0208610 EVINRUDE APPLIQUE,Front

Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1860 Retaining Ring Pliers 1
B 9U-6193 Valve Spring Compressor 1
416-0288 Adapter 1
416-0292 Head 1
C(1) 9U-6198 Crankshaft Turning Tool 1
C(2) 9U-7336 Housing 1
5P-7305 Engine Turning Tool 1
(1) The Crankshaft Turning Tool is used on the front pulley.
(2) This Tool is used in the aperture for the electric starting motor.Start By:
Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove".Note: Either Tooling (C) can be used. Use the Tooling that is most suitable.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The following procedure should be adopted to remove the valve springs when the cylinder head is installed to the engine. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install" for the procedure to remove the valve springs from a cylinder head that has been removed from the engine.Note: Ensure that the appropriate piston is at the top center position before the valve spring is removed. Failure to ensure that the piston is at the top center position may allow the valve to drop into the cylinder bore.
Plug the apertures for the push rods in the cylinder head in order to prevent the entry of loose parts into the engine.
Use a deep socket in order to remove the electrical connections from the electronic unit injectors. Use of incorrect tooling will result in damage to the electronic unit injectors.
Turn the battery disconnect switch to the OFF position.
Illustration 1 g01469791
Typical example
Follow Step 2.a through Step 2.h to remove the harness assemblies for the electronic unit injectors.
Place a temporary identification mark on connections (1).
Use a deep socket to remove connections (1) from electronic unit injectors (2).
Cut cable strap (3).
Disconnect plug (6) from harness assembly (4).
Use Tooling (A) to remove circlip (5).
From the outside of valve mechanism cover base (7), push harness assembly (4) inward. Withdraw the harness assembly from the valve mechanism cover base.
Remove O-ring seal (8) from harness assembly (4).
Repeat Step 2.a through Step 2.g to remove the remaining harness assembly.
Illustration 2 g01469792
Typical example
Personal injury can result from being struck by parts propelled by a released spring force.Make sure to wear all necessary protective equipment.Follow the recommended procedure and use all recommended tooling to release the spring force.
Ensure that the valve spring is compressed squarely or damage to the valve stem may occur.
Follow Step 3.a through Step 3.d to position the appropriate piston at top dead center.
Install Tooling (B) in position on the cylinder head to compress a valve spring for the appropriate piston.
Use Tooling (B) to compress valve spring (11) and open the valve slightly.Note: Do not compress the spring so that valve spring retainer (10) touches the valve stem seal.
Use Tooling (C) to rotate the crankshaft carefully, until the piston touches the valve.Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent valve stems.
Continue to rotate the crankshaft and gradually release the pressure on Tooling (B) until the piston is at the top center position. The valve is now held in a position that allows the valve spring to be safely removed.Note: Valve springs must be replaced in pairs for the inlet valve or the exhaust valve of each cylinder. If all valve springs require replacement the procedure can be carried out on two cylinders at the same time. The procedure can be carried out on the following pairs of cylinders. 1 with 4 and 2 with 3. Ensure that all the valve springs are installed before changing from one pair of cylinders to another pair of cylinders.
Do not turn the crankshaft while the valve springs are removed.
Apply sufficient pressure to Tooling