You will choose your year and model during registration and will have access to that one model for the subscription period. Alpha One 4. The Alpha One 4. Mercruiser parts for years to and Generation 2 years and up Seloc repair manuals for Chrysler, Force, Yamaha, Mariner, Mercury and Johnson outboards. Specificaly, I am looking for an exploded view of the gimbal assembly area on my alpha one stern drive.
It seems my hinge pin on the starboard side is not turning when you trim the unit, so therefore my trim position sensor is not working. MerCruiser MCM 4. Also for: Mercruiser mcm 4. A downloadable MerCruiser repair manual is a digitally delivered book of instructions that guides the mechanic in the proper procedures for maintenance, service, overhaul and troubleshooting of components e.
This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an outboard which is suspended. Outboards should be attached to work stands, or lowered to ground as soon as possible.
We reserve the right to make changes to this manual without prior notification. Refer to dealer service bulletins for other pertinent information concerning the products de- scribed in this manual. Section 1B - Maintenance Table of Contents. Section 5G - Diagnostics Special Tools. Cleaning and Inspection. Section 7C - Collectors Torque Specifications. Section 8C - Hurth Transmissions Identification. Introduction This comprehensive overhaul and repair manual is designed as a service guide for the mod- els previously listed.
It provides specific information, including procedures for disassembly, inspection, assembly and adjustment to enable dealers and service mechanics to repair and tune these engines.
Before attempting repairs or tune-up, it is suggested that the procedure first be read through to gain knowledge of the methods and tools used and the cautions and warnings required for safety. 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.
Page Numbering Two number groups appear at the bottom of each page. Following is an example and description. Directional References Front of boat is bow; rear is stern. Starboard side is right side; port side is left side. In this maintenance manual, all directional references are given as they appear when viewing boat from stern looking toward bow.
Engine Rotation Engine rotation is determined by observing flywheel rotation from the rear stern end of the engine looking forward toward water pump end.
Propeller rotation is not necessarily the same as engine rotation. When ordering replacement engine, short blocks or parts for engine, be certain to check engine rotation. Do not rely on propeller rotation in determining engine rotation.
The blade configuration also will affect performance. Two like propellers, same pitch and diameter, from two different manufacturers will perform differently.
Because of the many variables of boat design and operation, only testing will determine the best propeller for the particular application. To test for correct propeller, operate boat with an average load onboard at WOT and check rpm with an accurate tachometer. Engine rpm should be near top of the specified range so that, under heavy load, engine speed will not fall below specifications.
Normally, a change of approximately rpm will be achieved for each single inch of pitch change of a propeller. Operation under this condition will cause excessive fuel consumption, engine overheating and possible piston damage due to detonation. Conversely, installing a propeller, allowing engine to run above the specified rpm limit, will cause excessive wear on internal engine parts which will lead to premature engine failure.
Water Testing New Engines Use care during the first 20 hours of operation on new Mercury MerCruiser engines or possible engine failure may occur. If a new engine has to be water-tested at full throttle before the break-in period is complete, follow this procedure.
Start engine and run at idle rpm until normal operating temperature is reached. Run boat up on plane. Advance engine rpm in rpm increments until engine reaches its maximum rated rpm. Boat and Engine Performance Boat Bottom For maximum speed, a boat bottom should be as flat as possible in a fore-aft direction longi- tudinally for approximately the last 5 ft 1.
For best speed and minimum spray, the corner between the bottom and the transom should be sharp. A hook causes more lift on the bottom near the transom and forces the bow to drop. This increases wetted surface and reduces boat speed.
A hook, however, aids in planing and reduces any porpoising rhythmical bouncing tendency. A slight hook is often built in by the manufacturer. A hook also can be caused by incorrect trailering or storing the boat with support directly under the transom. The bottom is convex or bulged in the fore-and-aft direc- tion.
It can cause the boat to porpoise. Fouling adds up to drag, which reduces boat performance. In fresh water, fouling results from dirt, vegetable matter, algae or slime, chemicals, minerals and other pollutants. In salt water, barnacles, moss and other marine growth often produce dra- matic build-up of material quickly. Therefore, it is important to keep the hull as clean as possi- ble in all water conditions to maximize boat performance. Antifouling paint, if required, may be applied to boat hull observing the following precautions.
