0309781 EVINRUDE PLUG, Fuel passage

1. Disconnect oil line (1) from the BrakeSaver housing. 2. Remove the bolts and disconnect flanges (2) from the housing. 3. Remove four bolts, manifold (3) and the gasket from the bottom of the BrakeSaver housing. 4. Install tooling (A) on the BrakeSaver housing and rotor. This prevents damage to the rotor and seals when the BrakeSaver is removed. 5. Disconnect two air lines (4) and (5) at the air compressor. 6. Install tooling (B) and fasten a hoist to it. 7. Remove three bolts (6) from the BrakeSaver housing.8. Install two 3/8"-16 NC forcing screws (7) and remove the BrakeSaver. The weight of the BrakeSaver is 168 lb. (76 kg).Install BrakeSaver
1. Install tooling (B) on the BrakeSaver.2. Install two 5/8"-11 NC x 15" guide bolts (1).3. Put BrakeSaver (3) in position with the use of tooling (A) and a hoist.4. Make an alignment of dowel (2) in the crankshaft and the hole in the BrakeSaver. 5. Connect two air lines (4) and (5) to the air compressor. 6. Put O-ring seals (6) and (8) in position on the manifold.7. Put manifold (7) in position and install the bolts. 8. Put the gaskets and manifolds (9) in position and install the bolts. 9. Connect oil line (10) to the BrakeSaver housing.Disassemble BrakeSaver
start by:a) remove BrakeSaver1. Remove tool (A) from the BrakeSaver rotor and housing. Tool (A) prevents damage to the rotor seals and rings at removal of the BrakeSaver. 2. Remove bolts (1) from gear plate (2). Remove the plate. 3. Make identification as to the location of stator (3) with housing (4). Remove bolts (5) and the stator. 4. Turn the stator over and remove spiral ring (6). 5. Turn the stator over again. Remove sleeve assembly (9). Remove O-ring seal (7) and lip type seal (8) from the sleeve. 6. Remove seal (11) from around the housing and the six smaller seals from the oil lines.7. Remove rotor assembly (12).8. Remove seal ring (10) from both sides of the rotor. 9. Remove carrier (13) and wear sleeve (14) with tooling (B) from both sides of the rotor. 10. Remove spiral ring (15). Turn the housing over and remove sleeve assembly (17). Remove the lip type seal and O-ring seal (16) from the sleeve.Assemble Brakesaver
1. Put clean SAE 30 engine oil on the O-ring seal. Install seal (2) on sleeve (1).2. Install the sleeve in the BrakeSaver housing. Make alignment of the notch in the sleeve with the notch in the housing and install the dowel.3. Turn the housing over and install the spiral ring that holds the sleeve in the housing.
Make certain there is clearance behind the spiral ring when it is correctly installed.
4. Heat the carriers and the wear sleeves to a maximum temperature of 300°F (149°C). 5. Install carrier (5) on each side of rotor (3). Install wear sleeve (4) with the taper edge of sleeve in the "UP" position. Make sure the carrier is at bottom on the rotor and the sleeve is against the carrier. 6. Install a seal ring (7) in each of the carriers.7. Install the rotor assembly in BrakeSaver housing (6). 8. Put clean SAE 30 engine oil on the O-ring seal for the sleeve. Install O-ring seal (8) on the sleeve. Install sleeve (9) in the stator. Make alignment of the notch in the sleeve with the dowel in the stator. 9. Turn the stator over and install spiral ring (10) that holds the sleeve in the stator. 10. Put clean SAE 30 engine oil on the O-ring seals. Install seal (11) and six smaller seals (12) for the oil holes on the housing.11. Put the stator in the correct location on the housing with respect to the identification put on at removal. Make sure the oil holes in the stator and in the housing are in alignment.12. Install the bolts that hold the stator to the housing. Tighten the bolts to a torque of 40 5 lb.ft. (55 7 N m).13. The following steps are to be used with tooling (A) to install the lip type seals. a) Put clean SAE 30 engine oil on the lip of the seals.b) Put the pilot inside the seal. Install pilot and seal with the inside taper of the pilot against the wear sleeve. The lip of the seals must be toward the rotor.c) Install locator (13) and bolts (14) on the rotor. d) Put ring (17) over the locator and pusher plate (15) on the ring.e) Tighten nut (16) on the locator until tooling (A) is at bottom. 14. Install gear plate (18) and the bolts that hold it on the rotor. 15. Carefully turn the housing over and do Step 12 again to install the other lip type seal on the rotor. 16. Install tooling (B) to the rotor and the housing. Tooling (B) will prevent damage to the rotor seals and rings at installation.end by: a) install BrakeSaver