1991 Johnson/Evinrude EI Outboards 2.3 thru 8 Service Manual, Page 238Get this manual
Manual Starter Servicingthru 8 Removal
i and remove all spark plugs leads
'" 1Avoid accidental starting of engine while servicing, twist
J,1 2Remove the three starter housing retaining screwsLift starter housing from powerhead
r:;J 3Using screwdriver, apply pressure to one side of the starter lockout locking tab as shownWhile applying pressure, pull on cable until tab is clear of starter housingDisassembly
i manual starters because of rewind spring tension
'" Wear safety glasses while disassembling and assembling
rJl 1Pull the starter rope out far enough to tie slip knot in the ropePry the starter rope anchor out of the handleRemove the handle, release the slip knot and ease the pulley back until the rewind spring is fully unwound2Remove the spindle screw1sl Remove the retaining ring and lift pawl and links as an E.J assemblyRemove the spindle 4Hold the pulley in the starter housing while turning the starter over, leg downHold fingers clear of the pulley and jar the starter housing against bench to dislodge the rewind spring and pulleyCleaning and Inspection 1Wash metal components in solvent and dry with compressed air2Inspect the rewind spring for broken end loops and weak tension3Examine the pawl for wear and inspect the links4Inspect starter ropeReplace if frayedCut new rope to 59112 in(151 cm) lengthFuse ends of rope to length of 112 in(12 mm)5Examine the pulley and the starter housingLook for sharp edges and rough surfaces that could fray the starter ropeFile and polish to remove6Examine starter lockout partsReplace any worn or damaged parts