Service Manual Evinrude E-TEC 40-60 HP Powerhead [Installation]

Apply Permatex #2 to both sides of a new base gasket around the exhaust port only. Install gasket on exhaust housing. To ensure proper sealing, mating surfaces must be clean.

1. Exhaust port
2. Clean surface
3. Moly Lube

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

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 threaded portion of the powerhead screws.

Loosely install the powerhead screws and exhaust housing to powerhead nut.

Torque the eight large powerhead screws 18 to 20 ft. lbs. (24 to 27 N·m).

1. Powerhead screws

Large screw torque sequence, 1 – 10

IMPORTANT: Retorque powerhead mounting screws after outboard has been run at full operating temperature.

Apply Nut Lock to threads of exhaust water valve screws and tighten 60 to 84 in. lbs. (7 to 9.5 N.m).

1. Exhaust water valve

Adjust shift linkage as follows:

• Loosen adjustment screws on shift lever.

• Be sure that ball is centered in detent assembly.

• Adjust shift lever so that the screw hole in shift rod lever lines up with the hole in the gearcase shift rod when gearcase is in neutral.

• When correctly adjusted, the shift lever will be parallel with the vertical line of the outboard, and the distance between the shift lever pin and
  the center of the shift cable trunnion pocket should be approximately 7 in. (17.8 cm).

IMPORTANT: The shift rod height is the most critical of these adjustments and should not be moved during this procedure. Refer to SHIFT ROD ADJUSTMENT on p. 272.

• Tighten adjustment screws to 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Adjustment screws
2. Shift detent assembly
3. Shift lever pin
4. Trunnion pocket
5. 7 inch dimension

Position the shift rod in the shift rod lever. Install the retaining screw and washer. Torque screw to 60 to 84 in. lbs. (7 to 9.5 N·m).

1. Shift rod screw

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

Connect the power trim connectors and exhaust water valve connector (60 PL). Secure cables in clamps.

Connect cooling water hoses to exhaust housing.

1. Overboard indicator hose
2. Drain hose

ROPE START MODELS

Place starter housing on outboard. Install the three starter housing screws and washers.

1. Starter housing screws (3)

Installation of lower motor covers will be greatly simplified if the following steps are performed in sequence:

• Install air silencer on throttle body.

• Place starboard cover on outboard and route fuel hose and battery cable through grommet notch.

• Insert trim cable grommet into port side cover.

• Connect trim/tilt switch connector.

• Place port side cover into position on outboard.

1. Battery cable
2. Trim cable grommet
3. Trim/tilt switch connector

Start the screw above the exhaust relief grommet first. Tighten just enough to hold the grommet in place.

1. Start this screw first
2. Exhaust relief grommet

Start the top front screw next and draw cover halves together.

1. Start this screw second

Install remaining cover screws and tighten all screws to 24 to 36 in. lbs. (3 to 4 N·m).

1. Cover screws

1. Top, rear cover screw

IMPORTANT: Perform the following procedures before returning outboard to service:

• Index all spark plugs. Refer to Spark Plug Indexing on p. 144.

• Use the Evinrude Diagnostics Software program to initiate powerhead break-in. Refer to Powerhead Break-In on p. 98.

• Adjust timing pointer and check engine timing. Refer to TIMING ADJUSTMENTS on p. 142.

• Run outboard and check for water, fuel, or oil leaks.

• Confirm that engine reaches correct operating temperature and does not overheat.