REMOVAL, INSTALLATION AND ADJUSTMENTS 2 A

c. Torque pivot bolts to 25 lb. ft. (34 N·m). Bendwasher tab against flat on bolt head.10. If equipped with power steering, install steeringcable as follows:d. If unit is secured with pivot pins, spread cotterpin ends.a. Lubricate steering cable end with a liberalamount of Special Lubricant 101 and installcable end through guide tube.9. If equipped, connect power steering unit to steering lever as follows:b. Connect cable end to clevis with clevis pin.Secure clevis pin in clevis with cotter pin.Spread both ends of cotter pin.a. Lubricate clevis pin with Special Lubricant101.c. Tighten coupler nut. Torque to 35 lb. ft. (48N·m).b. Install clevis pin through clevis and steeringlever from top.d. Install locking plate on coupler nut and securewith screw and washer. Torque to 60-72 lb. in.(7-8 N·m).c. Secure clevis pin with cotter pin. Spread bothends of cotter pin.2203250483abcd-Clevis PinClevisSteering LeverCotter Pin! WARNINGSteering cable outer casing MUST BE free tomove back and forth for steering to functionproperly. DO NOT fasten any wires, cables or other items to steering cable, as this may prevent itfrom moving.22023abcdefg-Steering Cable EndCable Guide TubeClevis PinCotter PinCoupler NutLocking PlateScrew And WasherIndex90-12934--2 1097REMOVAL, INSTALLATION AND ADJUSTMENT 2A-13

11. If equipped with manual steering, install steeringcable as follows:a. Lubricate steering cable end with a liberalamount of Special Lubricant 101 and installcable end through guide tube.b. On single engine installations; connect steeringcable to steering lever and secure with clevis pinand cotter pin. Spread both ends of cotter pin.c. On dual engine installations; connect steeringcable to clevis assembly and secure with clevispin and cotter pin. Connect clevis and tie bar tosteering lever and secure with clevis pin andcotter pin. Spread both ends of cotter pins.d. Tighten coupler nut. Torque to 35 lb. ft. (48 N·m).e. Install locking sleeve on coupler nut and securewith cotter pin. Spread both ends of cotter pin.5048450483Dual Engine Installation22055Single Engine Installation - Earlier Style SteeringCableabcdefg-Steering Cable EndClevis PinCotter PinSteering LeverCoupler NutCotter PinLocking Sleeveabcdef-Steering Cable EndClevis AssemblyTie BarClevis PinsCotter PinsCoupler Nut12. Connect power steering hydraulic hoses to their corresponding fittings on the control valve. Torque largehose fitting to 20-25 lb. ft. (27-34 N·m). Torque smallhose fitting to 96-108 lb. in. (11-12 N·m).70373Single Engine Installation - Later Style SteeringCableabcdefg-Steering CableCable Coupler NutSteering Cable Guide TubeSteering Cable EndCotter PinClevis PinSteering Lever22023a - Large Fittingb - Small FittingIndex2A-14 –REMOVAL, INSTALLATION AND ADJUSTMENTS90-12934--2 1097

Sterndrive Unit Installation1. Install and align engine. (Refer to appropriate Engine Service Manual).4. Coat drive unit pilot and drive shaft O-rings with2-4-C Marine Lubricant. Coat the driveshaftsplines with Engine Coupler Spline Grease.IMPORTANT: Rubber gasket must be properlypositioned in bell housing bore before installingdrive unit, or water may leak into boat.2. Ensure that rubber gasket and water passage Oring are properly positioned in bell housing.3. Coat entire stud and threads with 2-4-C MarineLubricant.22061a - Drive Shaft Pilotb - Drive Shaft O-ringsc - Drive Shaft Splines5. Position bell housing shift shaft coupler so thatslot in coupler is positioned straight fore and aft.Do this by placing remote control shift lever in:Forward gear position for RH drive or Reverse gear position for LH drive unit.50636a - Rubber Gasketb - Water Passage O-ringc - Studs22061a - Shift Shaftb - Shift Shaft Couplerc - Shift SlideIndex90-12934--2 1097REMOVAL, INSTALLATION AND ADJUSTMENT 2A-15

