208
GEARCASE
CLEANING AND INSPECTION
CLEANING AND
INSPECTION
Discard all seals, O-rings, gaskets, and clutch dog
spring.
Clean all gearcase components in solvent and dry
with compressed air. After cleaning, coat all inter-
nal components with
HPF XR
gearcase lube to
prevent rusting.
Perform the following inspections:
•
Gearcase housing
— all gasket surfaces must
be free of gasket material. All threaded holes
must be free of corrosion and sealer.
•
Gearcase anode
— if anode has been reduced
to two-thirds of its original size, it must be
replaced. Refer to
section for
testing procedure.
•
Driveshaft
— check splines for chips, wear,
and cracks. Bearing and gear surfaces must not
show signs of metal transfer, corrosion, or dis-
coloration. Severe spline wear might indicate an
exhaust housing or gearcase has been dis-
torted by impact damage.
•
Water intake screen
— must be clear. If screen
can't be cleaned, it must be replaced.
•
All internal components
— must be visually
inspected for signs of wear, distortion, chipping,
metal transfer, pitting, galling, and discoloration
due to improper lubrication.
•
Water pump
— check impeller for wear, crum-
bling, and hub bonding. Check impeller cup and
plate for scoring and distortion.
•
Shift cam
— Inspect the stepped surfaces for
excessive wear, chips, or other damage.
Clutch Return Spring
Measure the clutch return spring free length.
Replace if out of specification:
•
Standard: 2.30 in. (58.5 mm)
•
Service limit: 2.22 in. (56.5 mm)
WARNING
Replace damaged components. Shift sys-
tem failure could cause loss of control
over direction of engine thrust.
To avoid personal injury, wear eye protec-
tion and regulate air pressure to not more
than 25 PSI (172 kPa).
8_8_2
