GO-DEVIL Surface Drive Installation and operating instructions

―INSTRUCTIONS ―
Operation and
Service Manual
July 2011
GO-DEVIL®Manufacturers of Louisiana, INC.
[phone] • Toll Free 1-888-490-3254 • Fax [phone]
18649 Womack Road • Baton Rouge, LA 70817
Please visit our website at www.godevil.com

SURFACE DRIVE SAFETY
•GASOLINE IS EXTREMELY FLAMMABLE! Always handle in properly approved
containers. Spilled fuel could ignite if it comes in contact with a hot engine or sparks!
•DO NOT LEAVE ANY FUEL TANK CONNECTED WITH THE VENT CLOSED (TANKS
SOLD BEFORE JULY 2011)!Heat from the suns radiation will build pressure inside the
fuel tank and will force fuel through the carburetor and into the crankcase. At this point the
crankcase will become over full and will blow oil into the air cleaner from the breather. After
the air cleaner becomes saturated with oil, the fuel mixture will become too rich and will foul
the spark plugs. It is recommended to disconnect an EPA approved Moeller tank when
the boat is not in use. These tanks are used starting July 2011.
•KEEP HANDS, FEET, HAIR, AND CLOTHING AWAY FROM ANY MOVING PARTS to
prevent accidents while engine is running both in the water and, most importantly, while on
land!
•WARNING!! – The trim knob is angled outward and away from a pinch point between the
engine and transom bracket. DO NOT PLACE HANDS BETWEEN ENGINE AND
TRANSOM BRACKET WHILE ENGINE IS RUNNING!!! If the skeg or prop strikes an
obstruction while underway, the engine may tilt violently and cause injury.
•NEVER TOUCH ENGINE COMPONENTS DURING OR IMMEDIATELY AFTER
OPERATION. Components can become extremely hot which could result in severe burns!
•NEVER RUN YOUR SURFACE DRIVE IN AN ENCLOSED AREA! Exhaust gasses contain
poisonous carbon monoxide! Always test run in a well ventilated area.
•ALWAYS ATTACH THE SAFETY ROPE TO THE HANDLE OF YOUR SURFACE DRIVE
AS DESCRIBED ON THE BOTTOM OF PAGE 4 BEFORE STARTING THE ENGINE! This
enables you to run your engine in a neutral position! (See bottom of page 4)
•ALWAYS OPERATE YOUR SURFACE DRIVE WITH THE SAFETY KILL SWITCH
LANYARD ATTACHED TO YOUR WRIST OR BELT LOOP! After warm up, always test
your safety kill switch to make sure it is operating properly!
•OPERATE YOUR SURFACE DRIVE FROM A SITTING POSITION, unless you install a
grab bar in your boat to operate while standing!
•BE ALERT FOR HAZARDS AT ALL TIMES! Shallow water areas in particular can present
a variety of challenges. Continually read the terrain for unexpected obstructions, turns, or
changes in water depth.
•KEEP YOUR SURFACE DRIVE IN SAFE CONDITION. It is important to keep your engine
properly maintained. Having a breakdown can be difficult, especially if you are far away
from help or land. To help avoid problems, inspect your engine before each use and
perform all recommended maintenance.

TABLE OF CONTENTS
SURFACE DRIVE SAFETY
ASSEMBLY AND BOAT SETUP......................................................................1-5
•Crate Removal............................................................................................1
•Boat Setup.............................................................................................. 1-5
•Bolting Engine To Transom........................................................................4
OPERATION INSTRUCTIONS.......................................................................... 6-9
•Surface Drive Features...............................................................................6
•Launching, Engine Starting.........................................................................7
•Low Speed Operation.................................................................................8
•High Speed Operation, Trim Adjustment.................................................8,9
LUBRICATION............................................................................................... 10-12
•Engine Lubrication....................................................................................10
•External Grease Fittings...........................................................................10
•Pressure Lubrication.................................................................................11
•Internal Drive Lubrication..........................................................................12
BELT TENSION AND INSTALLATION.........................................................13-15
•Tension Tester...How it Works!................................................................13
•Checking Belt Tension..............................................................................14
•Adjusting Belt Tension, Replacing belt.....................................................15
SPECIAL TOOLS TO SERVICE SURFACE DRIVES…………………………….16
PROPELLER REMOVAL AND INSTALLATION………………………………….17
LOWER SEAL REPLACEMENT……………………………………………………17
SHAFT REMOVAL AND INSTALLATION…………………………………………18
BUSHING REMOVAL AND INSTALLATION……………………………………...19
SURFACE DRIVE PROP SHAFT DRIVE ASSEMBLY…………………………...20
SURFACE DRIVE SEAL INSTALLATION………………………………………....21
WARRANTY

