6 A LOWER UNIT. Table of Contents. Specifications. Section 6A - Non-Bigfoot Gear Housing

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1 Tle of Contents LOWER UNIT Setion 6A - Non-Bigfoot Ger Housing NON-BIGFOOT GEAR HOUSING Speifitions A-1 Speil Tools A-2 Quiksilver Lurints nd Servie Aids.... 6A-5 Ger Housing (Drive Shft) (50/60) A-6 Ger Housing (Propeller Shft)(50/60) A-8 Generl Servie Reommendtions A-10 Berings A-10 Sels A-10 Drining nd Inspeting Ger Lurint.... 6A-11 Removl A-12 Disssemly A-13 Wter Pump A-13 Bering Crrier nd Propeller Shft A-15 Propeller Shft Disssemly A-18 Pinion Ger, Driveshft nd Forwrd Ger.. 6A-20 Upper Driveshft Bering A-21 Lower Driveshft Bering A-22 Forwrd Ger Bering Re A-22 Shift Shft A-23 Ger Housing Ressemly A-24 Shift Shft A-24 Propeller Shft A-26 Speifitions Forwrd Ger Bering Re A-27 Bering Crrier A-27 Reverse Ger A-30 Forwrd Ger A-31 Lower Driveshft Bering Instlltion... 6A-32 Upper Driveshft Bering Instlltion... 6A-33 Forwrd Ger, Pinion Ger, Upper Driveshft Bering Re, Retiner nd Driveshft Instlltion A-34 Pinion Ger Lotion nd Forwrd Ger Bklsh A-35 Determining Forwrd Ger Bklsh.... 6A-38 Bering Crrier nd Propeller Shft Instlltion A-40 Bering Crrier A-41 Wter Pump Re-ssemly nd Instlltion 6A-42 Ger Housing Pressure Test A-46 Ger Housing Instlltion A-47 Filling Ger Housing with Lurint A-47 Ger Housing Instlltion A-48 Propeller Instlltion A-50 Trim T Adjustment nd Replement.. 6A-51 6 A GEAR HOUSING (1.83:1) Ger Rtio Gerse Cpity Lurint Type Forwrd Ger Numer of Teeth Pinion Ger Numer of Teeth Pinion Height Forwrd Ger Bklsh Wter Pressure (Wrm rpm (WOT) Lek Test Pressure 1.83: fl oz (340 ml) Quiksilver Ger Lue-Premium Blend 22 Spirl/Bevel 12 Spirl/Bevel in. (0.64 mm) Pinion Ger Loting Tool ( A2) in. ( mm) Bklsh Inditor Tool ( ) MARK #4 or in. (9.3 mm) 1 3 psi (7-21 kp) psi ( kp) psi (68-83 kp) for 5 Minutes MAY 2000 Pge 6A-1

2 Speil Tools 1. Bering Prelod Tool A2 2. Bklsh Inditor Tool Puller Universl Puller Plte Driver Hed Driver Rod ( ) Pge 6A MAY 2000

3 7. Bering Retining Tool NON-BIGFOOT GEAR HOUSING 8. Puller Jws ( A1) 9. Dil Inditor ( A1) 10. Dil Inditor Adptor Kit ( ) 11. Puller Bolt ( ) 12. Forwrd Ger Bering Instller Wter Pump Bse Sel Instller MAY 2000 Pge 6A-3

4 14. Bering Crrier Sel Instller Pinion Ger Lotion Tool A Forwrd Ger Bering Re Driver Cup Needle Bering Instller Bklsh Inditor Tool A d Ref. Desription Qty. Plte 1 Nut 1 Stud 1 d Sleeve A-1 Updte Kit (Converts A-1 Bering Prelod Kit Tool to A-2) Pge 6A MAY 2000

5 19. Lower Driveshft Bering Driver Assemly A1. NON-BIGFOOT GEAR HOUSING 20. Driveshft Holding Tool /60 (2 stroke). 21. Driveshft Holding Tool A1 50/60 (4 stroke). Quiksilver Lurints nd Servie Aids Prt No. Desription Lotite RTV Silione Seler A1 Premium Blend Ger Lurint A1 Anti-Corrosion Grese A1 2-4-C w/teflon MAY 2000 Pge 6A-5

6 GEAR HOUSING (DRIVE SHAFT)(1.83:1 GEAR RATIO) IN./87.37MM TORPEDO DIA Lotite 271 ( ) Lotite 405 (Otin Lolly) C With Teflon ( A12) Pge 6A MAY 2000

