Re: Replacing Power Head in 40 HP Johnson
as said,Im sure you can do it,all the electrical parts can be removed in one piece ,work up toward the top of the eng.the stator and components under flywheel can lift off like a crown and all wiring except the starter which is too heavy,when you put back on the coils,solonoid coils will drape right into position.No special tools other than a torque wrench (inch pounds).The mounting bolts can be tough to remove ,especially if eng saw alot of salt water.a torch helps to heat the outside of the bolt passages.Best thing is to try removing using a 6 point wrench for best bite,if the bolt seems stuck,I have been lucky using MAPP gas and a torch tip that you can re-lite with a trigger.Heat and moving a bit one way then the other helps.I have found the best way is get a cheap air chisle,put a blunt tip I sometimes gut the chisle or pointed tip the sell and you have a round 3/8 punch.Put the air chisle on a low setting and vibrate on the head of the bolt,strait on the head,I have many times had the bolt back its self out under vibration.You will need to have a good machine shop knowledgable in outboards if you rebuild what you have.Or,buy a rebuild.IBOATS sells them.1900 is too much to pay to end up with a 92 40.I realize buying something used can be a gamble.But for 1500 I think you can get a decent ,probably newer eng.But if your eng is CLEAN,and you plan on keeping for a while,a remanufactured powerhead,you do lbor is not a bad idea.Be sure your carbs are nice and clean,rebuild is a good idea.They are easy.Carbs are mentioned because a lean run eng often is the reason for failure.