1
TOTHENEWOWNER
Dear Customer,
You have just purchased one of the toughest pieces of marine equipment ever built.
The GO-DEVIL Surface Drive will give you many years of service with very little
maintenance. Of the few problems that occur, most are due to dirty fuel or not running
the engine out of fuel at the end of the season. We have found that unleaded gasoline
will gum the carburetor in a few months if your engine is not in use. We recommend
adding a fuel stabilizer such as Briggs & Stratton part number 5041 to the fuel in your
last full tank of the season. Always disconnect the fuel hose from the tank and run the
engine completely out of fuel before storage!
Fuel tanks should also be checked periodically for water which may appear from
condensation. We recommend using a transom mounted water separating fuel filter
(Sierra part # 18-7852-1 or equivalent) to collect water before it reaches the engine.
ASSEMBLY AND BOAT SETUP
1. Lay the crated engine flat with the engine in a normal upright position.
2. Remove the plywood and 2x4’s surrounding the engine.
3. Locate the metal band holding down the prop end of the Surface Drive frame
and cut it with a pair of tin snips or remove the nails with a claw hammer.
4. Remove the plastic wrapping from the engine.
5. Inspect the engine for freight damage and contact our office immediately if
anything seems damaged. Note that the tail end of the skeg just in front of the
propeller is factory bent. This bend is designed to compensate for torque created
by the surfacing propeller.
6. Loosen the transom clamping studs located under the engine.
7. Locate the lifting eyes on the frame just below the muffler. Using the lifting eyes,
hoist the engine vertically from the crate and place it onto the transom of your
boat.
8. Center the engine on the transom measuring from the outside gunnel rails of the
boat to the edges of the transom bracket. Tighten the clamping studs using a
crescent wrench or 1-1/16” wrench or socket (15/16” wrench for galvanized
models).
9. Remove the tiller handle from the frame by cutting all plastic tie-wraps that have
not been trimmed.

2
10. The 3/8”x 2-1/2” bolt indicated by the arrow in the figure below is the pivot point
for the Adjustable/Floating handle. Remove the bolt and insert the handle into
the engine-mounted handle bracket. Reinstall the bolt into the bracket, passing it
through the hole at the end of the handle. Be sure to include the wire loom to
secure the cables as it was shipped. Install the washer and nut and tighten the
nut firmly or until a slight amount of drag can be felt while pivoting the handle up
and down from the grip. Attach the safety kill switch wires to the mating
terminals on the engine.
23 Vanguard Shown
11. Route the throttle cable through the opening near the lower rear section of the
engine and attach the throttle cable to the engine linkage as shown in the
following photos on page 3.A flat spot near the end of the black cable should be
visible, indicating the position where it was originally clamped at the factory.

3
35 HP Vanguard Kohler 27 HP
Vanguard 23 HP
Check to ensure that the throttle linkage on the engine moves throughout its full
range when the throttle lever is depressed and that it returns to the idle position
when released.
For added safety, a stainless steel throttle return spring has been installed during
factory assembly. This spring returns the throttle linkage to idle position when
the squeeze lever is released. To ensure that the throttle operates smoothly,
periodically lubricate the throttle linkages with a WD-40 type spray lubricant. For
freezing temperatures, stand the handle in a vertical position and inject
antifreeze into the throttle cable with a hypodermic needle and work the throttle
back and forth. This will keep any moisture from freezing your throttle.

