ALPHA ONE GENERATION II STERNDRIVE

Transcription

1 LPH ONE GENERTION II STERNDRIVE

2 Tle of Contents Pge Instlltion Speifitions Torque Speifitions Lurints, Selers, n hesives Speil Tools Trnsom Speifitions Instlltion Proeures Trnsom ssemly Instlltion Power Steering Control Vlve n Cle Instlltion Power Steering Hose Connetions Stern Drive Unit Instlltion Trim Cyliner Connetion Propeller Instlltion Drive Shft Housing Speifitions Torque Speifitions Upper Drive Shft Bering Prelo U-joint Bering Prelo Ger Shimming Speifitions Lurints, Selers, n hesives Speil Tools Drive Shft Housing Exploe Prts View U-Joint n Driven Ger Components Drive Shft Components Drive Shft Housing Shimming Ger Distne, Driven Ger Ger Distne, Drive Ger Drive Shft Housing Speil Informtion Top Cover Bering Cup Top Cover Bering Cup Drivers Stnr Rottion Ger Housing Speifitions Torque Speifitions Shimming Speifitions Lurints, Selers, n hesives Speil Tools Stnr Rottion Ger Housing Exploe Prts View Drive Shft Components Propeller Shft Components Speil Informtion For Stnr Rottion Ger Housing Pge Stnr Rottion Ger Housing ssemly Speifitions Pre-Disssemly Inspetion Pinion Ger Height Shift Spool En Ply Forwr Ger Bklsh Reverse Ger Bklsh Counter-Rottion Ger Housing Speifitions Torque Speifitions Shimming Speifitions Lurints, Selers, n hesives Speil Tools Counter-Rottion Ger Housing Exploe Prts View Drive Shft Components Propeller Shft Components Speil Informtion For Counter-Rottion Ger Housing Counter-Rottion Ger Housing ssemly Speifitions Pre-Disssemly Inspetion Forwr n Reverse Ger Ientifition Pinion Ger Height Shift Spool En Ply Forwr Ger Bklsh Reverse Ger Bklsh Trnsom ssemly Speifitions Torque Speifitions Speil Tools Lurints, Selers, n hesives lph One Trnsom ssemly Exploe View Bell Housing Components Giml Housing Components Inner Trnsom Plte Components Giml Ring n Steering Lever Components lph One Genertion II Sternrive

3 Instlltion Speifitions Torque Speifitions NOTE: Seurely tighten ll fsteners not liste elow. ITEM TORQUE l. in. l. ft. N m Exhust Pipe to Giml Housing Srews Propeller Nut Steering Cle Coupler Nut Tighten Nut Until It Bottoms Out ginst Flt Wsher, then Loosen 1/2 Turn Steering Cle Coupler Nut Steering system Pivot Bolts Trnsom ssemly tthing Srews n Nuts Power Steering Hyruli Hose Fittingsi Stern Drive Unit to Bell Housing tthing Nuts 1 : mount speifie is MINIMUM Trnsom Speifitions e f Trnsom Thikness-2-2 1/4 in. (51-57mm) - Trnsom Surfes-Prllel to within 1/8 in. (3.2 mm) - re Covere y Inner Trnsom Plte - Flt to within 1/8 in. (3.2 mm) - re Covere y Giml Housing ssemly - Flt to within 1/16 in. (1.6 mm) e - Trnsom ngle-10 to 16 f - Keel (if Equippe) - Remove 4 ft. (1.2 m) forwr of trnsom Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint with Teflon Quiksilver Speil Lurint Perfet Sel Liqui Neoprene Quiksilver Engine Coupler Spline Grese Speil Tools DESCRIPTION lignment Tool ssemly PRT NUMBER lph One Genertion II Sternrive 2-1

4 Instlltion Proeures Trnsom ssemly Instlltion! CUTION Steering lever groun wire MUST e positione s shown or wire my ftigue Speeometer Tue Pik-up Connetion 2 - Loknuts n Flt Wshers 3 - Srew 4 - Steering Lever Continuity Wire 5 - Trim System Wires 6 - Shift Cle 7 - Trim Hoses (n MerCthoe Wires, if so equippe) 8 - Ger Lue Hose Fitting 7 Torque Speifition 23 l. ft. (31 N m) l.in. (8-10 N m) 2-2 lph One Genertion II Sternrive

