Powerhead Mounting
Apply Permatex No. 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 and dry.
- Exhaust port
- Clean surface
- 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 Triple-Guard grease to the threads, and Gasket Sealing Compound to the shank of the powerhead screws.
Loosely install all powerhead screws before tightening:
- Powerhead screws
Tighten the eight powerhead screws to a torque of 18 to 20 ft. lbs. (24 to 27 N•m) in the sequence shown.
Large screw torque sequence, 1 – 10
IMPORTANT: Retighten powerhead mounting screws after outboard has been run at full operating temperature and allowed to cool.
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 screw
Check shift linkage adjustment. Refer to Shift Linkage Adjustment on p. 227.
IMPORTANT: Make sure the gearcase shifts solidly into both forward and reverse and that propeller shaft spins freely in neutral.
Apply Nut Lock to threads of exhaust water valve screws and tighten to a torque of 60 to 84 in. lbs. (7 to 9.5 N•m).
- Exhaust water valve
Connect cooling water hoses to exhaust housing.
- Overboard indicator hose
- Drain hose
Connect the power trim connectors and exhaust water valve connector (60, 65). Secure cables in clamps.
ROPE START MODELS
Install recoil starter ratchet and housing on out board. Refer to RECOIL STARTER INSTALLATION on p. 317.
- Starter housing screws (3)
Install the lower engine covers. Refer to LOWER COVER SERVICE on p. 82.
IMPORTANT: Perform the following procedures before returning outboard to service:
● Index all spark plugs. Refer to Spark Plug Indexing on p. 76.
● Adjust timing pointer and check engine timing. Refer to TIMING ADJUSTMENTS on p. 142.
● Use Evinrude Diagnostics software to start powerhead break-in oiling. Refer to Powerhead Break-In on p. 98.
● Prime oiling system. Refer to Oiling System Oil Supply Priming on p. 56.
● Run outboard and check for water, fuel, or oil leaks.
● Make sure engine reaches correct operating temperature and does not overheat.
Shift Linkage Adjustment
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. 280.
● Tighten adjustment screws to 60 to 84 in. lbs. (7 to 9.5 N•m).
- Adjustment screws
- Shift detent assembly
- Shift lever pin
- Trunnion pocket
- 7 inch dimension
