TOHATSU 2 Stroke Cylinder Series, Service Manual

Page: 157 / 268

GEARCASE
6-5
1-/ 2-Cylinder
General Equipment Required
TorqueWrench, 0- 150 in-lb[0 - 17 N-m / 0- 1.7 kg-m]
TorqueWrench, 0 - 150 ft-lb [0 - 200 N-m / 0 - 20 kg-m]
Dial Gauge, minimum scale0.0001 in [0.01 mm]
Gearcase Pressure Tester,
Stevens
®
S-34 or equivalent
Gearcase Vacuum Tester, Stevens
®
V-34 or equivalent
Seal Pullers
Seal hlStallers
Heat Gun
Consumables Required
Threadlocker, Loctite
®
242
Gasket Sealant, Permatex
®
High Tack Gasket Sealant
Anaerobic Gasket Maker, Loctite
®
518
Silicone Spray Lubricant, Permatex
®
Silicone Spray Lubricant
Genuine Grease or Equivalent Friction Surface Marine Grease
lsopropyl Alcohol
Cleaning Solvent
Engine Lubricant,
Genuine engine oil or NMMA certified TC-W3 oil
Gear Lubricant, Genuine gear oil or APl grade GL5, SAE #80 - #90
Cleaning Pads, Scotch-Brite
®
Abrasive Pads
Gasket Remover
WATER PUMP
If the engine has been run without water for any length of time, the
water pump should be serviced with a water pump repair kit. Use
the following procedures to install the repair kit.
Removal
1. Remove the gearcase. See Gearcase, this section.
2. Remove water pump mounting bolts (1) .
3. Hold upper pump case (2) securely and rotate driveshaft
clockwise to free impeller from upper pump case.
CAUTION
Do not rotate driveshaft counterclockwise. Doing
so will bend impeller fins in wrong direction and
may weaken or damage the impeller.
4. Slide upper pump case off driveshaft and remove pump
impeller
(3) and impeIIer key (4) .
5. lnsert a screwdriver in each lower pump case notch (5)
and gently pry upward to remove. Slide lower pump case off
driveshaft.
1
2
3
4
T1337
T1338
T1339
T1340