5 Power Steering Control Vlve n Cle Instlltion Steering Cle 2 - Grese Fitting 3 - Cle Coupler Nut 4 - Cle Guie Tue 5 - Cle En 6 - Clevis 7 - Clevis Pin 8 - Cotter Pin 9 - Flts on Guie Tue MUST Be Vertil 10- Pivot Bolt Lurints, Selers, n hesives - Quiksilver Speil Lurint Torque Speifition 35 l. ft. (47 N m) 50 l. ft. (68 N m) lph One Genertion II Sternrive 2-3

6 Power Steering Hose Connetions STERN DRIVE TO BELL HOUSING CONNECTION Typil Hose Routing Hose Fittings - Torque Both Fittings to 23 l. ft. (31 N m). Stern Drive Unit Instlltion USING THE LIGNMENT TOOL! CUTION Foring the lignment tool into position my mge the Giml Bering or Engine Coupler. Do not ttempt to fore the lignment tool! Rise or lower the engine s neessry until lignment tool moves freely Loknut n Flt Wshers - Torque to 50 l. ft. (68 N m) - Loknut n Continuity Ciruit Wsher - Torque to 50 l. ft. (68 N m) Trim Cyliner Connetion e lignment Tool - Giml Bering - Engine Coupler - ft nhor Pin - Bushings - Flt Wshers (2) - E-ring Clips (2) e - Plsti Cps (2) 2-4 lph One Genertion II Sternrive

7 Propeller Instlltion e f Typil Propeller - Propeller Shft - Forwr Thrust Hu - Propeller - Continuity Wsher e - Spline Wsher f - T Wsher g - Propeller Nut-Torque to 55 l. ft. (75 N m) g e f g Propeller With Flo-Torque Hu - Propeller Shft - Forwr Thrust Hu - Drive Sleeve - Propeller e - Drive Sleeve pter f - T Wsher g - Propeller Nut-Torque to 55 l. ft. (75 N m) lph One Genertion II Sternrive 2-5

8 Drive Shft Housing Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Top Cover Srews U-joint Retiner Nut Oil Vent Srew Upper Drive Shft Bering Prelo DESCRIPTION New Berings 6-15 Use Berings* NOTE: Seurely tighten ll fsteners not liste elow TORQUE l. in. N m *Berings re onsiere use if spun uner lo one. U-joint Bering Prelo DESCRIPTION New Berings 6-10 Use Berings* TORQUE l. in. N m *Berings re onsiere use if spun uner lo one. Ger Shimming Speifitions DESCRIPTION GER LOCTION inhes millimeters Drive Ger Driven Ger Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint with Teflon Quiksilver U-Joint n Giml Bering Grese 3M Brn hesive Quiksilver Bellows hesive Quiksilver Neele Bering ssemly Lurint Quiksilver Perfet Sel Permtex Ultr Blue Otin Lolly Silione Selnt Quiksilver Speil Lurint 101 Quiksilver High Performne Ger Lue Speil Tools DESCRIPTION PRT NUMBER ptor Bering Cup Driver Bering Driver Cup Driver Cup Driver Ro Driver Tool Oil Sel Driver Shimming Tool (Driven Ger) Shimming Tool (Drive Ger) Slie Hmmer Puller Torque Wrenh (l. in.) U-joint Bering Retiner Wrenh Universl Puller Plte lph One Genertion II Sternrive

9 TORQUE CONVERSION CHRT Use the following tle to torque the u-joint retiner to 200 l. ft. (271 N m). Torque Wrenh Length in Inhes (m) 15 (38) 16 (41) 17 (43) 18 (46) 19 (48) 20 (51) 21 (53) 22 (56) 23 (58) 24 (61) 25 (64) 26 (66) 27 (69) 28 (71) 29 (74) 30 (76) 31 (79) 32 (81) 33 (84) 34 (86) 35 (89) 36 (91) Torque Wrenh Reing in l. ft. (N m) to hieve 200 l. ft. (271 N m) of Torque 111 (151) 114 (155) 117 (159) 120 (163) 123 (167) 125 (170) 127 (172) 129 (175) 131 (178) 133 (180) 135 (183) 136 (184) 138 (187) 140 (190) 141 (191) 143 (194) 144 (195) 145 (197) 147 (200) 148 (201) 149 (202) 150 (203) - Torque Wrenh Length lph One Genertion II Sternrive 2-7