Do not apply antifouling paint to Mercury MerCruiser drive unit or transom assembly. In areas where Tri-Butyl-Tin-Adipate base paints are prohibited by law, copper base paints can be used on boat hull and boat transom. Corrosion damage that results from the improper application of antifouling paint will not be covered by the limited warranty.
For best top speed, all movable weight - cargo and passengers - should be as far aft as possible to allow the bow to come up to a more efficient angle 3 to 5 degrees. On the negative side of this approach is the problem that, as weight is moved aft, some boats will begin an unac- ceptable porpoise.
Secondly, as weight is moved aft, getting on plane becomes more difficult. Finally, the ride in choppy water becomes more uncomfortable as the weight goes aft. Operation in this configuration can produce an extremely wet ride, from wind-blown spray, and could even be unsafe in certain weather conditions or where bow steering may occur.
Weight distribution is not confined strictly to fore and aft locations, but also applies to lateral weight distribution.
In extreme rough water conditions, the safety of the boat and passengers may be in jeopardy. Water in Boat When a boat loses performance, check bilge for water. Water can add considerable weight to the boat, thereby decreasing the performance and handling. Make certain that all drain passages are open for complete draining. Elevation and Climate Elevation has a very noticeable effect on the wide-open-throttle power of an engine.
Since air containing oxygen gets thinner as elevation increases, the engine begins to starve for air. Humidity, barometric pressure and temperature do have a noticeable effect on the densi- ty of air. Heat and humidity thin the air.
This phenomenon can become particularly apparent when an engine is propped out on a cool dry day in spring and later, on a hot, humid day in August, does not have the same performance.
Although some performance can be regained by dropping to a lower pitch propeller, the basic problem still exists. The propeller is too large in diameter for the reduced power output. A Quicksilver Propeller Repair Station or experienced marine dealer can determine how much diameter to remove from a lower-pitch propeller for specific high-elevation locations. In some cases, installing high altitude gears in the drive unit is possible and very beneficial.
Weather conditions may effect the power output of internal combustion engines. Therefore, established horsepower ratings refer to the power that the engine will produce at its rated rpm under a specific combination of weather conditions. 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 mainte- nance 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.
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.
Check water pickups for debris or marine growth. Check coolant level. Inspect drive unit anodes and replace if 50 percent eroded. Check battery connections and fluid level. Clean air filter every 50 hours of operation.
Change crankcase oil and filter. Replace fuel filter s. Inspect U-joints, splines and bellows. Check clamps. Lubricate U-joints splines. Lubricate gimbal bearing and engine coupler.
Retorque engine mounts. Check and adjust idle speed. Clean flame arrestor and crankcase ventilation hoses. Inspect condition and tension of belts. Inspect both systems for damage or leaks. Clean seawater section of closed cooling system. Replace coolant. Check transmission fluid. Replace PCV valve. Clean, inspect and test pressure cap. Timing can- not be properly set using the conventional method.
Quarts Liters All capacities are approximate fluid measures. Fluid Ounces Milliliters All capacities are approximate fluid measures.
Add additional fluid as necessary. Correct break-in is essential to obtain minimum oil consumption and maximum engine per- formance. Shift into gear as soon as possible after starting and advance throttle above rpm if conditions permit safe operation.
During next 10 hours, occa- sional operation at full throttle is permissible 5 minutes at a time maximum. Refrain from pro- longed operation at maximum full throttle rpm.
If you are in an area where the product is operated continuously year-round operation , you should contact your dealer at the end of the first hours of operation, or once yearly, whichever occurs first. Engine damage resulting from use of improper gasoline is considered misuse of engine, and damage caused thereby will not be covered under the limited warranty. DO NOT use leaded gasoline.
Premium gasoline 98 RON is also acceptable. If unleaded gasoline is not available, use a major brand of leaded gasoline. This type of gasoline is required in certain areas of the USA.
Fuels containing alcohol and winter grade fuels will aggravate vapor lock problems. Other factors may combine to increase vapor locking. Other conditions should be ruled out before treating the problem as vapor locking. Contact your boat manufacturer for specific recommendations on the boats fuel system components fuel tanks, fuel lines, and fittings.
