ACCESSORIES. Table of Contents. Section 8A - All Models

Transcription

1 SERVICE MANUAL NUMBER 11 Tle of Contents ACCESSORIES Setion 8A - All Moels ACCESSORIES - ALL MODELS Speifitions A-2 Torque Speifitions A-2 Lurints/Selers/Ahesives A-2 Power Shift (P/N 38638A4) A-2 Desription A-2 Generl Informtion A-3 Cheking Vuum Drop-Off A-5 Power Shift Cyliner Repir A-6 Removl A-6 Disssemly A-6 Ressemly A-9 Shift Cle Replement n Ajustment A-13 Instlltion Preprtion A-13 Shift Cle Brrel Ajustment A-13 Instlling Input Cle A-14 Instlling Output Cle A-14 Atth Dust Cover A-15 Mounting Power Shift Cyliner A-15 Conneting Vuum Hose to Engine 8A-15 8 A MARCH 1998 Pge 8A-1

2 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 11 Speifitions Torque Speifitions DESCRIPTION Dust Cover Inlet Flnge Vlve Guie Brket Thru Bolts En Plte to Vlve Guie Brket En Plte to Cyliner TORQUE 34 l. in. (3.4 N m) l. in. (13-17 N m) l. in. (7-9 N m) l. in. (13-17 N m) l. in. (23-31 N m) Lurints/Selers/Ahesives DESCRIPTION PART NUMBER 2-4-C Mrine Lurint with Teflon A2 Power Shift (P/N 38638A4) Desription The Power Shift yliner is vuum tute yliner whih ssists the mehnil shifting. It utilizes the vuum proue in the intke mnifol. The vuum is route, y hose, to the shift yliner Power Shift Assemly 2 - Output Cle Stu 3 - Output Cle Stu Nut 4 - Clevis Pin 5 - Input Cle Wsher n Cotter Pin 6 - Cotter Pin 7 - Felt Power Shift Cyliner Plug 8 - Flnge 9 - Inlet Flnge Gsket 10 - Srew 11 - Lokwsher 12 - Dust Shiel 13 - Clmp 14 - Sper 15 - Vuum Hose Clmp 16 - Vuum Hose 17 - Vuum Hose to Engine Fitting Clmp 18 - Vuum Hose Fitting 19 - Vuum Hose Fitting Reuer Bushing 20 - T-fitting (use only with vuum guge) Pge 8A MARCH 1998

3 SERVICE MANUAL NUMBER 11 Generl Informtion ACCESSORIES - ALL MODELS Control Cles - Use quiksilver ontrol les for the input le, output le, n throttle le. ATTACHING OUTPUT SHIFT CABLE TO STERNDRIVE UNIT CABLE REPLACEMENT Refer to the Sternrive Unit Instlltion Mnul or Instlltion Setion of this mnul, n follow the proeure outline for tthing n justing the shift le. IMPORTANT: Do not instll the propeller efore tthing n justing the shift le. Do not tth the throttle le to the ruretor efore tthing n justing the shift le. The engine must e running n the Power Shift operting when the le justment proeure requires moving the remote ontrol hnle to the full forwr or full reverse positions. After the hnle hs een move, the engine my e stoppe. Filure to omply with the ove instrutions will result in improper unit shift le justment n possile mge to the sternrive shift mehnism. IMPORTANT: To ensure proper opertion of the remote ontrol n power shift, omply with the following: Control les must e orret length. Control les shoul follow the shortest route from the remote ontrol to the power shift, n from the power shift to the shift plte. Keep the ens to minimum numer n llow en with minimum of 12 in. (305mm) rius. DO NOT EXCEED 6 ft. (1.8m) in length of output le. i h e g f Shift Cle (To Drive Unit) - Output Cle (To Shift Plte) - Input Cle - Remote Control e - Throttle Cle f - Vuum Hose to Engine g - Vuum Hose Connetion t Engine h - Power Shift Cyliner i - Shift Plte MARCH 1998 Pge 8A-3

