'77 6hp Evinrude

[mfgniagara]

I was given a perfect running 6hp Evinrude the other day, it fires up and runs like new, has 115/111 compression and a ton of new parts on it. The coils are new, new water pump, new plugs, new prop, and new recoil rope and handle.
The guy that had it was getting it read to use on a small sailboat, but his son dropped it and broke the tiller handle off and the gear shift lever.
The motor side of the tiller pivot is shattered, and about 1/3 of the gear shift lever is gone.
I have a tiller or handle bracket, but need the shift lever.
My question is, Can you replace the handle without removing the power head?
The handle bolts to the top of the swivel pin with four bolts.
How much hassle is changing out the shift lever? Its usable as it is, but it's sharp, the part that's left is broken on a sharp angle, leaving only the forward part of the lever. I suppose I could bolt something to the remaining part of the handle to make work better. I was thinking of welding a rod to a plate and making a lever that reached forward a bit so it's easier to reach.

The handle has to be changed as there's no way to run the motor without it.

Is a 6hp worth the trouble? I had one of these years ago, a bit newer than this one and it was one of the best motors I've every owned. This one is in way better shape in that it's not all corroded up from saltwater. It's also a motor that starts with the slightest pull of the rope and runs perfect. I wouldn't want to disturb anything I don't have to for this very reason.

 

[oldcatamount]

Re: '77 6hp Evinrude

I think you do need to remove the powerhead to change the shift lever. That's not a real tough job although, there are some seals and a gasket under there that will need replacing. The seal is very important and should not be left out. I believe there are six bolts holding the powerhead.

 

[DJ]

Re: '77 6hp Evinrude

For parts go here: www.tcoutboard.com

 

[raczekp1]

Re: '77 6hp Evinrude

hi.to change shift lever is 1 hour of job.
take of the upper covling,
relase clip from arm acelerating magneto,
screw out slow speed needle,
take of bigger hose from fuel pump
put engine on the floor, lower unit up side up,
teke the key tool nr 7, 9,
lookin at engin from above you will see 6 bolts, unscreaw this botks,
tilt engin standing powerhead up,grab powerhaead and pull up
inf you will operate changing shift leaver in wise way you dont have to dissasemble lower unit from midsection.
under powerhead is one gasket, you can order this gasket or make it by yourself

 

[mfgniagara]

Re: '77 6hp Evinrude

Will the swivel pin and tiller mount or handle come off without pulling the power head?

 

[samo_ott]

Re: '77 6hp Evinrude

I have the parts manual for the '75 Johnson 6hp if you want it. Should be close but now sure how far ff it is. PM me with your email if so.

Removing the power head is easy. I would do it and replace the shift lever. I removed and replaced my '66 J20hp power head today to replace the base gasket that was leaking. And it was quick and easy. I also took the shifter out and replaced the O rings on it as it was leaking goop out the shifter. It's all easy to do. I'd recommend doing it right.

 

[mfgniagara]

Re: '77 6hp Evinrude

I found a parts break down and list online at BRP.com.
These motors look to be the same from about 1967 to the late 70's. The part numbers for the handle and the shift lever are the same over at least that time span on the 5.5 and 6hp motors.
My biggest concern is bolts being seized. It don't look bad but I've had other motors that were never near saltwater too with rusty bolts.

I guess I'll take a ride to the dealer and grab a few base gaskets and some shifter O rings, and maybe some paint to make the used handle and shift lever match.

 

[mfgniagara]

Re: '77 6hp Evinrude

I got lucky and found a seized up parts motor on CL for $25, I took the shift lever and handle from that motor. Both were in great shape and it gives me some other spare parts as well.
I went to the local dealer here and grabbed up a base gasket, two new mounts, and the O rings are no longer listed. I guess they have to come from a bulk O ring assortment now?
The gasket was $6, but I was there getting other parts as well. (Spent over $800 in all there but a lot of the parts were for a few other projects).

I'll get back to it on Monday after work now that I've got all the parts..

 

[mfgniagara]

Re: '77 6hp Evinrude

I hope to finally get around to the 6hp shift lever and handle swap tomorrow, the dealer made a comment about being careful about lowering the lower unit and aligning the pin that holds in the seal???
I unbolted the lower unit, disconnected the shift rod, and it dropped right down.
I don't see any pin or seal other than the pin for the impeller?
The parts break down he gave me shows a spring, seal, and some sort of pin up top? Am I missing something here?

In other words, what I took apart don't match the parts break down?
The motor is no doubt mid 1970's, the parts motor is a 1967, and I have a good running 1979, which looks just like this when it comes to the lower unit and drive shaft where it goes into the power head.
This motor still uses points, has the split case lower gear case, and both have the older larger diameter water pump impeller.

Do I need to replace the seal assembly? In the parts diagram, the parts I'm not seeing are numbered 1 through 8. The driveshaft on my 1979 doesn't even have a hole in it for a pin up top? The model number I assume this is is a 6705M.
The dealer figured that by process of elimination since the there is no tag on the motor.