Careful periodic inspection of entire fuel system is mandatory, particularly after storage. Any sign of leak- age or deterioration requires replacement before further engine operation. Because of possible adverse effects of alcohol in gasoline, it is recommended that only alco- hol-free gasoline be used where possible. If only fuel containing alcohol is available, or if the presence of alcohol is unknown, increased inspection frequency for leaks and abnorma- lities is required.
Long periods of storage, common to boats, create unique problems. In cars alcohol-blend fuels normally are consumed before they can absorb enough moisture to cause trouble, but boats often sit idle long enough for phase separation to take place.
In addition, internal corrosion may take place during storage if alcohol has washed pro- tective oil films from internal components.
Test For Alcohol Content In Gasoline The following is an acceptable and widely used field procedure for the detection of alcohol in gasoline. A pencil mark on a piece of adhesive tape may be used. Fill the container with water to the mark. Add fuel almost to fill the container, leaving some air space, then cap the container. The proportions of fuel to water are not critical, but there should be 2 to 3 times as much fuel as water.
Shake container vigorously and allow it to sit upright for 3 to 5 minutes. If the volume of water appears to have increased, alcohol is present.
If you are not sure, there is no need for concern. If the dividing line between water and fuel becomes cloudy, use the middle of the cloudy band. Hurth - Dexron IIl. If any non-compatible coolant is added to this coolant, coolant must be changed every 2 years or hours, whichever occurs first. Mercury MerCruiser V-8 engines can use any type of permanent antifreeze or any brand antifreeze solution that meets GM specification M.
Crankcase Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of Quicksilver 4-Cycle 25W Marine Engine Oil. This oil is a special blend of weight and weight oils for marine engines.
IMPORTANT: The use of non-detergent oils, multi-viscosity oils other than Quicksil- ver 25W or a good quality 20W or 20W , synthetic oils, low quality oils or oils that contain solid additives are specifically not recommended. The chart below is a guide to crankcase oil selection. The oil filter should always be changed with oil. The over-full condition results in the engine crankshaft splashing and agitating the oil, causing it to foam become aerated.
Care must be taken when checking engine oil level. It is normal for an engine to use a certain amount of oil in the process of lubrication and cooling of the engine. The amount of oil consumption is greatly dependent upon engine speed, with consumption being highest at wide-open-throttle and decreasing substantially as engine speed is reduced.
Stop engine and allow boat to come to a rest. Allow oil to drain back into oil pan - approximately 5 minutes. Remove dipstick.
Wipe clean and reinstall. Push dipstick all the way into dipstick tube. Remove dipstick and note the oil level. If oil level is below ADD mark, proceed to Steps 8. Remove oil filler cap from valve rocker arm cover.
Add required amount of oil to bring level up to, but not over, the FULL mark on dipstick. Changing Oil and Filter 1. Start engine and run until it reaches normal operating temperatures. Stop engine. Remove drain plug from oil pan or from oil drain hose.
See Quicksilver Accessory Guide. After oil has drained completely, reinstall drain plug if removed and tighten securely. Remove and discard oil filter and its sealing ring.
Coat sealing ring on new filter with engine oil, and install. Do not overtighten. Fill crankcase with oil. Start engine and check for leaks. Gasoline is extremely flammable and highly explosive under certain conditions. Be sure ignition key is OFF. Do not smoke or allow spark or open flame in area when changing fuel filter. Wipe up any spilled fuel immediately. CAUTION The electric fuel pump and factory installed water separating fuel filter have been carefully designed to function properly together.
MCM Sterndrive Models 1. Unsnap latch and slide top and bottom cover pieces from around the water separating fuel filter and bracket. Remove water separating fuel filter and sealing ring from mounting bracket and discard. Coat sealing ring on new filter with motor oil. Thread filter onto bracket and tighten securely by hand. Do not use a filter wrench. Start and run engine.
Check filter connection for gasoline leaks. If leaks exist, recheck filter installation. Install cover pieces around fuel filter. Be certain top part of cover latches to lower part. Position drive unit so that it is straight back. If fluid is not visible in reservoir, a leak exists in the power steering system. Find cause and correct. Engine Cold 1. With engine stopped, position drive unit so that it is straight back.
