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1996 Evinrude 6 hp impeller change - HELP!

Old 04-02-2018, 01:41 PM
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Default 1996 Evinrude 6 hp impeller change - HELP!

Hi All,

The boat shop doesn't have time for months ... so I'm attempting to replace the impeller in my 1996 6-hp Evinrude 2-stroke. I haven't run it, and it's a very very low-hours motor, but it's been in storage for 10 years ... so, lower unit oil change and impeller is my plan before running it and gittin' fishin'....

I can't find instructions on the web. One guy, for a different year, said "Shift into Fwd, disconnect linkage under cowling, remove 3 bolts and drop lower unit off." Tried that ... and it seems like it almost worked. The lower unit drops 1/4" and there is no lower shift linkage disconnect like the older models to disconnect - theoretically, the top end of the shaft is splined and you can just wiggle it and drop the whole thing. No go. If I shift to reverse, it'll drop most of an inch and I can see the housing for the impeller and the hex-head screws that hold it in place (looks like a nylon cover). That's the best I can get ... the shaft goes 'clonk' like there's a pin or something keeping it from dropping entirely out, regardless of shifter position. There are NO plates or access points along the mid-section that might be hiding such a thing. The linkage under the cowling IS disconnected. Perhaps I just need to unscrew the impeller housing and replace it somehow? Dunno ... local marina has repair books, but of course, NOT the one that I need.

Can someone help?? Why won't the lower unit slide out?

Thanks in advance, Brian
Old 04-02-2018, 02:12 PM
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Don't know the answer but have you tried the local public library? It used to be that ours stocked the Glenn repair manuals and one would have a good set of instructions for whatever I needed to do.

Edit to add, there is a Youtube video of a guy doing it, but not sure if it's your year. But it shows a coupler along the shift shaft being accessed through that gap once you drop it down an inch - not like the older ones where you had the plate on the side.
Old 04-02-2018, 02:24 PM
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Originally Posted by ronp364 View Post
Don't know the answer but have you tried the local public library? It used to be that ours stocked the Glenn repair manuals and one would have a good set of instructions for whatever I needed to do.

Edit to add, there is a Youtube video of a guy doing it, but not sure if it's your year. But it shows a coupler along the shift shaft being accessed through that gap once you drop it down an inch - not like the older ones where you had the plate on the side.
Yeah ... thanks. I did watch that video (actually a 3-part series), but that's for an earlier model than mine. Mine, according to what I was able to find out, has no roll pin at the top of the shaft (it's splined?) and no shifter disconnect just above the lower unit. Unfortunately, the video(s) didn't help and I couldn't find one that covered my motor. That said, I did just find a book or two on Amazon for this motor and dropped $58 on the table to have 2 different (but similar) sent my way. For now, I'm leaving the partially disassembled motor hang off the stern as-is until I get more info.

Brian
Old 04-02-2018, 02:30 PM
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Here's an oldie on the subject - but this is for a 1986. However it implies it's just stuck and a penetrant and time will do the job.

1986 6 hp evinrude lower unit removal
Old 04-02-2018, 07:00 PM
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Originally Posted by ronp364 View Post
Here's an oldie on the subject - but this is for a 1986. However it implies it's just stuck and a penetrant and time will do the job.
Thanks, Ron. I wrestled it around and got it to drop about another inch. I sprayed WD40 clear up inside the mid-section and am letting it soak... sure hope I'm not wrecking anything trying to jerk the lower unit off....

Brian
Old 04-02-2018, 07:04 PM
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Here's the manual you need. You can't download it, but you can print it.

Boatinfo - 1990-2001 Evinrude Service manual
Old 04-03-2018, 03:54 AM
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Originally Posted by Mud Runner View Post
Here's the manual you need. You can't download it, but you can print it.
Thanks, Mud Runner. I think I'll need the whole printed manual ... I stumbled through enough to see that the lower unit SHOULD just pull straight down, but I had trouble with the flash interface in getting to the right pages and what not - I got lost and couldn't find the pages again, so couldn't print .... the index pages don't match the manual, but I REALLY appreciate the help! Amazon says I'll have my manual in the mail tomorrow .... and I'll call a shop today to see if they have any hints on how to free up a stuck drive shaft.

One step at a time! Those Kokanee are calling my name....

