What, Where and Don't Do's of rebuild - 96' Evinrude 90hp

[RBuch1974]

About to tear down and rebuild powerhead (PH), among other things. Will create other posts for questions specific to the other component too but, the powerhead is my focus here.

What kind of kit should I get? Buy individual components and a complete gasket kit, Buy a complete kit? The complete kits seem logical to me but recently found out I could over bore one cylinder and its OK.:facepalm: But a would like to do a comprehensive rebuild for reliability.

Are there any recommendations for break down and assembly of PH? Is there common newbie mistakes that can be costly or time consuming yet easily avoided? I have rebuilt many other engines (small block, big blocks, dirt bike/four wheeler and such) never an outboard though. I will be relying on my repair manual, iboat forum, good local family owned machine shop and internet searches for this rebuild.

Appreciate any advice. Thanks

 

[RBuch1974]

Re: What, Where and Don't Do's of rebuild - 96' Evinrude 90hp

Any other posts that you know of that would be helpful too? I have read some and gotten some good advice, but only found a couple.

 

[emdsapmgr]

Re: What, Where and Don't Do's of rebuild - 96' Evinrude 90hp

Best advice-work from only an original factory service manual. It's superior to any others and has great pictures. If you don't have one-see this website: outboardbooks.com OMC made two completely different types of 90 hp engines that year. The old crossflow and the newer looper. As you ask for advice, you'll want to identify just which one you have. It is acceptable to overbore just one cyl. Make sure you match that piston with an oversize version of the other 3. (don't mix piston manufacturer brands on one block)