Hamilton Jet HJ212, Installation And Service Manual

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Installation and Service Manual
Overhaul
Reverse Link Removal and Inspection

Remove the link actuator [21], link ball [22], link o-ring [38] and flat washer [24] from the port arm of the
reverse duct by removing bolt [25].

If the tension spring [18] has not been disconnected, support the reverse duct [1] so as not to
overstretch the spring [18].

Check the link ball location and the link ball for signs of excessive wear. Replace if worn.

Check that the link attachment bolt [25] has not allowed the link ball to move excessively in the ball
recess.

Check the condition of the anti-rattle o-ring [38] and replace as necessary.

Remove the split pin [14], crank pin [12] and washers [24] from either side of the link actuator [21], if
these have not already been removed for reverse duct removal.

Remove the nut [17], spring washer [19], special washer [13] and cotter [16] securing the crank [11] to
the reverse shaft [8].

Remove the crank [11] and washer [31] from the rear end of the reverse shaft.

Remove the hub retaining screw [37], spring washer [19] and special washer [34] securing the reverse
shaft to the reverse latch hub [47]. Move the reverse latch assembly forward out of the reverse shaft
assembly and move the assembly out of the way.
The number and placement of the spacer washers [31] at the rear end of the reverse spacer fitted to
the forward end of the reverse shaft [8], so that these can be refitted in the correct order.

Slide the reverse shaft [8] forward out of the bushes [9] and [10], ensuring that the washers [31] and the
spacer [28] are removed from the end of the reverse shaft.

Remove the reverse shaft from the jet unit.

Inspect the o-ring [15] fitted at the forward end of bush [9] fitted to the jet unit intake in the vicinity of
the transom seal. Check for wear and damage, replace if worn.

Check the condition of the shaft bushes [9] and [10]. Replace if excessively worn or damaged.
Bush and O-Ring Replacement

With the reverse shaft [8] removed from the jet unit, remove the o-ring [15] from the front of bush [9]
and examine for wear, damage, cuts or deformity. Replace the o-ring if damaged or worn.

Press out the old bush using a suitable sized drift [9].

If the bush is hard to remove, apply light heat in the area of the bush to break the Loctite
®
bond.

Clean the bore of all old Loctite
®
and primer.

Apply a thin coating of primer 7471 to the whole surface of the bore and allow to dry.

Do NOT apply primer 7471 to the contact face of the bush [9].

Apply Loctite 680 to the bore in the intake flange and to the front edge of the replacement reverse shaft
bush [9].
The bore in the intake flange is to remain unpainted.
Loctite
®
primer 7471 must be used to refit the components otherwise the Loctite 680 will not cure.
There are to be NO dry areas between the bush and the bore once the bush is fitted.

Press the bush into the bore

Rotate the bush when fitting to distribute the Loctite
®
evenly.

Press the bush firmly home into the bore until the outer end of the bush is flush with the edge of the
intake flange bore.

Wipe away any excess Loctite
®
and primer/activator.

Smear a new o-ring [15] with grease and refit to the seal groove at the front of bush [9]. Ensure that the
seal is fitted correctly and is not twisted.
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