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1960 Evinrude 40 Need help with lower end

C

Cain B.

Guest
"I recently bought my first ou

"I recently bought my first outboard motor and I am having problems with the lower end kicking out of forward gear. I took it apart to check it out and noticed that there is a little bit of play in the forward gear and I think there might be a shim or spacer missing in there but I don't have any diagram to know what exactly I am missing. I also filed down the locking mechanism on the shift lever so that it is locked in forward. Upon taking her out for another ride the (bucking) popping out of gear was no longer happening for a while but then it started bucking again so I stopped and went to put it in netral and I broke the shift lever inside the motor. So now I have the power unit off and I jimmy rigged the shift lever and now I am trying to find a diagram of the lower end and there are no evinrude dealers within a 2 hour drive from here. ANY help or knowledge about the 1960 Evinrude 40hp Lark II is appreciated. Thank you. My email is [email protected]"
 
"Cain.... I'll get a diagr

"Cain.... I'll get a diagram to you later. For now, look over the following info.

(Jumping Out Of Gear - Manual Type)

This pertains to lower units on all OMC manual shift outboard engines, or any OMC engine with lower units defined as a Shift Assist or a Hydro Electric Shift unit which incorporates a "Shifter Clutch Dog".

Within the lower unit, splined to the prop shaft is what is most often referred to as a clutch dog, hereafter simply called dog. The dog has at least two lobes protruding from it on both ends, facing both forward and reverse gear. The forward and reverse gears also have lobes built into them near their center area. When the engine is running, in neutral, the gears are spinning constantly via the driveshaft being connected directly to the powerhead crankshaft, but the propeller does not turn due to the fact that the dog is centered between the two gears, and the dog lobes are not touching either of the gear lobes.

When the unit is put into either gear, shift linkages force the dog (and its lobes of course) to engage the lobes of the the gear. The lobes of the spinning gear grab the lobes of the dog, and since the dog is splined to the prop shaft, the propeller turns.

The lobes of the dog and gears are percisely machined, most with right angled edges that could be installed in either direction, and some with angles slightly varied that must be installed in one direction only (one end only must face the propeller). Dogs that can be installed in one direction only, if reversed, even if the dog and both gears were new.... would jump out of gear almost immediately. Keep in mind that the lobes are percisely machined with sharp angles!

Due to improper adjustment or worn shift linkages, but usually due to improper slow shifting, those percisely machined sharp edges of the lobes become slightly rounded. Now, with those lobes rounded, as the rpms increase, the pressure of the gear lobes upon the dog lobes increases to a point whereas they are forced apart (jumping out of gear), and due (usually) to the shift cable keeping tension on the engines shift linkages..... the unit is forced back into gear giving one the sensation that the engine has hit something, and the cycle continues.

Some boaters have the mistaken belief that shifting slowly is taking it easy on all of the shifting components..... Wrong! Shifting slowly allows those percisely machined sharp edges of the dog and gears to click, clank, bang, slam against each other many times before they are finally forced into alignment with each other..... and this is what rounds those edges off! The proper way to shift is to snap the unit into gear as quickly as possible.

Joe
"
 
I have a 1966 100hp evinrude.

I have a 1966 100hp evinrude. did not run for 15 yrs.I have since got it running but the ignition coil was bad and replaced with a lukus coil.Run's good until planes out and then starts missing until you back out of it a bit then runs ok.but when it get's hot it shut's down totaly if you leave it sit over night it starts right back up. The charging system is not working the bridge rectafire fuse is burnt.
 
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