'86 Evinrude 25HP Lower Unit Removal

[Ruler2112]

Last fall, my engine stopped peeing at low speed. I bought a water pump repair kit from here a few months ago and got a manual for my engine. I put off changing the water pump all winter because I've never done anything like it before and was more than a little apprehensive about it. The nice weather recently convinced me - I have to get this done.

So I read the appropriate section of the manual and followed the directions. However, as you guessed from my posting here, things did not go according to plan. I was finally able to get the bulk of the lower unit off, but for the life of me cannot seem to get the rods out of the engine itself so I can change the water pump.

I disconnected the shift shaft behind the water intake screen. The manual says to keep the plastic keeper between the two. There was nothing plastic between the two on mine. The reason there is a problem is that the nut on the end of the shift rod will not come off, which means it hits the back of the plate that the water pump housing mounts to.

I've attached pictures illustrating the way the engine sits now, as I probably couldn't follow what I've written here if I couldn't see it. The first shows the lower unit off. The second shows what is currently hanging out the bottom of my engine. The drive shaft is loose, but the shifter shaft won't budge. The last picture shows the nut on the end of the shifter shaft - this turns on the shaft, but will not unscrew. Either the shifter shaft needs to come off up top (which it does not say anything about in the manual) or this nut needs to come off to allow the shifter shaft to pass through the plate under the water pump housing.

I appreciate any advice or help.

 

[Cofe]

Re: '86 Evinrude 25HP Lower Unit Removal

In the second picture, grab the shifter nut half with a pair of pliers and move it up the shaft. Remove the plastic cone shaped keeper that was inside the nut half. The plastic keeper has a slit that runs vertical thru it. Use a fingernail or small screwdriver to open the split and remove.

 

[Ruler2112]

Re: '86 Evinrude 25HP Lower Unit Removal

That did it Cofe! Thank you so much for your help. My engine is now back together (except for the prop, which appears to have some really torn up rubber where it meets the engine). I plan on taking the prop to a marine store this coming week and asking if it's something to worry about.

This was the first time I've ever had the lower unit off any engine and I can safely say that this was the first time the water pump was changed on this 1986 engine - I was scratching the original paint off the bolt heads and nuts as I was removing them! While a little stressful, I learned a lot and it honestly went better than I expected.

 

[Cofe]

Re: '86 Evinrude 25HP Lower Unit Removal

Welcome to IBoats Ruler2112!
Sounds like you are learning to get to know your motor better. That's great!
Was glad I could help you out. This is a great forum to get answers on many boating questions. So jump on in.

 

[Ruler2112]

Re: '86 Evinrude 25HP Lower Unit Removal

LOL - 'getting to know' the motor is a relative term. I can disassemble a 4-stroke (lawnmower, snowthrower) to the valves and not have a problem, but 2-strokes are a different animal. Boat motors especially, with the transfer of power from the shaft to the prop, are a mystery to me. This is probably because I haven't tore one down to it's component parts and reassembled it, which I'll likely never do. (I really don't like boats and only own one so that I can have more options open for fishing effectively. )

I did find an online parts catalog that had an exploded view of my exact engine. iBoats REALLY beats them on price and I don't see where anybody could be better than the service I got, so I'll buy from and recommend iBoats to anybody who wants boat stuff. The exploded view of the gearcase of my specific engine was simply invaluable in trying to figure out where the 2 'mystery o-rings' that were in the kit I got here went. (A buddy of mine told me about the site when I was telling him about the o-rings; he called while I was trying to get it back together to give me a fishing report.)