Service Manual Evinrude E-TEC 40-60 HP Manual Starter [Disassembly]

To prevent accidental starting while servicing, twist and remove all spark plug leads.

Remove the clamp holding the oiling system wiring harness.

Remove the three starter housing screws and washers.

1. Clamp
2. Starter housing screws (3)

Lift starter housing from outboard.

Wear safety glasses while disassembling and assembling manual starters because of rewind spring tension.

Pull the starter rope out far enough to tie a slip knot in the rope. Pry the starter rope anchor out of the handle. Remove the handle, release the knot, and ease the starter pulley back until the rewind spring is fully unwound. If necessary, remove the starter handle bracket from the starter housing.

1. Knot
2. Rope anchor

Remove the rope guide shoulder screw and guide from the starter housing.

1. Screw
2. Guide

Remove the nut from the starter pawl retaining screw.

1. Nut

Remove the starter pawl retaining screw, washer, and starter pawl plate with plate return spring from the starter assembly.

1. Screw
2. Washer
3. Plate
4. Spring

Remove starter housing spring and starter pawl with spring washer from the starter assembly.

1. Spring
2. Starter pawl
3. Spring washer (under starter pawl)

Using a screwdriver, pry open the pulley lock ring, and remove ring from the starter.

1. Lock ring

Remove the friction plates and friction plate spring washer.

1. Friction plates
2. Friction plate spring washer

Hold the pulley in the starter housing while turning the starter over, legs down. Hold fingers clear of the pulley and jar the starter housing against a bench to dislodge the rewind spring and pulley. Remove the pulley bushing from the pulley.