5040532 EVINRUDE GROMMET THROTTLE SHAFT

1. Remove cover (1) and covers (2). 2. Remove louver (3) and cover (4). 3. Put a piece of cardboard (5) between stator (6) and rotor assembly (7). This step is necessary to prevent damage to the rotor assembly and stator when the generator fan is disconnected from the flywheel housing. 4. Loosen three bolts and nuts (8) on the front engine support. 5. Remove the bolts, mounts, sleeves and collars that hold the generator in place on the base. 3412 Generator Sets do not have mounts, sleeves or collars. 3412 Generator Sets have four bolts that hold the generator set to the base.6. Fasten a strap (9) and tool (A) to the generator as shown. Fasten a chain to the lifting bracket on the front of the generator.7. Lift the generator and the rear of the engine enough to install blocks (10) under the flywheel housing. Lower the generator and engine until the weight of the engine is on blocks (10). 8. Remove bolts (12) that hold fan (13) against the flywheel housing. Remove bolts (11) that hold the generator housing against the flywheel housing.9. Remove the generator from the engine. The weight of the generator is approximately 1134 kg (2500 lb.). 10. Remove bolts (14) and plates (15). 11. Remove fan (16) and shims (17).Install Generator
1. Put fan (1) in position in the generator housing. Make sure holes (2) are toward the outside as shown.2. Install a 1/2"-10 NC x 4" long guide bolt (4) in the generator hub.3. Check the thickness of the plates that are installed over shims (3). The thickness of shims (3) and the plates must be 12.116 0.406 mm (.477 0.16 "). Add or subtract shims (3) to get the correct thickness. 5. Install plates (5) on the hub. Remove the guide bolt and install the bolts that hold the shims and plates in position. 6. Remove the cover from the flywheel housing and install tool (B). Step 7 is for 3408 Generator Sets only.7. Make sure mounts (8) are in position on the base. Make sure the flat side of each mount is toward the bottom of the generator.8. Install a 5/8"-11 NC x 4" long guide bolt in the flywheel.9. Fasten tool (A) and straps (6) to the generator as shown. Fasten a chain to the lifting bracket on the generator. Put generator (7) in place on the engine. The weight of the generator is approximately 1133 kg (2500 lb.). Use tool (B), if necessary, to put the guide bolt in the flywheel housing in alignment with the holes in the plates and fan on the generator. 10. Install bolts (10) that hold fan (9) in position on the flywheel. Remove the guide bolt and install the bolt.11. Install the bolts that hold the generator housing to the flywheel housing. 12. Lift the generator and engine enough to remove blocks (11). Lower the generator and engine down on to mounts (8). Step 13 is for 3408 Generator Sets only.13. Install bolts (12), sleeves (13), collars (14), mounts (15) and nuts (16) that hold the generator in place on the base.14. On 3412 Generator Sets, install the four bolts that hold the generator in place on the base. 15. Tighten bolts (17) on the engine front support. 16. Remove cardboard (18) from between the rotor assembly and the stator. 17. Install louver (19) and cover (20). 18. Install covers (21) and (22).