1994 Johnson/Evinrude Outboards 40 thru 55 Service Manual, Page 265Get this manual
6Examine the pulley and the starter housingLook for sharp edges and rough surfaces that could fray the starter ropeFile and polish to remove7Examine the starter and starter lockout partsReplace any worn or damaged partsAssembly
ill manual starters because of rewind spring tension
"" Wear safety glasses while disassembling and assembling
(!TI 1Place the starter spring shield into the starter housing
Using OMC Starter Spring Winder and Installer PIN 392093, clamp spring winder base in viseInsert release plate into spring winder base
f1il3Apply OMC Triple-Guard grease or Lubriplate 777 to the rewind springInstall the rewind spring into the spring winder base with open loop of spring facing inwardInsert the pin ofthe crank and pin assembly into the loop ofthe rewind springSecure the crank and pin assembly to the starter winder base with the crank retainer screw4Rotate the crank and pin assembly in the direction shown on the toolWind the spring into the starter winder base until end of spring contacts the starter winder base