Brian
Old 04-04-2018, 06:40 AM
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LATEST: It appears that the shift rod is what is preventing the lower unit from dropping. Note that this little 6-hp motor has the shifter integrated in the throttle control - twisting in one direction both puts it into forward gear and opens the throttle and vice versa. Perhaps because of this, this motor might be different from others of the same model year. I read that these motors use a twisting shift rod to shift the lower fwd/reverse, but mine clearly goes up and down. Part of the shift rod is outside the mid-section of the outboard (below). I can move the motor up and down fairly easily now, unlike the first 1/4" or so where the lower unit resisted coming out and then came loose. I believe that was the splined driveshaft pulling out of the crankshaft (a good thing). Also, the lower can move up and down different amounts depending on whether you put it in forward or reverse, which also says it's the shift rod that's involved here. So, I don't see a way to disconnect the shift rod at the top, but believe it probably should be somehow disconnected at the bottom ... Anyone know how to do this? Here's some pictures and notes (the motor is camo-painted, FYI):


Here's the shifter under the cowling. The linkage (disconnected) is operated by the throttle. The shifter is the upright lever. I see no way to do any disconnecting here or on the bottom of the power head.



Upper end of the shift rod where it exits the power head and then enters the mid-section tube. It moves up/down when shifting. I don't believe that the collar (above) is retaining the shift rod ... it never strikes the shelf below it when you shift and/or pull the lower unit up and down... the travel is limited by something else (connection in the power head)




Here, the shift rod is shown entering the lower unit through the impeller housing. I wonder if this end should somehow be disconnected to let the lower unit come off???

Thanks, Brian
Old 04-04-2018, 07:23 AM
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What you refer to as a collar - can that be a connector, squeezing two different pieces of shift shaft together? Otherwise why is it there? I'd try removing that.
Old 04-04-2018, 07:42 AM
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Originally Posted by ronp364 View Post
What you refer to as a collar - can that be a connector, squeezing two different pieces of shift shaft together? Otherwise why is it there? I'd try removing that.
Hmmm... I definitely should try that. I ignored it because when I moved the lower up and down, the 'collar' never struck the metal shelf below it (that the shift rod passes through). But if it's a CONNECTOR instead of a stop-collar, then it could totally be the problem! This motor, with it's throttle-shift combo, is kind of an odd-ball and unlike standard-shift (side of powerhead) version of the same motor, it still utilizes and up/down shift rod movement instead of a rotating shift rod ... which is what the manuals cover ... well, from what I can see from the link above, but the Flash version of the manual is tough to negotiate. My printed manual should show up in the mail today.....

Thanks! I'll update as soon as I try taking the 'collar' off..... pix help!

PS: Looking at the pic above, I just realized something else (I'm thick-brained) ... that 'collar' pushes that big half-circle ring thing up when you shift into Neutral, and when that big ring is UP, you can tilt the motor up out of the water. When it's down, it prevents tilting the motor up - a safety feature to keep spinning props in the water. If that's all the collar is there for, then removing it may not help me. I'm hoping it's double-duty ... and is also a connector.

Brian
Old 04-04-2018, 08:05 AM
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That collar is there to prevent the engine from kicking up when the engine is in reverse. You'll have to follow the shift rod up to find the connector. Most likely under the carb.
Old 04-04-2018, 09:19 AM
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Originally Posted by Mud Runner View Post
That collar is there to prevent the engine from kicking up when the engine is in reverse. You'll have to follow the shift rod up to find the connector. Most likely under the carb.
Maybe that's what "disconnect the shift linkage" means in the (text only) instructions that I found on the web. I did look, but couldn't see a way to disconnect the shift rod on the top end, but will look again.... thx.

Brian
Old 04-05-2018, 06:10 AM
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Here's a little more info ... I won't get to work on this again until Sunday. My new manual did arrive, but was no help.

I'm still stuck on how to get the lower unit off, but have made progress, at least in knowledge. First, *MY* 1996 motor is *NOT* like others ... mine is a red-headed stepchild that uses the tiller to both open the throttle and to shift into forward or reverse just as you twist the handle off of idle. The standard side-shift motors, in 1996, have a shift rod that shifts the lower unit by twisting the shift rod rather than moving it up and down like the predecessors did. The Predecessors required disconnecting the shift rod (a brass clamp with a screw) down at the bottom near the lower unit. *MY* motor uses neither of these methods for how the shift rod connects to the lower unit (pix below). Right now, the lower unit is 'hanging' by the shift rod, and I know for certain that disconnecting it will release the lower unit to come out. The initial 1/4" drop, followed by release to 1-1/2" lower that I experienced was the driveshaft coming out of the crankshaft ... just a little sticky, but not bad. Somehow disconnecting my weird shift rod is next. FYI - My shift rod shifts the lower unit with in/out (up/down) movement, not the newer twist-movement shifting. I suspect that my lower unit is also a carry-on from this motor's predecessors, but the shift rod does not disconnect in the same way (the brass clamp w/screw at the bottom end).

