5041498 EVINRUDE STAY

Steps 1 and 2 are for generator sets with expansion tanks.1. Disconnect contactor (1) from the elbow. Remove two bolts (2) that hold elbow (3) against the other elbow. 2. Remove two bolts (4). Remove the bolts that hold elbow (3) to the cylinder head. Remove elbow (5), pipe (6) and elbow (3) from the engine as a unit. 3. Remove the bolt that holds clip (7) to the cover over the automatic timing advance.4. Remove nut (8). 5. Remove cover (9) from over the automatic timing advance. 6. Remove four bolts (10), the retainer and automatic timing advance (11).Install Automatic Timing Advance
1. Remove the plug and cover from the flywheel housing. Use tool (A) to turn the flywheel until the timing bolt can be installed in the flywheel through hole (1). Step 2 is for generator sets that have a Woodward PSG governor.2. Remove cover (2) from the governor drive housing.
Typical Example Step 3 is for generators that have a dashpot governor.4. On 3408 Generator Sets with a dashpot governor, remove plug (3). On 3412 Generator Sets with a dashpot governor, remove plug (4). 5. Turn the camshaft (5) until tool (B) can be installed in the groove (slot) in the camshaft. Remove the valve cover over the No. 1 cylinder. The engine is at top dead center on the compressor stroke if both rocker arms for the No. 1 cylinder can be moved up and down. If the rocker arms can not be moved, remove the timing bolt from the flywheel housing and turn the flywheel 360° more and install the timing bolt in the flywheel. 6. Install automatic timing advance (6), retainer (7) and four bolts (8). Tighten bolts (8) to a torque of 14 N m (10 lb.ft.). Tighten bolts (8) again to 68 N m (50 lb.ft.). Tighten bolts (8) again to a final torque of 136 7 N m (100 5 lb.ft.).7. Remove tool (B) and the timing bolt from the flywheel housing. Turn the flywheel two complete turns and install the timing bolt in the flywheel and tool (B) in the fuel injector pump housing to make sure the engine and fuel system is in the correct time.8. Remove tool (B) and install the cover (or plug) over the opening. Remove tool (A) and install the cover and plug in the flywheel housing. 9. Install bolt (9) in the cover as shown. There is not enough clearance to install bolt (9) for the expansion tank after cover (10) is installed.10. Install the gasket and cover (10). 11. Install the bolt that holds clip (11) in position on the cover. Install washer and nut (12). Steps 11 and 12 are for generator sets that have expansion tanks.12. Make sure the gasket is in position between elbow (13) and elbow (14). Make sure the gasket is in position between the cylinder head and elbow (16).13. Install elbow (14), pipe (15) and elbow (16) on the engine as a unit. Install the bolts that hold them in place. 14. Connect contactor (17) to elbow (16). Make sure the gasket is in position between elbow (16) and elbow (18). Install the bolts that hold elbow (16) to elbow (18).END BY:a) install expansion tank (if so equipped)Disassemble Automatic Timing Advance
START BY:a) remove automatic timing advance 1. Remove ring (1) and gear assembly (2) from the flange assembly.2. Remove the slides from the weights. 3. Remove springs (4) and weights (3) from the flange assembly. The automatic timing advance from the 6N3195 Governor and fuel pump drive group has three springs against each weight. The automatic timing advance from the 9N3959 Governor and fuel pump drive group has two springs against each weight. The automatic timing advance from the 8N8996 Governor and fuel pump drive group has only one spring against each weight.Assemble Automatic Timing Advance
1. Put weights (2) in position in flange assembly (1) as shown.2. Install springs (3) in flange assembly (1). The automatic timing advance from the 6N3195 Governor and fuel pump drive group has three springs against each weight. The automatic timing advance from the 9N3959 Governor and fuel pump drive group has two springs against each weight. The automatic timing advance from the 8N8996 Governor and fuel pump drive group has only one spring against each weight. 3. If pistons (6) were removed from the gear assembly because of wear, use new parts for replacement. Install new pistons (6) until they are 11.05 0.13 mm (.435 .005 in.) above the inside surface of gear assembly (4). Move the metal (peen) on the outside surface of gear assembly (4) in four places around each piston to hold them in position.4. Use 1P808 General Purpose Lubricant to hold slides (5) in position on gear assembly (4).5. Install gear assembly (4) on flange assembly (1). Make sure slides (5) fit in grooves of the weights.6. Install the ring that holds gear assembly (4) to the flange assembly.END BY:a) install automatic timing advance