7 GEAR HOUSING (DRIVE SHAFT)(1.83:1 GEAR RATIO) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 GEAR HOUSING 2 1 DRAIN SCREW SCREW WASHER-seling 5 1 DOWEL PIN 6 1 DOWEL PIN 7 1 PIPE PLUG 8 1 ROLLER BEARING 9 1 SEAL KIT 10 1 FILLER PLATE 11 1 PINION GEAR (14 TEETH) 12 1 NUT SHIFT SHAFT ASSEMBLY 14 1 RETAINING RING 15 1 BUSHING ASSEMBLY 16 1 O-RING 17 1 OIL SEAL 18 1 DRIVE SHAFT 19 AR SHIM SET (SIZES 006 THRU 038) 20 1 TAPERED ROLLER BEARING 21 1 CUP 22 1 NUT WATER PUMP BASE 24 1 O-RING 25 1 OIL SEAL 26 1 OIL SEAL 27 1 IMPELLER 28 1 KEY 29 2 WASHER 30 1 WATER PUMP 31 1 GASKET (LOWER) 32 1 GASKET (UPPER) 33 1 FACE PLATE 34 6 SCREW (M6x16) SHIFT CAM 36 1 COUPLER MAY 2000 Pge 6A-7

8 GEAR HOUSING (PROP SHAFT)(1.83:1 GEAR RATIO) 3.44 IN./87.37MM TORPEDO DIA Lotite 271 ( ) 94 Anti-Corrosion Grese ( A6) 2-4-C With Teflon ( A12) Pge 6A MAY 2000

9 GEAR HOUSING (PROP SHAFT)(1.83:1 GEAR RATIO) TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 GEAR HOUSING 37 AR SHIM SET (SIZES 006 THRU 048) 38 1 TAPERED ROLLER BEARING 39 1 CUP 40 1 FORWARD GEAR (23 TEETH) 41 1 ROLLER BEARING 42 1 CAM FOLLOWER 43 1 SLIDE 44 1 SPRING 45 1 CLUTCH 46 1 CROSS PIN 47 1 SPRING 48 1 PROPELLER SHAFT 49 1 REVERSE GEAR (23 TEETH) 50 1 BALL BEARING 51 1 BEARING CARRIER ASSEMBLY 52 1 O-RING 53 1 ROLLER BEARING 54 1 OIL SEAL 55 1 OIL SEAL 56 2 SCREW (M8x30) WASHER 58 2 THREADED INSERT 59 1 TRIM TAB 60 1 SCREW (M10 x 30) WASHER 62 1 THRUST HUB 63 1 PROPELLER NUT TAB WASHER 65 1 DECAL- Ger Rtio 66 4 WASHER 67 4 SCREW (M10 x 45) MAY 2000 Pge 6A-9

10 Generl Servie Reommendtions Berings Sels There my e more thn one wy to disssemle or ressemle prtiulr prt(s), therefore, it is reommended tht the entire proedure e red prior to repir. IMPORTANT: Red the following efore ttempting ny repirs. In mny ses, disssemly of su-ssemly my not e neessry until lening nd inspetion revels tht disssemly is required for replement of one or more omponents. Servie proedure order in this setion is norml disssemly-ressemly sequene. Threded prts re right hnd (RH), unless otherwise indited. When holding, pressing or driving is required, use soft metl vise jw protetors or wood for protetion of prts. Use suitle mndrel (one tht will ontt only the ering re) when pressing or driving erings. Whenever ompressed ir is used to dry prt, verify tht no wter is present in ir line. WARNING To void personl injury, wer eye protetion nd regulte ir pressure to not more thn 25 p.s.i. (172 kp) when drying erings with ompressed ir. Do not spin erings with ompressed ir s this my use erings to sore from lk of lurition. All erings must e lened nd inspeted. Clen erings with solvent nd dry with ompressed ir. Air should e direted t the ering so tht it psses through the ering. Do not spin ering with ompressed ir (see ove wrning). After lening, lurite erings with Quiksilver Ger Lurint. DO NOT lurite tpered ering ups until fter inspetion. Inspet ll erings for roughness, thes nd ering re side wer. Work inner ering re in-nd-out, while holding outer re, to hek for side wer. When inspeting tpered erings, determine ondition of rollers nd inner ering re y inspeting ering up for pitting, soring, grooves, uneven wer, imedded prtiles nd/or disolortion from over-heting. Alwys reple tpered ering nd re s set. Inspet ger housing for ering res tht hve spun in their respetive ores. If re(s) hve spun, ger housing must e repled. Roller ering ondition is determined y inspeting the surfe of the shft tht the roller ering supports. Chek shft surfe for pitting soring, grooving, imedded prtiles, uneven wer nd/or disolortion from overheting. The shft nd ering must e repled if suh ondition exists. As norml proedure, ll O-rings nd oil sels should e repled without regrd to pperne. To prevent lekge round sels, pply Lotite 271 to outer dimeter of ll sels. When using Lotite on sels or threds, surfes must e len nd dry. Apply 2-4-C w/teflon on ll O-rings nd on I.D. of oil sels. Apply 2-4-C w/teflon to externl surfes of ering rrier. Pge 6A MAY 2000

