Mercruiser Alpha 1 Repair Manual
Boatinfo requires FlashPlayer 9 or newer to display this document! E L Number 14 Sterndrive Units Alpha One Generation II Printed in U.S.A.2001, Mercury Marine 90-818177-3 APRIL 2001 MerCruiser #14 Sterndrive 90-818177-3 MerCruiser #14 Sterndrive Units 90-818177-3 SERVICE MANUAL NUMBER 14 GENERAL INFORMATION IMPORTANT INFORMATION Section 1A - General Information Table of Contents 1 A How To Use This Manual.
1A-2 Decal Application. 1A-5 Page Numbering. 1A-2 Decal Removal.
1A-5 Introduction. 1A-3 Instructions for “Wet” Application. 1A-5 Special Product Information. 1A-3 Painting Procedures.
1A-7 Directional References. 1A-3 Cleaning & Painting AluminumPropeller Rotation. 1A-4 Propellers & Gear Housings. 1A-7 Serial Number Locations and Engine Designation Decal.
1A-4 Sterndrive Unit Serial Number Location. 1A-5 90-818177-3 APRIL 2001 Page 1A-1 GENERAL INFORMATION SERVICE MANUAL NUMBER 14 How To Use This Manual This Manual is divided into sections which represent major components and systems. Some sections are further divided into parts which more fully describe the component. Sections and parts are listed at the front of this manual. Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. A b c d e f g a-Section Number b-Section Part c-Page Number d-Manual Part Number e-Revision Number f-Month Printed g-Year Printed Page 1A-2 90-818177-3 APRIL 2001 SERVICE MANUAL NUMBER 14 GENERAL INFORMATION Introduction This comprehensive overhaul and repair manual is designed as a service guide for the Mercury MerCruiser models previously listed.
It provides specific information, including procedures for disassembly, inspection, assembly and adjustment, to enable dealers and service mechanics to repair these products. Before attempting repairs, it is suggested that the procedure be read to gain knowledge of the methods and tools used and the cautions and warnings required for safety. Special Product Information During production of these models, special product improvements and changes have been made to increase product reliability and performance. Such changes to a sterndrive assembly component(s) are covered in the “Special Information” portion of the appropriate sterndrive assembly section.
(Refer to the section “Index”.) Serial number breaks are provided, where applicable, for ease of identification. Directional References Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this service manual, all directional references are given as they appear when viewing boat from stern, looking toward bow.
90-818177-3 APRIL 2001 Page 1A-3 GENERAL INFORMATION SERVICE MANUAL NUMBER 14 Propeller Rotation Propeller rotation for sterndrive can be right hand or left hand rotation as viewed from the aft end of the propeller. Right Hand Rotation Left Hand Rotation Serial Number Locations and Engine Designation Decal a b a-Transom Assembly Serial Number b-Engine Designation Decal Page 1A-4 90-818177-3 APRIL 2001 SERVICE MANUAL NUMBER 14 GENERAL INFORMATION Sterndrive Unit Serial Number Location b a Sterndrive Unit Serial Number Location - Port Decal (Also Located Under Decal On Housing) a-Sterndrive Unit Serial Number b-Sterndrive Unit Gear Ratio Decal Application Decal Removal 1. Mark decal location before removal to assure proper alignment of new decal. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal.
Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. Thoroughly dry decal contact area and check for a completely cleaned surface. Instructions for “Wet” Application NOTE: The following decal installation instructions are provided for a “Wet” installation. All decals should be applied wet. TOOLS REQUIRED 1. Plastic Squeegee.
2. Dish Washing Liquid/Detergent without ammonia. “Joy” and “Drift” are compatible for this process.
Automotive Body Filler Squeegee. Do not use a soap that contains petroleum based solvents.
90-818177-3 APRIL 2001 Page 1A-5 GENERAL INFORMATION SERVICE MANUAL NUMBER 14 SERVICE TIP: Placement of decals using the “Wet” application will allow time to position decal. Read entire installation instructions on this technique before proceeding. TEMPERATURE IMPORTANT: Installation of vinyl decals should not be attempted while in direct sunlight.
Air and surface temperature should be between 60°F (15°C) and 100°F (38°C) for best application. SURFACE PREPARATION IMPORTANT: Do not use a soap or any petroleum based solvents to clean application surface. Clean entire application surface with mild dish washing liquid and water.
Rinse surface thoroughly with clean water. DECAL APPLICATION 1. Mix 1/2 ounce (16 ml) of dish washing liquid in one gallon (4 l) of cool water to use as wetting solution. NOTE: Leave protective masking, if present, on the face of decal until final steps of decal installation. This will ensure that the vinyl decal keeps its shape during installation.
Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. Flood area where the decal will be positioned with wetting solution. Position pre-wetted decal on wetted surface and slide into position.
