Full service restore guide for 1971-1989 Johnson Evinrude Outboard Motor 1-60hp. Comes with complete particulars relating to technical knowledge, diagrams, an entire record of components and footage. Lower your expenses and revel in fixing machines.Covers: 1971-1989 Johnson Evinrude Outboard 1.2 – 60 Hp 1 and a pair of Cylinder, 2-Stroke Fashions
Contents listed beneath:
INTRODUCTION Filling Decrease Unit
CLEANING, WAXING, POLISHING Propeller Set up
CONTROLLING CORROSION SHIFT WITH NO DISCONNECT
PROPELLERS 4 DELUX THRU 8 HP 1980-’85
FUEL SYSTEM Description
LOADING Elimination
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 Kind I
SPARK PLUG INSPECTION Cleansing and Inspecting
IGNITION SYSTEM Assembling Kind I
SYNCHRONIZING Disassembling Kind II
BATTERY SERVICE Cleansing and Inspecting
CARBURETOR ADJUSTMENTS Assembling Kind II
FUEL PUMPS BOSCH STARTER MOTOR SERVICE
STARTER AND SOLENOID Elimination
INTERNAL WIRING HARNESS Disassembling Armature Testing
WATER PUMP CHECK Cleansing and Inspecting Assembling
PROPELLERS PRESTOLITE SERVICE
LOWER UNIT Elimination
BOAT TESTING Disassembling
3 POWERHEAD Armature Testing Cleansing
INTRODUCTION and Inspecting
Idea 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 Elimination
Reed Valve Adjustment Disassembling
Cleansing and Service Cleansing and Inspecting
Set up Assembling
BYPASS COVERS ELECTRIC GEAR BOXES AND
Set up SINGLE LEVER CONTROL
EXHAUST COVER Troubleshooting
Cleansing SINGLE LEVER SHIFT BOX SERVICE
Set up JOHNSON UNITS ONLY
TOP SEAL Disassembling
Elimination Cleansing and Inspecting
Set up 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 Decrease Unit Disassembling
Set up Cleansing and Inspecting
CRANKCASE COVER Decrease Unit Assembling
Elimination Water Pump Set up
Cleansing and Inspection Decrease Unit Set up
CONNECTING RODS AND PISTONS Practical Verify
Elimination 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 twenty HP
Elimination 1977 25 HP 1978
Cleansing and Inspection Shift Rod Disconnect
CYLINDER BLOCK SERVICE Decrease Unit Elimination
Honing Procedures Water Pump Elimination
Assembling Decrease Unit Disassembling
Piston and Rod Set up Cleansing and Inspecting
Crankshaft Set up Decrease Unit Assembling
Needle Major and Water Pump Set up
Rod Bearings Decrease Unit Set up
Crankshaft Set up Practical Verify
With Prime Needle Major Brg. LOWER UNIT SERVICE
and Babbitt Ctr. & Backside MANUAL SHIFT 40 HP THRU 1976
With Prime & Backside Needle Brg. Decrease Unit Elimination
and Ctr. Babbitt Brg. Water Pump Elimination
With All Babbitt Major Brgs. Decrease Unit Disassembling
Crankshaft Set up Babbitt Cleansing and Inspecting
Major and Rod Bearings Decrease Unit Assembling
Crankcase Cowl Set up Water Pump Set up
Major Bearing Bolt and Crankcase Decrease Unit Set up
Aspect Bolt Instl. Practical Verify
Backside Seal Set up PROPELLER EXHAUST
Reed Field Set up MECHANICAL SHIFT 9.9 HP
Head Set up 1974 & on15 HP 1974 & on
BREAK-IN PROCEDURES Description
TYPE IV CARBURETOR Troubleshooting
Elimination Decrease Unit Elimination
Disassembling Cleansing and Water Pump Elimination
Inspecting Assembling Set up Decrease Unit Disassembling
FUEL PUMP SERVICE Cleansing and Inspecting
Elimination and Set up Decrease Unit Assembling
Cleansing and Inspecting Water Pump Set up
FUEL TANK SERVICE Decrease Unit Set up
ELECTRIC PRIMER CHOKE Practical Verify
MANUAL PRIMER CHOKE 30 HP 1981 & on
OIL INJECTION SYSTEMS Description
VRO Oil Inject. Troubleshooting
AccuMix (AutoBlend) Decrease Unit Elimination
5 IGNITION Water Pump Elimination
INTRODUCTION Decrease Unit Disassembling
SPARK PLUG EVALUATION Cleansing and Inspecting
POLARITY CHECK Decrease Unit Assembling
WIRING HARNESS Water Pump Set up
FLYWHEEL MAGNETO IGNITION 1.25 hp Decrease Unit Set up
1987 &on 2 hp- 1986 2.5 hp Practical Verify
