Service Manual Evinrude E-TEC 40-60 HP Midsection [Cleaning And Inspection]

Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).

Clean all parts with parts cleaning solvent and dry with compressed air. All nut and screw threads coated with Screw Lock or Nut Lock must be thoroughly cleaned before reassembly. When using a thread locking product, be sure to prime the threads with Locquic Primer.

Discard all oil seals, O-rings, and gaskets.

Examine the rubber motor mounts and replace if deteriorated or damaged.

Inspect water tube for obstructions or kinks which may restrict water flow.

Inspect shift components for wear. Replace if deteriorated or damaged.

Inspect clamp screw assembly(s). Replace swivel plate and retainer if bent or loose. To install a new swivel plate, remove screw and old plate. Apply Locquic Primer to the threads of the screw and allow it to dry four to five minutes. Then apply Ultra Lock to threads. Install a new swivel plate with screw and tighten securely.

Before checking the exhaust housing for distortion, thoroughly clean the top and bottom mating surfaces and remove all sealer and corrosion.

Check the exhaust housing for distortion. Place the housing on a surface plate. Use a dial indicator to check flatness by measuring the run-out on the top edge of housing. The maximum allowable run-out is 0.009 in. (0.228 mm). If you do not have access to a dial indicator and surface plate, seek the services of a machine shop. DO NOT attempt to straighten a distorted housing; replace it.

1. Exhaust housing
2. Dial indicator

IMPORTANT: A distorted exhaust housing will cause upper driveshaft splines to wear excessively, and will also damage crankshaft splines.