service bulletin MR and Alpha One Shift Cable Adjustment
Contents
1. NOTE If it was necessary to replace drive unit shift cable repeat these instructions beginning with Installing Drive Unit Shift Cable listed previously 11 After remote control shift plate has been properly adjusted reinstall cable and shift assist assembly and secure with hardware as shown a Remote Control Shift Cable b Shift Assist Assembly c Large D Washer d Small I D Washer e Locknut Tighten Until Bottomed then Back off 1 2 Turn f Spacer Earlier Models With Metal Shift Lever a Remote Control Shift Cable b Shift Assist Assembly c Clevis Pin d Cotter Pin Spread both Prongs e Large I D Washer f Small I D Washer g Locknut Tighten Until Bottomed then Back off 1 2 Turn Later Models With Plastic Shift Lever IMPORTANT If an extra long remote control shift cable is used or if there are a large number of bends in remote control shift cable or remote control has inadequate output travel an addition al adjustment may be necessary Refer to Step 12 89 4 189 12 Shift remote control into reverse gear wide open throttle position while simultaneously rotating propeller shaft clockwise Clutch should engage and cause propeller shaft to lock If clutch does not engage loosen adjustable stud on shift lever and move it upward in slot until clutch engages with reverse gear Retighten stud Shift remote control several times and stop in reverse to re check shif2. Stud 89 4 189 6 After cable has been aligned turn brass barrel 4 turns away from cable end guide a End Guide b Brass Barrel 7 Temporarily install remote control shift cable on stud and install clevis pin SS 50308 a Remote Control Shift Cable b Clevis Pin c Stud 89 4 189 8 Shift remote control into reverse gear wide open throttle position while simultaneously ro tating propeller shaft clockwise until shaft stops to ensure full clutch engagement 22265 22267 a Propeller Shaft Rotate Clockwise 9 Check shift cutout switch lever position Roller must be centered 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 at shift plate 2 7 8 in 73mm to 3 1 8 in 80mm c Ifa 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 If cable is binding replace cable following instructions in stern drive service manaul d If shift cutout switch roller moves off center when shifting into reverse only drive unit shift cable may not be installed properly at bell housing Remove stern drive unit and ensure shift cable is installed properly Refer to stern drive service manual
3. adjustment and one person to stay at the control station of the boat Ensure boat is secured to dock and precautions have been taken to avoid damage to boat prior to placing drive unit into gear 1 Start engine and let it warm up Refer to operating procedures in Operation and Maintenance Manu al 2 Disconnect throttle cable s from carburetor s N os B yt LE I R BED L i oy pon m SIR N TIAN P STO o a miwan EA ss U gt N 22062 a Throttle Cable End Guide b Carburetor Throttle Lever 3 Disconnect remote control shift cable OO 22267 a Remote Control Shift Cable b Plastic Shift Lever c Clevis Pin and Cotter Pin d Locknut and Washer Later Models With Plastic Shift Lever a Remote Control Shaft Cable b Metal Shift Lever c Locknuts and Washers Earlier Models With Metal Shift Lever IMPORTANT When pushing or pulling on drive unit shift cable in the following steps apply just enough pressure so that shift cutout switch roller just starts to move off center of notch then ease up slightly Use a fine tip marking device to mark threaded tube to obtain an accurate measurement 22911 4 Check for excessive play in drive unit shift system as follows a Pushin on drive unit shift cable to shift into for ward gear position b Place a mark on shift cable threaded tube against cable end guide 50499 a Drive Unit Shaft Cab
