Johnson Evinrude Outboard Motor 1-60hp 1971-1989 Service Repair Manual
1971-1989 Johnson Evinrude Outboard Motor 1-60hp factory service manual PDF info:
Type: PDF, Size: 140.18MB
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This manual contains fully detailed step-by-step repair procedures with hundreds of high quality photos and illustrations to guide you through any repair, maintenance, overhaul, service specifications or troubleshooting procedure.
Covers: 1971-1989 Johnson Evinrude Outboard 1.2 - 60 Hp 1 and 2 Cylinder, 2-Stroke Models
Contents listed below:
INTRODUCTION Filling Lower Unit
CLEANING, WAXING, POLISHING Propeller Installation
CONTROLLING CORROSION SHIFT WITH NO DISCONNECT
PROPELLERS 4 DELUX THRU 8 HP 1980-'85
FUEL SYSTEM Description
LOADING Removal
HORSEPOWER 6 ELECTRICAL (CONT)
FLOTATION ALTERNATOR CHARGING
EMERGENCY EQUIPMENT CIRCUIT SERVICE
COMPASS Troubleshooting
ANCHORS CHOKE CIRCUIT SERVICE
MISCELLANEOUS EQUIPMENT STARTER MOTOR
BOATING ACCIDENT REPORTS CIRCUIT SERVICE
NAVIGATION Circuit Description
2 TUNING Starter Motor Description
INTRODUCTION Testing
TUNE-UP SEQUENCE STARTER DRIVE GEAR SERVICE
COMPRESSION CHECK Disassembling Type I
SPARK PLUG INSPECTION Cleaning and Inspecting
IGNITION SYSTEM Assembling Type I
SYNCHRONIZING Disassembling Type II
BATTERY SERVICE Cleaning and Inspecting
CARBURETOR ADJUSTMENTS Assembling Type II
FUEL PUMPS BOSCH STARTER MOTOR SERVICE
STARTER AND SOLENOID Removal
INTERNAL WIRING HARNESS Disassembling Armature Testing
WATER PUMP CHECK Cleaning and Inspecting Assembling
PROPELLERS PRESTOLITE SERVICE
LOWER UNIT Removal
BOAT TESTING Disassembling
3 POWERHEAD Armature Testing Cleaning
INTRODUCTION and Inspecting
Theory of Operation Assembling STARTER MOTOR TESTING
CHAPTER ORGANIZATION STARTER MOTOR INSTALLATION
POWERHEAD DISASSEMBLING 7 REMOTE CONTROLS
INTRODUCTION
SHIFT BOXES
3 POWERHEAD (CONT) DOUBLE-LEVER SHIFT
HEAD SERVICE BOX SERVICE
REED SERVICE Troubleshooting
Description Removal
Reed Valve Adjustment Disassembling
Cleaning and Service Cleaning and Inspecting
Installation Assembling
BYPASS COVERS ELECTRIC GEAR BOXES AND
Installation SINGLE LEVER CONTROL
EXHAUST COVER Troubleshooting
Cleaning SINGLE LEVER SHIFT BOX SERVICE
Installation JOHNSON UNITS ONLY
TOP SEAL Disassembling
Removal Cleaning and Inspecting
Installation Assembling
BOTTOM SEAL PROPELLER EXHAUST
Inspection MECHANICAL SHIFT 35 HP 1978
CENTERING PINS 20 HP 1974 & on 25 HP 1986 & on
MAIN BEARING BOLTS Water Pump Disassembling
AND CRANKCASE SIDE BOLTS Lower Unit Disassembling
Installation Cleaning and Inspecting
CRANKCASE COVER Lower Unit Assembling
Removal Water Pump Installation
Cleaning and Inspection Lower Unit Installation
CONNECTING RODS AND PISTONS Functional Check
Removal TROUBLESHOOTING
Disassembling MANUAL SHIFT 6.0 to 40 HP
Rod Inspection and Service ALL MODELS EXCEPT 35 HP
Piston and Ring Inspection WITH PROPELLER EXHAUST
and Service LOWER UNIT SERVICE MANUAL
Assembling SHIFT 6.0 HP
CRANKSHAFT 1979 9.5 HP to 20 HP
Removal 1977 25 HP 1978
Cleaning and Inspection Shift Rod Disconnect
