SONIC CATAMARAN DRIVE, Mk.

Owners Handbook

BY
-
SILLETTE SONIC LTD
 SONIC CATAMARAN DRIVE MK I1

CONTENTS

FOREWORD AND TECHNICAL SPECIFICATION PAGE 1

INSTALLATION DETAILS PAGE 2

HINTS FOR THE HELMSMAN PAGE 7

SERVICING PAGE 9

GENERAL INFORMATION + ASSEMBLY DRAWING PAGE 13

HYDRAULIC LIFT SUPPLEMENT PAGE 18

PARTS LIST AND ACCESSORIES PAGE 22

REVERSE LOCK SUPPLEMENT PAGE 25

EXTENDED LENGTH CATAMARAN DRIVE SUPPLEMENT PAGE 27

FOREWORD 1

The Sonic MK I1 Catamaran drive was first produced in 1979 and is a development of its
forerunner the MK I Catamaran drive. The MK I1 drive has been developed to minimise weight
and allow the use of standard inboard enginelgearbox combinations and providing charging
facilities whilst the unit is tilted when under sail or moored in harbour.

It should be remembered that these units are installed where they are subjected to all weather
conditions outside the craft. Therefore regular servicing and care are essential to ensure
troublefiee use. Attention should be paid to instructions and advice contained in this handbook.

This Catamaran drive is designed for use primarily as a sailboat auxiliary propulsion system, not
for a power cat application. Its lightness in construction, is demanded by the sailing enthusiast to
maximise sailing performance. Therefore when under power, remember prudence, and you will
receive good service.

Technical Specification 1
POWER CAPACITY: S.AE. ratings +MAX PETROL ENGINE 50 BHP - Subject to torque limits
(Subject to applications & to +MAX DIESEL ENGINE 38BHP - Subject to torque limits
be agreed with Sillette in +MAX INPUT TORQUE = ENGINE TORQUE X GEAR RAT10
writing prior to use) = I5 KGJMTR
NB Torque in excess of 10 KGIMTR & for longer lengths
reverse RPM should be restricted to '/s throttle.

TRANSMISSION DIRECT DRIVE, GLEASON - STRAIGHT CUT AS STANDARD

BEVEL GEARS, 1:1 RATIO
ROTATION - REVERSED INPUT TO OUTPUT
OPTION TO SPECIFY SPIRAL BEVEL GEARS

PROPELLERS 12 SPLINE DRIVE L OR R HAND

3 BLADE ALUMINIUM, 13" & 14" DIAMETER
17 SPLINE DRIVE L OR R HAND
14" & 15" ALSO 16" FOR SPECIAL APPLICATIONS

STEERING 30' TO PORT OR STARBOARD, OPERATED BY PROPRIETARY

PUSH PULL CABLE SYSTEM OR LINKED TO BOOM RUDDERS
(SEE NOTE).

MOUNTING AND TRIM ATI'ACHED PLATE TO BE MOUNTED TO A SEMI-VERTICAL

MOUNTING INCLINED AT 7'-12' ANGLE (TO GIVE HORIZONTAL
THRUST)
FOR AUTO LOCK 7' ONLY - SEE INSTALLATION DRAWING
FIG. 1.

TILT 65' MAXIMUM (USING 7' MOUNTING)

MANUAL OR HYDRAULIC OPERATION

INPUT TO OUTPUT SHAFT 800,900, 1000 & 1200MM AS STANDARD

Special lengths may be possible.

LUBRICATION INTERNAL, HYPOID 90 OIL

CAPACITY VARIES ACCORDING TO LENGTH
IN A RANGE 5-7 LTRS,FILL TO LEVEL STICK
(Slow Filler)
EXTERNAL, LIBERAL USE OF DUCKHAMS KEENOL GREASE

REVERSE LOCK DOWN a) MANUAL - PULL CABLE TO OPERATE

b) AUTOLOCK - PULL CABLE TO RELEASE

WEIGHT DRY
 INSTALLATION DETAILS 1

i) MOUNTING ARRANGEMENTS AND INSTALLATION DRAWINGS

ii) STEERING
iii) REVERSE LOCKING
iv) ENGINE COUPLING
V) PROPELLER
vi) PRE-SERVICE CHECKOUT

i) MOUNTING ARRANGEMENTS

There are two basic methods of Mounting the unit to the catamaran, Method a) whereby the unit is
mounted on top of the bridge deck to a suitable mounting pad, with the leg either projecting through
the deck or astern of the deck and equal distant between the booms. The whole installation can then
be enclosed in a lift off canopy for ease of servicing. (See Fig 3). This is a relatively simple
installation which invariably requires the longer length leg. Method b) is that normally adopted by
production boat builders, where a fibre glass pod is mounted below the sternmost part of the bridge
deck and equi-distant between the booms, a pad is provided afl of the pod to accept the drive
mounting plate, the engine being housed within the pod, access being gained by a hatch on deck. (See
Fig 4)

METHOD a)

First ascertain the length of drive required taking into account height of bridge deck above water line
using the following method.

LENGTH OF UNIT REQUIRED = HEIGHT OF BRIDGE DECK

ABOVE WATER LINE + 400MM (16") MIN + ENGINE SUMP CLEARANCE
ABOVE DECK + HEIGHT TO GEARBOX OUTPUT FLANGE

Then construct a suitable mounting cradle either using marine ply laminated and hardwood engine
bearers, (minimum sizes 40MM /I$") mounting pad thickness - 3 0 0 W 1 2 " wide. Depth to suit,
Engine bearers 5 0 W 2 " thick.

The width of the cradle will depend mainly on the engine mounting centres. The drive mounting pad
should span the engine bearers, be amply reinforced and tied in by diagonals to the engine bearers
which should be cross braced in the middle as well as the ends. The whole cradle then being suitable
attached to the bridge deck using spreader plates if necessary to distribute the load if the deck is of a
light construction. We do suggest close consultation with Sillette and your boat manufacturer on
these points. Another method of construction would be to use a steel fabrication with
50~50~6MM/2~2x?h" ANGLE IRON BEARERS and 15MM steel mounting plate reinforced by
diagonal braces and ties.