4
12. Bolt the engine to the transom as described below.
Looking from the rear of the engine, notice that the transom clamp has two
horizontal rows of holes. Either the two upper or two lower holes need to be used
to secure the engine to the transom. Four holes are provided to accommodate
various transom designs.
Using a 3/8” drill bit, drill through the lowest hole pattern on the bracket which
would allow the bolts to pass through a structural cross-member of the transom.
Install the two supplied 3/8”x3” bolts, washers and nylon insert nuts. For Go-
Devil boats, the engine should be bolted to the transom using the two top holes.
13. Tie a rope to the rib in your boat under the hand grip
of the Surface Drive and put a loop in the rope. Slip
the loop over the handle to hold the engine in a
neutral position while the handle is in its lowest
position. The rope should be short enough so that
the engine can idle with the prop out of the water. If
the handle is used often in a higher fixed position,
it may be necessary to attach an additional longer
rope along side the initial one or use a rope long
enough so that it can be tied securely at various lengths.
ATTENTION: The Go-Devil Surface Drive engine
MUST BE BOLTED TO THE TRANSOM!!!!!
Failing to do so will cause the transom clamp to
loosen while trailering, allowing the engine to
possibly fall off of the transom!!!!
BOLTS MUST PASS THROUGH A STRUCTURAL
CROSS-MEMBER OF THE TRANSOM!!!
(channel, tube, rib, etc.)

5
14. Connect the battery cables to the battery. Attach the red cable to the positive (+)
side of the battery and attach the black cable to the negative (-) side of the
battery.
The battery should be kept in a covered battery box secured to the floor of the
boat and away from gasoline vapors.
15. We recommend using a good nylon rope to tie
your boat instead of a boat strap. Tie the rope
to the trailer frame on one side of the boat
even with the hand grip. Bring the rope over
the boat and make a wrap around the hand
grip on the Surface Drive, then tie a loop in the
rope before the rope comes down the side of
the boat. Bring the rope around the trailer
frame and back up to the loop, cinch the rope
tight and tie it off.
This procedure will hold your boat as tight as any boat strap and will secure your
Surface Drive so it will not bounce when trailering. We also recommend that you
tie a red flag to the tail end of the Surface Drive when towing your boat down the
highway.

6
Surface Drive Features
OPERATION INSTRUCTIONS
ENGINE OIL
Fill the engine crankcase with the recommended amount and type of oil. With the
engine held perfectly level, check the oil level with the dip stick. Use a high detergent
motor oil of the same viscosity you are using in your car or truck for that time of the
year. In warm temperatures we recommend to use straight 30 weight oil. This will
reduce oil consumption.
Notice: For 23 Vanguard models it is important that the crankcase is not over filled with oil. Over
filling the crankcase will cause a decrease in vacuum at high speed, preventing the carburetor
from supplying an adequate amount of fuel to the engine. When this happens, the engine will
starve for fuel and temporarily lose performance. Ensure that the engine oil level does not exceed
the full level line on the dipstick.
FUEL
Fill the fuel tank with clean, fresh gasoline from a clean fuel can. Connect the fuel line
from the engine to the fuel tank and squeeze the primer bulb until firm. If the tank has a
vent (tanks sold before July 2011), the vent must stay open during operation. If you
purchased your tank July 2011 or after, disconnect your tank anytime it is not in use
because the tank does not have a vent.
Squeeze Throttle
Hand Grip
Kill Switch
Manual Trim
Knob
Trim Tabs
Industrial Engine
Adjustable/Floating Handle
Pressure
Lubricator
Access Panels
Transom Clamp
Cavitation Plate
Skeg
EZ Trim Lever

