0305196 EVINRUDE GASKET, Thermostat cover

This Program must be administered as soon as possible. When reporting the repair, use "PI3292" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3292" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
This Revised Service Letter replaces the June 8, 1999 (Revised August 1999) Service Letter. Changes have been made to the Affected Product.
Completion Date
December 31, 1999Termination Date
June 30, 2000Problem
Improvements have been made to the starter solenoids on certain 24 Volt Starter Motors to provide a reduced likelihood of the solenoid energizing contact points sticking together. Because this is primarily an early hour type of failure, only engines with fewer than 300 hours are eligible.
Affected Product
Model & Identification Number
Only engines with less than 300 hours are eligble for this PIP.
3176B (9WK484, 9WK486-487, 9WK500, 9WK502, 9WK507, 9WK509, 9WK512, 9WK514-516, 9WK519-521, 9WK530-531, 9WK534-537, 9WK541, 9WK550, 9WK553, 9WK555-556, 9WK559, 9WK562, 9WK565-566, 9WK570, 9WK575, 9WK577-578, 9WK580, 9WK587-589, 9WK591-592, 9WK594-596, 9WK604, 9WK611-612, 9WK616, 9WK618, 9WK621-622, 9WK647-648, 9WK652-655, 9WK660-665, 9WK667, 9WK677, 9WK681, 9WK684-686, 9WK688-691, 9WK694-696, 9WK698, 9WK709-717, 9WK721, 9WK724, 9WK727-728, 9WK733-735, 9WK738, 9WK740, 9WK742-745, 9WK748, 9WK753-754, 9WK765-769, 9WK772, 9WK774, 9WK776-777, 9WK785, 9WK791-792, 9WK795-796, 9WK802, 9WK807-808, 9WK813-816, 9WK819-820, 9WK822-823, 9WK828-833, 9WK836-837)
3176C (6BW336-337, 6BW358, 6BW378-383)
3196 (2XR466, 2XR476, 2XR479, 2XR482, 2XR485, 2XR489, 2XR492, 2XR494, 2XR529-530, 2XR542, 2XR570, 2XR574, 2XR577, 2XR581, 2XR588, 2XR590, 2XR593, 2XR596, 2XR599-601, 2XR610-611, 2XR613, 2XR638, 2XR643-644, 2XR654-655, 2XR657, 2XR659, 2XR669, 2XR671-672, 2XR677, 2XR694, 2XR698, 2XR722, 2XR724, 2XR729, 2XR736, 2XR739, 2XR743-744, 2XR754, 2XR757, 2XR768-771, 2XR778-779, 2XR783, 2XR795, 2XR804, 2XR806, 2XR818-819, 2XR821, 2XR828-829, 2XR834, 2XR840, 2XR844, 2XR846, 2XR850, 2XR854, 2XR856, 2XR891, 2XR898, 2XR900, 2XR904-905, 2XR922, 2XR939-941, 2XR945-948, 2XR954, 2XR964-966, 2XR973, 2XR983-984, 2XR1003-1012, 2XR1016-1017, 2XR1020-1022, 2XR1024-1032, 2XR1035-1040, 2XR1042, 2XR1064, 2XR1069, 2XR1071-1072, 2XR1074, 2XR1080-1081, 2XR1087-1091, 2XR1093-1095, 2XR1097-1100, 2XR1102-1103, 2XR1107-1122, 2XR1125-1126, 2XR1128, 2XR1131, 2XR1133, 2XR1168-1170, 2XR1179, 2XR1181, 2XR1184, 2XR1190, 2XR1192-1193, 2XR1195-1196, 2XR1202-1212, 2XR1214-1231, 2XR1234-1236, 2XR1238, 2XR1241-1249, 2XR1293-1294, 2XR1296-1302, 2XR1304, 2XR1306-1321, 2XR1326-1339, 2XR1342-1346, 2XR1351-1354, 2XR1371-1372, 2XR1375-1376, 2XR1381-1382, 2XR1385-1388, 2XR1398-1399, 2XR1410-1411, 2XR1417-1421, 2XR1424-1426, 2XR1430, 2XR1446-1447, 2XR1450-1451, 2XR1464-1469, 2XR1473-1474, 2XR1497-1527, 2XR1538-1539, 2XR1542-1544, 2XR1550-1552, 2XR1554-1555, 2XR1560-1566)
3406E (9WR448, 9WR450, 9WR476-477, 9WR480-481, 9WR493, 9WR513, 9WR516-520, 9WR524-529, 9WR532-533, 9WR537-539, 9WR541, 9WR552-554, 9WR556-559, 9WR564-567, 9WR572, 9WR580, 9WR582-588, 9WR595-597, 9WR599-616, 9WR621-622, 9WR624, 9WR626-629, 9WR631, 9WR634-638, 9WR641-642, 9WR645-648, 9WR650-654, 9WR657-658, 9WR660-, 9WR665-667, 9WR669-687, 9WR689-697, 9WR704-705, 9WR707-708, 9WR710-711)
