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Johnson J10RSUR Service Manual

9.9, 15 hp 2 stroke
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  • Page 3 Nut Lock™ DPL™ Lubricant QuikStart™ S.A.F.E.™ ® Evinrude ® S.L.O.W.™ Evinrude E-TEC™ ® ® Screw Lock™ Evinrude / Johnson XD30™ Outboard Oil ® ® SystemCheck™ Evinrude / Johnson XD50™ Outboard Oil ® ® ® Evinrude / Johnson XD100™ Outboard Oil...

  • Page 4: Table Of Contents

    CAUTION When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with Indicates a potentially hazardous situation equivalent characteristics, including type, strength which, if not avoided, MAY result in minor and material.
  • Page 5 DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 6: Table Of Contents

    ABLE ONTENTS SECTION ........PAGE INTRODUCTION .

  • Page 7: Introduction

    INTRODUCTION INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL ..........6 .

  • Page 8: Models Covered In This Manual

    Identifying Model and Serial Numbers THIS MANUAL Outboard model and serial numbers are located on the swivel bracket and on the powerhead. This manual covers service information on Johnson 9.9 and 15 HP 2-Stroke models. Model Number Start Shaft Steer J10RSUR Rope 15”...

  • Page 9: Model Designation

    INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION STYLE: J = Johnson E = Evinrude LENGTH: MODEL RUN HORSEPOWER PREFIX L = 20” Long or SUFFIX J 15 R L SU MODEL YR: DESIGN FEATURES: I = 1 AP = Advanced Propulsion N = 2...

  • Page 10: Typical Page - A

    INTRODUCTION TYPICAL PAGE – A TYPICAL PAGE – A Subsection title indicates beginning of the subsection. Italic subheading above Service Chart indicates pertaining models. Bold letter indicates liquid product to be applied to a surface Pay attention to torque specifications. Some units appear as in.

  • Page 11: Typical Page - B

    INTRODUCTION TYPICAL PAGE – B TYPICAL PAGE – B Section Title Section Title INSTALLATION AND PREDELIVERY OUTBOARD RIGGING PROCEDURE Subsection Title Section Title Cable, Hose, and Wire Routing If a water pressure gauge is to be used, install the water pressure hose fitting in the cylinder block. Route all hoses, control cables, and wiring Use Pipe Sealant with Teflon (P/N 910048) on the through a protective sleeve or conduit into the...

  • Page 12: Typical Page - C

    INTRODUCTION TYPICAL PAGE – C TYPICAL PAGE – C POWERHEAD INSTALLATION IMPORTANT: INSTALLATION The motor mount, washer, and screw are serviced as an assembly. Do not disas- Title in italics indicates semble. V4 M a procedure ODELS concerning a Install base gasket dry. Do not use Permatex Denotes necessary particular model step or information to...

  • Page 13: Typical Page - D

    INTRODUCTION TYPICAL PAGE – D TYPICAL PAGE – D OILING SYSTEM COMPONENTS Oil Pressure Switch Two pulse hoses connect the pump to pulse fit- tings on the front of the cylinder/crankcase. The oil pressure switch is located in the oil injec- •...

  • Page 14: Abbreviations Used In This Manual

    INTRODUCTION ABBREVIATIONS USED IN THIS MANUAL ABBREVIATIONS USED IN THIS MANUAL Units of Measurement List of Abbreviations Amperes ABYC American Boat & Yacht Council amp-hr Ampere hour ATDC after top dead center fl. oz. fluid ounce air temperature sensor ft. lbs. foot pounds barometric pressure sensor horsepower...

  • Page 15: Engine Emissions Information

    Beginning with 1999 model year outboards, man- EPA Emission Regulations ufacturers of marine outboards must determine All new 1999 and more recent Evinrude/Johnson the exhaust emission levels for each outboard outboards are certified to the EPA as conforming horsepower family and certify these outboards...

  • Page 16: Product Reference And Illustrations

    INTRODUCTION PRODUCT REFERENCE AND ILLUSTRATIONS PRODUCT REFERENCE SYMBOLS AND ILLUSTRATIONS Throughout this service manual, symbols are used to interpret electrical troubleshooting results BRP US Inc. reserves the right to make changes or to assign values in drawings. at any time, without notice, in specifications and Electrical models and also to discontinue models.

  • Page 17: Values

    INTRODUCTION SYMBOLS When “Ω” follows a value on the meter face, the When “≥” precedes a value on the meter face, it procedure is measuring resistance. Ω is the sym- indicates your reading must be greater than, or bol for ohm, the unit of measurement for resis- equal to, the value shown.

  • Page 18: Notes

    INTRODUCTION NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 19: Service Specifications And Special Tools

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SERVICE SPECIFICATIONS AND SPECIAL TOOLS TABLE OF CONTENTS TECHNICAL DATA ..............18 STANDARD TORQUE SPECIFICATIONS .

  • Page 20: Technical Data

    87 AKI (R+M)/2 or 90 RON ® Fuel Conditioner, Fuel System Cleaner, Carbon Guard Use only Evinrude/Johnson recommended fuel additives. Additives The use of other additives may result in engine damage. See Fuel Requirements on p. 43 for additional information.
  • Page 21 SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA 9.9, 15 12-Volt, 360 CCA (465 MCA) with Battery, Minimum 90 Minutes Reserve Capacity or Requirements 50 Ampere-Hour 5 A, Non-regulated Alternator (accessory) 5 Pulse / 10 pole Tachometer Setting (with alternator) A/C lighting Accessory Engine Fuse (20 Amp) P/N 514021...

  • Page 22: Standard Torque Specifications

    (locknut or patch screw) if its locking feature becomes weak. Definite resistance to turning must be felt when reusing a locking fastener. If replacement is specified or required because the locking fastener has become weak, only authorized Evinrude/ Johnson Genuine Parts.

  • Page 23: Special Tools

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS Electrical / Ignition Digital multimeter DRC7265 CD Peak reading voltmeter 49799 Analog multimeter P/N 501873 49793 Ohms resolution 0.01 P/N 507972 Purchase through local supplier Adapter, power pack load resistor 49797 Amphenol crimping pliers 30387 Coil locating ring P/N 334994...

  • Page 24: Fuel

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Ignition analyzer P/N 501890 49791 Ignition coil terminal extender CO3010 Spark checker P/N 508118 49798 P/N 502054 Tachometer/timing light P/N 507980 49789 Fuel Ball hex screwdriver P/N 327622 23664 Float gauge P/N 324891 23678 Nipple cleaning tool P/N 326623 23655...

  • Page 25: Gearcase

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Gearcase Forward gear bearing cup installer 23218 Driveshaft seal installer 32883 Prop shaft bearing housing bearing 32881 P/N 319929 (9.9-15 HP) P/N 326554 (9.9-15 HP) installer P/N 339751 (9.9-15 HP) Gearcase filler P/N 501882 49790 Pinion bearing spacer P/N 339753 32638...

  • Page 26: Powerhead

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS TYPICAL 49794 1. Retaining ring pliers 2036 P/N 331045 Gearcase pressure tester 2. Replacement tip set P/N 507977 (Stevens P/N S-34) P/N 395967 Gearcase vacuum tester P/N 507982 (Stevens P/N V-34) Powerhead Crankshaft lower seal installer 23660 Cylinder bore gauge P/N 771310 45303...

  • Page 27: Starter

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Wrist pin pressing pin 23668 Wrist pin retaining ring driver DR1641 9.9-15 HP: P/N 392511 P/N 392511 (driver and cone) Starter Starter rope threading tool 23682 Starter spring winder/installer 50068 P/N 378774 P/N 342682 Universal Drive handle P/N 311880 31932...
  • Page 28 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Puller wrench P/N 334359 23147 Tie strap installation tool 18105 Twist-Grip™ remover P/N COA6017 (use with puller jaws) P/N 323716 390767 Slide hammer P/N 391008 CO1577 Temperature gun P/N 772018 45240 Universal pinion bearing remover 33974 and installer kit P/N 391257 Slide hammer P/N 432128...

