Service Manual 40-90 HP.E-TEC Gearcase [Water Pump 2]

ft. lbs. (47 to 54 N·m). For adjustment, refer to Trim Tab Adjustment on p. 76.

1. Trim tab screw

2. Index mark

Place the shift rod in the shift rod lever. Install the retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Shift rod screw

To prevent loss of operator control, check for proper shifting operation and adjust, if necessary.

IMPORTANT: During break-in period of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.

Disassembly

Rotate the driveshaft counterclockwise to unlock the impeller key. Remove the four impeller housing screws.

1. Screws

Slide the water pump off the driveshaft. Remove the impeller drive key, O-ring, impeller plate, and gasket. Discard the gasket.

1. O-ring

2. Impeller plate

Remove all the parts from the housing.

Check impeller for overheating, hub separation, and other wear or damage.

Check liner and wear plate for scoring, distortion, and impeller material transfer.

Inspect the housing for cracks or melting.

Make sure gasket surface is clean and smooth.

Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs.

IMPORTANT: Do not allow any sealer to get into the air bleed groove in the impeller housing. If this groove is blocked by adhesive, the pump will lose its prime and will not pump water.

1. Seal ring groove

2. Ribs

3. Air bleed groove

Install the O-ring in groove in the impeller housing.

1. O-ring

Lightly coat the exterior rim of the impeller cup with Gasket Sealing Compound. Install the cup in the impeller housing. The cup locks in place in the housing with a square index tab.

Make sure vent hole in impeller cup is open.

Install the water tube grommet with the inside taper facing up.

1. Water tube grommet

Install the impeller housing cover and tighten screws to a torque of 24 to 36 in. lbs. (3 to 4 N·m).

Apply Adhesive 847 to flat side of the impeller housing grommet. Install the grommet, flat side down.

1. Impeller housing cover

2. Impeller housing grommet

Lightly coat the inside of the liner with Triple-Guard grease. With a counterclockwise rotation, install the impeller into the liner with the slot for the impeller key facing out.

Apply a thin bead of Adhesive 847 in the seal groove, and install the special shaped O-ring seal.

1. O-ring

Apply Gasket Sealing Compound to both sides of a new impeller plate gasket. Install the gasket and impeller plate.

Apply Triple-Guard grease to a new impeller O ring. Slide the O-ring down the driveshaft and half way over installed impeller key to temporarily hold key in place.

1. Impeller plate gasket

2. Impeller plate

3. O-ring

4. Drive key

The sharp edge of the key is the leading edge in clockwise rotation.

Slide the water pump down the driveshaft. Align impeller slot with the impeller key. Rotate the driveshaft to engage the key with the impeller, and slide water pump down over key. Be sure impeller key does not fall out of position.

1. Sharp edge of drive key

2. Direction of driveshaft rotation

Make sure the impeller engages the impeller key. Serious powerhead damage will result if impeller key is not in place.

Align the impeller housing with the gearcase. Apply Gasket Sealing Compound to threads of the four impeller housing screws. Install the screws and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

25 IN. MODELS

Place water tube spacer with grommet on the impeller housing cover.

25 in. Model Water Tube Spacer

1. Spacer

2. Grommet

Before installing gearcase, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 359.