starting new thread - general questions on alpha one gen 2

[MajBach]

So it's been quite a while since I've been here. I still more frequently than not get errors accessing this site and cannot figure why. Last weekend I got 504 Bad Gateway overtime I tried logging in. Even tried the "old site" but it said I wasnt registered. FYI for admins, I tried two different routers, tried 2 different computers and a phone, and also tried using data instead of wi-fi. No joy.

Anyway, I never got out in my boat last year: 2002 Maxum 2300 SC with 305 Merc Alpha One, Gen II. My last post was about conflicting information on identifying the engine. Right now though I have the leg apart in my garage. I wanted to change my trim and tilt sending units and do a bellows inspection etc. and basically just "learn the thing". I decided it needed a good check (less than 400 hours on engine/leg) considering its age but it was giving me an issue 2 years ago. I noticed when I made a sharp turn in either direction I would hear a bit of a soft clanking noise - not unlike a front wheel drive car when the CV joints go. The noise slowly got a little more pronounced over the season and was louder the sharper the turn or the more throttle.
Now that the leg is apart, the u-joint looks fine but I am not sure how to test it. I also noticed there are no nipples (or "zerks"?) to grease it. There is what looks like a flattened rivet where a nipple should be but looks OEM and not serviceable.
So far, this is the only issue I've come across I haven't been able to You-Tube or shop manual the answer.
Bach

 

[achris]

Unis are sealed, non-greaseable....
The clunking noise... Look for soft impact witness marks on the coupling between the unis. I had this recently on a drive I was servicing. A light grind of the area fixed it...

Chris......

P.S. welcome back.

 

[MajBach]

Hey thanks for the reply, Chris. I'm stalled on your use of the word "coupling" . You're not talking about engine coupling are you?
I did see a video the other day of someone who had marks on what I guess would be the housing assembly surrounding the u-joint but I didn't see that on mine. Could engine alignment cause this?

**EDIT**
I went and took a closer look and know what you meant now. No witness marks. The splines look nice and square as well. BTW, what grease is recommended for the splines (they are a little dry). 2-4-C? On my motorcycles I use a moly based grease but it seems a little thin for this application.

 

[achris]

No, not the engine coupler. There's 2 uni joints. The coupling that joins those 2... Look for where the end of the yokes runs inside that when it's on full lock... Look on both sides, both uni ends. So you'll be looking in 4 places. usually it's only 1 that's touching.

Coupler spline grease.... Any grease is better than no grease. Yeah, I also use 2-4-C... There is a specific Mercury 'spline grease', but most people use 2-4-C....

Chris......

 

[Bondo]

No joy.

Ayuh,..... iboats is still adjustin' the newest up-grade,......

I have taken apart u-joints that felt pretty much Perfect when assembled, that made noises,....
What I found were little tiny ridges on the cross bearin's wear surfaces,....
No slop, but still rattled,....
New u-joints cured the noise,...

Yer results may vary,.....

 

[Rick Stephens]

I'd agree with Bondo: if in doubt, replace em. Stick grease-able ones in from the auto parts store. There is a part number list in the Adults Only links.

 

[MajBach]

Still working on things. Will update with new info. Thanks.