Mercury Mercruiser Sterndrive Units Alpha One Generation II Service Repair Manual

Mercury Mercruiser Sterndrive Units Alpha One Generation II Service Repair Manual

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Mercury. Read and print pages, or copy the entire manual to your hard drive.

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.