transom Plate-Flat to within 1/8 in. (3.2 mm) d - Area Covered by Gimbal Housing Assembly-Flat to within 1/16 in. (1.6 mm) e - Transom Angle-10_ to 16_ f - Keel (if Equipped)-Remove 4 ft. (1.2 m) forward of transom

Lubricants, Sealers, and Adhesives

Description Quicksilver 2-4-C Marine Lubricant Quicksilver Special Lubricant 101 Perfect Seal Liquid Neoprene Quicksilver Engine Coupler Spline Grease Part Number 92-825407A2 92-13872A1 92-34227-1 92-25711--2 92-816391A4

INDEX
90-806534940 INSTALLATION AND ADJUSTMENT - 2A -1

Installation Procedures
Transom Assembly Installation

! CAUTION
Steering lever ground wire MUST be positioned as shown or wire may fatigue. a 4

5
70037

70011

Torque Specifications

23 lb. ft. (31 NSm)

1 2 3 4 5 6 7

-Speedometer Tube Pick-up Connection -Locknuts and Flat Washers -Bolt -Steering Lever Continuity Circuit Wire -Trim System Wires -Shift Cable -Trim Hoses (and MerCathode Wires, if so equipped)

2 a
50632

70012

a 7 7 2

2 a
70005 2A -2 - INSTALLATION AND ADJUSTMENT 50632

INDEX

90-806534940

Steering Cable Installation

Earlier Style Control Valve 3

1 b

6
Torque Specifications

a 7 b

35 lb. ft. (47 NSm) 25 lb.ft. (34 NSm)

8 Lubricants, Sealers, and Adhesives

A
Quicksilver Special Lubricant 101 . . . . . 92-13872A1

5 a

INDEX
90-806534940

1 2 3 4 5 6 7 8

Steering Cable End Cable Guide Tube Clevis Pin Cotter Pin Coupler Nut-Torque to 35 lb. ft. (48 NSm) Adaptor Block Grease Fitting Stearing Cable

50912

INSTALLATION AND ADJUSTMENT - 2A -3

Later Style Control Valve

6 8

9 5
71977

71906

1 2 3 4 5 6 7 8 9

Steering Cable Grease Fitting Cable Coupler Nut Cable Guide Tube Steering Cable End Clevis Clevis Pin Cotter Pin Flats On Cable Guide Tube

Torque Specifications

35 lb. ft. (47 NSm)

71901

3 2 1

71903

INDEX
2A -4 - INSTALLATION AND ADJUSTMENT 90-806534940

Earlier Style Hose Connections b

Stern Drive Unit Installation

Using the Alignment Tool

! CAUTION
Forcing the alignment tool into position may damage the Gimbal Bearing or Engine Coupler. Do not attempt to force the alignment tool! Raise or lower the engine as necessary until alignment tool moves freely.

c a

Torque Specifications a b 100 lb. in. (11.3 NSm) 23 lb. ft. (31 NSm)

22023

71463

Later Style Hose Connections

a - Alignment Tool b - Gimbal Bearing c - Engine Coupler

Stern Drive to Bell Housing Connection

a Torque Specifications a 23 lb. ft. (31 NSm)

71902

22062

a - Locknut and Flat Washers-Torque to 50 lb. ft. (68 NSm) b - Locknut and Continuity Circuit Washer-Torque to 50 lb. ft. (68 NSm)

INDEX
90-806534940 INSTALLATION AND ADJUSTMENT - 2A -5

TRIM CYLINDER CONNECTION

Remote Control Shift Cable Adjustment, Drive Unit Installed

c e IMPORTANT: Shift cable adjustment for a right hand (RH) rotation drive unit is different than the procedure for adjusting a left hand (LH) rotation drive unit. Be sure to refer to the appropriate procedure when performing the following steps. RIGHT HAND ROTATION - Install control cable in remote control so that cable end will move in direction A when shift handle is placed in the forward position.

LEFT HAND ROTATION - Install the control cable in remote control so that cable end will move in direction B when shift handle is placed in the forward position.
70027

a b c d e

Aft Anchor Pin Bushings Flat Washers (2) E-ring Clips (2) Plastic Caps (2)

23242

IMPORTANT: DO NOT run engine. 1. Remove remote control shift cable and shift assist assembly (if installed).

a b

50626

a - Shift Assist Assembly b - Remote Control Shift Cable

With shift Assist Assembly

INDEX
2A -6 - INSTALLATION AND ADJUSTMENT 90-806534940

(RH)

50636

a - Remote Control Shift cable

Without Shift Assist Assembly 2. Ensure shift lever adjustable stud is at bottom of slot. If necessary, loosen stud and move it to bottom of slot, then retighten stud.
22909

(LH)
50627

a - Adjustable Stud

3. Shift Remote Control as stated in aor b following: a. Right Hand (RH) Rotation Drive Unit - forward gear, past detent, into wide-openthrottle position. b. Left Hand (LH) Rotation Drive Unit - Reverse gear, past detent, into wide-openthrottle position.

22909

4. Place drive unit into gear by pushing in on the drive unit shift cable, while simultaneously rotating the propeller shaft counterclockwise until the shaft stops, to ensure full clutch engagement. Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel (this removes all slack from the cable).

