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    Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

    Adding photos...
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    Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

    Racer, yes detent is best way to describe the tactile feedback that is now missing when going into Neutral. Detent worked perfectly for several years when unbeknownst to me the Bushing and O-ring were missing. I confirmed it is a 3/16 ID with 5/16 OD O-ring that I installed. I can feel the...
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    Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

    I installed the Brass Bushing with O-ring underneath on the Shift Rod. Even with the Bushing installed as high as possible on the lowest dogleg bend of the Shift Rod there is a "sticky" action when i move the Shift Lever backward to Neutral position (backward pushes the Shift Rod downward)...
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    Gear Oil Everywhere

    Capt Bud, i lost sleep for a year over the black stuff that oozed out of my 2001 Johnson Oceanpro 90hp. My imagination concocted all manner of doom. Then eventually i saw the light and realized that these engines are DIRTY! It's just the nature of the beast, and maybe a main reason that...
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    Stuck water impeller stuck

    Photo is the 8hp impeller. I could see daylight between the metal hub and the rubber. I am certain the rubber was at least occasionally slipping around the hub. A good lesson to as to why the impeller should be changed every year or two. Changeout also assures all the bolts that secure Lower...
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    Stuck water impeller stuck

    In the past month I had this same situation on two motors--a 1990 4hp Evinrude and a 1998 8hp Evinrude. It was a little bit different because on both motors (admittedly much smaller than your 150hp) the rubber portion of the impeller had completely separated rom the brass/bronze hexagonal...
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    Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

    Crosbyman, ok I ordered parts, should arrive by Tuesday 3/23. I found the Bushing for only $10 including shipping--not so bad. Looks like a simple brass bushing with counterbore on one side (I'm assuming this goes underside to capture the O-ring which appears to be size #4). Thanks.
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    Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

    Thanks Oldboat and Racer. I did as you recommended and it worked-- but only after I placed the Gearcase (minus the Driveshaft, WaterPump etc) into the Midsection and worked the Gearshift Lever back and forth (Neutral/Forward--this has no Reverse) a couple times. Then I was able to fully insert...
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    Driveshaft into Gearcase 1990 4hp Evinrude E4RESR

    Recently in order to remove a stuck Impeller from Driveshaft (which I did so with lubricant, heat and tapping with visegrips) I had to pull the Driveshaft out of the Gearcase. Driveshaft will not go back into Gearcase. Normally I would remove #3 Bearing Housing Assembly 391171 from the Gearcase...
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    Removing Cylinder Head 1960 18hp Lightwin.

    Thanks Racer, that is what i was thinking too. I am quite sure this engine was stored in a garage or shed (where engine would not be exposed directly to rainwater). However any residual brackish water around the bottom/inside of exhaust tube could trickle back down into the exhaust manifold...
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    Removing Cylinder Head 1960 18hp Lightwin.

    Thanks All for the input...still working to take the carb and reed plate etc off. Meanwhile i ponder what might have caused all this, particularly rust in the cylinders, one spark plug was rusted/seized until i soaked it 1 week. When my nephew delivered this motor to the pickup location it...
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    Bolts ?

    I hear the best heat to apply is "The Blue Wrench" oxy/acetylene torch. Car mechanics adage "if ya can't turn it then burn it". I don't own a Blue Wrench but just yesterday i got a stuck bolt out a lower unit by soaking it with multiple penetrants for about a week (this alone didnt work) then...
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    Outboard Painting

    So to avoid leaving humps i will remove all original paint. Do you use paint stripper (like methylene chloride or newer less toxic formulas) or something different as a paint remover?
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    Removing Cylinder Head 1960 18hp Lightwin.

    I used a heat gun, tried various pry points, tried whacking alternate sides with hammer handle. No go. But the putty knife and hammer worked great--i was surprised how intact the Gasket stayed. Now the bad news. Cooling channels look like engine was not flushed on a regular basis, if at...
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    Outboard Painting

    If i am painting an aluminum prop using either zinc phosphate bbn or Rustoleum self-etching primer do i need to sand down the entire prop to bare aluminum? There are some areas where the original paint is well adhered and almost impossible to sand off with SiC paper. I am trying to feather-out...
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    Removing Cylinder Head 1960 18hp Lightwin.

    F_R, thanks i will give it a try. I was unsure what areas of the Head are strong enough to use as a pry point.
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    Removing Cylinder Head 1960 18hp Lightwin.

    Working on this neglected locked-up motor for my brother in law. Lower spark plug was seized to head but came loose after 1 week soak with various penetrants. Much to my surprise the Thermostat Cover came off easily, although Thermostat is missing! Also surprised 8 of 10 Head Bolts came loose...
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    Head gasket orientation 1990 4hp E4RESR

    Thanks Crosbyman. I am starting a 1960 18hp Lightwin project where Alumiweld and/or JB Weld will be needed.
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    Newly bought Johnson 7.5

    Glad to hear Leeroy's is helpful, there is a ton of knowledge on his site.
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    Outboard Painting

    Update: i stopped by my nearest/reputable marine supply store last week. They are unable to buy/stock zinc chromate any more--can order zinc phosphate, though. Apparently paints containing hexavalent chromium are now banned/unavailable. Which leads to this question: would Ospho Coat...
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