5040330 EVINRUDE TILT STOPPER BODY

1. Remove tube assembly (1). 2. Remove six bolts (2) that hold ground wire (3) and magneto drive (4) on the flywheel housing.3. Remove four bolts (5), and remove magneto drive (4) from the flywheel housing. 4. Remove bolt (6), and remove coupling (7) and gear (9) from housing (8). 5. Remove bushings (10) from both sides of housing (8).6. If necessary, remove dowels (11) from housing (8). 7. Remove bolt (12), and remove gear (13) from the end of the camshaft and the camshaft drive gear. The following steps are for the installation of the magneto drive.8. Install gear (13) and bolt (12) on the camshaft drive gear and camshaft. Use the following procedure to install the camshaft drive gear.a. Clean camshaft taper with a lint free cloth saturated with solvent to remove excess oil. Then clean camshaft taper with a lint free alcohol wiper to remove any residue. If the wipe is dirty after cleaning the camshaft taper, clean again with new alcohol wipe until the wipe comes back clean. It is critical that the camshaft taper be very clean, dry and free of residue before assembly.b. Repeat step a for the remaining camshaft.c. Clean camshaft drive gear tapered bore with a lint free cloth saturated with solvent to remove excess oil. Then clean camshaft drive gear tapered bore with a lint free alcohol wipe to remove any residue. If the wipe is dirty after cleaning the camshaft drive gear tapered bore, clean again with new alcohol wipe until the wipe comes back clean. It is critical that the camshaft drive gear tapered bore be very clean, dry and free of residue before assembly.d. Repeat step 3 for remaining camshaft drive gear.e. Check that Camshafts are pinned.f. Check that the flywheel is pinned.g. Place gears on the camshafts and remove backlash by rotating the gears in the opposite direction of engine rotation. For STANDARD ROTATION engines, turn the cam gears CLOCKWISE. For REVERSE ROTATION engines, turn the cam gears COUNTER CLOCKWISE.h. Install Timing Ring, accessory drive gear or plate, if applicable. Ensure that the hole in the timing ring is properly seated on the locating pin.i. Tighten cam gear retaining bolts to a torque of 360 N m (265 lb ft).j. Mark a vertical line on the cam gear retainer bolt head.k. Place drive against cam gear retaining plate and ring solidly with hammer 3-4 times.l. Retorque the cam gear retaining bolt to 360 N m (265 lb ft).m. Repeat steps k and l until the mark on the bolt has turned a minimum of 1/4 turn.n. Cam gear installation is complete.9. Make sure dowels (11) are installed in housing (8) so they extend 6.0 0.5 mm (.24 .02 inch) above the surface of the housing.10. Install bushings (10) in both sides of housing (8).11. Install gear (9) and coupling (7) in housing (8), and install bolt (6).12. Install the gasket and magneto drive (4) on the flywheel housing. Make sure the teeth of the gear on the magneto drive are engaged correctly with the teeth of the gear on the camshaft drive gear. Install bolts (5), ground wire (3) and bolts (2) to hold magneto drive (4) on the flywheel housing.13. Install tube assembly (1).End By:a. install magneto