Trim

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TO: SERVICE MANAGER MECHANICS

service bulletin No. 92-12


PARTS MANAGER

A. NEW TRIM LIMIT SWITCH AND TRIM SENDER KIT

Models
MCI/Alpha One/Alpha One Generation II/Bravo One/Two MC IITR/IITRS

Changes
The Trim Sender/Trim Limit for the MC I/Alpha One/Alpha One Generation II/Bravo One/Two and the MC IITR/
IITRS models are only available in a kit that includes both the trim sender and the trim limit in each kit. The
new trim sender and trim limit assemblies can be identified by the following changes:
a. The rotor assembly is now gray in color.
b. The lead assembly has a black plastic wrap over the outside.
c. The words TRIM SENDER STARBOARD and TRIM LIMIT PORT will be on the covers.
The new style trim sender and trim limit assemblies are being used on all Alpha and Bravo assemblies in pro-
duction today. The starting serial numbers are as follows: ALPHA [OD692187] BRAVO [OD695289]

Problem
The trim sender assembly would begin working erratically after a period of time of quit working completely.
Some units were found to have water inside, caused by either a pinched or damaged lead assembly. Other
units were found to have cut leads or small pin holes in the leads which after a period of time, would allow
water to wick down the lead into the sender or corrode the wire and cause it to stop working.

Parts Required
(1) 805320A1 Trim sender/Trim limit kit for MC I/Alpha One/Alpha One Generation II/Bravo One/Bravo Two
(1) 805320A2 Trim sender/Trim limit kit for MC IITR/IITRS

Repair
Remove both the trim sender and the trim limit assemblies and their wiring harnesses for the new units that
come in the kit, following the instructions included in each kit. [“DO NOT CUT AND/OR SPLICE ANY OF THE
LEADS”]. A copy of the instructions is included in the back of this bulletin.

Trouble Shooting
If, after installation of the trim sender or the trim limit switch assembly, you find that one of the other does not
work or register on the gauge do not check with an ohmmeter by poking through the casing of the wire. Check
the wires from the inside of the boat at the connectors. If you puncture the casing of the wire on the outside
of the boat water will leak into the wire and cause damage to the sender.

Dual Station Application


If you are using the kit on a dual station application you will need to order a rotor kit (P/N 805134A3) to install
in the trim sender. Otherwise, the gauges will read incorrectly at both stations.

Warranty
If the unit is under warranty fill out a warranty claim and send to your normal processing center.
Labor Code: MH34 for Alpha/Bravo Labor: 4.0
MH33 for MC IITR/IITRS Labor: 3.0

Printed in U.S.A. -1- 92-12 492


3. Remove trim position sender.

805130A2/A6
TRIM POSITION a

SENDER FOR ALPHA


AND BRAVO
MODELS
71220
a - Screws, Washers, and Retainers

NOTICE to INSTALLER 4. Earlier Alpha One Models - Loosen front hose clamp
After Completing Installation, These Instruc- on u-joint bellows. Remove bellows from flange.
tions Should Be Placed with the Product for
the Owner’s Future Use.

! WARNING
Disconnect both battery cables before installing new
sender.

Removal
1. Remove stern drive unit. a
2. Remove trim limit switch.
b

a 22116

a - U Joint Bellows
b - Clamp

a - Screws, washers, and Retainers 71221

92-12 492 -1- from 90-812584--2 1091


5. Bravo and Later Alpha One Models - Remove u-joint 7. Pull back on bell housing and rotate it 90 degrees to
bellows sleeve. gain access to the trim wire retainer bolt.

70179 23363

a - Bell Housing

a - Sleeve 8. Remove trim wire retainer.


b - Removal Tool (P/N 91-818169)

6. Remove both hinge pins.

a
c b

70197
a - Clamp
b b - Bolt

9. Disconnect trim position sender wires from engine har-


ness.
a - Bell Housing 22113
b - Gimbal Ring
c - Hinge Pin Tool (P/N 91-78310)

492 92-12 492 -2-


3. Earlier Alpha One Models - Prepare U-joint bellows
Installation for installation as follows:
1. Route new sender wires through hole. Bring together
a. Clean gimbal housing mounting flange with sand
the two grommet halves and ensure they are seated
paper and wipe clean with lacquer thinner.
tightly in the hole and that the flat edges that mate to-
gether are vertically aligned. Maintain light tension on b. Apply bellows adhesive to mounting surface on in-
the wires from inside the boat, to hold the grommets in side of bellows.
the hole.
c. Position grounding clip and hose clamp over bel-
lows end.

