5007527 EVINRUDE Service Manual - English

The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
The bellows must be supported at all times when the bellows are not installed in the application. Failure to support the bellows adequately could result in the failure of the bellows. Do not use power tools to disassemble or assemble any part of the flexible exhaust system.The alignment of the bellows is important. Incorrect alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the uniformity of the spacing between the convolutions on the bellows.Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. If there is any difficulty in installation after the repair, discard the bellows.
Illustration 1 g06464885
Typical example
The lateral alignment of the bellows is critical. All the components must be assembled in the same alignment as prior to disassembly. The components that require correct lateral alignment are shown at Positions (A, B, and C).
Illustration 2 g06464916
Typical example
Follow Steps 2a through Step 2d to remove the flexible exhaust as an assembly from the Clean Emission Module (CEM) and the exhaust back pressure valve.
Use suitable material to encase flexible exhaust pipe (5). Encasing the flexible exhaust pipe will prevent damage of the bellows. Encase bellows for the flexible exhaust pipe (5) between Position (D) and Position (E). Use cable straps to retain the suitable material.Note: Ensure that the flexible exhaust pipe is supported at all times.
Loosen clamp (1) on the flexible exhaust pipe assembly.
Loosen the bolt for V-band clamp (4).Note: If V-band clamp (4) remain tight on the flanges, apply releasing fluid on the V-band clamp. Lightly tap the bolt on the V-band clamp with a soft faced hammer to assist removal. Do not use a prybar to remove V-band clamp.
Remove the assembly of the flexible exhaust pipe from the CEM (2) and exhaust back pressure valve (3).Note: Ensure that the assembly of the flexible exhaust pipe is supported as the clamps are removed.Disassembly Procedure for the Flexible Exhaust Pipe Assembly
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Drill Bit
3 mm (0.118 inch) Ø 1
B - Drill Bit
6.5 mm (0.256 inch) Ø 1
Ensure that the flexible exhaust pipe is free from wear or damage. Replace any component that is worn or damaged.
Illustration 3 g06464932
Typical example
Illustration 4 g06465280
Typical example
If necessary, follow Step 2a through Step 2b to disassemble the flexible exhaust pipe assembly.
Loosen ball clamp (8) and remove the ball clamp and exhaust elbow (9).
Loosen clamp (7) and remove exhaust elbow (6).Note: Ensure that the flexible exhaust pipe bellows are not subjected to any undue stress.
Follow Step 3a through Step 3c to remove flexible exhaust pipe clamp (7).
Use the correct personal protective equipment when removing the clamp.
If original bellows are to be reinstalled, place the internal area in Position (G) (not shown) of the bellows on a suitable support. Use Tooling (A) to drill a pilot hole through the spot weld in Position (H) on clamp (7). Do not center punch the spot weld on clamp (7).
Use Tooling (B) to drill out spot weld in Position (H) on clamp (7). Remove clamp (7) from bellows (5).
Remove all burrs from the internal and external areas of bellows (5). Ensure that debris does not enter bellows.Assembly Procedure for the Flexible Exhaust Pipe Assembly
Ensure that all components of the flexible exhaust pipe assembly are clean and free from wear and damage. If necessary, replace any components of the flexible exhaust pipe assembly that are worn or damaged.
Illustration 5 g06465280
Typical example
If the flexible exhaust pipe assembly was previously disassembled. Follow Step 2a through Step 2g to assemble the flexible exhaust pipe assembly.