2003 75hp 4 Stroke

[Old Crow]

The lower unit was not winterized properly. Pulled the drain plug and nothing but water came out.
Refilled with oil and now when we run it on the garden hose I see oil leaking around the prop so the rear seal must be out.
Unit will not go into reverse either. When I put the shift leaver in reverse you lateral movement of the prop (not rotational)
Boat in located in MN and stored outdoors, -20F
It's a Yamaha

 

[Silvertip]

Re: 2003 75hp 4 Stroke

If the unit was stored outdoors in freezing temperatures with water in the lower unit, you apparently have some broken parts to contend with.

 

[Old Crow]

Re: 2003 75hp 4 Stroke

If the unit was stored outdoors in freezing temperatures with water in the lower unit, you apparently have some broken parts to contend with.

I started to pull it apart.
Found the tabs on the output shaft support housing cracked and the threads on the retaining nut striped.
After removing the retaining nut does the output shaft support housing just pull out or is there some special proceedure?
Thanks

 

[Silvertip]

Re: 2003 75hp 4 Stroke

You really need a factory service manual for your engine. They are available on E-bay. Doing this job wrong results in more damage than you already have.

 

[Old Crow]

Re: 2003 75hp 4 Stroke

You really need a factory service manual for your engine. They are available on E-bay. Doing this job wrong results in more damage than you already have.

Anyone have a preferred ebay seller? One you can trust to get you what you are looking for.

 

[vanner]

Re: 2003 75hp 4 Stroke

I replaced the lower unit seals on my 70hp yam 2 y ago. I had to use pullers to get it apart

 

[Silvertip]

Re: 2003 75hp 4 Stroke

I bought one from here: http://stores.ebay.com/Hustler-Sport-Center-Inc_W0QQ_trksidZp1638Q2em118Q2el1247

 

[Old Crow]

Re: 2003 75hp 4 Stroke

First I want to say I am not the one that did not properly winterize this motor. I bought the motor this spring broke.
Anyway I got it all put back together. I replace the output bearing support, output bearing, support nut and all seals and orings.
I didn't mess with any of the shims so all they're the same as from the factory.
When I shift into gear there is a pretty good clunk/grind (seems excessive) and you can hear a bit of gear whine when in reverse.
Like I said I bought the motor broke so I don't know what normal is.

 

[rodbolt]

Re: 2003 75hp 4 Stroke

on all yamaha units that use a retaining nut to hold the bearing carrier in place the reverse gear lash/tooth depth is controled by a shim pack between the housing and the carrier. change the housing, bearing carrier or reverse gear bearing and the unit needs to be reshimmed.
odds are high yours is no longer shimmed correctly. however its all in that service manual you bought, isnt it ?
units that use 2 retaining bolts shim with a pack between the reverse gear and the bearing carrier.
most anytime you replace a casting,bearing or shaft the shim for that gear needs to be checked

 

[Old Crow]

Re: 2003 75hp 4 Stroke

According to Yamaha web site and the manual I have there are no shims behind the reverse gear on this model.
Manual even says "Note: reverse gear shim selection is unnecessary."
I did not disturb the pinion or forward gear shims. I torqued the pinion nut and bearing carrier nut to specs.

 

[Old Crow]

Re: 2003 75hp 4 Stroke

While on the lake this past weekend I noted there are a lot of newer Yamaha outboards.

Seems the grind/clunk when shifting into gear is normal as I heard the same from many other motors.