11 Drining nd Inspeting Ger Lurint NON-BIGFOOT GEAR HOUSING WARNING If ger housing is instlled on engine, to void identl strting, disonnet (nd isolte) sprk plug leds from sprk plugs efore working ner the propeller. 1. With ger housing in norml running position, ple len pn under housing nd remove the two vent srews nd one fill/drin srew (with gskets) Vent Plug -Fill/Drin Plug 2. Inspet ger lurint for metl prtiles (lurint will hve metl flke pperne). Presene of fine metl prtiles (resemling powder) in the drin pn indites norml wer. The presene of metl hips in the drin pn indites the need for ger housing disssemly nd omponent inspetion. 3. Note olor of ger lurint. White or rem olor MAY indite presene of wter in lurint. Ger lurint whih hs een drined from ger se reently in opertion will hve yellowish olor due to lurint gittion/ertion. Ger lue whih is mixed with ssemly lurint (Speil Lue 101 or 2-4-C w/teflon) will lso e remy white in olor. This is norml nd should not e onfused with the presene of wter. If wter is suspeted to e present in gerse, pressure hek of gerse should e mde (with no lurint in gerse). Gerse should hold psi of pressure for 5 minutes without leking down. Pouring portion of the ger lurint into glss jr nd llowing the lurint to settle will llow ny wter in the lue to seprte nd settle to the ottom of the jr. 4. Presene of wter in ger lurint indites the need for disssemly nd inspetion of oil sels, sel surfes, O-rings, wter pump gskets, erings nd ering surfes, s well s ger housing omponents. If gerse is reuilt, gerse should e pressure heked efore filling with lurint MAY 2000 Pge 6A-11

12 Removl WARNING To prevent identl engine strting, remove (nd isolte) sprk plug leds from sprk plugs efore removing ger housing. 1. Remove (nd isolte) sprk plug leds from sprk plugs. 2. Shift engine into forwrd ger. 3. Tilt engine to full Up position. 4. Remove 4 olts nd wshers, two from eh side 5. Remove trim t. 6. Remove loknut nd wsher in trim t reess. 7. Remove ger housing Trim T -Loknut nd Wsher -Bolts(4) M10 x 45 nd Wshers(4) Pge 6A MAY 2000

13 Disssemly NON-BIGFOOT GEAR HOUSING Wter Pump NOTE: If wter tue sel styed on wter tue (inside of drive shft housing) when ger housing ws removed, pull wter tue sel from wter tue. 1. Reple wter tue sel, if dmged. 2. Remove 6 olts, wshers, nd isoltors (Design 1). 3. Remove over. NOTE: Isoltors from forwrd 2 srews re shorter thn the other isoltors. Retin these for proper ressemly (Design 1). NOTE: Design 1 inluded isoltors on the wter pump housing olts. Newer design versions did not use these isoltors. e d -Wter Tue Sel -Bolts (6) M6x30 -Wshers (6) d-isoltors (6) If so equipped e -Cover IMPORTANT: The irulr groove formed y the impeller seling ed should e disregrded when inspeting over nd plte, s the depth of the groove will not ffet wter pump output. 4. Reple over if thikness of steel t the dishrge slots is in. (1.524 mm) or less, or if groove(s) (other thn impeller seling ed groove) in over roof re more thn in. (0.762 mm) deep. 5. Lift impeller, drive key, nd gsket from drive shft Impeller -Drive Key -Gsket MAY 2000 Pge 6A-13

14 6. Inspet impeller. Reple impeller if ny of the following onditions exist: Impeller lde(s) re rked, torn, or worn. Impeller is glzed or melted (used y opertion without suffiient wter supply). Ruer portion of impeller is not onded to impeller hu. 7. Remove plte nd gsket. 8. Reple plte if groove(s) (other thn impeller seling ed groove) in plte re more thn in. (0.762 mm) deep. -Plte -Gsket Old Style Bse 9. Remove wter pump se y lifting gently s shown. Inspet refully for rks Wter Pump Bse New Style Bse 10. Remove wter pump se y lifting gently s shown. Inspet refully for rks. -Wter Pump Bse Pge 6A MAY 2000

15 11. Remove (nd disrd) sels, if dmged. Seure the se to enh top or lightly lmp se in vise when removing sels. -Sels 12. Remove sel nd plte if dmged or worn ÉÉÉ ÉÉÉÉÉÉÉ -Sel Plte Bering Crrier nd Propeller Shft 1. Remove fsteners Fsteners MAY 2000 Pge 6A-15

16 2. With propeller shft horizontl, use ering puller to remove rrier from ger housing. Remove propeller shft omponents s n ssemly, tking re not to lose m follower. e A1 Puller Jws Puller Bolt d Bering Crrier -Puller Jws ( A1) -Puller Bolt ( ) d-thrust Hu e -Propeller Shft 3. Reple reverse ger if ger teeth or luth teeth on reverse ger re hipped or worn. If reverse ger must e repled, pinion nd sliding luth should lso e inspeted for dmge. 4. If reverse ger ering is rusted or does not roll freely, reple ering. Remove ering nd reverse ger using ering puller Bering Puller ( ) Pge 6A MAY 2000

