Mercury 200 OptiMax Jet Drive Service Manual page 387

Pump Unit
5. Install the rubber ring onto the pinion shaft until it lightly touches the shaft seal.
Tube Ref No.
2-4-C with Teflon
95
Loctite 271 Threadlocker
7
Description
Pinion shaft housing screws (M8 x 25)
6. Rotate the pinion shaft ten revolutions to properly seat the roller bearings.
7. Insert the pinion location tool into the drive housing.
NOTE: Carefully inspect the location tool to ensure it is seated in the drive housing bearing.
a
Pinion gear
Backlash specification
Pinion Gear Height Location Tool
NOTE: 250 hp models, 1.15 gear ratio, use pinion height location tool 91‑882758.
Pinion Gear Height Location Tool
8. Insert the feeler gauge through the hole in the pinion location tool between the gauging surface of the tool and flats on the
bottom of the pinion gear teeth.
9. Use the 0.64 mm (0.025 in.) feeler gauge as a starting thickness. Adjust the thickness of the feeler gauge until a slight drag
is felt as the gauge is drawn out between the gauging surface of the tool and the pinion gear.
Page 5A-38
c
a
b
Description
45676
e
Where Used
Pinion shaft housing O-ring
Pinion shaft housing screw threads (M8 x 25)
a - Pinion location tool
91‑831897
91‑882758
a - Pinion assembly
b - O‑ring
c - Shims
d - Screw (M8 x 25) (4)
e - Rubber ring
d
45287
Nm lb‑in.
20.5 181
0.64 mm (0.025 in.)
90-8M0050731 MAY 2011
Part No.
92-802859A 1
92-809819
lb‑ft