  • Page 29: Shop Aids

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 Engine Tuner P/N 777185 Anti-Corrosion Spray P/N 777193 “6 in 1” Multi-Purpose Lubricant P/N 777192 D.P.L. Spray P/N 777183 Silicone spray P/N 775630 Oil - XD100™ P/N 777118 Oil - XD50™...
  • Page 30 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Moly Lube P/N 175356 Triple-Guard® Grease P/N 508298 Extreme Pressure Grease™ P/N 508303 Lubriplate† 777 P/N 317619 Needle Bearing Grease, P/N 378642 Starter Bendix Lube P/N 337016 Electrical Grease P/N 504824 Power Trim/Tilt and Power Steering Fluid †...
  • Page 31 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS 2 + 4™ Fuel conditioner P/N 775613 Fuel System Cleaner P/N 777184 Carbon Guard™ P/N 775629 Gel-Seal and Gasket Remover P/N 771050 Gel·Seal II P/N 327361 Gasket Sealing Compound P/N 317201 † † Pipe Sealant with Teflon P/N 910048 Permatex No.

  • Page 32: Notes

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 33: Installation And Predelivery

    INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS BOAT RIGGING ..............32 .

  • Page 34: Boat Rigging

    Remote control styles and applications are described in the Evinrude/Johnson Genuine Parts Installation Guidelines and Accessories Catalog. Plan the installation of Install the appropriate remote control following all all remote controls carefully.

  • Page 35: Battery Installation

    Read and understand the safety information supplied with the battery before installation. Battery Cable Requirements WARNING Evinrude/Johnson outboards are shipped with stranded copper battery cables for typical installa- Keep the battery connections clean, tight, tions in which the starting battery is positioned and insulated to prevent their shorting or close to the transom.

  • Page 36: Fuel System Requirements

    INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel System Requirements Fuel System Primer Outboards require a priming system capable of Overview refilling the fuel system after periods of non-use. Fuel systems must meet minimum specifications Primer Bulbs to insure the proper delivery of fuel to the out- board.
  • Page 37 INSTALLATION AND PREDELIVERY BOAT RIGGING Fuel Filters Boat-mounted fuel filters and water-separating fuel filter assemblies must meet the required fuel flow and filter specification. The filter must be mounted to a rigid surface above the "full" level of the fuel tank and accessible for servicing. Fuel Filter Assembly, P/N 174176, meets all requirements for a water-separating fuel filter.

  • Page 38: Outboard Installation

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION OUTBOARD • Check transom strength and height. INSTALLATION WARNING DO NOT install an outboard on a curved or Hull Preparation irregular surface. Doing so can wear, bind, and damage components, causing loss of Maximum Capacity control.

  • Page 39: Transom Measuring And Drilling

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Transom Measuring and Drilling Determine transom height by measuring from the top edge of the transom, along the centerline. Hull Centerline Use a straightedge as a reference to extend the Locate the centerline of the boat transom as it bottom of the boat.

  • Page 40: Lifting The Outboard

    Lift the outboard using the lift grips (NOT the tilt Mechanical Cables grip or steering handle) and place it in the center All Evinrude/Johnson outboards equipped with tilt of the boat’s transom. tubes are designed to be compatible with mechanical steering systems that meet ABYC Standard P-17.

  • Page 41: Outboard Mounting

    INSTALLATION AND PREDELIVERY OUTBOARD INSTALLATION Outboard Mounting IMPORTANT: Use a marine sealant rated for above or below waterline use. RTV silicone is not WARNING approved for below waterline use. Polyurethane sealants are not easily removed and may damage The outboard must be correctly installed. outboard or boat mounting surfaces when Failure to correctly install the outboard removed.

  • Page 42: Outboard Rigging

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING OUTBOARD RIGGING Extend the control cables and lubricate them with Triple-Guard grease. WARNING To prevent accidental starting of engine, confirm the battery cables are discon- nected at battery and spark plug leads are disconnected from spark plugs. Control Cable Installation Control Cable Identification IMPORTANT:...
  • Page 43 INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Shift Cable Installation Position the remote control handle in NEUTRAL. Be sure the throttle cable is retracted to IDLE position and shift cable is at mid-point of travel. Position shift linkage of outboard in NEUTRAL. Make sure gearcase is in NEUTRAL.

  • Page 44: Cable, Hose, And Wire Routing

    INSTALLATION AND PREDELIVERY OUTBOARD RIGGING Cable, Hose, and Wire Routing Route battery positive (+) cable to the starter sole- noid. Secure the cable to terminal. Position grom- IMPORTANT: met in lower engine cover. Provide sufficient slack at out- board end to permit unrestricted steering and tilt- ing of outboard.

  • Page 45: Fuel And Oil Priming

    Evinrude/Johnson 2+4 Fuel Conditioner will Minimum Octane help prevent gum and varnish deposits from form- Evinrude/Johnson outboards are certified to oper- ing in fuel system components and will remove ate on unleaded automotive gasoline with an moisture from the fuel system. It can be used con-...

  • Page 46: Fuel System Priming

    Evinrude/Johnson XD30 outboard oil is recom- electric fuel primer. mended for use in Johnson 2-Stroke outboards. Observe all fuel lines, both in the boat and on the If XD30 oil is not available, you must use an oil outboard.

  • Page 47: Before Start-Up

    INSTALLATION AND PREDELIVERY BEFORE START-UP BEFORE START-UP RUNNING CHECKS Gearcase Lubricant WARNING With outboard in vertical position, check the gear- DO NOT run outboard without a water sup- case lubricant level: ply to the outboard’s cooling system. Cool- • Remove the lubricant level plug. Lubricant must ing system and/or powerhead damage be even with the bottom of the threaded hole.

  • Page 48: Start-In-Gear Prevention

    INSTALLATION AND PREDELIVERY RUNNING CHECKS Remote Control Operation Water Pump Overboard Indicator Make sure that control can be easily moved into A steady stream of water should flow from the all gear and throttle settings. Do not shift remote overboard indicator. control when outboard is not running.

  • Page 49: Propellers

    Water testing with various propeller designs and each situation. sizes is the best method of propeller selection. • Refer to the Evinrude/Johnson Genuine Parts and Accessories Catalog for propeller styles The correct propeller, under normal load condi- and sizes. tions, will allow the engine to run near the mid- •...
  • Page 50 INSTALLATION AND PREDELIVERY PROPELLERS Install the spacer, engaging the propeller shaft Install the propeller nut and torque to 120 in. lbs. splines. (14 N·m). If cotter pin holes in the propeller nut and propeller shaft are not aligned, continue to tighten the nut until they are in line.

  • Page 51: Maintenance

    MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... . 50 ANTI-CORROSION PROTECTION .

  • Page 52: Inspection And Maintenance Schedule

    MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer. IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use applications require more frequent inspections and maintenance.
  • Page 53 Water pump, inspect and replace (1) Also recommended at 10-Hour Inspection (2) Emission-related component (3) Do not use light duty penetrating lubricants Evinrude/Johnson Anti-Corrosion Spray or Evinrude/Johnson “6 in 1” Multi-Purpose Lubricant HPF XR Gearcase Lubricant Power Trim/Tilt and Power Steering Fluid Triple-Guard grease...

  • Page 54: Anti-Corrosion Protection

    MAINTENANCE ANTI-CORROSION PROTECTION ANTI-CORROSION Testing Procedure – Continuity Connect meter leads between engine ground and PROTECTION anode surface. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. Salt, brackish, and polluted water can accelerate corrosion. “Sacrificial” anodes are intended to pro- tect the underwater metal components of the out- board from galvanic corrosion.

  • Page 55: Cooling System

    MAINTENANCE COOLING SYSTEM COOLING SYSTEM Remove the plug from the flushing port on exhaust manifold. Check the condition of cooling system compo- nents regularly. The outboard cooling system con- sists of: • water intake screens; • overboard water pressure indicator; •...

  • Page 56: Water Intake Screens

    MAINTENANCE LUBRICATION Flushing — Outboard Not Running LUBRICATION Outboard can be in VERTICAL (DOWN) or Steering System TILTED (UP) position. Remove the plug from the flushing port. Install WARNING flushing device and garden hose. Failure to grease as recommended could Turn water supply ON.

  • Page 57: Midsection

    MAINTENANCE LUBRICATION Midsection Throttle and Shift Linkage Lubricate the tilt tube/tilt shaft grease fittings, Lubricate the throttle linkage, shift linkage, starter clamp screws, tilt lever shaft grease fittings, and lockout mechanism, and carburetor linkage with swivel bracket with Triple-Guard grease. Apply Triple-Guard grease.

  • Page 58: Gearcase Lubricant

    MAINTENANCE LUBRICATION Gearcase Lubricant tive; however, long term durability may be affected with continued use. IMPORTANT: Always check the fill level of the IMPORTANT: The recommended gear lubri- gearcase lubricant prior to removing drain/fill plug. cants include special additives for marine applica- A tie strap can be used to check lubricant level.

