199
GEARCASE
LEAK TEST
9
To check for water contamination, drain lubricant
into a suitable glass container. Allow the drained
oil to settle for a minimum of one hour to deter-
mine if there is an abnormal amount of water in
the oil. Some gearcase lubricants are designed to
mix with a small amount of water from normal
water vapor condensation within the gearcase.
Refer to LEAK TEST on p. 199.
Overheated lubricant will give the lubricant a black
color and burned odor.
Internal gearcase inspection is recommended
when lubricant is contaminated or shows signs of
failure.
Filling
Secure the gearcase in a vertical position.
Remove the lubricant level plug and the lubricant
drain/fill plug.
Slowly fill the gearcase with HPF XR gearcase
lube through the drain/fill hole until it appears at
the oil level hole. Filling the gearcase too quickly
can cause air pockets and the gearcase may not
fill completely. Clean plug seal area and install the
lubricant level plug and new seal, then the lubri-
cant drain/fill plug and new seal. Tighten them to a
torque of 114 in. lbs. (13 N·m).
LEAK TEST
Drain lubricant before testing.
STEP 1
Install lubricant drain/fill plug and seal, thread
pressure test gauge fitting and seal in lubricant
level hole.
Pressurize 3 to 6 psi (21 to 42 kPa).
If pressure gauge indicates leakage, submerge
the gearcase in water to determine source of leak-
age.
If the gearcase pressure gauge does not indicate
leakage, increase pressure to 14 psi (100 kPa).
Check for leakage.
Make necessary repairs and repeat test.
IMPORTANT: Do not exceed pressure of 15.5
psi (110 kPa) or damage to oil seals will result.
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