IMPORTANT: Shift slide assembly is free to rotateon core wire, therefore, be careful that shift slide remains in upright position and is properly engagedwith shift shaft lever while installing drive unit.7. Place gasket on bell housing.8. Install sterndrive unit as follows:a. Position trim cylinder straight back (over topof acceleration plate). Be careful not toscratch acceleration plate or trim cylinders.b. Guide U-joint shaft through gimbal bearingand into engine coupler while simultaneouslyguiding shift slide into drive shaft housing.Make sure shift slide remains upright and engaged with bell housing shift shaft lever.IMPORTANT: If drive unit will not slide all the wayinto bell housing, check shift shaft coupler to ensure they are positioned properly. Do not forcedrive unit into position.c. If necessary, rotate propeller shaft counterclockwise slightly to help align U-joint shaftsplines with engine coupler splines, then,slide drive unit all-the-way into bell housing.50629a - Shift Shaft Leverb - Roller6. Position drive unit shift shaft coupler so that isstraight forward by turning coupler clockwisewhile simultaneously turning propeller shaftcounterclockwise.22062a - Gasketb - Shift Slided. Return remote control shift lever to the neutral position.22061a - Drive Unit Shift Shaft CouplerIMPORTANT: Be sure to install RH or LH drive uniton the appropriate transom assembly when making dual engine installations. The LH rotationdrive unit can be identified by the decal on theback side of the upper drive shaft housing, whichstates:“Alpha One-Counter Rotation”Index2A-16 –REMOVAL, INSTALLATION AND ADJUSTMENTS90-12934--2 1097

9. Fasten drive unit to bell housing with hardwareshown. Torque evenly, starting from center, to 50lb. ft. (68 N·m).11. Install trim cylinders (Aft End) on drive shafthousing. Tighten locknuts until they bottom onanchor pin shoulder.2206022062a - Locknuts And Flat Washersb - Locknut And Ground Plate (Do NOT Use Flat Washer)IMPORTANT: To aid in installing rubber bushings, use a water and soap solution.10. If removed, install trim cylinders on gimbal ring.Tighten until locknuts bottom on anchor pin shoulder.2244122948abcdefgh-abcdef-Anchor PinWashers (2)-Large I.D.Rubber Bushings (4)Washers (2)-Small I.D.Locknuts (2)Plastic Caps (2)Gimbal RingTrim Cylinders (Port And Starboard)Anchor PinFlat Washers (2)-Large I.D.Rubber Bushings (4)Flat Washers (2)-Small I.D.Locknuts (2)Plastic Caps (2)Index90-12934--2 1097REMOVAL, INSTALLATION AND ADJUSTMENT 2A-17

12. If equipped, reinstall remote oil reservoir hose.(Refer to Section 1B for filling instructions).IMPORTANT: If boat is equipped with A REMOTECONTROL THAT HAS SEPARATE SHIFT ANDTHROTTLE LEVERS, this shift assist assemblyshould NOT be used. The use of the shift assistassembly with this type of remote control cancause the shift lever to move out of gear unexpectedly.7133923253a - Shift Leverb - Throttle Levera - Adaptor Fittingb - Hose Fittingc - BracketShift Cable AdjustmentNOTE: Some models may be equipped with a shiftassist assembly. The only difference with these models is that the remote control shift cable attachinghardware is slightly longer. Shift cable adjustment isthe same as all other versions.NOTE: A difference exists between earlier and latermodel shift plates, in that the later models have a pinand cotter pin to secure the remote control shift cableto the shift lever, whereas the earlier models used astud with washers and locknut. However, adjustmentprocedures are the same.50308a - Shift Assist Assemblyb - Remote Control Shift Cable22911Earlier Models (With Metal Shift Lever)a - Remote Control Shift Cableb - Stud, Washers and LocknutIndex2A-18 –REMOVAL, INSTALLATION AND ADJUSTMENTS90-12934--2 1097

3. If equipped with shift assist assembly: Oncebrass barrel adjustment is correct, install endguide “stop clip” on threaded tube. Position asshown, with tang touching brass barrel.22265Later Models (With Plastic Shift Lever)50484a - Remote Control Shift Cableb - Pin and Cotter Pina - Stop Clipb - Brass BarrelInstalling Shift Cables1. Push in on drive unit shift cable while simultaneously turning propeller shaft counterclockwiseuntil shaft stops, to ensure drive unit is completely in gear. Maintain pressure on propeller shaftwith a suitable device (elastic strap).2. Measure distance between center of hole in shiftcable end guide and center of brass barrel. Measurement should be 6 in. (153 mm).4. Install drive unit shift cable as shown. Securebrass barrel in barrel retainer with cotter pin andspread both prongs. Secure cable end guide withwashers (one on each side of end guide) andlocknut. Tighten locknut until it bottoms out, thenback off 1/4-1/2 turn.2226650484a - End guideb - Brass Barrelc - 6 in. (153 mm)a - Cotter Pinb - Locknut And WashersIndex90-12934--2 1097REMOVAL, INSTALLATION AND ADJUSTMENT 2A-19