17 5. Remove ll ering from reverse ger using Universl Puller Plte nd mndrel. d Bll Bering -Reverse Ger -Universl Puller Plte ( ) d-driver Hed ( ) 6. If ering is rusted or does not roll freely, reple ering. Remove ering nd oil sels. Disrd oil sels d -Driver Rod ( ) -Driver Hed ( ) -Propeller Shft Needle Bering d-oil Sels (2) 7. Remove propeller shft sels nd ering rrier O-ring. -O-ring MAY 2000 Pge 6A-17

18 Propeller Shft Disssemly 1. Remove spring. Push out ross pin. d e -Spring -Cm Follower -Apply Pressure s Shown d-punh e -Cross Pin 2. Reple m follower if worn or pitted on either end. 3. Reple sliding luth if jws re rounded or hipped. Rounded jws indite the following: Improper shift le djustment. Engine idle speed too high while shifting. Shifting too slowly. e d Cm Follower -Guide Blok -Spring d-sliding Cluth e -Jws Pge 6A MAY 2000

19 4. Chek ering surfes of propeller shft. If shft is worn/pitted, reple shft nd orresponding ering. 5. Reple propeller shft if:. Splines re twisted or worn.. Bering surfes of propeller shft re pitted or worn.. Oil sel surfe is grooved in exess of in. (0.12mm). d. Shft hs notiele wole or is ent more thn in. (.152 mm). Chek with dil inditor nd V-loks. -V-Bloks -Bering Surfes -Chek with Dil Inditor Here MAY 2000 Pge 6A-19

20 Pinion Ger, Driveshft nd Forwrd Ger 1. Hold driveshft using Driveshft Holding Tool. Remove (nd disrd) pinion nut. Model Drive Shft Holding Tool 50/60 (4-Stroke) A1 55/60 Bigfoot (2 Stroke) Remove driveshft, pinion ger, nd forwrd ger. 3. Reple pinion ger if hipped or worn. 4. Reple lower driveshft ering if rusted or dmged; or does not roll freely. To remove, refer to Lower Driveshft Bering, following. 5. Reple forwrd ger if ger teeth re hipped or worn. e d -Pinion Nut -Driveshft -Pinion Ger d-bering e -Forwrd Ger 6. Reple forwrd ger needle ering if rusted or does not roll freely fter lening in solvent. Remove s shown. -Needle Bering Pge 6A MAY 2000

21 7. Reple forwrd ger tpered roller ering nd re if either ering or re re rusted or dmged; or if ering does not roll freely fter lening in solvent. Remove ering from ger using Universl Puller Plte nd Mndrel. To remove re, refer to Forwrd Ger Bering Re, following. -Bering/Re -Puller Plte ( ) -Mndrel Upper Driveshft Bering Reple ering nd re if either ering or re re rusted or dmged; or if ering does not roll freely fter lening in solvent. -Bering MAY 2000 Pge 6A-21

22 Lower Driveshft Bering 1. Remove lower driveshft ering using tool ( A1) with ushing instlled A Forwrd Ger Bering Re -Bering -Removl Tool ( A1) -Bushing IMPORTANT: Retin shim(s) for re-ssemly. 1. Remove re nd shim(s) using ering puller. -Re -Shim(s) -Bering Puller ( ) Pge 6A MAY 2000

23 Shift Shft 1. Remove shift shft oupler nd sper. NON-BIGFOOT GEAR HOUSING Coupler -Sper 2. Remove shift shft ushing nd shift shft. Protet shift shft to prevent spline dmge. -Shift Shft Bushing -Shift Shft 3. Remove shift shft m, reple if worn Shift Shft Cm (55/60 2 Stroke shown) MAY 2000 Pge 6A-23

24 NOTE: Remove ny urrs or shrp edges on the shift shft splines efore removing the shift shft ushing. 4. Remove shift shft ushing nd E lip from shift shft. Reple shift shft if splines re twisted or dmged on either end of shft. Remove (nd disrd) O-ring if dmged. d -Shift Shft Bushing - E Clip -Shift Shft d-o-ring 5. Remove (nd disrd) sel if dmged Sel Pge 6A MAY 2000

25 Ger Housing Ressemly NON-BIGFOOT GEAR HOUSING Shift Shft 1. Apply Lotite 271 on O.D. of new sel. Instll with sel lip up, s shown. 2. Press sel into shift shft ushing until sel ottoms. Use suitle tool. 3. Apply 2-4-C w/teflon on O-ring nd I.D. of sel C With Teflon ( A12) 7 Lotite 271 ( ) Sel Lips Fing Up -Shift Shft Bushing -Tool 4. Assemle omponents. d C With Teflon ( A12) -Shift Shft - E Clip -Bushing d-o-ring MAY 2000 Pge 6A-25

