Trim Limit N Switch Install Instructions
Trim Limit N Switch Install Instructions
Trim Limit N Switch Install Instructions
805320A1
TRIM SENDER AND TRIM LIMIT SWITCH KIT
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The
Owner’s Future Use.
Removal
WARNING
Always disconnect battery cables from battery before working around electrical
system components to prevent injury to yourself or damage to electrical system.
1. Disconnect both battery cables from battery.
2. Remove stern drive unit.
3. Remove trim limit switch and trim position sender.
a
b
c
c
71221
71220
4. Earlier Alpha One Models - Loosen front hose clamp on U-joint bellows. Remove
bellows from flange.
23158
a - U-Joint Bellows
b - Clamp
5. Bravo/Blackhawk and Later Alpha One Models - Remove U-joint bellows sleeve.
a
70179
a - Sleeve
b - Removal Tool (91-818169)
a
c
b
22113
a - Bell Housing
b - Gimbal Ring
c - Hinge Pin Tool (91-78310)
Page 2 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
7. Pull back on bell housing and rotate it 90 degrees to gain access to the trim wire retainer
bolt.
23363
a - Bell Housing
70197
a - Clamp
b - Bolt
9. Disconnect trim limit switch wires at the power trim pump. Also, disconnect trim sender
wires at the engine harness.
Installation
1. Route new trim limit switch wires through hole. Bring together the two grommet halves
and ensure they are seated tightly in the hole and that the flat edges that mate together
are vertically aligned. Maintain light tension on the wires from inside the boat, to hold
the grommets in the hole.
a b
70198
a - Trim Limit Switch Wires
b - Trim Position Sender Wires
Page 3 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
2. Reinstall retainer and torque to 90-100 lb. in. (10.2 - 11.3 N⋅m).
70197
a - Clamp
b - Bolt
3. Earlier Alpha One Models - Prepare U-joint bellows for installation as follows:
a. Clean gimbal housing mounting flange with sandpaper and wipe clean with lacquer
thinner.
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.
23363
a - Bell Housing
Page 4 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
23158
a - U-Joint Bellows
b - Clamp
75268
22116
a - Bell Housing Flange
Page 5 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
c. Lubricate sleeve O.D. with water or engine cleaner and install sleeve with tool and
suitable driving rod.
a
c
70207
70208
a - Sleeve
b - Installation Tool (91-818162)
c - Suitable Driving Rod
7. Apply Loctite 277 or 8831 to bell housing threads and install hinge pins. Torque Hinge
Pins to:
Alpha Models: 95 lb. ft. (129 N⋅m)
Bravo/Blackhawk Models: 150 lb. ft. (203 N⋅m)
d b
23292
a - Bell Housing
b - Gimbal Ring
c - Hinge Pin Tool (91-78310)
d - Torque Wrench (lb. ft.)
Page 6 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
b. Turn center rotor of trim position sender to align index mark with index mark on
sender body.
71218
a - Index Marks
71220
25269
a - Jumper Wires
Page 7 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
11. Turn ignition key to the “RUN” position. DO NOT START ENGINE. Rotate sender until
needle is at bottom of arc on gauge.
22175
12. Tighten trim position sender retaining screws and recheck gauge reading.
13. Reconnect trim limit switch wires to trim pump harness. Secure wires in retainer with
sta-strap.
a 22031
71218
a - Index Marks
Page 8 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
71221
15. Secure the trim limit switch harness to the water hose with the plastic clip on later Alpha
and Bravo/Blackhawk models.
a
71184
a - Plastic Clip
a
b
a
22091
a - Screws
b - Slots
Page 9 of 10
805320A1 TRIM SENDER AND TRIM LIMIT SWITCH KIT
22091
a
50464
Earlier R/MR/Alpha One Models
a - 21-3/4 in. (554 mm) Max.
b
70136
Alpha One Generation II Models
b - 20-3/4 in. (520 mm) Max.
c
50464
Bravo/Blackhawk Models
c - 21-3/4 in. (554 mm) Max.
Page 10 of 10