The cradle can be mounted on the sternmost part of the deck, whereby the drive is fiee to tilt astern,
or alternatively (subject to confirmation from your boatbuilder) the installation can be brought
forward and the drive taken through a hold in the deck.

The size of which should allow for sufficient Aft tilt so as to clear the water when under sail.
2.
 METHOD b)

First ascertain input Centre Line in relation to bridge deck (which ideally should be below deck
level). Use the following method.

RELATIVE POSITION OF INPUT CENTRE LINE TO BRIDGE DECK =

HEIGHT OF BRIDGE DECK ABOVE WATER LINE + 200MM(16" )MIN - LESS 800MM OR
900MM OR 1 OOOMM OR 1200MM MIN DEPENDING ON MODEL.

A positive answer signifies this centre line is below the bridge deck. a negative answer above deck.

From this dimension and those shown in Fig. 1 & 2 together with engine dimensions one can sketch
out the size of pod required if not already part of your craft.

The pod can either be constructed of marine ply and glass over or can be of a fibre glass
construction to 250 grrn (802) lay up specifications with mounting pad bounded in to give a 40MM
minimum sandwich construction.. The whole pod being suitably attached to the underside of the
deck and an aperture cut in the deck to gain access to the pod for engine fitting and future
servicing. Bearers should be bounded into the pod at suitable height and centres to take your
engine, alternatively a Sillette mounting frame can be fitted, room permitting.

It has been suggested that a suitable sized dinghy be used as a pod, the transom of which could be
thickened to 40MM to accept the drive mounting plate, this could then save a lot of time.

Of course if the craft is already fitted with a suitable pod as in the case of Prouts, then the work so
far is not necessary.

The pod, or on deck mounting (Methods a and b) being completed, the following procedure should
be adopted. Having ascertained the crankshaft centre line height, mark in pencil on the mounting
pad, horizontal and vertical lines (see fig 2 points ak and bld) then position the template on centre
lines and tape in position. Proceed to cut out the 2 apertures with a jig-saw tool, and drill 6 holes
12MM (7116") diameter as shown on the template. It may be necessary to angle the tiller arm
aperture to afford the tiller its full arc. Remove the template and check the mounting face of the
pad is flat. Glue " 0ring supplied, into the drive mounting plate groove using "Super Glue7', say,
6" at a time. When finally attached, coat the sealing surfaces of the pad and the drive mounting
plate with "Selastic" or suitable waterproof mastic. Then offer up the drive unit and bolt in
position with six lOMM (8") stainless steel bolts fitted with mudguard washers on the inside,
ensure that there is plenty of mastic around the bolts to avoid future leakages and tighten evenly all
round.
Fit Sonic anodes to back plate mounting and propeller shaft thrust cap, if not already fitted.

Note for methods a) or b), an additional thrust pad should be provided below the mounting plate,
constructed of stainless steel bracketry and faced with a hard wood block positioned and shaped to
take forward thrust, in the following situations.

.80 mtr unit, motors exceeding 3 5HP Diesel

.90 mtr unit, motors exceeding 30HP Diesel
1 .OO mtr unit, motors exceeding 25HP Diesel

of course the 1.20 mtr unit is supplied as standard with a lower thrust support.

If in doubt contact Sillette or your local dealer.

 INSTALLATION DIETAILS

FIG 3.

an-
-'- -

METHOD A METHOD

On deck mountlng Pod mounted

 ii) STEERING

A proprietary push pull cable system can be used independent of the boom rudders either using a
separate helm wheel or a stick control type Morse D2 control with UD617 cable. The latter requries
the tiller arm to be re-drilled to accept a 150MM (6") stroke cable in lieu of the 230MM (9") stroke
used on conventional helms.

Either system is available fiom Sillette.

Alternatively the drive unit can be steered in conjunction with the boom rudders by means of a
connecting link to the boom rudder tie bar or tiller. The point of attachment must not exceed a 9"
linear movement to the drive tiller arm. Also the connecting link should have a universal swivel at
each end and must have a quick release facility for when the drive is tilted -
NB. The drive can not be steered when in the tilted position.

iii) REVERSE LOCKING - Manual lock and Auto lock

This is operated by a 33c cable to portside of the unit and attached to the drive by means of a clamp
& shim and by a stainless steel ball joint to the lever - for manual lock. Auto lock, needs only a cable
to release and is again a 33c type fed through the transom plate, sealed then with silicon rubber. The
outer cable being anchctiJjnboard by a clip bracket, whilst release action is achieved via 2 nuts
locked to the inner cable.

For both applications see sketches pages 25 and 26 in the handbook. Both cable kits and advice are
available fiom Sillette.

iv) E N G N COUPLING

Ensure that when positioning the engine, that it is directly in line with the drive flange. Adjustment
can be made by either packing under the engine mounting feet or by using adjustable mounts. The
engine must always be flexible mounted.

To couple the engine to the Sonic Catamaran drive, a double flexible coupling assembly must be used
(available fiom Sillette) with a two bolt fixing. This is bolted to the drive flange and to the flywheel
adaptor on the engine. (See Fig 1.).

To install engine, first bolt the double flexible coupling to the drive unit. Then lift the engine
complete with flywheel adaptor and flexible mounts into position and connect up the flexible
coupling. Line up the engine by eye, pack mountings as necessary or adjust to suit. Partially bolt or
screw down flexible mountings with suitable fasteners as per your engine suppliers advice. To check
alignment of coupling first view fiom above and fiom the side, adjust to give visual alignment. Then
measure using a packer and feeler gauge or similar) between the opposing bolt heads on each side of
the coupling whilst the heads are horizontal to each other, then rotate through 90" to a vertical
alignment. In all cases the gap should be identical when the engine is in line. Finally, bolt down
engine and re-check coupling tightness. Check alignment several times and adjust as necessary. Re-
check once the engine has run.

