5007707 EVINRUDE GEARCASE Assy, Complete - White

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     4C-5598     Anti-Seize Compound     -    
B     195-4609     Seal Pick     1    
C     -     Isopropyl Alcohol     -    
D     5P-4996     Plug     2    
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Open the right side engine door.
Illustration 1 g02174349
Disconnect harness assemblies (1) , (2) , and (5) .
Disconnect tube assemblies (3) . Plug the coolant lines with Tooling (D) .
Remove flame detection temperature sensor (6) .
Remove bolts (4) and position the elbow out of the way.
Illustration 2 g02174351
Remove nuts (11) and remove combustion head (10) .
Remove gasket (9) , tube assembly (8) , and gasket (7) .
If required, remove studs (12) .
Illustration 3 g02174350
Remove fittings (13) and (14) .
Remove spark plug (15) and remove filter (16) .
Illustration 4 g02483739
Use Tooling (B) in order to remove O-ring seals (17) and (18) from harness assembly (5) . Discard O-ring seals (17) and (18) .Installation Procedure
Install combustion head (10) in reverse order.
Apply Tooling (A) onto the threads of studs (12) . Install the studs. Tighten studs (12) to a torque of 17 2 N m (150 18 lb in).
Apply Tooling (A) onto the threads of the studs and nuts (11) .
Illustration 5 g02174426
Using the torque sequence illustrated in Illustration 5 to tighten nuts (11) to a torque of 23 3 N m (204 27 lb in). Tighten nuts (11) again using the torque sequence illustrated in Illustration 5 to a torque of 28 3 N m (21 2 lb ft). Tighten nuts (11) again using the torque sequence illustrated in Illustration 5 to a torque of 28 3 N m (21 2 lb ft).
Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
Lubricate new O-ring seals (17) and (18) with Tooling (C) prior to installation.
Tighten filter (16) to a torque of 60 6 N m (44 4 lb ft).
Tighten fittings (14) and (13) to a torque of 30 2 N m (22 1 lb ft).
Tighten spark plug (15) to a torque of 47 4 N m (35 3 lb ft).
Apply Tooling (A) to the threads of flame detection temperature sensor (6) and install the sensor. Tighten flame detection temperature sensor (6) to a torque of 45 5 N m (33 3 lb ft).
Install a new gasket before installing bolts (4) .
Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.
Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".