  • Page 59: Electric Starter

    MAINTENANCE BATTERY AND BATTERY CONNECTIONS BATTERY AND BATTERY Electric Starter Lubricate the starter pinion area of the starter CONNECTIONS shaft with Starter Lube. Check battery connections frequently. Clean and IMPORTANT: Do not use liquid or aerosol service battery connections at regular intervals. spray lubricants.

  • Page 60: Fuel System

    Fuel Filter See table below for recommended spark plug data and gap setting. Johnson outboards are equipped with a service- able fuel filter element. Clean or replace the ele- Models Recommended Spark Plug ment as needed.

  • Page 61: Synchronization And Linkage Adjustments

    MAINTENANCE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS SYNCHRONIZATION Turn the connector clockwise until it seats. Turn counterclockwise no more than one-half turn to AND LINKAGE align it with the throttle lever. Install the retaining pin. ADJUSTMENTS IMPORTANT: Synchronization and linkage pro- cedures MUST be followed in sequence and be performed exactly as described to ensure consis- tent engine idling and smooth operation through- out the RPM range.

  • Page 62: Cam Follower Pickup Point

    MAINTENANCE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS completely and check the cam to roller alignment. Advance the throttle until the tip of the amplifier Repeat procedure if necessary. begins to move. At this point, the center of the roller should align with the indicator mark on cam. 1.

  • Page 63: Wide Open Throttle Adjustment

    MAINTENANCE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS Wide Open Throttle Adjustment Maximum Spark Advance Adjust wide open throttle (WOT) stop screw until No maximum spark advance adjustment is neces- the tip protrudes 0.25 in. (8 mm) through the throt- sary. Correct ignition primary lead position is all tle lever.

  • Page 64: Shift Lever Detent

    Twist-Grip IMPORTANT: All Johnson outboard owners are throttle is held at the full throttle position (tiller encouraged to return their new engines to an models).

  • Page 65: Storage

    Clean and grease propeller shaft. • 5 gallons (18.9 liter) of fuel; • Lubricate all grease fittings and linkages. • 2 quarts (1.9 liter) of Evinrude/Johnson Storage • Clean or replace fuel filter element. Fogging Oil; • Inspect outboard, steering system, and con- •...

  • Page 66: Pre-Season Service

    MAINTENANCE PRE-SEASON SERVICE PRE-SEASON SERVICE SUBMERGED ENGINES If outboard was removed from boat for storage, Once an outboard has been submerged in fresh make certain it has been reinstalled with factory or salt water, it must be serviced within three (3) specified hardware.

  • Page 67: Engine Dropped Overboard (Running)

    MAINTENANCE SUBMERGED ENGINES Remove carburetor for draining, disassembly and Engine Dropped Overboard cleaning. (In Salt Water) Disconnect fuel supply hose from outboard. Drain Follow the same procedures used for Engine and clean all fuel hoses, filters, and fuel tanks. Dropped Overboard (Not Running) and Engine Dropped Overboard (Running).

  • Page 68: Notes

    MAINTENANCE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 69: Electrical

    ELECTRICAL ELECTRICAL TABLE OF CONTENTS CHARGING SYSTEM COMPONENTS ........... 68 .

  • Page 70: Charging System Components

    ELECTRICAL CHARGING SYSTEM COMPONENTS CHARGING SYSTEM Stator The alternator stator has windings wrapped COMPONENTS around metal laminations. The flywheel's mag- netic lines of force cutting through the stator wind- Information in this section may only apply if any of ings produce alternating current. the following kits have been installed: •...

  • Page 71: Charging System Tests

    ELECTRICAL CHARGING SYSTEM TESTS CHARGING SYSTEM TESTS Charging System Check Chart Where to Look Cause Procedure Reference Battery defective or worn out Check condition and charge Low electrolyte level Add water and recharge Accessories Service Battery Manual Terminal connections loose or corroded Clean and tighten Excessive electrical load Evaluate accessory loads...

  • Page 72: Stator Resistance Tests

    ELECTRICAL CHARGING SYSTEM TESTS Stator Resistance Tests If a stator lead is grounded, repair it or replace the stator assembly. Disconnect the battery cables at the battery. Disconnect all stator leads. ∞ Calibrate ohmmeter on appropriate scale. Con- nect meter leads between the two stator yel- low/gray leads.

  • Page 73: Tachometer Circuit Test

    ELECTRICAL TACHOMETER CIRCUIT TEST TACHOMETER CIRCUIT STEP 2 Move ohmmeter lead from engine ground to recti- TEST fier red lead. Connect the other meter lead to the yellow/gray rectifier leads. Note the reading. Reverse the ohmmeter connections or press the IMPORTANT: The tachometer circuit is driven "reverse polarity"...

  • Page 74: Electric Starter Tests

    ELECTRICAL ELECTRIC STARTER TESTS ELECTRIC STARTER STEP 4 With the engine running at 1000 RPM, check for TESTS voltage between the instrument harness gray lead and black lead at the dash. Start Switch Test • If voltmeter shows 0 V, go to STEP 5. •...
  • Page 75 ELECTRICAL ELECTRIC STARTER TESTS STEP 3 STEP 5 Move the voltmeter red lead to the start switch Move the voltmeter red lead to the start switch connection. Check the voltage between the start output lead. Push the start button. Check the volt- switch connection and rectifier terminal.
  • Page 76 ELECTRICAL ELECTRIC STARTER TESTS TYPICAL DRC6305 1. Battery positive (+) 2. Battery negative (-) 3. Rectifier terminal ground 4. Start switch connection 5. Powerhead ground 6. Start switch output lead 7. Start button 8. Starter terminal 9. Pinion...

  • Page 77: Voltage Drop Tests

    ELECTRICAL ELECTRIC STARTER TESTS Voltage Drop Tests Remove voltmeter positive (+) lead from starter solenoid and stop cranking engine. WARNING Avoid accidental starting while testing; twist and remove all spark plug leads. STEP 1 ≤ 0.2V Connect voltmeter positive (+) lead to battery pos- itive (+) post.

  • Page 78: Starter Solenoid Test

    ELECTRICAL ELECTRIC STARTER TESTS STEP 4 Starter Solenoid Test Connect voltmeter positive (+) lead to battery neg- IMPORTANT: All engine wiring must be discon- ative (–) lead common powerhead ground screw. nected from the solenoid before proceeding. Connect voltmeter negative (–) lead to battery negative (–) post.

  • Page 79: No Load Current Draw Test

    ELECTRICAL ELECTRIC STARTER SERVICING ELECTRIC STARTER No Load Current Draw Test Securely fasten starter in a vise or suitable fixture SERVICING before proceeding with this check. Removal Use a battery rated at 350 CCA or higher that is in good condition and fully charged. Disconnect the battery cables at the battery.

  • Page 80: Cleaning And Inspection

    ELECTRICAL ELECTRIC STARTER SERVICING Remove the brush end cap from the frame and Cleaning and Inspection magnet assembly. Inspect the brushes for wear and damage. Replace brushes if damaged or worn. Replace weak brush springs. 1. Scribe marks 32986 2. Bolts 3.

  • Page 81: Assembly

    ELECTRICAL ELECTRIC STARTER SERVICING Assembly Lubricate the armature shaft bearing surface with Moly Lube. Lubricate the armature shaft on and above the pinion helix with Starter Pinion Lube, P/N 337016. Assemble the brush end cap with brushes and springs to the armature shaft. Place a new gasket on the brush end cap.

  • Page 82: Installation

    ELECTRICAL ELECTRIC STARTER SERVICING Place the washer on the armature shaft. Place a Installation new gasket on the drive end cap. Install the starter on the bypass cover. The elec- tric starter motor must be held firmly against the Align the drive end cap mark with the mark on the bracket while bolting it to the bypass cover.

  • Page 83: Accessory Components

    ELECTRICAL ACCESSORY COMPONENTS ACCESSORY Disconnect the yellow/blue, yellow/gray, and yel- low wires. Remove the red wire and two screws COMPONENTS retaining the rectifier and black cables. Remove the rectifier. Use these procedures if it is necessary to remove any of the following accessory components: •...

