Mercury Optimax 115 User Manual

6
A
RIGHT HAND NON-RATCHETING
90-855347R1 JANUARY 1999 Page 6A-1
LOWER UNIT
Section 6A – Right Hand Non-Ratcheting
Table of Contents
Gear Housing Specifications (Standard Rotation) 6A-1.
Special Tools 6A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes: 6A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing (Drive Shaft)(Standard Rotation) 6A-6. .
Gear Housing (Prop Shaft)(Standard Rotation) 6A-8. . .
General Service Recommendations 6A-10. . . . . . . . . . .
Removal, Disassembly, Cleaning and Inspection
– Standard Rotation 6A-11. . . . . . . . . . . . . . . . . . . . . . . . .
Removal 6A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining and Inspecting Gear Housing
Lubricant 6A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bearing Carrier and Propeller Shaft Removal 6A-16.
Shift Shaft 6A-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 6A-20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Actuator Rod 6A-22. . . . . . . . . . . . . . . . . . . . . .
Pinion Gear and Driveshaft 6A-22. . . . . . . . . . . . . . . .
Forward Gear 6A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Housing 6A-26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly and Installation Standard Rotation 6A-26.
Driveshaft Needle Bearing 6A-26. . . . . . . . . . . . . . . . .
Bearing Carrier 6A-27. . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear 6A-30. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward Gear Bearing Race 6A-31. . . . . . . . . . . . . . .
Driveshaft and Pinion Gear 6A-32. . . . . . . . . . . . . . . .
Pinion Gear Depth/Forward Gear
Backlash/Reverse Gear Backlash 6A-34. . . . . . . . . .
Clutch Actuator Rod 6A-38. . . . . . . . . . . . . . . . . . . . . .
Shift Shaft Bushing 6A-38. . . . . . . . . . . . . . . . . . . . . . .
Propeller Shaft 6A-39. . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump 6A-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gear Lubricant Filling Instructions 6A-45. . . . . . . . . .
Installing Gear Housing to Driveshaft Housing 6A-45
Propeller Installation 6A-46. . . . . . . . . . . . . . . . . . . . . .
Gear Housing Specifications (Standard Rotation)
Ratio Pinion Depth
Forward Gear
Backlash
Reverse Gear
Backlash
1.87:1
0.025 in. (0.635 mm)
With Tool 91-12349A2
using Disc #2 and
Flat #7
0.018 in. to 0.027 in.
(0.460 mm to 0.686
mm) Pointer on line
mark #1
0.030 in. to 0.050 in.
(0.762 mm to 1.27 mm)
2.0:1
0.025 in. (0.635 mm)
With Tool 91-12349A2
using Disc #2 and
Flat #7
0.015 in. to 0.022 in.
(0.38 mm to 0.56 mm)
Pointer on line mark
#2
0.030 in. to 0.050 in.
(0.762 mm to 1.27 mm)
2.3:1
0.025 in. (0.635 mm)
With Tool 91-12349A2
using Disc #2 and
Flat #7
0.018 in. to 0.023 in.
(0.46 mm to 0.58 mm)
Pointer on line mark
#4
0.030 in. to 0.050 in.
(0.762 mm to 1.27 mm)
Gearcase Lubricant Capacity
All Ratios 22.5 fl. oz. (665.4 ml)

Mercury Optimax 115 Specifications

General

Brand	Mercury
Model	Optimax 115
Category	Outboard Motor
Language	English