4. of the Shift Assist Assembly submit a completely filled out warranty claim to your Regional Service Center Make sure the engine and stern drive serial numbers are on the claim Only claims for the models that fall within the engine serial numbers will be hon ored The following part number and labor flat rate codes and times must be on the warranty claim Readjust Shift System Flat rate code 22140 Labor allowance 5 hour Install Shift Assist Assembly Part Number 813995A2 Flat rate code 25240 Labor Allowance 5 hour e a a MARINE DIVISION OF BRUNSWICK CORPORATION January 1989 Dear MerCruiser Customer At the time you purchased and took delivery of your boat it is possible that the shift system was not properly adjusted If so it may remain in gear with the propeller turning in spite of the fact that the control handle is in neutral This may happen when the control handle is shifted from either forward to neutral or from reverse to neutral WARNING A PERSON NEAR THE PROPELLER MAY BE SERIOUSLY INJURED IF HIT BY A PROPELLER UNDER POWER EVEN AT IDLE SPEED You may be able to identify this condition by the feel of the control handle when shifting into neutral It can also be visually identified by trimming out the drive unit until the propeller is visible and watching the propeller while slowly shifting into neutral from both forward and then reverse If you find that the propeller continues turning under
5. power after the control is shifted into neutral have your drive unit inspected and adjusted by your authorized MerCruiser dealer Please understand that adjustments to the shifting system were not made by Mercury Marine These adjustments were made by the boat builder and or dealer but most often the dealer at the time the drive unit was installed prior to delivery to you Mercury Marine goes to great lengths to train boat builders and dealers in the proper method of adjusting shift systems and in addition provides written adjustment instructions with every unit It is reasonable we believe that as a result of these efforts Mercury Marine should not bear the cost associated with the readjustment However in the interest of good customer relations we have decided to absorb the labor cost up to one half hour for readjusting the shift system In addition there is a Shift Assist Assembly available from your dealer free of charge This shift Assist Assembly will ensure return of the throttle shift handle to the neutral detent position It can be installed by your dealer at the time the shift readjustment is made Here again the installation labor expense up to one half hour will be absorbed by Mercury Marine SAFE BOATING PRACTICES REQUIRE THAT THE ENGINE BE TURNED OFF WHEN ANYONE IS NEAR THE PROPELLER We urge you to do this and instruct other operators of your boat to do so as well As a reminder of this safe boating practice enclosed
6. threaded tube Position as shown with tang touching brass barrel a Stop Clip b Brass Barrel 89 4 189 ee 4 Install drive unit shift cable as shown Secure brass barrel in barrel retainer with cotter pin spreading both prongs Secure end guide to shift lever with a washer on each side of end guide and locknut Tighten locknut until it bottoms then back off 1 2 turn OoOQA00 Drive Unit Shift Cable Brass Barrel Cotter Pin End Guide Washers Locknut Installing Remote Control Shift Cable ie Install sleeve spring and large I D washer on stud as shown 25431 a Sleeve b cC Spring Large D Washer 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 a Adjustable Stud 3 Place drive unit into forward gear by pushing in on drive unit shift cable while simultaneously rotat ing propeller shaft counterclockwise until shaft stops to ensure full clutch engagement a Drive Unit Shift Cable Push In 4 Place remote control into forward gear wide open throttle position N F R 5 Lightly pull on remote control shift cable end guide to remove slack from remote control and cable and adjust brass barrel as necessary to align attaching points with shift lever clevis pin hole and stud a End Guide b Brass Barrel c Shift Lever Clevis Pin Hole d
