Exhaust Housing Removal
Before removing the midsection:
● The gearcase must be removed. Refer to Gear case GEARCASE REMOVAL AND INSTAL- LATION on p. 271.
● The powerhead must be removed. Refer to POWERHEAD REMOVAL on p. 215.
Remove and discard four lower mount screws.
Remove the steering arm ground lead and screw.
Remove two upper mount screws.
- Ground lead (removed)
Remove the exhaust housing.
Remove lower mount covers and inspect the lower mounts.
TYPICAL
If replacement is necessary, lubricate mount with soapy water and carefully pry at both ends to remove.
Exhaust Housing Disassembly
Remove two front adapter to outer exhaust housing screws.
Remove three nuts at rear of the adapter.
Loosen and remove the upper mount plate screws and remove the mount plate.
Lubricate the upper mount with soapy water and pry up to remove it from the adapter housing.
Lift the adapter/inner exhaust housing out of the exhaust housing. .
Cleaning and Inspection
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).
Clean all parts with parts cleaning solvent and dry with compressed air. All nut and screw threads coated with thread locking material must be thoroughly cleaned before assembly. When using a thread locking product, be sure to prime the threads with Locquic Primer .
Examine the upper and lower thrust mounts, and replace if deteriorated or damaged.
Before checking the exhaust housing for distortion, thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion.
Check the exhaust housing for distortion. Place the housing on a surface plate. Using a dial indicator, check flatness by measuring the run-out on the top edge of housing. The maximum allowable run-out is 0.009 in. (0.228 mm). If you do not have access to a dial indicator and surface plate, seek the services of a machine shop. DO NOT attempt to straighten a distorted housing. Replace it.
IMPORTANT: A distorted exhaust housing will cause the upper driveshaft splines to wear excessively and will damage the crankshaft splines.
Inspect the water tube for obstructions or kinks, which may restrict water flow.
Exhaust Housing Assembly
Apply Adhesive 847 to the bottom flange of the inner exhaust housing. Install a new seal. Apply Triple-Guard grease to outer seal surface.
Install grommet and water tube in the inner exhaust housing.
- Water tube grommet
Clean and degrease the adapter housing and outer exhaust housing mating surfaces with Cleaning Solvent . Apply Gel-Seal II sealant to the adapter flange of the exhaust housing.
Place the adapter/inner exhaust housing into the exhaust housing. Guide the water tube through the hole in the outer housing.
Loosely install the small retaining screws, nuts, and washers.
Lubricate the upper mount with soapy water and push into place in the adapter housing. The mount radius must face aft with the “TOP” mark facing up.
Apply Locquic Primer and Nut Lock to the upper mount plate screws and install the plate and screws loosely. Install the ground lead and star washer under the forward starboard screw.
Align the outer exhaust housing and adapter by placing two powerhead mounting screws through their holes.
- Powerhead mounting screws
Install four mount plate screws and washers and tighten to a torque of 22 to 24 ft. lbs. (30 to 33 N•m).
Tighten the small adapter to exhaust housing screws and nuts to a torque of 60 to 84 in. lbs. (7 to 9.5 N•m).
If removed, coat the lower mounts with soapy water and press into the exhaust housing with the “OUTSIDE” mark facing outward.
Install the mount covers. Apply Nut Lock to screws, install washers and screws, and tighten to a torque of 156 to 180 in. lbs. (18 to 20 N•m).
Exhaust Housing Installation
Bring the exhaust housing into position with the stern bracket.
Install four new lower mount screws with lock patch. Tighten screws to a torque of 38 to 45 ft. lbs. (51 to 61 N•m).
- Lower mount screws
Apply Ultra Lock to upper mount screws and tighten to a torque of 50 to 60 ft. lbs. (68 to 81 N•m).
Attach the ground lead and star washer to the steering arm’s starboard side.
If necessary, replace the exhaust adapter to lower engine cover seal. Attach with Adhesive 847 .
Install gearcase. Refer to Gearcase GEARCASE REMOVAL AND INSTALLATION on p. 271.
Install powerhead. Refer to POWERHEAD Install powerhead. Refer INSTALLATION on p. 237.
