5041272 EVINRUDE ENGINE BASEMENT GASKET

2. Disconnect the air lines from starter (1). 3. Fasten a hoist to starter (1). Remove bolts (2) and remove the starter from the flywheel housing. The weight of starter (1) is 54 kg (120 lb.).4. Fasten a hoist to starter (1) and put it and the gasket in position. Install bolts (2) that hold the starter to the flywheel housing.5. Connect the air lines to starter (1) and open the air pressure supply to the system.Disassemble Air Starter
start by:a) remove air starter Make sure there is a complete set of new gaskets, vanes, seals and O-ring seals before the air starter is disassembled.1. Remove elbow (1) from cover assembly (2).2. Remove silencer group (4) from motor housing (3). 3. Make marks to show the position of motor housing (3) in relation to gear case (7) for assembly purposes. Remove bolts (5) to remove gear case (7) and drive housing (6) as a unit from motor housing (3). 4. Use tool (A) to remove ring (9) from drive gear (8). This air starter is a right hand model and bolt (10) has left hand threads. The bolt for a left hand model starter has right hand threads. 5. Remove bolt (10) and washer (11) to remove drive pinion (12), a sleeve and spring from the end of the drive shaft.6. Make marks to show the position of drive housing (6) in relation to gear case (7) for assembly purposes. Remove bolts (13) and remove drive housing (6) from gear case (7). 7. Remove O-ring seal (14) from drive housing (6).
The drive shaft assembly, the piston and drive gear are under a spring force.
8. Install tooling (B) between drive gear (8) and piston (15). Use a press to make a compression of the piston return spring and remove the ring that holds the drive shaft assembly and piston in the drive housing. 9. Slowly release the press to remove the force of piston return spring (17). Remove tooling (B) from between the drive gear and piston and remove ring (16) from the piston. Remove the drive gear, the piston and drive shaft assembly as a unit from the drive housing. Remove piston return spring (17) from the drive housing. 10. Use a 5/16" hex wrench to loosen the drive gear bolt until the threads are free and remove drive shaft assembly (18) and piston (15) as a unit from drive gear (8). 11. Remove bulkhead (19) from piston (15). 12. Remove O-ring seals (20) from bulkhead (19). 13. Remove ring (21) from piston (15) and remove the piston from drive shaft assembly (18). Later model air starters will not have bumper (23).14. Remove O-ring seal (24), bumper (23) and seal (22) from piston (15). 15. Remove ring (33), cup (32), spring (31), driven clutch jaw (30), driving clutch jaw (29), bearing (28), washer (27), lockwasher (26) and bolt (25) from drive shaft assembly (18). Any time ring (34) is removed a replacement must be made.16. Remove ring (34) to remove bearing (35) from drive shaft (18). 17. Use tool (C) to remove ring (37) and remove bearing (36) from gear case (7). Later model air starters will not have bumper (38) and backup ring (39). 18. Remove bumper (38) from drive housing (6). 19. Remove backup ring (39) from drive housing (6). 20. Remove seat (40) and bearing (41) from drive housing (6). 21. Remove seal (42) from drive housing (6). 22. Make marks to show the position of cover assembly (2) in relation to motor housing (3) for assembly purposes. Remove cover assembly (2) and an O-ring seal from motor housing (3). 23. Remove bolt (44) to remove rotor pinion (43) from rotor shaft. 24. Loosen setscrew (46) and remove nut (45) from