POWERHEAD INSTALLATION
Apply Permatex No. 2 to both sides of a new base gasket around the exhaust port only. Install gasket on adapter. To ensure proper sealing, mating surfaces must be clean and dry.
- Inner exhaust area
Coat the driveshaft splines with Moly Lube. Do not apply lubricant to end of driveshaft.
Use Lifting Tool, P/N 396748, and hoist to slowly lower powerhead onto exhaust housing. If necessary, rotate flywheel in a clockwise direction to align crankshaft and driveshaft splines.
Apply Gasket Sealing Compound to the threads of all powerhead screws.
Loosely install all fasteners before tightening.
Tighten the 3/8 in. diameter powerhead screws to a torque of 18 to 20 ft. lbs. (25 to 27 N·m) in the sequence shown.
Tighten the 5/16 in. diameter powerhead screws to a torque of 144 to 168 in. lbs. (16.5 to 19 N·m) in the sequence shown.
IMPORTANT: Retighten powerhead mounting screws after outboard has been run at full operating temperature and allowed to cool.
Install two front and one rear powerhead nuts. Tighten nuts 144 to 168 in. lbs. (16.5 to 19 N·m).
- Front powerhead nut (2)
- Rear powerhead nut
Place the shift rod in the shift rod lever. Install the retaining pin and washer. Tighten pin to a torque of 60 to 84 in. lbs. (7 to 9.5 N·m).
- Shift rod pin
IMPORTANT: Make sure the gearcase shifts solidly into both forward and reverse and that propeller shaft spins freely in neutral.
Install water hoses and exhaust back pressure hose.
Cooling hose (from exhaust plenum)
Cooling hose (from vapor separator)
Speedometer hose
Cooling hose (to exhaust plenum)
Exhaust back pressure hose (to EMM)
Cooling hose (from block)
Route power trim harness through clamp and connect to engine harness.
Trim harness
Clamp
- Trim/tilt connectors
Install flywheel. Refer to FLYWHEEL AND STATOR SERVICING on p. 145.
Install air temperature sensor, air silencer, and fly wheel cover. Tighten flywheel cover screws to a torque of 30 to 42 in. lbs. (3.5 to 5 N·m).
- Air temperature sensor
Install the lower engine covers. Refer to LOWER COVER SERVICE on p. 89.
IMPORTANT: Perform the following procedures before returning outboard to service:
Index all spark plugs. Refer to Spark Plug Indexing on p. 82.
Adjust timing pointer and check engine timing. Refer to TIMING ADJUSTMENTS on p. 147.
Use Evinrude Diagnostics software to start powerhead break-in oiling. Refer to Powerhead Break-In on p. 104.
Prime oiling system. Refer to Oiling System Oil Supply Priming on p. 59.
Run outboard and check for water, fuel, or oil leaks.
Make sure engine reaches correct operating temperature and does not overheat.