4 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 11 DETERMINING INPUT CABLE LENGTH 1. Mesure the istne from the remote ontrol (t the point where the les leve the housing), to the power shift yliner (t the point where the vuum hose tthes); mke the le ens of 12 in. (305 mm) rius or lrger. 2. Selet the input le length. Use the next full foot longer le thn the mesurement tken. EXAMPLE: Mesure istne = 16 ft. 3 in. (4.88 mm). Use 17 ft. (5.18mm) le. DETERMINING OUTPUT CABLE LENGTH 1. Mesure istne from power shift yliner (t the point where the vuum hose tthes), to the shift plte, following the pth tht the le will trvel, keeping ens to minimum. Mke ens 12 in. (305 mm) or lrger rius. 2. Selet the output le length. Use the next full foot longer le thn the mesurement. EXAMPLE: Mesure istne = 16 ft. 3 in. (4.88 mm). Use 17 ft. (5.18 mm) le. IMPORTANT: For the power shift unit to work properly, there must e en in the output le. Mount the power shift yliner t to the shift plte. DO NOT mount the yliner in line with the shift plte. IF RELOCATING THE POWER SHIFT CYLINDER 1. Selet lotion ove the height of the intke mnifol to mount the power shift yliner in the ot. The lotion must not llow shrp ens in the le. Bens must form not less thn 12 in. (305 mm) rius, n the lotion must ple the power shift yliner within istne (mesure long the le pth) of not less thn 3 ft. (914mm) nor more thn 6 ft. (1.8 mm) from the shift plte. 2. Position rilling templte ( ) n rill holes. Temporrily mount the power shift yliner in the selete lotion, reusing the lg srews (or olts). Fill n sel the mounting holes in the former lotion. Pge 8A MARCH 1998

5 SERVICE MANUAL NUMBER 11 Cheking Vuum Drop-Off ACCESSORIES - ALL MODELS 1. Connet lek proof shut-off vlve n pressure guge in-line etween the Power Shift yliner input flnge n the vuum onnetion t the engine mnifol, with the vlve towr the mnifol sie n the guge towr the power shift yliner. - Engine Mnifol to Power Shift Cyliner Vuum Hose Disonnet t the Power Shift Cyliner g e Components * - Vuum Guge - Coupling - T-fitting - Hose Br Coupling e - Hose Clmp f - Short Vuum Hose g - Lek Proof Shut-off Vlve h - Coupling i - Hose Br * Otin Lolly i h e f With the engine running t ile, turn off the vlve in the vuum line. If the vuum rops to 0 (zero) in less thn 5 seons, in either test, instll gsket reuil kit.. TEST1: With the yliner piston in neutrl.. TEST 2: With the yliner piston in reverse. - Neutrl - Reverse MARCH 1998 Pge 8A-5

6 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 11 Power Shift Cyliner Repir Removl Disssemly 1. Loosen the lmps (2) n remove the ust over from the vlve guie rkets. 2. Remove the inlet hose lmp t the inlet flnge, n remove the inlet hose. 3. Remove the lg srews (or olts, if use), whih nhor the yliner to the ot. 4. Remove the yliner from the mounting surfe. 1. Remove the 4 olts n lokwshers on the en plte. Then, remove the yliner. - 4 Bolts n Lokwshers - Cyliner 2. Remove the piston sel n O-ring from the piston (the O-ring is uner the piston sel in the sme groove). 3. Remove the otter pin seuring the shft en plug. Remove the snp ring whih seures the piston to the shft Piston Sel - O-ring - Cotter Pin - Snp Ring Pge 8A MARCH 1998

7 SERVICE MANUAL NUMBER 11 ACCESSORIES - ALL MODELS 4. Remove the piston y first removing the O-ring from the shft (ehin the piston, next to the 2n snp ring), n then removing the snp ring. 5. Remove the shft en plug Shft En Plug - Piston - O-ring (Behin Piston) - Snp Ring 6. Remove the 2 olts n opper seling wshers inite elow. - 2 Bolts n Copper Wshers 7. Remove the 2 thru-olts whih seure the en plte to the vlve guie rket. - 2 Thru-olts MARCH 1998 Pge 8A-7

