www.motorka.org LOWR CHAPTR 6 LOWR UNIT LOWR UNIT...6- RMOVING TH LOWR UNIT...6- RMOVING TH PROPLLR...6-3 CHCKING TH PROPLLR...6-3 INSTALLING TH PROPLLR...6-3 INSTALLING TH TRIM TAB...6-3 WATR PUMP...6-4 RMOVING TH WATR PUMP...6-4 CHCKING TH WATR PUMP HOUSING...6-5 CHCKING TH IMPLLR AND INSRT CARTRIDG...6-5 CHCKING TH WOODRUFF KY...6-5 INSTALLING TH IMPLLR AND WATR PUMP HOUSING...6-5 SHIFT ROD...6-6 RMOVING TH SHIFT ROD...6-6 PROPLLR SHAFT HOUSING...6-7 RMOVING TH PROPLLR SHAFT HOUSING...6-7 DISASSMBLING TH PROPLLR SHAFT HOUSING...6-8 DISASSMBLING TH PROPLLR SHAFT...6-9 RMOVING TH PROPLLR SHAFT HOUSING... 6-0 DISASSMBLING TH PROPLLR SHAFT HOUSING... 6-0 CHCKING TH RVRS GAR... 6- CHCKING TH BARING... 6- CHCKING TH PROPLLR SHAFT HOUSING... 6- ASSMBLING TH PROPLLR SHAFT HOUSING...6- CHCKING TH DOG CLUTCH...6-3 CHCKING TH PROPLLR SHAFT...6-3 CHCKING TH SHIFT PLUNGR...6-3 CHCKING TH SPRING...6-3 DRIV SHAFT... 6-4 RMOVING TH DRIV SHAFT... 6-4 RMOVING TH DRIV SHAFT...6-5 RMOVING TH DRIV SHAFT BARING...6-5 DISASSMBLING TH FORWARD GAR...6-5 CHCKING TH PINION AND FORWARD GAR...6-6 CHCKING TH DRIV SHAFT...6-6 CHCKING TH BARINGS...6-6 ASSMBLING TH FORWARD GAR...6-6 INSTALLING TH DRIV SHAFT BARING...6-6 INSTALLING TH DRIV SHAFT...6-7 3 4 5 6 7 8 9
www.motorka.org LOWR LOWR CAS...6-8 DISASSMBLING TH LOWR CAS...6-8 CHCKING TH DRIV SHAFT SLV... 6-9 CHCKING TH NDL BARING...6-0 ASSMBLING TH LOWR CAS...6-0 SHIMMING...6- SLCTING TH PINION SHIMS...6- SLCTING TH FORWARD GAR SHIMS...6-4 SLCTING TH RVRS GAR SHIMS...6-6 BACKLASH...6-8 MASURING TH FORWARD GAR BACKLASH...6-8 MASURING TH RVRS GAR BACKLASH...6-9 3 4 5 6 7 8 9
www.motorka.org LOWR LOWR UNIT 6 LOWR UNIT RMOVING TH LOWR UNIT Step Job/Part Q ty Remarks Cotter pin Not reusable Castle nut 3 Washer 4 Spacer 5 Propeller 6 Spacer 7 Nut 8 Shift connector 9 Bolt (with washer) 0 Trim tab Bolt Anode 3 Screw Continued on next page. 6-
www.motorka.org LOWR LOWR UNIT Step Job/Part Q ty Remarks 4 Nut 5 Water inlet cover 6 Water inlet cover 7 Gear oil level check screw 8 Gasket 9 Gear oil drain screw 0 Gasket Bolt 4 Lower unit 3 Pin 6-
www.motorka.org LOWR LOWR UNIT RMOVING TH PROPLLR Remove: Propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the lanyard engine stop switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning. CHCKING TH PROPLLR Check: Blades Splines Bent/cracks/damage/wear Replace. Bushing Slippage Replace. INSTALLING TH PROPLLR Install: Propeller WARNING Do not hold the propeller with your hands when removing or installing it. Be sure to remove the battery leads from the batteries and the lanyard engine stop switch. Put a block of wood between the cavitation plate and propeller to keep the propeller from turning. NOT: If the groove in the propeller nut is not aligned with the cotter pin hole, tighten the nut further until they are aligned. INSTALLING TH TRIM TAB Install: Trim tab NOT: To ease installation, mark the original position of the trim tab. Steering load varies depending on the trim tab position as installed. 6-3
WATR PUMP WATR PUMP RMOVING TH WATR PUMP Step Job/Part Q ty Remarks Bolt 4 Plate 3 Water tube 4 O-ring Not reusable 5 O-ring Not reusable 6 Water seal rubber 7 Water pump housing 8 Insert cartridge 9 O-ring Not reusable 0 Impeller Impeller plate Dowel pin 3 Woodruff key 6-4