7
BASIC OPERATION
Launching
When launching your boat always leave the handle rope secured in the neutral position
(shaft horizontal). This also applies when starting the engine.
Before starting the engine on the water, always put on your life vest as you would in any
boat with any engine.
Attach the safety kill switch lanyard to your belt loop or wrist.
Starting the Engine
ALWAYS check engine oil level before starting!!
WARNING!!
Never run the engine in an enclosed area! Exhaust contains poisonous carbon
monoxide gas that may cause a loss of consciousness and/or death!
To Start the engine, first pull the choke rod to the choke position. The engine is
equipped with a mercury tilt switch so the shaft must be in a level position with the prop
out of the water for the starter to engage. Tilt the engine forward into the boat and turn
the key to the start position. It may be necessary to run the engine on choke for a few
seconds until the engine warms up. You should run the engine for a few minutes to
ensure that it runs properly. If the engine runs rough after warm up, the carburetor may
need adjustment. (Refer to the engine Manual.)
To Stop the engine, release the throttle and allow the engine to idle for a few seconds.
Turn the key switch to the OFF position.
EMERGENCY STOP! The engine may be stopped at any time by pulling and detaching
the emergency kill switch lanyard from the kill switch. Note: It is the operator’s
responsibility to ensure that the kill switch operates properly before each use.
CAUTION! – Lowering the propeller into the water at high engine rpm may cause a
standing operator or passenger to lose balance or be ejected from the boat. A L W A Y S
ALLOW THE ENGINE TO COME TO IDLE BEFORE LOWERING THE PROPELLER
INTO THE WATER!
NOTE: AFTER YOUR FIRST TEST RUN ON THE WATER IT IS NECESSARY TO
REMOVETHEDRAINPLUG(SHOWNONPAGE10)ATTHEREAROFTHEDRIVE
HOUSING TO CHECK FOR WATER LEAKING IN. THIS BOX MUST RUN
COMPLETELY DRY. IF WATER COMES OUT OF THE DRAIN PLUG THE COVER
PLATES MUST BE REMOVED AND RE-SEALED WITH A GOOD GRADE SILICONE.
PERFORM THIS CHECK ANY TIME THE COVERS ARE REMOVED AND
REPLACED.

8
Low Speed Operation
As described before, let the engine warm up for a few minutes. Holding the handle
carefully, remove the handle rope and get a feel for the balance of the engine.
Neutral position is acquired by lifting the prop out of the water. While the engine is
idling, lower and lift the prop into and out of the water. Get used to low speed
maneuvering and docking the boat before attempting to increase speed.
For the first time operating your new Surface Drive engine, turn the trim adjustment
knob counterclockwise until the prop and cavitation plate can be fully submerged while
the boat is floating at rest. Under normal conditions the trim can be adjusted for high
speed performance and need not be changed while idling or getting back up on plane.
Steer the engine slowly to avoid getting water into or overturning the boat. The
Go-Devil Surface Drive engine is better suited for wider bottomed boats (48” or wider).
Use extreme caution- even while idling -when making sharp turns on narrow boats.
To turn the boat around in a tight situation, allow the boat to nearly come to a complete
stop. While the engine is idling with the prop out of the water, turn the engine all the
way to one side and lower the prop into the water slowly. Most boats will turn in their
own length when this is done.
TIP! - Turning left at low speed requires less reach due to the handle being on the left
side of the engine. When reversing direction from rest or idle speed, set up to turn left
whenever possible. This will become instinctive with time.
High Speed Operation
As its name implies, the Go-Devil “Surface Drive”, uses a surface piercing propeller.
The surface propeller is designed to be run primarily with a fraction of each blade
breaking the surface of the water with each revolution. To get maximum performance
from the engine, propeller depth can be fine tuned using the manual trim.
The manual trim mechanism is a standard feature on all SD models. The trim is simply
a bottom stop on the tilt axis of the engine which allows the engine to tilt upward freely
when an underwater obstacle is struck.
Manual Trim Adjustment
WARNING!! – The trim knob is angled outward and away from a pinch point between
the engine and transom bracket. DO NOT PLACE HANDS BENEATH THE ENGINE
WHILE IT IS RUNNING!!! If the skeg or prop strikes an obstruction while underway,
the engine may tilt violently and cause injury.