26 5. Instll shift m; lign hole in shift m with shift shft pilot ore Shift Shft Pilot Bore -Shift Cm numers up (2 Stroke) -Shift Shft numers down (4 Stroke) 6. Instll shift shft ssemly; insert splines into shift m. Propeller Shft -Shift Shft Assemly Instll omponents. Cluth should e instlled with long end (non-rtheting) towrd propshft reverse shoulder. d 2-4-C w/teflon ( A1) -Spring -Cluth (Align Hole with Slot in Prop Shft) -Guide Blok d-cm Follower (Hold in Ple with 2-4-C w/teflon) e -Propshft Shoulder e Pge 6A MAY 2000

27 2. Instll ross pin. NON-BIGFOOT GEAR HOUSING Cross Pin -Cm Follower -Apply Pressure in This Diretion 3. Instll spring. NOTE: Spring windings must ly flt in luth groove. DO NOT llow spring oils to overlp eh other. -Spring MAY 2000 Pge 6A-27

28 Forwrd Ger Bering Re 1. Ple shim(s), retined from disssemly, into housing. If shim(s) were lost or dmged, or new gerse is eing ssemled, strt with.010 in. (.254mm) shim. 2. Drive ering re into housing. Use led hmmer to void dmge to propshft. d Needle Bering Assy. Lu. ( A1) -Shim(s) -Driver Cup ( ) -Propeller Shft d-assemled Bering Crrier Bering Crrier 1. Lurite O.D. of needle ering with 2-4-C w/teflon. 2. Instll needle ering. Instlltion Note: Push ginst numered end of ering C With Teflon ( A12) -Needle Bering -Instller ( ) Pge 6A MAY 2000

29 3. Apply Lotite 271 on O.D. of smll dimeter oil sel. Sel lip should fe wy from shoulder on Instlltion Tool. Press sel in until Instller Tool ottoms out Lotite 271 ( ) Smll Dimeter Sel -Instller Tool ( ) 4. Apply Lotite 271 on O.D. of lrger dimeter oil sel. Sel lip should fe towrds shoulder on instlltion tool. Press in until Instller tool ottoms out Lotite 271 ( ) -Lrge Dimeter Sel -Instller Tool ( ) MAY 2000 Pge 6A-29

30 Instlltion Note: If servie tools re not ville, the following referene dimensions pply for instlling ering nd sels to proper depths..82 in. (20mm) -Bering in. (11mm).04 in. (1mm) -Oil Sel (Instll with Lip Down) -Oil Sel (Instll With Lip Up) Pge 6A MAY 2000

31 Reverse Ger NON-BIGFOOT GEAR HOUSING 1. Lurite I.D. of ering with 2-4-C w/teflon. Use suitle mndrel nd press onto ger until ering ottoms. 2-4-C With Teflon ( A12) -Bering -Suitle Mndrel Lurite O.D. of ering with 2-4- w/teflon. Use suitle mndrel nd press reverse ger/ering ssemly into ering rrier until ering ottoms out. 2-4-C With Teflon ( A12) -Reverse Ger nd Bering Assemly -Suitle Mndrel -Bering Crrier MAY 2000 Pge 6A-31

32 Forwrd Ger 1. Lurite O.D. of ering with 2-4-C w/teflon. Press new propshft ering into ger until Instller Tool ottoms. Instlltion Note: Push ginst numered end of ering C With Teflon ( A12) -Instller Tool ( ) Lurite I.D. of ering with 2-4-C w/teflon. Use suitle mndrel nd press tpered roller ering onto ger until ering ottoms on ger. 2-4-C With Teflon ( A12) Bering (Lurite I.D. Before Assemly) -Suitle Mndrel Pge 6A MAY 2000

33 Lower Driveshft Bering Instlltion 1. Lurite O.D. of ering with 2-4-C w/teflon. 2. Instll ering into housing. Press until Instller Tool ottoms out. Instlltion Note: Push ginst numered end of ering. NON-BIGFOOT GEAR HOUSING mm 7.07 in.( 179.5mm) A C With Teflon ( A12) -Needle Bering (Lurite O.D. Before Assemly) -Bering Instller Tool ( A1) -Referene (Bering Depth) MAY 2000 Pge 6A-33

34 Upper Driveshft Bering Instlltion 1. Lurite I.D. of ering with 2-4-C w/teflon. Using suitle mndrel press upper driveshft ering onto driveshft until ering ontts driveshft shoulder. 2-4-C With Teflon ( A12) Upper Driveshft Bering (Lurite I.D. Before Assemly) Pge 6A MAY 2000