WATR PUMP CHCKING TH WATR PUMP HOUSING Check: Water pump housing Cracks/damage Replace. CHCKING TH IMPLLR AND INSRT CARTRIDG Check: Impeller Insert cartridge Cracks/damage/wear Replace. CHCKING TH WOODRUFF KY Check: Woodruff key Damage/wear Replace. INSTALLING TH IMPLLR AND WATR PUMP HOUSING Install: Impeller Insert cartridge Water pump housing NOT: When installing the insert cartridge, align its projection with the hole in the water pump housing 3. When installing the water pump housing, turn the drive shaft clockwise. Apply Yamaha grease A (water resistant grease) on the impeller, the insert cartridge, and the water pump housing 3. 3 6-5
SHIFT ROD SHIFT ROD RMOVING TH SHIFT ROD Step Job/Part Q ty Remarks Impeller plate Refer to "WATR PUMP" on page 6-4. Bolt Bracket 3 Plate 4 O-ring Not reusable 5 Oil seal housing 6 Lower casing packing Not reusable 7 Dowel pin 8 Shift rod 9 Rubber seal 0 Oil seal 6-6
PROPLLR SHAFT HOUSING PROPLLR SHAFT HOUSING RMOVING TH PROPLLR SHAFT HOUSING Step Job/Part Q ty Remarks Gear oil Refer to "CHANGING AND CHCKING TH GAR OIL" on page 3-0. Shift rod assembly Refer to "SHIFT ROD" on page 6-6. Bolt Propeller shaft housing 3 Washer 4 Propeller shaft 6-7
PROPLLR SHAFT HOUSING DISASSMBLING TH PROPLLR SHAFT HOUSING Step Job/Part Q ty Remarks O-ring Not reusable O-ring Not reusable 3 Reverse gear 4 Reverse gear shim * 5 Ball bearing 6 Oil seal 7 Needle bearing 8 Propeller shaft housing 9 Washer * As required 6-8
PROPLLR SHAFT HOUSING DISASSMBLING TH PROPLLR SHAFT Step Job/Part Q ty Remarks Shift plunger Cross pin ring 3 Cross pin 4 Spring 5 Dog clutch 6 Propeller shaft 6-9
PROPLLR SHAFT HOUSING RMOVING TH PROPLLR SHAFT HOUSING Remove: Propeller shaft housing Bearing housing puller claw... 90890-06564 Stopper guide plate... 90890-0650 Center bolt... 90890-06504 3 DISASSMBLING TH PROPLLR SHAFT HOUSING. Remove: Reverse gear Bearing separator... 90890-06534 Stopper guide plate... 90890-0650 Stopper guide stand... 3 90890-06538 Bearing puller ass y... 4 90890-06535 6-0
PROPLLR SHAFT HOUSING 3. Remove: Ball bearing Stopper guide plate... 90890-0650 Stopper guide stand... 90890-06538 Bearing puller ass y... 90890-06535 3 NOT: Do not reuse the bearing. Always replace it with a new one. 3. Remove: Oil seal Needle bearing Driver rod L3... 90890-0665 Needle bearing attachment... 90890-0665 CHCKING TH RVRS GAR Check: Teeth Dogs Damage/wear Replace. CHCKING TH BARING Check: Bearing Pitting/rumbling Replace. CHCKING TH PROPLLR SHAFT HOUSING Check: Propeller shaft housing Cracks/damage Replace. 6-
PROPLLR SHAFT HOUSING 3 b ASSMBLING TH PROPLLR SHAFT HOUSING. Install: Needle bearing a Needle bearing position... 3.0-3.5 mm (. -.4 in) Driver rod-ss... 90890-06604 Needle bearing attachment... 90890-0665 Bearing depth plate... 90890-06603 a 3 NOT: Install the needle bearing with its manufacturer s marks b facing up. Apply Yamaha motor oil. A. Install: Oil seals a Oil seal position... 6.0-6.5 mm (0.4-0.6 in) Driver rod L3... 90890-0665 Needle bearing attachment... 90890-066 a CAUTION: It is essential that the oil seals are installed correctly (as shown in the illustration). If they are installed the wrong way round, oil or water will leak out. 6-
,,,, LOWR PROPLLR SHAFT HOUSING 3. Install: Reverse gear Reverse gear shim(s) Ball bearing 3 Propeller shaft housing NOT: Before press-fitting the ball bearing, install the reverse gear shim(s). Install the ball bearing with its manufacturer s marks a facing the reverse gear. 4,,,,,,,,,,, CAUTION: Place a suitable base under the gear to protect it from damages. CHCKING TH DOG CLUTCH Check: Dog clutch Damage/wear Replace. CHCKING TH PROPLLR SHAFT Check: Propeller shaft Damage/wear Replace. Maximum runout 0. mm (0.004 in) CHCKING TH SHIFT PLUNGR Check: Shift plunger Wear Replace. CHCKING TH SPRING Check: Spring Weak Replace. 6-3
