5040686 EVINRUDE SHIFT LEVER SHAFT ASSEMBLY

1. Drain the coolant from the cooling system into a suitable container for storage or disposal.2. Disconnect the water supply line from the water pump inlet. 3. Remove the bolts and retainers from both ends of tube (1) and remove tube (1) from the engine. 4. Remove the bolts and remove damper guard (2) from the engine. 5. Remove bolts (3) that hold the pump to the water line adapter. 6. Fasten a strap and a suitable lifting device to water pump (4) and remove the four bolts that hold the water pump to the oil and water pump drive adapter. Remove water pump (4) from the engine. The weight of the water pump is 39 kg (85 lb).Install Water Pump
1. Make sure the gasket for the water line adapter and the O-ring seal on the pump are in position. Put clean engine oil on the O-ring seal. Fasten a strap and a suitable lifting device to water pump (1) and put water pump (1) in position on the engine. Make sure the splines on the water pump shaft are correctly engaged and install the bolts to hold the water pump to the oil and water pump drive adapter. 2. Install bolts (2) to hold the pump to the water line adapter. 3. Install damper guard (3) on the engine. 4. Make sure the O-ring seals on both ends of tube (4) are in position and put clean engine oil on the seals. Put tube (4) in position and install retainers and bolts to hold the tube in position.5. Connect the water supply line to the water pump inlet.6. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual.Disassemble Water Pump
Start By:a. remove water pump 1. Remove elbow (1) from housing assembly (2). Remove the O-ring seal from elbow (1). 2. Remove O-ring seal (5) from the back of housing assembly (2).3. Remove washer (4) that holds shaft assembly (3) in housing assembly (2). 4. Remove cover (6) from housing assembly (2). Remove the O-ring seal from cover (6). 5. Loosen bolt (8) and the washer that hold impeller (7) to the pump shaft. Use Tool (A) to loosen impeller (7) from the end of the pump shaft. Remove Tool (A), bolt (8), the washer and impeller (7) from the pump shaft and housing assembly (2). 6. Remove spring (10) from seal assembly (9) and shaft assembly (3).7. Use a soft faced hammer and push shaft assembly (3) out of seal assembly (9) and housing assembly (2). Remove seal assembly (9) from housing assembly (2). 8. Remove ceramic seal (11) from the rubber ring. Remove the rubber ring from housing assembly (2). 9. Remove seal (12) from the back of housing assembly (2).Assemble Water Pump
1. If necessary, make a replacement of the two filters in the pump housing at location (1).2. If necessary, make a replacement of plug (2) and the seal.3. Use Tool (A) to install the seal in the housing assembly. Make sure the lip of the seal is toward the outside as shown. Put clean engine oil on the lip of the seal. 4. Install shaft assembly (3) in housing assembly (4). Install washer (5) and the bolts to hold shaft assembly (3) in position.
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
5. Put ceramic seal (6) in position in the rubber ring. Use hand pressure and the tool (which is with the replacement seal) to install the ceramic seal. 6. Remove spring from seal assembly (7). Use hand pressure and the tool (which is with the replacement seal) to install the seal assembly. Push seal assembly on shaft until seal faces make light contact. 7. Install spring (8) on the pump shaft as shown.8. Install impeller (9) on the pump shaft as shown. 9. Install washer (11) and bolt (10). Tighten bolt (10) to a torque of 90 15 N m (66 11 lb ft). Hit the bolt with a hammer and tighten it again to a torque of 90 15 N m (66 11 lb ft). Make sure the studs for cover (12) are tightened to a torque of 27 4 N m (20 3 lb ft) in the pump housing. 10. Put clean engine oil on O-ring seal (13) and install it on cover (12). Put cover (12) in position and install nuts to hold it to the pump housing. 11. Put clean engine oil on the O-ring seal and install it in elbow (14). Put elbow (14) in position on housing assembly (4) and install the bolts to hold the unit together.12. Put clean engine oil on the O-ring seal and install it on the back of housing assembly (4).End By:a. install water pump