63' Evinrude 40 (40353D) Powerhead Assembly

[JJBoatr]

Hey all,

I've got my motor torn down to replace the crank, bad upper seal allowed the upper bearing to corrode which pitted the crank end beyond repair. I don't have a manual since this was an unexpected project so I was hoping someone could help me out with the following torque specs;
Connecting rod cap bolts
cylinder head bolts
Crankcase bolts (both 7/16" perimeter bolts and 9/16" main bearing bolts).

I really appreciate your help thanks.

 

[F_R]

I don't remember which rod bolts a '63 has. If you used a 5/16" 12point socket to get them out, the torque is 348-372 inch pounds. Head bolts are 168-192 inch pounds. Upper and lower crankcase bolts are 150-170 inch pounds. Center crankcase bolts are 162-168 inch pounds. small ones are 60-80 inch pounds. Flywheel nut is 100-105 foot pounds.

 

[JJBoatr]

I don't remember which rod bolts a '63 has. If you used a 5/16" 12point socket to get them out, the torque is 348-372 inch pounds. Head bolts are 168-192 inch pounds. Upper and lower crankcase bolts are 150-170 inch pounds. Center crankcase bolts are 162-168 inch pounds. small ones are 60-80 inch pounds. Flywheel nut is 100-105 foot pounds.

Thank you F_R, much appreciated sir. And my rod bolts are 5/16 head, sorry for not giving that info. Forgot there were different sizes.

 

[jimmbo]

I know F_R already gave you the info you asked for. Give this link a try, lots of info on your engine
http://www.fiberglassics.com/library...service002.pdf

 

[JJBoatr]

I know F_R already gave you the info you asked for. Give this link a try, lots of info on your engine
http://www.fiberglassics.com/library...service002.pdf

Thanks jimmbo. Additional information is always appreciated.

 

[JJBoatr]

I pulled the crank out of my 33 parts motor yesterday and it is in excellent condition. The connecting rod bearing surfaces still have cross hatching on them. If I do my part in assembling this motor correctly I should have a motor that out lives me. Can't wait to run a 40 on my little Crestliner, should be good fun

 

[JJBoatr]

any recommendations for assembly lube on the rods and main bearings? I usually just coat everything with 2-stroke oil ;is that good enough? Or, should I use some lubriplate? Thanks

 

[jimmbo]

If you use an assembly lube/grease, make sure it is not resistant to gasoline as it needs to be flushed out soon after initial start up. Mercury used to market an assembly grease, but mercury also used uncaged needle bearings on the piston pin and the grease was to hold the pieces in place. I believe the bearings on your engine are all caged. Generous/copious amounts of TCW-3 are all that are needed

 

[JJBoatr]

Thanks. I got it all together and running (twice). Gotta do some fine tuning today and hopefully take it out for a test run. I need to set my points with a meter because the idle is pretty shaky. One thing I noticed in this rebuild process is the low speed jet is very blunt compared to what I'm used to seeing. It was really rich at 1 turn out and I turned it in to about 1/4 turn out to achieve a stable idle. I thought maybe someone shortened the jet due to damage but it appears to be the factory shape. Any insight on this?

 

[jimmbo]

can you post a pic of the low speed needle? It should be quite pointy

 

[JJBoatr]

I looked it up, its supposed to be blunt like I described. Not as blunt as a high speed jet, but still more blunt than I'm used too. The picture of it on marine engine dot com is what I have.
Another question I have is with regard to the fuel pump. As I ran it on high idle (starting throttle) the glass filter bowl level dropped to about half full. Am I mistaken in assuming the bowl should always be full? I don't understand how it even stayed running with the fuel pickup as high as it is in the bowl. If I squeezed the primer bulb it would fill up but then the level would drop again. Am I being over paranoid? I'm taking it out tomorrow morning for its maiden voyage and would appreciate any information. Oh and my hot water choke works perfectly!!!

 

[jimmbo]

The glass bowls on our 63 40hp and 65 90hp were always like what you describe. They seemed to run fine

 

[racerone]

Nope.-----That filter / bowl is magic.----Motor will run all day long with that bowl appearing to be empty.---Or take the filter out as a test to see how it behaves then !

 

[JJBoatr]

Lol! "Magic" is the way I would describe it too. Thanks for the replies gents, I'm more at rest for tomorrow's test run now. I'll post results after I get back in the morning.

 

[JJBoatr]

Test run was a complete success! Wow that is a quiet motor! Had my 14" pitch prop on it and hit 29mph, but gps accuracy was pretty low so it might be faster or it might be slower. Either way I don't care because it gets on plane with some serious authority now. I don't have a tach in boat so I don't know what the motor was actually turning for rpm. It sounded good but I can't tell the difference between 4000 and 4500 rpm by ear. I couldn't be happier with how this motor turned out. Hats off to all that gave me the necessary assistance in re-assembling the power head. I'm going to upload a video on YouTube and post the link in here shortly.

 

[JJBoatr]

Idling out
https://youtu.be/lFptnXmGKT8

 

[JJBoatr]

Fly by
https://youtu.be/YPyeD9DXh98

https://youtu.be/ajLah7BtS0w