0776290 EVINRUDE DECAL SET, Flag (Blue models)

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     -     Loctite 5900     -    
B     198-9113     Seal Installer     1    
C     8T-5096     Dial Indicator Group     1    
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The engine should be mounted on a suitable stand and placed in the inverted position.
Clean the crankshaft and inspect the crankshaft for wear or damage. Refer to Specifications, "Crankshaft" for more information. If necessary, replace the crankshaft or recondition the crankshaft.
Ensure that the parent bores for the crankshaft bearings in the cylinder block are clean. Ensure that the threads for the bearing bolts in the cylinder block are clean and free from damage.
Clean the crankshaft bearings and the thrust washers. Inspect the bearings and the thrust washers for wear or damage. If necessary, replace the bearings and the thrust washers.Note: If the crankshaft bearings are replaced, check whether oversize bearings were previously installed. If the thrust washers are replaced, check whether oversize thrust washers were previously installed.
Ensure that all of the lubrication passages are clean and free of debris.
Illustration 1 g01360029
Typical example
Install upper bearings (7) to the cylinder block. Ensure that the locating tabs for the upper bearings are seated in the slots in the cylinder block.Note: The upper bearings have a groove and two oil holes.
Lubricate upper thrust washer (8) . Install the upper thrust washer to the rear of the cylinder block with the oil grooves toward the outside. Ensure that holes (X) in the thrust washer are aligned with dowels (Y) in the cylinder block.
Lubricate upper bearings (7) with clean engine oil.
Illustration 2 g01359996
Typical example
Attach Tooling (A) and a suitable lifting device to crankshaft (3) . Carefully lift the crankshaft into the cylinder block. The weight of the crankshaft is approximately 32 kg (70 lb). Remove Tooling (A) .Note: Do not damage any of the finished surfaces on the crankshaft. Do not damage the bearings.
Illustration 3 g01359992
Number 5 main bearing cap
Install lower bearings (4) to main bearing caps (2) . Ensure that the locating tabs for the lower bearings are seated in the slots in the bearing caps.Note: The lower bearings are plain bearing with no oil holes.
For number 5 main bearing cap, follow Steps 10.a through 10.c in order to install the lower thrust washers (5) to the main bearing cap.
Ensure that lower thrust washers (5) are clean and free from wear or damage. If necessary, replace the thrust washers. Lubricate the thrust washers with clean engine oil.
Install lower thrust washers (5) to main bearing cap (2) . Ensure that holes (X) in the thrust washers are aligned with dowels (Y) in the main bearing cap.
Illustration 4 g01354237
Apply a bead of Tooling (A) to the corners of the recess in the cylinder block at positions (Z) .
Lubricate the crankshaft journals and the lower main bearings with clean engine oil. Install main bearing caps (2) to the cylinder block. Ensure the correct orientation of the main bearing caps. The locating tab for the upper and the lower bearing should be on the same side of the engine.Note: For number 5 main bearing cap, ensure that the rear face of the main bearing cap is flush with the rear face of the cylinder block.
Illustration 5 g01359531
Typical example
Inject a small quantity of Tooling (A) into the two grooves in number 5 main bearing cap. Position new seals (3) in the grooves. Ensure that rounded edges of the seals are outward. Push the first 25 mm (1 inch) of the seal into the grooves by hand.
Illustration 6 g01354238
Typical example
Use Tooling (B) in order to push seals (3) fully into the grooves.
Illustration 7 g01353474
Typical example
Lubricate the threads of bolts (1) with clean engine oil. Lubricate the underside of the heads of the bolts with clean engine oil.
Install bolts (1) to main bearing caps (2) . Evenly tighten the bolts in order to pull the main bearing caps into position. Ensure that the caps are correctly seated.Note: Do not tap the main bearing caps into p