One final check is to measure between 1 set of 2 opposing bolt heads and rotate through 90" - 3 times
checking the gap at each 4 turn - This should not vary more than .01" - .25MM.

Follow your engine supplierdmanufacturersinstructions to complete your engine installation.

<
 v) PROPELLER

Having selected a suitable propeller for the craft (See Chapter 3). Check that the handing is correct
for the gear box you are using, remember the Sonic Catamaran Drive reverses the rotation fiom input
to output. To fit, first grease the propeller shaft with Duckhams 'Keen01 Grease'. Fit the spacer
followed by the propeller, then locate the tab washer on the splines. Whilst holding the tab washer in
situ, screw the nose cone fully home with a suitable wrench and bend back two locking tabs onto the
flats on each side of the nose cone.

vi) PRE-SERVICE CHECKOUT

Before launching.

Check all external screws for tightness. Remove oil filler/level plug and fill with oil to level using
Hypoid 90 oil. It may be necessary to squeeze the convolute gaiter to aid the oil flow into the
mounting plate housing, leave for 4 hour and top up as necessary. To check level, rest the head of
fillerflevel plug on the top cover and take a dipstick reading whilst the craft is level top up if necessary
and replace fillerAevel plug using 'Instant Gasket' to seal the threads. (NB. Use the correct size box
spanner for tightening filler plug - 25MM/lnAm).

Lubricate all external pivot points with Duckhams 'Keeonol Grease' and check for fiee movement of
all pivot points. Spray cable with 'WD40'. Check drain plug for tightness and re-check mounting
bolts. Finally visually check unit for any oil seepage.
After launching.

It is advisable to chock the unit into the full tilt position whilst launching, when in the water remove
chock and lower unit.

Having made all necessary engine checks start up engine in neutral, let engine reach running
temperature and adjust idling RPM as low as possible, consistent with keeping an even tick over.

With the craft safely moored, engage forward and astern gears, remember to engage reverse lock on
manual lock models, run in each gear for 5 to 10 minutes, check for any signs of oil seepage.
It is necessary to run in new oil seals to bed them in. Stop engine and re-check coupling bolt engine
mountings and alignment. With everything in order and other work being completed, proceed with
sea trials taking note of points in Chapter 3 and running in instructions in Chapter 4.

For the auto lock model it is necessary to power the unit into lock once lowered. For example with
craft safely moored lower drive unit, engage ahead and gradually increase r.p.m. until a click fiom the
lock is heard, switch off and ascertain it is safely locked down before re-starting and proceeding to
sea trials.
HINTS FOR TNE HELMSMAN 3

i) USE OF GEAR SHIFT

ii) STEERING CONTROL
iii) TRIM SETTING
iv) PROPELLERS
v) SEA AND ESTUARY

i) USE OF GEAR SHIFT

Avoid engaging gear whilst running at more than idle r.p.m. Remember to engage reverse lock
before attempting to go astern - preferably before throttling back if you have a remote lock fitted.
We suggest a small notice to this affect be placed in the cockpit for the novice helmsman.

ii) STEERING CONTROL

We do not recommend maximum power whilst the unit is on hll lock. Always throttle back, steer the
craft and apply the throttle to give a smooth turn. Also we do not recommend large additional rudder
area to be fitted to the Sonic Drive, as this causes excessive wear on the steering system.

Remember, if you drive unit is connected in Tandem with the boom rudders, it must be disconnected
when the unit is tilted, as damage will occur to the steering linkage.

If a remote steering system is fitted remember to keep in the ahead position when tilting the unit for
sailing.

iii) TRlM SETTING

The Sonic Catamaran Drive is designed to accept a mounting pad angle of 7" or 12O from the vertical
(see Fig 1) or 7" only for autolock models, adjust hlly in for a 7" pad and to middle hole for 12" pad.

Always ensure your craft is well trimmed as excessive bow weight will cause the unit to cavitate due
to lack of depth in the water. (see Fig I).

iv) PROPELLERS

The size of propeller you require will depend on the size of engine, gearbox reduction, design speed
of craft and tonnage. The diameter of the prop will match the engine size and output RPM whilst the
pitch will be calculated to suit the craft and power availability without overloading the engine.

It is very dficult in the first instance to prescribe the exact propeller with so many variants. The
results of the first propeller chosen may not be ideal, therefore it is often necessary to try out a second
size. The manufacturers are often able to assist in this exercise.

You may also find it an advantage to have two propellers, one for good weather and a prevailing
wind and one for bad weather conditions. The former having a coarser pitch than the latter.
 v) SEA AND ESTUARY

When using this drive unit for sea and estuary it is imperative that "Anodes" are fitted (a) around the
propeller and (b) to the mounting back plate. Contact Sillette for these accessories. If anodes are not
fitted serious corrosion will take place. Also ensure that the anodes make metal to metal contact and
are not insulated by paint, do not paint over the anode.

If anti-fouling is used on the craft it is important to use a copper free anti-fouling, MPX, otherwise
corrosion will take place. This MPX anti-fouling can be used on the Sonic drive unit.

Never run the craft at maximum r.p.m. for prolonged periods as this affects the lifeef both engine and
drive unit.

Never leave the drive unit in its down position if moored where the tide leaves moorings dried out.

The tilt can either be operated by a pulley block system, or the hydraulic lift accessory can be fitted.

Always ensure reverse lock is operative before going astern.

When input torques in excess of 10 KG MTR are used or lengths in excess of 800MM, or propeller
size over 14" diameter. The reverse r.p.m. should be restricted to half throttle, and caution observed
whilst on full lock, in either ahead or astern.

When going astern, remember if your Sonic drive should impact, there will be a potential for
structural damage to the drive. Likewise in a head especially with the auto lock model - remember
this is a sail boat auxiliary, built for sail boats not for tanks.

Always engage reverse lock (manual system) whilst manoeuvring in harbour, both ahead and astern.
When at sea apply lock before reducing throttle, otherwise leg will Sift off and the lock will be
inoperative.

Slamming of the drive leg must be avoided, likewise impact between drive leg and other objects. This
causes a potential for damage.

