5040521 EVINRUDE PUMP CASE LINER

1. Remove five bolts (2) and cover (1) from housing assembly. 2. Remove screw (5) and collar (4) from bolt.3. Bend the tabs on lock and remove two bolts (3) and the torque spring assembly. 4. Remove lock (6), bar (7), spacer (8) and retainer (9). 5. Remove collar (11) and spring (10) from bolt. 6. Remove four bolts (13) and housing assembly (12) from housing. 7. Bend the tab on lock (15) and remove bolt (17).8. Remove shaft (16) and lever (14) from housing assembly. 9. Remove seal (19), plug and bearing (20) from housing assembly.10. Put identification on screw (18) or count the number of turns when screw is removed. Remove screw. 11. Remove seat (21), spring (23) and spring washer (22).
There are two washers and one spring under seat assembly. Care must be used during seat assembly removal so these parts do not become lost.
12. Lift up on retainer ring (25) and remove pin (26) and seat assembly (24). 13. Remove two washers (27), spring (30) and rod (28) from seat (29). 14. Remove sleeve and bearing assembly (31) from the cylinder and weight assemblies. Remove lockring (32) that holds weight assembly to cylinder. 15. Remove ring (33), races (36) and bearing (34) from sleeve (35). 16. Remove weight assembly (37) from cylinder. 17. Bend the tabs on lock (38) and remove three bolts (40).18. Remove cylinder (39) from cover. 19. To remove the piston assembly from pin (43) lift up on sleeve (41) and slide piston (42) from pin. The bottom of the piston has an opening (notch) that engages with the top of pin. When piston (42) is correctly engaged with top of pin (43), the sleeve (41) can be moved into place. 20. Remove valve (45) and sleeve (41) from piston (42). Remove seal (44) from sleeve. 21. Bend the tab on locks (48) and remove bolts. Remove bolt (46) and washer used to fasten gear on shaft assembly. Remove cover (47) from housing.
Support shaft assembly to prevent damage during disassembly.
22. With a press and tooling (A) remove shaft assembly (50) from gear and cover (49). 23. Install shaft assembly (50) in press and remove gear (51). 24. Remove gear (52) from bushing. Remove pin (43) from housing. To remove pin from housing turn shaft (53) counterclockwise and remove pin from lever assembly inside housing. The bottom of pin has an opening (notch) that engages with lever. 25. Remove bearing (54) from housing. 26. Bend the tabs on locks (56) and (57). Remove bolts that hold the shaft in the housing and hold lever to shaft. Slide lever (55) on shaft and remove key from shaft. Remove shaft (53) from housing. 27. Remove plug assembly (58) from housing. 28. Remove seal (60) and two bearings (61) from housing.29. Remove oil bypass valve assembly (59) from housing. 30. Remove pin (65), piston (64) and spring (63) from body (62).Assemble Governor
1. Install two needle bearing assemblies in housing with a press and tool (A). Install bearing in bore (1) until bearing surface is even with the edge of the housing surface. Install the other bearing until it is even with the top of the seal counterbore. Install seal as shown with tool (A). 2. Install plug assembly (2) in housing and tighten to a torque of 50 10 lb.ft. (70 14 N m). 3. Install washer (3), spring (4), piston (5) and pin (6) in body. 4. Install oil bypass valve assembly (7) in housing and tighten to a torque of 50 10 lb.ft. (70 14 N m). 5. Slide shaft (8) through lever (9) and install lock and bolt to hold shaft in housing. Install key in shaft. Slide lever (9) on key and install lock and bolt. The shaft must turn freely in bearings with .020 to .060 in. (.508 to 1.524 mm) end play. 6. Install bearing (10) in housing with a press and tool (A). Height from housing to top of bearing is .470 .005 in. (11.94 0.13 mm). 7. Install pin (11) in housing. Pin has an opening (notch) that engages in lever (9). 8. Install gear (12) on bearing. 9. Use a press and install gear (14) on shaft (13). Install gear until it makes contact with shoulder of shaft. 10. Install cover (16), gear (15), washer and bolt on shaft assembly. Install assembly in housing.11. Install two locks and bolts in position on cover. 12. Inspect O-ring seal (17) and make a replacement if necessary. 13. Install valve (19) in piston (20). Install sleeve (18) on piston.14. Install piston assembly on pin (11) as follows: Lift up on sleeve (18) and slide piston (20) on pin (11). The bottom of the piston has an opening (notch) that engages with the top of pin. When piston is correctly engaged with pin, the sleeve (18) can be moved into place. 15. Install cylinder (21) on cover. 16. Install lock (24) and three bolts (23) in position on cylinder.17. Install weight assembly (22) on cylinder. Install lockpin on weight assembly. 18. Put races (28) and bearing (26) in position on sleeve (27). Install ring (25) that holds the races and bearings on the sleeve. 19. Put sleeve assembly (29) in position on valve. Make an alignment of the holes in the sleeve and valve. 20. Install bolt (31), washers (30) and spring (33) in seat.21. Put seat (32) in position on sleeve assembly (29).22. Make an alignment of the holes in the seat, sleeve assembly and valve. Install dowel (35) that holds the seat, sleeve assembly and valve together. 23. Install retaining ring (34) that holds dowel (35) in place. 24. Put spring washer (37) in position on the bolt.25. Put spring (38) and seat (36) in position on the weight assembly.