5041497 EVINRUDE PTT SOLENOID SWITCH (A)

1. Disconnect tube assemblies (2) from diverter valve (3), and disconnect tube assemblies (1) from the shutoff control. 2. Remove the bolts to remove cover (5), tube (4) and the diverter valve as a unit from the shutoff drive housing assembly and the shutoff control. 3. Disconnect tube assemblies (6), (7) and (9) from the shutoff control. Remove the bolts and hydramechanical shutoff control (8) from the shutoff drive housing assembly. 4. Remove coupling (10) from the end of the shutoff drive gear.Install Hydramechanical Shutoff Control
1. Install coupling (2) on the end of the shutoff drive gear.2. Put hydramechanical shutoff control (1) and the gasket in position on the shutoff drive housing assembly. Make sure the shaft of the shutoff control is correctly engaged with the coupling, and install the bolts to hold the shutoff control in position. 3. Connect tube assemblies (3), (4) and (5) to the shutoff control. 4. Put clean engine oil on the O-ring seals, and install tube (6) in the bottom of the shutoff control. Put cover (7) and the diverter valve as a unit in position on tube (6) and the shutoff drive housing assembly. Install the bolts to hold these in position. 5. Connect tube assemblies (8) to the shutoff control, and connect tube assemblies (9) to the diverter valve.Disassemble Hydramechanical Shutoff Control
Start By:a. remove hydramechanical shutoff control 1. Remove the bolts, and remove actuator valve (1) from the pressure control valve.
There is spring pressure on cover (2). Remove the bolts that hold cover (2) slowly to release the spring pressure.
2. Remove the bolts, and remove cover (2) from the actuator valve body. 3. Remove springs (4), spacer (5) and valve assemblies (3) from the valve body. 4. Remove tube assembly (7) from the shutoff control.5. Remove pressure control valve (6) from the shutoff control. 6. Put identification marks on valve assemblies (12) and (13) for assembly purposes. Remove rack shutoff valve (12) and air inlet shutoff valve (13) from the pressure control body assembly. Remove the three O-ring seals from each valve.7. Remove plug (11) to remove pilot valve (10) and spring (9) from the pressure control body assembly.8. Remove manual shutoff valve (8) as a unit from the pressure control body assembly. 9. Loosen nut (16) to remove knob (17) and nut (16) from valve (14). Remove adapter (18) and spring (19) from valve (14). Remove O-ring seal (15) from adapter (18). 10. Remove seal (20) from adapter (18). 11. Remove eight bolts (22) to remove gerotor pump group (21) from the shutoff control housing assembly. 12. Use tool (A) to remove ring (24) and the washer from the carrier assembly shaft. Do not remove bolts (23) at this time. 13. Remove carrier assembly (25) from the gerotor pump group. 14. Remove dowels (27) to remove weights (26) from carrier (25). Remove pin (28), and use a press to remove shaft (29) from carrier (25). 15. Remove washer (30) from the pump group. 16. Remove two bolts (23) (see illustration B47968X1) to remove cover assembly (31) from the plate. 17. Remove gasket (32) from the plate. 18. Remove plate (33) from the housing assembly. 19. Remove seal (34) from plate (33). Carefully remove driven gear (36) from sleeve (35) so brush (39) and spring (38) do not become lost.20. To remove the gerotor assembly, remove drive gear (37), driven gear (36) and sleeve (35) from the housing assembly.21. Remove brush (39) and spring (38) from driven gear (36). 22. Use tool (B) to remove snap ring (43), and remove seat (42), spring (41) and plunger assembly (40) from the housing assembly. 23. Remove O-ring seal (44) from the housing assembly. 24. Remove speed sensing valve (46), spring (45) and the seat from the housing assembly guide. 25. Remove ring (50) to remove race (49), bearing (51) and race (48) from seat (52). Loosen nut (47) to remove seat (52) and nut (47) from speed sensing valve (46). 26. Remove shaft (53) to remove lever (54) from the housing assembly. 27. Remove the wire seal and bolts (55) to remove cover (56), the two seats and the spring from the housing assembly. 28. Use tool group (C) to remove the guide from the housing assembly.Assemble Hydramechanical Shutoff Control
1. If necessary, make a replacement of dowels (2), and make sure they are 3.0 0.5 mm (.12 .02 in.) above the surface of the housing assembly.2. Put guide (1) in position in the housing assembly, and make sure the dash mark on the end of the guide is in alignment with hole (3). Use tool group (A) to install guide (1) in the housing assembly. 3. Put lever (5) in position in the housing assembly as shown, and install shaft (4) to hold lever (5) in position. Make sure the end of the shaft is even (flush) 0.25 (.010 in.) with the housing assembly. 4. Put the seat, spring (7) and seat (6) in position in cover (8), and put cover (8) and the gasket in position on the housing assembly. Install the bolts to hold the cover in position. 5. Install nut (15) and seat (10) on speed sensing valve (9). Make sure the dimension between the end of the valve and the nut face of the seat is 117.21 0.25 mm (4.614 .010 in.), and tighten the nut. Put race (14), bearing (11) and race (13) in position on seat (10), and install ring (12) to hold these in position. 6. Install seat (16), spring (17) and speed sensing valve (9) on the housing assembly guide. 7. Put clean engine oil on O-ring seal (18), and put O-ring seal (18), plunger assembly (19), spring (20) and seat (21) in position in the housing assembly. Use tool (B) to install snap ring (22) to hold the plunger assembly, the spring and seat in position. 8. If necessary, make a replacement of pin (24), and make sure pin (24) is 3.96 0.50 mm (.156