section 2 - installation and adjustment
Contents
1. 90 806535940 893 oimultaneously rotate the propeller shaft clockwise until the shaft stops to ensure full clutch engagement Rotate Propeller Shaft Clockwise 9 Check shift cutout switch lever position Roller must be centered a Shift Cutout Switch Roller 10 If roller is not centered a Check to ensure adjustable stud is at bottom of slot in shift lever b Check remote control for proper shift cable output 3 in 76 mm 1 8in 8 mm Refer to Installation Requirements c If a and b are correct check to ensure drive unit shift cable is not crushed or kinked If drive unit shift cable is binding the shift cutout switch roller will move off center when shifting into and out of forward and reverse NOTE If the shift cable was damaged during installa tion install a new shift cable assembly in accordance with stern drive service manual instructions then re peat shift cable adjustment procedure INDEX 90 806535940 893 11 After properly adjusting remote control shift cable reinstall cable and shift assist assembly if applicable and secure as shown If the shift assist assembly attaching points will not align push in or pull out on the end of the shift assist assembly to install Do not attempt to read just shift cable rate 50308 Remote Control Shift Cable Shift Assist Assembly Clevis Pin Cotter Pin Not Seen Spread Both Pron2. Anchor Studs QOO INDEX 2A 8 MCM MODELS 90 806535940 893 3 On Engines With Electronic Fuel Injection a Place remote control handle s in neutral idle position b Remove flame arrestor 71481 Flame Arrestor b Locknuts c Install cable end guide on throttle lever then push cable barrel end lightly toward throttle le ver end This will place a slight preload on shift cable to avoid slack in cable when mov ing remote control lever Adjust barrel on throttle cable to align with hole in anchor plate Ensure hole in barrel positions cable as shown 71711 a Cable Barrel b Anchor Plate d Secure throttle cable with hardware as shown and tighten securely e Place remote control throttle level in the wide open throttle W O T position Check to en sure that throttle plates are completely open INDEX 90 806535940 893 Qa QOO 9 1 Return remote control throttle lever to idle position and check to ensure that throttle plates are completely closed Ks Sum NE RSS SAE a TT f 72191 a o 71761 Cable End Guide Cable Barrel Bolt Locknut Throttle Lever Flat Washer and Locknut Throttle Plates 72794 Throttle Lever Positive Stop Screw Throttle Stop Lever Throttle Stop Screw MCM MODELS 2A 9 4 Reinstall flame arrestor and tighten locknuts se curely Position crankcase vent hose against flame
3. INSTALLATION AND ADJUSTMENT MCM MODELS INDEX Table of Contents Page Torque Specifications 2A 1 3 0L and 3 0LX 2A 1 8 2 1 V 8 With Drive Shaft Extensions 2 2 Tools Lubricants Adhesives Sealants 2A MCM Engine Removal 2 Installation 2 Engine Installation Alignment 2 Engine Connections 2 Throttle Cable Adjustments 2 2 Barrel 2 Weber 4 Barrel Carburetor 2 Shift Cable Adjustment For Alpha Drives 2A 10 Shift Cables Installation and Adjustments For Bravo Drives 2A 15 MCM With Driveshaft Extension 2A 17 Engine Mount Adjustment Was Not Disturbed During Service 2A 17 INDEX 2A MCM MODELS 90 806535940 893 Torque Specifications IMPORTANT Listed below are the torque specifications for those fasteners which have a specific torque value Tighten all other fasteners not listed securely 3 0L and 3 0LX Lb Ft Nm Lb in Nm Rear Engine Mounts 30 40 Ib ft 47 54N m Bolts Nut Power Trim Cylinders to Anchor Tighten until they bottom out Pins Nuts Shift Cable End Guide Attaching Tighten each nut until it bottoms Nuts out against flat washer then back off 1 2 turn Stern Drive Unit To Bell
