Hamilton Jet HJ212 Installation And Service Manual page 92

Overhaul
Reverse shaft reassembly
Lightly grease the reverse shaft and bushes [8, 9, 10].

Assemble the reverse spacer [28] and washers [31] in the correct order onto the reverse shaft [8].

From inside the vessel, fit the reverse shaft through seal [15] and bush [9]. Continue pushing the reverse

shaft rearwards through bush [10] until the reverse spacer [28] and washer [31] are pushed firmly
against the transom seal ring on the jet unit intake.
From outside the vessel fit flat washer [31] to the end of the reverse shaft [8] protruding from the rear of

the jet unit.
Fit the reverse crank [11] to the reverse shaft and ensure that the reverse crank is fitted with the flat side

of the reverse crank facing rearwards.
Secure the reverse crank to the reverse shaft with cotter [16], special washer [13], spring washer [19]

and nut [17]. Torque load to the recommended torque.
Check for freedom of movement between the reverse shaft and the reverse latch hub.

Reverse link reassembly
Lightly grease the bores on the link actuator [21].
Apply Loctite 263 to the bolt [25].
Re-assemble the link ball [22], link actuator [21], link o-ring [38] and flat washer [24] onto the bolt [25].
Attach the link actuator [21] to the outside of the port reverse duct arm.
Tighten nut to the specified torque. Refer to section: Tightening Torques on page 10-28.
This is important as the bolt [25] may work loose and fall out, with reverse duct movement.
Reverse duct reassembly
Ensure the thread and surfaces of the reverse duct pivot bolts [4], reverse duct pivots [2] and the reverse

duct pivot bushes [5] are clean.
Coat the reverse duct pivots [2], pivot bushes [5] and washers [3] with a recommended marine grease.

Fit the reverse pivots [2] to the reverse duct arms from inside the reverse duct arms.

Support the reverse duct so that the pivots in the reverse duct are aligned with the threaded holes in the

tailpipe.
Fit washers [3] to the pivot bolts [4] and fit the pivot bolts [4] using Loctite 222 to secure the reverse duct

to the tailpipe.
Tighten the pivot bolts [4] to the recommended torque 95Nm (70lbf ft).

Once the reverse duct is refitted to the jet unit, raise the reverse duct and connect the link actuator [21]

to the reverse crank [11]. Ensure that washers [60] are fitted either side of the head of the reverse crank
[11].
Secure with crank pin [12], washers [60] and split pin [14].

Refit the tension spring [18] to the location point on the starboard side of the jet unit and connect the

free end to the bolt [6] mounted on the starboard upper side of the reverse duct.
Carry out a functional check to ensure the proper operation of the reverse mechanism and adjust the

reverse detent plate [23]. Refer to section: Zero Speed Detent on page 5-12
9-10
Installation and Service Manual