New Alignment Issue.

[brokemerc]

To update I have a 1995 Bayliner Capri Alpha1 gen2 3.0,, I have installed a 3.0 out of a 1989 Searay (complete assy). I went step by step with the manual as far as installation and alignment and the tool will only go probably half way in. I've even tried loosening all engine mount bolts and no change. To look at it by eye everything looks to be in line but no such luck. I am using everything from the 3.0 Searay,, is there any chance that the motor mounts could be different, or the bell housing, one has the extension with grease fitting the searay doesn"t??? To slide the alignment tool forward it's obviously hitting something by the sound of it,, it will slide forward to the point where the tool gets to the seal on the forward side of the gimbral bearing. Any ideas before I invest in a granade..

 

[flabum]

Re: New Alignment Issue.

The bearing you are pushing the alignment bar through could be out of alignment a little....you can move it around using the bar . Just move the bar up and down and side to side until you can get the bar to the splines of the coupler. once there, put som grease on the tip of the bar and insert into the splines as far as it will go without force....do n ot spin the bar. Pull tha bar straight out and look for where the grease is rubbed off. This will give you an indicatio of which way the motor has to go.


That motor will work as will the coupler. Merc added the grease fitting on the newer setups and everything else is the same. you can use a newer drive with an older coupler.

Personally, I would have replaced the coupler just to have a new one there.

 

[Don S]

Re: New Alignment Issue.

I've even tried loosening all engine mount bolts and no change

.

Did you try adjusting the front mount up and down? The mounts are similar in design, but you still have to adjust them to fit your particular boat.
Also, when centering the gimbal bearing, stick the alignment bar in the in the coupler till it binds, then bump (with your hand or tap with a mallet lightly) side to side and up and down to center the bearing.
On your 3.0L use the big nut on the center post to raise and lower the front of the engine as needed to get the alignment in. Then turn the engine 90 180 and 270 degrees and recheck.

 

[brokemerc]

Re: New Alignment Issue.

Yes i've done/tried all of that. I even dropped the two lock down nuts off and have raised and lowered it as much as possible and still no luck. I've rotated, banged, tapped,, everything but hammered.. I thought for sure breaking the motor loose front and back would at least do the trick but nothing. I may just pull the motor up just to be sure this alignment tool will slide in the motor,, I just dropped the front and rear mounts/bellhousing off the old motor,, I may just swap them out just for s_ _ _'s and giggles.. It's a rainy day here in Va. can't hunt might as well get frustrated.. Thanks,,

 

[Don S]

Re: New Alignment Issue.

Do you have all the proper hardware under the rear mounts? The double wound lock washer and fiber washer?
Should be like this ............... Unless you have the new style mounts.

 

[brokemerc]

Re: New Alignment Issue.

Yes mine is exactly the way pictured (first time I put the bushing under the engine mount but I would never admit to that in court)... I just broke down the old block,, I'm going to swap out everything including the fly wheel,, which I should have done prior to installing the new motor.. I'll let ya know how many cuss words I say... Thanks..

 

[brokemerc]

Re: New Alignment Issue.

Do ya know the torque on these fly wheel bolts??

 

[Don S]

Re: New Alignment Issue.

Do ya know the torque on these fly wheel bolts??

Not right off, but if you go here http://www-alt.mercurymarine.com/mnetdata/sisdata/srvcovr.pdf and download manual #10 you can find it.
PS: #14 is for your drive, and #13 is for your old motor.

 

[brokemerc]

Re: New Alignment Issue.

Well, swapped front engine mount, bell housing ect ect from the old engine.. While it was apart I made sure the alignment bar would slide all the way forward through the gimbrel bearing and also up inside the bell housing into the engine,, definately not the alignment bar. I installed exactly the way the book says, installed rear mounting bolts torqued to 40 ft lbs switched hoist to center lifting ring by thermostat housing and hoisted while trying to insert alignment bar,,, no luck,, worked bar around in circles still no luck.. Large hammer may be next...

