5040122 EVINRUDE * PLUNGER, Choke Solenoid

The rack extension is connected to the lever on governor drive housing (2). Carefully remove the governor drive housing.1. Remove bolts (1), governor drive housing (2) and the gasket from the fuel injection pump housing. 2. Remove bolts (4) and support (3) from the fuel injection pump housing. 3. Remove gear (5) from support (3). 4. If necessary remove dowels (7) and bearing (6) from support (3).Install Governor Drive Housing (Woodward)
1. Use tool group (A) and install dowels (1) in support (2) 3.81 0.508 mm (.15 .02 in.) above the outside surface.2. Remove plug (3) from support (2) so that bearing (4) can correctly be installed.3. Use tool group (A) and install bearing (4) even with the outside surface of support (2) and the oil supply hole in the bearing centered in the hole of the support.4. Install plug (3) in support (2) and tighten the plug to a torque of 4.5 0.6 N m (40 5 lb.in.). 5. Put gear (5) into position in support (2) as shown. 6. Put support (2) in position on fuel injection pump housing and install the bolts. 7. Put gasket (8) and governor drive housing (9) in position on the fuel injection pump housing. Make sure rack extension (6) is installed in the fork of lever (7).END BY:a) remove governorDisassemble Governor Drive Housing (Woodward)
START BY:a) remove governor drive housing 1. Loosen nut (3) and remove lever (1) and the key from the shaft.2. If necessary, remove linkage (4) from lever (1).3. Remove stud (2) from the shaft. 4. Remove bolt (8) and plate (7) from the governor drive housing.5. Remove the wire, bolt (5) and cover (6) from the governor drive housing. 6. Remove switch (9) from the governor drive housing. 7. If necessary, remove lock (11) and nut (10) from switch (9). 8. Remove pin (12) and, if necessary, dowel (13) from the governor drive housing. 9. Bend lock (17) away from bolts (16) and remove bolts (16), shaft (14) and plate (15) from the governor drive housing. 10. Remove ring (18) from the shaft. 11. Move lever (22) away from the spring so it is disconnected from sleeve (21).12. Turn shaft (19) so bolt (20) can be seen for removal as shown. Remove bolt (20). 13. Remove shaft (19), sleeve (21), spring (23) and lever (22) from the governor drive housing. 14. Bend lock (26) away from bolts (25) and remove bolts (25) and plate (24) from lever (22). 15. If necessary, remove bearings (27) and dowel (28) from the governor drive housing. 16. If necessary remove seals (30) and bearings (29) from the governor drive housing.Assemble Governor Drive Housing (Woodward)
1. Use tool group (A) and install bearing (3) in the governor drive housing to a diameter of 72.14 mm (2.84 in.) from the inside face of counterbore (1) to inside face of bearing (3). Make sure the bearing is pushed on the stamped side only.2. Use tool group (A) and install bearing (5) in the governor drive housing to a dimension of 130.56 mm (5.14 in.) from outside surface (2) of the governor drive housing to inside face of bearing (5). Make sure the bearing is pushed on the stamped side only.3. Install dowel (6) in the goveror drive housing to a dimension of 28.45 mm (1.12 in.) from inside surface (4) of the governor drive housing to the end of dowel (6). 4. Use tool group (A) and install bearing (7) in the governor drive housing to a dimension of 13.46 mm (.53 in.) from the inside face of counterbore (1) (see picture B65771X1) to the inside face of bearing (7). Make sure the bearing is pushed on the stamped side only.5. Use tool group (A) and install bearing (10) in the governor drive housing to a dimension of 14.73 mm (.58 in.) from outside surface (2) of the governor drive housing to inside face of bearing (10). Make sure the bearing is pushed on the stamped side only.6. Use tool group (A) and install seal (8) with the lip toward the inside as shown to a dimension of 1.27 mm (.05 in.) from the inside face of counterbore (1) (see picture B65771X1) to inside face of seal (8).7. Use tool group (A) and install seal (9) with the lip toward the inside as shown to a dimension of 2.032 mm (.08 in.) from outside surface (2) of governor drive housing to inside face of seal (9).8. After seals (8) and (9) have been installed, put clean engine oil on the lips of the seals. 9. Put plate (14) in position on lever (11) and install lock (13) and bolts (12) as shown.10. Bend lock (13) against the flat side of the bolts as shown. 11. Put spring (16) in position on sleeve (15) and make an alignment of the bolt holes as shown.12. Put sleeve (15) and lever (11) in position in the governor drive housing and install shaft (17) as shown. 13. Make an alignment of the bolt holes in the spring, the sleeve and the shaft and install the washer and bolt (18). 14. Turn shaft (17) until lever (11) can be connected to sleeve (15). 15. Install ring (19) on the shaft. 16. Put shaft (20) and plate (21) in position in the governor drive housing. Make sure dowel (6) is in the notch of plate (21). 17. Install lock (23) and bolts (22) that hold the plate to the shaft.18. Bend lock (23) against the flat side of bolts (22) as shown. 19. Install pin (24) in the governor drive housing to a dimension of 1.575 mm (.062 in.) above the outside surface. 20. Install pin (25) in the governor drive housing with the chamfered end installed first and the collar end last. 21. Install lock (28) and nut (27) on switch (26).22. Install switch (26) in the governor drive housing. 23. Install cover (29) and bolt (30) in the governor drive housing. 24. Install plate (34)