9
With the boat floating at rest, set the trim low enough to fully submerge the propeller
and cavitation plate below the waters surface. After getting up on plane and to full
throttle, take notice of the propeller depth.
Since the SD engine is a balanced drive, the prop may initially have a tendency to lift up
and surface too high at top speed without being held by the trim mechanism. If the prop
surfaces too high, a large amount of vibration will be felt at the handle as the prop
blades “slap” the surface of the water. If this happens, bend both trim tabs upward
slightly on the rear with a large crescent wrench as shown in the figure below. For
maximum performance and comfort, you should be able to relax the weight of your arm
and hand comfortably while holding the hand grip at full speed.
If the trim tabs are adjusted properly,
the prop should stay down firmly until
the engine is trimmed up to the desired
depth. To adjust the trim while
underway, lightly push down on the
handle to free the trim and turn the trim
knob Clockwise ( ) to trim up and
Counterclockwise ( ) to trim down.
Trim the engine up until maximum
performance and comfort is achieved.
For the average boat and engine
combination, the prop should be run
with approximately 1/3 of its diameter
above the surface. Different hull designs and horsepower to weight ratios will affect
optimum propeller depth and performance while on plane. If necessary, the drive ratio
may be reduced to accommodate extremely large hulls and loads.
Starting on May 15th, 2008 all Surface Drive Engines are equipped with an EZ Trim
Lever. The EZ Trim Lever allows the prop height to be dropped approximately 5” without
adjusting the manual trim knob. This allows a smooth and efficient transition between
your trim height for running on plane and “digging” out of a situation where you are
stuck or in extremely shallow water. Simply push down on the Surface Drive handle and
flip down the EZ Trim Lever to drop your prop height. After getting on plane and you are
in a sufficient water depth, push down on the Surface Drive handle again and flip the EZ
Trim Lever back up to come back to your normal trim height.
An engine mounted tachometer/hour meter is a highly recommended accessory since it
allows you to view both engine rpm and total run time. Maximum performance will
generally be achieved between 3400-3800 RPM since the engines make maximum
horsepower within this range. Idle RPM should be 1100 out of the water and 900 RPMs
in the water at idle.

10
LUBRICATION
ENGINE LUBRICATION
CHECK ENGINE OIL BEFORE EACH USE. We recommend changing engine oil after the first
10 hours on a new engine and every 50 hours or yearly after that. When changing oil, run the
engine to heat the oil before draining. When changing the oil filter always fill the filter with oil
before installing. Fill crankcase and then prime the oil pump by spinning the engine with the
electric starter for about 10 seconds with the safety kill switch in the kill position. Start the
engine and let it idle for a few minutes before speeding up.
Lubricate the engines throttle linkage as needed with a WD-40 type spray lubricant. This may
or may not be necessary depending on environmental conditions. An occasional spray will help
keep the throttle functioning smoothly.
EXTERNAL GREASE FITTINGS
The Surface Drive unit has 3external grease fittings which require periodic lubrication. One
fitting is located on the drive tube and the other two are located on the tilt axis and steering axis
(see photos below). We recommend using a #1 or #2 marine grade waterproof grease such as
AQUA-LUBE to lubricate all fittings.
Grease the steering and tilt axes after every 10-20 hours of run time. Any more often will be
excessive and messy. In addition to lubricating the fittings, apply a small amount of grease to
the transom clamp bolts yearly or as needed.
The fitting shown in the figure on the right below is used for lubricating the prop shaft and lower
bushing and seal system. A pressure lubricator shown to the left of the fitting feeds grease to
the system as needed and allows for heat expansion inside the drive tube. See the following
section on PRESSURE LUBRICATION on page 11 for proper lubrication and maintenance.
The drain plug shown is used to check for water leakage inside the frame housing. This should
be checked after your first test run on the water and again each time the panels are removed
and reinstalled. While the engine is out of the water, remove the plug and tilt the engine back
so that any water inside the housing will drain out of the drain hole. If water comes out when
checked, the panels should be resealed with a good grade silicone.
Grease Fittings
PRESSURE LUBRICATOR
DRAIN PLUG

