Clueless, and Removing Exhaust Housing

[brettagostini]

I'm doing a total teardown on a 78 Evinrude 140. But I have no idea what I'm doing!! You're all going to get sick of me here very quickly.

I've removed the lower unit. I've mostly dismantled the powerhead. However, I can't seem to figure out how to get the powerhead and the exhaust housing separated, or in any other way remove the exhaust housing.

I've taken out every bolt I can find, but it is still attached firmly. It almost looks as if its glued together at the location I've taken the bolts out. Do they do that? Glue joints as well as bolt them?

Part of the problem is there is no mention, whatsoever, of this section of the motor in my Seloc manual. All about the lower unit and the powerhead, but not the big chunk of metal that connects them.

Help would be greatly appreciated. This motor and boat were my late dad's, and he'll come back and haunt me if I don't get it running!

Thanks.

 

[brettagostini]

Clueless, and Dismantling Power Head

Clueless, and Dismantling Power Head

I'm using a Seloc manual and a digital camera in an attempt to tear down and rebuild a long unused motor... a '78 Evinrude 140.

I'm now trying to get the crankcase cover off of the powerhead block. I've taken out the main bolts and all side bolts, but can't get the crankcase cover off the powerhead block. I've banged the crankshaft with a mallet like the manual says... no dice. The top separates about 1/16 of an inch, but it still seems like it is bolted together at the bottom, even though I can find no bolts.

Now, if I look underneath, I can see two bolts which appear to be coming OUT of the crankcase cover and protruding through the pan. But these are the threaded ends of bolts, not the heads. I don't know how, or if, I should attempt to remove these, and my Seloc manual doesn't mention bolts of this nature at all.

How do I get the crankcase cover removed from the powerhead??

Help would be greatly appreciated. This motor and boat were my late dad's, and he'll come back and haunt me if I don't get it running!

Thanks.

 

[Dhadley]

Re: Clueless, and Dismantling Power Head

Re: Clueless, and Dismantling Power Head

Are you saying you don't have the powerhead off the midsection yet? If that's the case -- STOP!!! Please don't hit anything else!

You have to pull the powerhead off the mid -- then remove the screws from the top & bottom bearing caps, then remove the taper pins. Remember, the pins drive out from the back to the front. Do not hit them from the front to the back.

 

[Dhadley]

Re: Clueless, and Removing Exhaust Housing

OK, try to keep everything in one thread. I get confused real easy.......

 

[brettagostini]

Re: Clueless, and Removing Exhaust Housing

Sorry... I was actually trying to make is simpler. Since I was asking to (seemingly) unrelated questions, I thought it would be easier to do two separate threads. I'll try and keep it in one thread from now on.

 

[HighTrim]

Re: Clueless, and Removing Exhaust Housing

Im going to take for granted that all the standard items are removed such as the starter, solenoid, air silencer, fuel pumps, carbs, intake manifold, flywheel, stator, timer assembly, all electrical component brackets, coils, cylinder heads and exhaust covers. After that there are a number of bolts and screws to remove, which should be covered in your manual. I find the original manual much better, compared to the SELOC. The shift rod has to be disconnected from the bellcrank. Power head ground lead on star side disconnected. You will then of course need a lifting eye to pull the power head up and away.

oops, typing at same time sorry, Dhadley is the man to help you out

 

[brettagostini]

Re: Clueless, and Dismantling Power Head

Re: Clueless, and Dismantling Power Head

That is correct. I DO NOT have the powerhead off the midsection yet.

I can't get it off!! I've removed every bolt I can find, but it is still as firmly and completely attached to the midsection as ever. There is no information in the manual specifically discussing how to get it separated from the mid section.

The manual talks about all the steps to take the crankcase off... but it never mentions that you you need to take the powerhead off the midsection first. I know that's one of those things that probably never gets said cuz "everyone knows that."

So, what do I do to get the powerhead off. I can't find anything else to unscrew or unbolt!

 

[brettagostini]

Re: Clueless, and Removing Exhaust Housing

Yep, I've done all those things. As I was telling Dhadley in my other thread... I've taken off everything I can. The when I crank up the lifting eye I just start picking the &$#&ing boat up off the trailer!!