INDEX
90-806534940 INSTALLATION AND ADJUSTMENT - 2A -7

IMPORTANT: Do not use excessive force when holding pressure on the drive unit shift cable. Excessive force would be indicated by movement of the shift cutout switch.

a a
50628 50631

b
22266

a - End Guide b - Brass Barrel

7. Temporarily install remote control shift cable on stud and install clevis pin.

a - Drive Unit Shift Cable-Push in b - Propeller Shaft-Rotate Counterclockwise

5. Lightly pull on the remote control shift cable end guide (to remove the slack from the remote control and cable) and adjust brass barrel as necessary to align attaching points with shift lever clevis pin hole and stud. Be sure to maintain light pressure on the drive unit shift cable. a d b

50631

a - Remote Control Shift Cable b - Clevis Pin

50627

a b c d

End Guide Brass Barrel Shift Lever Clevis Pin Hole Stud

6. After cable has been aligned, turn brass barrel 4 turns away from cable end guide.
2A -8 - INSTALLATION AND ADJUSTMENT

INDEX

90-806534940

8. Shift remote control as stated in a or b following: a. Right Hand (RH) Rotation Drive Unit - reverse gear, past detent, into wide-openthrottle position. b. Left Hand (LH) Rotation Drive Unit - forward gear, past detent, into wide-open-throttle position. (RH) (LH)

9. Check shift cutout switch lever position. Roller must be centered. a

22058

a - Shift Cutout Switch Roller

10. If roller is not centered: a. Check to ensure adjustable stud is at bottom of slot in shift lever. b. Check remote control for proper shift cable output [3 in. (76 mm) " 1/8 in. (3 mm)]. c. If a and b are correct, check to ensure drive unit shift cable is not crushed or kinked. (If drive unit shift cable is binding, the shift cutout switch roller will move off center when shifting into and out of forward and reverse.

22909

Simultaneously rotate the propeller shaft clockwise until the shaft stops to ensure full clutch engagement.

22267

Rotate Propeller Shaft Clockwise

INDEX
90-806534940 INSTALLATION AND ADJUSTMENT - 2A -9

11. After properly adjusting remote control shift cable, reinstall cable and shift assist assembly (if applicable) and secure as shown. If the shift assist assembly attaching points will not align, push in or pull out on the end of the shift assist assembly to install. Do not attempt to readjust shift cable.

IMPORTANT: If an extra long remote control shift cable is used, or if there are a large number of bends in the remote control shift cable, or if remote control has inadequate output travel, an additional adjustment may be necessary. Refer to step 12 or 13 as applicable. 12. Remote Control with Single Lever Shift/ Throttle Control: a. Right Hand (RH) propeller rotation drive unit - Shift the remote control into reverse gear wide-open-throttle position while simultaneously rotating propeller shaft clockwise. Clutch should engage and cause the propeller shaft to lock. If the clutch does not engage, loosen the adjustable stud on the shift lever and move it upward in the slot until the clutch engages the reverse gear. Retighten the stud. Shift the remote control several times and stop in reverse to recheck the shift cutout switch position. Roller must be centered. b. LEFT HAND (LH) propeller rotation drive unit - Shift the remote control into forward gear, wide-open-throttle position while simultaneously rotating the propeller shaft clockwise. The clutch should engage and cause the propeller shaft to lock. If the clutch does not engage, loosen the adjustable stud on the shift lever and move it upward in the slot until the clutch engages the forward gear. Retighten the stud. Shift remote control several times and stop in forward to recheck the shift cutout switch position. The roller must be centered. 13. Remote Control with Separate Shift and Throttle Levers: a. RIGHT HAND (RH) propeller rotation drive unit - While turning the propeller shaft clockwise, move the remote control shift handle into full reverse position. The clutch should engage before the shift lever comes to a stop. If the clutch does not engage, loosen adjustable stud on the shift lever and move it upward in the slot until clutch engages with reverse gear. Retighten the stud. Shift remote control several times and stop in reverse to recheck shift cutout switch position. Roller must be centered.

g c

f b e a d
50626

a b c d e f g

Remote Control Shift Cable Shift Assist Assembly Clevis Pin Cotter Pin (Not Seen; Spread Both Prongs) Large I.D. Washer with Spring Beneath (Not Seen) Small I.D. Washer Locknut (Tighten Until Bottomed)

WITH SHIFT ASSIST ASSEMBLY

g f

h b

d a

c
a b c d e f g h i -

50636

Remote Control Shift Cable Pin Cotter Pin Spring Beneath Washer Washer Washer Spacer Washer Locknut (Tighten Until Bottomed, Then Back Off One Turn)

Without shift assist assembly

2A -10 - INSTALLATION AND ADJUSTMENT

INDEX

90-806534940

b. LEFT HAND (LH) propeller rotation drive unit - While turning the propeller shaft clockwise, move the remote control shift handle into the full forward position. Clutch should engage before the shift lever comes to a stop. If the clutch does not engage, loosen adjustable stud on the shift lever and move it upward in the slot until the clutch engages the forward gear. Retighten stud. Shift remote control several times and stop in forward to recheck shift cutout switch position. Roller must be centered.

Propeller Installation

a b c d g
a b c d e f g Propeller Shaft Forward Thrust Hub Propeller Continuity Washer Spline Washer Tab Washer Propeller Nut-Torque to 55 lb. ft. (75 NSm)

50627

a - Adjustable Stud

INDEX
90-806534940 INSTALLATION AND ADJUSTMENT - 2A -11

Check Cutout Switch Timing

Set Ohmmeter to Rxl Scale. Position Roller moved 1/8 in. (3mm) Action Circuit closes (full continuity reading) a

c
a - Move Roller 1/8 in.

70078

a d b

50497

a b c d e f

Terminal Block Cutout Switch White/Green Wire Cutout Switch Black Wire Ohmmeter Positive lead Ohmmeter Negative Lead Roller

INDEX
2A -12 - INSTALLATION AND ADJUSTMENT 90-806534940