7. 0 NOTE Tool shown will be available thru Quicksilver at a later date Refer to the end of this instruction booklet for the pattern and dimensions needed to fab ricate a similar tool 4 Slowly move cutout switch roller off of its seat Cir cuit should close full continuity reading when roller is moved 1 8 in 8mm Use the 1 8 in rod onthe end of special tool to gauge this movement 50497 a Special Tool b 1 8 in 8mm If switch closes too early less than 1 8 in Roller must be bent away from its seat If switch closes too late more than 1 8 in Roller must be bent toward its seat If necessary use special tool to bend lever as shown 50499 a Lever b Roller c Special Tool 5 Once cutout switch is timed properly reconnect wires at terminal block and coat terminals with liquid neoprene a Black Wires b White Green Wires 89 4 189 Installing Drive Unit Shift Cable 1 Push in on drive unit shift cable while simulta neously turning propeller shaft counterclockwise until shaft stops to ensure drive unit is completely in forward gear Maintain pressure on propeller shaft with a suitable device elastic strap 2 Measure distance between center of hole in shift cable end guide and center of brass barrel Mea surement should be 6 in 153mm a End Guide b Brass Barrel c 6 in 153mm 3 Once brass barrel adjustment is correct install end guide stop clip on
8. LZ MerCruiser STERN DRIVES amp INBOARDS service bulletin TO SERVICE MANAGER O TECHNICIANSO PARTS MANAGER O MR and Alpha One Shift Cable Adjustment Inspection and Readjustment A letter is being sent to all registered owners of the fol lowing MerCruiser models Copy of letter on page 3 Starting Engine Ending Engine Model Serial Number Serial Number MCM 120 2 5L 6809472 OB576607 MCM 140 3 0L 6830416 OB577119 MCM 170 165 6824707 OB578008 MCM 190 180 6833166 OB556528 MCM 185 175 6820516 OB579468 MCM 205 6919687 OB580208 MCM 200 6812472 OB581038 MCM 230 6833717 OB581284 MCM 260 6825413 OB582057 MCM 350 Magnum OA635178 OB558606 MCM 454 Magnum OA613912 OB583847 MCM 300 Tempest 6668730 OB430365 MCM 320 EFI OA543604 OB517505 Shift cable adjustment inspection and readjustment applies to all gear ratios of MR and Alpha One Stern Drives only Alpha One SS Stern Drives do not need this inspection Also only Stern Drives that fall be tween the following Stern Drive serial numbers may need the inspection and readjustment Starting Stern Ending Stern Drive Serial Drive Serial Model Number Number MR Alpha One 6862702 OB551555 As stated in the customer letter it is possible that the shift system was not properly adjusted before the de livery of the boat This misadjustment may cause the drive unit to remain in forward or reverse gear when shifting the remote control handle into neutral gear from either forward or rever
9. are two decals for your boat the small one part number 37 814828 1 for placing in sight at the operator s station and the larger one part number 37 814828 2 on the transom visible to people in the area of the propeller If you no longer own this boat please forward this letter to the current owner Very truly yours Mercury Marine W6250 WEST PIONEER ROAD e P O BOX 1939 e FOND DU LAC WI 54936 1939 U S A e PHONE 414 929 5000 FAX 414 929 5060 Mercury Outboards e MerCruiser Stern Drives and Inboards Mariner Outboards Quicksilver Parts and Accessories Bae ae 89 4 189 QUICKSILVER MARINE PARTS AND ACCESSORIES 813995A2 Shift Assist Assembly Installation IMPORTANT If boat is equipped with A REMOTE CONTROL THAT HAS SEPARATE SHIFT AND THROTTLE LEVERS this shift assist assembly should NOT be used The use of the shift assist assembly with this type of remote control can cause the shift lever to move out of gear unex pectedly a Shift Lever b Throttle Lever The following checks must be performed to ensure all segments of the shifting system are functioning properly Checking for Excessive Play Checking the drive unit for excessive play in shift sys tem can be done with the boat in the water or on land Refer to appropriate procedure following 89 4 189 Boat in Water Engine Running At least two people will be needed for the following procedure one person to check the
10. ck wise until shaft stops to ensure full clutch engagement Place a mark on shift cable threaded tube against edge of end guide c While maintaining pressure on propeller shaft in a counterclockwise direction to keep clutch locked with forward gear lightly pull out on drive until shift cable end guide and place another mark on threaded tube d Measure distance between both marks Dis tance should be 9 16 in 14mm or less a Drive Unit Shift Cable b Propeller Shaft Rotate c Threaded Tube Mark Here a 9 16 in 14mm or Less b Propeller Shaft Maintain Pressure If play 9 16 in 14mm or less No further attention to drive unit is needed Proceed with adjustments If play is