11
PRESSURE LUBRICATION
A pressure lubricator shown on the previous page is mounted on the upper end of the drive
tube and features a spring loaded piston which creates a small amount of grease pressure
inside the drive tube. This grease volume lubricates the prop shaft, lower bronze bushing, and
lower seals. During assembly the lubricator is intentionally oriented so that the factory grease
fitting is inaccessible. Lubricate ONLY the grease fitting mounted adjacent to the lubricator to
ensure that grease is fed into the drive tube and not just into the lubricator. Pumping grease
through this fitting will fill both the drive tube and the lubricator.
•Visually inspect the position of the lubricator piston before and after each use.
•The lubricator should be kept about ¾ full so that grease consumption can be easily monitored. The
lower drive system should use up very little or no grease at all when functioning properly.
•If the grease level does not seem to change after several hours of run time, pump grease into the
drive tube until the piston starts to rise. This ensures that the lubricator piston is not “stuck” and giving
a false impression that the tube is full. If the lubricator and drive tube are properly filled, the piston
should move upward after only a few pumps of grease.
•The lubricator cannot be damaged by over-lubricating the drive unit. The lubricator is designed so that
grease will expel from under the cap if over-filled.
•ATTENTION: The lubricator piston will not reach the bottom of the cup. When the piston is at
its lowest position, the visual grease column will be approximately 3/8” high. When the piston reaches
this level it will no longer supply grease to the tube. In order to insure proper lubrication, the piston
must be kept above this level at all times.
•IT IS THE CUSTOMER’S RESPONSIBILITY TO CHECK AND INSURE THAT THE LUBRICATOR IS
WORKING PROPERLY!! Remove and clean the lubricator yearly to ensure that it is working properly
and the piston is not stuck. If working properly, it should expel grease from the bottom hole when
removed.
•Do not clean the lubricator with a petroleum solvent such as gasoline, varsol, kerosene, thinner,
or carburetor cleaner. Petroleum solvents will destroy the plastic components. Wipe excess grease
with paper towels and clean components with mild dishwashing liquid.
SEAL AND BUSHING WEAR
As the lower and/or upper seals start to wear, the unit may start to consume more grease. It
may be time to replace the seals if the lubricator ever becomes empty after a normal operation
period or requires 10 pumps or more from the grease gun to fill on two occasions. DO NOT
DELAY THIS PROCEDURE!!! If the drive unit is run without grease, premature wear on the
prop shaft and lower bushing will occur and will elevate the cost of repair. The life of the lower
seals is determined by how the shaft is lubricated and how abrasive the material is that the
engine is run in, such as mud, sand, and silt. Under extensive or commercial use, especially in
brackish or salt water, the lower seals should be replaced annually.

12
INTERNAL DRIVE LUBRICATION
The Surface Drive unit has 4 internal grease fittings located within the frame housing.
One fitting is located on each of the two universal joints and also on both the upper
bearing housing supporting the prop shaft and on the sprocket shaft bearing housing
shown in the photo below.
After every 75-100 hours of use, lubricate the upper bearing housing and the
universal joint fittings shown below with 2-3 pumps from a grease gun.
The Sprocket Shaft Bearing
Housing shown contains a set of
Tapered Roller Bearings. This
Housing is sealed and grease
lubricated.
After every 75-100 hours of use,
remove the vent tube connected to
the barb fitting shown below and
pump grease into the grease fitting
until grease starts to exit the top of
the housing through the barb fitting.
Collect excess grease with a paper
towel and continue pumping grease
into the housing until clean grease
starts to expel through the barb
fitting. Replace the vent tube when
finished.
Upper Bearing
Housing
Grease Fittings
Sprocket Shaft
Bearing Housing
Grease Fitting
Sprocket
Replace the lower access
panel following the same
instructions as for the
upper panel described on
the bottom of page 15.
Add an additional amount
of Silicone to the corner
areas where the bend in
the lower access panel
mates to the frame.
Panels must be sealed
properly to keep water out
of the frame housing.
Double U-Joint
Barb Fitting

13
BELT TENSION AND INSTALLATION
Gates Tension Testers are available
directly from Go-Devil or any local
Gates Dealer. (See page 14 for
Instructions)
Gates Tension Tester...How it works!
The tension tester is pushed against the center of the belt width through the inspection
hole. Pencil type tension testers like this one measures belt tension by showing the
force required to deflect the belt a predetermined distance. Force and deflection on
Surface Drive Engines should be kept within the tolerance listed below. Belts that are
run too loose will cause an increase in driveline vibration resulting in reduced belt life.
When tensioning, adjust to the high end of the given tolerance to allow for belt stretch.
Never tension belt more than specified! Over-tensioning the belt may cause
premature wear or damage to the engine and drive unit bearings.
Standard 16” Transom Models 20” High Transom Models
Force = 11-15 lbs. Force = 9-13 lbs.
Deflection = 1/4” Deflection = 1/4”
TOOLS REQUIRED
Torque Wrench (to 250 Lbs.-In.)
3/8” Socket
9/16” Socket
6” long Socket Extension
Ratchet
9/16” Wrench
Gates Tension Tester
Gates Tension Tester
(Product No. 7401-0076)
- Up to 30 lbs. -
Deflection FORCE Scale
Deflection DISTANCE Scale
Sliding Rubber
“O” Ring