  • Page 84: Installation

    ELECTRICAL CONNECTOR SERVICING Remove the two screws retaining the electrical CONNECTOR bracket. Remove the bracket. SERVICING Amphenol Connectors Terminal Removal To remove a terminal from the plug or receptacle, lubricate both ends of the cavity with isopropyl alcohol. Pick the proper tool for the service being per- formed.
  • Page 85 ELECTRICAL CONNECTOR SERVICING Pin and socket terminals may be replaced if dam- Push terminal into connector until step of insert aged. Strip 1/4 in. (6 mm) insulation from wire and tool touches connector body. crimp new terminal onto wire with crimping pliers. 1.

  • Page 86: Notes

    ELECTRICAL NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 87: Ignition

    IGNITION IGNITION TABLE OF CONTENTS COMPONENTS ..............86 .

  • Page 88: Components

    IGNITION COMPONENTS COMPONENTS Sensor Coil The sensor coil contains many windings of wire Flywheel wrapped around a metal lamination. Once the fly- wheel exceeds a minimum cranking RPM, the fly- The flywheel contains permanent magnets which wheel's magnetic lines of force cutting through the energize the charge coil, sensor coil, and alterna- sensor coil windings produce approximately 3 V.

  • Page 89: Stop Button

    IGNITION COMPONENTS Stop Button When activated, this switch directs power pack output to ground, stopping the ignition system. The stop button, and emergency stop switch are connected to the power pack through the engine wiring harness. When activated, these switches direct the power pack output to ground, stopping the ignition system.

  • Page 90: Troubleshooting

    IGNITION TROUBLESHOOTING TROUBLESHOOTING outside the spark plug hole. This indicates the number 1 piston is near top dead center. Complete these tasks to obtain fast, accurate test results when troubleshooting the capacitor dis- charge ignition system. • Visual Inspection – Check wiring for broken, pinched, or loose leads.

  • Page 91: Ignition System Tests

    IGNITION IGNITION SYSTEM TESTS IGNITION SYSTEM If equipped, install the clip onto the emergency stop switch. Crank the engine. Spark should jump TESTS each tester gap alternately. • If tester shows good output on both cylinders, go to Power Pack Running Output on p. 94. CAUTION •...
  • Page 92 IGNITION IGNITION SYSTEM TESTS Crank engine and observe results at spark tester. STEP 2 • If there is no spark at one gap, go to Power Install the emergency stop switch clip and lanyard. Pack Cranking Output on p. 94. Disconnect 5-pin Amphenol...

  • Page 93: Charge Coil Test

    IGNITION IGNITION SYSTEM TESTS Charge Coil Test STEP 2 Set peak-reading voltmeter to: STEP 1 • 9.9/15 – "NEG" and "500." Disconnect 5-pin Amphenol connector between Attach voltmeter black lead to ignition plate con- ignition plate and power pack. nector, terminal "A." Attach meter red lead to ter- Set peak-reading voltmeter to: minal "D."...

  • Page 94: Sensor Coil Test

    IGNITION IGNITION SYSTEM TESTS STEP 3 Sensor Coil Test IMPORTANT: All ohmmeter tests must be per- STEP 1 formed with the engine NOT running. Disconnect 5-pin Amphenol connector between ignition plate and power pack. Insert jumper wires in ignition plate connector, ter- minals "A"...
  • Page 95 IGNITION IGNITION SYSTEM TESTS STEP 2 STEP 3 Set peak-reading voltmeter to: IMPORTANT: All ohmmeter tests must be per- • 9.9/15 – "NEG" and "50," or "SEN" and "50" on formed with the engine NOT running. Stevens CD-77 meter. Insert jumper wires in ignition plate connector, ter- Attach voltmeter black lead to ignition plate con- minals "B"...

  • Page 96: Power Pack Cranking Output

    IGNITION IGNITION SYSTEM TESTS Power Pack Cranking Output Power Pack Running Output Twist and remove primary leads from ignition Twist and remove primary leads from ignition coils. coils. Connect number 1 ignition coil primary lead to Use a clockwise twist to install Stevens Number Stevens Number PL-88 Pack Load Adapter, TS-77 terminal extenders, or equivalent, to igni- P/N 507983, red lead.

  • Page 97: Ignition Coil Tests

    IGNITION IGNITION SYSTEM TESTS Ignition Coil Tests STEP 2 Calibrate ohmmeter on appropriate scale. Con- DANGER nect meter red lead to coil primary terminal. Con- nect meter black lead to coil spark plug terminal. To avoid personal injury from electrical •...
  • Page 98 IGNITION IGNITION SYSTEM TESTS Ignition Coil Analyzer Tests Surface Leakage Test The ignition coil and spark plug lead should be IMPORTANT: When conducting these tests to tested for leakage or insulation failures using the the coil, do not exceed its maximum specified ignition analyzer.

  • Page 99: Spark Plugs

    IGNITION SPARK PLUGS SPARK PLUGS FLYWHEEL SERVICING Remove and inspect the spark plugs for the fol- IMPORTANT: In order to produce the voltage lowing conditions: necessary to run an ignition system, the flywheel • Worn electrodes magnets must be of a particular strength. Weak •...

  • Page 100: Installation

    IGNITION FLYWHEEL SERVICING Apply Moly Lube to threads of pressing screw and Installation center hole of crankshaft. Install the flywheel key with its outer edge parallel to taper of crankshaft. 32845 Assemble the following components from Univer- DR2115 sal Puller Set, P/N 378103: •...

  • Page 101: Ignition Plate Servicing

    IGNITION IGNITION PLATE SERVICING IGNITION PLATE Installation Place the retainer plate, then the support plate on SERVICING the powerhead. Align support plate with four screw holes in powerhead. Apply Nut Lock to Removal threads of the four support plate screws. Install the screws and torque to 48 to 60 in.

  • Page 102: Charge Coil And Sensor Coil

    IGNITION CHARGE COIL AND SENSOR COIL Lubricate the ignition plate bearing groove with CHARGE COIL AND Moly Lube. SENSOR COIL Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. Remove the screws retaining the ignition compo- nent that is being replaced.

  • Page 103: Installation

    IGNITION CHARGE COIL AND SENSOR COIL Loosen the ignition plate screws. Lift the ignition Install plate on bottom of the ignition plate. plate from the powerhead. 1. Plate 32288 32324 Install the wire clamp on ignition plate. Remove the plate from the bottom of the ignition plate.

  • Page 104: Ignition Coil

    IGNITION IGNITION COIL Check for sufficient slack on ignition component IGNITION COIL leads. Route component leads through wire clamps. Removal Twist and remove cover. Remove the spark plug Position Coil Locating Ring, P/N 334994, over and primary leads from the ignition coils. machined bosses on the ignition plate.

  • Page 105: Fuel System

    FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS FUEL SYSTEM TROUBLE CHECK CHART ..........104 COMPONENTS .

  • Page 106: Fuel System Trouble Check Chart

    FUEL SYSTEM TROUBLE CHECK CHART INTAKE FUEL TANK LINKAGE MANIFOLD CARBURETOR AND FILTER ADJUSTMENT & LEAF PLATE ASSEMBLY ENGINE WILL NOT START STARTS, WILL NOT IDLE WILL NOT IDLE SLOWLY SPITS AT IDLE, LEAN ENGINE RICH AT IDLE EXCESSIVE OIL USE STALLS ON ACCELERATION SURGES AT HIGH SPEED RUNS RICH AT HIGH SPEED...

  • Page 107: Components

    FUEL SYSTEM COMPONENTS COMPONENTS Fuel mixture enrichment for cold starting is con- trolled by a choke. The carbureted fuel system consists of the follow- ing components: • Fuel pump • Carburetor • Intake manifold assembly Fuel Pump The fuel pump is a diaphragm-displacement type and is operated by changes in crankcase pres- sure.

  • Page 108: Fuel Pump Pressure Test

    FUEL SYSTEM FUEL PUMP PRESSURE TEST FUEL PUMP PRESSURE FUEL PUMP SERVICE TEST Before replacing a suspect fuel pump, remove and clean the fuel filter and install a new filter ele- Perform this test with the outboard in a test tank or ment.

  • Page 109: Assembly

    Emissions Compliance • Confirm the large O-ring is seated in its groove in the cover and the small O-ring is in place Johnson 9.9/15 models are manufactured in around center post. accordance with United States of America Envi- • Install cover. Position inlet nipple between ronmental Protection Agency (EPA) standards screw heads.

