0435657 EVINRUDE DECAL SET, 250

3. Disconnect wire harness (2). There will be a loss of oil when hose assembly (1) is disconnected.4. Disconnect hose assembly (1) from the radiator. 5. Disconnect hose assembly (3) from the radiator.6. Loosen hose clamps (5). Move hose (4) away from the radiator. 7. Loosen the hose clamps that hold hose (6) in place. Disconnect hose (6) from the radiator.8. Remove the bolts that hold guard assemblies (7) in place. Remove the guard assemblies from each side of the radiator. 9. Fasten a hoist and tooling (A) to radiator (8) as shown. Remove eight bolts (9), and remove the radiator from the machine. The weight of the radiator is 186 kg (410 lb). The following steps are for installation of the radiator.10. Fasten a hoist and tooling (A) to the radiator. Put the radiator in position on the frame, and install eight bolts (9).11. Put guard assemblies (7) in position on each side of the radiator. Install the bolts that hold them in place.12. Connect hose (6) to the radiator.13. Put hose (4) in position on the radiator. Tighten clamps (5).14. Connect hose assembly (3).15. Connect hose assembly (1) to the radiator.16. Connect wire harness (2).17. Install the plate assemblies on each side of the engine compartment. Install the hood.18. Fill the cooling system with coolant to the correct level. See the Maintenance Manual.19. Check the oil level of the transmission. See the Maintenance Manual.Disassemble Radiator (Folded Core)
Start By:a. remove radiator 1. Remove the bolts that hold shield assemblies (1) in place. Remove the four shield assemblies. 2. Remove the bolts that hold angle assemblies (2) and (3) in place. Remove the angle assemblies. 3. Put the radiator in position on the floor with the radiator core up as shown.4. Fasten a hoist and tooling (A) to radiator core (4).5. Remove bolts (5) that hold the radiator core in place in the radiator guard. Remove the radiator core. The weight of the radiator core is 73 kg (160 lb). 6. Remove bolts (7) that hold tank assembly (6) in position, and remove the tank assembly. 7. Remove four seals (8) from tank assembly (6). 8. Remove two bolts (11) that hold core assembly (9) to two straps (12) (one on each side of the core assembly).9. Loosen two bolts (10) that hold the other end of straps (12). Move the straps away from core assembly (9). Remove the core assembly.10. Repeat steps 8 and 9 to remove the remaining core assemblies. 11. Remove seals (13) from the bottom of the core assemblies.Assemble Radiator (Folded Core)
1. Make sure the core assemblies and the holes in the bottom tank are clean and free of dirt and foreign material.2. Lightly lubricate the inside diameter and the sealing surfaces of the seals, the bottom tank and the core assemblies with liquid soap. There are two different seals used on the top and bottom of the core assemblies. The distance between the projections on each end of the core assemblies is different. Make sure the correct seal is installed on each end of the core assemblies. 3. Install the correct seals (1) on the bottom of core assembly (2).4. Put core assembly (2) in position on the bottom tank assembly with locating projections (4) aligned with locating holes (3) in the bottom tank assembly. 5. Put straps (7) in position on core assembly (2), and install bolts (6) and (5). Do not tighten the bolts at this time.6. Inspect the seals to make sure they are not damaged, pinched or folded.7. Repeat steps 3 through 6 for the remainder of the core assemblies if they were removed. 8. Make sure the holes in the top tank are clean and free of dirt and foreign material.9. Lightly lubricate the sealing surface and the inside diameter of the seals, the top tank and the core assemblies with liquid soap.10. Install the correct seals on core assemblies (2).11. Put top tank (8) in position on the core assemblies with each core assembly aligned with the holes in the top tank.12. Install bolts (9) that hold the top tank to the side rails. Do not tighten the bolts at this time.13. Inspect the seals to be sure they are not damaged, pinched or folded.14. Adjust the gap between the edges of the core assemblies on the front side of the radiator. Adjust the core assemblies until there is 6.5 1.5 mm (.26 .06 in) between the edges of the cores. Adjust the center core assemblies first; then work toward the baffle assemblies on each side of the radiator.15. Tighten the bolts that hold straps (7) to the core assemblies.16. Tighten bolts (9) that hold the top tank to the side rails. 17. Fasten a hoist and tooling (A) to radiator core (10). Put the radiator core in position in the radiator guard, and install bolts (11). 18. Install angle assemblies (12) and (13). 19. Install shield assemblies (14) and (15).End By:a. install radiator