0383767 EVINRUDE GEARCASE ADN BEARING ASSY

Do not perform any procedure outlined in this publication or order any parts until you have read and understood this information.
Selection Of Service Harness
Many optional features have been provided for the G3500 Engines. Each of these features may require additional wires within the original harness. It is not possible to provide a service harness that will match all different combinations of options. In an attempt to minimize the total number of harnesses and to meet as many applications as possible it has become necessary to group all wires into four main engine categories. The four categories are:* Electric Power Generation (EPG)* Industrial* Landfill* CoGenEach category contains wiring for its most used options while excluding those wires of its least used options. As a result, any given service harness may contain unused wires and connectors while, at the same time, require the customer to provide custom wiring for the lesser used options. The following is a listing of items that are not supported with a service harness.* Electric Starter* Alternator* Water Level Alarm Switch* Left Hand Air Starter* Digital Voltage RegulatorEach of the four G3500 harness categories identifies a service harness for a particular application. To determine which part number is needed, refer to Chart 1 entitled "Service Harness Part Numbers And Engine Categories". Determination Of Service Harness Design
G3500 EIS engines were built with two slightly different harness designs. The two designs are differentiated by the terms "early build" harnesses and "current production" harnesses. Chart 2 entitled "Serial Numbers And Service Harness Designs" indicates the serial numbers appropriate for the G3500 EIS Engines and the two unique harness designs. Selection Of Miscellaneous Parts Kit
A 131-2217 Harness Parts Kit of miscellaneous hardware pieces has been provided for all "early build" harnesses. This kit is needed only for "early build" harnesses and is not required when servicing harnesses on engines with serial numbers larger than those listed in Chart 2.Chart 3 entitled "Miscellaneous Parts For 131-2217 Harness Parts Kit" shows a complete listing for all parts found in 131-2217 Harness Parts Kit. Optional Hardware
As indicated above, the electric starter and alternator wires are not supplied with the service harness. Therefore, if this option is part of the original engine installation, then custom wires must be provided, power distribution box and its contents must be removed, and starter solenoid switch must be relocated. Refer to Chart 4 entitled "Optional Hardware" in order to locate the appropriate optional parts. It should also be understood that the type of optional hardware chosen will have an outcome on the required amount of custom wiring. For a better understanding, refer to the Installation Procedures (Steps 9-11) in this Special Instruction and compare them to 121-0121 Wiring Diagram (Page 10) and 4P-9570 Wiring Diagram (Page 11). Installation Procedures
G3500 EIS service harnesses have many design features not found in earlier harnesses. For "early build" engines the installation of this service harness will update the electrical system with many of the latest improvements. Items such as new wire identifications will identify each individual wire as to its circuit function and its termination point within the engine-mounted terminal box. This will prevent the constant need to refer to a circuit diagram when connecting wires. It will also minimize the potential for wiring errors.Harness routing has become more direct and, as the result, has become easier to install. Illustration 1 entitled "Engine Harness Routing" provides four views of the engine harness routing.
Illustration 1. Engine Harness Routing: (1) Front view. (2) Rear view. (3) Left side view. (4) Right side view.Harness wires within the engine-mounted terminal box have been preformed to fit and, upon initial installation, will fall near the termination points. Other new features of interest include the removal of the power distribution box, termination of the manifold air pressure sensor (MAPS) to the engine-mounted terminal box, addition of a second magnetic pickup for governor control, addition of a second E-Stop contact, and installation of starter solenoid switch within the engine-mounted terminal box.A successful installation of the service harness depends greatly on the repair person's overall understanding of the entire procedure. The step-by-step procedures are provided as a general guide through the replacement process. As stated above, the procedures can in no way provide complete detail of all situations. The procedures are as follows:1. Shut off the main gas valve.2. Completely isolate all electrical power sources, battery chargers, batteries, and other electrical power and control signals from the engine wiring by disconnecting both the positive and negative leads.3. Using the appropriate tool, remove each engine harness wire lead from the terminal blocks found within the engine-mounted instrument panel. DO NOT remove any of the interconnect harness leads.Chart 5 entitled "Early Production Wire Removal And Service Harness Replacement Cross-Reference" provides identifications for the correct removal of wires on the third column marked "Early Production Wire Ident." and respective terminal numbers on the second column marked "Terminal No.". This chart lists every all wiring options. It should be understood that any single engine arrangement may not contain all wires listed. Also, as a general rule, most wires to be removed will be located on the right hand side of the right column of terminals and on the left hand side of the left column of terminals. 4. Remove and store in a safe place all four screws, washers, and nuts used to mount the DDT connector. Remove the connector and attached wires and discard. A new connector with wires are provided in the service harness.5. After disconnecting all engine harness wires from the instrument panel terminal strip, cut all associated nylon tie straps and disconnect all connectors inside the engine-mounted terminal box. Carefully remove and store in a safe place for later installation of the plate-mounting screws, nuts, and washers holding the cable grip bushing, lock nut, and cable onto the instrument panel bottom.6. Remove the engine harness from the panel.7. Remove all nylon tie straps from the various clipping locations along the engine-mounted ignition and safety harnessing. It is not necessary