  • Page 110: Disassembly

    FUEL SYSTEM CARBURETOR SERVICE Loosen two retaining screws and remove air Loosen two mounting nuts and remove carburetor. silencer. 002558 1. Screws 32957 Cut tie strap securing fuel hose to carburetor. Remove the choke lever. 35009 35005 Disassembly Remove the cam follower O-ring. IMPORTANT: Changing original factory fuel mixture calibrations beyond the limits allowed by...

  • Page 111: Cleaning And Inspection

    FUEL SYSTEM CARBURETOR SERVICE HR Models Only Cleaning and Inspection Remove the low-speed needle and spring from IMPORTANT: Do not clean carburetor or its the carburetor body cover. components by submerging in strong carburetor All Models cleaner or hot soaking tank. Strong cleaners might damage components or remove sealing com- Remove the six cover screws.
  • Page 112 FUEL SYSTEM CARBURETOR SERVICE Visually inspect all gasket surfaces for nicks or irregularities. Check for excessive throttle shaft play. Check for throttle valve misalignment. If necessary, remove the calibration pocket core plug to inspect the pocket for damage or restric- tions.

  • Page 113: Assembly

    FUEL SYSTEM CARBURETOR SERVICE Install a new lead shot. Flatten shot with flat end Assembly punch and plastic mallet. Check for leakage. When installing new parts from a carburetor rebuild kit, inspect gaskets and compare to origi- nal gaskets to ensure all holes are correctly punched.
  • Page 114 FUEL SYSTEM CARBURETOR SERVICE gauge up, next to float. Top of float should be Install the float chamber and a new gasket. between notches on gauge. Tighten the screws to a torque of 8 to 10 in. lbs. (0.8 to 1.2 N·m), following sequence embossed on Use notch that is indicated "9.9 &...

  • Page 115: Installation

    FUEL SYSTEM CARBURETOR SERVICE Installation Install cam follower on post. Position O-ring on the post to secure cam follower. Attach the fuel supply hose, and secure with a tie strap. 35007 35009 Install the choke lever. Position a new gasket on the intake manifold. Install the carburetor.

  • Page 116: Carburetor Mixture Adjustment

    FUEL SYSTEM CARBURETOR MIXTURE ADJUSTMENT CARBURETOR MIXTURE consistent RPM is attained. Allow 15 seconds after each adjustment for the engine to respond. ADJUSTMENT IMPORTANT: Changing original factory fuel mixture calibrations beyond the limits allowed by the tamper resistant device is a violation of federal law.

  • Page 117: Intake Manifold

    FUEL SYSTEM INTAKE MANIFOLD INTAKE MANIFOLD Inspection IMPORTANT: Removal Do not lift or bend leaf valves by hand. This may damage them so they may not Remove the powerhead. Refer to Powerhead seal properly or may break after the engine is REMOVAL on p.

  • Page 118: Disassembly

    FUEL SYSTEM INTAKE MANIFOLD Inspect the intake manifold: IMPORTANT: The 9.9 and 15 leaf valves are • All gasket surfaces must be smooth and free of not interchangeable. The thickness of the valves nicks. is not the same. • Use a machinist's straightedge to check for flat- Assembly ness in all directions.

  • Page 119: Installation

    FUEL SYSTEM INTAKE MANIFOLD Apply Screw Lock to mounting screws. Wipe off Tighten screws securely. excess adhesive. 12320 12322 Installation Assemble leaf valve shim (if required) and leaf Position leaf plate assembly and new gaskets on stop. Install screws finger tight. powerhead.

  • Page 120: Notes

    FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 121: Powerhead

    POWERHEAD POWERHEAD TABLE OF CONTENTS TORQUE CHART ..............120 GENERAL .

  • Page 122: Torque Chart

    POWERHEAD TORQUE CHART TORQUE CHART Description 9.9/15 Lubricant 60 to 70 in. lbs. Apply Evinrude/Johnson Connecting Rod Cap Screws (7 to 7.5 N·m) Outboard Lubricant to threads 60 to 84 in. lbs. Apply Gasket Sealing Lower Crankcase Head Screws (7 to 9 N·m) Compound to threads.

  • Page 123: General

    POWERHEAD GENERAL GENERAL Retaining Ring Pliers Cylinder Compression Testing Start and run outboard until it achieves operating temperature, then shut OFF. Remove all spark plugs and disconnect the 5-pin power pack connector. Advance throttle linkage to WOT. Install compression tester’s hose attachment into spark plug hole (14 mm threads).

  • Page 124: Engine Temperature Check

    POWERHEAD ENGINE TEMPERATURE CHECK ENGINE TEMPERATURE Start outboard and run at 3000 RPM for at least five minutes. CHECK Reduce engine speed to 900 RPM. At 900 RPM, the digital pyrometer or Temperature Gun should Temperature Gun, P/N 772018, or a digital pyrom- indicate 140°...

  • Page 125: Upper Crankcase Seal

    POWERHEAD UPPER CRANKCASE SEAL UPPER CRANKCASE Installation To install a new seal, apply Gasket Sealing Com- SEAL pound to the outside diameter of the metal casing. Position seal on crankshaft with lip facing crank- General case assembly. The presence of oil under the flywheel could indi- Upper Crankshaft Seal Installer cate a leaking upper crankcase seal.

  • Page 126: Shift Linkage

    POWERHEAD SHIFT LINKAGE SHIFT LINKAGE Remove the choke lever and grommet. Removal Remove the lower engine covers as described in REMOVAL on p. 128. Remove the clip and drive pin from shift handle. 32333 Remove the pin, shift rod, and grommet. 32338 Remove the screw retaining the shift handle.

  • Page 127: Installation

    POWERHEAD SHIFT LINKAGE Bend lock tab back and remove screw. Remove Installation lock tab from shift arm. Installation is essentially the reverse of removal. Pay close attention to any additional task that may be required for installation. Install the two shift arm bushings. Install the pin and shift lever, and secure with cotter pin.

  • Page 128: Start Switch

    POWERHEAD SHIFT LINKAGE Start Switch Disconnect the red wires and from the starter motor and electrical box connection. Removal Remove screw and wave washer retaining the shift handle. 1. Starter wire 32824 2. Start switch wire Pull wires out of grommet. 1.

  • Page 129: Neutral Start Protection

    POWERHEAD NEUTRAL START PROTECTION NEUTRAL START Shift outboard into FORWARD and REVERSE and press start button. No continuity should be PROTECTION indicated in either position. To adjust, loosen the start button screw. With the Manual Starter outboard in NEUTRAL, center the button in the Manual start outboards are equipped with starter switch recess.

  • Page 130: Removal

    POWERHEAD REMOVAL REMOVAL Remove the two screws from the top front of the lower engine cover. WARNING To prevent accidental starting of engine while servicing, twist and remove all spark plug leads. On electric start models, dis- connect battery cables at the battery. Dis- connect battery positive (+) cable first and then the battery negative (–) cable.

  • Page 131: Disassembly

    POWERHEAD DISASSEMBLY DISASSEMBLY Remove the six retaining screws, powerhead to the exhaust housing. IMPORTANT: To simplify reassembly, lay out the various screws and clamps in the order of their proper location. Remove the three screws retaining the crankcase head to the powerhead. Using a mallet and a punch, drive the seals from the crankcase head.
  • Page 132 POWERHEAD DISASSEMBLY Remove the thermostat assembly and tempera- Remove the intake bypass cover from the cylinder ture switch (if equipped). block. Clean the gasket surfaces. 32387 32384 Remove the six intake manifold screws, intake manifold, leaf plate assembly, and gaskets. 32386 Remove the cylinder head screws.
  • Page 133 POWERHEAD DISASSEMBLY face. Do not use any tool smaller than taper pin Using a rawhide mallet, lightly tap upward on the bore to remove the pin. crankshaft until the halves just begin to separate. Lift up and remove the crankcase. 1.
  • Page 134 POWERHEAD DISASSEMBLY Use a 5/32 in. Allen wrench to remove connecting Remove the retaining ring from groove of the cen- rod screws. Remove the rod caps and bearing ter main bearing. Separate the bearing and retainers. remove the 23 loose needle bearings. 32393 COB1127 Lift the crankshaft out of the cylinder block.

  • Page 135: Cleaning

    POWERHEAD CLEANING CLEANING Use Retaining Ring Pliers or equivalent to remove wrist pin retaining rings. Discard the rings. IMPORTANT: Before inspecting or assembling powerhead, all internal components must be per- fectly clean and free of contaminants. Remove any carbon accumulation from exhaust port areas.

