1994 Johnson/Evinrude "ER" 2 thru 8 outboards Service Manual, Page 240Get this manual
Removal
'" 1To avoid accidental starting of engine while servicing, twist and remove all spark plug leads
r,l2Pull the starter rope out far enough to tie slip knot in the rope behind starter handleUntie knot in end of rope and remove the handle and rubber bumper3Release the slip knot while holding the pulley, and allow the starter spring to slowly unwindf214Grasp the end of the starter spring and pull spring out as far as it will goThis will relieve spring tensionfil5Remove the port ignition coil from the powerheadRemove the starter assembly adjustment screw fil6While holding the starter assembly together, remove shoulder screw Remove the starter assembly from the powerheadDisassembly f411off the idler gear armidler gearand idler gear arm spnng 1sl2Lift the pulley out of the cup and stop assembly Unhook spring and spring retainer CD from pin in pulleyNote position of spring loopRemove rope from pulleyRemove washer Q) from cup and stop assemblyCleaning and Inspection 1Wash all parts, except rope, in solvent and dry with compressed air2Remove any traces of corrosionPrevent further corrosion by wiping metal parts with an oil dampened cloth3Inspect starter spring end loopsReplace spring if weak, corroded, or cracked4Inspect ropeReplace rope if frayedCut new rope to 59112 in(151 cm) in lengthFuse ends of rope5Inspect pulley and bushing in cup and stop assemblyReplace if cracked or chippedAssembly 1Lightly coat inside of cup and stop assembly and idle gear arm with OMC Triple-Guard grease or Lubriplate 777If removed, insert bushing in idler gear arm2Place washer Q) in cup and stop assembly&