DRIV SHAFT DRIV SHAFT RMOVING TH DRIV SHAFT Step Job/Part Q ty Remarks Propeller shaft housing Pinion gear nut Pinion gear 3 Drive shaft 4 Forward gear 5 Drive shaft bearing Refer to "PROPLLR SHAFT HOUS- ING" on page 6-7. 6-4
DRIV SHAFT RMOVING TH DRIV SHAFT Remove: Pinion gear nut Drive shaft Drive shaft holder 3... 90890-0657 Removing Steps () Apply mm wrench on the pinion gear nut. () Support the lower case with rags to hold the wrench in position. (3) Turn the drive shaft holder. RMOVING TH DRIV SHAFT BARING Remove: Taper roller bearing Bearing inner race attachment... 90890-06643 DISASSMBLING TH FORWARD GAR Remove: Taper roller bearing Forward gear Bearing separator 90890-06534 CAUTION: Place a suitable base on the gear axle to prevent damage to the top of the axle. 6-5
DRIV SHAFT CHCKING TH PINION AND FORWARD GAR Check: Teeth Dogs Damage/wear Replace. CHCKING TH DRIV SHAFT Check: Drive shaft Damage/wear Replace. Maximum runout 0.5 mm (0.00 in) CHCKING TH BARINGS Check: Bearings Pitting/rumbling Replace. ASSMBLING TH FORWARD GAR Install: Forward gear Taper roller bearing Bearing inner race attachment... 90890-06644 INSTALLING TH DRIV SHAFT BARING Install: Drive shaft bearing Bearing inner race attachment... 90890-06645 6-6
DRIV SHAFT INSTALLING TH DRIV SHAFT. Install: Forward gear (with the tapered roller bearing) Drive shaft (with the tapered roller bearing) Pinion gear Drive shaft holder 3... 90890-0657. Tighten: Pinion gear nut T R.. Pinion gear nut 50 N m (5.0 kgf m, 37 ft lb) Tightening steps () Apply mm wrench on the pinion gear nut. () Support the lower case with rags to hold the wrench in position. (3) Turn the drive shaft holder. NOT: Tighten the pinion gear nut with the same tools that were used for removal. 6-7
LOWR CAS LOWR CAS DISASSMBLING TH LOWR CAS Step Job/Part Q ty Remarks Drive shaft bearing outer race Pinion gear shim * 3 Drive shaft sleeve 4 Needle bearing 5 Tapered roller bearing outer race 6 Forward gear shim * * As required 6-8
LOWR CAS 3. Remove: Drive shaft bearing outer race Pinion gear shim(s) Stopper guide plate... 90890-0650 Bearing puller ass y... 90890-06535 Stopper guide stand... 90890-06538 3. Remove: Drive shaft needle bearing and sleeve Driver rod L3... 90890-0665 Needle bearing attachment... 90890-0665 3. Remove: Forward gear bearing outer race and shim(s) Stopper guide plate... 90890-0650 Bearing puller ass y... 90890-06535 CHCKING TH DRIV SHAFT SLV Check: Drive shaft sleeve Damage/wear Replace. 6-9
LOWR CAS CHCKING TH NDL BARING Check: Needle bearing Pitting/rumbling Replace. ASSMBLING TH LOWR CAS. Install: Forward gear shim(s) Tapered roller bearing outer race Bearing outer race attachment 90890-066 Driver rod LL 90890-06605 3. Install: Drive shaft needle bearing a Depth a 85.0-86.0 mm (7.8-7.3 in) Needle bearing attachment... 90890-0665 Driver rod SL... 90890-0660 Bearing depth plate... 90890-06603 3 NOT: Install the drive shaft needle bearing with the manufactuer s marks facing up. b a 3. Install: Pinion gear shim(s) a Drive shaft bearing outer race b Driver rod LS... 90890-06606 Bearing outer race attachment... 90890-0668 6-0
SHIMMING SHIMMING NOT: There is no need to select shims when reassembling with the original case and inner part(s). Shim calculations are required when reassembling with the original inner parts and a new case (the difference between the original inner parts and the new case). Measurements and adjustments are required when replacing the inner part(s). 6-