8 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER Slip the en plte from the vlve guie rket, n off of the shft. It my e neessry to tp off the plte with rwhie mllet. 9. Drive the ol sels out of the en plte. - Ol Sels Remove the olts, inlet flnge, n gsket. Loosen the thru-olts n tp out the sel tue. Press or rive the ol sel out of the tue. e Bolts - Inlet Flnge - Thru-olts - Sel Tue e - Ol Sel Pge 8A MARCH 1998

9 SERVICE MANUAL NUMBER 11 Ressemly ACCESSORIES - ALL MODELS 1. Press the new oil sels into the en plte/housing until the sels ottom out. The sel lips fe in the iretion shown. - New Oil Sels Wrp the imeter of the shft (re, ) with msking tpe to protet the sel lips. Generously lurite the shft with 2-4-C Mrine Lurint with Teflon. Lurite the sel lips with 2-4-C Mrine Lurint with Teflon, then slie the en plte housing onto the shft. It my e neessry to tp the housing into the vlve guie rket, to set it fully. Remove the msking tpe from the shft en.. Instll thru-olts, flt wshers n nuts. Tighten the olts y hn.. Torque the en plte olts n opper seling wshers to l. in. (13-17 N m).. Torque the thru-olts to l. in. (7-9 N m) Put Msking Tpe Over Shft Dimeter (Are ) - En Plte Bolts - Thru-olts - Drive Shft MARCH 1998 Pge 8A-9

10 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER Press new sel, lip fing out, into the sel tue, so tht the sel is flush with the en of the tue. Lurite the I.D. of the sel with 2-4-C Mrine Lurint with Teflon. - Sel Tue - New Sel - Lip Ple msking tpe over the shft en to protet the se. Lurite the shft with 2-4-C Mrine Lurint with Teflon. Slie the sel tue (with the sel instlle) onto the shft n slie the sel tue into the vlve guie rket. While holing the sel tue firmly in the sete position in the vlve guie rket, tighten the thru-olts. Torque the thruolts to l. in. (7-9 N m). Remove the msking tpe from the shft en. - Sel Tue - Thru-olts 5. Instll the inlet flnge () long with new gsket. Seure the flnge n gsket with two olts n lokwshers. Torque the olts to l. in. (13-17 N m). - Inlet Flnge - Two Bolts n Lokwshers Pge 8A MARCH 1998

11 SERVICE MANUAL NUMBER 11 ACCESSORIES - ALL MODELS 6. If the piston sel is not pre-ut, mke igonl ut/seprtion s shown. 7. Instll the O-ring in the O.D. groove in the piston. Instll the piston sel over the O-ring. 8. Instll the snp ring on the shft. Mke sure the snp ring is fully sete in its groove. Instll the O-ring onto the shft. Slie the O-ring own to the snp ring. 9. Slie the piston onto the shft. Seure the piston with snp ring. Mke sure the snp ring is fully sete in its groove. h f g e i f i g h Piston Sel - O-ring (Uner Piston Sel) - Snp Ring (Outer) - O-ring (On Shft) e - Csting Numer (This Sie In, Towr The En Plte) f - Piston g - Shft h - En Plte/Housing i - Snp Ring (Inner) MARCH 1998 Pge 8A-11