4. tighten stud a Stud b 3in 76mm Center of Pivot Bolt to Center of Stud Install drive unit shift cable 6 200 m eiae A 7 0 23345 Washers 2 Lock Nut Tighten Until Contact Then Back Off 1 2 Turn Cotter Pin Insert from Bottom and Spread Both Ends OOo pm p Place adjustment tool over drive unit shift cable as shown Hold tool in place using a piece of tape over the barrel retainer MCM MODELS 2A 15 5 Locate center of remote control and control cable play backlash a Shift remote control to neutral b Pushinon control cable end with enough pressure to remove play and mark position a on tube c Pullouton control cable end with enough pressure to remove play and mark position b on tube d Measure distance between marks and b and mark position c half way between marks a and 71656 IMPORTANT Be sure to keep center mark c aligned with control cable end guide edge when making the following adjustment 6 Adjust control cable as follows a Temporarily install control cable end guide into shift lever and insert anchor pin b Adjust control cable barrel so that hole in barrel centers with vertical centerline of stud Ensure that backlash center mark is aligned with edge of con trol cable end guide CAUTION DO NOT attempt to install or remove control cable barrel from stud without first rem
5. A lifting bar must be used on EFI en gines to prevent damage to components INDEX 90 806535940 893 13 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when sus pended 2 M OCIA BB 1 E 0 oe E AST CS 1 wN AB A 4 A ee ic C 50633 MCM 4 Cylinder a Lifting Eye b Suitable Sling MCM MODELS 2A 3 MCM V 6 a Lifting Eye b Suitable Sling INDEX 2A 4 MCM MODELS SY Pe We i EN c gt V 7 V 8 Typical Lifting Eye b Suitable Sling c Lifting Bar IMPORTANT A lifting bar must be used on EFI en gines to prevent damage to components 90 806535940 893 MCM Installation Engine Installation Alignment a 1 Follow instructions a Becertain fiber washers cemented in place on inner transom plate are present Inspect fi ber washers Replace if worn or damaged b Install double wound lockwashers onto inner transom plate inside fiber washer c Becertain rear engine mount locknuts are in position as shown d Lubricate exhaust bellows with soap and wa ter to ease installation e Lubricate engine coupling splines with Quick silver Engine Coupler Spline Grease Double Wound Lockwasher Fiber Washer Cemented in Place Inner Transom Plate Mount Engine Support Locknuts
6. Housing 50 Ib ft 68 N m Attaching Nuts Power Steering 20 25 Ib ft 27 34 N m Hydraulic Hose Fittings 96 108 Ib in 11 12 N m MCM V 6 and V 8 Fastener Location Lb Ft N m Drive Unit Shift Cable Barrel Spread Cotter Key Cable Cable End Guide See Note Hose Clamps Rear Engine Mounts 35 40 47 54 Power Steering Fluid Hoses Fittings 20 25 27 34 Remote Control Securely Shift Cables Cable Barrel Cable End Guide See Note Remote Control Throttle Cable Cable Barrel Securely Cable End See Note Note Tighten then back nut off one full turn INDEX 90 806535940 893 MCM MODELS 2A 1 MCM V 8 With Drive Shaft Extensions 50 65 3087 Rear Engine Mount Bracket 50 68 Power Steering Fluid Hose Fitting 20 25 27 34 Hemote Control Cable Throttle Cable Barrel Securely Cable End See Note NOTE Tighten then back off nut one full turn Tools Lubricants Adhesives Sealants 92 816391A4 Quicksilver Engine Coupler Grease 92 86154A1 Quicksilver 2 C 4 Marine Lubricant 92 25711 2 Quicksilver Liquid Neoprene Obtain Locally Loctite Pipe Sealant with Teflon 91 805475A1 Engine Alignment Tool INDEX 2A 2 MCM MODELS 90 806535940 893 MCM Engine Removal Disconnect BOTH battery cables from battery be fore proceeding with removal to prevent possi ble injury or damage to equipment should wires be accidentally shorted 1 Disconnect battery cables from battery 2 Remo
7. arrestor as shown 71764 a Crankcase Vent Hose Shift Cable Adjustment For Alpha Drives IMPORTANT Shift cable adjustment for a right hand RH rotation drive unit is different than the procedure for adjusting a left hand LH rotation drive unit Be sure to refer to the appropriate pro cedure when performing the following steps IMPORTANT Drive unit must be installed IMPORTANT DO NOT run engine 1 Remove remote control shift cable and shift assist assembly if installed 50308 a Shift Assist Assembly b Remote Control Shift Cable INDEX 2A 10 MCM MODELS WITH SHIFT ASSIST ASSEMBLY 50310 a Remote Control Shift Cable WITHOUT SHIFT ASSIST ASSEMBLY 2 Ensure shift lever adjustable stud is at bottom of slot If necessary loosen stud and move it to bot tom of slot then retighten stud 9 fa HEU 50309 a Adjustable Stud 90 806535940 893 3 Shift Remote Control as Stated in a or b 4 Place drive unit into gear by pushing in on the following a Right Hand RH Rotation Drive Unit for ward gear past detent into wide open throttle position drive unit shift cable while simultaneously rotat ing the propeller shaft counterclockwise until the shaft stops to ensure full clutch engagement Maintain a light pressure on the drive unit shift cable to hold it at the end of its travel this removes b Left Hand LH Rotation Drive Unit Re all slack from the ca