 

[95yj]

Re: New Alignment Issue.

Large hammer may be next...

Hrmmm. I believe that's the one thing the books says NOT to do. You can screw up your coupler that way.

 

[brokemerc]

Re: New Alignment Issue.

Well if I stand back and kick it it'll go in,, takes two hands and a bunch of wiggling to get it out.. Even with the engine removed it was a very snug fit into both the boat bearing and the engine..

 

[Don S]

Re: New Alignment Issue.

Well if I stand back and kick it it'll go in,, takes two hands and a bunch of wiggling to get it out..

Keep track of how to pull the engine, you will be replacing the coupler quite often if that is what you are going to do.

Now, I asked before, do you have the new style motor mounts in the flywheel housing. Cause if you do, they have different hardware, no double wound washer and possibly a spacer.

You keep trying to go UP, did you try down?????
Put some grease on the alignment bar and push it into the coupler as far as possible, pull it straight out and READ the pattern on the bar. Is it hitting on the top or bottom of the bar?

 

[brokemerc]

Re: New Alignment Issue.

Yes I actually removed the jam nuts to give it even more up and down travel.. plus I had the mount bolts removed. Not sure about the new/old style mount, this is the original one that was in the boat and is the exact same as what the manual shows,, fiber washer, special lock type washer, bolt, washer, spacer.. Just like the manual shows. I may see if I can get my hands on another alignment bar just to settle my curiosity,, this one went in hard even when the engine was removed, both in the boat bearing and the engine.. It will go in with a nudge from my foot..

 

[achris]

Re: New Alignment Issue.

Are you aware that the old alignment tool will not fit into the new couplers without some machining? I have the information at home, but I'm a bit far from home at the moment. Maybe one of the other 'sperts can give you the drawing.

That maybe all your problem is.

Chris..............

 

[Don S]

Re: New Alignment Issue.

this one went in hard even when the engine was removed,

It shouldn't, either the bearing is bad or the alignment bar is.
Here is what the alignment bar should be, what Chris was talking about.

http://www-alt.mercurymarine.com/mnetdata/Service/Cruiser/Bullet/92/Sb92_09.pdf

 

[brokemerc]

Re: New Alignment Issue.

Yea I actually got an alignment tool from "Imported_Theman" when I got the motor from him,, I had my machinists' use their CNC and make me one,, they assured me it was exact but who knows, that's why i'm curious to try another one just to see.. Then i'll fire a machinist. With everything torqued down and the front mount jam nuts tight if the alignment was off I wouldn't think all the kicking in the world would make a steel bar slide in.. We"ll see,, i'm pretty sure it'll be the tool.. Thanks.

 

[flabum]

Re: New Alignment Issue.

Maybe your machinist was a little conservative..... have him knock off a couple hairs off it.

 

[achris]

Re: New Alignment Issue.

With everything torqued down and the front mount jam nuts tight if the alignment was off I wouldn't think all the kicking in the world would make a steel bar slide in..

Yes it will. The coupler is a rubber hub with an aluminium spline in it. If you use enough force when the alignment is out, then the rubber will give enough for the tool to go in. This is bad. If you put a leg on in that condition the rubber will eventually take a set and you'll never get the alignment right. And then you'll be buying a new coupler.

Chris......

 

[watermellonI]

Re: New Alignment Issue.

Just a thought cause it sounds like you may have one in your shed, but have you thought of checkin the tool with a mic? you have the specs Don sent you so if you have a micrometer(?) you cn check to see if the tool is in spec.

 

[mcleaves]

Re: New Alignment Issue.

Yes it will. The coupler is a rubber hub with an aluminium spline in it. If you use enough force when the alignment is out, then the rubber will give enough for the tool to go in. This is bad. If you put a leg on in that condition the rubber will eventually take a set and you'll never get the alignment right. And then you'll be buying a new coupler.

Chris......

And still have an alignment problem to deal with