5. Ensure shift lever adjustable stud is at bottom ofslot. If necessary, loosen stud and move it to bottom of slot, then retighten stud.b. Left Hand (LH) Rotation Drive Unit-reversegear, past detent, into wide-open-throttleposition.2290950309a - Adjustable StudIMPORTANT: Shift cable adjustment for a righthand (RH) rotation drive unit is different than theprocedure for adjusting a left hand (LH) rotationdrive unit. Be sure to refer to the appropriate procedure when performing the following steps.IMPORTANT: Drive unit must be installed.7. Place drive unit into gear by pushing in on driveunit shift cable, while simultaneously rotating propeller shaft counterclockwise until shaft stops, toensure full clutch engagement. Maintain a lightpressure on the drive unit shift cable to hold it atthe end of its travel (this removes all slack fromthe cable).IMPORTANT: Do not use excessive force whenholding pressure on the drive unit shift cable. Excessive force would be indicated by movementof the shift cutout switch.IMPORTANT: DO NOT run engine.6. Shift remote control as stated in “a” or “b” following:22266a. Right Hand (RH) Rotation Drive Unit-forward gear, past detent, into wide-openthrottle position.22909a - Drive Unit Shift Cableb - Propeller Shaft RotationIndex2A-20 –REMOVAL, INSTALLATION AND ADJUSTMENTS90-12934--2 1097

8. Lightly pull on remote control shift cable endguide (to remove slack from remote control andcable) and adjust brass barrel as necessary toalign attaching points with shift lever clevis pinhole and stud. Be sure to maintain light pressureon drive unit shift cable.11. Shift remote control as stated in “a” or “b”following:a. Right Hand (RH) Rotation Drive Unit reversegear,pastdetent,intowide-open-throttle position.b. Left Hand (LH) Rotation Drive Unit forwardgear,pastdetent,intowide-open-throttle position.abcd-End GuideBrass BarrelShift Lever Clevis Pin HoleStud503099. After cable has been aligned, turn brass barrel 4turns away from cable end guide.2290912. Simultaneously rotate propeller shaft clockwiseuntil shaft stops to ensure full clutch engagement.50308a - End Guideb - Brass Barrel10. Temporarily install remote control shift cable onstud and install clevis pin.22267a - Propeller Shaft-Rotate Clockwise50308a - Remote Control Shift Cableb - Clevis PinIndex90-12934--2 1097REMOVAL, INSTALLATION AND ADJUSTMENT 2A-21

13. Check shift cutout switch lever position. Rollermust be centered.15. After remote control shift cable has been properlyadjusted, reinstall cable and shift assist assembly(if applicable) and secure with hardware as shown.If shift assist assembly attaching points will notalign, push in or pull out on end of shift assist assembly to install. Do not attempt to readjust shiftcable.22058a - Shift Cutout Switch Roller14. If roller is not centered:a. Ensure adjustable stud is at bottom of slot inshift lever.b. Check remote control for proper shift cableoutput [3 in. (76 mm) 1/8 in. (3 mm)]. Referto “Installation Requirements.”c. If “a” and “b” are correct, ensure drive unitshift cable is not crushed or kinked. (If driveunit shift cable is binding, the shift cutoutswitch roller will move off center when shifting“into” and “out of” forward and reverse).NOTE: If shift cable was damaged during installation,install new shift cable assembly in accordance withinstructions contained in sterndrive service manual,then repeat shift cable adjustment procedure.50484Earlier Models (With Metal Shift Lever) With ShiftAssist Assemblyabcdef-Remote Control Shift CableShift Assist AssemblyLarge I.D. WasherSmall I.D. WasherLocknut-Tighten Until Bottomed then Back Off 1/2 TurnSpacer50308Later Models (With Plastic Shift Lever) With ShiftAssist Assemblyabcdef-Remote Control Shift CableShift Assist AssemblyClevis PinCotter Pin-(Spread Both Prongs)Large I.D. WasherSmall I.D. WasherIndex2A-22 –REMOVAL, INSTALLATION AND ADJUSTMENTS90-12934--2 1097

