1994 Johnson/Evinrude "ER" 2 thru 8 outboards Service Manual, Page 158Get this manual
Disassemblythru Deluxe
fN=J To simplify reassembly and wiring installation, layout the
1Remove carburetor, leaf valve assembly and intake manifoldDiscard gaskets2Remove the cylinder head and gasketDiscard the gasket
various screws and clamps in the order of their proper location
3With an indelible ink marker, mark the top piston dome, "No1", and the bottom piston dome, "No2" 4Remove exhaust coverDiscard gasket
[!J 5Remove the lower crankcase head6Remove seal and remove snap ring from crankcaseUsing tool as drawn on page 4-8, or equivalent, push the crankcase taper pin toward intake manifold surfaceDo not use any tool smaller than taper pin bore to remove the pin8Remove the six main crankcase to cylinder block screws and flange screwsLoosely install the cylinder head to prevent the pistons from falling out when the crankshaft is removed1sl 9Turn the powerhead so that the intake manifold surface t=.J faces upUsing rawhide mallet, lightly tap upward on the crankshaft until the halves just begin to separateLift up and remove the crankcase10Remove center main bearing linerCollect and retain the 30 needle bearingsPistons, connecting rods, and needle bearings are wearing parts and seat with the operation of the engineBecause of this, it is essential to maintain their original positions at reassemblyUsing an indelible ink marker, mark each component when removed to ensure correct mating and keep the needles of each cylinder together26073