1. As shown in previous pix of lower unit, the lower end of shift rod has no disconnect . There are no access plates or anything similar on the mid-section tube that might've been hiding a disconnect somewhere.

2. As shown in previous pix, there is a collar on the shift rod that for one, operates a lever that prevents the motor from rotating up when in reverse (a safety feature). This collar MIGHT be a disconnect - will find out this weekend.

3. The new information is that you can shift the motor, wiggle the lower unit etc, and see that the lower unit is clearly hanging by the shift rod - Disconnecting the shift rod is the last challenge that will allow the lower unit to come off. The picture below shows where the shift rod comes into the cowling underneath the carburetor .... It is raised and lowered, reverse and forward respectively, as you shift with by rotating the throttle. I've looked at both ends of the shaft that the lever is on, and can't for the life of me see any way to disconnect the shift rod here. If this *IS* the place to do it ... perhaps someone here can let me in on the secret:


Arrows show the movement that occurs when shifting. I sure don't see a way to disconnect the shift rod here!


Thanks,
Brian
Old 04-05-2018, 07:10 AM
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The area in green is your shift rod connection. Look at either end of the horizontal shaft. Most times it a matter of removing a "C" clip or a clevis pin. The connector in green slides sideways to release the shift rod.
Old 04-05-2018, 07:22 AM
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Originally Posted by Mud Runner View Post
The area in green is your shift rod connection. Look at either end of the horizontal shaft. Most times it a matter of removing a "C" clip or a clevis pin. The connector in green slides sideways to release the shift rod.
Who'd have guessed that? The axle that goes through the lever (in green above), if memory serves, has a bolt in the end of it on the other side of the motor. I wonder if I take that bolt off, that the axle shaft will slide over and release the shift rod? Wish I had time to jump right on this and try it out ... gotta wait for Saturday morning early, then we're heading out of town and I won't get to try again until Monday (my day off). I'll look for a C-clip or clevis too....


Thanks!
Brian
Old 04-05-2018, 08:51 AM
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Good Lord people .... This motor was on a little skiff that I've had in storage several hundred miles away from here for the last 13 years, which is why I'm putting in a new impeller. The motor's on the boat without the cowling and the cowling is on a shelf .... I've been thinking that I had a 6-hp Evinrude all this time and realized that I was wrong. (I'm embarrassed!) ... it is a Mercury! I have to go home and take a look at the cowling for sure, but I found an old pic on my phone of the manufacturer's label:



This would certainly explain why the manual did NOT match my motor when it comes to how to take off the lower unit, how to disconnect the shift rod etc .... I thought I had a b-tard child of a motor because of the weird throttle that shifts into forward and reverse automatically as you twist the throttle handle, but in reality the motor didn't match the manual not the other way around - someone smack me upside the head, please.....


Brian
Old 04-05-2018, 09:10 AM
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That does change things.

Take a look at this:

Around 1:45-2:00.

The camerman needs to lay off the caffeine, but it looks like in that diagram you posted showing the connection to the rod, the plate nearest the camera may hinge up like the one in the video? And then that lets you pull the pin out of the shift rod. This would imply there is no pin on the far end (which would be a nightmare if there was, because when putting it back in, it's going to miss and drop off into oblivion.)
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Old 04-05-2018, 11:05 AM
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Ron, thanks ... and yes, that looks exactly like mine, to a 'T'. I'm sure that I won't have any issues now... will report back when done (likely Sunday or Monday)... I just wish I hadn't just dropped $58 on the table for two brand new Evinrude manuals ... and I need to go back to the marina and get the right impeller too .

Brian
Old 04-05-2018, 11:37 AM
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If you can't return the books, there's always 'Amazon Marketplace' and sell them to someone. Good luck.
Old 04-05-2018, 01:12 PM
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I thought it was a Mercury, when you said it shifter with the tiller but I'm not there. Here's the info you need.


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