How to Rebuild an Outboard

Disassembly

1). Familiarize yourself with the parts by reading over the manual. Note the list of parts and where things go. During the disassembly process, you will be required to compare all parts that you remove to the manual to check for consistency. You must write down on a piece of paper what is inconsistent and needs replacement.
2). Remove the case by unscrewing all screws and removing all the bolts. Set the case down and diagnose the case by checking the parts for consistency.
3). Unplug the spark plug and check for consistency. Remove the control panel by disconnecting all wires from the motor and unscrewing all screws. Lift it off. Check for consistency.
4). Unbolt and lift away the cylinder and check both the cylinder and the piston for consistency with the manual. Put your hands around the carburetor carefully and lift it up from the driveshaft. Check for rust and consistency with the manual. Unscrew the driveshaft from the bottom and pull it out. Check for rust and broken parts.

1). Order replacement parts for your outboard motor according to the list of broken parts. Rusted parts need not be replaced.
2). Use the sandpaper to rub off all rust from the parts and cover the driveshaft with waterproof lubricant.
3). Put aside parts that need to be replaced and replace them with new parts.
4). Assemble your outboard according to your manual. It should have clear instructions on assembly.
5). Test out your outboard and repeat the process until it works properly.