8. c Screws 3 Used Two Hidden in This View Use Loctite 271 72033 Top Shield Bottom Shield 4 Screws Nuts 2 Hidden 9 Screws 2 Hidden Engine End Shown QOO 10 Proceed to Engine Connections section instruc tions following INDEX 90 806535940 893 MCM MODELS 2A 19
9. Engine Mounting Bolts QOO Oo CAUTION Center lifting eye located on top of thermostat housing is used for engine alignment only DO NOT use to lift entire engine CAUTION DO NOT allow lifting sling to hook or compress engine components or damage will occur 2 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when sus pended Refer to Removal section for loca tion of lifting eyes INDEX 90 806535940 893 3 Lift engine into position in boat using an over head hoist 4 Align rear engine mounts with inner transom plate mounts while simultaneously aligning exhaust tubes with exhaust pipe hoses bellows IMPORTANT Engine attaching hardware must be installed in sequence shown 5 Install both rear engine mounting bolts and hard ware as shown Torque to 35 40 Ib ft 47 54 N m Bolt Rear Engine Mounting Washer Large Steel 72535 Spacer Metal Rear Engine Mount Double Wound Lockwasher Fiber Washer Inner Transom Plate Mounts Locknut Hidden in This View A CAUTION When lowering engine into position DO NOT set engine on shift cable Shift cable outer casing can be crushed causing difficult or improper shifting TO o ooolsqpv MCM MODELS 2A 5 6 Set engine down on stringers and relieve hoist tension Disconnect sling from engine lifting eyes and relocate sling to center lifting eye L1 1 jy TT 72024 a Ce
10. INDEX 90 806535940 893 MCM With Driveshaft Extension Engine Mount Adjustment Was Not Disturbed During Service CAUTION Center lifting eye located on top of thermostat housing is used for engine alignment only DO NOT use to lift entire engine CAUTION DO NOT allow lifting sling to hook or compress engine components or damage to them will oc cur 1 Attach a suitable sling to lifting eyes on engine and adjust so that engine is level when sus pended Refer to Removal as previously mentioned in this section for location of lifting eyes m Lift engine into approximate position in boat us ing an overhead hoist oet engine on stringers Grease drive shaft universal joints with Quicksil ver 2 4 C Marine Lubricant CAUTION When attaching shaft in next step BE SURE that the pilot on drive shaft flanges are engaged in in put shaft and output shaft flanges Flanges MUST BE flush to each other prior to tightening screws or screws may come loose during operation CAUTION Failure to align shaft flanges with matching marks made on disassembly may cause improp erly aligned drive unit and extension drive shaft U joint centerlines resulting in a severe vibration problem MCM MODELS 2A 17 5 As shown attach engine output flange to drive shaft flange exactly as marked during disassem bly Torque fasteners to 50 Ib ft 68 Nem Engine End Shown Output Shaft Flange Drive Sh
11. aft Screw 7 16 20 x 1 1 2 In 38 mm Long 4 Used Nut 7 16 20 4 Used Matching Marks Made upon Disassembly Aligned om IMPORTANT Failure to properly position output shaft flange may result in bearing damage 6 Relieve hoist tension from engine then slide en gine fore or aft as needed to obtain 1 4 in 6 mm clearance between flange shoulder and exten sion shaft housing bearing 72591 a Flange Shoulder b Bearing C 1 4 In 6 mm INDEX 2 18 MCM MODELS 7 Position engine for correct engine and drive shaft lateral alignment as follows a Measure the length of a and b to the cen ters of bolt holes They MUST BE EQUAL If they are not equal slide the aft and forward ends of the engine equal amounts in opposite directions to obtain equal lengths for a and b b Recheck Step 6 If Step 6 is not as specified adjust and recheck Step 7a Continue this process until both Steps 6 and 7a are as spe cified These Dimensions Must Be Equal 8 After engine has been aligned correctly fasten front and rear engine mounts to stringers Tighten mounting bolts securely 90 806535940 893 9 Apply Loctite 271 to threads of bottom drive shaft shield retaining screws and install bottom shield on engine end as shown Torque screws to 30 Ib ft 41 Nem Then install top shield as shown Torque screws and nuts to 30 Ib ft 41 Nem a Shaft Housing b Bottom Shield