10 Drive Shft Housing Exploe Prts View U-Joint n Driven Ger Components D D C B B lph One Genertion II Sternrive

11 1 - Drive Shft Housing 2 - Srew 3 - O-ring 4 - Spring ssemly 5 - Oil Sel 6 - Wer P 7 - Plug 8 - Universl Joint 9 - Yoke, Universl Joint - Ger En 10- Soket, Center - Universl Joint 11- Cross n Bering 12- Yoke ssemly, Universl Joint - Coupling En 13- O-ring 14- Retiner 15- Ring 16- O-ring 17- Crrier ssemly 18- Oil Sel 19- Roller Bering n Cups 20- Cup Sper 21- Shim 22- Shim 23- Drive Ger ssemly 24- Roller Bering n Cup 25- Wsher 26- Nut 27- Shims 28- Groun Plte 29- Srew Lurints, Selers, n hesives C Mrine Lurint with Teflon B - Quiksilver High Performne Ger Lue C - Quiksilver Speil Lurint D - Quiksilver Engine Coupler Spline Grese Torque Speifition 200 l. ft. (271 N m) - See Chrt on Pge 7 Rolling Prelo Tighten in Smll Inrements Until 6-10 l. in. ( N m) of Rolling Prelo lph One Genertion II Sternrive 2-9

12 Drive Shft Components B Cover, top 2 - Bering n Cup 3 - Shim 4 - O-ring 5 - Srew 8 - Drive Shft, upper 9 - Filler Wll 10- Wsher 11 - Nut 12- noi Plte 13- Srew 14- Lokwsher 15- Srew 16- Sel 17- Wter Tue 18- Stuffer Plug Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon B - Quiksilver High Performne Ger Lue Torque Speifitions 20 l. ft. (27 N m) 35 l. ft. (47.5 N m) 2-10 lph One Genertion II Sternrive

13 Drive Shft Housing Shimming Ger Distne, Drive Ger SHIMMING TOOL Ger Distne, Driven Ger SHIMMING TOOL Overll Drive Unit Ger Rtio 1.47:1 1.62:1 1.81:1 1.94:1 2.40:1 Tool Position Z X Y Y Y Overll Drive Unit Ger Rtio 1.47:1 1.62:1 1.81:1 1.94:1 2.40:1.025 (0.64mm) Tool Position Z Y Y Y Y.025 (0.64mm ) Feeler Guge in. (0.635mm) - Feeler Guge in. (0.635mm) lph One Genertion II Sternrive 2-11

14 Drive Shft Housing Speil Informtion Top Cover Bering Cup Drivers Use the pproprite river for instlltion of the ering up. Top Cover Bering Cup The lter style ering up is thinner thn the erlier style up. e Erlier Style Bering Cup in. Dimeter (Prior to S/N OF680000) - Lter Style Bering Cup in. Dimeter (S/N OF n ove) Shims - Bering Cup - Bering Cup Driver ( ) use with Bering OR Bering Cup Driver ( ) use with Bering - Driver Ro ( ) e - Top Cover 2-12 lph One Genertion II Sternrive

15 Stnr Rottion Ger Housing Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Wter Pump Boy Srews Pinion Ger Nut Ger Housing to Drive Shft Housing Srews Ger Housing to Drive Shft Housing Nuts Trim T Srew Shift Shft Bushing Srews Drive Shft Retiner Ber Crrier Retiner Oil Fill/Drin Srew NOTE: Seurely tighten ll fsteners not liste elow Propeller Nut Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint with Teflon M Brn hesive Quiksilver Bellows hesive Quiksilver Neele Bering ssemly Lurint Quiksilver Perfet Sel Permtex Ultr Blue Silione Selnt Otin Lolly Quiksilver Speil Lurint Lotite Quiksilver High Performne Ger Lue : mount speifie is MINIMUM. Shimming Speifitions DESCRIPTION GER LOCTION inhes millimeters Pinion Ger Height Forwr Ger Bklsh Reverse Ger Bklsh lph One Genertion II Sternrive 2-13

16 Speil Tools DESCRIPTION PRT NUMBER Bklsh Initor Ro Bering Crrier Retiner Wrenh Bering Prelo Tool Belleville Wsher Dil Initor Dil Initor Holing Tool Drive Shft Nut Wrenh Cup Driver Drive Shft Bering Wrenh Neele Bering Driver Neele Bering Driver Oil Sel Driver Oil Sel Driver Pinion Ger Shimming Tool Pinion Nut pter Drive Shft pter Puller Bolt Puller Jws Slie Hmmer Puller Torque Wrenh (Inh Poun) Wter Pump lignment Pins Universl Bering Removl n Instlltion (Inlues the Following Items) Bering pter Bering Instlltion Tool DESCRIPTION PRT NUMBER Collr Driver He Driver He Driver He Driver He Driver He Driver He Ro Nut Pilot Wsher Pilot Wsher Pilot Wsher Puller Plte Puller He Puller He Puller He Puller Ro Puller Shft Roller Bering Removl n Instlltion Tool Wsher *The Bering Prelo Tool is lso use on Merury n Mriner V-6 ger ses. Chek your inventory efore uying. NOTE: Wter Pump Fe Sel Tool is not ville seprtely, is kit prt numer whih inlues the tool n the fe sel lph One Genertion II Sternrive