more than 9 16 in 14mm Drive unit must be removed to further isolate excessive play xg 89 4 189 Isolating Excessive Play NOTE Tools shown will be available thru Quicksilver at a later date Refer to the end of this instruction booklet for templates and patterns needed to fabri cate similar tools 1 To determine shift shaft rotational end play use a tool such as the one shown to measure degrees of play in shift shaft with clutch locked and held in forward gear a Install tool as shown 50498 a Shift Shaft Coupler b Pointer c Scale c While maintaining pressure on propeller shaft to keep clutch locked with gear lightly turn shift shaft coupler counterclockwise Make note of pointer locatio
11. le b Threaded Tube Mark Here 89 4 189 c Lightly pull on drive unit shift cable end guide and place another mark on threaded tube d Measure distance between both marks Dis tance should be 9 16 in 14mm or less Waw Cm D N P EP aa FENI 50497 a 9 16 in 14mm or Less If play is 9 16 in 14mm or less No further atten tion to drive unit is needed Proceed with adjust ments If play is more than 9 16 in 14mm Drive unit must be removed to further isolate excessive play Boat Out of Water Engine Off 1 Disconnect remote control shift cable rey Se b z A 22267 a Remote Control Shift Cable b Plastic Shift Lever c Clevis Pin and Cotter Pin d Locknut and Washer Later Models With Plastic Shift Lever 89 4 189 a Remote Control Shaft Cable b Metal Shift Lever c Locknuts and Washers Earlier Models With Metal Shift Lever IMPORTANT When pushing or pulling on drive unit shift cable in the following steps apply just enough pressure so that shift cutout switch roller just starts to move off center of notch then ease up slightly Use a fine tip marking device to mark threaded tube to obtain an accurate measurement 22911 Check for excessive play in drive unit shift system as follows a Place drive unit into forward gear by pushing in on drive unit shift cable while simulta neously rotating propeller shaft counterclo
12. n 50498 a Pointer Installed on Shift Shaft b Scale 1 Increments c Nut Hand Tight only b Rotate shift shaft coupler clockwise while simultaneously turning propeller shaft counterclockwise until clutch locks into forward gear Make note of pointer location on scale 50498 a Shift Shaft Coupler b Pointer c Scale 89 4 189 8 d Determine total degrees of movement If 12 or less Problem is with the drive unit shift cable upper shift shaft assembly andlever assembly If more than 12 Problem is with gear case shift spool assembly Whichever the case refer to Stern Drive Service Manual for repair of applicable components Installing New Remote Control Shift Cable Attaching Hardware EARLIER MODELS WITH METAL SHIFT LEVER 1 Remove short studs from locations shown Apply Loctite to coarse threads of new longer studs and install as shown Tighten securely 25443 a Metal Shift Lever b 2 7 8 in Stud 73mm c 2 1 8 Stud 54mm LATER MODELS PLASTIC SHIFT LEVER 1 Remove and discard short clevis pin Remove short stud from location shown Apply Loctite to coarse threads of new longer stud and install as shown Tighten securely 25444 a Plastic Shift Lever b Longer Clevis Pin c 2 7 8 Stud 73mm Checking Remote Control Shift Cable Output IMPORTANT Remote control must provide a shift cable travel at the shift plate end of 2 7 8 in 73mm t
13. o 3 1 8 in 80mm with a 15 20 Ib 6 8 9 kg load applied to the cable end guide This mea surement can be taken by installing the remote control shift cable and using the shift assist assem bly provided to place the proper load of the shift cable drive unit shift cable should not be installed 1 Place remote control in forward gear wide open throttle position Place a mark on threaded tube against edge of cable end guide 89 4 189 2 Place remote control in reverse gear wide open Checking Cutout Switch Timing throttle position Measure the distance between the edge of shift cable end guide and the mark 1 Disconnect cutout switch white green wire from made in step 1 Total shift cable output is not to be terminal block less than 2 7 8 in 73mm or more than 3 1 8 2 Connect ohmmeter positive lead to cutout 80mm If output is incorrect remote control and switch white green wire and ohmmeter negative or shift cable should be replaced lead to cutout switch black wire at terminal block 3 Set Ohmmeter on RX1 scale a Terminal Block b Cutout Switch White Green Wire c Cutout Switch Black Wire Shift Assist Assembly Remote Control Shift Cable In Forward Gear Position Place a Mark on Tube Against Edge of Cable End Guide Remote Control Shift Cable In Reverse Gear Position Measurement Taken from Mark to Edge of Cable End Guide 2 7 8 in 73mm to 3 1 8 in O O ow 89 4 189 1
