0115327 JOHNSON OWNER'S MANUAL, Evinrude, English only

Disassembly
Rocker arms and rocker shaft disassembly sequence(1) Rocker cover(2) Rocker stay bolt(3) Rocker arm/rocker shaft assembly(4) Snap ring(5) Rocker arm(6) Rocker stay(7) Rocker spring(8) Rocker shaft Key Points For Disassembly(1) Removing Rocker Arm/Rocker Shaft Assembly
(a) Loosen the rocker arm adjusting screws by approximately one turn each.
Removing rocker stay bolt(b) Remove the rocker stay bolts, then remove the rocker arm/rocker shaft assembly.
Removing rocker arm/rocker shaft assembly(2) Disassembling Rocker Arm/Rocker Shaft Assembly
When removing the rocker arms, arrange them in a line matching their installed positions to ensure that they are later refitted in the correct sequence. The rocker arms must be refitted in their original positions to prevent changes in the clearances between the rocker arms and rocker shaft.
Disassembling rocker arm/rocker shaft assemblyInspection and Repair
Points to check rocker arm/rocker shaft assembly KEY POINTS FOR INSPECTION AND REPAIR Measuring Rocker Arm-to-Rocker Shaft ClearanceMeasure the rocker arms' inside diameters and the rocker shaft's outside diameter, and calculate the clearances from the measurements. Replace any rocker arm where the clearance exceeds the specified limit.
Measuring rocker arm inside diameter and rocker shaft outside diameterAssembly
Tightening torques and oil application locationsPerform assembly by following the disassembly sequence in reverse: KEY POINTS FOR ASSEMBLY(1) Assembling Rocker Arm/Rocker Shaft Assembly
Install each pair of rocker arms such that the identification mark (a hole with a diameter of 3 mm (0.12 in.)) is positioned on the side closer to the front of the engine.
Rocker shaft identification mark(2) Adjusting Valve Clearance
(a) Loosen the rocker arm nut, then adjust the clearance to the standard value using the adjusting screw and a thickness gauge. (b) Hold the adjusting screw in position while tightening the nut.
Adjusting valve clearance
When adjusting the valve clearances after performing disassembly and reassembly, turn the crankshaft two or three times then check again that the clearances are within specification.
Cylinder Head and Valves
Disassembly
Cylinder head and valve disassembly sequence(1) Push Road(2) Main Bolt(3) Sub-bolt(4) Cylinder head(5) Cylinder head gasket(6) Valve retainer lock(7) Retainer(8) Valve spring(9) Valve (intake/exhaust)(10) Valve stem seal(11) Valve guide (Remove if it appears defective.) Key Points For Disassembly(1) Removing Cylinder Head
(a) Withdraw the push rods.
Withdrawing push rods(b) Loosen the cylinder bolts in the sequence shown in the drawing. Go through the sequence two or three times, loosening the bolts a little each time. Do not completely remove any bolt in isolation.
Cylinder head bolt loosening sequence
In the event of a cylinder head fault, use a torque wrench to check the bolts for looseness before deciding to remove them.(c) Lift the cylinder head assembly straight upward to remove it.
Removing cylinder head assembly
If the cylinder head gasket sticks to the cylinder head assembly and cylinder block and prevents them being separated, tap the thickest parts on the sides of the cylinder head using a plastic-faced hammer.(2) Removing Valves and Valve Springs
(a) Use a valve lifter (commercially available) to compress the valve spring, then remove the valve lock.(b) Remove the retainer, spring and valve.
Removing valve spring
Keep together the valves and other parts for each cylinder after removing them. Do not allow parts for different cylinders to become mixed up.(3) Removing Valve Stem Seals
Grip and remove each valve stem seal (1) with pliers.
Removing valve stem seal
Do not reuse any valve stem seal.Inspection and Repair
Points to check on valves, cylinder head, and push rods KEY POINTS FOR INSPECTION AND REPAIR(1) Valves and Valve Guides
(a) Measure the valve stem's outside diameters and the valve guides' inside diameters, and calculate the clearances from the measurements. If any clearance exceeds the specified limit, replace the valve and valve guides or the cylinder head assembly.Unit: mm (in.)
Measuring valve stem outside diameter
Measuring valve guide inside diameter
Before taking measurements, remove any carbon deposits from the valves and valve guides.(b) Replacing Valve Guides1) Remove the valve guide by using a press and a suitably shaped implement to push it from the bottom of the cylinder head toward the top.2) Install a new valve guide from the top of the cylinder head using a press. After installation, the valve guide should protrude by the dimension shown in the drawing.3) Insert a new valve and make sure it slides properly.4) Inspect the contact pattern of the valve and valve guide.
Press-fitted height of valve guide(2) Valves and Valve Seats
(a) Inspecting Valves Faces1) Apply a thin coat of minimum to the valve face, then use a valve lapper (commercially available) to strike the valve against the valve seat once. Inspect the contact pattern indicated by the minimum.
Inspecting valve face2) The minimum should indicate uniform contact wi