GEARCASE LEAK TEST
Drain lubricant before testing.
Use Gearcase Pressure Tester, P/N 507977. Install lubricant drain/fill plug and seal, thread pressure test gauge fitting and seal in lubricant level hole.
Pressurize 3 to 6 psi (21 to 42 kPa).
If pressure gauge indicates leakage, submerge the gearcase in water to determine source of leak.
If the gauge does not indicate leakage, increase pressure to 16 to 18 psi (110 to 124 kPa). Check for leaks.
Make necessary repairs and repeat test.
Install Gearcase Vacuum Tester, P/N 507982. Apply 3 to 5 in. of vacuum (76 to 127 mm) Hg. with pump.
If vacuum gauge indicates leakage, apply oil around suspected seal. If leak stops or oil is drawn in, seal is defective.
Repeat test, gearcase must hold minimum of 15 in. vacuum (381 mm) Hg.
GEARCASE REMOVAL AND INSTALLATION
Gearcase Removal
To prevent accidental starting while servicing, twist and remove all spark plug leads.
During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.
Remove pin and washer from shift rod lever to release the lower shift rod.
- Shift rod screw