 

[wilde1j]

Re: Clueless, and Dismantling Power Head

Re: Clueless, and Dismantling Power Head

You'd be better served with an OEM shop manual, which describes in detail the proper procedure to remove/replace the powerhead. You'll need it anyway for the correct procedure for removing the conn rods, pistons, bearing, etc.

 

[tashasdaddy]

Re: Clueless, and Dismantling Power Head

Re: Clueless, and Dismantling Power Head

keep your post together, please. i have merged both post.

 

[F_R]

Re: Clueless, and Dismantling Power Head

Re: Clueless, and Dismantling Power Head

Two nuts, front
two hex bolts front corners
6 long bolts, 3 on each side
two nuts, rear.

12 total....if I didn't miss any.

 

[HighTrim]

Re: Clueless, and Removing Exhaust Housing

I can envision your 12 FR, and Im not sure, but on my 76 there are also 2 exhaust cover screws port and starboard, and 2 lower motor cover screws and rear exhaust cover in addition to those, 16 in total

 

[F_R]

Re: Clueless, and Removing Exhaust Housing

You are talking about the two lower trim covers that hide all the bolts? I assumed he already had them off. But if not, well no duh he cant get the powerhead off.

 

[GeneH]

Re: Clueless, and Removing Exhaust Housing

Jim (5 posts above) is correct. You need to get the correct factory manual for your engine. The after-market manuals just don't have enough accurate information unless you really know what you are doing. They are better than nothing but not by much. Ebay is a good place to try and stop before you break something. If you don't use the manual for this part of the job, you will need it later. Good luck!

 

[brettagostini]

Re: Clueless, and Removing Exhaust Housing

Thanks for the input. Sorry to sound stupid!

OK, I've taken a second (20th!) look.

From about the pan, I've removed all wiring and fuel line tubing. The only bolts above the pan that seem to hold the powerhead in place are the four rubbermounted ones. I've removed these.

From beneath the pan, I've removed three small bolts at the front of the exhaust housing and two small bolts at the back. These are bolted in downward. I've also removed the six long bolts along the sides of the exhaust housing, bolted in pacing upwards.

I can't find anything else that seems to hold the midsection up, nor anything else that seems to hold the powerhead down, but I can't remove either.

Any ideas???

I know this may sound stupid, but there are definite seams visible with an unidentified substance hardened and oozing out. Could this be some sort of sealant that was applied in a liquid form that has hardened over the years and is acting like a glue?

 

[samo_ott]

Re: Clueless, and Removing Exhaust Housing

As everyone has mentioned, get the proper manual or there might be some haunting going on...!

 

[Dhadley]

Re: Clueless, and Removing Exhaust Housing

The 2 bolts thru the rubber mounts in the front (one on each side) are the only ones you need to remove. The 2 in the rubber mounts in the rear don't need to come out to remove the powerhead.

You'll have a bolt and a nut from underneith on each side at the front (going up). 2 nuts from under at the middle of the rear (going up). 3 bolts on each side going up.

The bolts you are removing (going down) do not hold the powerhead on.

 

[F_R]

Re: Clueless, and Removing Exhaust Housing

The seam/goo is between the powerhead adapter and the exhaust housing. Those two parts do not separate when removing the powerhead. The adapter stays with the exhaust housing. In fact, it the downward bolts you removed are the ones that hold the adapter to the exhaust housing, put them back in so you don't break that seal.

 

[brettagostini]

Re: Clueless, and Removing Exhaust Housing

The 2 bolts thru the rubber mounts in the front (one on each side) are the only ones you need to remove. The 2 in the rubber mounts in the rear don't need to come out to remove the powerhead.

You'll have a bolt and a nut from underneith on each side at the front (going up). 2 nuts from under at the middle of the rear (going up). 3 bolts on each side going up.

The bolts you are removing (going down) do not hold the powerhead on.

OK, so then I've got everything removed that needs to be removed. What steps then should I take if the powerhead still seems to be, for lack of a better word, stuck. Can I put some pressure on using the winch and tap somewhere with a hammer? Is there some trick to this?

Thanks guys.

 

[brettagostini]

Re: Clueless, and Removing Exhaust Housing

I've found this item on eBay:

"1978 Evinrude 85 115 140 HP Outboard Service Manual." Its not the Seloc manual, but the actual red and blue Evinrude service manual.

Is this what you are referring to when you say "OEM Manual?" (What does OEM stand for, by the way?)