5007003 EVINRUDE EXHAUST HOUSING, 15 inch models

Disassemble Magneto
start by:a) remove magneto1. Remove four screws that hold cover (1) to intermediate housing (2) and unplug connector (3).
Put a mark for alignment on the connector halves. Hold both halves of the connector. Do not pull the wires to separate the connector.
2. Remove timing cover (4), screw (5) and timing label (6).3. Remove screws (7) and nut (8) for the diode.4. Remove driven gear (9).5. Tilt circuit board (10) away from pick-up coils and unplug the wires from the pick-up coils at the circuit board pin connectors. Do not lose plastic brace when circuit board is moved away from pick-up coils.
Use needle nose pliers to unplug the receptacles at the pin connectors. Do not pull the wires to disconnect the pin connectors.
6. Use tool (A) to give support to end cover (1) in a press.7. Use tool (B), or rod of same dimension, in a press to move distributor shaft, bearing and timer arm assembly (11) out of end cover (1).8. Use tool (A) to hold timer arm assembly (11) so shaft bearing can be pressed out of aluminum hub in timer arm assembly (11). 9. Remove spring pin (12) and drive coupling (13).
Put identification on flange (14) and housing (15) so flange (14) can be installed in the same position.
10. Remove flange (14) from front housing (15).11. Give support to flange (14) with tool (A) in a press and use tool (C) to remove seal (16) from the flange.12. Disconnect stator wires from clamp (18).13. Remove three screws that hold intermediate housing (17) to stator and front housing (15) and remove intermediate housing (17). use a soft hammer to separate intermediate housing (17) from the stator.
Intermediate housing (17) fits on a bearing rubber cover on the rotor assembly.
Put a mark for alignment on stator (21) and front housing (15).
14. Remove drive gear (19), bearing rubber cover (20) and stator (21).15. Put front housing (15) in tool (A) in a press shaft and rotor assembly out of front housing (15).
Do not let the shaft and rotor assembly fall after it is clear of the bearing.
16. Put front housing (15) on tool (A) in a press and use tool (C) to remove the bearing from the front housing.17. Use tool (A) to hold bearing (22) in a press. Press shaft and rotor assembly (23) out of bearing (22).
Do not let the shaft and rotor assembly fall after it is clear of the bearing.
18. Replace all parts contained in the repair kit.19. Clean all parts and remove metal filings from the magnet-rotor.Assemble Magneto
1. Put spacer (2) in position on the drive gear end of shaft and rotor assembly (3).2. Give support to the shaft and rotor assembly (3) with tool (A) in a press.3. Use tool (B) to press bearing (1) against spacer (2). 4. Give support to front housing (4) with tool (A) in a press. Use tool (D) to install the bearing into front housing (4).5. Use tool (A) in a press to hold the rotor of shaft and rotor assembly (3).6. Use tool (C) with a 11.1125 mm (.4375 in.) hardened washer to install front housing (4) and bearing onto the coupling end of the shaft of shaft and rotor assembly (3).7. Before further assembly check dimensions (X) and (Y) of the shaft and rotor and front housing.Dimension (X) from the drive gear end of the bearing is 15.6 mm (.615 in.). Be sure the rotor is against spacer (2).Dimension (Y) from the coupling end of the shaft to the bearing is 38.7 mm (1.524 in.).8. Put stator (6) in position in front housing (4). Use the mark put on at disassembly for alignment reference. Be sure the screw holes are in alignment. Do not damage the teflon wrapping.9. Install bearing rubber cover (5) on bearing (1).10. Install drive gear (7) on shaft.
Put vaseline petroleum jelly in the base for the bearing in intermediate housing (8).
11. Put intermediate housing (8) in position on stator (G). Be sure the wires are on the same side as the flat base on front housing (8). Put wires in clamp (9).12. Install three screws through intermediate housing (8), stator (6) into front housing (4). Tighten the screws evenly to bring the housings together over the stator.
Do not damage the teflon wrapping on stator (6).
13. Put 9S3263 Sealant on the outside of seal (10) and use tool (D) to install seal (10) into flange (11). The lip of the seal faces out.14. Install the gasket between flange (11) and front housing (4). Align the mark and install the four screws.15. Install coupling (12) and spring pin (13).16. Give support to end cove