5040577 EVINRUDE * PIN

At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Drain the coolant only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap from the radiator slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to avoid personal injury.
1. Drain the coolant from the cooling system and cylinder block into a suitable container for storage or disposal.2. Put covers on the crankshaft journals for protection from dirt and coolant. 3. Remove the cylinder liner with Tool (A). 4. Remove seals (1) and filler band (2) from the cylinder liner.Install Cylinder Liners
1. Install the gasket and spacer plate.2. Clean the cylinder liners and liner bores in the cylinder block.3. Install the cylinder liners in the cylinder block without seals or bands. 4. Check the cylinder liner projection as follows: a. Install four bolts (4) and washers from Tool (A) around each cylinder liner as shown. Tighten the bolts evenly to a torque of 95 N m (70 lb ft).b. Install crossbar (2), plates (3) and bolts (1) from Tool (A). Be sure the crossbar is in position at the center of the liner and the liner surface is clean. Tighten bolts (1) evenly to a torque of 70 N m (50 lb ft).c. Check the distance from the bottom edge of crossbar (2) to the top edge of the spacer plate. The distance on each end of the crossbar must be the same.d. Check the liner projection with Tool (B) at four locations around the liner. Liner projection must be 0.059 to 0.199 mm (.0023 to .0078 in). The difference between the four measurements on the same liner must not be more than 0.05 mm (.002 in).
If the liner is turned in the cylinder block, it can make a difference in liner projection.
5. If the liner projection is not 0.059 to 0.199 mm (.0023 to .0078 in), check the thickness of the following parts: a. Spacer plate (X): 10.313 0.025 mm (.4060 .0010 in).b. Spacer plate gasket (Y): 0.208 0.025 mm (.0082 .0010 in).[All surfaces must be clean and dry when gaskets are installed].c. Cylinder liner flange (Z): 10.65 0.02 mm (.419 .001 in).6. Put a mark on the cylinder liners and block so the liners can be installed in same position.7. Remove Tool (A) and Tool (B). Remove the liner. 8. Put liquid soap on seals (5), grooves of the liner and the bore of the block. Install the seals on the cylinder liner.9. Put the filler band completely in clean engine oil for a moment. Install filler band (6) in the groove under the liner flange without delay. 10. Install the liner immediately after the filler band is installed before expansion of the band. Make sure the mark on the liner is in alignment with the mark on the block. Use Tool (C) to push the liner into position.11. Use Steps 7 through 10 for the remainder of the liners.End By:a. install pistons