Find cause and Index correct. All air must be removed, or fluid in pump may foam during operation and be discharged from pump reservoir. Foamy fluid also may cause power steering system to become spongy, which may result in poor boat control. Turn steering wheel back and forth to end of travel in each direction several times. Recheck fluid level and add fluid, if necessary. Install vented fill cap. Tighten securely. Start engine and run at fast idle rpm until engine reaches normal operating temperature.
During this time, turn steering wheel back and forth to end of travel in each direction several times. Position drive unit so that it is straight back and stop engine. Remove fill cap from pump. Allow any foam in pump reservoir to disperse. Reinstall fill cap. If fluid is still foamy in Step 5 , repeat Steps 7. Sudden loss of pressure could cause hot coolant to boil and discharge violently. Coolant level in heat exchanger should be full to bottom of filler neck. Coolant level should be between the ADD and FULL marks on coolant recovery reser- voir with the engine at normal operating temperature.
Flushing System MCM Sterndrive If engine is operated in salty, polluted or mineral-laden water, flush seawater cooling system preferably after each use to reduce corrosion and prevent the accumulation of deposits in the system.
Thoroughly flush the seawater cooling system prior to storage. NOTE: For additional protection against freezing and rust to the exhaust manifolds and other components, a mixture of antifreeze and water can be run through the engine during Power Package Layup. Install flushing attachment over water pickup holes in gear housing as shown. Attach a water hose between the flushing attachment and a water tap.
To avoid possible injury, remove propeller. Suction created by seawater pick- up pump may collapse flushing hose, causing engine to overheat. DO NOT use full water pressure. Place remote control in neutral, idle speed position, and start engine.
Operate engine at idle speed in neutral for 10 minutes, or until discharge water is clear, then stop engine. Shut off water tap. Remove water hose and flushing attachment. Raise drive unit to full UP position.
Lower drive unit to full IN position. Operate engine at idle speed in neutral for 10 minutes, then stop engine. As a precautionary measure, attach a tag to the ignition switch or steering wheel of the boat with the warning: Open seacock or reconnect water inlet hose before starting engine.
IMPORTANT: If a seacock is to be installed for this purpose, valve used must have an internal cross-sectional area equal to or greater than water inlet hose to prevent restricting water flow during normal operation. If boat is in water, close seacock, if so equipped, or disconnect and plug seawater inlet hose to prevent seawater from entering boat. Remove inlet hose from seawater pickup pump. Using an adaptor, connect a water hose from a water tap to seawater pump inlet.
Do not use full water pressure. Place the remote control lever in neutral position and start engine. Operate engine at idle speed in neutral for 10 minutes, or until discharge water is clear. Remove water hose and adaptor from pump inlet and reconnect water inlet hose. Be sure to tighten hose clamp securely. If boat is not fitted with a valve, leave water inlet hose disconnected and plugged. Transmission Fluid NOTE: Due to the various installation angles and oil cooler set-ups, it may be necessary to adjust oil level.
Hot oil can cause burns. Small particles of dirt can cause damage to internal components and cause valves to stick. Oil will expand when heated. Oil will drain back from the cooler. Expansion and drain-back can significantly affect oil level. When the transmission is at operating temperature, place selector lever in neutral. Shut off engine. Carefully remove dipstick and wipe clean. Immediately insert clean dipstick and read oil level. NOTE: Oil level must be checked immediately after engine shut-down to prevent an incor- rect reading.
Oil drains back into the transmission from the cooler and cooler lines. Add or remove oil as necessary until the oil is at the required mark. NOTE: For ease of checking the oil prior to engine start-up, a cold oil level mark can be made. To find the cold oil level mark, the oil level must first be set according to the warm oil level checking procedure. Let the boat sit overnight. Page Synchronizing Dual Engines Section 2 - Getting to Know Your Power Package Synchronizing Dual Engines The auto synchronizing feature, when engaged, will automatically adjust the port engine speed to match the speed of the starboard engine.
Page Power Trim Section 2 - Getting to Know Your Power Package Power Trim Power trim allows the operator to adjust the sterndrive angle while underway, to provide the ideal boat angle for varying load and water conditions. Also, the trailering feature allows the operator to raise and lower the sterndrive unit for trailering, beaching, launching, low speed below RPM engine speed and shallow water operation. This can result in an unexpected turn in either direction called bow steering or over steering if any turn is attempted or if a significant wave is encountered.
