Gearcase Assembly; Water Intake Screens; Shift Housing, Gear, And Propeller Shaft Installation - BRP Evinrude E-TEC G2 Service Manual

Gearcase

Gearcase Assembly

Check squareness of the bearing housing mount-
ing surface by holding the shim gauge bar against
the pinion while rotating just the bearing hous-
ing. Use a feeler gauge to measure clearance
between the gauge bar and the bearing housing
between each pair of screw holes. Replace the
bearing housing and repeat check if variance is
greater than 0.004 in. (0.101 mm).
Check squareness of the pinion to the driveshaft.
Hold the shim gauge bar against the bearing
housing (between the screw holes) while rotating
just the driveshaft and pinion assembly. Mea-
sure clearance between the gauge bar and the
pinion at several locations. If variance is greater
than 0.002 in. (0.050 mm) replace the pinion or
driveshaft, as necessary, and repeat check.
Subtract the average clearance measurement
from 0.020 in. (0.508 mm) to determine the cor-
rect shim thickness required. Select the fewest
number of shims to achieve the correct thickness.
Remove the driveshaft from the tool and add the
required shims between the bearing housing and
the thrust washer.
IMPORTANT:
Use extreme care when removing
bearing housing to avoid damaging the seals. Use
Driveshaft Seal Protector, P/N 318674.
Check clearance again.
between the gauge bar and pinion should be
0.020 in. (0.508 mm).
Remove the nut and pinion from the driveshaft.
Discard the nut.
392
The measurement
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Gearcase Assembly

Water Intake Screens

Install water intake screens. Tighten screws to a
torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
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1. Water intake screen
Shift Housing, Gear, and
Propeller Shaft Installation
Apply Triple Guard grease the rear edge of the
shifter housing as shown.
1. Triple Guard grease applied to rear edge of shifter
housing
Push shifter detent into farthest downward posi-
tion. Tip the rear of the gearcase slightly down-
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