nson

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L1!!J

3/S" (9.5 mml

tq 1/4-;'-(6.4 mml
!--=---

1/4" (6.4 mml-!

C02241

1191_________

1201 _________

D_R_20_6--11

[}I][!!]

14. Using OMC Bearing and Seal Remover PIN 391259,

remove and discard both gearcase head seals at the same
time . Be careful that you do not inadvertently hook the jaws of
the puller in the bearing. Make sure you are behind the two seals.
Also, the jaws of the puller must be modified according to the
dimensions shown . If you grind the jaws yourself, grind them very
slowly and quench them often in water so that you do not lose
the temper of the jaws.

[I[] 15.

Using OMC Propeller Shaft Bearing Remover and Installer

PIN 392091, remove and discard the gearcase head bearing.
Place the gearcase head on a flat surface and drive the bearing
out.

DR2062

-------------'

120 f21l 16. Install two new seals back-to-back in the gearcase
head using OMC Seal Installer PIN 327572. Apply OMC
Gasket Sealing Compound to the metal casing of the seals. Install
the inside seal with the lip facing inward and the outside seal CD
with the lip facing outward. Apply OMC Triple-Guard grease to the
lips after installing . Lightly apply OMC Triple-Guard grease to a new
O-ring and install it in groove of the housing.
1221 17. Using OMC Bearing Remover and Installer PIN 392091,
oil and drive a new gearcase head bearing into the gearcase
head. Remember that the lettered side 0 of the bearing must
go toward the tool to prevent damage to the bearing .

1221 ____ ____

CO_A_
333_9_'

1231 18. Using OMC Pinion Bearing and Seal Remover PIN
391259, remove and discard the two driveshaft seals from
the gearcase. These seals are removed both at the same time.
1241 19. To remove the upper and lower CD driveshaft bearings,
assemble the components of the OMC Driveshaft Bearing
Remover and Installer PIN 392092 (Guide Plate @ , Small Disc
with flat side toward bearing, and Rod @ ) within the gearcase.
Attach OMC Slide Hammer PIN 391008 to the rod and remove
both bearings at the same time.

o
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III
II)

II)

o
3

4C

6-13

2.5 - 4

Assembly
Proceed slowly. Make no forced assemblies unless a
pressing operation is called for. All internal components
must be perfectly clean and lightly coated with Johnson or
Evinrude Outboard Lubricant.

INote I Use

new gaskets, oil retainers, and O-rings during

assembly.

1. If removed, install upper main bearing through bottom of

crankcase. Press against lettered side of bearing case until bearing
is recessed 0 .062 in. (1,5 mm) below finish thrust face of
crankcase.
2. Apply OMC Gasket Sealing Compound to the outside diameter
of a new upper crankshaft seal. Install the seal, lip down, until
flush with top of crankcase. Use OMC Seal Installer PI N 330219.
3. Apply a coat of oil to wrist pin and wrist pin hole in piston.

r:J1l

4 . Insert wrist pin through " L" side of piston. Oil wrist pin
bearing in connecting rod and place in position . Install wrist
pin using OMC Wrist Pin Pressing Pin PI N 326624 and OMC
Piston Cradle PIN 326572.

1Note 1 Pressing pin must enter "L" (loose) side of piston .

G"2l

5. Install piston rings on piston . Spread each ring with a ring

expander just enough to slip it over the head of the piston
and down into place.
6. Coat the piston and cylinder bore with oil.

1131 7.

Place the piston in OMC Ring Compressor PI N 327017 .

Make certain that the rings are correctly positioned in their
grooves with respect to the dowel pins. Damaged pistons and
broken rings may result from imperfect alignment of the ring gap
and the dowel pins.

1Note 1

piston rings must be correctly located on their dowel

pms to prevent permanent powerhead damage.

1141 8.

Start the piston into bore of the cylinder with deflector

of the piston (sharp edge) toward intake port side of
the cylinder block. Install the piston until head of the piston is
flush with top of cylinder.

o
VI
III

::;;

."

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o
3

4C

4-15

Colt, Junior

1988 "CC" Colt / Junior thru 8 Models

Service Manual, P/N 507659
Original 1988 Johnson/Evinrude service manual for Colt / Junior thru
55 HP outboard motors.

Buy this Manual

OMC Part Number: 507659

Manual chapters:
- Safety Section
1. General Information
2. Fuel System
3. Ignition System
4. Powerhead
5. Midsection
6. Gearcase
7. Manual Starter
8. Electrical System
- Color Diagrams
Manual covers service information on the following Johnson/Evinrude models:
Colt, Junior Models
. . . EJR-CC
...
JCO-CC . . .
2.5 Models
E3RCC
J3RCC
4 Models
J4RLCC
E4RCC
E4RLCC
J4RCC
E4BRLCC
J4BRCC
J4BRLCC
E4BRCC
E4BRHCC
E4BRHLCC
J4BRHCC
J4BRHLCC
J4RDHCC
J4RDHLCC
E4RDHCC
E4RDHLCC
5 Models
E5DRCC
E5DRLCC
J5DRCC
J5DRLCC
6 Models
E6BACC
E6BALCC
J6BACC
J6BALCC
E6DRCC
E6DRLCC
J6DRCC
J6DRLCC
E6RCC
E6RLCC
J6RCC
J6RLCC
E6SLCC
J6SLCC
6.5 Models
7RSY
7RSLY
8 Models
E8BACC
E8BALCC
J8BACC
J8BALCC
E8RCC
E8RLCC
J8RCC
J8RLCC
E8SRLCC
J8SRLCC
Manual PDF file is indexed and searchable. Manual includes hi-resolution images and

color diagrams.

Buy this Manual

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Johnson Evinrude Outboard Motor