17 THIS PGE IS INTENTIONLLY BLNK lph One Genertion II Sternrive 2-15

18 Stnr Rottion Ger Housing Exploe Prts View Drive Shft Components f D (ID) C E 4 h B D lph One Genertion II Sternrive

19 1 - Ger Housing 2 - Pin 3 - Stu 4 - Oil Fill/Drin Srew 5 - O-ring 6 - Sel 7 - Dowel Pin 8 - Roller Bering 9 - Speeometer Fitting 10- Drive Shft 11- Shim 12- Bering n Cup 13- Nut 14- Ger Drive 15- Wsher 16- Nut 17- Fe Plte 18- Crrier 19- Oil Sel 20- Oil Sel 21- O-ring 22- Wter Pump 23- Gsket 24- Gsket 25- Fe Sel 26- Srew 27- Impeller 28- Key 29- Coupling 30- O-rings 31- Sleeve 32- Shift Shft 33- Retining Ring 34- Sleeve 35- Bushing ssemly 36- Oil Sel 37- O-rings 38- Srew Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon B - 3M Brn hesive C - Lotite D - Quiksilver High Performne Ger Lue E - Quiksilver Neele Bering ssemly Lurint Torque Speifitions 60 l. in. (6.8 N m) e f g h 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) l. in. ( N m) lph One Genertion II Sternrive 2-17

20 Propeller Shft Components E C 32 e B C D C (OD) F g 24 (ID) lph One Genertion II Sternrive

21 1 - Ger Housing 2 - Shift Crnk 3 - Shift Spool ssemly 4 - Shim, Bering Outer Re 5 - Bering n Cup 6 - Forwr Ger 7 - Roller Bering 8 - Sliing Cluth 9 - Cross Pin 10- Spring 11- Propeller Shft 12- Reverse Ger 13- Thrust Wsher 14- Thrust Hu 15- Bll Bering 16- O-ring 17- Roller Bering 18- Bering Crrier ssemly 19- noe 20- Srew 21- Str Wsher 22- Oil Sel (Insie) 23- Oil Sel (Outsie) 24- T Wsher 25- Retiner 26- Thrust Hu 27- Continuity Wsher 28- Spline Wsher 29- T Wsher 30- Loknut - Propeller 31- noi Trim T (noi Plte - Some Moels) 32- Srew 33- Str Wsher 34- Srew 35- Nut Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon B - Lotite C - Quiksilver High Performne Ger Lue D - Quiksilver Perfet Sel E - Permtex Ultr Blue Silione Selnt Otin Lolly F - Quiksilver Speil Lurint Torque Speifitions 60 l. in. (6.8 N m) e f g 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) lph One Genertion II Sternrive 2-19

22 Speil Informtion For Stnr Rottion Ger Housing! CUTION voi mge to stern rive unit. Drive unit mge will our if Lter Style prts re intermixe with Erlier Style prts. SHIFT SPOOL SSEMBLY The lter style shift spool ssemly hs lrger gp thn the erlier style. This lter style shift spool eginning with seril numer 0K is sol s whole ssemly n n e use when repling the erlier style (Prior to S/N 0K041000). The en ply for the spool will remin the sme s the erlier moels ( in mm). FORWRD GER BERING BORE The lter style forwr ger ering ore is smller ( to in.) thn the erlier style ( to in.) This slightly smller ering ore for the forwr ger ering pter is pproximtely 1/4 in. (6.3 mm) smller to Erlier Style Forwr Ger Bore (Prior to S/N OF680000) to Lter Style Forwr Ger Bore (S/N OF n ove) - Erlier Style Shift Spool ssemly (Prior to S/N 0K041000) - Lter Style Shift Spool ssemly (S/N 0K n ove) - Mesure En Ply Here t Gp The lter style ering up is thinner n hs smller imeter thn the erlier style Erlier Style Ger Bering Cup in. imeter (Prior to S/N OF680000) - Lter Style Ger Bering Cup in. imeter (S/N OF n ove) 2-20 lph One Genertion II Sternrive

