Service Manual 5007215_Evinrude E-TEC 200-250 HP Gearcase [Water Pump]

Disassembly

Rotate the driveshaft counterclockwise to unlock the impeller cam. Remove the four impeller housing screws.

1. Screws

Slide the water pump off the driveshaft. Remove the impeller drive cam, O-ring, impeller plate, and gasket. Discard the gasket.

1. O-ring
2. Impeller plate

Remove all the parts from the housing.

Inspection

Check impeller for overheating, hub separation, and other wear or damage.

Check liner and wear plate for scoring, distortion, and impeller material transfer.

Inspect the housing for cracks or melting.

Assembly

Apply a drop of Adhesive 847 in the seal ring groove at each of the four ribs.

Do not allow any adhesive to get into the air bleed groove in the impeller housing. If this groove is blocked by adhesive, the pump will lose its prime and will not pump water.

1. Seal ring groove
2. Ribs
3. Air bleed groove

Install the O-ring in groove in the impeller housing.

1. O-ring

Lightly coat the exterior of the impeller cup with Gasket Sealing Compound. Install the cup in the impeller housing.

Install the water tube grommet with the inside taper facing up.

1. Water tube grommet

Install the impeller housing cover and torque two screws to 24 to 36 in. lbs. (2.7 to 4.1 N-m).

Apply Adhesive 847 to flat side of the impeller housing grommet. Install the grommet, flat side down.

1. Impeller housing cover
2. Impeller housing grommet

Lightly coat the liner with Triple-Guard grease. With a counterclockwise rotation, install the impeller into the liner with the slot for the impeller cam facing out.

Run a thin bead of Adhesive 847 in the seal groove, and install the special shaped O-ring seal.

1. O-ring

Apply Gasket Sealing Compound to both sides of a new impeller plate gasket. Install the gasket and impeller plate.

Apply Triple-Guard grease to a new impeller O-ring. Slide the O-ring down the driveshaft and slide half way over installed drive cam to temporarily hold cam in place.

1. Impeller plate gasket
2. Impeller plate
3. O-ring
4. Drive cam

The sharp edge of the cam is the leading edge in clockwise rotation. Triple-Guard grease or Adhesive 847 can be used to retain the drive cam during water pump installation.

Slide the water pump down the driveshaft. Align impeller slot with the impeller cam. Rotate the driveshaft to engage the impeller cam with the impeller, and slide water pump down over cam. Be sure impeller cam does not fall out of position.

1. Sharp edge of drive cam
2. Direction of driveshaft rotation

Make sure the impeller engages the impeller cam properly. Serious powerhead damage will result if impeller cam is displaced.

Align the impeller housing with the gearcase. Apply Gasket Sealing Compound to threads of the four impeller housing screws. Install the screws and torque to 60 to 84 in. lbs. (7 to 9.5 N-m).

25 IN. AND 30 IN. MODELS

Place water tube spacer with grommet on the impeller housing cover.

TYPICAL

1. Spacer
2. Grommet

Before installation of gearcase on motor, shift rod adjustment MUST be checked. Refer to SHIFT ROD ADJUSTMENT on p. 290.

Check the shift rod height from the shift rod hole to the surface of the gearcase using Universal Shift Rod Height Gauge, P/N 389997.

With the shift rod and detent lever in NEUTRAL, rotate the shift rod up or down as necessary for correct adjustment. Once correct height is achieved, rotate rod one half turn or less to face offset forward.

The NEUTRAL detent is a two step design. Make sure the NEUTRAL detent ball is in the center step before checking shift rod height.

Shift Rod Heights