The yoke item 35 is the most vulnerable component to suffer impact damage, this item is usually the
first to fail, by design in most cases. In doing so it protects more expensive components. You may
consider this a useful spare part along with your onboard spares kit.
SERVICING 4

i) RUNNING IN AND FIRST SERVICE

ii) GENERAL SERVICING
iii) WINTERISING AND DE-WINTERISING

i) RUNNING IN AND FIRST SERVICE

a) Run the Catamaran Drive for at 20 Hrs at a maximum of 4 engine r.p.m. during the running in
period, i.e. 2500 maximum for petrol engines, 1500 maximum for diesel engines. This should be in
general use using both ahead and astern gears. After which the following service should be carried
out.

b) If possible slip or crane out the craft, if this is not practicable partially tilt the unit or work
between tides. Remove, drain and filler plug and drain off oil. Check condition for emulsification, if
heavily emulsified check cause and rectifjr, leave to drain for 4 hour and replace drain plug, refill with
fresh Hypoid 90 gear oil, leave for 15 minutes and check oil level by taking a dipstick reading with
fillerllevel plug, as previously described, whilst the craft is level. Top up if necessary and replace
fillerneve1plug, sealing threads with 'Instant Gasket'.

c) Check tightness of all bolts, screws, nuts etc.

d) Check tightness of coupling and mounting bolts.

e) Check all pivot points, latch reverse locking system for free movement and lubricate with
Duckhams 'Keenol Grease', applied with a paint brush.

f ) Check reverse lock or release cable and lubricate with 'WD40'.

g) Check steering for free movement.

h) Check unit for oil seepage, contact your agent if in doubt.

Refer to Fig 5 for details.

ii) GENERAL SERVICING

The normal periodic attention required is at intervals of 40 Hrs running or monthly. (Whichever is the
shorter period). However, we recommend a weekly check of the oil level and for signs of
contamination (a and b instruction).

Proceed as follows.
a) Remove dipstick and check oil level by resting dipstick on the top cover. Top up with Hypoid 90
gear oil if necessary.

b) Check oil for contamination, if this appears excessive, (i.e. the oil has emulsified, in which case it
will be much lighter in colour than fresh oil and thinner) ascertain cause and rectitjr. Replace filler
plug, re-sealing with 'Instant Gasket', if oil is found to be clean.
NB. Ideally the oil is best checked for emulsification when the unit has been run for 4 hour.

c) Check astern lock for correct hnctioning, either type and lubricate with Keenol grease applied
with a paint brush.

d) Lubricate Astern lock or release cable, with WD40 and Duckhams 'Keenol Grease', applied with
a paint brush. 9.
 e) Check paintwork for signs of damage. Repair and make good if necessary. Check visible zinl
anode for corrosion, replace if 4 corroded.

f) Visually check propeller for damage, if blades are chipped or bent the propeller should be repairec
or replaced, otherwise this will damage the propeller shaft bearings and cause vibrations which cal
lead to other damage.

g) Check steering linkage and lubricate all cables and links with 'WD40' and Duckhams 'Reeno
Grease'.

h) Check all fasteners for tightness. Check gaiters for damage and seals for oil leaks, rectifl i
necessary.

i) Check tightness of mounting bolts and coupling bolts - recheck engine alignment.

j) Check all linkages and pivot points for fiee movement and lubricate with Duckhams 'Keeno
Grease'.

NI3. Gearbox oil should be changed every 100 Hrs or at the end of the season.

Refer to Fig 5 for details.

iii) WINTERISING AND RE-WINTERISING

At the end of each season the Catamaran Drive unit should be winterised as follows.

a) Ideally, the craft should be out of the water over winter. If this is not possible, precautions shoulc
be taken against fieezing water conditions.

NI3. Freezing water conditions cause differential contractions with consequence of possible oil leak:
in the coming season.

b) In either case, drain the oil as previously described and'refil with a lay up or preservative oil
Check that there are no oil leaks fiom the unit.

c) Clean off any scale or weed that may be attached, repair any point defects.

d) Remove propeller and send away for repair if damaged.

e) Check anodes, if more than 4 corroded or powdery, replace.

f ) Coat all pivot points with Duckhams 'Keen01 Grease'

(

g) If the boat is on hard standing for the winter, ensure no weight of the hull is resting on the drivt
unit. If the boat is afloat for the winter tilt the drive. In both cases uirap the Transmission leg wit1
plastic sheeting, tie in place. Lash the leg unit in the full tilt position if afloat for the winter.

To De-Winterise, adopt the following procedure.

a) Unwrap the leg unit and check for any leakage.

b) Drain, lay up oil.

c) Check the propeller shaft for free play, if necessary rectifjl as explained in chapter 5.
In
 SERVICE CHART FIG. 5.

Instruction weekly 40 hrs yearly

1 Check oil level with dipstick filler
- 2 Remove dipstick and check oil for emulsification
1 3 1 Drain and refill with Hv~oid90 Gear oil I I 1 . 1
1 4 1 Check input shaft oil seal for leakage 1 I
5 Check prop shaft oil seal for leakage
6 Check visible anode for corrosion
7 Check prop shaft anode for corrosion
8 Check propeller for condition
9 Remove prop, check prop shaft, side play and runout
10 Lubricate astern lock cable with WD40 and Keen01 Grease
11 Check astern lock cable finction
12 Check gaiter for damage and seepage -
13 Check bolts, screws and fasteners for tightness
14 Check pivot points for fiee movement and lubricate with Keen01 Grease
15 Check paintwork for damage and repair if necessary
d) Rectie any oil leaks found at a).

e) Repeat as at c), d), e), g), h), i), j), under General Servicing (ii).

f) Replace propeller and tab in situ as previously described.

g) Replace drain plug, sealing threads with 'Instant Gasket',

h) Refill with Hypoid 90 oil, leave for 4 hour - re-check level, top up and replace fillerflevel plug,
sealing threads with 'Instant Gasket'.

i) Check oil seals for seepage.