23 Stnr Rottion Ger Housing ssemly Speifitions Pre-Disssemly Inspetion tion Move propeller shft from one sie to nother Rotte propeller shft Reing Less thn.003 in. (0.08 mm).005 in. (.127 mm) or less Shift Spool En Ply NOTE: The lter style shift spool ssemly hs lrger gp thn the erlier style. This lter style shift spool eginning with seril numer OK is sol s whole ssemly n n e use when repling the erlier style (Prior to S/N OK041000). The en ply for the spool will remin the sme s the erlier moels ( in mm) Erlier Style Shift Spool ssemly (Prior to S/N 0K041000) - Lter Style Shift Spool ssemly (S/N 0K n ove) - Mesure En Ply Here t Gp Pinion Ger Height Chek pinion height t four lotions. verge pinion ger height:.025 in. (0.64 mm) lph One Genertion II Sternrive 2-21

24 Forwr Ger Bklsh pply forwr pressure to the propeller shft with puller jws. Torque the puller olt to 45 l. in. (5 N m ). Reverse Ger Bklsh Use the pinion nut ptor to pply kwr pressure on the propeller shft. Torque Propeller nut to 45 l. in. (5 N m) Puller Jws - Puller Bolt Tke reings t four ifferent lotions, 90 prt, n verge them for the klsh reing. Bklsh reing: in. ( mm) e f Pinion Nut ptor - Wsher - Propeller Nut Bklsh reing: in. ( mm). e f Nuts (4) - Three Ro - Dil Initor Holing Tool - Dil initor e - Initor Pointer-Set t I on Bklsh Initor Ro f - Bklsh Initor Ro Nuts (4) - Three Ro - Dil Initor Holing Tool - Dil initor e - Initor Pointer-Set t I on Bklsh Initor Ro f - Bklsh Initor Ro 2-22 lph One Genertion II Sternrive

25 Counter-Rottion Ger Housing Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Wter Pump Boy Srews Pinion Ger Nut Ger Housing to Drive Shft Housing Srews Ger Housing to Drive Shft Housing Nuts Trim T Srew Shift Shft Bushing Srews Drive Shft Retiner Ber Crrier Retiner Oil Fill/Drin Srew NOTE: Seurely tighten ll fsteners not liste elow Propeller Nut Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver 2-4-C Mrine Lurint with Teflon m Brn hesive Quiksilver Bellows hesive Quiksilver Neele Bering ssemly Lurint Quiksilver Perfet Sel Permtex Ultr Blue Silione Selnt Otin Lolly Quiksilver Speil Lurint Lotite Quiksilver High Performne Ger Lue : mount speifie is MINIMUM. Shimming Speifitions DESCRIPTION GER LOCTION inhes millimeters Pinion Ger Height Forwr Ger Bklsh Reverse Ger Bklsh lph One Genertion II Sternrive 2-23

26 Speil Tools Desription Tool Prt Numer Bklsh Initor Ro Bering ptor Instlltion Tool Bering Crrier Retiner Wrenh Bering Driver Bering Prelo Tool Bering Removl Tool Belleville Wsher Dil Initor Dil Initor Holing Tool Drive Shft Nut Wrenh Drive Shft Bering Retiner Wrenh Guie Plte Neele Bering Driver Oil Sel Driver Oil Sel Driver Pinion Ger Shimming Tool Pinion Nut ptor Speil Tools (ontinue) Desription Tool Prt Numer Drive Shft ptor Puller Bolt Puller Shft Puller Jws Puller Jws Slie Hmmer Puller Forwr Ger Instlltion Tool Torque Wrenh (Inh Poun) Universl Puller Plte Wter Pump lignment Pins Universl Bering Removl n Instlltion Tool Driver He Driver He Ro Nut Pilot Wsher Puller Plte Puller/Driver He *The Bering Prelo Tool is lso use on Merury n Mriner V-6 ger ses. Chek your inventory efore uying. NOTE: Wter Pump Fe Sel Tool is not ville seprtely, is kit prt numer whih inlues the tool n the fe sel lph One Genertion II Sternrive

27 THIS PGE IS INTENTIONLLY BLNK lph One Genertion II Sternrive 2-25

28 Counter-Rottion Ger Housing Exploe Prts View Drive Shft Components f D (ID) C E 4 h B D lph One Genertion II Sternrive