12. ble verse gear past detent into wide open throttle position INDEX 90 806535940 893 D IMPORTANT Do not use excessive force when holding pressure on the drive unit shift cable Ex cessive force would be indicated by movement of the shift cutout switch ay KON LY 22909 te QUICKSILVER a Drive Unit Shift Cable Push in b Propeller Shaft Rotate Counterclockwise MCM MODELS 2A 11 o Lightly pull on the remote control shift cable end guide to remove the slack from the remote con trol and cable and adjust brass barrel as neces sary to align attaching points with shift lever clevis pin hole and stud Be sure to maintain light pres sure on the drive unit shift cable 50309 End Guide Brass Barrel Shift Lever Clevis Pin Hole Stud After cable has been aligned turn brass barrel 4 turns away from cable end guide ES og NA S Cn 50308 a End Guide b Brass Barrel INDEX 2A 12 MCM MODELS 7 Temporarily install remote control shift cable on stud and install clevis pin a Remote Control shift Cable b Clevis Pin 8 Shift remote control as stated in a or b follow ing a Right Hand RH Rotation Drive Unit re verse gear past detent into wide open throttle position b LeftHand LH Rotation Drive Unit forward gear past detent into wide open throttle position RH te QUICKSILVER LIE
13. eller shaft clock wise The clutch should engage and cause the propeller shaft to lock If the clutch does not engage loosen the adjustable stud on the shift lever and move it upward in the slot until the clutch engages the forward gear Retigh ten the stud Shift remote control several times and stop in forward to recheck the shift cutout switch position The roller must be cen tered 13 Remote Control with Separate Shift and Throttle Levers a RIGHT HAND RH propeller rotation drive unit While turning the propeller shaft clock wise move the remote control shift handle into full reverse position The clutch should engage before the shift lever comes to a stop If the clutch does not engage loosen adjust able stud on the shift lever and move it upward in the slot until clutch engages with reverse gear Retighten the stud Shift remote control several times and stop in reverse to recheck shift cutout switch position Roller must be centered INDEX 2A 14 MCM MODELS b LEFT HAND LH propeller rotation drive unit While turning the propeller shaft clock wise move the remote control shift handle into the full forward position Clutch should engage before the shift lever comes to a stop If the clutch does not engage loosen adjust able stud on the shift lever and move it upward in the slot until the clutch engages the forward gear Retighten stud Shift remote control several times and stop in forward to recheck shi
14. front mounts to boat stringer using appropri ate hardware lag bolts or thru bolts etc e Recheck alignment with alignment tool Tool must enter coupler splines freely If not read just front mounts f When alignment is correct tighten locknut or nut with lockwasher on each mount securely g Bendtab washer down against flat on adjust ing nut 72536 Nut and Lockwasher 350 Magnum Locknut Only Adjustment Nut c Turn Adjustment Nut in This Direction Counterclockwise to Raise Front of Engine d Slotted Hole toward Front of Engine e Tab Washer h Remove alignment tool if not already re moved INDEX 90 806535940 893 Engine Connections Fuel Supply Connections Avoid gasoline fire or explosion Improper installation of brass fittings or plugs into fuel pump or fuel filter base can crack casting and or cause a fuel leak e Apply 592 Loctite Pipe Sealant with Teflon to threads of brass fitting or plug DO NOT USE TEFLON TAPE e Thread brass fitting or plug into fuel pump or fuel filter base until finger tight e Tighten fitting or plug an additional 1 3 4 to 2 1 4 turns using a wrench DO NOT OVER TIGHTEN e Install fuel line To prevent over tightening hold brass fitting with suitable wrench and tighten fuel line connectors securely e Check for fuel leaks 1 Connect fuel line from fuel tank s to engine Make certain connections are secure Check for leaks 2 Connect thr