CYLINDER BLOCK SERVICE Lower Unit Removal
Honing Procedures Water Pump Removal
Assembling Lower Unit Disassembling
Piston and Rod Installation Cleaning and Inspecting
Crankshaft Installation Lower Unit Assembling
Needle Main and Water Pump Installation
Rod Bearings Lower Unit Installation
Crankshaft Installation Functional Check
With Top Needle Main Brg. LOWER UNIT SERVICE
and Babbitt Ctr. & Bottom MANUAL SHIFT 40 HP THRU 1976
With Top & Bottom Needle Brg. Lower Unit Removal
and Ctr. Babbitt Brg. Water Pump Removal
With All Babbitt Main Brgs. Lower Unit Disassembling
Crankshaft Installation Babbitt Cleaning and Inspecting
Main and Rod Bearings Lower Unit Assembling
Crankcase Cover Installation Water Pump Installation
Main Bearing Bolt and Crankcase Lower Unit Installation
Side Bolt Instl. Functional Check
Bottom Seal Installation PROPELLER EXHAUST
Reed Box Installation MECHANICAL SHIFT 9.9 HP
Head Installation 1974 & on15 HP 1974 & on
BREAK-IN PROCEDURES Description
TYPE IV CARBURETOR Troubleshooting
Removal Lower Unit Removal
Disassembling Cleaning and Water Pump Removal
Inspecting Assembling Installation Lower Unit Disassembling
FUEL PUMP SERVICE Cleaning and Inspecting
Removal and Installation Lower Unit Assembling
Cleaning and Inspecting Water Pump Installation
FUEL TANK SERVICE Lower Unit Installation
ELECTRIC PRIMER CHOKE Functional Check
MANUAL PRIMER CHOKE 30 HP 1981 & on
OIL INJECTION SYSTEMS Description
VRO Oil Inject. Troubleshooting
AccuMix (AutoBlend) Lower Unit Removal
5 IGNITION Water Pump Removal
INTRODUCTION Lower Unit Disassembling
SPARK PLUG EVALUATION Cleaning and Inspecting
POLARITY CHECK Lower Unit Assembling
WIRING HARNESS Water Pump Installation
FLYWHEEL MAGNETO IGNITION 1.25 hp Lower Unit Installation
1987 &on 2 hp- 1986 2.5 hp Functional Check
1987 on 4 hp-1984 6 hp - 1976 ELECTRIC SHIFT
9.5 hp-19773 18 hp - 19773 20 hp TWO SOLENOIDS
1971 -72 25 hp - 1972 40 hp-1973 50 HP 1977
TROUBLESHOOTING Description
Wiring Harness Troubleshooting
Key Switch Lower Unit Removal
Compression Water Pump Removal
Condenser "Frozen" Propeller Shaft
Breaker Points Cleaning and Inspecting
SERVICING FLYWHEEL MAGNETO Lower Unit Assembling
IGNITION SYSTEM Water Pump Installation
Removal Lower Unit Installation
Cleaning and Inspecting Functional Check
Assembling MECHANICAL SHIFT
4 FUEL HYDRAULIC ASSIST
INTRODUCTION SHIFT DISCONNECT UNDER
GENERAL CARBURETION LOWER CARBURETOR
INFORMATION 50 HP 1977
FUEL SYSTEM Description
TROUBLESHOOTING Trouble shoot ing
Fuel Pump Tests Lower Unit Removal
Fuel Line Test Water Pump Removal
Rough Engine Idle "Frozen" Propeller Shaft
Excessive Fuel Consumption Cleaning and Inspecting
Engine Surge Lower Unit Assembling
JOHNSON/EVINRUDE Water Pump Installation
CARBURETORS Lower Unit Installation
TYPE I CARBURETOR Functional Check 171
Removal MECHANICAL SHIFT
Disassembling SHIFT DISCONNECT UNDER
Cleaning and Inspecting LOWER CARBURETOR
Assembling 40 HP 1977 & on
Installation 50 HP 1977
CHOKE SYSTEM SERVICE 50 HP 1975 and 1980 & on
ALL ELECTRIC CHOKE REMOVAL 55 HP 1978
TYPE II CARBURETOR 60 HP 1980 & on