29 1 -Ger Housing 2 -Pin 3 -Stu 4 -Srew 5 -Oil Fill/Drin Srew O-ring 6 -Sel 7 -Dowel Pin 8 -Roller Bering 9 -Speeometer Fitting 10-Drive Shft 11 -Shim 12-Bering n Cup 13-Nut 14-Ger Drive 15-Wsher 16-Nut 17-Fe Plte 18-Crrier 19-Oil Sel 20-Oil Sel 21-O-ring 22-Wter Pump 23-Gsket 24-Gsket 25-Fe Sel 26-Srew 27-Impeller 28-Key 29-Coupling 30-O-rings 31-Sleeve 32-Shift Shft 33-Retining Ring 34-Sleeve 35-Bushing ssemly 36-Oil Sel 37-O-rings 38-Srew 39-Stuffer Plug Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon B - 3M Brn hesive C - Lotite D - Quiksilver High Performne Ger Lue E - Quiksilver Neele Bering ssemly Lurint Torque Speifitions 60 l. in. (6.8 N m) e f g h 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) l. in. ( N m) lph One Genertion II Sternrive 2-27

30 Propeller Shft Components e 2 F H E (ID) G (OD) E g lph One Genertion II Sternrive

31 1 - Ger Housing 2 - Srew - Trim Plte or T 3 - Nut 4 - Srew 5 - Lokwsher 6 - noi Plte or T 7 - Shift Crnk 8 - Shift Spool ssemly 9 - Shims 10- Bering pter - Reverse Ger 11- Roller Bering 12- Thrust Wsher 13- Thrust Bering 14- Roller Bering 15- Reverse Ger 16- Retiner Spring - Cross Pin 17- Cluth 18- Cross Pin 19- Propeller Shft 20- Forwr Ger 21- Shim Sper 22- Thrust Bering 23- Roller Bering 24- Bering pter - Forwr Ger 25- Thrust Wsher 26- Thrust Bering 27- Thrust Re 28- Keepers 29- O-ring 30- Neele Bering 31- Bering Crrier 32- Propeller noe n Srews 33- Sels 34- T Wsher 35- Retining Nut 36- Thrust Hu 37- Continuity Wsher 38- Spline Wsher 39- T Wsher 40- Loknut Lurints, Selers, n hesives - Quiksilver 2-4-C Mrine Lurint with Teflon B - 3M Brn hesive C - Quiksilver Bellows hesive D - Quiksilver Neele Bering ssemly Lurint E - Quiksilver Perfet Sel F - Permtex Ultr Blue Silione Selnt Otin Lolly G - Quiksilver Speil Lurint H - Lotite I - Quiksilver High Performne Ger Lue Torque Speifitions 60 l. in. (6.8 N m) e f g 70 l. ft. (95 N m) 28 l. ft. (38 N m) 35 l. ft. (47 N m) 23 l. ft. (31 N m) 100 l. ft. (136 N m) 210 l. ft. (285 N m) lph One Genertion II Sternrive 2-29

32 Speil Informtion For Counter-Rottion Ger Housing! CUTION PROPELLER SHFT The lter style propeller shft hs groove on the shft where the luth slies onto the shft. The keeper slot is lso move towr the forwr en of the shft. voi mge to stern rive unit. Drive unit mge will our if Lter Style prts re intermixe with Erlier Style prts. SHIFT SPOOL SSEMBLY The lter style shift spool ssemly for the ounter rottion hs lrger gp thn the erlier style. This lter style shift spool eginning with seril numer OF is sol s whole ssemly n must e use when repling the erlier style (Prior to S/N OF726586) Erlier Style Propeller Shft (Prior to S/N OF680000) - Lter Style Propeller Shft (S/N OF n ove) FORWRD GER BERING BORE The lter style forwr ger ering ore is smller ( to in.) thn the erlier style ( to in.)this slightly smller ering ore for the forwr ger ering ptor is pproximtely 1/4 in. (6.3 mm) smller to Erlier Style Shift Spool ssemly (Prior to S/N OF726586) e - Lter Style Shift Spool ssemly (S/N OF n ove) f - Mesure En Ply Here t Gp. Erlier Style Forwr Ger Bore (Prior to S/N OF680000) to Lter Style Forwr Ger Bore (S/N OF n ove) 2-30 lph One Genertion II Sternrive