15. ft cutout switch position Roller must be centered 50309 a Adjustable Stud b Shift Cutout Switch Roller 90 806535940 893 Shift Cables Installation and Adjustments For Bravo Drives NOTE Using Adjustment Tool 91 12427 shift cables can be adjusted without or with the stern drive installed using the following procedure IMPORTANT For Bravo One and Two Drive unit propeller rotation is determined by the shift cable installation in the remote control e If shift cable end guide moves in direction A when control lever is placed in Forward remote control is setup for RIGHT HAND RH propeller rotation e If shift cable end guide moves in direction B when control lever is placed in Forward remote control is setup for LEFT HAND LH propeller rotation BRAVO ONE AND TWO IMPORTANT For Bravo Three Front propeller on Bra vo Three drive unit is always LH Rotation and rear pro peller is always RH Rotation Shift cable end guide must move in direction A when control lever is placed in Forward gear position 71656 BRAVO THREE INDEX 90 806535940 893 IMPORTANT When installing shift cables be sure that cables are routed in such a way as to avoid sharp bends and or contact with moving parts DO NOT fasten any items to shift cables 1 Install shift cable into remote control Refer to appro priate remote control instructions 2 Loosen stud and move it to dimension as shown Re
16. gs Large 1 0 Washer with Spring Beneath Not Seen Small D Washer Locknut Tighten Until Bottomed WITH SHIFT ASSIST ASSEMBLY Remote Control Shift Cable Pin Cotter Pin Spring Beneath Washer Washer Washer Spacer Washer Locknut Tighten Until Bottomed Then Back Off One Turn 20 ro Anoop MCM MODELS 2A 13 WITHOUT SHIFT ASSIST ASSEMBLY IMPORTANT If an extra long remote control shift cable is used or if there are a large number of bends in the remote control shift cable or if re mote control has inadequate output travel an additional adjustment may be necessary Refer to step 12 or 13 as applicable 12 Remote Control with Single Lever Shift Throttle Control a Right Hand RH propeller rotation drive unit Shift the remote control into reverse gear wide open throttle position while simul taneously rotating propeller shaft clockwise Clutch should engage and cause the propel ler shaft to lock If the clutch does not engage loosen the adjustable stud on the shift lever and move it upward in the slot until the clutch engages the reverse gear Retighten the stud Shift the remote control several times and stop in reverse to recheck the shift cutout switch position Roller must be centered b LEFT HAND LH propeller rotation drive unit Shift the remote control into forward gear wide open throttle position while simul taneously rotating the prop
17. nter Lifting Eye CAUTION DO NOT use an alignment tool from another manufacturer Alignment tools other than Quick mE silver Alignment Tool 91 57797A3 may cause im a Alignment Tool Use Only Quicksilver Alignment Tool P N 91 805475 1 proper alignment and damage to gimbal bearing b Insert This End of Alignment Tool through Gim and or engine coupler bal Housing Assembly A CAUTION To avoid damage to gimbal bearing engine cou pler or alignment tool 71401 e DO NOT attempt to force alignment tool e DO NOT raise or lower engine with alignment tool inserted or partially inserted in gimbal bearing or engine coupler 7 Align engine as follows a Attempt to insert solid end of Quicksilver Alignment Tool through gimbal bearing and into engine coupler splines If it will not insert easily proceed to the following 72585 b While observing the above precautions a Alignment Tool CAREFULLY raise and lower front of engine b Gimbal Bearing with hoist as required until tool will SLIDE c Engine Coupler FREELY all the way in and out of engine cou pler splines NOTE Engine couplers may differ from drawing INDEX 2A 6 MCM MODELS 90 806535940 893 IMPORTANT Turn both front engine mount ad justment nuts an equal amount in direction re quired to align engine c Adjust front engine mounts until they rest on boat stringers d Relieve hoist tension entirely and fasten both