! WARNING
Be sure to read and follow package label directions
when using bellows adhesive.
4. Install bell housing between gimbal ring. Push on bell
housing and guide U-joint bellows onto gimbal housing
mounting flange.
a b

a - Trim Limit Switch Wires


b - Trim Position Sender Wires 70198

2. Reinstall retainer and torque to 90-100 lb.in. (10.2 -


11.3 N⋅m).
a

23363

a a - Bell Housing

a - Clamp
70197
b - Bolt

-3- 92-12 492


5. Position u-joint bellows hose clamp as shown and b. Lubricate sleeve O.D. with water or engine cleaner
tighten securely. and install sleeve with tool and suitable driving
rod.

a b

70207

22116

a - U Joint Bellows
b - Clamp

6. Bravo and Later Alpha One Models - Connect U-


joint bellows to bell housing as follows:
a. Position U-joint bellows on bell housing. Ensure
that the bell housing flange rests in the second
groove from the end of bellows.

70208

a - Sleeve
b - Installation Tool (P/N 91-818162)
c - Suitable Driving Rod

22116
a - Bell Housing Flange

492 92-12 492 -4-


7. Apply Loctite Primer “T” to internal bell housing c. Install trim position sender and secure with attach-
threads and external hinge pin threads and allow to ing hardware.
dry. Apply Loctite 271 to bell housing threads and in-
stall hinge pins. Torque hinge pins to 95 lb.ft. (129
N⋅m).

a
a

b 71220

a - Screws, Washers, and Retainers


23292
9. Reinstall battery cables.
10. Reconnect trim position sender wires to engine har-
a - Bell Housing ness.
b - Gimbal Ring
c - Hinge Pin Tool (P/N 91-78310) NOTE: Trim position sender kit contains two jumper wires
that can be used if your model requires ring terminals to
8. Reinstall trim position sender as follows: connect to the engine harness.
a. Place stern drive unit in the full down/in position.
b. Turn center rotor of trim position sender to align in-
dex mark with index mark on sender body.

25269

71218

a - Index Marks

-5- 92-12 492


11. Turn ignition key to the “RUN” position. DO NOT c. Install trim limit switch and secure with attaching
START ENGINE. Rotate sender until needle is at bot- hardware.
tom of arc on gauge.

71221
22175
a - Screws, Washers, and Retainers

14. Secure the trim limit switch harness to the water hose
12. Tighten trim position sender retaining screws and re- with the plastic clip.
check gauge reading.
13. Reinstall trim limit switch as follows:
a. Place drive unit in full “DOWN/IN” position.
b. Align index marks on switch.

a - Plastic Clip 71184

71218
a - Index Marks

492 92-12 492 -6-


15. Adjust trim limit switch as follows:
a. Loosen screws and turn trim limit switch clockwise
to end of slots.
a

b
a - 21-3/4 in. Max. (554mm) 50464

EARLIER R/MR/ALPHA ONE MODELS


a

22091
b
a - Screws
b - Slots

b. Ensure drive unit is in the full “DOWN/IN” position. b - 20-3/4 in. Max. (520mm)
70136

c. Trim drive unit “UP/OUT”. Do not use trailer switch.


ALPHA ONE GENERATION II MODELS
d. Slowly turn trim limit switch counterclockwise until
trim cylinders extend to dimension shown (Refer to
appropriate illustration).

a
50464
c - 21-3/4 in. Max. (554mm)

BRAVO MODELS

a - Rotate Counterclockwise to Adjust 22091

e. Retighten screws when adjustment is correct.

-7- 92-12 492


492
92-12 492
Warranty Payment Info.
Trim Sender/Switch
STOP Warranty will be paid only if all
of the following are met:
$
1. Both Sender and Switch must be replaced

-8-
and returned together.
2. Both Sender and Switch must be replaced
and returned complete.
(i.e. No splicing or interchange of parts)

Note: Do not forget to clip the trim limit


wire to the water hose.
(Read the Instructions!)

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