Page 1: Table Of Contents
TABLE OF CONTENTS SAFETY SEAL 3-12 Removal 3-12 INTRODUCTION BOTTOM SEAL 3-13 Inspection CLEANING, WAXING, 3-14- CENTERING PINS AND POLISHING 3-15 CONTROLLING CORROSION MAIN BEARING BOLTS PROPELLERS AND CRANKCASE SIDE BOLTS 3-15 FUEL SYSTEM CRANKCASE COVER 3-16 LOADING Removal 3-16 HORSEPOWER 1-10 Cleaning...
Page 2 FUEL SYNCHRONIZA TION FUEL ". IGNITION SYSTEMS 5-26 4--1 INTRODUCTION Primary Pickup Adjustments GENERAL CARBURETION and Locations 5-26 4--1 INFORMATION 4--4- FUEL SYSTEM 6 ELECTRICAL 4--4- TROUBLESHOOTING 4--6 Fuel Pump Tests INTRODUCTION 4--7 Fuel Line Test BATTERIES 4--8 Testing with Pressure Tank Mar ine Batteries 4--10...
Page 3 7-14 8-66 Assembling Cleaning and Inspecting 7-15 Water Pump Installation 8-72 Assembling 7-16 8-74 Lower Unit Installation PUSH BUTTON SHIFT BOX SERVICE EVINRUDE UNITS ONLY 7-18 Troubleshooting 7-19 9 HAND STARTERS Disassembling 7-21 Cleaning and Inspecting 7-22 INTRODUCTION Assembling 7-22...
Page 4 Removal 9-40 9 HAND STARTERS (CONT) Disassembling 9-40 - TYPE I STARTER Cleaning and Inspecting 9-42 Assembling 9-43 CYLINDER WITH PINION GEAR ALL 9.5 HP ENGINES 9-11 Rope Installation 9-43 Starter Rope Replacement 9-11 Starter Installation 9-46 Removal 9-11 Installation 9-12 10 MAINTENANCE Starter...
Page 6: Safety
SAFETY will be required to remove stubborn dirt, oil, 1-1 INTRODUCTION and other unsightly deposits. Stay away from harsh abrasives or strong Your boat probably represents a sizeable chemical cleaners. A white buffing com- investment for you. In order to protect this investment and to receive the maximum...
Page 7: Controlling Corrosion
SAFETY small a zinc plate will cause more rapid deterioration of the metal you- are trying to protect. If in doubt, consider the fact that is is far better to replace the zincs than to replace planking or other expensive metal parts from having an excess of zinc.
Page 8 PROPELLERS Arrangement of propeller and associated parts, in order, for small horsepower engine. Diameter and Pitch Only two dimensions of the propeller are of real interest to the boat owner: diameter and the pitch. These two dimen- sions are stamped on the propeller hub and al ways appear in the same order: the diam- eter first and then the pitch.
Page 9 SAFETY with average loads, therefore, it may be from your boat and engine. Therefore, take necessary to make a change in size or pitch, time to make the proper propeller selection in order to obtain the desired results for the for the rated rpm of your engine at full hull design or load condition.
Page 10 PROPELLERS Ventilation two-blade props and luxury cruisers have Ventilation is the forming of voids in the four- and five-blade props installed. water just ahead of the propeller blades. Marine propulsion designers are constantly Shock Absorbers fighting the battle against the formation of The shock absorber in the propeller plays these voids due to excessive blade tip speed a very important...
Page 11 SAFETY If the power train was to absorb an impact great enough to stop rotation, even for an instant, something would have to give and be damaged. If a propeller is subjected to repeated striking of underwater objects, it would eventually slip on its clutch hub under normal loads.
Page 12: Fuel System
PROPELLERS service and protection against leakage. The cup has the effect of adding to the inforced flexible sections should be installed propeller pitch. Cupping usually will reduce in fuel lines where there is a lot of motion, full-throttle engine speed about to 300 such as at the engine connection.
Page 13 SAFETY Taking On Fuel The fuel tank of your boat should be kept full to prevent water from entering system through condensation caused by tem- perature changes. Water droplets forming is one of the greatest enemies of the fuel system. By keeping the tank full, the air space in the tank is kept to an absolute minimum and there is no room for moisture...
Page 14: Loading
LOADING not want to replace the filler pipe with a opening the fill pipe deck fitting. One way metal one, then it is possible to connect the to ground yourself is to dip your hand in the deck fitting to the tank with a copper wire. water overside to discharge the electricity The wire should be 8 gauge or larger.
