0434495 EVINRUDE MOTOR & O-RING AY.

1. Release the pressure in the hydraulic system by slowly loosening the fill plug located on the top of the hydraulic oil tank.
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 nough 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.
2. Release the pressure in the cooling system by slowly loosening the fill cap on the radiator. 3. Open the access door for the radiator. Open valve (1) to drain the coolant from the radiator. The capacity of the cooling system is 55 liters (14.5 U.S. gal). 4. Disconnect upper radiator hose (2) at the radiator.5. Disconnect lower radiator hose (4) at the radiator.6. Remove the bolts and washer that hold support rods (5) to each side of the radiator.7. Fasten a hoist to lifting eyes (3) on each side of the radiator. 8. Remove the three bolts and washers from panel (6).9. Remove the three bolts and washers and the tube support clip from panel (7).10. Disconnect tube (9) from reserve tank (11).11. Remove two clamps (8). Two bolts (10) are located in front of the radiator. The other two bolts (10) are located behind the radiator.12. Remove four bolts (10), the washers and nuts that hold the radiator and oil cooler assembly to the frame of the machine.
Do not damage the radiator core or the oil cooler core during removal.
13. Remove the radiator and oil cooler assembly from the machine. The weight of the radiator and oil cooler assembly as a unit is 191 kg (420 lb).14. Remove the two shims that are located between the radiator and oil cooler assembly and the frame of the machine. 15. Disconnect tube (9) from the radiator filler neck. Slip the tube through the grommet in panel (12). Remove lower fan guard (13).16. Remove the hoist from the lifting eyes on the radiator, and refasten the hoist to the lifting eyes on the oil cooler. 17. Remove the four bolts, support clip (14), tube (9) and panel (12) from the radiator.18. Remove the oil cooler from the radiator. The following steps are for the installation of the radiator.19. Put the oil cooler and panel (12) in position in the mounting flange of the radiator.20. Install support clip (14) that holds tube (9) in place. Install the washers and the four bolts that hold panel (12) to the radiator and the oil cooler.21. Reinstall lower fan guard (13).22. Slip tube (9) through the grommet in panel (12). Connect the tube to the tube on the radiator filler neck.
Do not damage the radiator core or the oil cooler core during installation.
23. Fasten a hoist to the radiator and oil cooler assembly. Put the original amount of shims and the radiator and oil cooler assembly in position on the frame of the machine. Install four bolts (10), the washers and nuts that hold the unit in place.24. Reinstall two clamps (8).25. Connect tube (9) to reserve tank (11).26. Install the tube support clip and the three bolts and washers in panel (7).27. Install the three bolts and washers in panel (6).28. Install the bolts and washers that hold support rods (5) to the sides of the radiator.29. Connect lower radiator hose (4) to the radiator.30. Connect upper radiator hose (2) to the radiator.31. Fill the hydraulic oil tank with oil and the cooling system with coolant to the correct levels. See the Operation & Maintenance Manual for the correct filling procedures.