1991 Evinrude 100hp gear case removal.

SnowDaddy

Recruit
Joined
Jun 4, 2012
Messages
5
Firstly, hello everyone, nice to find a forum like this, let me introduce myself...I am not really new to boating, but I am brand new to owning a boat, some say I have joined the mariners "Money Pit" but I don't care I am here and until I die or drown I am not leaving.

Now, my first problem, and I know this is going to make some of you groan, and those more sadistic will have a belly laugh, at my expense...so be it... this boat has been sitting by the side of its PO's garage for more than a year, with out being stored properly obviously, and or being started periodically, by some of the posts I have read here already, trying to research my immediate problem.

I have brought it home and cleaned all the canvas and algae covering the boat, looks real nice now. Then I attempted to get the motor started, with no luck... bought new battery, new plugs, a few minor parts that were missing from the throttle linkage, PO said to use a little starter fluid when trying to start it, a big no no to some in the boating community...but never mentioned to hook up the water hose to the water intake on the bottom of the motor.

Here is where the moaning and groaning will begin, I got it started, it was running really rough for a while, then it started to run nicely...and then, and then, this buzzer went off on the shift lever at the helm. I shut the motor off and called the PO to ask him what it was, see how new I really am to owning a boat... anywhooooo, hooked the hose to the thingy that goes over the water intake, and started again, ran it for a while, but the buzzer did not shut off, so I shut the motor off again.

The water did not seem to be going into the motor as it should, cleaned out the intake screen of minor debris, and it would still not take any water, it was just gushing out the side of the thingy, and the axle housing.

Called the PO and asked if he had any ideas, he suggested that I may have damaged the water pump, got my manual out and started to remove the gear case, to inspect and/or rebuild the water pump, followed all the instructions, but when I got all the bolts out, the unit separated from the mid-section but would not release or come out completely. Felt like something was holding it at the top. Went a little further into that manual, and it seems to me that from the illustrations, the top of the shaft locks into the power head.

Now my question is...how does that shaft release from the power head...I have experienced, from other types of mechanical repairs I have done, that there may be a locking clip or snap ring that will release when pried but I don't want to do any prying unless I am sure that is what is holding it. The manual cautions not to bend the shaft as it has dire consequences.

Another obvious question would be is there any more serious damage that could have occurred running it dry like that??

I hope someone here can be of some help, it would be greatly appreciated.

Thanks for taking the time to read and respond.

SD
 

boobie

Supreme Mariner
Joined
Nov 5, 2009
Messages
20,826
Re: 1991 Evinrude 100hp gear case removal.

Look under the lower carb on the port side and you will see the shift linkage attached to the shift rod. Remove that screw in the linkage and the shift rod will drop out. Go to shop.evinrude.com and look up your mtr and look at cyl/cc. You'll see the linkage. Then go out and get an OEM Factory Service Manual.
 

SnowDaddy

Recruit
Joined
Jun 4, 2012
Messages
5
Re: 1991 Evinrude 100hp gear case removal.

Look under the lower carb on the port side and you will see the shift linkage attached to the shift rod. Remove that screw in the linkage and the shift rod will drop out. Go to shop.evinrude.com and look up your mtr and look at cyl/cc. You'll see the linkage. Then go out and get an OEM Factory Service Manual.

I have a manual, and it doesn't describe things as simply as you do...nothing about removing the rod, just the pin.

Thanks, I figured it was something as easy as that, but when you don't know and your sitting there reading the manual, WTH are you supposed to do.

Thanks a heap for your input, will get on it first thing in the morning...

SD
 

SnowDaddy

Recruit
Joined
Jun 4, 2012
Messages
5
Re: 1991 Evinrude 100hp gear case removal.

Did you perhaps mean the starboard side, because there is no linkage on the port side of this particular motor.

here are some pics...boat motor 021.jpgboat motor 020.jpg
 

boobie

Supreme Mariner
Joined
Nov 5, 2009
Messages
20,826
Re: 1991 Evinrude 100hp gear case removal.

My mistake. Sorry! In your pic I can see the pin you have to pull and just slide the shift arm to port to unhook the upper shift rod. I guess I had a little touch of HUA.
 

SnowDaddy

Recruit
Joined
Jun 4, 2012
Messages
5
Re: 1991 Evinrude 100hp gear case removal.

OK...now I have a different problem...aligning the shift rod to the linkage up top...I may have turned the shift rod while working on the pump...and now I can't get the linkage to hook up. You would think that the manual would include instructions on re-assembly, instead of having to rely on "blind touchy feely" method.

Is there any "trick of the trade" to accomplish this task, and is the adjustment that precise? oops sorry, a Homer moment just overcame me. I am sure it is critical.

Any thoughts???

SD

BTW, what is HUA
 
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