0305537 EVINRUDE ROD, Shift, upper

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Overheating of the engine can occur during machine operations when the machine is equipped with the 290-9911 Engine Enclosure Seal Kit () or with the 291-5437 Engine Enclosure Seal Kit . The various seals, covers, and brushes that are used in these kits for blocking the entry of debris also reduce ventilation of the engine compartment.Solution
Increasing ventilation of the engine compartment will reduce the possibility of the engine overheating during machine operations when the machine is equipped with the debris kit. Perform the following procedure in order to modify the rear door for improved ventilation inside the engine compartment.Modification of the Rear Door
Required Parts
The parts that are required for this modification are identified below:
A grill (1) for installation on the inside of the rear door. The material for grill (1) should be perforated SAE 1008 Modified carbon steel. The dimensions for grill (1) will be 805 5 mm (31.69 0.20 inch) by 305 2 mm (12.01 0.08 inch) by 3 mm (0.12 inch) thickness. The perforations should be no greater than 6.5 mm (0.26 inch) with a minimum open area of 58%.
A new service film (2) for installation on the inside of the rear door. See Table 1 in order to determine the correct service film for your machine.
Three 3S-2093 Cable Straps (3) and one 7K-1181 Cable Strap (4) for reinstalling the harness on the rear door.
Table 1
Film    Machines    
295-7208 Film     257B, 257B2    
295-7207 Film     247B, 247B2    
295-7199 Film     216B, 216B2, 226B, 226B2    
295-7200 Film     232B, 232B2, 242B, 242B2    Modification Procedure
Remove the 258-3427 Film (Caterpillar) from the outside of the rear door.Note: Use a heat gun and apply heat to the film in order to aid in removing the film.Discard the film.
Illustration 1 g01517368
(A) 216-4703 Rear Lighting Harness As (B) 258-0930 Stop and Tail Lamp Gp (C) 161-2539 Alarm As (D) 6V-7357 Bolt (E) 8T-4205 Hard Washer (F) 3S-2093 Cable Strap (G) 7K-1181 Cable Strap (H) 231-3925 Bracket As (J) 7X-2537 Bolt (K) 5P-4116 Hard Washer (L) 131-3540 Locknut (M) Service film (N) 159-8405 Shoulder Bolt (O) 2K-4973 Locknut
Perform Step 2.a through Step 2.e in order to remove components from the inside of the rear door. Refer to 1.
Disconnect the two lamps (B) from harness (A). Then, remove the two lamps (B) from the rear door.Retain the two lamps (B) for reinstallation.
Disconnect backup alarm (C) from harness (B). Then, remove the two bolts (D), the two hard washers (E), and alarm (C) from the rear door.Retain the two bolts (D), the two hard washers (E), and alarm (C) for reinstallation.
Remove the three cable straps (F) and cable strap (G) in order to disconnect harness (A) from the rear door.
Remove the two bolts (J), the four hard washers (K), and the two locknuts (L) that fasten bracket assembly (H) to the rear door.Note: Do not remove the 285-5794 Coolant Recovery Gp from bracket assembly (H). Also, do not disconnect the 5P-1420 Hose from the coolant overflow reservoir.Temporarily secure the bracket assembly with the coolant recovery group to the frame inside the engine compartment.Retain the two bolts (J), the four hard washers (K), and the two locknuts (L) for reinstallation.
Remove the service film (M) from the inside of the rear door.Note: Use a heat gun and apply heat to the film in order to aid in removing the film.Discard the service film.
Remove the two bolts (N) and the two locknuts (O) that secure the rear door to the frame. Then, remove the rear door from the machine. Lay the rear door on a flat surface with the outside surface upward.Retain the two bolts (N) and the two locknuts (O) for reinstallation.
Illustration 2 g01517369
(V) 104 mm (4 inch) (W) 283 mm (11 inch) (X) 382 mm (15 inch) (Y) 764 mm (30 inch) (Z) 64 mm (2.5 inch) Radius
Cut a rectangular opening in the rear door per the dimensions that are specified in Illustration 2. Grind the edges of the opening in order to smooth the edges.
Turn over the rear door so that the inside surface is upward.
Illustration 3 g01518613
(1) Grill (T) 152.5 mm (6 inch) (U) 402.5 mm (15.8 inch)
Center grill (1) over the opening in the rear door. See Illustration 3.Then, weld the grill to the rear door. Make 2.0 mm (0.08 inch) fillet welds 25 mm (0.98 inch) long. Make these welds around the entire perimeter of the grill. Leave a 50 mm (1.97 inch) space between welds.
Prime the exposed surfaces of the metal, the grill, and the welds. Then, paint all of the exposed surfaces of the metal, the grill, and the welds. Use Caterpillar yellow primer and Caterpillar yellow paint.
Reinstall the rear door on the machine. Use the two bolts (N) and the two locknuts (O) that were retained. Tighten the bolts to a torque of 27 4 N m (19.9141 2.9502 lb ft).
Illustration 4 g01518612
(A) 216-4703 Rear Lighting Harness As (B) 258-0930 Stop and Tail Lamp Gp (C) 161-2539 Alarm As (D) 6V-7357 Bolt (E) 8T-4205 Hard Washer (H) 231-3925 Bracket As (J) 7X-2537 Bolt (K) 5P-4116 Hard Washer (L) 131-3540 Locknut (N) 159-8405 Shoulder Bolt (O) 2K-4973 Locknut (1) Grill (2) Service film (3) 3S-2093 Cable Straps (4) 7K-1181 Cable Strap
Perform Step 9.a through Step 9.e in order to install components on the inside of the rear door. Refer to 4.
Install the new service film (2) on the inside of the rear door.
Install harness (A) on the inside of the rear door. Use three cable straps (3) and