816431A 1 Mercruiser BELLOWS ASSEMBLY, Universal Joint

Install Spring Washers As Shown(3) Seat. Install a spring washer, flat washer and spring washer between seat (3) and spring (4) as shown.(4) 9L6447 Spring for the governor: Color code (stripes) ... one brown, one redPut force on spring of ... 18.0 N (4.00 lb)Then add more force to make spring shorter by ... 22.86 mm (.900 in)Total test force ... 69.9 1.3 N (15.70 .30 lb)Free length after test ... 56.9 0.8 mm (2.24 .03 in)Outside diameter ... 35.3 mm (1.39 in)(4) 9L6449 Spring for the governor: Color code (stripes) ... one green, one brownPut force on spring of ... 22.3 N (5.00 lb)Then add more force to make spring shorter by ... 22.86 mm (.900 in)Total test force ... 86.6 1.8 N (19.46 .40 lb)Free length after test ... 56.9 1 mm (2.24 .04 in)Outside diameter ... 35.2 mm (1.39 in)(4) 9L6448 Spring for the governor: Color code ... one green stripe, one yellow stripePut force on spring of ... 22.2 N (5.00 lb)Then add more force to make spring shorter by ... 22.86 mm (.900 in)Total test force ... 73.0 1.5 N (16.60 .34 lb)Free length after test ... 56.9 0.8 mm (2.24 .03 in)Outside diameter ... 35.3 mm (1.39 in)(4) 9L6446 Spring for the governor: Color code ... one green stripe, one blue stripePut force on spring of ... 17.8 N (4.00 lb)Then add more force to make spring shorter by ... 20.32 mm (.800 in)Total test force ... 55.2 1.1 N (12.40 .24 lb)Free length after test ... 56.9 1.0 mm (2.24 .04 in)Outside diameter ... 34.8 mm (1.37 in)(4) 8L9790 Spring for the governor: Color code ... one end pinkPut force on spring of ... 17.8 N (4.00 lb)Then add more force to make spring shorter by ... 22.86 mm (.900 in)Total test force ... 59.9 1.2 N (13.45 .27 lb)Free length after test ... 59.4 1.0 mm (2.34 .04 in)Outside diameter ... 35.1 mm (1.38 in)(4) 8N1312 Spring for the governor: Color code ... three white stripesPut force on spring of ... 13.4 N (3.00 lb)Then add more force to make spring shorter by ... 20.00 mm (.787 in)Total test force ... 41.4 1.2 N (9.30 .28 lb)Free length after test ... 57.0 1.0 mm (2.20 .04 in)Outside diameter ... 34.6 mm (1.36 in)(4) 8N1310 Spring for the governor: Color code ... two green stripesPut force on spring of ... 13.4 N (3.00 lb)Then add more force to make spring shorter by ... 20.00 mm (.787 in)Total test force ... 36.1 1.1 N (8.12 .24 lb)Free length after test ... 57.0 1.0 mm (2.20 .04 in)Outside diameter ... 34.3 mm (1.35 in)(4) 8N1309 Spring for the governor: Color code ... one white stripe, one yellow stripePut force on spring of ... 13.4 N (3.00 lb)Then add more force to make spring shorter by ... 20.00 mm (.787 in)Total test force ... 34.4 1.0 N (7.72 .23 lb)Free length after test ... 57.0 1.0 mm (2.20 .04 in)Outside diameter ... 34.3 mm (1.35 in)(4) 1W1635 Spring for the governor: Color code ... one blue stripe, one red stripePut force on spring of ... 22.2 N (5.00 lb)Then add more force to make spring shorter by ... 25.40 mm (1 inch)Total test force ... 53.4 .9 N (12.00 .20 lb)Free length after test ... 68.6 .8 mm (2.70 .03 in)Outside diameter ... 34.7 mm (1.37 in)(5) 9M6303 Spring: Length under test force ... 4.57 mm (.180 in)Test force ... 45.0 4.0 N (10.11 .90 lb)Free length after test ... 8.74 mm (.344 in)Outside diameter ... 12.19 mm (.480 in)(6) Diameter of the outer surface of the cylinder (new) ... 38.100 0.013 mm (1.5000 .0005 in) Bore in the gear (new) ... 38.151 0.013 (1.5020 .0005 in)(7) Put marks in alignment on pinion-stop and gear before installing dowel.(8) Bore in the bearing (new) ... 22.263 0.038 mm (.8765 .0015 in) Diameter of the gear at the hub (new) ... 22.187 0.013 mm (.8735 .0005 in) (9) Distance from the face of the plate to the bearing for the governor drive assembly ... 0.51 0.25 mm (.020 .010 in)(10) Dowel installation: Angle A must be ... 54 10 degreesDimension B must be ... 7.9 0.5 mm (.31 .02 in)(11) Install dowels to get a dimension of ... 5.6 0.5 mm (.22 .02 in)
Control Shaft Bearings(12) Bore in the governor control shaft bearings (after assembly) ... 15.761 0.038 mm (.6205 .0015 in) Diameter of the governor control shaft (new) ... 15.720 0.008 mm (.6189 .0003 in)(13) Distance between the bearings for the governor control shaft ... 60.58 0.13 mm (2.385 .005 in)(14) Distance from the face of the housing to the end of the bearing for the governor control shaft ... 43.38 0.15 mm (1.708 .006 in)
Shutoff Shaft Bearings(15) Bore in the shutoff shaft bearing (new) ... 12.713 0.013 mm (.5005 .0005 in) Diameter of the shutoff shaft (new) ... 12.637 0.013 mm (.4975 .0005 in)(16) Torque for insulator ... 4.5 0.6 N m (40 5 lb in)(17) Needle bearing.(18) Distance from center of bolt hole to outside end