How to Remove Starter from 2009 Evinrude E-TEC 40 hp

Yes, we all know what a starter is, it is an automatic device used to start a machine, especially the outboard engine. Taking the starter motor off of a 2009 Evinrude E-TEC 40 horsepower outboard motor is a pretty simple task. Regardless, always refer to the engine’s factory service manual (on this page). The manual provides the same removal procedures factory trained technicians use when separating the starter from your boat motor.

Starter removal

There are a couple precautions you need to adhere to before taking off the starter. Number one, never attempt to clean the starter drive while the starter motor is currently installed on the engine. Doing so could cause the cleaning solvent to drain internally into the starter motor. This could cause dirt and gunk to wash into the starter bearings and its commutator. 

1. Make sure you unfasten the battery cables at the batter terminals.
2. Remove the engine’s lower motor covers and air silencer. If you are not sure you this is done, refer to “Lower Cover Removal” in the factory service manual.
3. Disconnect the (+) stater positive wire from the starter positive post.
4. Disconnect the (-) negative wire from the starter’s double-ended stud.
5. Lastly, take off the starter mounting screws (2) and the double-ended stud. At this point you should be able to remove the starter. See image 002293 for more information.

If you intend to rebuild the starter, make sure you refer to starter disassembly directions in the manual. The manual also list starter cleaning and inspection procedures as well as starter assembly and starter installation instructions. 

How to starters work?

When you turn the ignition switch to the ON position, the outboard’s starter motor is energized, and the electromagnet within the starter’s body engages. This intern pushes a rod outward to which the pinion gear is connected. The gear engages the flywheel and the pinion turns. This rotates the engine over.

At the same time the motor sucks in air and fuel while simultaneously sending an electrical current to the spark plug wires and through the spark plugs to ignite the fuel ink the combustion chamber.

When the engine turnover and begins to run the starter disengages and the electromagnet stops, and the rod retracts back into the starer. Lastly the pinion gear disengages from the flywheel.

Applicable models

These service procedures apply to all 2009 40hp, 50hp, 60hp, 65hp 52.7 cubic inch, 2-Cylinder Evinrude E-TEC models, including engines with model number...