Refer to Fig 5 for details.

 GENERAL INFORMATION 5

i) USE OF LOCTITE AND INSTANT GASKET

ii) PROPELLER SHAFT BEARING ADJUSTMENT AND SEAL REPLACEMENT
iii) INPUT SEAL REPLACEMENT
iv) REVERSE LOCK SET UP, ALL MODELS
v) CHANGING CV. BELLOWS ITEM 62

i ) USE OF LOCTITE AND INSTANT GASKET

(Both available fiom the manufacturers)

When fitting bearings, screws and fasteners, loctite must be used as follows: -
a) Degrease both mating parts with loctite primer 'T' or cellulose thinners.' Allow 5 to 10 minutes to
curddry.
b) Apply a minimal film of loctite bearing fit, or equivalent to one of the mating parts and spread
evenly over the contact surface.
c) Fit mating parts together and allow to cure for two to three hours without disturbing.

All jointing surfaces of your Sonic are sealed with Hematite 'Instant Gasket'. It is therefore,
imperative that these are re-sealed, should you have cause to break the seal.

Sealing procedure as follows: -

d) Thoroughly clean jointing surfaces and check for score marks.

e) Make up gasket if one was previously fitted.
f ) Apply 'Instant Gasket' to both surfaces and fit gasket, if required.
g) Fit the two mating parts together (do not hlly tighten, say, within 4 a screw turn), leave for one
hour to cure. Wipe off excess 'Instant Gasket'.
h) Finally, tighten down and trim excess 'Instant Gasket' with a knife.

ii) PROPELLER SHAFT BEARING ADJUSTMENT AND SEAL REPLACEMENT

REFER TO FIG.7.
a) Remove propeller.

b) Check for fiee play on propeller shaft (i.e. side movement).

c) Drain oil.

d) Unscrew 4 screws, (Item 87), and 8 screws, (Item 88).

e) Remove skeg, (Item 34), and propeller cap, (Item 38), a tap with hide mallet is required to break
seal.
f ) The prop shaft, (Item 1I), is then fiee to drop downwards complete with bearings and gear.

g) Check bearings for damage. Replace if necessary, polish-shaft (11) where seals have been
running. If worn by seals replace shaft.

h) It is advisable to replace the two shaft oil seals, (Item 53), at this stage, these are housed in Item
38 and should be driven out as a pair.
NB. They are mounted back to back.

h)i) Anode replacement is best carried out at this point, drift out through from seal side, clean up
housing, and top in a replacement anode. 13.
i) Clean seal housing and press in new seals back to back. Apply waterproof grease to O/D of seal
before fitting and to seal tips after fitting.

j) Remove gasket shims fiom behind flange of (Item 38) cap - clean up all mating faces, or add shim
between cap (38) and bearing (5 1).

k) Bind masking tape around splines of prop shaft and form a lead onto the sealing diameter. Slide
prop cap (Item 38) onto shaft (1 1) over tape.

1) Offer up to leg casting (Item 33) and check gap behind cap flange, (Item 38) and mating face with
bearings suitably loaded, using a feeler gauge. Then make up gasket shims to .005" more if shimming
between the cap (38) and bearing (5 1).

m) Refit Items 11 and 38, fitting shim gaskets and sealing with 'Instant Gasket'.

n) Tighten up screws (Items 87 and 88) evenly.

o) Lightly tap end of prop shaft (Item 11) to seat.

p) Check for any side play and that the shaft will turn with a slight resistance.

q) If side play exists, remove shim gaskets, .005" at a time and repeat m to p. If shaft will not turn,
add shim gaskets .005" at a time. The reverse will apply if shimming between cap (38) and bearing
(51).

In either case then repeat m to p.

r) Refill with Hypoid 90.

s) Replace propeller.

iii) INPUT SEAL REPLACEMENT

NB. Leaving unit in situ.

a) Disconnect flexible coupling fiom drive flange (9) and release engine mountings, move engine
forward 75MM13" and remove flexible coupling complete. Syphon out 1 ltr of oil from the Sonic
Drive unit through the filler plug hole.

b) Holding flange (9) from the turning, unscrew and remove nut and washer (75) and (76) using
15/16'' AF box spanner.

c) Tap flange (9) forward and out of housing.

d) Unscrew 4 Allen screws (80) and tap out retaining caplseal housing 43.

e) Press out old seal (52) using a 62MM/2 7/16" dia drift.

f ) Clean up seal housing and mating face of mounting plate (39).

g) Fit replacement seal (52) pressing in fiom outer face of seal housing (43) note correct way round,
(See Fig. 7) and leave seal flush with outside face, use Duckhams 'Keen01 Grease' to aid assembly of
seal to housing.
h) Apply Duckhams 'Keenol Grease' to seal lip (52) and apply 'Instant Gasket' to sealing face of
retaining caplseal housing (43) and re-fit using 4 Allen screws 80.

i) Polish seal groove in flange (9) with wet and dry, grade 380 and grease with Duckhams 'Keenol'.

j) With a colleague holding the CV Joint (46) in position through the gaiter (62) outside the craft,
refit the flange (9) first engaging the splines and finally tapping home with a hide mallet very carefully.

k) Refit nut and washer (75 and 76) and loctite in situ.