Page 15: Horsepower
1-10 SAFETY 5- Coast Guard Approved equipment Jar ifica tion Much confusion arises from the terms, equipment which has been approved by the Commandant of the U.S. Coast Guard and certification, requirements, approval, regu- lations, etc. Perhaps following has been determined to be in compliance clarify a couple of these points.
Page 16 FLOTATION I-II and with passengers clinging to the hull. Type III PFD is designed to permit One restriction is that the total weight of wearer place himself (herself) in a motor, passengers, equipment vertical or slightly backward position. aboard does not exceed the maximum load Type III device has the same buoyancy as capacity listed on the plate.
Page 17: Emergency Equipment
1-12 SAFETY your crew and advise each member to wear The only exceptions are during daytime (sunrise to sunset) for: If you are a crew member ask your skipper to issue you one, especially when Recrea tional boats less than 16 ft. (5 boating in rough weather, cold water, meters) in length.
Page 18: Compass
COMPASS 1-13 manufacture and at such time the device None-pyrotechnic visual distress signal- can no longer be counted toward the min- ing devices must carry the manufacturer's imum requirements. certification that they meet Coast Guard requirements. They must be in serviceable condition and stowed so as to be readily...
Page 19 1-14 SAFETY pins, eye-washing cup, and a hot water bot- 1- Inboard engine or engines. tle. The supplies in the kit should include: 2- Closed compartments under thwarts assorted bandages in addition to the various and seats wherein portable fuel tanks may sizes of "band-aids", adhesive tape, absorb- be stored.
Page 20 MISCELLANEOUS EQUIPMENT 1-15 gauges or indicating devices must be weigh- ed and tagged every 6 months. If the gross weight of a carbon dioxide (CO?) fire extin- guisher is reduced by more than 10% of the net weight, the extinguisher is not accept- able and must be recharged.
Page 21 1-16 SAFETY Second, give some thought to comfort in or iron objects. If the compass cannot be heavy weather and poor visibil conditions placed at least two feet (six feet would be during the day and night. In some cases, the better) from one of these influences, then...
Page 22: Steering
NAVIGATION 1-17 Check to be sure the intended compass 2- Keep even "innocent" things clear of site is solid. Vibration will increase pivot the compass to avoid any possible error in wear. the boat's heading. Now, you are ready to mount the com- REMEMBER, boat moving through the pass.
Page 23 1-18 SAFETY The anchor must be of sui table size, hook, fenders, spare propeller, spare engine type, and weight to give the skipper peace parts, tools, an auxiliary means of propul- of mind when his boat is at anchor. Under sion (paddle or oars), spare can of gasoline, certain conditions, a second, smaller, lighter flashlight,...
Page 24 NAVIGATION 1-19 position until it is deactivated. Measure the to avoid reefs, rocks, shoals, and other haz- ards. distance between the point the switch was In the spring of 1983, the Coast Guard activated and the point it was deactivated. For proper service, the switch should deact- began making modifications to U.S.
Page 25 1-20 SAFETY almost a synopsis of the rules and should not Waterway Rules On the water, certain basic safe-operat- be considered in any way as covering ing practices must be followed. You should entire subject. learn and practice them, for to know, is to Powered boats must yield the right-of- be able to handle your boat with confidence way to all boats without...
Page 26 TUNING 2-1 INTRODUCTION compression must be corrected or the tune- up will not give the desired results. The efficiency, reliability, fuel economy The opposite of poor compression would and enjoyment available from engine perfor- be to consider good compression as evidence mance are all directly dependent on having of a satisfactory...
Page 27 TUNING A practical maintenance program that is Major Tune-up followed throughout the year, is one of the Remove head. best methods of ensuring the engine will Clean carbon from pistons and cylinders. give satisfactory performance at any time. C lean and ver haul carbu retor .
Page 28 COMPRESSION CHECK 5- Check carburetor adjustments An overheating condition may also be and the need for an overhaul. See Chap- caused by running the engine out of the ter 4. water. For unknown reasons, many opera- 6- Check the fuel pump for adequate tors have formed a bad habit of running a performance and delivery.
Page 29 TUNING Inspect the threads in the spark plug opening of the head and clean the threads before installing the plug. If the threads are damaged, the head should be removed and and a Hell-coil insert installed. If an tempt is made to drill out the opening with the head in place, some of the filings may fall into the cylinder and cause damage to the cylinder wall during operation.
