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  1. #1
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    Rebuild/Re-assemble Sportmaster lower

    Hi guys, I tried searching but couldn't find any info on re-assembling lower units/gearboxes.

    I have a disassembled sportmaster lower that I want to re-assemble (to spec) with the 25" driveshaft ouf of my current lower unit (the sporty has a cut shaft). I understand that it's not just a "bolt it all together" kinda deal... Is anyone able to point me to a manual that specifies how to re-assemble and stick to factory specs (i'm thinking backlash, torque etc - not that I've ever assembled a lower before!).

    Motor is a late 80's Merc laser 220. The current lower has a slightly bent prop shaft but otherwise runs fine).

    Thanks in advance

    Gene

  2. #2
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    Factory service manuals are online in pdf form. Special tools are involved that are quite expensive. I used to have a thread on it, but phototoilet...

  3. Likes NICE PAIR liked this post
  4. #3
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    The mercury 2.5L 245/260 hp hipo manuals have all the break downs, disassembly and reassembly for CLE and sportmaster gearcases
    15.5 cobra 175 hp merc - sold
    18 tahiti tiger O/B 200 hp merc - sold
    19 STV euro - 245 hp merc

  5. #4
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    aalsmeer
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  6. #5
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    Thanks guys, if it's not possible without specialty tools I guess that counts me out, dammit. That document's pretty helpful tho cheers Ronnie. It's tricky finding anyone around here to do the job!

  7. #6
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    aalsmeer
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    auckland maybe?

  8. #7
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    I've found a local merc dealer that seems pretty confident in their ability....will go have a yarn with them next week.

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