18. ottle cable using hardware retained and adjust as follows a On Engines With Carburetor 1 Place remote control handle s in neutral idle position IMPORTANT Be sure that cable is routed in such a way as to avoid sharp bends and or contact with moving parts DO NOT fasten any items to throttle cable Outer cable must be free to move when cable is actuated 2 Install cable end guide on throttle lever then push cable barrel lightly toward throttle lever end This will place a slight preload on cable to avoid slack in cable when moving remote control lever Ad just barrel on throttle cable to align with anchor stud 3 Secure throttle cable with hardware re tained as shown Tighten cable end guide locknut until it bottoms out and then back off one full turn Tighten cable barrel securely DO NOT OVER TIGHTEN as cable must pivot freely MCM MODELS 2A 7 Throttle Cable Adjustments 2 BARREL CARBURETOR 70392 a Throttle Lever Contacts b in Idle Position b Idle Speed Adjustment Screw Idle Position Cable End Guide Attaching Hardware DO NOT Over Tighten Cable Barrel Anchor Studs QOO Oo WEBER 4 BARREL CARBURETOR BD E f LAS A A O ORS TSS pee 71159 a Throttle Shaft Lever Contacts b at W O T Position b Carburetor Body Casting Wide Open Throttle Position 72014 Cable End Guide Attaching Hardware DO NOT Over Tighten Cable Barrel
19. oving end guide anchor pin from shift lever and removing cable Attempting to bend control cable to install or remove barrel will place undue stress on cable end guide and shift lever and damage to both could occur INDEX 2A 16 MCM MODELS c Remove control cable end guide from shift lever by removing anchor pin m QOO Do 23345 Control Cable End Guide Anchor Pin Backlash Center Control Cable Barrel Stud Install control cable 23345 Lock Nut Tighten Until Bottomed Out Washers Both Sides of Barrel Anchor Pin Cotter Pin Not Visible Spread Both Ends Remove adjustment tool Shift remote control lever into full forward position Place end of adjustment tool in barrel retainer 90 806535940 893 RH ROTATION BRAVO ONE AND TWO AND ALL BRA VO THREE MODELS Rear slot in tool should fit over shift lever stud LH ROTATION BRAVO ONE AND TWO MODELS For ward slot in tool should fit over shift lever stud If slot does not fit over stud loosen shift lever stud and slide stud up or down until slot in tool fits over stud When adjust ment is correct retighten stud RH ROTATION BRAVO ONE AND TWO AND ALL BRAVO THREE MODELS LH ROTATION BRAVO ONE AND TWO MODELS a Adjustment Tool b Barrel Retainer c Shift Lever Stud d Shift Lever Adjustment Slot 10 Remove adjustment tool 11 Lubricate shift cable pivot points with 30W oil
20. ve instrument harness connector plug from engine harness receptacle after loosening clamp Be careful when working on fuel system Gasoline is extremely flammable and highly explosive under cer tain conditions Do not smoke or allow spark or open flame in area Wipe up any spilled fuel immediately 3 Disconnect and suitably plug fuel line to prevent fuel in tank from leaking into bilge 4 Disconnect throttle cable from carburetor or throttle body on EFI models Retain locknuts and hardware 5 Disconnect bullet connectors of trim sender wires coming from transom assembly from engine harness NOTE After wires are disconnected be sure to loos en them from clamps or Sta Straps retaining them to engine or hoses 6 Slide sleeves back on BLACK and WHITE GREEN or GRAY wires and disconnect engine harness wires from shift cut out switch harness 7 Disconnect MerCathode wires from MerCathode controller if so equipped 8 Disconnect seawater inlet hose from gimbal housing 9 Disconnect exhaust elbow hoses bellows 10 Remove both shift cables from shift plate Retain locknuts and hardware 11 Disconnect any grounding wires and accessories that are connected to engine 12 Disconnect and suitably plug fluid hoses from power steering control valve on transom CAUTION Center lifting eye is used for engine alignment only lifting eye on top of thermostat housing Do not use to lift entire engine IMPORTANT
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