Service Manual 40-90 HP Gearcase [Water Pump Service]

(47 to 54 N·m). For adjustment, refer to Trim Tab Adjustment on p. 31.

1. Trim tab screw

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.

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

Disassembly

Remove the four impeller housing screws.

1. Impeller housing screws

Slide the water pump off the driveshaft. Remove the impeller key, impeller plate, and gasket. Dis card the gasket.

1. Impeller plate
2. Drive key

Remove all the parts from the housing.

Inspection

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.

Assembly

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.

1. Index tab

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. Air bleed groove

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.

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

1. Impeller
2. O-ring seal

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

Apply Triple-Guard grease to temporarily hold drive key in place.

1. Impeller plate gasket
2. Impeller plate
3. 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).

Install the water tube grommet on the impeller housing.

Apply a thin bead of Adhesive 847 to groove of the impeller housing grommet. Install the grommet on the impeller housing.

1. Housing screws
2. Water tube grommet
3. Impeller housing grommet

Before installing gearcase, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 300.

Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

With the gearcase in NEUTRAL, rotate the shift rod up or down as necessary for correct adjustment. Once correct height is achieved, rotate rod one half turn or less to direct offset to the rear.

Shift Rod Height:

• 21.38 in. (543 mm) ± One-Half Turn