14. ry Marine will not pay for the part s or labor The Shift Assist Assembly assists the boat operator in returning to true neutral gear Because of this the Shift Assist Assembly will be installed on all Alpha One power packages produced after January 1989 This Shift Assist Assembly will not provide any assis tance if the shift cables are not adjusted properly Also the Assembly will not correct any existing shift ing problems caused by worn or damaged parts This Shift Assist Assembly can be added to any MC type stern drive outside the serial number range giv en in this service bulletin that has the short slot 7 8 in 22mm long in the Lever Assembly for shift cables on the shift plate Mercury Marine will not pay for the part s or labor on any models other than those identified on the proceeding page Two WARNING decals Figure 1 were sent with the letter to the registered owner One decal is to be put on the dash so it is visible to the operator of the boat The second decal is to be placed on the transom in a location that is visible to anyone in the vicinity of the propeller 89 4 189 For application to dash y A WARNING Avoid injury Turn engine off il someone is near propeller gunae For application to transom AWARNING Y Avoid injury Stay away from propeller when engine is running 17 Al4d Gt Figure 1 89 4 189 To be reimbursed for allowable labor and installation
15. se gear Many remote control handles have a detent for each gear position forward neutral reverse If the shift system was adjusted for forward and reverse gear with the control handle in the forward and reverse gear detent the system was not adjusted correctly The installation manual shipped with each power package states that Printed in U S A No 89 4 m when making shift cable adjustments the remote con trol handle must be placed in forward gear full throttle position Please understand that adjust ments to the shifting system were not and can not be made by Mercury Marine However in the interest of customer relations we have decided to absorb the la bor cost up to one half hour for readjusting the shift system on the models that fall between the engine serial number listed previously It is suggested that the Shift Assist Assembly P N 813995A2 be ordered and be installed on these models also Follow the instruction as outlined on page 4 thru 17 of this bulletin to inspect and readjust the shift system The installation of the Shift Assist Assembly is also covered in these pages Here again in the interest of customer relations Mercury Marine will absorb the cost of the part plus up to one half hour labor to install this part NOTE Read IMPORTANT on page 4 about two lever remote controls If during the inspection other parts are found to be worn or damaged because of long term mis adjust ment Mercu
16. t cutout switch position Roller must be centered a Adjustable Stud b Shift Cutout Switch Roller 89 4 189 Checking Operation 1 Reconnect throttle cable s removed earlier 2 Place boat in water and start engine Check the following a Shift into forward and reverse gear making sure that clutch engages before engine be gins to accelerate Accelerate engine in forward and reverse gear to ensure engine does not shut down Check that shift cutout switch roller is cen tered in notch of shift cutout lever with drive unit in forward and reverse gear Shifting from in gear position to neutral check to ensure drive unit is in neutral before remote control shift lever comes to neutral detent position SZ 0S 3HIAA d43l1S BIg tutu 9 L Ul 9L L utu 9 L tutu Ot ul Ce Ul 9L L e q Ul 8 L Cn MAIA dO L D 1OOL LNAAWLSNFav HOLIMS LNOLND NMOHS SV GN38 J MIIA Adis GHVO8S8GQdVO HO ti3dVd WOOLS AAV3H OL 31SVd YALNIOd 31VO9S 3 194 89 4 189 yee
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