Service Manual Evinrude E-TEC 40-60 HP Gearcase [Water Pump]

27 N·m). For adjustment, refer to Trim Tab Adjustment on p. 69.

1. Trim tab screw

Position the shift rod in the connector.

Install and torque shift rod screw to 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Shift rod screw

To prevent loss of operator control, check for proper shifting operation and adjust, if necessary.

IMPORTANT: During break-in period of a reassembled gearcase, change the gearcase lubricant between 10 to 20 hours of operation.

Disassembly

Remove the four impeller housing screws.

1. Impeller housing screws

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

1. Impeller plate
2. Drive cam

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.

IMPORTANT: 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 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. The cup locks in place in the housing with a square index tab.

1. Index tab

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

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

1. Impeller
2. O-ring seal

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

Apply Triple-Guard grease or Adhesive 847 to temporarily hold drive cam in place.

1. Impeller plate gasket
2. Impeller plate
3. Drive cam

The sharp edge of the cam is the leading edge in clockwise rotation.

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

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

Install the water tube grommet on the impeller housing.

1. Water tube grommet

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

Apply a thin bead of Adhesive 847 to groove of the impeller housing grommet. Install the grommet on the impeller housing.

1. Water tube bracket
2. Impeller housing grommet

IMPORTANT: Before installation of gearcase on motor, shift rod adjustment must be checked. Refer to SHIFT ROD ADJUSTMENT.