  • Page 136: Inspection

    25 psi (172 kPa). Air dry cylinder block and crankcase. Blow out all holes and passages with compressed air. Cover the cylinder walls with a liberal amount of Johnson/Evinrude Outboard Lubricant to protect TYPICAL 32389 them from corrosion.
  • Page 137 POWERHEAD INSPECTION Use Cylinder Bore Gauge, P/N 771310, to inspect IMPORTANT: If any cylinder is outside these each cylinder bore for an out-of-round, oversize, tolerances, it must be bored oversize. One over- or tapered condition. Make sure the gauge or size piston is available for this engine 0.020 in.

  • Page 138: Assembly

    Proceed slowly. Make no forced assemblies unless a pressing operation is called for. All internal components must be perfectly clean and lightly coated with Johnson/Evinrude Outboard Lubricant. Using Wrist Pin Pressing Pin, P/N 392511, seat a new retaining ring in groove of the piston.
  • Page 139 POWERHEAD ASSEMBLY Using wrist pin driver, oil and start the wrist pin into the piston wrist pin boss opposite where the retaining ring is installed. Do not allow the wrist pin to enter the piston cavity. 1. Needle bearings COB1135 Slide the connecting rod with the needle bearings and washer up and off the wrist pin, being careful not to disturb the bearings.
  • Page 140 POWERHEAD ASSEMBLY Coat the piston and cylinder bore with oil. If removed, oil and press a new lower main bear- ing onto the crankshaft. When pressing on the Place piston Ring Compressor, bearing, support the crankshaft between the two P/N 339754, (P/N 339755 for oversize pistons). lower counterweights and press against the let- Make certain that the rings are correctly posi- tered side of the bearing.
  • Page 141 POWERHEAD ASSEMBLY wheel end of the crankshaft. Secure sleeves Position the rods on the crankpins at this time. together with the retaining ring. Place other retainer halves and bearings on crankpins. COB1144 Remove the rod caps from connecting rods. Place one retainer half and bearings on each rod.
  • Page 142 POWERHEAD ASSEMBLY IMPORTANT: IMPORTANT: Replace connecting rod assem- Gel-Seal II has a shelf life of at bly if proper cap and rod alignment cannot be least one year when stored at room temperature. achieved. Test the Gel-Seal II or replace it if the age of the tube can not be determined.
  • Page 143 POWERHEAD ASSEMBLY Apply Gasket Sealing Compound to metal case of a new upper main bearing seal. Install seal using Seal Installer, P/N 326271, with lip of seal facing crankcase assembly. 1. Seal (large diameter) COA6230 Oil and place a new O-ring on the crankcase head.
  • Page 144 POWERHEAD ASSEMBLY Lightly coat both sides of a new cylinder head Apply Gasket Sealing Compound to both sides of gasket with Gasket Sealing Compound. Install the two new exhaust cover gaskets. Install the inner gasket and cylinder head. Tighten the cylinder and outer exhaust covers.

  • Page 145: Installation

    POWERHEAD INSTALLATION INSTALLATION Install the intake manifold and leaf valve assembly using new gaskets. Do not use sealer on these gaskets. Tighten the screws to a torque of 60 to IMPORTANT: Remove the gearcase to aid in 84 in. lbs. (7 to 9 N·m). guiding the water tube into the water pump grom- met.
  • Page 146 POWERHEAD INSTALLATION Apply Gasket Sealing Compound to the six pow- erhead retaining screws and install the screws. Tighten the six powerhead retaining screws and torque 60 to 84 in. lbs. (7 to 9 N·m). 1. Lower crankcase head 32401 2. Long water tube 3.

  • Page 147: Powerhead Views

    POWERHEAD POWERHEAD VIEWS POWERHEAD VIEWS Port/Starboard View, Manual Start DP0019 DP0020...

  • Page 148: Rear View, Manual Start

    POWERHEAD POWERHEAD VIEWS Rear View, Manual Start DP0021...
  • Page 149 MIDSECTION MIDSECTION TABLE OF CONTENTS TORQUE CHART ..............148 STEERING HANDLE .

  • Page 150: Torque Chart

    MIDSECTION TORQUE CHART TORQUE CHART Description 9.9/15 Lubricant 60 to 84 in. lbs. Upper Mount to Exhaust Housing Nut Lock (7 to 9 N·m) Upper Side Mount to Exhaust Housing Nut Lock 18 to 20 ft. lbs. Upper Mount to Steering Bracket Nut Lock (24 to 27 N·m) Lower Mount to Exhaust Housing...

  • Page 151: Steering Handle

    MIDSECTION STEERING HANDLE STEERING HANDLE from the plug using Socket Removal Tool, P/N 322699. Removal WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. Remove the lower motor covers, manual starter, and air silencer. Remove the throttle cable pin from the throttle 35283 lever.

  • Page 152: Disassembly

    MIDSECTION STEERING HANDLE Disassembly Remove throttle end cap from inner handle. Using Twist-Grip Remover, P/N 390767, depress the grip detents. Tighten screw and remove the grip by pulling grip and turning the idle adjustment knob clockwise. 24298 Remove stop switch cover screws and cover/stop switch assembly.

  • Page 153: Inspection

    MIDSECTION STEERING HANDLE Remove throttle cable from the steering handle. Assembly Install the throttle cable seal in inner handle. Snap the stop switch assembly with the throttle cable into the cover. Be sure the protective sleeve covers the stop switch wires and throttle cable. 32293 Remove stop switch assembly with throttle cable from cover.
  • Page 154 MIDSECTION STEERING HANDLE Place the throttle end cap into inner handle. The Be sure the twist-grip's speed indicator line is tab on the cap goes into the recess of the inner positioned with the speed range symbol on the handle. handle.

  • Page 155: Installation

    MIDSECTION STEERING HANDLE Installation Secure the stop button ground lead behind the ignition coil on the lower screw, with starwasher Insert the throttle cable and stop switch wires next to block. through the lower motor cover grommet. Use iso- propyl alcohol to ease assembly. IMPORTANT: Make sure the protective sleeves are on the throttle cable and stop switch wires.
  • Page 156 MIDSECTION STEERING HANDLE Thread the throttle cable anchor onto the cable Hook cable retainer around throttle cable and housing until anchor is flush with end of threads. install air silencer. Thread the cable end connector on the cable until seated. 1.

  • Page 157: Exhaust Housing

    MIDSECTION EXHAUST HOUSING EXHAUST HOUSING Remove the five screws and lift the lower engine cover support off the exhaust housing. Disassembly Remove the following: • Powerhead; refer to Powerhead REMOVAL on p. 128. • Gearcase; refer to Gearcase REMOVAL AND INSTALLATION on p.

  • Page 158: Cleaning And Inspection

    MIDSECTION EXHAUST HOUSING Remove the two upper mount to steering bracket Cleaning and Inspection screw caps and discard O-rings. Remove the two Clean all parts with parts cleaning solvent and dry upper mount screws. Separate the exhaust hous- with compressed air. All nut and screw threads ing from the swivel bracket assembly.

  • Page 159: Assembly

    MIDSECTION EXHAUST HOUSING IMPORTANT: retaining screws and torque to 60 to 84 in. lbs. A distorted exhaust housing will (7 to 9 N·m). cause the upper driveshaft splines to wear exces- sively and will damage the crankshaft splines. 33363 Place the upper thrust mount and plate in position on the swivel bracket assembly.
  • Page 160 MIDSECTION EXHAUST HOUSING Place the lateral mounts in the lower mount brack- ets. Apply Nut Lock to threads of lower mount bracket screws. Install the lower mount brackets. Tighten screws to a torque of 60 to 84 in. lbs. (7 to 9 N·m).

  • Page 161: Swivel Bracket

    MIDSECTION SWIVEL BRACKET SWIVEL BRACKET Remove the thrust washer, O-ring, and bushing from bottom of swivel bracket. Disassembly Loosen the swivel bracket adjustment screw. Lift the steering bracket and pilot shaft from the swivel bracket. Remove the upper thrust washer/seal. 1.

  • Page 162: Assembly

    MIDSECTION SWIVEL BRACKET Assembly IMPORTANT: Lubricate pilot shaft and bush- ings with Triple-Guard grease. If any of the swivel bracket components were removed, refer to the two reference pictures for correct reassembly. TYPICAL 32478 If the tilt bolt is removed, tighten the bolt to a torque of 60 to 84 in.
  • Page 163 MIDSECTION SWIVEL BRACKET the threads. Torque screws to 18 to 20 ft. lbs. (24 Install the upper thrust washer on the swivel to 27 N·m). bracket. 1. Screws 32482 1. Upper thrust washer 32481 1. Friction adjustment screw Assemble the friction block and liner. Lubricate and place the liner and friction block in the swivel Apply Triple-Guard grease to the lower bushing.