14
CHECKING BELT TENSION
Checking Belt Tension on the Surface Drive does not require removal of the rear access
panels. An inspection hole on the side of the frame is provided to inspect and check
belt tension from outside of the frame.
Belt tension should be checked every 30-50 hours of run time as described below
and readjusted if necessary.
1. Locate the black hole plug on the side of the frame behind the engine.
2. Carefully slip a knife blade behind the plug flange and pry it out of the hole.
3. Use a flashlight to look inside the hole and locate the belt. When using the
tension tester, force must be applied to the belt by pushing the tester in the
center of the belt width. The inspection hole may or may not be centered on the
belt width.
4. Touch the tester against the center of the belt
width as shown to the right. To measure
deflection, slide the outer o-ring ¼” from the belt
housing. Use the inch scale on the tester to set
the o-ring.
5. Next, push the tester against the belt inward ¼”
until the o-ring touches the belt housing. Be sure
to use the inch scale and not the metric scale
on the tester.
6. Remove the tester from the hole and view the
sliding “O” ring location on the force scale. The
force applied to deflect the belt is indicated by
the location of the bottom of the “O” ring on the
force scale.
7. Repeat steps 4-6 several times or until you
achieve the same result for each measurement.
8. If the measured force falls below specs shown
below, re-tension the belt as described on the following page (15).
Standard 16” Transom Models 20” High Transom Models
Force = 11-15 lbs. Force = 9-13 lbs.
Deflection = 1/4” Deflection = 1/4”

15
ADJUSTING BELT TENSION
1. REMOVE UPPER ACCESS PANEL: Remove all ¼” bolts holding the Upper
access panel with a 3/8” socket and ratchet. The panel is sealed with Loctite 598
High Performance RTV Silicone Gasket Maker. The panel will need to be pried
from the frame with a large screwdriver.
2. Locate the 3/8” bolts shown in the photo to the
right. Using a 9/16” socket, ratchet and extension,
loosen the top 4 bolts around the engine
crankshaft. Hand tighten the bolts to allow the
frame to slide up and down but remain against the
engine.
3. Loosen the lower 4 bolts using the ratchet and
9/16” wrench. Snug the bolts as done for
the upper bolts to allow the frame to slide
up and down.
4. Loosen the Upper Tension Adjustment nut on the
jack bolt using a 9/16” open end wrench.
5. NEW BELT ONLY - If installing a new belt, loosen
the Lower adjustment nut and turn the Upper
adjustment nut clockwise to loosen the belt.
Remove all four of the 3/8” bolts securing the sprocket shaft bearing housing
shown on page 12. The sprocket unit can then be lifted enough to change the
belt. Apply Blue Loctite to bolts and reinstall them with the new belt in place
around the sprocket. Torque all four bolts to 250 In.-Lbs. (21 Ft.-Lbs.)
6. To increase belt tension, turn the Lower Tension Adjustment nut counterclockwise
until the proper tension is achieved as indicated by the tension gauge instructions
listed on page 14.
7. Tighten all 8 of the 3/8” bolts shown above to 250 In.-Lbs. (21 Ft.-Lbs.)
8. Tighten the Upper Tension adjustment nut.
9. After tightening all bolts and nuts listed above, check belt tension
again and readjust if necessary using the same procedures.
Replace the inspection hole plug when finished.
10. Remove existing RTV Silicone from frame and access panel and
insure that mating surfaces are clean. Apply a continuous 1/8”
bead of silicone to the frame surface and inside the bolt holes.
Ensure that the bead is continuous around the perimeter to