Disassembling Description
Cleaning and Inspecting Troubleshooting
Assembling LOWER UNIT (CONT)
Adjustments Lower Unit Removal
TYPE III CARBURETOR Water Pump Removal
Removal "Frozen" Propeller Shaft
Disassembling Cleaning and Inspecting
Cleaning and Inspecting Lower Unit Assembling
Assembling Water Pump Installation
Installation Lower Unit Installation
Flywheel Removal "FROZEN" PROPELLER
Armature Plate Removal Starter Disassembling
Armature Plate Installation Cleaning and Inspecting
Charge or Sensor Coil Removal Assembling
Charge or Sensor Coil Installation
Installation Adjustment
Charge or Sensor Coil TYPE V MOUNTED ATOP
Adjustment FLYWHEEL WITH NO
Flywheel Installation RETURN SPRINGS
Power Pack Replacement 40 HP- 1977 & 1988
Timing Check Adjustment Removal
SYNCHRONIZATION FUEL Cleaning and Inspecting
AND IGNITION SYSTEMS Assembling
Primary Pickup Adjustments Rope Installation
and Locations Starter Installation
The No. A Location TYPE VI MOUNTED ATOP FLYWHEEL
The No. B Location WITH ONE OR TWO NYLON PAWLS
The No. C Location COLT, JUNIOR,
The No. D Location & ULTRA 1986 & on 2 HP 19785 2.5 HP
The No. E Location 1987 & on 4 HP 1980 & on 18 HP
6 ELECTRICAL 1973 20 HP 1977, 1985 & on 25 HP
INTRODUCTION 1971 & on 35 HP 1978
BATTERIES Starter Removal
Marine Batteries Disassembling
Battery Construction Cleaning and Inspecting
Battery Ratings Starter Assembling
Battery Location Rope Installation
Battery Service Starter Installation
Jumper Cables TYPE VII MOUNTED ATOP FLYWHEEL
Storage WITH LARGE PAWL PLATE
Dual Battery Installation Starter Removal
GAUGES AND HORNS Disassembling
Constant Voltage System Cleaning and Inspecting
Temperature Gauges Starter Assembling
Warning Lights Starter Installation
Thermomelt Sticks 9 HAND STARTERS
FUEL SYSTEM INTRODUCTION
Fuel Gauge Emergency Starting
Fuel Gauge Hookup TYPE I STARTER
Fuel Gauge Troubleshooting CYLINDER WITH PINION GEAR All
TACHOMETER ]HP All 6 HP All 7.5 HP All 8 HP
HORNS Starter Rope Replacement
ELECTRICAL SYSTEM Removal
GENERAL INFORMATION Installation
GENERATING CHARGING Starter Removal
CIRCUIT SERVICE Disassembling
Troubleshooting Cleaning and Inspecting
Removal and Disassembling Assembling
Armature Testing TYPE II STARTER
Cleaning and Inspecting CYLINDER WITH PINION GEAR
Assembling All 9.5 HP
LOW TENSION FLYWHEEL Rope Removal
MAGNETO IGNITION SYSTEM Rope Installation
9.9 hp - 1976 Starter Removal
15 hp-1976 Cleaning and Inspecting
18 hp- 1973 Assembling
20 hp - 1973 Installation
25 hp - 19776 TYPE III STARTER
35 hp - 1976 COIL SPRING WITH SWING ARM
40 hp - 1976 VERTICAL MOUNT 4 HP 19778
40 hp Comm. - 1983 4 HP DELUX 1982 & on 4.5 HP
Description 1980-84
Theory of Operation Removal
Troubleshooting Disassembling
Removal Cleaning and Inspecting
Cleaning and Inspecting Assembling
Assembling TYPE IV STARTER
COIL SPRING WITH SLIDING GEAR
TYPE I CAPACITOR DISCHARGE HORIZONTAL MOUNT
(CD) All 9.9 HP
FLYWHEEL MAGNETO WITH All 15 HP
TIMER BASE 50 hp Removal
- 1977 55 hp - 1977 Starter Rope Replacement
Description 10 POWER TRIM/TILT
Theory of Operation SYSTEM DESCRIPTION
Troubleshooting FILLING SYSTEM
