0382397 EVINRUDE CRANKCASE HEAD, Seal & brg. assy., upper

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
Illustration shows the fuel shutoff solenoid and the tachometer adapter removed.1. Remove six bolts (1), two top bolts (2), housing (3) and the gasket. 2. Remove governor spring (4) and seat (5). 3. Remove bolts (6), cover (7) and the gasket. Use tool (A) to remove seal (8). 4. Remove low idle adjustment screw (9) and spring (10). 5. Remove shaft assembly (12) and levers (11) and (13). 6. Remove the two snap rings from pins (15) and remove pins (15). Remove plates (14) and stop (16). 7. Remove pins (18) and (17) and spring (19). 8. Remove two bolts (20) adapter (22), the coupling, and the O-ring seal.9. Remove contact (23) and body (24).10. Remove two bolts (25), cover (27), and the gasket.11. Remove two bolts (21), shutoff solenoid (26), and the gasket. 12. Remove shaft (28) and lever (29).
The check valve will be damaged during removal. Remove check valve (30) only if a replacement is necessary.
13. Remove check valve (30) if a replacement is necessary. 14. Remove seal (31) and adjustment screw (32).
Typical Example15. Remove bolt (33), housing (34), and the gasket from the fuel injection pump housing. 16. Remove bolts (35) and torque control group (36).17. Disassemble the torque control group and inspect the spacer, the spring and the insulator for damage or wear. 18. Remove two bolts (38) and block (37). 19. Remove the bolt that holds collar (39) to bolt (40). Remove collar (39), spring (41) and bolt (40).20. Remove the stop screw from collar (39) if a replacement is necessary. 21. Remove bolts (42) and governor servo (43). 22. Remove lockring (48), seat (47), spring (broken link spring) (46) and sleeve (45). Remove the other lockring (48) from the groove in the center of valve (44). 23. Remove valve (44), sleeve (49) and piston (51). Remove the O-ring seal from sleeve (49).24. Remove pin (50) and lever (52). 25. Use tool (B) to hold spring (54) in compression for removal of ring (53). Spring (54) is used to put a preload on the thrust bearing for the camshaft in the fuel injection pump housing.26. Remove ring (53) and tool (B). 27. Remove bearing (55), sleeves (56) and spring (54). 28. Remove ring (57) and dashpot assembly (58). 29. Use tool (C) to remove snap ring (64). Remove ring (63) and spool (62).30. Remove seat (61) from spring (60) and remove spring (60) from seat (59). 31. Remove spring (overfueling spring) (65) and riser (66). 32. Remove ring (67), races (68) and bearing (69). Make a replacement of shield (70) any time it is removed.33. Use a screwdriver to remove shield (70) as shown. 34. Remove bolts (71) and carrier (72). 35. Remove dowels (73) and flyweights (75).36. Remove shaft (74) and the dowel from shaft (74). 37. Remove races (76) and bearing (77).Assemble Governor
Put clean oil on all parts before assembly. Be sure all oil passages are clear. 1. Install one race (76), bearing (77) and the other race on the camshaft in the fuel injection pump housing. 2. Put flyweights (75) in position on carrier (72) and install the dowels to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in) end play. 3. Install dowel (78) in governor shaft (74) and install the governor shaft in the carrier as shown. 4. Put carrier (72) in position and install bolts (71). Make a replacement of shield (70) any time it is removed.5. Install shield (70) on the carrier and use tool (D) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° 15° apart next to the holes in the shield. 6. Install race (68), bearing (69), race (68). Use tool (C) to install the ring on riser (66) as shown. 7. Install riser (66) and spring (overfueling spring) as shown. 8. Assemble the dashpot as follows:a. Install spring (60) on seat (59) and install seat (61) in spring (60).b. Put spool and ring (63) in position on seat (61) and use tool (C) to install snap ring (64). 9. Install dashpot assembly (58) as shown. 10. Install ring (57) in the lower groove in the governor shaft. Install sleeve (56), spring (54), sleeve (56) and bearing (55). Spring (54) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. 11. Use tool (B) to hold spring (54) in compression and install ring (53) in the groove in the governor shaft. Remove tool (B). 12. Put lever (52) in position on the governor servo and install pin (50) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90° apart on the outside surface on both legs of the governor servo to hold pin (50) in place.13. Install the O-ring seal on sleeve (49). Install piston (51) and sleeve (49) as shown.14. Install valve (44) as shown. 15. Install one lockring (48) in the groove near the center of valve (44). Put sleeve (45), spring (broken link spring) (46) and seat (47) in position on valve (44) and install the second lockring (48). 16. Put the governor servo in position on the fuel injection pump housing with piston (51) engaged over rack (79) and install the bolts. 17. Install torque rise adjust