Service Manual 15-30 HP Powerhead [Powerhead Installation]

Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.plines.

Be sure water tube is placed in upper and lower grommets.

1. Water tube
2. Grommet

Slowly lower powerhead onto exhaust housing. If necessary, rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines.

Apply Triple-Guard grease to the threads of the powerhead screws.

Loosely install all powerhead screws before tightening:

1. Powerhead screws

Tighten the eight powerhead screws to a torque of 18 to 20 ft. lbs. (24 to 27 N·m) in the sequence shown.

Large screw torque sequence, 1 – 12

IMPORTANT: Retighten powerhead mounting screws after outboard has been run at full operating temperature and allowed to cool.

Place the upper shift rod in the shift rod connector. Install the retaining screw and lock washer. Tighten screw to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).

Install water screens.

1. Shift rod screw

Check shift linkage adjustment. Refer to Shift Linkage Adjustment on p. 189.

IMPORTANT: Make sure the gearcase shifts solidly into both forward and reverse and that propeller shaft spins freely in neutral.

Connect the power trim connectors. Secure cables in clamps.

Install recoil starter ratchet and housing on outboard. Refer to RECOIL STARTER INSTALLATION on p. 282.

Install the lower engine covers. Refer to Lower Cover Installation on p. 45.

Adjust shift linkage as follows:

STEP 1: Move shift lever into neutral position.

• Make sure shift lever detent is in neutral position.
• Make sure gearcase is in neutral.
• Loosen two shift lever screws.

1. Shift lever
2. Shift lever detent
3. Shift lever screws

STEP 2: Find shift lever midpoint.

• Move the shift lever forward to the limit of free play. Mark this as forward line on the neutral detent.
• Move the shift lever rearward to the limit of free play. Mark this as rearward line on the neutral detent.
• Measure the midpoint between the forward and rearward lines. Make a third line on the on the neutral detent. Mark this as midpoint line.
• Align the shift lever to the midpoint line.

1. Forward line
2. Rearward line
3. Midpoint line

STEP 3: Secure shift lever to shift lever detent.

• Remove one shift lever screw. Clean screw and apply Nut Lock to threads.
• Reinstall the shift lever screw.
• Hold shift lever on midpoint line and tighten screw to a torque of 80 to 106 in. lbs. (9 to 12 N·m).
• Remove remaining shift lever screw. Clean screw and apply Nut Lock to threads. Reinstall and tighten screw to a torque of 80 to 106 in. lbs. (9 to 12 N·m).

1. Shift lever
2. Shift lever screws

Adjust neutral switch. Refer to Neutral Switch Adjustment on p. 25.

After installing a new or rebuilt powerhead, perform the following procedures before returning outboard to service:

• Index all spark plugs. Refer to Spark Plug Indexing on p. 36.
• Use Evinrude Diagnostics software to start powerhead break-in oiling. Refer to Powerhead Break-In on p. 62.
• Use Evinrude Diagnostics software to make sure engine management software version and revision are current. Update as required.
• Use Evinrude Diagnostics software to confirm neutral switch operation. Refer to Neutral Switch Adjustment on p. 25.
• Prime fuel system.
• Prime oiling system. Refer to Oil Supply Priming on p. 150.
• Use Evinrude Diagnostics software to check engine timing. Refer to TIMING ADJUSTMENTS on p. 106.
• Run outboard and check for water, fuel, or oil leaks.
• Make sure engine reaches correct operating temperature and does not overheat.