16. Remote Control with Single Lever Shift/Throttle Control:a. RIGHT HAND (RH) propeller rotation driveunit-Shift remote control into reverse gear,wideopenthrottlepositionwhilesimultaneously rotating propeller shaftclockwise. Clutch should engage and causepropeller shaft to lock. If clutch does notengage, loosen adjustable stud on shift leverand move it upward in slot until clutchengages with reverse gear. Retighten stud.Shift remote control several times and stop inreverse to recheck shift cutout switchposition. Roller must be centered.22910Earlier Models (With Metal Shift Lever) WithoutShift Assist Assemblyabcdef-Washer (Same Size I.D.)LocknutWasher (Large I.D.)Washers (Small I.D.) (2)Cable End GuideShift Leverb. LEFT HAND (LH) propeller rotation driveunit-Shift remote control into forward gear,wideopenthrottlepositionwhilesimultaneously rotating propeller shaftclockwise. Clutch should engage and causepropeller shaft to lock. If clutch does notengage, loosen adjustable stud on shift leverand move it upward in slot until clutchengages with forward gear. Retighten stud.Shift remote control several times and stop inforward to recheck shift cutout switchposition. Roller must be centered.17. Two Lever Remote Control with SeparateShift and Throttle Levers:22266Later Models (With Plastic Shift Lever) WithoutShift Assist Assemblyabcdefg-PinCotter PinWasher (Large I.D.)Washer (Small I.D.)Cable End GuideShift LeverLocknutIMPORTANT: If an extra long remote control shiftcable is used, or if there are a large number ofbends in remote control shift cable, or remotecontrol has inadequate output travel, an additional adjustment may be necessary. Refer tostep 15 or 16 as applicable.a. RIGHT HAND (RH) propeller rotation driveunit-While turning propeller shaft clockwise,move remote control shift handle into full reverse position. Clutch should engage beforeshift lever comes to a stop. If clutch does notengage, loosen adjustable stud on shift leverand move it upward in slot until clutch engages with reverse gear. Retighten stud. Shiftremote control several times and stop in reverse to recheck shift cutout switch position.Roller must be centered.b. LEFT HAND (LH) propeller rotation driveunit-While turning propeller shaft clockwise,move remote control shift handle into full forward position. Clutch should engage beforeshift lever comes to a stop. If clutch does notengage, loosen adjustable stud on shift leverand move it upward in slot until clutch engages with forward gear. Retighten stud. Shiftremote control several times and stop in forward to recheck shift cutout switch position.Roller must be centered.Index90-12934--2 1097REMOVAL, INSTALLATION AND ADJUSTMENT 2A-23

Propeller Installation! WARNINGBe sure that remote control is in neutral positionand ignition key is removed from switch.! WARNINGPlace a block of wood between the anti-ventilation plate and propeller to protect hands frompropeller blades and to prevent propeller fromturning.503091. To aid in future propeller removal, liberally coatthe propeller shaft splines with one of the following lubricants. Install propeller as shown. Special Lubricant 101 2-4-C Marine Lubricant Perfect SealIMPORTANT: Installation is correct when at least2 threads of propeller shaft are exposed throughpropeller nut.22058a - Adjustable Studb - Shift Cutout Switch Roller18. Place boat in water and start engine. Check thefollowing:a. Shift into forward and reverse gear, makingsure that clutch engages before engine begins to accelerate.b. Accelerate engine in forward and reversegear to ensure engine does not shut down.c. Check that shift cutout switch roller is centered in notch of shift cutout lever, with driveunit in forward and reverse gear.d. Shifting from “in gear position” to neutral, ensure drive unit is in neutral before remote control shift lever comes to neutral detent position.22074abcdefg-Propeller ShaftForward Thrust HubPropellerContinuity WasherSpline WasherTab WasherPropeller Nut2. Tighten propeller nut until a torque of 55 lb. ft. (75N·m) is obtained and continue until 3 tabs on tabwasher align with grooves on spline washer.Bend tabs into spline washer.Index2A-24 –REMOVAL, INSTALLATION AND ADJUSTMENTS90-12934--2 1097

Jun 06, 2012 · to power trim pump. 4. Connect power trim pump hydraulic hoses. Torque to 70-150 lb. in. (8-17 N·m). 5. Connect trim limit switch wires. 22031 Oildyne Power Trim Pump (Plastic Reservoir) a - Black Hose (Up Hose) b - Gray Hose (Down Hose) c - Trim Limit Switch Wires d - Wire Retainer And Sta-Strap 50483 Oildyne