1966 Evinrude Starflite V 75hp Reseal Lower Unit Advice

[malarky]

I have a 1966 Evinrude Starflite that has an obvious leak in a least one lower unit seal. Bought this from a guy that had not used it for two seasons. He said the LU had a "minor leak". Did a drain and fill of the LU with type C, and it clearly has water intrusion and its not minor. I took it to a boat ramp to do some test runs. Engine coughed and wheezed but it is running great now. I put it into gear and after about 10 minutes the engine labored while in gear and shifted very hard. I immediately shut it down, and inspected the LU fluid. Very milky. So now I need to reseal. Is this a job for a novice or best left to a pro? I love to boat- its a 1966 Glasspar with a great look to it, and the engine while old really adds to its classic appearance, so if possible I'd like to make it work.

 

[racerone]

Well --1965 was the last year for the model marketed as a 75 hp.----In 66 the same unit was marketed as 80 HP.----Your location ?-----It may not be easy to find a shop to take on work on these motors.------Some areas are blessed with a " grey mechanic " who will say " yes that can be done "

 

[F_R]

????Isn't your Starflite Electric Shift? So how is it "hard to shift"? Sounds like a major problem to me.

Model number is???

 

[malarky]

The PO, who owned it since 1985 stated it was a '65, but the title says '66. May have been manufactured in '65 and not title till the following year. As for the model, I need to get that. I have not had access to it in the last 24 hours.

Referring to the shift issue specifically, when I was referencing a "hard shift", I was referring to the feel as shifted from neutral to forward. When the LU oil is fresh, it shifts smoothly into forward and thrusts up to 1/2 WOT without issue (I was on a ramp and I did not go WOT as there were other park patrons trying to fish). After about 10 min of 1/2 WOT there was a significant labor on the motor before stalling. Shifting to neutral prevented this on subsequent tests and each time it shifted into forward it would labor significantly. Shifting while smooth early became quick jerky, very jerky after about 10 minutes as well.

There was clear evidence on the rear of the prop of gear fluid as well as drainage from one of the port side weep holes above the LU.

Here is the good news. I am in NE Ohio and after making a few calls yesterday found a mechanic willing to take a stab at it. He said most mechanics won't touch an outboard older than '90 and some older the '00. He put me in touch with a collector in Columbus who had a matching and working (and not leaking) LU. Picked it up last night and mechanic has a bay open this week. Collector was able to provide a repair manual for reference. Fingers crossed I can be on the water this weekend.

 

[racerone]

Likely nothing wrong with the lower unit to cause the " labor " issue of the motor.----I say the motor needs some attention / tune-up.-----Sounds like it may have been running on 2 cylinders.

 

[malarky]

I read on other threads here that water intrusion into the gear box could eventually seize the engine?

 

[racerone]

Well---yes if you get all water in there and run at full load then the motor would come to a-----" dynamic halt "----The trouble shooting is all up to you.----I can not see or hear your motor !

 

[malarky]

Got a model and Serial #
Model # is 75393E
Serial # is E03629

So when I google this it says I have a 1963?!! Could that be correct?

As for the water issue. The PO told me it did have a small prop leak, but regularly changed the fluid. But apparently not after his last outing 2 years ago. When I opened the LU drain, 1/4 or more liquid that came out was straight water, followed by very soupy/milky looking fluid. I am thinking this froze in the LU for two winters.

 

[F_R]

Yep, 1963

Not a diagnosis, but just a possibility, it could be trying to go into forward and reverse at the same time. That certainly would lock it up and likely destroy something--if it isn't already destroyed.

 

[malarky]

I was reading through the service manual and started to think the same thing. Unlike other Evinrude Electric Shift models, these do not default to forward- it has two leads, one engages forward and the other reverse, otherwise its in neutral. Perhaps the higher water content is causing a short.

 

[racerone]

Sorry----The water content has nothing to do with the shifting.-----I think there are issues with your motor.----Spark / compression or the carburetor.----One set of points may be bad / need cleaning and motor might be running on 2 cylinders.

 

[malarky]

Swapping the lowers on Thursday. I’ll post back the results.

 

[malarky]

Just to update this. I had the lower swapped out and the problem appears to be solved. Mechanic told me there was a significant amount of gear oil in the water pump and by his observance thought the driveshaft seal had failed. Ran with the new lower Thursday, Friday and Saturday.