Starting at the center of the decal, “lightly” squeegee out the air bubbles and wetting solution with overlapping strokes to the outer edge of the decal. Continue going over the decal surface until all wrinkles are gone and adhesive bonds to the cowl surface. Wipe decal surface with soft paper towel or cloth. Wait 10 - 15 minutes.
Starting at one corner, “carefully and slowly” pull the masking off the decal surface at a 180° angle. NOTE: To remove any remaining bubbles, pierce the decal at one end of the bubble with stick pin and press out the entrapped air or wetting solution with your thumb (moving toward the puncture).
Page 1A-6 90-818177-3 APRIL 2001 SERVICE MANUAL NUMBER 14 GENERAL INFORMATION Painting Procedures Cleaning & Painting Aluminum Propellers & Gear Housings WARNING Avoid serious injury from flying debris. Avoid serious injury from airborne particles. Use eye and breathing protection with proper ventilation. PROPELLERS 1.
Sand the entire area to be painted with 3M 120 Regalite Polycut or coarse Scotch-Brite, disc or belts. Feather edges of all broken paint edges. Try not to sand through the primer. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). If bare metal has been exposed, use Quicksilver’s Light Gray Primer.
Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. Apply the finish coat using Quicksilver’s EDP Propeller Black.
GEAR HOUSINGS The following procedure should be used in refinishing gear housings. This procedure will provide the most durable paint system available in the field. The materials recommended are of high quality and approximate marine requirements. The following procedure will provide a repaint job that compares with a properly applied factory paint finish.
It is recommended that the listed materials be purchased from a local Ditzler Automotive Finish Supply Outlet. The minimum package quantity of each material shown is sufficient to refinish several gear housings. Procedure: 1. Wash gear housing with a muriatic acid base cleaner to remove any type of marine growth, and rinse with water, if necessary.
Wash gear housing with soap and water, then rinse. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. Clean gear housing thoroughly with (DX-330) wax and grease remover. Spot repair surfaces where bare metal is exposed with (DX-503) alodine treatment.
IMPORTANT: Do not use any type of aerosol spray paints as the paint will not properly adhere to the surface nor will the coating be sufficiently thick to resist future paint blistering. Mix epoxy chromate primer (DP-40) with equal part catalyst (DP-401) per manufacturers instructions, allowing proper induction period for permeation of the epoxy primer and catalyst. IMPORTANT: Do not paint sacrificial zinc trim tab or zinc anode. Cut out a cardboard “plug” for trim pump pocket to keep paint off of mating surface to maintain good continuity circuitry between trim tab and gear housing. 90-818177-3 APRIL 2001 Page 1A-7 GENERAL INFORMATION SERVICE MANUAL NUMBER 14 8.
Allow a minimum of one hour drying time and no more than one week before top coating assemblies. Use Ditzler Urethane DU9000 for Mercury Black and DU33414M for Sea Ray White. Catalyze the colors with Ditzler DU5 catalyst mixed 1:1 ratio.
Reduce with solvents per Ditzler label. CAUTION Be sure to comply with instructions on the label for ventilation and respirators. Using a spray gun, apply one half to one mil even thickness.
Let dry, flash off for five minutes and apply another even coat of one half to one mil film thickness. This urethane paint will dry to the touch in a matter of hours, but will remain sensitive to scratches and abrasions for a few days. The type of spray gun used will determine the proper reduction ratio of the paint.
Page 1A-8 90-818177-3 APRIL 2001 SERVICE MANUAL NUMBER 14 GENERAL INFORMATION THIS PAGE IS INTENTIONALLY BLANK 90-818177-3 APRIL 2001 Page 1A-9 GENERAL INFORMATION SERVICE MANUAL NUMBER 14 THIS PAGE IS INTENTIONALLY BLANK Page 1A-77-3 APRIL 2001 SERVICE MANUAL NUMBER 14 MAINTENANCE IMPORTANT INFORMATION Section 1B - Maintenance Table of Contents 1 B Trim Pump Specifications. 5A-2 Checking Lubricant for Water. 1B-10 Valve Pressure Specifications. 5A-2 Changing Lubricant. 1B-12 Maintenance Schedules. 1B-2 General Maintenance.
1B-14 Maintenance Intervals. 1B-2 Maintaining Power PackageGas Sterndrive.
1B-2 Exterior Surfaces. 1B-14 Routine Maintenance.
Mercruiser Alpha 1 Repair
1B-2 Steering Head and RemoteScheduled Maintenance. 1B-3 Control Maintenance. 1B-14 Quicksilver Maintenance Products. Ptc mechanica quick guide. 1B-4 Checking Quicksilver MerCathodeLubricating Shift Cable Pivot Points. 1B-4 System. 1B-14 Lubricating Propeller Shaft.
1B-4 Maintaining Anodic Trim Tab orLubricating Steering System. 1B-5 Plate.
1B-14 Power Steering Models. 1B-5 Checking Optional QuicksilverManual Steering Models. 1B-5 Anti-Corrosion Anode Kit. 1B-14 Lubricating Tie Bar Pivot Points.
