Mercury Mercruiser Sterndrive Units Alpha One Generation II Factory Service Repair Manual + Wirings

Mercury Mercruiser Sterndrive Units Alpha One Generation II Factory Service Repair Manual + Wirings

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. 

715  Pages

MODELS COVER:

Mercury Mercruiser Sterndrive Units Alpha One Generation II

MANUAL COVERS:

SECTION 1 – Important Information

A – General Information

B – Maintenance

C – Troubleshooting

SECTION 2 – Removal and Installation

All Models

SECTION 3 – Sterndrive Unit

Drive Shaft Housing

Gear Housing Standard Rotation

Gear Housing (Counter Rotation)

SECTION 4 – Transom Assembly

Minor Disassembly

Major Disassembly

SECTION 5 – Power Trim

Olidyne Trim Pump

Trim Cylinders

Dual Power Trim System

Auto Trim II

SECTION 6 – Steering System

Power Steering

Manual Steering

SECTION 7 – Corrosion Protection

Wiring Diagram

 This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• Gear lube monitoring: A lube monitor bottle was added in the engine compartment with an audible alarm to warn the operator of low gear lube levels.
• Corrosion resistance: The 
  Generation II

   utilizes XK 360 low-copper aluminum alloy for better resistance to corrosion in saltwater environments. The drive is also coated with a three-layer process (Tri-Paint System) for extra protection.

• Maintenance-free components:
  • Permalube® U-Joints: These were designed to be virtually maintenance-free.
  • Permanently lubricated hinge pins: Unlike the Gen I’s greasable pins, these require no maintenance.
• Improved water pump: The water pump and impeller were redesigned for better cooling and durability.
• Easier servicing: A greaseable drive coupler that can be lubricated from inside the boat was added.
• Redesigned shift mechanism: The new mechanism offers smoother shifting and is less prone to the problems sometimes found in the Gen I’s linkage.
• Enhanced gear design: Spiral-cut steel gears were introduced for quieter operation and enhanced durability.
• Improved mounting: The 
  Gen II

   features a wider mounting dimension for the trim cylinders and is attached with e-clips, unlike the Gen I which was secured with nuts.

• Non-interchangeable units: Due to significant design changes, 
  Alpha One Gen I

   and Gen II sterndrive units are not interchangeable. 

• Engines: The 
  Alpha One Gen II

   is compatible with a wide range of gasoline engines up to 300 hp, such as the 4.3L V6 and 5.0L/5.7L V8 packages. It can also be paired with diesel engines up to 150 hp.

• Boats: It is suitable for small- to mid-sized recreational boats, including runabouts, pontoons, and cruisers.
• Applications: Its hydrodynamic design and reliable performance make it a popular choice for water sports like water skiing and wakeboarding, as well as general cruising. 

• Water pump impeller: Despite improvements, the impeller should still be inspected and replaced annually or every 100 hours to prevent engine overheating.
• Corrosion: While more resistant, corrosion is still a potential issue in saltwater. Regular rinsing with fresh water and anode inspection are crucial.
• Gimbal bearing: Some sources indicate that the Gen II may have more gimbal bearing failures than the Gen I, though proper lubrication can mitigate this.
• Oil change: Draining and refilling the gear lube is an important annual maintenance task.