Yamaha T8 Rigging Manual page 86

Outboard Rigging Guide - 2001
Assembly and Installation
Refer to the appropriate assembly drawing for the
40 and 50 models, or the 90 and V4/V6 model jet
drives.
NOTE: Using Yamaha Marine Grease or NLGI
No. 1-rated grease, grease all bolt threads, and use
lockwashers on all bolts except where noted oth-
erwise.
1. Fit the two 6 x 16mm (90TJR model) or 8 x
12mm (V4-V6) dowel pins in the recesses on
top of the 3/4" - thick adapter plate, and
install the plate on the bottom of the motor.
Torque the 10mm-diameter and 3/8" - diame-
ter bolts to 22 ft-lb.; for the 8mm- diameter
bolt, 11 ft-lb.
NOTE: 90TJR and V4/V6 model jet drives use a
3/8" by 1-1/12" pin to locate the disconnected
shift rod. Grease this pin prior to installation of
the adapter plate.
2. Make sure the three O-rings on the bearing
housing surface are in place. Line up the three
grease passage holes in the bearing housing
with the passages in the jet drive casing.
3. Bolt the driveshaft and bearing housing
assembly to the jet drive casing. Torque the
5/16-18 x 1 bolts (90TJR and V4/V6 models)
to 12 ft-lb. For models '96 and earlier use 1/4-
20 bolts torque to 8 ft-lb. The two 10-24
machine screws (40 and 50 models) should
be tightened by hand, using a screwdriver.
4. Invert and support the jet drive casing, so the
long end of the driveshaft is standing upright.
5. Install the brass water tube extension onto the
copper water tube.
6. Fit the two dowel pins into the aluminum
spacer.
7. Using gasket sealer, place the gasket that has
two curved slots and one round hole on top of
the aluminum housing (note the position of
the dowel holes).
Jet Drive Eng. Mtg., Maintenance,
Shift Cable Instruction, Service Info.
8. Place the steel plate (tangs down) on top of
the gasket.
9. Tap the special key into place in the drive-
shaft.
10. Lightly grease the rubber water pump
impeller and fit it on the shaft (note the
impeller can be fitted only one way).
11. Fit the other gasket over the dowel pins.
12. Slip the steel cartridge into the water pump
housing, making sure the tang at the bottom
of the carrier registers with the wide slot
inside the housing. This ensures the holes for
the shaft will line up properly.
13. Place the water pump housing over the end of
the shaft, down to the rubber impeller.
Subsequently, slowly rotate the driveshaft
clockwise, while pressing downward on the
housing so the impeller enters the cartridge.
NOTE: Do not press so hard that the vanes of the
impeller will be damaged.
14. Once the impeller has fully started into the
cartridge, cease the rotation and press the
housing onto the dowel pins.
15. Grease the bolt threads and start the four
bolts, with lockwashers (the 90 and V4/V6
models use special "D" washers) into the jet
drive casing; once all are snug, tighten them,
using a torque setting of 11 ft-lb.
16. For the 40 and 50-model jet drives, install the
plastic shift rod guide in the spline of the shift
rod to prevent the rod from rattling.
17. Grease and fit the two 3/16" by 1/2" dowel
pins into the jet drive casing, and liberally
grease the driveshaft splines and rubber water
tube guide.
18. Grease the threads on all securing bolts, and
bolt the jet drive assembly to the motor
(torque setting on the 5/16"-diameter bolts is
11 ft-lb and the 3/8-diameter bolts is 22 ft-
lb.).
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