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 Change Decrease Unit Elimination
Compression Water Pump Elimination
Condenser “Frozen” Propeller Shaft
Breaker Factors Cleansing and Inspecting
SERVICING FLYWHEEL MAGNETO Decrease Unit Assembling
IGNITION SYSTEM Water Pump Set up
Elimination Decrease Unit Set up
Cleansing and Inspecting Practical Verify
Assembling MECHANICAL SHIFT
4 FUEL HYDRAULIC ASSIST
INTRODUCTION SHIFT DISCONNECT UNDER
GENERAL CARBURETION LOWER CARBURETOR
INFORMATION 50 HP 1977
FUEL SYSTEM Description
TROUBLESHOOTING Hassle shoot ing
Gas Pump Assessments Decrease Unit Elimination
Gas Line Take a look at Water Pump Elimination
Tough Engine Idle “Frozen” Propeller Shaft
Extreme Gas Consumption Cleansing and Inspecting
Engine Surge Decrease Unit Assembling
JOHNSON/EVINRUDE Water Pump Set up
CARBURETORS Decrease Unit Set up
TYPE I CARBURETOR Practical Verify 171
Elimination MECHANICAL SHIFT
Disassembling SHIFT DISCONNECT UNDER
Cleansing and Inspecting LOWER CARBURETOR
Assembling 40 HP 1977 & on
Set up 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
Cleansing and Inspecting Troubleshooting
Assembling LOWER UNIT (CONT)
Changes Decrease Unit Elimination
TYPE III CARBURETOR Water Pump Elimination
Elimination “Frozen” Propeller Shaft
Disassembling Cleansing and Inspecting
Cleansing and Inspecting Decrease Unit Assembling
Assembling Water Pump Set up
Set up Decrease Unit Set up
Flywheel Elimination “FROZEN” PROPELLER
Armature Plate Elimination Starter Disassembling
Armature Plate Set up Cleansing and Inspecting
Cost or Sensor Coil Elimination Assembling
Cost or Sensor Coil Set up
Set up Adjustment
Cost or Sensor Coil TYPE V MOUNTED ATOP
Adjustment FLYWHEEL WITH NO
Flywheel Set up RETURN SPRINGS
Energy Pack Alternative 40 HP- 1977 & 1988
Timing Verify Adjustment Elimination
SYNCHRONIZATION FUEL Cleansing and Inspecting
AND IGNITION SYSTEMS Assembling
Main Pickup Changes Rope Set up
and Areas Starter Set up
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 Elimination
Marine Batteries Disassembling
Battery Building Cleansing and Inspecting
Battery Rankings Starter Assembling
Battery Location Rope Set up
Battery Service Starter Set up
Jumper Cables TYPE VII MOUNTED ATOP FLYWHEEL
Storage WITH LARGE PAWL PLATE
Twin Battery Set up Starter Elimination
GAUGES AND HORNS Disassembling
Fixed Voltage System Cleansing and Inspecting
Temperature Gauges Starter Assembling
Warning Lights Starter Set up
Thermomelt Sticks 9 HAND STARTERS
FUEL SYSTEM INTRODUCTION
Gas Gauge Emergency Beginning
Gas Gauge Hookup TYPE I STARTER
Gas Gauge Troubleshooting CYLINDER WITH PINION GEAR All
TACHOMETER ]HP All 6 HP All 7.5 HP All 8 HP
HORNS Starter Rope Alternative
ELECTRICAL SYSTEM Elimination
GENERAL INFORMATION Set up
GENERATING CHARGING Starter Elimination
CIRCUIT SERVICE Disassembling
Troubleshooting Cleansing and Inspecting
Elimination and Disassembling Assembling
Armature Testing TYPE II STARTER
Cleansing and Inspecting CYLINDER WITH PINION GEAR
Assembling All 9.5 HP
LOW TENSION FLYWHEEL Rope Elimination
MAGNETO IGNITION SYSTEM Rope Set up
9.9 hp – 1976 Starter Elimination
15 hp-1976 Cleansing and Inspecting
18 hp- 1973 Assembling
20 hp – 1973 Set up
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
Idea of Operation Elimination
Troubleshooting Disassembling
Elimination Cleansing and Inspecting
Cleansing 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 Elimination
– 1977 55 hp – 1977 Starter Rope Alternative
Description 10 POWER TRIM/TILT
Idea of Operation SYSTEM DESCRIPTION
Troubleshooting FILLING SYSTEM
Servicing TROUBLESHOOTING
Stator and Cost Coil SERVICING
Alternative ELECTRICAL MOTOR SERVICE
Timer Base and Sensor Cleansing & Inspecting
Meeting Alternative Testing
Energy Pack Alternative II MAINTENANCE
Timing Verify 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.
