REPAIR OF TRANSOM PLATES  PARTS FOR REPAIR JOB  ECONOMY KIT

1)Remove outdrive and rams(separate instructions)

2)Remove the pivot pins on the side of the bell housing

3)Some pins have nails which hold them in these must be removed then the pins are drifted inward until they fall out

4)If you have the later style there are two bolts screwed in from each side under the ear muffs. These have a 12 point hole which can be turned by a 1/2 allen wrench. If they resist removal a torch may be necessary. With a piece of allen wrench in a 1/2 socket mounted on an impact wrench try to remove the screws, if not keep the wrench in reverse and running while the torch is applied to the bell housing close to the screws, when the loc-tite gives the screw will zip out. keep screws and washers

5) Pull out on the bell housing and apply a razor knife to the top bellows while pulling, the bellows will fall in half. make note of where the clamps sit and face because they must be put back in the same position.

6) Pull rearward on the housing and cut and remove the lower bellows in the same way.

7)If you are changing the cable bellows but not the cable follow these instructions. from inside the boat remove the plastic tip from the lower shift cable ,unscrew the s.s. tube and pull the cable out of the boat through the boot after removing the clamp on the end of the bellows. Pull core out appx 1 to protect tip. Lubricate and slide the new boot up the cable and leave it til later.

8)Clean the surface where the exhaust bellows goes on the boat side glue it and clamp it. note where the clamp goes. Then place the u-joint bellows on the bell side, glue and clamp it.

NOTE the flats on the u/j bellows face front of boat and face sideward.GEN II BELLOWS HAVE ONLY ONE END CLAMP AND THE O/D END FITS INSIDE. WITH INSIDE RING TO FIX IT INTO THE BELL HOUSING. ON GEN II THE EXHAUST BELLOWS GOES ON FIRST AND THE U/J BELLOWS GOES NEXT. CLAMP FRONT SIDE FIRST WITH GLUE THEN PULL THE REAR END INTO THE BELL. SNAP IT INTO THE GROVES WITH VERY LITTLE GLUE ON THE REAR END. SAND THE INSIDE EDGE TO MAKE THE RING EASIER TO INSTALL. PUT SOME SOAP TO EASE THE REPLACEMENT.(If the ring is held on dry ice just before the placement it becomes much smaller)

If you are changing the water hose or the gimbal bearing do it now before going on. The u-joint bellows has two flat spots they must be on the sides toward the boat half way down.

9)To install the boat 1/2 of the u-j bellows, with clamp loosely around and glue on the inside push the bell and bellows over the shoulder, put one hand inside to feel that it is seated properly hold until glue sets. Release pressure and clamp. Replace the pins or screws that hold the bell housing. push the shift cable back into boat and clamp the boot at both ends, be sure the cable does not get twisted or crimped when it is pulled back in. Replace the core. the threaded tube and plastic tip and reinstall in its mounting.

10) Pull the exhaust bellows back and clamp it to the bell hse This is easier if the bellows was expanded over a plastic tube overnight or soaked in hot water. Replace the out drive.