0206398 EVINRUDE OWNER'S MANUAL

Table 1
Specifications for 329-8423 Front Housing Gp    
Callout     Part Number     Part Name     Specification Description    
6     340-0571     Gear     Torque 8.8 graded bolt to...................
95 N m (70 lb ft)
Torque 10.9 graded bolt to...................
120 N m (89 lb ft)
Number of teeth...................72    
7     342-1306     Idler As     Torque bolts to...................
44 N m (33 lb ft)
Width of light duty idler gear and bearing assembly is
19.95 to 20.05 mm (0.78543 to 0.78937 inch).
Width of medium duty and heavy duty idler gear and bearing assembly is
25.45 to 25.55 mm (1.00197 to 1.00590 inch).
Inside diameter of light duty idler gear bearings is
60.022 to 60.052 mm (2.36307 to 2.36425 inch).
Inside diameter of medium duty and heavy duty idler gear bearings is
56.00 to 56.03 mm (2.20472 to 2.20590 inch).
Outside diameter of light duty idler gear hub is
59.95 to 59.97 mm (2.36023 to 2.36102 inch).
Outside diameter of medium duty and heavy duty idler gear hub is
55.95 to 55.97 mm (2.20275 to 2.20354 inch).
Clearance of light duty idler gear bearing on hub is
0.052 to 0.102 mm (0.00205 to 0.00402 inch).
Clearance of medium duty and heavy duty idler gear bearing on hub is
0.03 to 0.08 mm (0.00118 to 0.00315 inch).
The end play of the light duty idler gear is
0.05 to 0.25 mm (0.00197 to 0.00984 inch).
The end play of the medium duty and heavy duty idler gear is
0.05 to 0.25 mm (0.00197 to 0.00984 inch).
Number of teeth...................97    
-     328-7837     Gear     Torque the nut to...................
64 N m (47 lb ft)
Number of teeth...................36    
-     -     Gear     Number of teeth...................21    
-     -     Gear     Inside diameter of oil pump idler gear bearing is
16.012 to 16.038 mm (0.6304 to 0.6314 inch).
Outside diameter of oil pump idler gear shaft is
15.966 to 15.984 mm (0.6286 to 0.6293 inch).
Clearance of oil pump idler gear bearing on shaft is
0.028 to 0.072 mm (0.0011 to 0.0028 inch).
End play of the oil pump idler gear is
0.050 to 0.275 mm (0.0019 to 0.0108 inch).
End play of the oil pump drive gear is
0.005 to 0.090 mm (0.00020 to 0.00354 inch).    
9     338-1402     Crankshaft Gear     Bore diameter of crankshaft gear is
51.00 to 51.03 mm (2.0079 to 2.0091 inch).
Outside diameter of crankshaft hub is
51.021 to 51.002 mm (2.0087 to 2.0079 inch).
Clearance of gear on crankshaft is
−0.021 to +0.028 mm (−0.00083 to 0.00110 inch).
Number of teeth...................36    Removal Procedure
Table 2
Required Tools    
Tool     Part Number     Part Description     Qty    
A     9U-7336     Housing     1    
5P-7305 Engine Turning Tool     1    
B     230-6284     Timing Pin (Camshaft)     1    
C     364-9107     Timing Pin
(Fuel Injection Pump)     1    
D     136-4632     Timing Pin (Crankshaft)     1    
268-1966 Adapter     1    
E     298-5564     T40Torx Socket     1    Start By:
Remove the front cover. Refer to Disassembly and Assembly, "Front Cover" for the correct procedure.
Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Dispose of all fluids according to local regulations and mandates.
Note: Care must be taken in order to ensure that the fuel injection pump timing is not lost during the removal of the front gear group. Carefully follow the procedure in order to remove the gear group.
Illustration 1 g02485936
Remove plug (1) from the cylinder block. Remove O-ring seal (2) from the plug.
Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding Top Center Position for No.1 Piston" for the correct procedure. Install Tooling (D) through Hole (W) in order to lock the crankshaft so that number one piston is at top dead center on the compression stroke.
Remove Tooling (D) .
Use Tooling (A) in order to rotate the crankshaft in a clockwise direction and position the crankshaft at the safe position. Refer to System Operation, Testing and Adjusting, "Position the Valve Mechanism Before Maintenance Procedures" for the correct procedure.