5040246 EVINRUDE NEUTRAL SWITCH ACTUATOR

START BY:a) remove valve cover The removal and installation of the rocker shaft assembly on the 3408 and 3412 Generator Sets is similar so only one will be shown. 1. Remove fuel lines (1) with tool (A). Put caps and plugs in the openings to keep dirt out of the fuel system. 2. Remove bolt (2) that holds the bracket to the front of the aftercooler housing. On 3412 Generator Sets, also remove the bolt that holds the bracket to the side of the aftercooler housing.3. Remove nuts (3), locks (4) and adapters (5) from the base. 4. Remove the cover from the flywheel housing and install tool (B). Use tool (B) to turn the crankshaft to release any pressure against the rocker arms.5. Use tool (C) to move the rocker arms away from push rods (6) far enough so the push rods can be removed. 6. Put identification on valve bridges (9) as to their location for correct installation. Remove valve bridges (9).7. Remove bolts (7) and rocker shaft assembly (8). The 3408 Generator Set has one rocker shaft assembly on each side of the engine. The 3412 Generator Set will have two rocker shaft assemblies on each side of the engine.Install Rocker Shaft Assembly
1. Put rocker shaft assembly (1) in position on the engine. The tightening sequence in Step 2 is for 3408 Generator Sets only.2. Put clean engine oil on all the bolts that hold the rocker shaft assembly in position. Install bolts (2), (3), (4) and (5). Use the following procedure to tighten the bolts.a) Tighten bolts (2) through (5) in numerical sequence to 271 27 N m (200 20 lb.ft.).b) Tighten bolts (2) through (5) in numerical sequence to 447 20 N m (330 15 lb.ft.).c) Do Step 2b again to make sure all the bolts are tightened to the correct torque. The tightening sequence in Step 3 is for 3412 Generator Sets only.3. Put clean engine oil on all the bolts that hold the rocker shaft assemblies in position and install them on the rocker shaft assemblies. Use the following procedure to tighten the bols.a) Tighten bolts (6) through (11) in numerical sequence to 270 25 N m (199 18 lb.ft.).b) Tighten bolts (6) through (11) in numerical sequence to 450 20 N m (332 15 lb.ft.).c) Do Step 3b again to make sure all the bolts are tightened to the correct torque. 4. Put clean engine oil on the valve bridge dowels. Install valve bridges (12) in their original positions on the engine. 5. Use tool (A) to make sure there will be no pressure against push rod (13) and rocker arm (14). Use tool (B) to pull rocker arm (14) away from push rod (13). Put push rod (13) in position under the rocker arm. If the rocker arm can not be moved enough to put the push rod in position, turn the crankshaft with tool (A).6. Make an adjustment of the valves to have a clearance of .038 mm (.015 in.) for intake and 0.76 mm (.030 in.) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING. 7. Make sure the O-ring seal is in position on the adapter. Put clean engine oil on the O-ring seal. Put adapter (20) in position in the valve cover base.8. Install spacer (18), the washer, lock (19), washer (17) and nut (15). Tighten nut (15) to a torque of 14 3 N m (10 2 lb.ft.). Connect the fuel lines to the adapter. Tighten nut (16) to a torque of 41 7 N m (30 5 lb.ft.).9. Do Steps 7 and 8 again for the rest of the adapters. 10. Install bolt (21) that holds damper (22) to the front of the aftercooler. On the 3412 Generator Sets, install the bolt that holds the damper on the side of the aftercooler. 11. Put fuel lines (23) in position. Tighten the fuel line nuts to a torque of 41 7 N m (30 5 lb.ft.). It will be necessary to use tool (C) to tighten nut (24).END BY:a) install valve coverDisassemble Rocker Shaft Assembly
START BY:a) remove rocker shaft assembly The disassembly and the assembly of the rocker shaft assemblies for the 3408 and 3412 Generator Sets is similar so only one will be shown. 1. Remove retainer (3), washers (2) and rocker arm (4) from the rocker shaft assembly.2. Make sure dowel (1) is free of oil. 3. Put tooling (A) in position on dowel (1). Pull rocker arm (6) away from bracket assembly (5). Remove the dowel with tooling (A). Remove bracket assembly (5). 4. Remove rocker arms (9), spring (8) and brackets (7). Use tooling (A) to remove the dowel that holds bracket assembly (6) on the rocker shaft. 5. Remove nuts (10) and screws (11) from the rocker arms if a replacement is necessary. 6. Remove plug (12) from rocker shaft (13) if a replacement is necessary.