6B-0 - LOWER UNIT
90-824052R3 JUNE 2002
Table of Contents
Page
Gear Housing Specifications
(Counter Rotation)
6B-1
. . . . . . . . . . . . . . . . . . . . . .
Pinion Depth
6B-1
. . . . . . . . . . . . . . . . . . . . . . .
Reverse Gear Backlash
6B-1
. . . . . . . . . . . . . .
Forward Gear Backlash
6B-1
. . . . . . . . . . . . . .
Lubricant Capacity
6B-1
. . . . . . . . . . . . . . . . . .
Special Tools
6B-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Driveshaft)(Counter Rotation)
(S/N-0G437999 & BELOW)
6B-6
. . . . . . . . . . . . . .
Gear Housing (Prop Shaft)(Counter Rotation)
(S/N-0G437999 & BELOW)
6B-8
. . . . . . . . . . . . . .
Gear Housing (Driveshaft)(Counter Rotation)
(Sportmaster)
6B-12
. . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Prop Shaft)(Counter Rotation)
(Sportmaster)
6B-16
. . . . . . . . . . . . . . . . . . . . . . . . .
General Service Recommendations
6B-20
. . . . . . .
Removal, Disassembly, Cleaning and
Inspection of Counter Rotation (Left Hand)
Gear Housing
6B-21
. . . . . . . . . . . . . . . . . . . . . . . . .
Removal
6B-21
. . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear
Housing Lubricant
6B-22
. . . . . . . . . . . . . . . .
Water Pump
6B-23
. . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection
6B-23
. . . . . . . . . . . .
Removal and Disassembly
6B-23
. . . . . . . . . .
Bearing Carrier and Propeller Shaft
Removal
6B-24
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Shift Shaft
6B-27
. . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection
6B-27
. . . . . . . . . . . .
Disassembly
6B-27
. . . . . . . . . . . . . . . . . . . . . .
Cleaning/Inspection - Bearing Carrier
6B-27
.
Disassembly- Bearing Carrier
6B-27
. . . . . . . .
Propeller Shaft
6B-28
. . . . . . . . . . . . . . . . . . . . . . .
Inspection
6B-28
. . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly
6B-28
. . . . . . . . . . . . . . . . . . . . . .
Clutch Actuator Rod
6B-30
. . . . . . . . . . . . . . . . . .
Cleaning and Inspection
6B-30
. . . . . . . . . . . .
Disassembly
6B-30
. . . . . . . . . . . . . . . . . . . . . .
Forward Gear and Bearing Adapter
6B-31
. . . . .
Disassembly/Cleaning/Inspection
6B-31
. . . .
Pinion Gear and Driveshaft
6B-32
. . . . . . . . . . . .
Removal
6B-32
. . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning/Inspection
6B-34
. . . . . . . . . . . . . . . .
Reverse Gear
6B-35
. . . . . . . . . . . . . . . . . . . . . . . .
Removal and Disassembly
6B-35
. . . . . . . . . .
Cleaning and Inspection
6B-35
. . . . . . . . . . . .
Gear Housing
6B-36
. . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Inspection
6B-36
. . . . . . . . . . . .
Page
Reassembly and Installation of Counter
Rotation Gear Housing
6B-36
. . . . . . . . . . . . . . . . .
Driveshaft Needle Bearing
6B-36
. . . . . . . . . . . . .
Reassembly/Installation
6B-36
. . . . . . . . . . . . .
Bearing Carrier, Forward Gear and
Bearing Adaptor
6B-37
. . . . . . . . . . . . . . . . . . . .
Reassembly
6B-37
. . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft Needle Roller Bearing
and Oil Seal Installation
6B-37
. . . . . . . . . . .
Reverse Gear and Bearing Cup
Adaptor Reassembly
6B-38
. . . . . . . . . . . . .
Driveshaft and Pinion Gear
6B-39
. . . . . . . . . . . .
Reassembly/Installation
6B-39
. . . . . . . . . . . . .
Pinion Gear Depth
6B-41
. . . . . . . . . . . . . . . . . . . .
Determining Pinion Gear Depth
6B-41
. . . . . .
Setting/Checking Driveshaft End Play
(Sport Master Only)
6B-42
. . . . . . . . . . . . . .
Reverse Gear
6B-44
. . . . . . . . . . . . . . . . . . . . . . . .
Determining Reverse Gear Backlash
6B-44
.
Forward Gear
6B-45
. . . . . . . . . . . . . . . . . . . . . . . .
Determining Forward Gear Backlash
6B-45
.
Propeller Shaft/Forward Gear Bearing
Adapter/Bearing Carrier
6B-47
. . . . . . . . . . . . .