1B-6 Boat Bottom Care. 1B-15 Models With Control Valve MountedAntifouling Paint.
1B-15 On Starboard Transom Assembly. 1B-6 Maintaining Ground CircuitModels With Control Valve Mounted Continuity. 1B-15 On Port Transom Assembly. 1B-6 Power Package Layup (Out ofLubricating Transom and Gimbal Season Storage). 1B-16 Assembly,Hinge Pins and Gimbal Bearing. 1B-16 1B-7 Sterndrive.
1B-16 Checking and Adding Sterndrive Oil. 1B-8 Power Package Recommissioning. 1B-18 Models Without Drive Unit GearEngine. 1B-18 Lube Monitor. 1B-8 Sterndrive. 1B-18 Models With Gear Lube Monitor.
1B-9 90-818177-3 APRIL 2001 Page 1B-1 MAINTENANCE SERVICE MANUAL NUMBER Maintenance Schedules Maintenance Intervals Maintenance intervals and the tasks to be performed, as shown in this current schedule, or as found in a previously printed schedules, are generally based on an average boating application and environment. However, individual operating habits and personal maintenance preferences can have an impact on the suggested intervals. In consideration of these factors, Mercury MerCruiser has adjusted some maintenance intervals and corresponding tasks to be performed. In some cases, this may allow for more individual tasks to be performed in a single visit to the serving dealer, rather than multiple visits. Therefore, it is very important that the boat owner and servicing dealer discuss the current Maintenance Schedule and develop appropriate maintenance intervals to coincide with the individual operating habits, environment, and maintenance requirements. CAUTION Always disconnect battery cables from battery BEFORE working around electrical systems components to prevent injury to yourself and damage to electrical system should a wire be accidentally shorted. Gas Sterndrive Routine Maintenance.
Each Day Start Each Day End Weekly Every Two Months Check crankcase oil (interval can be extended based on experience). If operating in salt, brackish or polluted waters, flush cooling system after each use. Check drive unit oil level, trim pump oil level and power steering pump fluid level. Check water pickups for debris or marine growth. Check water strainer and clean.
Mercruiser Alpha One Gen 1 Repair Manual
Check coolant level. Inspect drive unit anodes and replace if 50 percent eroded.
Inspect fuel pump sight tube and have pump replaced if fuel is present. Check battery connections and fluid level. Lubricate propeller shaft and the retorque nut (if operating in only freshwater, this maintenance may be extended to every four months). Operating in Saltwater Only: treat engine surface with corrosion guard.
Only perform maintenance which applies to your particular power package. Page 1B-2 90-818177-3 APRIL 2001 SERVICE MANUAL NUMBER 14 MAINTENANCE Gas Sterndrive (Continued) Scheduled Maintenance. Annually Every 100 Hours or Annually Every 200 Hours or 3 Years Every 300 Hours or 3 Years Every 2 Years Every 5 Years Touch-up paint power package and spray with corrosion guard.
Change crankcase oil and filter. Change drive unit oil and retorque connection of gimbal ring to steering shaft. Replace fuel filter. Check steering system and remote control for loose, missing or damaged parts. Lubricate cables and linkages. Inspect U-joints, splines and bellows.
Check clamps. Check engine alignment. Lubricate U-joint splines. Lubricate gimbal bearing and engine coupler. Check continuity circuit for loose or damaged connections. Test MerCathode unit output on Bravo models.
Retorque engine mounts. Check spark plugs, wires, distributor cap and ignition timing. Check and adjust idle speed. Clean flame arrestor and crankcase ventilation hoses.
Replace PCV valve. Check electrical system for loose, damaged or corroded fasteners. Inspect condition and tension of belts.
Check cooling system and exhaust system hose clamps for tightness. Inspect both systems for damage or leaks. Disassemble and inspect seawater pump and replace worn components. Clean seawater section of closed cooling system.
Clean, inspect and test pressure cap. Replace coolant.
. Only perform maintenance which applies to your particular power package. Whichever occurs first. Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time. Interval will be reduced if not using extended life coolant.
90-818177-3 APRIL 2001 Page 1B-3 MAINTENANCE SERVICE MANUAL NUMBER Quicksilver Maintenance Products We recommend the use of Quicksilver Maintenance Products where specified. Lubricating Shift Cable Pivot Points a 22245 a-SAE 20 Or 30 Engine Oil Lubricating Propeller Shaft a a-Special Lubricant 101, 2-4-C Marine Lubricant With Teflon Or Perfect Seal With Teflon (Listed In Order Of Effectiveness) Page 1B-4 90-818177-3 APRIL 2001 SERVICE MANUAL NUMBER 14 MAINTENANCE Lubricating Steering System WARNING Transom end of steering cable MUST BE fully retracted into cable housing when lubricating cable. If cable is lubricated while extended, hydraulic lock of cable could occur.