SHIMMING SLCTING TH PINION SHIMS NOT: Select the shim thickness (T3) by using the specified measurement(s) and the calculation formula. Select: Shim thickness (T3) Selecting steps () Install the pinion height gauge, drive shaft and bearing (with bearing race). Pinion height gauge... 90890-0670 Drive shaft holder 3... 90890-0657 NOT: Attach the pinion height gauge to the drive shaft so that the shaft is at the center of the hole. After the wing nuts contact the fixing plate, tighten them another /4 of a turn. () Install the pinion gear and pinion gear nut. T R.. Pinion gear nut 50 N m (5.0 kgf m, 37 ft lb) (3) Measure (M). Digital caliper 90890-06704 M NOT: Measure the clearance between the pinion height gauge and the pinion, as shown. Perform the same measurement at three points on the pinion. Find the average of the measurements (M). When using the digital caliper, be sure to place it at right angles to the pinion. Otherwise, measurement will be incorrect. 6-
SHIMMING (4) Calculate the pinion gear shim thickness (T3). Pinion gear shim thickness (T3) = M - 7 mm - P/00 mm NOT: "P" is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.0 mm units. If the "P" mark is missing or unreadable, assume a "P" value of "0", and check the backlash when the unit is assembled. If the "P" mark is negative (-), then add the "P" value to the measurement. xample: If M is "8.30 mm" and "P" is "+5", then: T3 = 8.30 mm - 7 mm - (+5)/00 mm =.3 mm - 0.05 mm =.5 mm (0.049 in) If M is "8.4 mm" and "P" is "-3", then: T3 = 8.4 mm - 7 mm - (-3)/00 mm =.4 mm + 0.03 mm =.7 mm (0.05 in) (5) Select the pinion gear shim(s) (T3). Calculated numeral at /00th place more than or less Using shim.0.0..0.30.3.30.40.4.40.50.5.50.60.6.60.70 0.7,.0.70.83 0.7,. Available shim thickness 0.7,.0,.,.,.3,.4,.5 and.6 mm 6-3
SHIMMING SLCTING TH FORWARD GAR SHIMS NOT: Select the shim thickness (T) by using the specified measurement(s) and the calculation formula. Select: Shim thickness (T) Selecting steps () Measure (M). Shimming plate... 90890-0670 Digital caliper... 90890-06704 NOT: Turn the tapered roller bearing outer race two or three times so that the rollers seat. Then, measure the height of the bearing, as shown. Perform the same measurement at three points on the tapered roller bearing outer race. Find the average of the measurements (M). When using the digital caliper, be sure to place it at right angles to the shimming plate. Otherwise, measurement will be incorrect. () Calculate the forward gear shim thickness (T). Forward gear shim thickness (T) = 7.5 mm + F/00 mm - M NOT: "F" is the deviation of the lower case dimension from standard. It is stamped on the trim tab mounting surface of the lower case in 0.0 mm units. If the "F" mark is missing or unreadable, assume an "F" value of "0", and check the backlash when the unit is assembled. If the "F" mark is negative (-), then subtract the "F" value from the measurement. 6-4
SHIMMING xample: If M is "6.5 mm" and "F" is "+4", then: T = 7.5 mm + (+4)/00 mm - 6.5 mm = 7.5 mm + 0.04 mm - 6.5 mm =.9 mm (0.05 in) If M is "6.6 mm" and "F" is "-3", then: T = 7.5 mm + (-3)/00 mm - 6.6 mm = 7.5 mm - 0.03 mm - 6.6 mm =. mm (0.048 in) (3) Select the forward gear shim(s) (T). Calculated numeral at /00th place Using shim more than or less.00.0.0.0.0..0.30..30.40.3.40.50.4 Available shim thickness.0,.,.,.3 and.4 mm 6-5