1) Refit coupling and re-align engine in position.

m) Top up drive unit with Hypoid 90 gear oil and replace fillerflevel plug (616) sealing threads with
'Instant Gasket'.

n) Bed in seal for 1 hour at 4 throttle and check for leaks, if OK proceed with normal use.

iv) REVERSE LOCK SET UP - MOST MODELS TO 1984

See sketch Fig. 6A for close up of locking mechanism. As standard, the pivot bracket assembly (62 1,
622, 623) is set up for a 12" mounting plate installation. 7" and 17" installations require the bracket
to be re-mounted either nearer or further from the craft along the lug of mounting plate (39), 9" either
side of the 12" mid position. It is advisable to have this pre-set by the factory prior to purchase,
however, should you require to do this at a later stage proceed as follows.

a) The unit being set for 12", it is necessary to convert for say, 7". First remove bracket assembly
(62 1,622 and 623) and disconnect stop cable.

b) Remove rest bar assembly (19,91 and 93) and refit in the hole nearest the craft.

c) Allow the drive to clip onto the new position. Offer up the bracket assembly (621, 622 and 623)
hinge the lock bar into the lock position as shown in Fig. 6B, leaving &" clearance to the top of the
latch (25). The bracket assembly should now be approximately 9"closer to the craft. Clamp the
bracket in this position with a suitable 'G' clamp.

d) Transfer the two mounting holes, drilling $" dia in the back plate (39), in line with the
counterbored holes in the bracket. Then tap $" UNC Allen screws and clean out threads.

e) Refit two 5/16" UNC Allen screws and loctite in position.

f) Reconnect and synchronise stop cable, repositioning clamp if necessary.

For a 7" mounting, repeat as above, only move bracket and rest bar further from the craft instead of
towards.

NB. Stop cable fitting instructions, either synchronised or remote are supplied with cable assembly
accessory from Sillette.
 iv) CONTINUED - MANUAL REVERSE LOCK. GENERALLY FROM 1984

Introduced in 1984 this lock system is mounted on the port side of the transom plate 39, it is possible
to convert to this system with the aid of engineering drawing for item 39, supplied when purchasing
the necessary conversion part; referred to as items 330-339, see page 25 for detail of the assembly.
The system is operated manually by a 33c cable, with 'T' handle conversion inboard which should be
mounted horizontally. A tube cut through on one side can be used to drop over the 'T' handle rod to
form a positive lock once pulled out by hand. The lock cable, 'T' handle and mounting accessories
are available from Sillette in a kit form. This lock system can be used with 7" and 12" mounting face
angles. The lock assembly being positioned to suit either 7" or 12" trim setting, see assembly drawing
on page 25 for detail. It is important that the correct mounting holes are used for each trim setting.
A shim is also provided for mounting between items 330 and 39 if necessary to limit the clearance
between items 332 and 25, for fine and necessary adjustment.

iv) CONTINUED - AUTO LOCK SUPPLIED AS AN OPTION FROM 1990

This system was introduced to avoid the helmsman forgetting to engage lock when going astern. It
to can be retrofitted to all models with the aid of a drawing. See page 26 for detail of the system,
which operates only in the 7" trim position, originally supplied to operate on the port side, as per the
above. During 1994 a double claw system was developed to handle larger engines, which the
boatbuilders wished to fit. To operate both systems the leg is lowered and powered into lock. From
which it is restrained at aU times until released by operations a 33c cable, and 'T' handle system,
which should be hlly depressed again once the leg is released and lifted. Please note the return spring
on the assembly cannot be relied upon to pull the 'T' handle home. This should be pushed in by hand.
Fitting of the cable system to the lock is clearly shown on page 26. Due to the number of moving
parts on this assembly it should be regularly checked for correct fhctioning and lubricated with
Keenol grease applied with a paint brush.

Im~ortant- Never work in close ~roximitvof the rotatine ~ r o ~ e l l e r .

v) CHANGING CV. BELLOWS ITEM 62

The above can be carried out either ashore or afloat the latter of course with more difficulty.
First drain down the oil to below the level of the Bellows via the drainplug or by siphon pump from
filler hole. Disconnect the steering linkage outside the boat either by removing pin No 17 retained by
a socket grub screw or disconnect at the ball item 29 by removing the ball cap item 27.

Disconnect tilt cylinder anchorage to the leg or tilt rope if fitted.

Whilst supporting the weight of the leg remove 2 pins No 14 which are retained by one or two $"
socket screws. Unclip the old CV Bellows on the leg side and slide the leg assembly sternwards
taking care to catch the floating connecting shaft NO8 within the CV. Bellows.

- Remove the old CV. Bellows 62 by removing the second clip. Thoroughly clean and degrease the
mounting diameters for the CV. Bellows. Fit new Bellows 62 to the Transom side first, largest
diameter to the Transom plate and tighten clip. Fit shaft N08; with assistance offer up leg to the shaft
- NO8 and slide home, re-fitting pins N014. Re-clip Bellows to leg side, re-fit all retaining screws to pin
N014. Re-connect steering linkage. TO^ up with oil, check for leaks. NB. Use Keenol grease when
replacing pins and socket screws.
-
HYDRAULIC TILT SUPPLEMENT 6

i) INSTALLATION
ii) OPERATING INSTRUCTIONS
iii) PERIODIC SERVICING

i) INSTALLATION

a) Attaching Hydraulic Ram to Sonic Drive. (If purchased separately).

First bolt rear pivot in position, (215, 213 and 212) on Transom plate lug (39), which is already pre-
drilled to drawing, using loctite as previously described. Ensure that the pivot anchor is square to the
centre line of drive unit when finally bolted in position.

Attach ram to rear anchor and retain with bolt and washer (21 1, 213). Align from pivot (214) to
piston rod with 2 - 3/32" diameter split pins. Then ensure that both pivots are parallel, position front
pivot to steering yoke (35) below life pivot centre line as Fig. 5. Then transfer the two holes from the
from the fiont pivot (214) to the yoke (35) - drilling first 5MM and then tapping $" UNC x f " deep.
Finally, bolt the front pivot (214) in position using 2 - $" Allen screws supplied, not forgetting to use
loctite as before. Refer to Fig. 8 for further information.

b) Applies to all applications.