35 Forwrd Ger, Pinion Ger, Upper Driveshft Bering Re, Retiner nd Driveshft Instlltion NOTE: If shim(s) were lost or re not reusle (dmged), strt with pproximtely.015 in. (0.361mm). Instll omponents in sequene shown. d g e f g ASSEMBLY SEQUENCE -Forwrd Ger/Bering: Apply Premium Blend Ger Lue to Bering Rollers Before Instlltion -Pinion Ger -Driveshft d-upper Driveshft Bering Re nd Shim(s) e -Upper Driveshft Bering Retiner. Tighten to Speified Torque using Tool ( ) f -Driveshft Holding Tool g-pinion Nut (New) (See Note t Pinion Ger Depth, Following.) Reess in Nut is Instlled Towrd Pinion Ger (See Inset). Model Drive Shft Holding Tool 50/60 (4-Stroke) A1 55/60 (2 Stroke) Upper Driveshft Bering Retiner Torque 75 l-ft (101.7 Nm) MAY 2000 Pge 6A-35

36 Pinion Ger Lotion nd Forwrd Ger Bklsh DETERMINING PINION GEAR LOCATION NOTE: Red entire proedure efore ttempting ny hnge in shim thikness. IMPORTANT: Forwrd ger ssemly pilots the end of the pinion gge nd must e instlled in ger housing when heking pinion ger depth. Without it n inurte mesurement will e otined. 1. Clen the ger housing ering rrier shoulder nd dimeter. 2. Position ger housing upright (driveshft vertil). Instll Bering Prelod Tool ( A2) in sequene shown. h 3/4 in. (19mm) I.D. i i f g e d INSTALLATION SEQUENCE: Bering Prelod Tool ( A2) -Plte -Adptor: Bering surfes len nd free of niks -Thrust Bering: Oiled nd le to move freely d-thrust Wsher: Clen nd free of niks nd ends e -Spring f -Nut: Threded ll the wy onto olt g-bolt: Held snug ginst spring h-sleeve: Holes in sleeve must lign with set srews i -Set Srew (2): Tighten ginst drive shft, olt should not slide on driveshft Pge 6A MAY 2000

37 3. Mesure distne etween top of nut nd ottom of olt hed. 4. Inrese distne y 1 in. (25.4mm). 5. Rotte driveshft 10 revolutions. This properly sets upper driveshft tpered roller ering. -Distne, 1 in. (25.4 mm) -Nut -Bolt Insert Pinion Lotion Tool. Position ess hole s shown. Insert feeler guge etween guging surfe nd pinion ger. d A2 -Pinion Lotion Tool ( A2) -Aess Hole -Guging Surfe d-pinion Ger MAY 2000 Pge 6A-37

38 7. The orret lerne etween the guging surfe nd the pinion ger is.025 in. (0.64mm). 8. If lerne is more thn.025 in. (0.64mm) remove shims from under the upper ering up. If lerne is less thn 0.25dd shims under the upper ering re. 9. After finl djustment to pinion height, nd forwrd ger klsh hs een estlished, pply Lotite 271 to threds nd torque new pinion nut to speified torque. NOTE: Clen driveshft nd pinion nut threds with Lotite Primer of suitle de-greser efore pplying Lotite Lotite 271 ( ) -Bering Re -Shim(s) -Pinion Nut (Reessed Side Towrd Pinion) Pinion Nut Torque 50 l-ft (67 Nm) Pge 6A MAY 2000

39 Determining Forwrd Ger Bklsh NON-BIGFOOT GEAR HOUSING NOTE: Red entire proedure efore ttempting ny hnge in shim thikness. 1. Otin orret pinion ger lotion; refer to Determining Pinion Ger Lotion, preeding. 2. Instll Bering Prelod Tool on driveshft; refer to Determining Pinion Ger Lotion, preeding. 3. Instll omponents s shown. 4. While holding the driveshft, torque the puller olt to 45in-l. 5. Rotte driveshft 5-10 revolutions. This should properly set the forwrd ger tpered roller ering. Repet step 4. d A1 Puller Jws Puller Bolt Propeller Shft* -Bering Crrier* (Assemled) -Puller Jws ( A1) d-puller Bolt ( ) Puller Bolt Torque 45 l-in. (5.1 Nm) *Refer to Bering Crrier nd Propeller Shft Instlltion, following MAY 2000 Pge 6A-39

40 6. Instll omponents s shown. e f d Dil Inditor Adpter Kit A1 Dil Inditor Bklsk Inditor Threded Rod (Otin Lolly) d-dil Inditor Adptor Kit ( ) -Wshers e -Dil Inditor ( A1) -Nuts f -Bklsh Inditor Tool ( ) 7. Position Dil Inditor on pproprite line (from hrt) mrked on Bklsh Inditor Tool. BACKLASH INDICATOR ALIGN POINTER OF DIAL INDI- MODEL TOOL CATOR WITH MARK 50/60 (4-Stroke) OR in. (9.3 mm) 55/60 (2-Stroke) Turn driveshft k-nd-forth (hek for no rottion t the propeller shft). 9. Dil Inditor registers mount of klsh, whih must e etween speifitions shown in hrt. MODEL DIAL INDICATOR MINIMUM DIAL INDICATOR MAXIMUM 50/60 (4-Stroke) in. (0.28 mm) in. (.43 mm) 55/60 (2-Stroke) in. (0.33 mm) in. (.48 mm) 10. If klsh is less thn the minimum reding, remove shim(s) from in front of the forwrd ger ering re. If klsh is more thn the mximum reding, dd shim(s) in front of the forwrd ger ering re. When finl mesurement hs een mde, pply Lotite 271 to threds of pinion nut. NOTE: By dding or sutrting.001 in. (0.025mm) shim, the klsh will hnge in. (0.032mm). Pge 6A MAY 2000

