Installation Instructions for Lower Unit Seal Kit with Prop Shaft Oil Seal for 6 to 9.9 HP Outboard Motor

Tools Needed:

• Screwdriver (Flat-head and Phillips)
• Socket wrench set (specific sizes may vary)
  -Pliers
  -Torque wrench
• Oil seal installer or flat piece of wood (for even installation of the oil seal)
  -Cleaning rags or cloth
• Marine-grade grease
• Safety goggles and gloves

Installation Steps:

1. Preparation:

   • Ensure the outboard motor is in a stable position, preferably on a workbench or securely mounted.
   • Gather all necessary tools listed above.

2. Remove the Lower Unit:

   • Disconnect any cables or wires attached to the lower unit.
   • Remove the bolts securing the lower unit using the socket wrench.
   • Gently pull the lower unit away from the motor, taking care not to damage any connecting parts.

3. Disassemble the Lower Unit:

   • Once the lower unit is removed, identify the prop shaft and the oil seal location.
   • Remove the propeller and any retaining hardware. Set aside for re-installation later.

4. Replace the Oil Seal:

   • Carefully remove the old oil seal from its housing using a flat-head screwdriver or a seal puller tool.
   • Clean the area thoroughly to avoid contamination.
   • Apply a thin layer of marine-grade grease to the new oil seal edges to ensure proper seating.
   • Using an oil seal installer or a flat piece of wood, evenly tap the new oil seal into place. Ensure it is flush with the housing.

5. Install the Cotter Pin:

   • Insert the cotter pin into the prop shaft hole according to the kit instructions.
   • Bend the ends of the cotter pin securely to prevent it from coming loose.

6. Reassemble the Lower Unit:

   • Reattach the propeller and secure it with the retaining hardware.
   • Align the lower unit back onto the motor and gently push it into place.
   • Replace and tighten the mounting bolts to the manufacturer's specified torque settings.

7. Final Checks:

   • Reconnect any cables or wires that were detached.
   • Check for any visible gaps or signs of improper assembly.
   • Test the motor to ensure proper operation before heading to the water.

8. Regular Maintenance:

   • Schedule regular inspections and seal replacements as necessary to prolong the life of your outboard motor.

Safety Note:

Always wear safety goggles and gloves during the installation process to protect yourself from debris and other hazards.

By following these instructions and using the appropriate tools, you can effectively replace the seals in your outboard motor, ensuring optimal performance and longevity.