INTRODUCTION

GENERAL
SERVICE
INFORMATION
FUEL
SYSTEM

".

IGNITION
SYSTEM
POWER
HEAD

LOWER
UNIT

,,,

ELECTRICAL
SYSTEM
MANUAL
STARTER

FOR EXCLUSIVE USE IN . . .

..
[....

...

EVINRUGE MOTORS DIVISION

OUTBOARD MARINE CORPORATION OF CANADA LTD. PETERBOROUGH, CANADA
OIJTBOARD MAR I NE CORPORAT ION 1975

LITHO U.S. A .

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12. 2. 1 7

Figure 5-19A. Cleaning Carbon From Lower

Ring Groove

)
12. 2.1 8

Figure 5-22. Checking Fit of Ring in Groove

Figure 5-20. Checking Piston Skirts for Roundness

Figure 5-23. Checking Groove Side Clearance

damaging the groove.
A tool for cleaning ring
grooves can be made by breaking an old ring, grinding an angle on the edge, and breaking the lower
sharp edge to prevent damage to lower ring land.
See Figure 5-19A. Check piston for size and roundness, using a micrometer . See Figure 5-20. Piston
skirt must be perfectly round and not scratched .
Correct sizes are given in Section 2.
Before installing new piston rings, check gap between
ends of ring by placing ring in its respective cylinder
bore, then pushing the ring down in the bore slightly
with the bottom of the piston to square it up . Discard and replace with new ring if gap is excessive.
See Figure 5-21. Check each ring in its respective
ring groove for evidence of tightness or binding by
rolling the ring around the piston ring groove. See
Figure 5-22. Check for groove side clearance with
feeler gage. See Figure 5-23. Correct gap and side
clearances are given in Section 2.

Figure 5-21. Checking Ring Gap in Cylinder

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5-9

Qi

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Grease Part Number 378642. Align notches in clutch

dog with detent balls in propeller shaft, Figure

g. Apply a fine bead of OMC Adhesive "M" to gear

housing pump plate surface, and place impeller plate
in position on gearcase. Install driveshaft in gearcase. Check gearcase for freeness.

6-18A.

' IIl'NOTE
If notches in clutch dog appear off center, ro-

tate clutch dog 180 0 on propeller shaft.

Slide clutch dog, groove forward, onto shaft and
center over the detent balls (neutral position), Figure 6-18B. This will prevent accidental movement
of the clutch dog during assembly and possible loss
of the detent balls and spring. Assemble oil retainer housing, washers, gears and bearings to the
propeller shaft in the sequence shown in Figure 6-18.
Bronze side of the reverse gear thrust washer must
face gear. Install propeller shaft and components
in gearcase with tabs on thrust washer facing up and
down. Place cradle and shifter lever in position.
See Figure 6-11.

53630

Figure 6-19B. Impeller Positions as Viewed from

Powerhead
Oil driveshaft and slide water pump impeller down
driveshaft aligning keyway with impeller pin. Install
impeller hOUSing, twisting driveshaft clockwise as
viewed from top to locate impeller vanes in proper
direction of rotation. See Figure 6-19B. Attach
impeller housing to gearcase with screws dipped in
OMC Gasket Sealing Compound and tighten to torque
specified in Section 2. Place new internal "0" ring
in crankshaft groove. See Figure 6-19A.

e. Apply OMC Adhesive "M" to seal groove. Seat

the new seal in the groove and cut with 1/32 inch
overhang at each end to obtain a good butt seal
against the oil retainer housing. See Figure 6-19.
Apply Adhesive "M" to upper gearcase and around
screw holes.
f. Attach skeg to gearcase with screws dipped in
OMC Gasket Sealing Compound. Tighten end screws
first. Install pivot screw and gasket. Check to make
sure seal is not pinched between gear case and skeg.
Tighten the remaining screws, starting at the center
and alternating from side to side progressively
toward the ends. Tighten to torque specified in Section 2.

GEARCASE PRESSURE TEST

To test gearcase sealing, proceed as follows:
a. Remove drain plug and screw in a pressure test
gauge. See Figure 6-20. Stevens Experimental pressure test gauge illustrated.
b. Pump pressure up to 3-6 pounds. Gearcase must
hold 3-6 pounds. If pressure gauge indicates leakage, submerge gear case in water to determine source
of leakage as evidenced by bubbles. If gearcase
pressure gauge does not indicate leakage, increase
pressure to 16-18 pounds. Pressure should also hold
at 16-18 pounds. If pressure does not hold, submerge gearcase in water and check for source of
leakage. Make necessary repairs and repeat test.
Gearcase must hold within the range of 3-6 pounds
and 16-18 pounds pressure.

OVERLAP

43 136

Figure 6-19. Gearcase Seal

43 156

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Figure 6-19A. Crankshaft Internal "0" Ring

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Figure 6-20. Pressure Testing Gearcase

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6-8

40/ 4

ii

1976 Evinrude 40HP outboards Service

Manual
This Service Manual includes the specific information you will need to Buy this Manual
service the motor. All general procedures are covered in abbreviated
form, mostly by reference to procedural illustrations.
The specific procedures which apply only, or primarily, to this motor are covered in fullyillustrated, detailed, step-by-step instructions.
Part No. 406447
Full factory workshop manual for this Vintage Outboard engine. Covers every aspect of
service and repair.
Manual covers the following outboard models:
- 40604
- 40605
- 40654
- 40655
Manual Chapters:
- INTRODUCTION
- GENERAL SERVICE INFORMATION
- FUEL SYSTEM
- IGNITION SYSTEM
- POWER HEAD
- LOWER UNIT
- ELECTRICAL SYSTEM
- MANUAL STARTER
Unlike aftermarket repair manual this is the Original service manual which includes all
information specific to 1976 40HP Evinrude Outboards.
This is NOT a Seloc or Clymer repair manual.

Buy this Manual

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