  • Page 164: Adjustments

    MIDSECTION ADJUSTMENTS ADJUSTMENTS Idle Speed Adjustment The idle speed adjusting knob is located on the Tilt Friction Adjustment steering handle. Turning the knob clockwise increases idle speed, turning it counterclockwise Use 9/16 in. wrench to tighten the tilt shaft nut decreases idle speed.
  • Page 165 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............164 PROPELLER .

  • Page 166: Service Chart

    GEARCASE SERVICE CHART SERVICE CHART 60 to 84 in. lb. (7 to 9 N·m) 96 to 120 in. lb. (11 to 14 N·m) 84 to 86 in. lb. (9 to 10 N·m) 60 to 84 in. lb. (7 to 9 N·m) 84 to 86 in.

  • Page 167: Propeller

    GEARCASE PROPELLER PROPELLER LUBRICANT Inspection Draining • Damaged blades and signs of propeller cavita- WARNING tion (burned paint, etc.) • Spun or overheated inner hub Gearcase lubricant may be under pressure • Worn or twisted splines and inadequate lubri- and/or hot. If plug is removed from a cant recently operated outboard, take precau- •...

  • Page 168: Inspection

    GEARCASE LEAK TEST Inspection LEAK TEST Inspect the lubricant for water contamination. Drain lubricant before testing. Water can make the lubricant milky in appear- ance. However, normal aeration can also cause STEP 1 the same appearance. Install lubricant drain/fill plug and seal, thread pressure test gauge fitting and seal in lubricant To check for water contamination, drain lubricant level fill hole.

  • Page 169: Removal And Installation

    GEARCASE REMOVAL AND INSTALLATION REMOVAL AND Remove six screws attaching gearcase to exhaust housing. INSTALLATION Removal WARNING During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.

  • Page 170: Installation

    GEARCASE REMOVAL AND INSTALLATION Installation and tighten the screw with washer to a torque of 60 to 84 in. lbs. (7 to 9 N·m). IMPORTANT: On models with a gearcase extension kit, make sure the driveshaft tube extension, water tube extension, and gearcase exhaust seals are in place.

  • Page 171: Water Pump

    GEARCASE WATER PUMP WATER PUMP Inspection Check impeller for overheating, hub separation Disassembly and visible signs of wear or damage. Check impeller cup and plate for scoring, distortion, and Remove gearcase from exhaust housing as impeller material transfer. Inspect housing for described in REMOVAL AND INSTALLATION on cracks or melting.
  • Page 172 GEARCASE WATER PUMP in housing. Coat the inside surface of grommet Apply a thin bead of Adhesive 847 to the with Triple-Guard grease. machined surface, on the top of the gearcase that contacts the impeller plate. Slide the plate down over the driveshaft and position it.

  • Page 173: Disassembly

    GEARCASE DISASSEMBLY DISASSEMBLY tool to locate and remove the two shifter detent balls and one detent spring from the gearcase. Remove gearcase. Refer to REMOVAL AND INSTALLATION on p. 167. Remove water pump and driveshaft from gear- case. Refer to WATER PUMP on p. 169. 44107 Remove shift lever pivot pin from gearcase.

  • Page 174: Bearing And Seal Removal

    GEARCASE BEARING AND SEAL REMOVAL BEARING AND SEAL Use long-nose pliers to remove the clutch dog from the gearcase. REMOVAL IMPORTANT: Inspect bearings for damage while in place. If bearing is damaged, remove and discard. If the bearing is removed for any reason, it must be replaced.

  • Page 175: Pinion Bearings

    GEARCASE BEARING AND SEAL REMOVAL Pinion Bearings Secure the puller jaws into grooves behind the cup. Use Wrench, P/N 334359, to hold the puller Place bearing removal tool in the driveshaft cavity. while tightening the jaws. Use a mallet to drive the two pinion bearings into the propeller shaft cavity of gearcase.

  • Page 176: Prop Shaft Bearing Housing Seals And O-Ring

    GEARCASE BEARING AND SEAL REMOVAL Remove and discard the O-ring(s) and washer Using Puller Bridge, P/N 432127, and Small Puller from the bushing. Jaws, P/N 432131, remove seal(s). Discard seal(s). 1. Small puller jaws 32555 1. Adapter DRC1505 Prop Shaft Bearing Housing 2.

  • Page 177: Cleaning And Inspection

    GEARCASE CLEANING AND INSPECTION CLEANING AND Using Puller Bridge, P/N 432127, and Bearing Puller, P/N 432130, remove the larger propeller INSPECTION shaft bearing located in the front of the bearing housing. Discard the bearing. WARNING Replace damaged components. Shift sys- tem failure could cause loss of control over direction of engine thrust.

  • Page 178: Seal And Bearing Installation

    GEARCASE SEAL AND BEARING INSTALLATION SEAL AND BEARING Propeller Shaft Bearing Housing Seals and O-ring INSTALLATION Use Seal Installer, P/N 342663, to install a new seal in the rear of the bearing housing. Apply DPL IMPORTANT: Make no dry assemblies. Lubri- Penetrating Lubricant to the casing of the seal cate all bearings, shafts, and gears with HPF XR before installing.

  • Page 179: Forward Bearing

    GEARCASE SEAL AND BEARING INSTALLATION Forward Bearing Pinion Bearings Remove the gearcase from the holding fixture, Install the pinion bearings using the following and place the nose of it on a wooden block on the components of the Universal Pinion Bearing floor.

  • Page 180: Driveshaft Bearing

    GEARCASE SEAL AND BEARING INSTALLATION Driveshaft Bearing Driveshaft Seals Oil and install a new driveshaft bearing in the Install new seals, back to back, in the driveshaft bearing sleeve using Bearing Installer, bore using the appropriate seal installer. P/N 319931, and an arbor press. Press against Apply Gasket Sealing Compound to the metal the lettered side of bearing until the tool is seated casing of the seals before installing.

  • Page 181: Assembly

    GEARCASE ASSEMBLY ASSEMBLY Install the pinion in the gearcase. IMPORTANT: Make no dry assemblies. Lubri- cate all bearings, shafts, and gears with HPF XR gearcase lubricant. Oil and place the forward bearing cone and roller assembly in the forward bearing cup. To install the forward gear and the shifter lever and yoke assembly, begin by threading Yoke Locator, P/N 319991, through the shift rod bush-...
  • Page 182 GEARCASE ASSEMBLY until seated. Then back out shift rod until slotted Using long-nose pliers, place the clutch dog in the face of connector faces the driveshaft. cradle. Groove on the clutch dog must face the forward gear. 32538 32541 Pull shift rod up and install cradle on yoke. Hold propeller shaft in place and move shift rod to NEUTRAL position.
  • Page 183 GEARCASE ASSEMBLY Slide the reverse gear onto the propeller shaft. Install the driveshaft. Rotate the driveshaft to allow the splines in the pinion to engage the splines on the driveshaft. 32573 Lightly apply Gasket Sealing Compound to the aft 32572 support flange of the propeller shaft bearing hous- ing.

  • Page 184: Notes

    GEARCASE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...

  • Page 185: Manual Starter

    MANUAL STARTER MANUAL STARTER TABLE OF CONTENTS GENERAL ............... . 184 .

  • Page 186: General

    MANUAL STARTER GENERAL GENERAL REMOVAL Starter Rope Length WARNING Model Rope Length Avoid accidental starting of engine while 9.9/15 59 in. (150 cm) servicing, twist and remove all spark plug leads. Torque Chart IMPORTANT: Use of Starter Spring Installer Kit, Model Description N·m...

  • Page 187: Rope Replacement

    MANUAL STARTER ROPE REPLACEMENT ROPE REPLACEMENT Remove link from lockout cam. Lift starter from powerhead. WARNING Wear safety glasses to avoid personal injury. Pull rope out completely and retain pulley in posi- tion with stop tool from Starter Spring Installer Kit, P/N 342682.

  • Page 188: Disassembly

    MANUAL STARTER DISASSEMBLY DISASSEMBLY Remove the starter spindle screw and locknut. Hold the pulley down in housing and lift out spin- dle. Carefully lift out pulley, leaving spring in hous- WARNING ing. Wear safety glasses while disassembling and assembling manual starters to avoid personal injury caused by rewind spring tension.