SHIMMING SLCTING TH RVRS GAR SHIMS NOT: Select the shim thickness (T) the specified measurement(s) and the calculation formula. Select: Shim thickness (T) Selecting steps () Measure (M). Shimming plate... 90890-0670 Digital caliper... 90890-06704 NOT: Measure the height of the gear as shown. Perform the same measurement at three points on the gear. Find the average of the measurements (M). When using the digital caliper, be sure to place it at right angles to the shimming plate. Otherwise, measurement will be incorrect. () Calculate the reverse gear shim thickness (T). Reverse gear shim thickness (T) = 80 mm + R/00 - M NOT: "R" is the deviation of the lower case dimension from standard. It is stamped on the anode mounting surface of the lower case in 0.0 mm units. If the "R" mark is missing or unreadable, assume a "R" value of "0", and check the backlash when the unit is assembled. If the "R" mark is negative (-), then subtract the "R" value from the measurement. 6-6
SHIMMING xample: If M is "78.79 mm" and "R" is "+5", then: T = 80 mm + (+5)/00 mm - 78.79 mm = 80 mm + 0.05 mm - 78.79 mm =.6 mm (0.050 in) If M is "78.75 mm" and "R" is "-3", then: T = 80 mm + (-3)/00 mm - 78.75 mm = 80 mm - 0.03 mm - 78.75 mm =. mm (0.048 in) (3) Select the reverse gear shim(s) (T). Calculated numeral at /00th place Using shim more than or less.00.0.0.0.0..0.30..30.3.3 Available shim thickness.0,.,. and.3 mm 6-7
BACKLASH BACKLASH NOT: Do not install the water pump components when measuring the backlash. Measure both the forward and reverse gear backlashes. If both the forward and reverse gear backlashes are larger than specification, the pinion gear may be too high. If both the forward and reverse gear backlashes are smaller than specification, the pinion gear may be too low. MASURING TH FORWARD GAR BACKLASH. Measure: Forward gear backlash Out of specification Adjust. Forward gear backlash 0.3-0.7 mm (0.0-0.08 in) Measuring steps () Set the shift rod into the neutral position. () Install the propeller shaft housing puller so it pushes against the propeller shaft. Bearing housing puller claw... 90890-06564 Stopper guide plate... 90890-0650 Center bolt... 90890-06504 3 T R.. Center bolt 5 N m (0.5 kgf m, 3.7 ft lb) 6-8
BACKLASH (3) Install the backlash indicator onto the drive shaft (6mm (0.63 in) diameter). Backlash indicator... 90890-06706 4 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator. Magnet base plate... 90890-07003 Dial gauge set... 90890-05 Magnet base... 90890-06705 (5) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash.. Adjust: Forward gear backlash Remove or add shim(s). 5 6 7 Forward gear backlash Less than 0.3 mm (0.0 in) More than 0.7 mm (0.08 in) Shim thickness To be decreased by (0.5 - M) 0.49 To be increased by (M - 0.5) 0.49 Available shim thickness:.0,.,.,.3 and.4 mm M : Measurement MASURING TH RVRS GAR BACKLASH. Measure: Reverse gear backlash Out of specification Adjust. Reverse gear backlash 0.93 -.65 mm (0.037-0.065 in) 6-9
www.motorka.org LOWR BACKLASH Measuring steps () Set the shift rod into the neutral position. () Load the reverse gear by installing the propeller without the collar, and then tighten the propeller nut. T R.. Propeller nut 5 N m (0.5 kgf m, 3.7 ft lb) (3) Install the backlash indicator onto the drive shaft (6 mm (0.63 in) diameter). Backlash indicator... 90890-06706 (4) Install the dial gauge onto the lower unit and have the dial gauge plunger contact the mark on the backlash indicator. Magnet base plate... 90890-07003 Dial gauge set... 90890-05 Magnet base... 90890-06705 (5) Slowly turn the drive shaft clockwise and counterclockwise. When the drive shaft stops in each direction, measure the backlash.. Adjust: Reverse gear backlash Remove or add shim(s). 3 4 5 Reverse gear backlash Shim thickness Less than 0.93 mm (0.037 in) More than.65 mm (0.065 in) Available shim thickness.0,.,. and.3 mm M : Measurement To be decreased by (.9 - M) 0.49 To be increased by (M -.9) 0.49 6-30