0434177 EVINRUDE GEARCASE ASSY., X-long

At operating temperature, the engine cooling system is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the fill cap on the radiator is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.
1. Drain the coolant from the radiator. The capacity of the cooling system is 30 liters (7.8 U.S. Gal). 2. Disconnect air lines (2) and (4).3. Disconnect sender (3) from air cleaner (1).4. Remove four bolts and washers (5), and remove air cleaner (1). 5. Mark for identification and location purposes, and disconnect five wires (6) from starter (7), along with two ground wires to the frame located underneath the starter (7). 6. Disconnect two heater hoses (8) leading to the water pump.7. Disconnect the upper and lower radiator hoses (9). 8. Mark for identification and location purposes, and disconnect wires (10) from alternator (12). Disconnect one electrical connector (13).9. Disconnect one wire leading to sensor (11). 10. Remove ten bolts and washers (15), and remove guard assembly (14). 11. Remove six bolts and washers, and remove fan assembly (16). 12. Disconnect governor control cable (17).13. Disconnect two fuel lines (18).14. Disconnect one hose (19). 15. Mark for identification and location purposes, and disconnect two wiring harness leads (20).16. Disconnect one electrical connector (21). 17. Support the engine and hydraulic pump (22) with a hoist and chains as shown. Remove four bolts (23) from the engine mounts, and remove the engine and hydraulic pump (22) as a unit. The weight of the engine and hydraulic pump (22) is 680 kg (1500 lb). The following steps are for the installation of the engine and hydraulic pump.18. Position the engine and hydraulic pump (22) into the frame, and secure with four bolts and washers (23).19. Connect one electrical connector (21) and two leads off of wiring harness (20).20. Connect one hose (19) and two fuel line hoses (18).21. Connect governor control cable (17).22. Position fan assembly (16), and secure with six bolts and washers.23. Position guard assemblies (14), and secure with six ten bolts and washers (15).24. Connect one lead (11) to sensor.25. Connect one electrical connector (13).26. Connect all wires (10) from the wiring harness to their original position on alternator (12).27. Position and connect two heater hoses (8).28. Connect the upper and lower radiator hoses (9).29. Place in their original positions, and connect wires (6) to starter (7).30. Position air cleaner (1), and secure with four bolts and washers (5).31. Connect air lines (2) and (4). Connect sender (3) to air cleaner (1).32. Add coolant to the radiator. See the topic "Lubricant Viscosities & Refill Capacities" in the Operation & Maintenance Manual for the proper fluid amount and refill procedures.End By:a. install hydraulic oil tankSeparate & Connect Engine & Hydraulic Oil Pump
Start By:a. remove engine and hydraulic oil pump 1. Position hydraulic pump (1) and engine (3) on Tooling (A) as shown.2. Fasten a nylon strap to the hydraulic pump (1), and support with a hoist as shown.3. Remove twelve bolts (2), and carefully separate the hydraulic pump (1) from engine (3). For the connection of the hydraulic pump and the engine, reverse steps 1 through 3.End By:a. install engine and hydraulic oil pump