Mount the hand pump in position using the 2 -,%" holes provided and ensure that there is sufficient
space for the hand lever to be operated through its full stroke. The pump should be mounted upright
in a position higher than the stern drive. If the position of the nylon filler plug on the pump reservoir
is in an inaccessible position, it is permissible to slacken the knurled cap on the bottom of the
reservoir and rotate the reservoir to a more convenient position, then tighten the knurled screw.

c) Route the flexible hose through the craft between the hand pump and the stern drive unit. Ensure
that the pipe does not pass around any sharp edges or in any position where it may become punctured
or kinked and then clip in position to avoid chaffing. Ensure that the hose passes through the
Transom at a minimum of 14" above the water line.

d) Remove the plastic caps from the hose end fittings, hand pump union and tilt ran union, then
connect one end of the hose to the pump and tighten firmly.

e) Remove the nylon filler plug from the reservoir and fill to the level with hydraulic power steering
fluid/ATF (This fluid is less damaging to paintwork than conventional hydraulic fluid and is suitable
for the seals in the system).

f ) Ensure that the lock and release knob on the pump is screwed closed. Operate the pump until fluid
is seen at the opposite end of the hose, then connect this end to the tilt ram union outside the craft
and tighten firmly.

g) Release reverse lock top up hydraulic reservoir and continue operating the hand pump until the leg
unit is half raised than slacken release knob $14 turn to allow the leg to lower itself naturally.
h) Close release knob and top up the reservoir.

i) Pump the leg to its full tilt position and lower as before.

j) Repeat the procedure twice more to remove most of the air trapped in the system. (if not, repeat
until clear).

k) Top up reservoir in the lowered position and replace nylon plug, clean away any excess fluid.

1) Ensure that the lock and release knob is closed at all times except for lowering the unit.

m) Smear a l l external pivot points, hose end and the piston rod when fully extended. Use Duckhams
'Keen01 Grease'.

n) Finally, fit vent pipe to the piston rod end of ram and pass through Transom into the engine
compartment at a minimum of 14" above water level.

ii) OPERATING INSTRUCTIONS

a) With craft at rest and drive unit reverse lock disengaged, ensure lock release knob is fully
tightened, pump the operating level approximately fifteen to twenty times to achieve full tilt, heavy
resistance will be felt when the leg has reached full tilt.

b) To lower, unscrew the locklreleke knob f/! turn and allow the leg to lower under its own weight,
check the unit is hlly down and close the lock release knob.

c) Do not raise the leg whilst the craft is underway. Do not attempt to raise the unit whilst in astern
gear. Do not hurry the pumping operation but maintain a steady and even pumping action. When
trailing do not rely upon the hydraulics to hold the unit up, always chock and rope the unit in
position. (This also applies to the manual tilt mechanism).

d) This tilt method is intended for maintenance purposes and fine weather sailing. For bad weather
conditions where slamming is encountered the drive leg should be lashed in the tilt position, to avoid
strain to the hydraulic components.

e) There is a secondary valve fitted to the right of the pump this should be closed once fully tilted to
avoid creep. Open again when lowering.
 -
ITEM DESCRIPTION lTEM DESCRIPTION
3 PROPELLER SHAFT GEAR 201 REAR CAP 607 CV SHAFT GEAR
4 VERTICAL SHAFT GEAR 202 CYLINDER BODY 608 CV GEAR SPACER
8 SPLINED CONNECTOR 203 PISTON 609 BALL RACE
9 INPUT FLANGE 204 BLEAD FllTlNG 610 HEX BOLT 318"
10 TILLER ARM 206 '0' RlNG 1" 611 WASHER ST STEEL 318" 0
11 PROPELLER SHAFT 207 '0' RlNG 15116" 612 41 + 17 STEERING LINK ASSY
13 SWIVEL PIN 208 '0' RlNG 1 114" 613 BEARING HOUSING
14 LIFT PINS 209 SPLIT PIN 3/32' 615 LID
17 STEERING PIN 210 ALLEN SCREW 5116" X 1" L 616 FILLER
18 TILLER PIN 211 HEX BOLT 318" X ll2" L 620 WASHER 3/8"DIA
19 REST BAR 212 HEX BOLT318"Xl 112'L 621 LOCK CASTING
20 LATCH PIN 213 WASHER 318" 622 ALLEN SCREW 5/18' X 314"
25 LATCH 214 FRONT PIVOT 623 PIN PIVOT LOCK
27 BALL CAP 215 REAR ANCHOR 624 LOCK CABLE HOLDER
29 STEERING BALL 8 STUD 626 216 MALE ADAPTOR 631 UPPER VERTICAL SHAFT 4
34 SKEG CASTING 217 DUST PLUG F 632 UPPER VERTICAL SHAFT 8"
35 STEERING YOKE 218 DUST PLUG M 633 EXTENSION CASTING 4"
38 PROP CAP 219 114" BALL 634 EXTENSION CASTING 8"
39 TRANSOM MOUNTING PLATE 220 RELIEF BUSH 635 LOCATION PIVOT
43 BEARING CAP TRANSOM END 221 RELEASE SCREW 636 EXTENSION CASTING 16"
46 TRANSOM CV JOINT 222 RESERVOIR 637 SADDLE
47 BALL RACE - 30 223 PICK UP TUBE 638 LOCKING BOLT
-
49 BALL RACE 40 224 PISTON GUIDE 639 CABLE SLEEVE
50 BALL RACE - 35 225 OUTLET 640 REVERSE CATCH
-
51A AC BALL RACE 30 226 SPACER 641 TOP VERTICAL SHAFT
518 TAPER ROLLER 30 - 227 RETURN TUBE 642 COLLAR
52 TRANSOM PLATE OIL SEAL 228 RELIEF SCREW 643 RETAINING PIN
53 PROP SHAFT OIL SEAL PAlR 229 HANDLE 645 LOCKING SCREW
60 cv CLlP 230 BODY 646 GREASE NIPPLE
61 TILLER CLlP 231 RESERVOIR BASE 647 PADS
62 CV JOINT GAITER 232 PISTON 648 SLEEVE SPACER
63 TILLER GAITER 233 3/16" BALL 649 CAP S C W X 1 3 / 4 "
64 314" DU BUSH 112' OR 314" LONG 234 '0' RlNG 1 5/8" 650 HEX NUT
66 ll2" HEADED NYLON BUSH 235 MAIN SEAL 651 VERTICAL UPPER SHAFT
67 3/4" NYLON WASHER -
236 '0' RING 114" 652 SINGLE AUTOLOCK
68 518" NYLON WASHER 237 NYLON PLUG 653 LATCH 7116"
70 BUMP RUBBER 238 PIN 1" 654 REST BAR 7116"
73 LATCH SPRING 239 PIN 1 114" 655 STOPS
74 NAME PLATE 240 SPRING 3/16" 658 NUT 114"
75 518" NUT 241 PLASTIC BALL 1" 657 WASHER 7116"
76 518" WASHER 242 PLASTIC BALL 1 112' 668 SHlM PLATE
T7 BOLT HEX 114" X 3/12" LONG 243 FIBRE WASHER 114" 659 DOUBLE AUTOLOCK
78 MUDGUARD WASHER 244 ClRCLlP 7/8" 660 SHlM MAT 72MM
80 ALLEN SCREW BLACK 114" X 3/4" 245 ClRCLlP 114" 661 TOP LEG CASTING .9 MTR
85 HAMMER DRIVE SCREW 246 BALL RETAINER 662 ALLEN SC HT 114" X ll2"
86 OWNERS HANDBOOK 247 BREATHER HOSE 663 ALLEN SC AZ 114" X 1 114"
87 ALLEN SCREW STAINLESS 114" X 314" LONG -
248 MAIN HOSE 12 FT 664 SHAKE PROOF WA 114"
88 ALLEN SCREW STAINLESS 114" X 1" LONG 249 ELBOW FllTlNG 665 SHlM MAT 62MM
89 GRUBSCREW STAINLESS 25Dl251 OPTION 1.251 GEARS PAlR SPIRAL BEVEL GEAR ITEMS
90 LOCK NUT STAINLESS 318" OR 112" 252 NOSE CONE SMALL SHAFT 700 PINION RH
91 318" WASHER STAINLESS 253 NOSE CONE LARGE SHAFT 701 PROP GEAR LH
93 118" SPLIT PIN 254 SPACER SMALL 702 INPUT GEAR LH
94 3/32" SPLIT PIN 255 SPACER LARGE 703 INSIDE ERG HSG
95 PAINT SPEC ETCH PRIMER 256 TAB WASHER SMAL 704 SPACER SLEEVE
AND TOP COAT 257 TAB WASHER LARGE 705 CSK WASHER
97 GASKET MATERIAL 8 SHlM 258 PROP SHAFT ANODE 706 BOlTOM VERT SHAFT
98 SEALAND 8 LOCTITE REPAIR KIT 259 TRANSOM ANODE 707 UPPER VERT SHAFT .8
99 DRAIN PLUG 330 332,334,339 8 331 MANUAL 708 UPPER VERT SHAFT .9
105 GRUBSCREW 5/16" X 318" LOCK ASSEMBLY LATE TYPE 709 UPPER VERT SHAFT 1.O
106 ALLEN SCREW STAINLESS 600 CONNECTING SLEEVE 710 UPPER VERT SHAFT 1.l
114 X 112" LONG 601 TOPLEG CASTING 711 UPPER VERT SHAFT 1.2
107 SONIC LABEL 602 BOlTOM LEG 712 CSK SC M i 0
113 LABEL SERIAL NO 603 EXTERNAL ClRCLlP 713 BALL RACE Q30
120 LARGE PROP SHAFT 17SP 604 TOP VERTICAL SHAFT 714 BALL RACE (2.875"
200 FRONT CAP 605 BOlTOM VERTICAL SHAFT 715 BALL RACE Q35
606 SINGLE VERTICAL SHAFT 716 WASHER 518"
 SONIC MK II CATAMARAN DRIVE