33 BERING CRRIER The lter style ering rrier is somewht slimmer n out n 1/8 of n inh tller thn the erlier style ering rrier. FORWRD GER BERING DPTOR The forwr ger ering ptor hs the neele ering presse into the ptor. For future referene, the neele ering insie the ering pter oes not require speil river. The neele ering is presse into the ptor until the ering is flush with the ege of the ptor ore Erlier Style Bering Crrier (Prior to S/N OF680000) - Lter Style Bering Crrier (S/N OF n ove) THRUST COLLR The lter style thrust ollr is thinner thn the erlier style, ut still mintins the sme imeter Erlier Style Thrust Collr (Prior to S/N OF680000) - Lter Style Thrust Collr (S/N OF n fter) REVERSE GER BERING DPTOR The lter style reverse ger ering ptor hs smller imeter thn the erlier style ptor n is esigne to fit into the smller ore ger housing. - Erlier Style Forwr Ger Bering ptor (Prior to S/N OF680000) - Lter Style Forwr Ger Bering ptor (S/N OF n ove) - Lter Style Forwr Ger Bering ptor Neele Bering - Erlier Style Thrust Wsher Erlier Style Reverse Ger Bering ptor (Prior to S/N OF680000) - Lter Style Reverse Ger Bering ptor (S/N OF n ove) lph One Genertion II Sternrive 2-31

34 Counter-Rottion Ger Housing ssemly Speifitions Pinion Ger Height Tke reings in three lotions, 120 prt. Reings:.025 in. (0.64 mm). Pre-Disssemly Inspetion CTION Move propeller shft from one sie to nother Rotte propeller shft REDING Less thn.003 in. (0.08 mm).005 in. (.127 mm) or less Shift Spool En Ply Forwr n Reverse Ger Ientifition e f g IMPORTNT: The forwr n reverse gers look lmost ientil. There re two wys to istinguish etween the reverse n forwr gers. The reverse ger hs shorter hu n it hs groove ut into the k of the ger just insie the thrust ering re. h REVERSE - Shorter Hu - Groove FORWRD Wshers (2) - Spring - Retiner - Spool e - Shift Shft f - Cstle Nut g - Cotter Pin h - En Ply Mesurement:.002 in. (.05mm) to.010 in. (.25mm) 2-32 lph One Genertion II Sternrive

35 Forwr Ger Bklsh pply slight prelo on forwr ger using tools s shown. Reverse Ger Bklsh pply slight prelo on reverse ger using tools s shown Torque Wrenh ( ) - Propeller Nut [Torque to 45 l. in. (5 N m)] - Wsher ( ) - Pinion Nut ptor ( ) Chek Bklsh in four ples. Rotte the rive shft 90 fter eh hek. Bklsh Reing: in ( mm). e f - Torque Wrenh ( ) - Driver Bolt [Torque to 45 l. in. (5N m)] - Bering ptor Instlltion Tool ( ) - Reverse Ger Chek Bklsh in four ples. Rotte the rive shft 90 fter eh hek. Bklsh Reing: in. ( mm). e f Nuts (4) (otin lolly) - Three Ro [3/8 in. (9.5 mm) otin lolly] - Dil Initor Holing Tool ( ) - Dil Initor ( ) e - Initor Pointer-set initor pointer t I on klsh initor ro f - Bklsh Initor Ro ( ) - Nuts (4) (otin lolly) - Three Ro [3/8 in. (9.5 mm) otin lolly] - Dil Initor Holing Tool ( ) - Dil Initor ( ) e - Initor Pointer-set initor pointer t I on klsh initor ro f - Bklsh Initor Ro ( ) lph One Genertion II Sternrive 2-33

36 THIS PGE IS INTENTIONLLY BLNK 2-34 lph One Genertion II Sternrive

37 Trnsom ssemly Speifitions Torque Speifitions DESCRIPTION TORQUE l. in. l. ft. N m Shift Cle Core Wire nhor Srews Bellows Hose Clmps 35 4 Giml Ring to Bell Housing Hinge Pins Giml Ring Srews Steering Srew n Nut Trnsom ssemly tthing Srews, Nut 90 Fitting Nut NOTE: Seurely tighten ll fsteners not liste elow Fitting Oil Fill/Drin Srew Speil Tools DESCRIPTION PRT NUMBER Bering Removl n Instlltion Tool Bellows Expner Tool Slie Hmmer Puller Shift Cle Removl n Instlltion Tool Driver Driver Driver Driver He Driver Ro Drive Shft Nut Wrenh lignment Tool ssemly Expner Tool Hinge Pin Tool Mnrel Nut Speil Tools (ontinue) DESCRIPTION PRT NUMBER Plte (2) Puller Puller He Puller Shft Wsher Bushing Instlltion T Tool Sleeve Instlltion Tool Sleeve Removl Tool Lurints, Selers, n hesives DESCRIPTION PRT NUMBER Quiksilver Bellows hesive Quiksilver 2-4-C Mrine Lurint with Teflon Quiksilver U-Joint n Giml Bering Grese Perfet Sel nti-corrosion Grese Loqui Primer T Lotite Quiksilver Speil Lurint lph One Genertion II Sternrive 2-35