Reassembly
6B-47
. . . . . . . . . . . . . . . . . . . . . . .
Clutch Actuator Rod
6B-50
. . . . . . . . . . . . . . . . . .
Reassembly/Shimming
6B-50
. . . . . . . . . . . . .
Shift Shaft Bushing
6B-51
. . . . . . . . . . . . . . . . . . .
Reassembly
6B-51
. . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft
6B-51
. . . . . . . . . . . . . . . . . . . . . . .
Reassembly/Installation
6B-51
. . . . . . . . . . . . .
Water Pump
6B-55
. . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly/Installation
6B-55
. . . . . . . . . . . . .
Gear Lubricant Filling Instructions
6B-57
. . . . . . .
Installing Gear Housing to Drive
Shaft Housing
6B-57
. . . . . . . . . . . . . . . . . . . . . .
Propeller Installation
6B-58
. . . . . . . . . . . . . . . . . .
6B - LOWER UNIT
Summary of Contents for 105/140 JET
Page 5: ...1 A IMPORTANT INFORMATION SPECIFICATIONS...
Page 14: ...1 B IMPORTANT INFORMATION MAINTENANCE...
Page 25: ...C 1 IMPORTANT INFORMATION GENERAL INFORMATION...
Page 34: ...D 1 B A D C IMPORTANT INFORMATION OUTBOARD MOTOR INSTALLATION...
Page 50: ...A 2 ELECTRICAL IGNITION SYSTEM...
Page 79: ...2A 28 ELECTRICAL 90 824052R3 JUNE 2002 SPARK PLUG WIRE ROUTING HIGH PERFORMANCE OUTBOARDS...
Page 80: ...B 2 51797 ELECTRICAL BATTERY CHARGING SYSTEM AND STARTING SYSTEM...
Page 101: ...C 2 ELECTRICAL TIMING SYNCHRONIZING ADJUSTING...
Page 117: ...D 2 ELECTRICAL WIRING...
Page 133: ...90 824052R3 JUNE 2002 ELECTRICAL 2D 15 Notes...
Page 149: ...A 3 FUEL SYSTEMS FUEL PUMP...
Page 159: ...B 3 54350 FUEL SYSTEMS CARBURETORS...
Page 161: ...90 824052R3 JUNE 2002 FUEL SYSTEMS 3B 1 Notes...
Page 206: ...C 3 FUEL SYSTEMS FUEL INJECTION SN 0G303045 AND BELOW...
Page 213: ...1 2 3 4 5 6 7 8 3C 6 FUEL SYSTEMS 90 824052R3 JUNE 2002 Fuel Management System...
Page 272: ...D 3 55173 FUEL SYSTEMS FUEL INJECTION SN 0G303046 AND ABOVE...
Page 344: ...E 3 FUEL SYSTEMS OIL INJECTION...
Page 370: ...4 51804 A POWERHEAD...
Page 418: ...90 824052R3 JUNE 2002 POWERHEAD 4A 47 Notes...
Page 429: ...4 51804 B POWERHEAD COOLING...
Page 434: ...4B 4 POWERHEAD 90 824052R3 JUNE 2002 Notes...
Page 436: ...90 824052R3 JUNE 2002 4B 6 POWERHEAD...
Page 441: ...A 5 MID SECTION CLAMP SWIVEL BRACKET AND DRIVESHAFT HOUSING...
Page 443: ...90 824052R3 JUNE 2002 MID SECTION 5A 1 Notes...
Page 457: ...B 5 MID SECTION POWER TRIM SQUARE MOTOR AND ROUND MOTOR DESIGN...
Page 495: ...A 6 LOWER UNIT E Z SHIFT GEAR HOUSING STANDARD ROTATION...
Page 554: ......
Page 555: ...B 6 LOWER UNIT COUNTER ROTATING LEFT HAND GEAR CASE...
Page 616: ...C 6 LOWER UNIT MERCURY XR6 MARINER MAGNUM III GEAR HOUSING...
Page 651: ...D 6 LOWER UNIT E Z SHIFT GEAR HOUSING NON RATCHETING STANDARD ROTATION STARTING S N 0G438000...
Page 657: ...90 824052R3 JUNE 2002 LOWER UNIT 6D 5 Notes...
Page 697: ...90 824052R3 JUNE 2002 LOWER UNIT 6E 5 Notes...
Page 740: ...6 F JET OUTBOARDS...
Page 742: ...90 824052R3 JUNE 2002 JET OUTBOARDS 6F 1 Notes...
Page 759: ...7 ATTACHMENTS CONTROL LINKAGE...