A circuit breaker provides protection for the engine wiring harness and the instrumentation power lead. The circuit breaker can be tested by pushing the red button. If the circuit breaker is functioning properly, the yellow lever will appear. Reset the yellow lever after testing, or if tripped, by pushing the yellow lever back into the housing.
A 20 amp fuse may be located in the ignition switch "I" terminal lead to protect the electrical system. Check for blown fuse if the ignition key is turned to the "START" position and nothing happens and circuit breaker is not tripped.
The Audio Warning System will not protect the engine from damage. It is designed to warn the operator that a problem has occurred. For example, if the water inlet becomes partially blocked, Engine Guardian Strategy will reduce the available power level of the engine to help prevent damage from decreased water flow to the engine.
Page Safe Boating Suggestions Know and obey all nautical rules and laws of the waterways. Courses are offered in the U. Page Be Alert To Carbon Monoxide Poisoning Most boats are rated and certified for maximum load weight capacities refer to your boat capacity plate. Know your boat's operating and loading limitations. Know if your boat will float if full of water.
When in doubt, contact your authorized Mercury MerCruiser dealer or the boat manufacturer. Example of desired air flow through the boat. If engine. Page Stopping The Engine If adequate road clearance is a problem, place the sterndrive unit in full trailer position and support it with an optional trailer kit which is available from your authorized Mercury MerCruiser dealer.
Page Freezing Temperature Operation Components on your engine will be damaged if submerged. The SmartStart feature incorporates push button starting. Rather than holding the start button or key switch to start the engine and then releasing it when the engine starts, SmartStart completely controls the starting process. Shift the drive system only when the engine is at idle RPM.
Page Trailering The Boat Components on your engine will be damaged if submerged. Avoid wave or wake jumping whenever possible. Instruct all occupants that if a wake or wave jump occurs, get low and hang on to any boat hand hold. Page Drive Unit Impact Protection After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts.
If damage is present or suspected, the power package should be taken to an authorized Mercury MerCruiser dealer for a thorough inspection and necessary repair.
Sand, silt or mud could be sucked into the water inlets restricting or shutting off the water supply to the engine. Extreme care should be exercised when operating a boat equipped with low water inlets while maneuvering in shallow water.
We do not know what percentage your boat's fuel system will withstand. Page Engine Oil To help obtain optimum engine performance and to provide maximum protection, we strongly recommend the use of the following oils listed in the order of recommendation: 1.
Electronic ignition and special fuel delivery systems provide greater fuel economies, but also are more complex for the untrained mechanic. Check the clamps. Check the engine alignment. Discharge of oil or oil waste into the environment is restricted by law. Do not spill oil or oil waste into the environment when using or servicing your boat. Engine oil should be changed before placing the boat in storage.
Remove the bilge drain plug. Pull tether through the bilge drain. Place the oil drain hose in a suitable container. Remove the drain plug from the oil drain hose. After oil has drained completely, install the drain plug in the oil drain hose. Fill to full line with specified fluid. Filling 1. Page Changing Heat exchanger cap 2. The coolant level in the heat exchanger should be at the bottom of the filler neck.
If the coolant level is low, contact your authorized Mercury MerCruiser dealer. Install the cap onto the heat exchanger. Page Filling 2. Fill to the "FULL" line with the specified coolant. Tube Ref No. Description Where Used Part No. Strict compliancewith these special instructions while performing the service, plus common sense operation,are major accident prevention measures. NOTE: Indicates information that helps in the understanding of a particular step or action.
WARNINGThe operator driver is responsible for the correct and safe operation of the boat, theequipment aboard and the safety of all occupants aboard. We strongly recommend thatthe operator read this Operation, Maintenance and Warranty Manual and thoroughlyunderstand the operational instructions for the power package and all related accessoriesbefore the boat is used. WARNINGThe engine exhaust from this product contains chemicals known to the state of Californiato cause cancer, birth defects or other reproductive harm.
Warranty Registration: United States andCanada Consumer Application Warranty Chart Lanyard Stop Switch Digital Gauges Home Documents Mercruiser 4. Post on Jan 1.
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