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Once you’ve rinsed the outside, hook up a flushing device and do the same for the inside. On all motors except the 2. Remove the two oufboard securing the lower unit to the exhaust housing.

If oil can get out, then water can get in. The last, most important task you can perform to help keep your gearcase in top shape, is to flush the inside and outside of the gearcase after each use. If necessary for service or overhaul, drain the gear oil from the gearcase. Thoroughly inspect the gearcase and exhaust housing for signs of damage. The second most important task for proper gearcase maintenance is checking and maintaining honda outboard repair manual pdf download oil inside the case.

Not only is it important make honda outboard repair manual pdf download the oil is at t k proper level not above or belowbut it is important to check the oil for signs of contamination from moisture.

The gearcase contains the propeller shaft, the driven and pinion gears, the drive shaft from the powerhead and the water pump.

Workshop Service Manual Repair Application: Make sure all mating surfaces are clean and free of debris, corrosion or damage. Be sure to coat only the SIDES of the splines and not the top of the pdc, as that could hydraulically prevent the driveshaft from fully seating in the crankshaft spline.

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If necessary, turn the propeller shaft slowly hohda when viewed from the shaft end in align the splines. Reppair, refill the unit honda outboard repair manual pdf download fresh oil and test the outboard by using it! Apply a light coat of clean liquid soap to the water tube grommet.

On models equipped with shifting capabilities, the forward and reverse gears, together with the clutch, shift assembly, and related linkage, are all housed within the case. If necessary for service or access, remove the propeller, for details refer to the procedure in the Maintenance and Tune-Up section.

Download a manual straight to your computer in just seconds. Also, significant amounts of water mixed with the oil will give the appearance of an overfilled condition. And, water, mixing with or replacing the oil in the gearcase will wreak havoc with the shafts and gears contained within the housing. YES Works on all computers! But, in some cases, if honda outboard repair manual pdf download leak was pff in manuall, and there is no significant wear, damage or corrosion in the gearcase, the propeller shaft seal can usually be replaced with the gearcase still installed to honda outboard repair manual pdf download outboard.

If any oil leaks out or water enters, either the propeller shaft seal must be replaced or the gear case must be disassembled, inspected and completely overhauled.

Remove any sand, silt or dirt that could potentially damage seals or clog passages. Taking Care not to damage the driveshaft and the water tube, separate the lower unit from the exhaust housing by pulling straight outbpard.

Again, details are found in the Maintenance and Tune-up section, look under Flushing the Cooling System. For safety, disconnect the spark plug lead, then ground it to the cylinder head.

The gear case manaul considered that part of the outboard below the mid section exhaust housing. If you suspect water in the gearcase, start by draining and closely inspecting the fluid refer to the procedures found in the Maintenance and Tune-Up section. Performing the scheduled maintenance is very important.

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Cleaning the gearcase will also help you spot potential. It compensates for the initial wear that occurs during the life of the engine.

To be honest, a complete overhaul is recommended, honea corrosion and damage may have occurred if moisture was in the gearcase long enough. A neglected lower unit cannot be expected to perform to maximum efficiency, compared with a unit receiving TLC tender loving care trouble, such as gearcase oil leaks, cracks or damage that may have occurred during use.

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Follow the Maintenance Schedule recommendations to ensure that the engine is in peak operating condition. Apply a light coating of OMC Nut Lock, or equivalent thread lock to the threads of the 2 gearcase mounting screws.

Watch the fluid level closely after the test, and for honda outboard repair manual pdf download first few outings. The most common reason for removrng and installing the gearcase IS to perform service inspect or replace the water pump impeller. The single most important task for proper gearcase maintenance is inspecting it for signs of leakage after each use. Water entering the gear case will usually cause the oil to turn a slightly milky-white color.