Reply To: 1981 Evinrude 4.5 HP Bolt torque

[Don]

Yes, that engine is a little “over engineered” with the integral tank, crazy choke/tank valve control and that little fuel pump.  God forbid you want to add the option of using a remote tank,  another pile of crazy plumbing.

Change that gear lube often, like I say, those gearcases have a few unforgiveable engineering flaws, especially on tenders or sailboats that use reverse gear often.

The impeller housing water tube grommet is another way to get tricked on these things.   The little 4.5hp uses the same water pump kit except for one part, that grommet.  The little engines have a water tube with a narrow diameter, the larger 6-8hp units have a larger diameter water tube.  I’m thinking both grommets are included in the kit, but who knows these days.

The other problem area on this style is the crankshaft/driveshaft splines, they love to seize/rust.  It is critical to get these gearcases down every couple of years to clean and relube the splines, replace the oring (on models that use one).   The beauty part of this added service is it only takes a few minutes because there is no shift rod connector.  Just shift into forward and pull the gearcase down, be sure to lube up all the retaining bolts liberally with grease.

And yes, that gearcase cover is made of cheesy plastic, but to be fair, nothing would be much of a match for the power of salt when it builds up between the plastic and the metal sleeve.   This part should have been made out of aluminum.