Evinrude 40hk -90 reverse problem.

[Khajjan]

As the title says a 40hp Evinrude -1990 (E40EESR).

last summer I noticed that the reversed worked but "jumped" a bit when I pulled the throttle.

Now last week I was going to launch the boat and test drive, forwards it went well, but backwards I got nowhere.

So I picked up the boat and started googling and looking around a bit for help. Took the gear housing apart and thought I would measure the gear pin how long it was as I read that this could matter, but I can't find any information at all regarding my engine. The numbers I find there is no way I can adjust the pin to (404mm) for a short, and the closest I get is 425mm if I thread the pin in the bottom.

Finally found a guy who mentioned 429-431mm (check attached pictures), but according to my book it should be 404mm or 531mm?..

I'm a little bit aware that it could be the clutch dog that is bad, so that will probably be the next step in case this doesn't work, but would be grateful for all the help I can get before you take it upon yourself to tear apart the entire gearbox!

 

[racerone]

21 15/16" is the measurement !----And how are you measuring this ?----Set at 557 mm for long shaft.

 

[Khajjan]

21 15/16" is the measurement !----And how are you measuring this ?----Set at 557 mm for long shaft.

I took off The whole shaft and measured it, and its only 61.5~mm(24inches) and its connected at The bottom of The gear case so i have nothing near 21" on my measurement

I measure from the flat surface in the gear case to The center of The hole, like this pic, but i just did my own tool for it

 

[racerone]

Just stop-----The correct shift shaft height for your 1990 model is 21 15/16 for long shaft and 16 15/16 ( 430 mm ) for short shaft.------Are you measuring this in neutral ?-----Make sure you get this right.----These gearcases are not robust and mistakes are expensive.---And finding a used short gearcase for an 89 / 90 / 91 / 92-model will not be easy or cheap !!.----And yes , I know what the parts look like !

 

[Khajjan]

21 15/16" is the measurement !----And how are you measuring this ?----Set at 557 mm for long shaft.

I took off The whole shaft and measured it, and its only 61.5~cm(24inches) and its connected at The bottom of The gear case so i have nothing near 21" on my measurement

I measure from the flat surface in the gear case to The center of The hole, like this pic, but i just did my own tok for it

 

[Khajjan]

Just stop-----The correct shift shaft height for your 1990 model is 21 15/16 for long shaft and 16 15/16 ( 430 mm ) for short shaft.------Are you measuring this in neutral ?-----Make sure you get this right.----These gearcases are not robust and mistakes are expensive.---And finding a used short gearcase for an 89 / 90 / 91 / 92-model will not be easy or cheap !!.----And yes , I know what the parts look like !

I did post x2 lol, yeah i know, all books etc is saying what u just wrote but i just cant get it right.. Gonna take it off maybe tonight so ill take pictures so i can show what i mean, hard to describe

 

[Khajjan]

Just stop-----The correct shift shaft height for your 1990 model is 21 15/16 for long shaft and 16 15/16 ( 430 mm ) for short shaft.------Are you measuring this in neutral ?-----Make sure you get this right.----These gearcases are not robust and mistakes are expensive.---And finding a used short gearcase for an 89 / 90 / 91 / 92-model will not be easy or cheap !!.----And yes , I know what the parts look like !

Okey, so i maybe have short shaft If its 430, because that measurement is what i can get with my height, all those inches etc doesnt make sense to me (swedish) and tried to calculate on Google but its a mess 429-431mm is what i found on The internet, and when i assembled everything with 430mm on The shift rod it goes perfect in to The "gear select" beneath The engine

 

[racerone]

Your model number tells me it is a short shaft.----Did you measure this with gearcase in neutral ?

 

[Khajjan]

Your model number tells me it is a short shaft.----Did you measure this with gearcase in neutral ?

Yes, i pulled/pressed The shaft and checked IF it goes into gear by rotation The prop wich it did, then put it in the middle so The prop spin free, then I did The measure, but my biggest concerc is that The clutch dog is worn down, seems like a common thibg, but fingers crossed

 

[racerone]

Did you measure the 430 MM with the gearcase in neutral , yes or no ?-----You need to be specific and answer questions----You are about 6000 km away and I cannot set this to 1 mm for you.

 

[Khajjan]

Did you measure the 430 MM with the gearcase in neutral , yes or no ?-----You need to be specific and answer questions----You are about 6000 km away and I cannot set this to 1 mm for you.

Yes, gear in neutral, then took measure from bottom to center of The hole and measured in 430mm

 

[racerone]

If it does not shift into reverse with that measurement and shift cable is moving correctly , you have an issue in the gearcase.

 

[Khajjan]

If it does not shift into reverse with that measurement and shift cable is moving correctly , you have an issue in the gearcase.

Havevt tried yet with this measurement (unclear what it was when i took it apart ), and adjust The cable, but most likely The clutch, is it a big procedure? Im working as a mechanic for Volvo trucks so i know how to get myself around, just never did anything big with boatengines

 

[racerone]

Put boat in the water and test run.-----I doubt clutch is worn to not be able to get reverse.----And what book were you using ??-----And are you sure this book had measurements for 89 and newer models ??-----The 88 and older motors were different !!

 

[Khajjan]

Put boat in the water and test run.-----I doubt clutch is worn to not be able to get reverse.----And what book were you using ??-----And are you sure this book had measurements for 89 and newer models ??-----The 88 and older motors were different !!

Found online for 89 and forward om Evinrude 40hp, and also got a guy to send me a copy of his manual.

Will try and put The boat in the water and try, it goes in to reverse gear, but it jumps out of gear

 

[racerone]

Is cable adjusted correctly ?----Remove cable at the motor.----Put motor in neutral.-----Adjust cable to fit the motor.

 

[Khajjan]

I took it off yesterday, but when i got it out of The holder it was very off, so adjusted it, so i will try The engine in the weekend

 

[racerone]

Need to adjust the cable to match gearcase --In NEUTRAL ----with the rod set at 430 mm.

 

[Khajjan]

Need to adjust the cable to match gearcase --In NEUTRAL ----with the rod set at 430 mm.

Yeah i did that, gonna try it out

 

[Khajjan]

Took everything apart because i had The time and energy to do so, just in case i found something..

All The gears look fine, no worn down pieces or dsmsges, and The clutch looked like this (video) but dont feel that its worn down almost anything, not enough to make The reverse not to engage?

Could be bad quality of The video though...