TOHATSU 2 Stroke Cylinder Series, Service Manual

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GEARCASE
6-23
1-/ 2-Cylinder
Assembly
CAUTION
Gearcase must be secured in a suitable holding
fixture during assembly.
Assembly — 2.5 / 3.5
1. Install propeller shaft assembly.
2. lnstall water pump case.
3. lnstall pump impeller key.
4. Install pump impeller.
Assembly — 3.5B
1. Install the clutch, clutch spring and the clutch push rod to propeller
shaft.
2. Install propeller shaft assembly.
3. Fix the clutch cam to the cam rod with a spring pin, and insert it
into the gear case. Also, insert the drive shaft and install the lower
pump case.
4. Lift the drive shaft a little and install the bevel gear B.
5. Install the pump guide plate gasket, guide plate, cam rod bush
and upper pump case gasket.
6. lnstaII the pump impeller key.
7. lnstall the pump impeIIer.
8. Install the pump case liner in the case.
9. Install the water pump case.
NOTE
When installing the water tube, apply oil to the inner
circumference of the lower water pipe rubber seal.
2.5 / 3.5 only
10. Install the gear case head.
2.5 / 3.5 Only
11. lnstall the upper driveshaft and attach the driveshaft guard pipe