5040343 EVINRUDE STARTER MOTOR ASSEMBLY

Start By:a. remove rocker shaft assemblies and push rodsb. remove front drive housing 1. Remove the bolts that hold the brackets for shaft (3) to the front of the cylinder block. Disconnect the levers on shaft (3) from the levers on shafts (1) and (2), and remove shaft (3) from the engine. 2. Remove levers (5) and (6) and brackets (4) from shaft (3). 3. Remove bearing (7) from brackets (4) with tool group (A). 4. Remove access covers (8) from over the camshafts. 5. Remove bolts (10) and the caps that hold the levers of rod assemblies (9) to fuel control shafts (1) and (2).6. If necessary, remove the cover from the front right side of the flywheel housing, and use tool (B) to turn the engine flywheel until the camshaft is moved in a position so the levers of rod assemblies (9) can be removed between the cylinder block and camshaft. 7. Remove bolts (12), and remove lever assemblies (11) and fuel control rod assemblies (9) as a unit from each cylinder head assembly. See Step 6 if the levers on the lower ends of rod assemblies (9) do not have enough clerance to be removed from the engine. 8. Remove locknut (13) and the washer to remove rod assembly (9) from lever assembly (11). 9. Remove levers (15) from control shafts (1) and (2).10. Remove the bolts and supports (14) from each side of the engine. If necessary, remove bearings (16) from supports (14) with tool group (A).
Steps 11, 12, 13, 14 and 16 are not necessary in order to remove the fuel injection control linkages on 3508 Engines. The previous steps except Step 12 are not necessary to remove the fuel injection linkages on the later 3512 and 3516 Engines. New thicker walled fuel control shafts are now used on the 3508 and 3512 Engines. On the 3512 Engines a one piece shaft is now used instead of the two piece shaft that was held together with a collar. Formerly, different shafts were used on each side of the 3508 and 3512 Engine. The new shafts can be used on either side of the engine. It is Caterpillar's recommendation that if a replacement shaft is necessary, both shafts be installed at the same time for correct weight balance.
Earlier 3512 Shown11. Remove the bolts, and remove collar (17) that holds the control shafts together from each side of the engine. 12. Remove bolts (19) that hold bracket assembly (18) to each side of the engine block.13. Remove the bolts that hold collars (20) to control shafts (1) and (2). 14. Remove collars (20) and bracket assembly (18) from both of the control shafts. 15. Pull control shafts (1) and (2) out of each side of the engine block. 16. Remove the shorter control shaft (21) from bracket assembly (18) on each side of the engine, and remove the shafts from the engine.17. Remove the bolts, and remove bracket assembly (18) on each side of the engine. 18. Use tool group (A), and remove bearings (22) from brackets (18).Install Fuel Injection Control Linkage
1. Use tool group (A) to install the bearings in brackets (1) until they are in the center of their bores. Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in.). 2. Install bracket assembly (1) at the rear of the engine block on each side. Steps 3, 5, 6 and 7 are not necessary to install the 3508 fuel injection control linkage. Only Step 6 is necessary for the later 3512 and 3516 Fuel injection control linkage installation.3. Install the shorter control shaft (2) in bracket assembly (1) on both sides of the engine block. The earlier 3512 Engines with two-piece shafts (3) have identification marks on the front inside diameter of the shafts as to their location. The right control shaft has green dykem and the left control shaft has red dykem. The later 3512, 3508 and the 3516 Engines have shafts that are one piece and can be used on either side of the engine.4. Put control shafts (3) in position in each side of the engine block. 5. Put collars (4) and bracket assembly (1) in position on each control shaft (3). Install the bolts that hold collars (4) to the control shafts. 6. Install the bolts that hold bracket assembly (1) to each side of the engine block.
Earlier 3512 Shown7. Install collar (5) to connect shaft (3) to shaft (2) on both sides of the engine. 8. Use tool group (A), and install the bearings in the center of the bores in supports (6). Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in.). 9. Install supports (6) to hold the front of the control shafts. Install levers (7) on each of the control shafts. 10. Connect lever assembly (9) to rod assembly (8). 11. Install lever assembly (9) and rod assembly (8) as a unit in each cylinder head assembly. If necessary, use tool (B) to turn the engine flywheel until the camshaft moves enough to permit the lever of the rod assembly to move into position.12. Make sure lever assembly (9) is engaged correctly with the fuel injection pump rack, and install the two bolts and washers to hold it in place. 13. Make sure the lever for the fuel control and assembly is in position on the control shaft, and install the bolt and cap (10). 14. Install access covers (11) and the seal over the camshafts and control rods. 15. Use tool group (A), and install the bearings in the center of the bores in front control shaft brackets (12). Check the bore in the bearings after assembly. The bearing bores must be 21.925 0.015 mm (.8632 .0006 in.). If necessary, make a replacement of the pins in brackets (12). The pins must extend 8.00 0.50 mm (.315 .020