1990 johnson outboard motor manual

Excavator Manuals. Jet-Ski Manuals. Motorcycle, Scooter Manuals. Mower Manuals. Power Tool Manuals. Outboard Manuals. Snowmobile Manuals. Tractor Manuals. This is not because they are not capable of the task, but because that's what a machinist does day in and day out.

A machinist is naturally going to be more experienced with the procedures. If a complete powerhead overhaul is necessary on your outboard, we recommend that you find a local machine shop that has both an excellent reputation and that specializes in marine work. Some machine shops would prefer to perform the disassembly themselves. In these cases, you can usually remove the powerhead from the gearcase and deliver the entire unit to the shop for disassembly, inspection, machining and assembly.

If you decide to perform the entire overhaul yourself, proceed slowly, taking care to following instructions closely. Consider using a digital camera if available to help document assemblies during the removal and disassembly procedures.

This can be especially helpful if the overhaul or rebuild is going to take place over an extended amount of time. It is better to proceed slowly, asking help when necessary from your trusted parts counterman or a tech with experience on these motors. Keep in mind that anytime pistons, rings and bearings have been replaced, the powerhead must be broken-in again, as if it were a brand-new motor.

Once a major overhaul is completed, refer to the section on Powerhead Break-In for details on how to ensure the rings set properly without damage or scoring to the new cylinder wall or the piston surfaces.

Careful break-in or a properly overhauled motor will ensure many years of service for the trusty powerhead. The gearcase contains the propeller shaft, the driven and pinion gears, the driveshaft from the powerhead and the water pump. On models equipped with shifting capabilities, the fonvard and reverse gears, together with the clutch, shift assembly, and related linkage, are all housed within the case. The single most important task for proper gearcase maintenance is inspecting it for signs of leakage after each use.

If oil can get out, then water can get in. And, water, mixing with or replacing the oil in the gearcase will wreak havoc with the shafts and gears contained within the housinq. The second most important task for proper gearcase maintenance is checkinq and maintainina the oil inside the case. Water entering the gearcase will usually cause the oil to turn a slightly milky-white color.

Also, significant amounts of water mixed with the oil will give the appearance of an overfilled condition. If you suspect water in the gearcase, start by draining and closely inspecting the fluid refer to the procedures found in the Maintenance and Tune-Up section.

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