Idea of Operation REGULATOR SPECIFICATIONS
Troubleshooting GENERATOR SPECIFICATIONS
Checking Kind 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, Extremely, & 4 hp
Cleansing and Inspecting -1984 & on
Assembling 4 Delux via 55 hp w/CD 2ign.,
SINGLE-LEVER REMOTE w/guide begin;
CONTROL SHIFT BOX Additionally fashions outfitted
Troubleshooting with A.C. lighting
Disassembling 9.9 hp and 15 hp
Assembling w / electrlc begin – 1976
SHIFT BOX REPAIR 9.9 hp and 15 hp
Disassembling w/electrlc begin – 1978
Cleansing and Inspecting 9.9 hp and 15 hp
Assembling w/electrical begin 1986 & on 27
CABLE END FITTING INSTALLATION I8 hp, 20 hp, & 25 hp
AT THE ENGINE END w / electrical begin – 1971 -7 2
FOR ALL SHIFT BOXES EXCEPT SINGLE 28 18 hp, 20hp,& 25 hp
LEVER REMOTE CONTROL w/electrical begin – 1976
8 LOWER UNIT 35 hp w/electrical begin – 1976
DESCRIPTION 25 hp and 35 hp-19778
Chapter Protection 20 hp via 90 hp w/std. shift
Illustrations & w/electrical begin 19783
PROPELLER SERVICE 40 hp w/generator, w/std. shift
Propeller with Shear Pin & w/electrical begin 1973
Elimination 40 hp w/alternator, w/std. shift
Exhaust Propeller & w/electrlc begin – 1976
Elimination 30 hp w / alternator
Propeller with Shear Pin 4 w/electrical begin – 1972
Set up 50 hp w/alternator
Exhaust Propeller Set up & w/electrlc begin – 1977
LOWER UNIT LUBRICATION Additionally 55 hp with no
Draining thermo swap 1977
Filling 50 hp w/guide Begin 1980-83
NO SHIFT LOWER UNIT SERVICE 55 hp w/electrical begin – 1977
1.25 to 4.0 HP 1971 & on 50 hp & 53 hp
Description w/electrical begin 1978
Troubleshooting 50 hp – 1979, 55 hp – 1983,
Elimination & 60 hp – 1980-81
Water Pump Elimination all w/electrical begin
Decrease Unit Disassembling 20 hp, 23 hp, 30 hp, 33 hp,
Cleansing and Inspecting 40 hp, 30 hp, and 60 hp
Assembling w/distant electrical begin 1985
40 hp & 30 hp w/tiller
Water Pump Set up electrical begin 1986 & on
Decrease Unit Set up 40 hp & 50 hp w/distant
electrical begin – 1986 & on
Distant Management Field
Tags: Johnson Evinrude Outboard Motor 1-60hp, Brakes, Alternator, Repair Manual, Service Manual, Change oil, Suspension, Coolant, Store Manual, Engine, Steering, Spark plugs, Troubleshooting, Starter, Air Conditioner, Air Luggage, 4-Cylinder, Timing Belt, Diagnose, Battery, Air Filter, Radiator, 6-Cylinder, Cooling System