  • Page 189: Cleaning And Inspection

    MANUAL STARTER CLEANING AND INSPECTION CLEANING AND ASSEMBLY INSPECTION WARNING Wash metal components in solvent and dry with Wear safety glasses while disassembling compressed air. and assembling manual starters to avoid personal injury caused by rewind spring Inspect the rewind spring for broken end loops tension.
  • Page 190 MANUAL STARTER ASSEMBLY Place pulley over mandrel and secure with pulley rope channel in pulley. Secure pulley in place by retainer (taper toward pulley) and left hand thread installing stop tool into pulley and housing holes. nut from Starter Spring Installer Kit, P/N 342682. 1.
  • Page 191 MANUAL STARTER ASSEMBLY Remove nut and pulley retainer from mandrel and Check the operation of the pawl. The pawl should remove starter assembly. extend when the starter rope is pulled and retract when the starter rope rewinds. Install spindle, screw, and locknut. Tighten locknut 120 to 144 in.

  • Page 192: Installation

    MANUAL STARTER INSTALLATION INSTALLATION Install starter screws. Tighten screws 60 to 84 in. lbs. (7 to 9 N·m). Position starter on engine. Connect starter lockout link to cam. Turn cam screw IN carefully until screw head contacts cam. Do not overtighten. 1.
  • Page 193 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 194 S–2...

  • Page 195: Marine Products And The Safety Of People Who Use Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM WARNING This Safety section contains information relevant to the safety of boaters and people that ser- vice boats. Please read this section carefully and share it with all shop technicians. Always follow common shop safety practices.

  • Page 196: Outboard Shift Systems And Safety

    SAFETY Outboard Shift Systems and Safety The outboard Shift The outboard Shift System starts here System starts here at the remote at the remote control lever... control lever..and ends here at the propeller. When control lever is in What is most important? FORWARD, NEUTRAL or REVERSE...

  • Page 197: Outboard Speed Control System And Safety

    SAFETY Outboard Speed Control System and Safety The outboard speed control system starts here at the remote control lever... (single lever remote control) ...and ends here on the powerhead. What is most important? When control lever is moved from FORWARD (or REVERSE) to NEUTRAL...

  • Page 198: Outboard Steering Control System And Safety

    SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: • Must not come apart; • Must not jam;...
  • Page 199 SAFETY How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When • Follow warnings marked “ ” closely. rigging •...

  • Page 200: Outboard Fuel, Electrical System, And Safety

    SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? •...
  • Page 201 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads Sleeves, boots, shields •...
  • Page 202 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard GASOLINE Check for leaks under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.

  • Page 203: Outboard Mounting System And Safety

    SAFETY Outboard Mounting System and Safety The mounting system includes: • outboard parts • bolts, nuts, and washers • boat’s transom What is most important? • Outboard must stay in position on boat’s transom. What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...
  • Page 204 SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.

  • Page 205: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety

    SAFETY Outboard Hydraulic Tilt/Trim Shock Absorption System and Safety What is most important? • Shock absorption system must always be ready to absorb some blows to the lower parts of the outboard. • Outboard must not trim in too far suddenly. What can happen? Without shock protection, a blow like this could cause serious damage to the outboard and injury to boat occupants from the outboard or its parts entering the boat.

  • Page 206: Outboard Emergency Stop System And Safety

    SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? • The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop / key switch.
  • Page 207 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.

  • Page 208: Summing Up

    SAFETY Summing up Now you know some things that can take the joy out of boating. No doubt about it—proper safety takes time! • Reading and understanding instructions • Re-reading warnings marked “ ” • Putting parts together correctly • Making correct adjustments •...

  • Page 209: Marine Products And The Safety Of People Who Fix Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: •...
  • Page 210 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
  • Page 211 SAFETY Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
  • Page 212 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 213: Handling Lead/Acid Batteries

    SAFETY Handling Lead/Acid Batteries If spilled or Strong acid solution splashed on any (sulfuric acid) part of body... If solution gets into eyes, wash and contact a doctor immediately. Wash with lots of water. Charging lead acid batteries 1) Attach and remove these cables with charger UNPLUGGED from 110 V wall socket.

  • Page 214: Gasoline - Handle With Care

    SAFETY Gasoline – Handle With Care! Gasoline vapor and air mixtures explode easily and violently when 1 Part Gasoline mixed as shown... Parts Volume When you smell ANY odor of gasoline, explosion is possible. Fumes If the air around you is calm, the pilot light in the heater could ignite Gasoline fumes are heavy and will sink...

  • Page 215: Hazardous Products

    SAFETY Hazardous Products Know how items in the shop can hurt people... READ • “How and where to use” • “How to give First Aid.” Have recommended First Aid materials on hand should an emergency arise • “How to dispose of can” It’s all on the back of the can or bottle label.

  • Page 216: Safety Awareness Test

    6) Have you received training related to common shop safety practices to protect your- self and others around you? 7) When replacement parts are required, will you use Evinrude /Johnson Genuine ® ® Parts or parts with equivalent characteristics, including type, strength and material?

  • Page 217: Index

    INDEX INDEX Break-In Oiling 44 Abbreviations 12 Procedure 46 Accessories Electrical Bracket 81 Installation 82 Cable, Hose, and Wire Routing 42 Primer 81 Cables Rectifier 81 Battery Cables 42 Removal 81 Cam Follower Pickup Point Solenoid 81 9.9/15 60 Adjustments Carburetor 107 Control Cable 41 Assembly 111...
  • Page 218 INDEX Cooling Disassembly 77 Engine Temperature Check 122 Installation 80 Flushing 53 Lubrication 57 Maintenance 53 No Load Current Draw Test 77 Thermostat 19 Removal 77 Type 19 Test 127 Water Intake Screens 54 Electrical Cables Cooling System Battery 42 Operating Temperatures 46 Remote Electrical Harness 42 Turbulence 36...
  • Page 219 INDEX Fuel System Ignition Additives 18, 43 Charge Coil Test 91 Carburetor Servicing 107 Components 86 Components 105 Ignition Coil 19 Filter 35 Ignition Coil Tests 95 Fuel Filter 58 Maximum Spark Advance – 9.9/15 61 Fuel Requirements 43 Power Pack Cranking Output Test 94 Minimum Octane 43 Power Pack Running Output Test 94 Pre-Season Checks 64...
  • Page 220 INDEX Lubrication 18, 54 Power Pack 86 Electric Starter 57 Cranking Output Test 94 Engine Oil 44 Description 86 Gearcase 56 Running Output Test 94 Midsection – 9.9/15 55 Powerhead Propeller Shaft 56 Assembly – 25/30 143 Schedule 50 Assembly – 9.9/15 136 Shift Linkage 55 Cleaning 133 Starter Shaft 57...
  • Page 221 INDEX Steering System Lubrication 54 Safety S–1 Requirements 38 Sensor Coil 86 Stern Bracket 159 Description 86 Stop Button 87 Installation 101 Stop Circuit Test 89 Removal 100 Storing the Engine 63 Test 92 Submerged Engines 64 Serial Number Location 6 Swivel Bracket Shift Lever Detent –...
  • Page 222 INDEX Gearcase Bearing Housing Puller, P/N Taper Pin Tool 121, 130 386631 171 Temperature Gun, P/N 772018 122 Lifting Eye, P/N 321537 S–17 Thermal Joint Compound, P/N 322170 122 Pack Load Adapter, P/N 507983 94 Torx Screwdriver, P/N 351204 114 Pin Insert Tool, P/N 322697 82, 153 Twist-Grip Remover, P/N 390767 150 Pin Remover, P/N 322698 82...
  • Page 223 Water Flow Diagram 9.9 - 15HP DR4698...
  • Page 224 MWS Instrument Wiring Harness DRC6165R...
  • Page 225 Lanyard Switch / Emergency Stop Circuits Single Outboard Dual Outboards 000705...
  • Page 226 MWS Key Switch and Neutral Safety Switch START CHOKE/PRIMER 000954...
  • Page 227 MWS DASHBOARD S Y S T E M CHE CK T A CHOM E T E R S PE E DOM E T E R PUL / +12V LIG HT S W IT CH W A T E R PR E S . FU E L V OLT M E T E R T R IM / T ILT...
  • Page 228 9. 9 / 1 5 HP DRC 6217...

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