2001-2012 MerCruiser Alpha One (Gen II) Sterndrive Service & Repair Manual

Number 14 Printed in U.S.A. 90-818177-3 APRIL 2001 2001, Mercury Marine Sterndrive Units Alpha One Generation II SERVICE MANUAL

MerCruiser #14 Sterndrive Units 90-818177-3 MerCruiser #14 Sterndrive Units 90-818177-3

1 A GENERAL INFORMATION SERVICE MANUAL NUMBER 14 90-818177--3 APRIL 2001 Page 1A-1 IMPORTANT INFORMATION Section 1A - General Information Table of Contents How To Use This Manual 1A-2 . . . . . . . . . . . . . Page Numbering 1A-2 . . . . . . . . . . . . . . . . . Introduction 1A-3 . . . . . . . . . . . . . . . . . . . . . . . . Special Product Information 1A-3 . . . . . . . . Directional References 1A-3 . . . . . . . . . . . . . . . Propeller Rotation 1A-4 . . . . . . . . . . . . . . . . . . . Serial Number Locations and Engine Designation Decal 1A-4 . . . . . . . . . . . Sterndrive Unit Serial Number Location 1A-5 . . . . . . . . . . . . . . . . . . . . . . . . Decal Application 1A-5 . . . . . . . . . . . . . . . . . . . Decal Removal 1A-5 . . . . . . . . . . . . . . . . . . . Instructions for “Wet” Application 1A-5 . . . Painting Procedures 1A-7 . . . . . . . . . . . . . . . . . Cleaning & Painting Aluminum Propellers & Gear Housings 1A-7 . . . . . . .

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 Page 1A-2 90-818177--3 APRIL 2001 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

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 90-818177--3 APRIL 2001 Page 1A-3 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.

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 Page 1A-4 90-818177--3 APRIL 2001 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 22031 a b a- Transom Assembly Serial Number b- Engine Designation Decal

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 90-818177--3 APRIL 2001 Page 1A-5 Sterndrive Unit Serial Number Location 22026 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. 2. Carefully soften decal and decal adhesive with a heat gun or heat blower while removing old decal. 3. Clean decal contact area with a 1:1 mixture of isopropyl alcohol and water. 4. 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. Stick Pin 3. 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.

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 Page 1A-6 90-818177--3 APRIL 2001 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. 2. Place the decal face down on a clean work surface and remove the paper backing from “adhesive side” of decal. 3. Using a spray bottle, flood the entire “adhesive side” of the decal with the pre-mixed wetting solution. 4. Flood area where the decal will be positioned with wetting solution. 5. Position pre-wetted decal on wetted surface and slide into position. 6. 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. 7. Wipe decal surface with soft paper towel or cloth. 8. Wait 10 - 15 minutes. 9. 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).

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 90-818177--3 APRIL 2001 Page 1A-7 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. 2. Feather edges of all broken paint edges. Try not to sand through the primer. 3. Clean the surface to be painted using PPG Industries DX330 Wax and Grease Remover or equivalent (Xylene or M.E.K.). 4. If bare metal has been exposed, use Quicksilver’s Light Gray Primer. 5. Allow a minimum of 1 hour dry time and no more than 1 week before applying the finish coat. 6. 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. 2. Wash gear housing with soap and water, then rinse. 3. Sand blistered area with 3M 180 grit sandpaper or P180 Gold Film Disc to remove paint blisters only. Feather edge all broken paint edges. 4. Clean gear housing thoroughly with (DX-330) wax and grease remover. 5. 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. 6. 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. 7. 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.

GENERAL INFORMATION SERVICE MANUAL NUMBER 14 Page 1A-8 90-818177--3 APRIL 2001 8. Allow a minimum of one hour drying time and no more than one week before top coating assemblies. 9. 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. 10. The type of spray gun used will determine the proper reduction ratio of the paint.

2001-2012 MerCruiser Alpha One (Gen II) Sterndrive Service & Repair Manual

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