41 Bering Crrier nd Propeller Shft Instlltion NON-BIGFOOT GEAR HOUSING 1. Lurite O-ring, ering rrier nd relted gerse housing ores, in res shown, with Quiksilver 2-4-C w/teflon. 2. Insert propeller shft ssemly into ering rrier. 3. Instll ering rrier nd propeller shft ssemly into ger housing. Use re not to disple m follower C w/teflon ( A1) -O-ring -Cm Follower 4. Disrd the thin in. (1.60 mm) flt wshers nd the 25 mm long olts on models listed. Instll thiker flt wshers nd longer olts. 55/60 (3 Cylinder - 2 Stroke) Non Big Foot USA 0G nd elow Belgium NA -Bolt 25 mm Long - Disrd -Thin Flt Wsher in. (1.60 mm) thik - Disrd 5. Instll thiker flt wshers nd longer olts. -Bolt ( ) 1.18 in. (30 mm) Long -Wsher ( ) in. (2.29 mm) MAY 2000 Pge 6A-41

42 6. Torque olts to speified torque Lotite 271 ( ) -Bolts (2) M8x Bering Crrier Bolt Torque 225 l-in. / 18.8 l-ft. (25.5 Nm) Wter Pump Re-ssemly nd Instlltion 1. Ple sel on longer shoulder side of tool. Sel spring should fe the shoulder of the tool during instlltion. Apply Lotite 271 to O.D. of sel. 2. Press into wter pump se until tool ottoms Lotite 271 ( ) Sel -Sel Instlltion Tool ( ) Pge 6A MAY 2000

43 3. Ple sel on shorter shoulder side of tool. Sel spring should fe the shoulder of the tool during instlltion. Apply Lotite 271 to O.D. of sel. 4. Press into wter pump se until tool ottoms Lotite 271 ( ) -Sel -Shorter Side of Tool -Sel Instlltion Tool ( ) NOTE: If instlltion tool is not ville, press sels in s shown to depths indited in. (1.02 mm) Sel (Instll with spring visile when instlled.) -Sel (Instll with spring visile when instlled.) -Sel Bottom 5. Instll O-ring. Apply Quiksilver 2-4-C w/teflon to o-ring,sel lips nd ger housing ore MAY 2000 Pge 6A-43

44 6. Instll wter pump se into ger se C w/teflon ( A1) -O-ring -Wter Pump Bse -Ger Cse 7. If removed previously, re-instll sel nd filler plte. ÉÉÉ ÉÉÉÉÉÉÉ -Sel -Filler Plte Pge 6A MAY 2000

45 8. Instll gsket nd fe plte. NON-BIGFOOT GEAR HOUSING -Gsket -Fe Plte IMPORTANT: If the old impeller is re-used, instll in the originl (lokwise) diretion of rottion. 9. Instll drive key nd impeller Drive Key -Impeller 10. Lurite I.D. of over with Quiksilver 2-4-C w/teflon. Instll gsket with ed fing up C With Teflon ( A12) -Gsket -Bed Towrd Cover MAY 2000 Pge 6A-45

46 11. Rotte driveshft lokwise nd push wter pump housing down. Seure over. d d d Wter Pump Housing Assemly - Isoltors, (Design 1) Note: 2 isoltors for forwrd srews re different from remining 4 isoltors -Wshers (6) d-bolts (6) M6x16; Apply Lotite 271 on threds nd torque to speified torque NOTE: Torque over srews s shown Cover Bolt Torque 60 l-in. (6.8 Nm) Pge 6A MAY 2000

47 12. If wter tue sel styed on wter tue (in driveshft housing), pull sel from wter tue. 13. Lurite I.D. of wter tue sel with Quiksilver 2-4-C w/teflon nd instll Wter Tue Sel Ger Housing Pressure Test 1. Remove vent plug nd instll pressure test guge. Tighten seurely. 2. Pressurize housing to PSI (69-83 kp) nd oserve guge for 5 minutes. 3. Rotte driveshft, prop shft nd move shift rod while housing is pressurized to hek for leks. 4. If pressure drop is noted, immerse housing in wter. 5. Re-pressurize to PSI (69-83 kp) nd hek for ir ules. 6. Reple leking sels s neessry. Retest housing. NOTE: Gerse ssemly should hold PSI (69-83 kp) for 5 minutes. 7. Remove tester from housing. Instll vent plug nd new seling wshers MAY 2000 Pge 6A-47

