Dropping the lower unit for water pump

[perrycell]

I need to change water pump and seals for a 1961 5.5 hp evinrude.
I heard you need to remove the power head on certain units.
will this engine require removal of power head?
If so any advice on how to remove the extremely rusted bolts would be apreciated. Any suggestions on howto repair bolts if they bust?

 

[1946Zephyr]

Re: Dropping the lower unit for water pump

Yes, you do have to remove the powerhead on those. You should find 7 bolts securing it. You'll easily see the 5 on the rear half and there are 2 on the front corners kind of hidden in the lower cowl.
On that model, you'll also want to remove the throttle lever, choke knob, fuel line and both adjustment knobs from the carburetor.
Carefully lift the powerhead straight up and be careful to not destroy the driveshaft seal on the end of the drive shaft. Take careful note how it all goes back together. When you get your reseal kit, you should find the cork gasket, that goes against the bottom of the crankshaft.
As far as rusted bolts go? All you can do is hope for the best on a motor that's almost 50 years old. If any break off, you'll want to deal with those once the powerhead is removed. I believe those bolts take a 3/8" socket.
If they are rusted, it would be a good idea to replace them with new ones the same size and I would go with stainless if possible.

I hope this helps.

 

[F_R]

Re: Dropping the lower unit for water pump

Powerhead removal is required. Are they screwdriver slotted bolts or hex head? If screwdriver, a hand impact screwdriver is the outboard mechanic's best friend. The blade rotates when the tool is whacked with a hammer. You will only make matters worse by trying to get them out with a regular screwdriver.

If hex head, be sure to use a 6-point socket. If they are too far gone for that, sometimes a metric socket will work, if you are lucky. Otherwise, you are in for trouble.

Breaking them should be avoided. Heat, etc may help. If you do break one, oh well. Then you will discover the joys of drilling out broken bolts. Heli-coils are the outboard mechanic's second best friend. Drilling out screws is an art and skill learned only by much practice. You will mess up the first ones.

Replace the bolts with the CORRECT new ones from a dealer. NOT stainless, or you will be setting yourself up for even more problems next time.