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Here’s a parts diagram for the 1949 model. This was a 1 year and done model for the last year of the Zephyr. I view the gearcase as the predecessor of the “weedless” gearcases on the 1952-1967 OMC 3 Hp motors. Quite different from the earlier Zephyr gearcase.
Improvise-Adapt-Overcome
Another thought / caution on Zephers in general. The close proximity of fuel and high voltage within the close confines of the front shroud have all the makings for FIRE. Be sure that there no fuel leaks. as for the potential of a stray spark… consider using short body spark plugs… why? The original style champion plugs had slightly shorter bodies than the modern equivalents. The longer bodies put the terminals closer to the aluminum front shroud.,, potential for a stray spark. Short body plugs of the correct heat range are available from both Champion and NGK. I like the NGK – BM7A… they seem to have the right heat range and also have screw-on terminal nuts.
Joe B
Good advice for sure. Regarding the screw-on terminals, this 1949 Zephyr has rubber spark plug boots and rubber coated wires like a 1950’s classic would have. I’m gathering that earlier models had open terminals like other motors from that time, but maybe someone can verify that. Did the pre-war 1941-1942 models also have cloth insulated wires? Regarding the fire danger from fuel leaks, that is a serious consideration with the sparkplugs and wires right up front with the carburetor and fuel lines. No amount of fuel leakage is acceptable here.
After disassembling and cleaning the fuel tank, it was noted that there was no tank filter. I thought it was missing, but the parts diagram I have does not show one. Is this correct? Do they rely on a filter internal to the carburetor and nothing more?
Improvise-Adapt-Overcome
Somewhere around 10 years ago, I bought this 1949 Evinrude Zephyr. Many projects were put ahead of this motor, but now it’s time to get it running.
From reading other posts over the years, the two things that I’ll be needing are the impeller and the primer cups. Both parts are out of production to my knowledge.
Is there an impeller in production that can be modified to work? Is there a substitute for the primer cups or something that can be modified? I recall old friend Mumbles made his primer cups using a lathe.
Improvise-Adapt-Overcome
Topic: Zephyr question
I picked up a pair of 4429 Zephyrs at Tomahawk with the intent of making one a runner and one for parts. These are the 1949 model, the only year with a rubber impeller. Can anyone tell me the part number and if they were used on other motors? Thanks
Topic: Question for Zephyr Guys
I am working on a Evinrude Zephyr M#4404. I found a drilling in the bottom of the carburetor. This drilling is lined up with a drain tube that looks like it dumps out behind the motor. The tube is not connected to the carb, is it suppose to be? I have a hankering to plug that hole off. Has anyone tried that? Maybe I need a small fitting and hose to replace the original. I sure don’t like a fuel leak under the front cover. Will try to send a couple pictures.
dale