48 Ger Housing Instlltion Ger Housing Instlltion WARNING Disonnet (nd isolte) sprk plug leds efore instlling ger housing onto driveshft housing. 1. Position shift linkge into forwrd ger position. Models 50/60 (4-Stroke) Models 60 (2-Stroke) Remote Control Model Shown (50/60 4-Stroke) -Shift Lever -Shift Blok 2. Tilt engine to full Up position. Engge tilt lok lever. 3. Shift ger housing into neutrl. Propeller shft will rotte freely in either diretion. 4. Instll wter tue sel, sper nd shift shft oupler Lotite 405 (Purhse Lolly) 2-4-C w/teflon ( A1) -Wter Tue Sel -Sper -Shift Shft Coupler Pge 6A MAY 2000

49 CAUTION NON-BIGFOOT GEAR HOUSING Do not lurite top of driveshft. Exess lurint will not llow driveshft to fully engge rnkshft. Tightening the ger housing fsteners (if exess lurint is on top of driveshft) will lod the driveshft/rnkshft nd my dmge either or oth powerhed nd ger housing. Wipe the top of driveshft free of lurint. 5. Lightly pply Quiksilver 2-4-C w/teflon onto the driveshft splines. 6. Shift ger housing into forwrd ger. Ger housing will not engge when propeller shft is turned lokwise. 7. Position driveshft into driveshft housing. Move ger housing towrds driveshft housing while ligning shift shft oupler, wter tue sel nd driveshft splines. NOTE: If the driveshft splines will not lign with the rnkshft splines, instll propeller nd turn the propeller shft ounterlokwise while pushing ger housing onto driveshft housing. It my lso e neessry to move the shift lok (on the powerhed) to lign the shift shft splines for proper re-ssemly. 8. Instll 4 olts nd wshers, (two eh side). Apply Lotite 271 on ottom hlf of olt threds prior to instlltion. 9. Instll loknut nd wsher. 10. Torque olts nd loknut to speified torque. 7 7 Lotite 271 ( ) Bolts nd Wshers (4) M10x45 -Loknut nd Wsher Bolts nd Loknut Torque 40 l-ft (54 Nm) 11. Chek shift opertion.. Propeller shft will not rotte in ounterlokwise diretion when in forwrd ger. Cluth will rthet (liking noise) when rotted lokwise.. Propeller shft will rotte freely in either diretion when gerse is in neutrl.. Propeller shft will not rotte in either diretion when gerse is in reverse. IMPORTANT: If shift opertion is not s desried, remove the ger housing nd orret the shift opertion MAY 2000 Pge 6A-49

50 Filling Ger Housing with Lurint NOTE: Ger housing lurint pity is pproximtely 11.5 fl. oz. (340 ml). WARNING If ger housing is instlled on outord, disonnet (nd isolte) sprk plug leds from sprk plugs efore working ner the propeller. CAUTION Do not use utomotive grese in the ger housing. Use only Quiksilver Ger Lue. 1. Remove ny gsket mteril from Fill/Drin nd Vent plugs nd ger housing. Instll new seling wshers on Fill/Drin nd Vent plugs. IMPORTANT: Never dd lurint without removing Vent plugs. Ger housing nnot e filled euse of trpped ir. Fill ger housing when driveshft is in vertil position. 2. Remove Fill/Drin plug nd seling wsher. 3. Insert lurint tue in Fill/Drin hole, then remove Vent plugs nd seling wsher. 4. Fill until exess lurint flows out of left Vent hole. 5. Reple left Vent plug nd seling wsher nd ontinue to fill until lurint flows from right Vent hole. 6. Reple right Vent plug nd seling wsher. 7. Instll Fill/Drin plug nd seling wsher. 8. Torque srews to speified torque Fill/Drin Plug - Vent Plug - Vent Plug Srew Torque 58 l-in. (6.5 Nm) Pge 6A MAY 2000

51 Trim T Adjustment nd Replement NON-BIGFOOT GEAR HOUSING IMPORTANT: The trim t is mde of speil lloy to id in proteting the drive shft housing nd ger housing from glvni orrosion (orrosion nd pitting of metl surfes). Do not pint or ple protetive oting on the trim t, or trim t orrosion protetion funtion will e lost. 1. Reple trim t if 50% (or more) orroded. Mrk lotion of old trim t on nti-ventiltion plte efore removl; instll new trim t in sme lotion. 2. The trim t will offset (lne) some of the steering lod tht is used y propeller torque t higher speeds. If t higher speeds the ot turns more esily to the left, loosen olt, move the trim t (triling edge) to the left (when viewed from ehind); re-tighten olt. Turn trim t (triling edge) to the right if the ot turns more esily to the right. -Trim T -Anti-Ventiltion Plte -Retining Bolt nd Wsher M10x Retining Bolt Torque 22 l-ft (29.8 Nm) MAY 2000 Pge 6A-51