Tools and supplies you will
Cover Shaft Kit includes:
|1. Cut drill template out on
solid black line as close as possible.
2. Place pattern on Gimbal,
lining bottom edge of pattern with bottom flat edge of
Gimbal Housing, centering template from right to left
and scotch tape pattern to housing. Do not remove
this pattern until all holes are center punched, drilled
and window is removed!!!
|3. Using center punch, center
punch each red and green circle around the opening to be
cut out and the 4 bolt hole locations. Center
punch as close to the center of the X as possible.
|4. Using a 3/32 drill, drill
all 4 tap bolt holes first 7/16" deep maximum.
|5. Using a 3/32 drill, drill
all green holes in window pattern first, drilling just
deep enough to break through.
|6. Using a 3/32 drill, finish
drilling cutout in the red drill holes being very
careful not to break the drill. If drill breaks,
go on to the next hole with a new drill, (2) 3/32 drills
|7. Using a #3 drill supplied,
drill out the 4 bolt holes. This is the size of
drill for a 1/4-28 tap. Only drill 7/16"
|8. Using a die grinder,
insert the 1/8 arbor (supplied in kit). Install
one of the 2 cutting disks and tighten with a
|9. Carefully cut out window
pattern with die grinder cutting through all of the 3/32
holes. Cut through all green holes first and red
holes last. Do not slip and cut outside of window
pattern!! This must be done carefully so that
gasket and plate will seal on final assembly!! You
may need a small hammer & punch to tap out window
opening. Once removed, you can use a die grinder
or file to clean up all ragged edges of opening.
|10. Now that window opening
is removed, remove drill template from Gimbal Housing.
|11. Using a 1/4-28 tap in a
hand tap holder, apply a small amount of oil in each
hole and on tap. Tap the 4 stainless plate bolt
holes. Be sure to tap holes straight, cleaning the
tap after each hole. After tapping, clean out
holes. Then screw the 1/4-28 socket head cap screw
into each hole to be sure hole has been tapped deep
enough. (Screw should be able to go all the way in
the tapped hole). If hole is not tapped deep
enough, re-drill hole with #3 drill and re-tap to depth
|12. Using wrench Kit Part
#2501, loosen tiller arm bolt & nut.
Note: Wrenches in Wrench Kit have been altered to
allow easy access of tightening and loosening tiller arm
bolt and swivel shaft nut.
13. Remove swivel
shaft. Replace bushings and seal, re-install
Gimbal Ring with new JR Marine High Performance Swivel
Shaft and tighten to OEM specifications. (JR
Marine also carries seals and bushings).
What is left of OEM sticker on Gimbal Housing does not
have to be removed. This is an option left up to
the installer. Note: Sticker is very hard to
get off. Cover and gasket will seal over top of
sticker. Clean surface thoroughly with lacquer
thinner at this time before mounting gasket & cover
plate. Using silicone, apply a dab of silicone in
each of the (4) 1/4-28 bolt holes. With your
finger, smear a nice even coat of silicone over gasket
area only. (Do not lay a bead of silicone on
gasket area. You must put an even coat on
surface.) Place gasket and stainless steel plate
on Gimbal and tighten down evenly with 4 screws supplied
until tight (45 inch pounds of torque max).
Silicone will squeeze out from under gasket. You
may not see silicone come out when tightened.
Don't worry, housing is sealed. After silicone has
fully set up approximately 24 hours, trimming of gasket
with razor blade is optional. We do not recommend
trimming gasket, as it increases the possibility of
15 You may
call JR Marine for questions or technical
assistance. If you get an answering machine and
can't wait for a return call, you can call Ron Bender on
his cell phone at 216-390-1330. He will be glad to
assist you in any questions you may have or go to
jrmarine.com and click on install instructions. We
have photo's and steps to assist you.