ACCESSORES

Nose Cone assembly including Tab Washer - Specify 12 or 17 spline type

Tab Washer - Specify 12 or 17 spline type
Flexible Coupling Kit including Bolts - Metalastic double type
Polymer type available as a spare part - Specify when ordering
Gearbox Adapter including Bolts for fixing to Rubber Coupling.
Prices on application. State Engine & Gearbox when ordering.

Propellers as listed (diameter x pitch) all three Blade aluminium with cushioned hub. Left or Right hand.

I 13"x14"- 12 spline I 14"x17"- 12spline 1 -

14"x15"- 17spline I 15"x15" 17spline I 16"x16"- 17spline I
13"x13"- 12 spline 14"x16"- 12 spline - -
14"x14" 17 spline 15"x14" 17 spline 16"x14" 17 spline -
13"x12"- 12'spline 14"x14"- 12 spline -
14"x13" 17 spline 15"x13" - 17 spline 16"x12" - 17 spline
13"xll"- 12 spline 14"x13"- 12 spline -
14"x12" 17 spline 15"x12" - 17 spline
13"xlO"- 12 spline 14"x12"- 12 spline - -
14"x11W 17 spline 15"xll" 17 spline
13"x 9"-12spline 14"x1lW-12spline 14"xlO"-17spline 15"x1OW-17spline
I 13"x 8"- 12 spline 1 14"x1On-12 spline - -
14"x 9" 17 spline ( 15" x 9" 17 spline I
I 14"x 9"- 12 spline
Anodes for Propeller Shaft and Transom Unit.

Transom Mounting Bolts.

Hydraulic Tilt Kit, hand hydraulic or electrohydraulic.

-
Manual release cable and fittings for Autolock systems Spec@ length of cable.

-
On-board Spares Kit standard or with yoke item 35.
On-board Tool Kit

Also available: -
1. -
Steering Systems Morse.
2. -
Gear Change Controls Morse.
3. Marine Conversion Parts, for most popular engines.
4. Marine Engines to order, Yanmar, Lornbardivi, Beta.
5. Complete Transmission packages, petrol or diesel.

For service and spares

SILLETTE SONIC LTD
182 CHURCH HILL ROAD
NORTH CHEAM, SUTTON
SURREY SM38NF UK
Tel0181-715-0100 Fax 0181-288-0742

Should you require any further assistance, advice or details, do not hesitate to contact Sillette.

The Manufacturers and distributors reserve the right to alter any specification, instruction or dimension without
prior notice.

Always remember this is a sailboat auxiliary propulsion system.