*On 3196,2XR1566 - 2XR1723,if the Starter Motor is a Delco Model 50MT (Part No. 6V0890), then this rework does NOT apply. See the attached Starter Model Comparison. This program applies only to engines that have the 6V5539 (3176, 3196) and 3T2650/6V5539 (3406E) Starter Motors - 24 Volts. See "Action Required" Section for identifying 24 Volt versus a 12 Volt Starter.
Parts Needed
Dealers will need to order parts for this Program.
1 - 9X9511 Solenoid1 - 4H7869 Gasket**On the 3406E, the gasket you remove may be a different part number. The 155-8725 Gasket is used only to prevent the initial E-Coat from bleeding into the housing / starter joint. The 4H7869 is completely satisfactory for the 3406E after E-Coat.Action Required
This Program will replace the solenoid on engines having a 24V (6V5539 or 3T2610) starters. In most cases, only the solenoid should be replaced without removing rhe starter from the engine. If the starter must be removed to change the solenoid, then new seed stock Starters will be used for initial replacements. Only Dealer Branches with population of these engines should order starters. Orders will be limited to two starters per Branch. Bring the replaced starters back to the shop for solenoid replacement and use for the next engine to be updated. Stamp a "CS" in the lower right corner of the border after starter has been reworked.
Parts Stock
Replace the Solenoid on all 6V5539 and 3T2650 Starters in Dealer Stock which have a Date Code which indicates a starter built prior to Jul 28, 1998 (98G28). The Date Code is located in the left lower portion of the border that encircles the name plate on the starter. The first two numbers represent the year. The Letter represents the month in alphabetic succession without using "i" and the next two numbers, the day of the month. See Illustration Below for example.
For Reman Starter Motors, use the following information for identification.
Replace the Solenoid on all 0R4259 Starters in Dealer Stock which do not have a date code of NRDD, NADD, NLDD, NKDD, NODD, OR NDDD.
Affected Product
See the attached Rework Procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the removed solenoids in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(1-Rework Procedure)(1-Starter Model Comparison)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
1. Inspect the starter motor to determine if it is the 24V 42MT (6V5539 or 3T2650) that needs to be reworked.2. Remove the old solenoid and install a new 9X9511 Solenoid. 3. If the solenoid is inaccesable on the engine, remove the starter per the instructions in the Disassembly and Assembly section of the Service Manual. Check and adjust the pinion clearance per the following procedure. A. Disconnect the negative terminal wire from the ground (G) terminal of the solenoid.B. Connect two 12 V batteries to the starting motor as shown. Connect one jumper cable from the battery negative (-) post to the solenoid ground (G) terminal. Connect another jumper cable from the battery positive post to the solenoid start (S) terminal.C. Momentarily flash a third jumper lead from the solenoid ground (G) terminal to the motor (Mtr) terminal. The pinion drive will now shift into the cranking position and remain there until the batteries are disconnected.D. Push the pinion back towards the commutator to remove any free play.E. measure the clearance between pinion (3) and pinion drive housing (2). Clearance (X) must be:42-MT...9.1 0.8 mm (0.36 0.03 in)F. If the clearance is not correct, remove the plug on the shift lever housing. Turn adjustment nut (1) until the clearance is correct. Turning the nut clockwise