1964-2006 Mercruiser Stern Drive Type 1, Alpha/MR and Bravo I and II units service manual

Table of Contents

1 Safety

• Introduction
• Cleaning, Waxing, Polishing
• Controlling Corrosion
• Propellers
• Fuel System
• Loading
• Flotation
• Emergency Equipment
• Boating Safety
• Steering
• Miscellaneous Equipment
• Avoiding Accident Reports
• Navigation

2 Tuning

• Introduction
• Tuning for Performance
• General Tasks
  • Carburetors
  • Spark Plugs
  • Ignition Timing
  • Idle Mixture
  • Idle Speed
• Fuel System

3 Engine

• Introduction/Chapter Coverage
  • General Principles
  • Safety Precautions
  • Tools, Fasteners & Conventions
• General Information
• Troubleshooting
• Engine Removal/Installation
• Engine Disassembly/Assembly
• Cylinder Head Service
• Cylinder Block Service
• Crankshaft, Piston & Rod Service
• Timing Gear Service
• Valve & Seat Service
• Camshaft Service
• Main Bearing Service
• Oil Pump Service
• Intake Manifold Service
• Exhaust Manifold Service
• Cooling System Service
• Fuel System Service
• Electrical System Service
• Lubrication System Service

4 Fuel

• Introduction/Chapter Coverage
• Troubleshooting
• Fuel Pump and Filters
• Modern Fuels
• Carburetors, General Info
• Rochester 2GC
• Rochester 4MV
• Holley Carburetors
• EFI (Electronic Fuel Injection)

5 Ignition

• Description
• Troubleshooting
• Distributor Service
• Servicing a Delco-Remy Distributor
• Servicing a Mallory Distributor
• Servicing a Mercury Marine Distributor
• Adjusting Point Gap
• Servicing Breakerless Ignition System

6 Electrical

• Introduction
• Batteries
• Jumper Cables
• Dual Battery Installation
• Gauges and Horns
• Charging System
  • Alternator
  • Voltage Regulator
• Cranking System
  • Starter
  • Solenoid
• Engine Instrumentation

7 Remote Controls

• Introduction
• Shift/Steering Cable
• Shift Lever Pre-Shift Cable
• Service for Prior to 1973 Models

8 Tilt Mechanism

• Description and Operation
• Troubleshooting
• Tilt Motor
• Hydraulic Pump
• Mechanical Steering
• Hydraulic Steering

9 Cooling

• Disassembling
• Troubleshooting
• Water Intake Replacement

10 Stern Drive

• Description
• Early Stern Drive Units (1964-1977)
  • Troubleshooting
  • Removal and Installation
  • Upper Gear Housing
  • Exhaust Housing
• Stern Drive Units Since 1978
  • Troubleshooting
  • Removal and Installation
  • Lower Gear Housing

11 Intermediate Housing

• Introduction
• Troubleshooting
• Intermediate Housing

12 Maintenance

• Fiberglass Hulls
• Winterizing
• Off-Season Storage
• Pre-Season Preparation

The 1964-2008 Mercruiser stern drive Type 1, Alpha/MR and Bravo I and II units service manual is a valuable resource for mechanics, technicians, and boat owners. It provides in-depth information on maintenance, troubleshooting, engine, electrical system, power steering, rigging, and more.

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