TOHATSU 2 Stroke Cylinder Series, Service Manual

Page: 179 / 268

GEARCASE
6-27
1-/ 2-Cylinder
19. Align the clutch push rod with the clutch cam and slide the
propeller shaft and housing into the gearcase opening. Push
forward and rotate the propeller shaft as needed until bevel gears have
engaged. Ensure the propeller shaft housing bolts are completely
clean and apply Loctite 242 to the bolt threads. lnstall and torque the
bolts evenly to prevent improper seating of the housing.
20. Move the cam rod to each position and rotate the driveshaft
to test gearcase function in all gears. Check the propeller shaft
for looseness in the forward and reverse directions. If looseness
exceeds 0.016 in [0.40 mm], replace bevel gear C washer
(26) with one
of correct thickness.
NOTE
Refer to current Parts Catalog for washer availability
21. Before adding gear oil, pressure test and vacuum test
the gearcase as follows:
• Remove the oil level plug and install gearcase pressure tester.
• Pump pressure tester until gauge indicates 3 - 6 psi [20 - 39
kPa / 0.2 - 0.4 kg/cm
2
]. lf pressure loss occurs, determine source
of leakage by submerging gearcase in water. Make necessary
repairs to correct the problem and retest.
• Remove the pressure tester and install gearcase vacuum tester.
32
33
34
T1400
T1743
T1402
34