Servicing TROUBLESHOOTING
Stator and Charge Coil SERVICING
Replacement ELECTRICAL MOTOR SERVICE
Timer Base and Sensor Cleaning & Inspecting
Assembly Replacement Testing
Power Pack Replacement II MAINTENANCE
Timing Check and Adjustment INTRODUCTION
TYPE II CD FLYWHEEL MAGNETO IGNITION ENGINE SERIAL NUMBERS
WITH SENSOR COIL 2.5 hp 1987 & on FIBERGLASS HULLS
4 hp Dlx. 1984 & on 4.5 hp-1980-85 ALUMINUM HULLS
5 hp - 1985 BELOW WATERLINE SERVICE
6 hp - 1979 SUBMERGED ENGINE SERVICE
6 hp - 1982 & on WINTER STORAGE
7.5 hp -1980-85 LOWER UNIT SERVICE
8 hp 1984 &on Propellers
9.9 hp 1977 & on BATTERY STORAGE
15 hp- 1977 & on PRESEASON PREPARATION
20 hp - 1981 & on APPENDIX
25 hp - 1977 & on METRIC CONVERSION CHART
30 hp 1985 & on DRILL SIZE CONVERSION CHART
35 hp - 19784 TORQUE SPECIFICATIONS
40 hp 1984 & on TUNE-UP SPECIFICATIONS 4 to 17
50 hp - 1978 & on POWERHEAD SPECIFICATIONS
55 hp - 1983 OIL/FUEL MIXTURE
60 hp - 1980-85 GEAR OIL CAPACITIES
Description STARTER MOTOR SPECS.
Theory of Operation REGULATOR SPECIFICATIONS
Troubleshooting GENERATOR SPECIFICATIONS
Checking Type II System CONDENSER SPECIFICATIONS
PUSHBUTTON TYPE SHIFT BOX STARTER ROPE SPECIFICATIONS
SERVICE - EVINRUDE ONLY WIRE IDENTIFICATION DRAWINGS
Troubleshooting Typical I-cylinder pwhd.
Disassembling 2.5 hp, Excel, Ultra, & 4 hp
Cleaning and Inspecting -1984 & on
Assembling 4 Delux thru 55 hp w/CD 2ign.,
SINGLE-LEVER REMOTE w/manual start;
CONTROL SHIFT BOX Also models equipped
Troubleshooting with A.C. lighting
Disassembling 9.9 hp and 15 hp
Assembling w / electrlc start - 1976
SHIFT BOX REPAIR 9.9 hp and 15 hp
Disassembling w/electrlc start - 1978
Cleaning and Inspecting 9.9 hp and 15 hp
Assembling w/electric start 1986 & on 27
CABLE END FITTING INSTALLATION I8 hp, 20 hp, & 25 hp
AT THE ENGINE END w / electric start - 1971 -7 2
FOR ALL SHIFT BOXES EXCEPT SINGLE 28 18 hp, 20hp,& 25 hp
LEVER REMOTE CONTROL w/electric start - 1976
8 LOWER UNIT 35 hp w/electric start - 1976
DESCRIPTION 25 hp and 35 hp-19778
Chapter Coverage 20 hp thru 90 hp w/std. shift
Illustrations & w/electric start 19783
PROPELLER SERVICE 40 hp w/generator, w/std. shift
Propeller with Shear Pin & w/electric start 1973
Removal 40 hp w/alternator, w/std. shift
Exhaust Propeller & w/electrlc start - 1976
Removal 30 hp w / alternator
Propeller with Shear Pin 4 w/electric start - 1972
Installation 50 hp w/alternator
Exhaust Propeller Installation & w/electrlc start - 1977
LOWER UNIT LUBRICATION Also 55 hp with no
Draining thermo switch 1977
Filling 50 hp w/manual Start 1980-83
NO SHIFT LOWER UNIT SERVICE 55 hp w/electric start - 1977
1.25 to 4.0 HP 1971 & on 50 hp & 53 hp
Description w/electric start 1978
Troubleshooting 50 hp - 1979, 55 hp - 1983,
Removal & 60 hp - 1980-81
Water Pump Removal all w/electric start
Lower Unit Disassembling 20 hp, 23 hp, 30 hp, 33 hp,
Cleaning and Inspecting 40 hp, 30 hp, and 60 hp
Assembling w/remote electric start 1985
40 hp & 30 hp w/tiller
Water Pump Installation electric start 1986 & on
Lower Unit Installation 40 hp & 50 hp w/remote
electric start - 1986 & on
Remote Control Box