16
prevent water leakage.
11. Install the Upper Access Panel and lightly tighten the ¼” bolts. Allow Silicone to
cure for several hours and then torque all bolts to 125 In.-Lbs. (10 Ft.-Lbs.)
TOOLS
SPECIAL TOOLS TO SERVICE SURFACE DRIVES
TOTAL $255.00
These tools can be rented for $20.00 plus shipping with a $255.00 deposit.
OTHER TOOLS NEEDED TO SERVICE SURFACE
DRIVES
18” PIPE WRENCH
1/2” DRILL
8” OR 10” CRESCENT WRENCH
1 1/16” SOCKET OR COMBINATION WRENCH
1 1/8” DEEP SOCKET OR COMBINATION WRENCH
PAIR OF CHANNEL LOCK PLIERS
4 TO 5 LB HAMMER
5/16” DRILL BIT
7/8-9 10 TPI DIE NUT
7/8-9 10 TPI TAP
PART #
DESCRIPTION
USED FOR
PRICE
PW2-3BL
PROP WRENCH
T-BAR TO REMOVE PROP
$50
SHBUPU
PULLER FOR
SHAFT & BUSHINGS
(SLIDE HAMMER)
USED WITH:
SHAFT ADAPTER TO REMOVE SHAFT
BUSHING PULLER- TO REMOVE BUSHING-
(MUST USE 1” TAP TO THREAD INNER
BUSHING FOR BUSHING PULLER INSERTION.)
$50
SHAD
SHAFT ADAPTER
USED WITH PULLER TO REMOVE SHAFT
$15
BUPU
BUSHING PULLER
USED WITH PULLER TO REMOVE BUSHING
$20
BUIN
BUSHING INSTALLER
TO INSTALL BUSHINGS
$10
T1
1” TAP
USED TO THREAD INNER BUSHING FOR
INSERTION OF BUSHING PULLER FOR
REMOVAL OF BUSHING.
$40
R78
7/8” REAMER
AFTER BUSHING INSTALLATION, USED TO
REAM THE BUSHING FOR PROPER SHAFT
PLACEMENT/FIT.
$70

17
PROPELLER REMOVAL
1. Using a 1 7/16” wrench, hold back on the forward jam nut (1A1-78)and remove the
rear nylon insert nut (1A4-78) with a 1 1/4” wrench.
2. Using a prop wrench (PW2-3BL) unscrew the prop. If prop wrench is not available,
use a large pipe wrench with the sides of the jaws touching the end of the propeller
blades to unscrew the prop. If the prop is stuck, as they usually are, pull very hard.
DO NOT STRIKE THE ENDS OF THE BLADES TO BREAK IT FREE. THIS NEVER
WORKS. If you cannot break the prop free, heat the front of the hub red hot. This will
only damage the seals.
If the prop is still stuck: Remove the shaft with the prop still on it. Place the shaft
(ahead of where the bushing rides) in a pipe vice. This will eliminate the spring
action in the shaft. Using the same steps as above, unscrew the prop. It may be
necessary to re-heat the hub. Remove any scars on the shaft that the vice
created with a smooth mill file.
PROPELLER INSTALLATION
1. Inspect the forward jam nut and forward brass washer ( B W -78), replace if
necessary. It may be necessary to run a die nut (7/8”-9) over the threads of the shaft
to clean them. It may also be necessary to run a tap (7/8”-9) through the propeller.
2. Apply never-seize to the shaft. Screw the prop on the shaft clockwise (right hand
threads). When installing a used propeller use caution, the blades may be very
sharp from wear. Use leather gloves to prevent injury.
3. Install the rear brass washer (BW-78) followed by the nylon insert nut (1A4-78). The
nylon insert nut should be tightened as tight as possible. DO NOT USE AN IMPACT
GUN!
LOWER SEAL REPLACEMENT
(Drawing for this procedure on PAGE 21)
1. Determine if the lower bushing should also be changed by holding the cavitation
plate with one hand and moving the propeller up and down then left to right with the
other hand. If no movement is felt, there is no wear in the bushing. Once the
movement becomes 1/16” or more, it will be necessary to replace the bushing.
2. Remove the propeller. (Refer to PAGE 17 Propeller Removal)
3. Remove the brass washer (BW-78) and forward jam nut (1A1-78).
4. Remove the lower housing cap (LHC-78-which has left hand threads). (Must turn
clockwise to remove) Clean thoroughly of any grease or Loctite.
5. Pick old seals out with a tool such as an ice pick with a 90 degree bend on the end.
6. Pack the first seal with grease and insert it into the housing with the spring-side
facing the engine and screw the seal on over the threads on the shaft or by using a
split plastic sleeve to slide over the threads. These seals can be pushed in with a 1”
plastic pipe. This procedure may shave a small amount of material off of the outside
diameter of the seal. Insert the next seal with the spring facing the prop. Pack the
area between the two seals with grease.