12 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER Instll new O-ring onto the shft en plug. Lightly lurite the O-ring with 2-4-C Mrine Lurint with Teflon, then insert the plug into the shft en. Be reful not to mge the O-ring. A mge O-ring will use vuum lek. Align the otter pin holes n seure the en plug to the shft with otter pin. Spre oth ens of the otter pin O-ring - Shft En Cp - Cotter Hole(s) - Cotter Pin Ens Lierlly pply 2-4-C Mrine Lurint with Teflon to eh sie of the slie rils n wheel. - Slie Rils - Wheel Instll pper gsket onto the en plte. Hol the gsket in ple with 2-4-C Mrine Lurint with Teflon. Then, tth the yliner to the en plte with 4 olts n lok wshers. Torque the olts to l. in. (23-31 N m) Cyliner - En Plte - 4 Bolts n Lokwshers - Pper Gsket Pge 8A MARCH 1998

13 SERVICE MANUAL NUMBER 11 Shift Cle Replement n Ajustment ACCESSORIES - ALL MODELS Instlltion Preprtion If instlling new shift le(s), omplete the hookup to the remote ontrol n route the shift le(s) efore strting the following proeures. Shift Cle Brrel Ajustment 1. Shift the remote ontrol into neutrl. 2. Push in on the input shift le en guie with enough pressure to remove free-ply n mrk position on the tue. 3. Pull out on the input shift le en guie with enough pressure to remove free-ply n mrk position. 4. Mesure the istne etween mrks n, then mrk position hlfwy etween them. Position mrks the enter of free-ply. 5. Position the le en guie t the enter of free-ply (position ). 6. Ajust the rrel so tht the istne etween the enterline of the le en guie mounting hole, n the enterline of the le rrel hole is 7 1 / 16 in. (179mm) prt (with the en guie in position ). 7 1 / 16 in Position - Position - Position MARCH 1998 Pge 8A-13

14 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER 11 Instlling Input Cle 1. Instll the input le s shown. Tke re not to hnge the position of the rrel. 2. Ple roun felt plug in the vlve guie rket hole on top of the le rrel g - Input Cle Brrel - Vlve Guie Brket - Cle En Guie - Cotter Pin e - Clevis Pin f - Input Cle Brket g - Roun Felt Plug Instlling Output Cle 1. Instll output le s shown. 2. Ple retngulr felt sper in the reess of the vlve guie rket. f e f h e g Output Cle Brrel - Cotter Pin - Yoke - Three Stu e - Nut f - Vlve Guie Brket g - Output Cle En h - Retngulr Felt Sper Pge 8A MARCH 1998

15 SERVICE MANUAL NUMBER 11 Atth Dust Cover ACCESSORIES - ALL MODELS 1. Ple the ust over in to position s shown. The slot in the over shoul e on ottom when the power shift yliner is mounte to the ot. 2. Ple lmps roun eh en of the over. Tighten seurely. - Dust Cover - Clmps NOTE: For shift le justment, refer to Setion 2A of this mnul. Mounting Power Shift Cyliner Seurely fsten the power shift yliner to the ot with lg srews (or olts). 2. Fsten the input le to the ot. Do not fsten the le within 18 in. (457mm) of the power shift yliner. IMPORTANT: Do not seure the output le to the ot or ny other le or hose. The outer onuit of the le must e free to move k n forth when the unit is shifte. Conneting Vuum Hose to Engine IMPORTANT: Keep the vuum hose in s stright n inline, from the yliner to the engine hose fitting, s possile. Avoi sg (low spot) in the hose. 1. Connet the vuum hose to power shift yliner, s shown. 2. Seurely tighten the hose lmp. - Vuum Hose - Hose Clmp 3. If repling the vuum hose, ut the hose to the length require MARCH 1998 Pge 8A-15

16 ACCESSORIES - ALL MODELS SERVICE MANUAL NUMBER Ple the hose lmp over the en of the hose n slie the hose over the fitting. Tighten the hose lmp seurely Engine WITHOUT Vuum Guge Instlle - Vuum Hose - Hose Clmp - Hose Connetor Fitting - Reuer Fitting e Engine WITH Vuum Guge Instlle - Vuum Guge Line (To Instrument Pnel) - T-fitting - Vuum Hose (From Power Shift Cyliner) - Hose Clmp e - Reuer Fitting Pge 8A MARCH 1998