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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Getting towards the end of the project now. Here is a photo of the painted gearcase: And after running the prop through the media blaster and all painted up:
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Cleaned the lower unit really well with degreaser, wet sanded with 400 grit sandpaper, masked and primed: You can see that I used the Johnson stripe as my masking line. Tape removed and I'll let it dry for a few days before wet sanding again in preparation for...
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    Weird warning horns

    Re: Weird warning horns This is a copy of the Decal that you can buy from OMC: I have a laminated copy on the boat close to the throttle controls.
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Here are some of the leftover parts that didn't get destroyed during the disassembly: In the bottom right of the photo: Liners and needles from the connecting rod. I replaced this because of the discoloration in the liner. Bottom center: Ball bearing from the...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Running 25:1 in a test barrel is really messy: Going to have to really degrease this thing before painting:
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Nice sunny day here yesterday to I got the rest of the powerhead finished and bolted the lower unit onto the midsection. The primer pump on this outboard made it very easy to restart. On the 2nd pull, it fired right up: Notice tht the knob for the primer pump...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Ignition coils mounted: Power pack and tell tale hose: I broke the cam follower & lever trying to remove it due to the brittle plastic: A new cam follower was ordered for $16 because I wanted the safety feature.
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Fuel pump and primer pump mounted: Plate, sleeve, coil and sensor: Throttle lever and cable: Kind of screwed up here. The knob for the primer pump gets mounted AFTER the air silencer is installed:
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild The exhaust tube was bolted to the power head and the power head bolted back onto the mid-section: Now, time to start hanging the "stuff" back onto the power head: This part is not going to be much fun: But, I was able to replace the pull rope and get...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Media blasted the Exhaust Tube and now it's ready for painting and reassembly:
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Not much time to work on the little outboard lately due to work (+ I'm waiting on a missing and last part but thats another story in itself). I did take the time to inspect the old water pump impeller that I changed last month and this must be why it is...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Time to install the upper crankshaft seal: A deep socket works perfectly for a seal driver: Seal installed and ready for the next step:
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild While replacing the O-Rings (71 cents each) on the Drain and Vent Plugs I got to wondering if I could buy these O-Rings in bulk and found the following: $5.75 for 100 (< 6 cents each) and my son gets free shipping so I had him place the order for me. 8 oil...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Drained the gear oil and installed the Water Pump Repair Kit today.
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Cleaned up the and reassembled the midsection yesterday and I noticed that I forgot to take position photos of the shift rod gears (#10 & 101) while in the neutral position: Does this look correct in the neutral position?
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild So I started to do some comparisons between my 1988 6hp (the one that I am rebuilding) and my 1990 6hp (just purchased - new/unused) and noticed that the 2 crankcases were very similar. The 1988 Crankcase is NLA and last sold for $400.55 The 1990 Crankcase...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild My camera batteries died during the reassembly of the crankcase, everything went together with no issues: Crankcase assembled, exhaust tube not attached just sitting on top of the midsection (I have one bolt installed so it doesn't fall off the midsection):
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Crankcase assembly time and oh joy, a total of 90 uncaged needle bearings to work with: #1 Rod Bearings: #2 Rod Bearings: Center Crank Bearing: On a side note, I inventoried all the parts that I received by part # but I never verified that the correct...
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild Masked and repainted the lower engine cover this morning:
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    My 1988 6hp Johnson Rebuild

    Re: My 1988 6hp Johnson Rebuild I may have answered my own question. Look at the picture that I found on eBay after submitting my posting: Notice that this part already has the cutout in the "Exhaust Cover, Inner". Guess I'll be making that cutout after all.
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