Service Manual Evinrude E-TEC 40-60 HP Midsection [Stern Bracket Manual Tilt Models]

Remove bumpers from the upper mount retaining screws.

1.Bumpers

Remove screws, upper mount, and ground lead from the bracket.

1. Screws
2. Upper mount
3. Ground lead

Slide the pivot shaft and upper thrust washer out of the swivel bracket.

1.Upper thrust washer

Using an appropriate tool, pry the upper and lower seals from the swivel bracket.

Loosen the steering friction screw while pushing outward on the steering friction pin. When the pin is flush with the inside surface of the casting, remove the steering friction thrust ring.

1. Steering friction screw

1. Steering friction pin
2. Steering friction thrust ring

Tighten the steering friction screw until the steer ing friction pin can be removed. Then, remove the steering friction screw.

Remove the two setscrews from the swivel bracket.

1. Setscrews

Drive the steering friction bushing up and out of the swivel bracket.

Remove the thrust rod from the stern brackets. Remove one tilt tube nut, and remove tilt tube from the stern brackets and swivel bracket. Remove the port and starboard stop link screws and nuts from the stern brackets.

1. Thrust rod
2. Tilt tube nut
3. Stop link screw and nut

Remove the two stern bracket flange screws and separate the stern brackets from the swivel bracket.

1. Flange screws

Place the tilt/run lever in the RUN position. Loosen the bellcrank set screw.

1. Bellcrank setscrew

Remove the tilt/run lever, port stop link, and bush ing from the swivel bracket.

1. Tilt/run lever
2. Port stop link
3. Bushing

Remove the starboard stop link retaining screw and nut from the swivel bracket.

1. Starboard stop link screw

Remove the cotter pins from both reverse lock pins. Remove the reverse lock pins and springs.

1. Cotter pin
2. Reverse lock pin

Remove the reverse lock assembly from the swivel bracket.

Place the reverse lock springs in the swivel bracket. Insert the reverse lock pins in the swivel bracket and part way through the reverse lock springs. Place the reverse lock assembly between the springs. Push the pins through the springs and the reverse lock assembly.

1. Reverse lock springs
2. Reverse lock pins

Install the washers on the reverse lock pins. Install the link spring on the port pin. Install the two cotter pins in the reverse lock pins.

1. Washers

1. Link spring

Install the bushing, the port stop link, and the tilt/run lever in the swivel bracket. The tilt/run lever should be in the RUN position.

1. Tilt/run lever
2. Port stop link
3. Bushing

Install the wave washer and the bellcrank on the tilt/run shaft. Tighten the setscrew.

1. Bellcrank setscrew

Install the starboard stop link on the swivel bracket. Install and tighten the screw and the nut to a torque of 144 to 168 in. lbs. (16 to 19 N·m).

1. Starboard stop link screw

Position the swivel bracket between the stern brackets.

Install the tilt tube through the following parts and install the tilt tube nuts loosely:

• Starboard stern bracket

• Thrust washer

• Bushing

• Swivel bracket

• Bushing

• Thrust washer

• Port stern bracket

Apply Nut Lock to threads of the two flange screws. Install the two screws through the star board stern bracket flange into the port stern bracket flange. Tighten the screws to a torque of 144 to 168 in. lbs. (16 to 19 N·m).

Tighten the tilt tube nuts 40 to 45 ft. lbs. (54 to 61 N·m), then back off 1/8 to 1/4 turn.

1. Tilt tube nuts
2. Flange screws

Install the thrust rod in the stern brackets.

Install the larger shoulder screw through the port stop link, wave washer, and port stern bracket.

Install and tighten the nut to a torque of 144 to 168 in. lbs. (16 to 19 N·m).

1. Port stop link screw
2. Wave washer

Install the smaller shoulder screw through the starboard stop link and stern bracket. Install and tighten the nut to a torque of 144 to 168 in. lbs. (16 to 19 N·m).

Install the large setscrews in the swivel bracket, one thread from being flush with the casting. Apply Ultra Lock to threads of screws before installing.

1. Setscrews

Place the steering friction bushing in the swivel bracket with groove in line with the setscrews.

Apply Triple-Guard grease to the steering friction pin. Install the pin in the swivel bracket flush with inside surface. The pin should point up.

1. Steering friction pin

Install the steering friction thrust ring, bevel side up, in the swivel bracket. Thread the steering friction screw in the swivel bracket. Turn the screw until the steering friction pin makes contact with top of the thrust ring. Do not tighten the screw.

1. Steering friction thrust ring

Install new upper and lower seals in the swivel bracket with lips of seals facing away from the bracket.

Slide the upper thrust washer on the pivot shaft. Slide the pivot shaft through the swivel bracket.

1. Upper thrust washer

Lubricate the swivel bracket through the four lubrication fittings with Triple-Guard grease.

Apply Nut Lock to threads of the upper mount to steering arm screws. Position the upper rubber mount, the upper mount washers, and the retaining washers on the steering arm with the word “UP” on the mount facing up. Be sure to place the ground lead between the mount (starboard side) and the steering arm. Install and tighten the mount retaining screws to a torque of 24 to 26 ft. lbs. (32.5 to 35 N·m).

1. Upper mount
2. Upper mount washers
3. Retaining washers
4. Ground lead
5. Retaining screws

Place the mount screw bumpers on the upper mount screws.

IMPORTANT: Tilt Assist Kit, P/N 5006139, may be added to manual tilt models to make tilting the outboard easier.

Tilt Assist Components

1. Cylinder assembly
2. Upper pivot pin
3. Bushing
4. Washer
5. Cotter pin
6. Lower pivot pin
7. Set screw (not all applications)

If the starboard stern bracket includes an access hole for the lower tilt pin, the cylinder can be serviced without disassembly of the stern bracket.

1. Lower pivot pin access hole

When servicing the tilt cylinder, the upper pivot pin is assembled as shown:

1. Bushings
2. Washers
3. Pivot pin
4. Cotter pins

Secure cylinder and lower pivot pin between the stern brackets.

If equipped, install a new set screw in starboard stern bracket lower pivot pin access hole and tighten securely

1. Lower pivot pin access hole