0512400 EVINRUDE BASE, Junction box

Illustration 1 g02137093Inspect the breather tube (1) for damage. Ensure that the outlet (2) is clean and free from any obstructions. Ice can cause obstructions in adverse weather conditions.Inspect the Engine for Leaks and for Loose Connections
A walk-around inspection should only take a few minutes. When the time is taken to perform these checks, costly repairs and accidents can be avoided.For maximum engine service life, make a thorough inspection of the engine compartment before starting the engine. Look for items such as oil leaks or coolant leaks, loose bolts, worn belts, loose connections, and trash buildup. Make repairs, as needed:
The guards must be in the correct place. Repair damaged guards or replace missing guards.
Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination.
For any type of leak (coolant, lube, or fuel) clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking is suspected, check the fluid levels more often than recommended until the leak is found or fixed, or until the suspicion of a leak is proved to be unwarranted.
Accumulated grease and/or oil on an engine is a fire hazard. Remove the accumulated grease and oil. Refer to this Operation and Maintenance Manual, "Engine - Clean" for more information.
Ensure that the cooling system hoses are correctly clamped and that the cooling system hoses are tight. Check for leaks. Check the condition of all pipes.
Inspect the water pump for coolant leaks.Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur, as the engine cools down and the parts contract.Excessive coolant leakage may indicate the need to replace the water pump. Remove the water pump. Refer to Disassembly and Assembly , "Water Pump - Remove and Install".
Inspect the lubrication system for leaks at the front crankshaft seal, the rear crankshaft seal, the oil pan, the oil filters, and the rocker cover.
Inspect the piping for the air intake system and the elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses.
Ensure that the areas around the rotating parts are clear.
Inspect the alternator belts and any accessory drive belts for cracks, breaks, or other damage.
Inspect the wiring harness for damage.Belts for multiple groove pulleys must be replaced as matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belts are stretched. The additional load on the new belt could cause the belt to break.High Pressure Fuel Lines
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
After the engine has stopped, wait 10 minutes in order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is performed. If necessary, perform minor adjustments. Repair any leaks from the low-pressure fuel system and from the cooling, lubrication, or air systems. Replace any high-pressure fuel line that has leaked. Refer to Disassembly and Assembly Manual, "Fuel Injection Lines - Install".If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a fluid penetration hazard. Refer to Operation and Maintenance Manual, "General hazard Information".Visually inspect the high-pressure fuel lines for damage or signs of fuel leakage. Replace any damaged high-pressure fuel lines or high-pressure fuel lines that have leaked.Ensure that all clips on the high-pressure fuel lines are in place and that the clips are not loose.
Inspect the rest of the fuel system for leaks. Look for loose fuel line clamps.
Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system.
Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires. Check for any loose tie-wraps or missing tie-wraps.
Inspect the ground strap for a good connection and for good condition.
Disconnect any battery chargers that are not protected against the current drain of the starting motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintenance free battery.
Check the condition of the gauges. Replace any gauges that are cracked. Replace any gauge that cannot be calibrated.