"Guru,
Thank you for your r
"Guru,
Thank you for your reply. I am mechanically inclinded, and did figure it out. Its just that the on line manuals stop at 2000. I keep reading "ask your local dealer" and of course they said that there is none out.
For those of you who are trying to do the same thing: MAKE SURE THE ENGINE IS IN NEUTRAL AND DISCONNECT THE BATTERY IF IT IS ELECTRIC START.
1) pull the prop- remove the cotter pin, and back out the castelated nut and washer. At this point you just pull on the prop. If the prop does not want to budge, simple taps (not hard) will loosten any materials (gunk) and do this repeadedly if you are not successful at first. Patience is the key. Never ever force anything. You would be amazed and what a few taps and some patience will yield. I always use a penetrating oil or wd-40. When you tap what ever it is that you are trying to remove, is helps the penetrating oil to work its way into the parts that you are trying to release.
2) remove the two nuts that are holding in the plate that is holding the shaft.
2)Next remove the bronze bearing behing the prop. It should come out very easily. It has splines on it and you should see a fair amount of grease on it.
3) I pulled out the shaft next. DO NOT USE TOOLS ON THE SPLINES. THE SPLINES (GROOVES ALONG THE SHAFT) MUST NOT GET MARRED UP. The shaft will come out fairly easily as well. Just jiggle it back and forth. Some times you will have to rotate it a hair to get the gear load off of it.
4) Loosten the 4 bolts that hold the lower unit to the upper unit housing. This is where I ran into trouble. The bolts came off, but the lower unit would not come off. It dropped about 3/4 of an inch, then stopped. You will see two rods extending down from the upper unit. The forward one (shift shaft) is smaller, and the aft one was the drive shaft. The drive shaft is attached to the lower unit, and the shifter (forward one) is attached to the upper unit. Around the forward (shift shaft or linkage) is a round white disc. You have to take an 8 mm open end wrench and loosten it, and rotate the little dog ear (retainer piece) that holds the white round plastic piece in place. This is when I used wd-40 and shot the plastic piece and tapped on the fins of the lower unit. I said TAPPED, nothing more. I could not get the lower unit off. I went away for the night and tried to get information (to no avail) The next day, I came back and tried it again. It seperated very easily. The power of wd-40 and patience.
5) You will see a white housing with 4 nuts on the lower unit. That is the water pump housing. Remove the 4 nuts, and pull the housing up and over the drive shaft. Now if you flip it over, you will see the impeller. Take note of the direction of the impeller blade. On mine the impeller blades were bent counter clockwise. When you put the new impeller in you will have to bend the blades of the impeller the same way for it to fit into the housing. Next you will have to remove the stainless (supposedly) cup that is in the housing. This is also a practice in patience. Lube it up well with penetrating oil. You will see two little hole in it. I used the two holes for the oil to get into. I tapped the housing a bunch of times to get the oil between the cup and the housing. If you look closely, and flip the housing over (you will no longer be looking at the impeller) there is a little notch where you use some sort of a tool to pry out the cup from the housing. I used a very small file with the end bent over to grab that cup and pull it out. Again it was an excecise in patience. You definately do not want to crack the housing the cup is in. It will come out if you keep at it. Just walk away, if you are getting impatient. You will also replace the metal gasket that sits on the bottom of the housing.
Do everything in reverse. Dont forget to replace the little retaining clip that holds the white round thing that fits into the lower unit as you put the two together again.
The problem I ran into next was getting the lower unit back up and fit snuggly to the upper unit. I found that if I pulled the pull start chord just a hair, it would line everthing up and the lower unit would sit snuggly back up to the upper unit.
I hope this helps, just e-mail me and I will walk you throug it if you run into problems."