38 lph One Trnsom ssemly Exploe View Bell Housing Components B 22 C B (O.D.) B C E F lph One Genertion II Sternrive

39 1 - Bell Housing ssemly 2 - Gsket 3 - Connetor 4 - Pipe Plug 5 - Bushing 6 - Bushing 7 - Gsket (Ruer) 8 - O-ring 9 - Wsher (Synthne) 10-Stu 11- Wsher 12- Nut 13- Universl Joint Bellows 14- Groun Clip 15- Clmp 16- Sleeve 17- Hose 18- Clmp 19- Exhust Bellows 20- Sels 21- Clmp 22- Lever ssemly 23- Wsher 24- Srew 25- Shift Shft (Upper) 26- Coupling ssemly 27- Tuing 28- Clip 29- Clmp 30- Fitting ssemly 31- Connetor 32- Clmp 33- Hose 34- Clmp 35- Connetor 36- O-ring 37- Vlve ssemly 38- O-ring Lurints, Selers, n hesives - Quiksilver Bellows hesive B - Lotite C - Perfet Sel D - Speil Lurint E - Quiksilver High Performne Ger Lue F - 3M Brn hesive Torque Speifitions Tighten Seurely pproximtely 35 l. in. (4 N m) 50 l. ft. (68 N m) 8 l. ft. (11 N m) lph One Genertion II Sternrive 2-37

40 Giml Housing Components 43 B C D lph One Genertion II Sternrive

41 1 - Giml Housing 2 - Stu 3 - Lower Bushing 4 - Oil Sel 5 - Upper Bushing 6 - Grese Fitting 7 - Lurip 8 - Grese Sel 9 - Bering ssemly 10- Tolerne Ring 11- O-Ring 12- Stu 13- Sel 14- Pipe Plug 15- Wter Tue 16- Bushing 17- Cover 18- Srew 19- Lower Swivel Pin 20- Cotter Pin 21- Wsher 22- Bolt 23- Wsher 24- Wsher 25- Nut 26- Bolt 27- Clmp 28- Clmp 29- Wsher 30- Nut 31- Gsket 32- Connetor 33- Lokwsher 34- Nut 35- noi Plte 36- Sel 37- Gsket 38- Srew 39- Lokwsher 40- Hose 41- Clmp Fitting 43- Nut 44- Wsher 45- O-ring 46- Connetor 47- Continuity Wire 48- Continuity Wire Connetion 49- Hose Clmp Lurints, Selers, n hesives - Quiksilver Bellows hesive B - Quiksilver Perfet Sel C - Lotite D - Quiksilver U-Joint n Giml Bering Grese Torque Speifitions l. in. (8-10 N m) l. ft. (14-19 N m) l. in. ( N m) 25 l. ft. (34 N m) lph One Genertion II Sternrive 2-39

42 Inner Trnsom Plte Components Trnsom Plte ssemly 2 - Pivot Bolts 3 - T Wshers 4 - Srew Engine Mounting 5 - Wsher 6 - Sper 7 - Wsher - Fier 8 - Lokwsher - Doule Woun 9 - Loknut 10- Wsher 11- Loknut 12- Shift Cle Outer Csing 13- En Guie 14- Core Wire nhor 15- nhor Srews 16- Core Wire 17- Shift Slie 18- Srew - Core Wire Cvity 19- Giml Housing Eyelet 20- Cle Wrpping Torque Speifitions 25 l. ft. (34 N m) 23 l. ft. (30 N m) 37 l. ft. (50 N m) 2-40 lph One Genertion II Sternrive

43 Giml Ring n Steering Lever Components Giml Ring 2 - Bushing 3 - Grese Fitting 4 - Lurip 5 - Hinge Pin 6 - Trim Limit Swith 7 - Wsher 8 - Srew 9 - Lokwsher 10- Retiner 11- Trim Wire Clmp 12- Srew 13- Steering Lever 14- Swivel Shft 15- Wsher 16- Wsher 17- Nut 18- Srew 19- Nut 20- Srew 21- Wsher 22- Wsher 23- Loknut 24- Clevis Pin 25- Cotter Pin 26- Trim Position Sener Lurints, Selers, n hesives - Resiwel Seler Torque Speifitions 60 l. ft. (81 N m) 55 l. ft. (74 N m) 110 l. ft. (148 N m) l. in. (10-11 N m) lph One Genertion II Sternrive 2-41