So....
I'm trying to be a good sailor and give my outboard motor some love. While it is pumping water just fine, I have never replaced the impeller so figure this is a good time to do it. I got the lower unit off; but the drive shaft stayed in the power head.
This. Is. Not. Good. It is well and truly stuck and I need, somehow, to get it out of the power head so I can install it properly in the gearbox.
A Google search results in a lot of crazy ideas for shaft removal. More than one suggests the shaft will probably not survive. I've got the motor upside down now and I'm gonna try and get some penetrating oil down the shaft. Maybe it will come out. I'm not in the mood to remove the powerhead. I'm certainly not in the mood to get a new motor. Especially since I just spend $147 on new parts for this one.
Clamp a pair of vice grips on the shaft (of course, no where near the waterpump seal) and tap on them until the shaft comes out. (I am sure I do not need to say tap on them down and away from the power head, but will anyway... just in case it is unclear). :)
It is unlikely you will damage the shaft in any real way... you can soak it in PB blaster where it goes into the power head for a bit before you start to tap if you want....
Good luck.
What year?
I have a 1979 Johnson 6 HP long shaft "Sea Horse" that when I ordered some parts for it, the guy I ordered from cautioned me on removing the lower unit. The way the drive shaft connects to the power head requires a 90 degree turn of the lower unit prior to disconnecting the shaft from the upper end.
I have no idea if this is relevant to your engine, but it was the first thing I thought of when I read your post. Johnson and Evinrude are close enough 'cousins' that I thought it worth mentioning.
I think Johnson and Evinrude are brothers. The motor is a 1994 8hp Yachtwin. I don't see any reason why I would need to turn the lower unit 90*. Certainly it wasn't mentioned in my manual.
I did the vice grip and tap thing. Didn't work. Right now I have it soaking in a 50/50 mix of ATF and acetone (because I happened to have both at home after the stores closed on Sunday, and because I read about it on another page). We'll see what happens when I get home.
Iirc, there was a pin in the end of shaft that had to be disengaged by turning shaft while engine kept from turning.
May not apply to your engine, though. It is quite a bit newer.
I bought a 9.9hp 2-stroke on ebay for $600 (there is an agreement for an inspection...just in case it isn't as advertised).
At least I'll get out sailing (NEXT WEEK). When I get some time I'll keep plugging away at the Evinrude. If I can get the stupid drive shaft out I'll sell one of the motors.