Page 30 IGNITION SYSTEM plugs will fire early; if adjusted with exces- will sive gap, the plugs fire too late, efficient operation. Therefore, correct point adjustment and synchronization essential for proper engine operation. engine may be in apparent excellent chanical condition, but perform poorly, un- less the points and synchronization have been adjusted...
Page 31 TUNING Clean the top of the battery. The top of a 12-volt battery should be kept especially clean of acid film and dirt, because of the high voltage between the battery terminals. For best results, first wash the battery with a diluted ammonia or baking soda solution to neutralize any acid present.
Page 32 CARBURETOR ADJUSTMENT make the connection it will not be near the battery. An arc near the battery could cause an explosion, destroying the battery and causing serious personal injury. If it is necessary to use a fast-charger a dead battery, ALWAYS disconnect one of the boat cables from the battery...
Page 33 However, larger or smaller ward (COUNTERCLOCKWISE) until the en- needle valves may be installed for different gine peaks out at the highest rpm. elevations. On all Johnson/Evinrude If the high-speed needle valve adjust- gines, the high-speed needle valve is the ment is too lean, the low-speed adjustment lower valve on the carburetor.
Page 34 FUEL PUMP an y leaner than necessary to obtain a smooth Start the engine and allow it to warm to operating temperature. idle. CAUTION: Water must circulate through If the engine hesitates during acceleration the lower unit to the engine any time the en- after adjusting the idle mixture, the mixture is gine is run to prevent damage to the water...
Page 35 NEVER use liquid Neoprene on fuel line fittings. Always use Permatex when making fuel line connections. Permatex is available at almost all marine and hardware stores. Only one Johnson/Evinrude fuel pump the many types fuel purr installed may be rebuilt, see accompanying...
Page 36 An internal wiring harness is only used the right side of the scale. on the larger horsepower engines covered in On all Johnson/Evinrude engines" the case this manual. If the engine is equipped with of the solenoid does NOT provide a suitable a wiring harness, the following checks and ground to the engine.
Page 37 2-12 TUNING Resistance Test (See the Wiring Diagram in the electrical components. Check for fray- ed or chafed insulation and/or loose connec- the Appendix.) tions between wires and terminal connec- Use a magneto analyzer, set on Scale tions. No.2. Clip the small red and black leads Check the harness connector for signs of together.
Page 38 2-13 PROPELLER Using flush attachment with garden hose hook- water clean the engine circulation system with water. fresh This arrangement may also be used while operating the engine idle speeds make adjust- ments. Sometimes during adjustment proce- dures, it is necessary to run the engine with a flush device attached to the lower unit.
Page 39 2-14 TUNING and intended operation. The correct propel- ler should be installed on the engine to ENTANGLED enable operation at recommended rpm. F SH LINE Two rpm ranges are usually given. lower rpm is recommended for large, heavy slow boats, or for commercial applications.
Page 40 SLOWLY using a small- Draining Lower Unit spout oil can to allow air to pass out the The fill/drain plug on Johnson/Evinrude opening, there is no doubt but what the unit lower units may be located towards will be filled to capacity.
Page 41 2-16 TUNING the center, the bow will be light and the bottom carefully for marine growth or evi- dence of a "hook" or a "rocker" in the boat will "plane" more efficiently. For this bottom. Either one of these conditions will test the boat must be operated in a body of greatly reduce performance.
Page 42 POWERHEAD pattern in order for them to be open and 3-1 INTRODUCTION closed off at an exact moment by the piston as it moves up and down in the cylinder. The carburetion and ignition principles The exhaust port is located slightly higher of two-cycle engine operation be un-...
Page 43 POWERHEAD First, it creates turbulence when the with each revolution of the crankshaft. Compare this system with a four-cycle incoming charge of fuel enters the combus- gine. A stroke of the piston is required to tion chamber. This turbulence results accomplish each phase of the cycle and the more complete burning of the fuel than if...
Page 44 INTRODUCTION Pressure in the crankcase decreases as the is ignited; and the power stroke begins. piston moves upward and a fresh charge of air reed valve was open because as the piston flows through the carburetor picking up fuel. moved upward, the crankcase volume increased, which reduced the crankcase pressure to less As the piston approaches top dead center, the than the outside atmosphere.
Page 45 Special tools may be called out in cer- plete instructions for the work to be per- tain instances. These tools may be purchas- ed from the local Johnson/Evinrude dealer formed. Because of the many countless number of outboard...
Page 46 DISASSEMBLING Parts MUST be cleaned and thoroughly in- spected before they are assembled, install- ed, or adjusted. Use proper lubricants, their equivalent, whenever they are recom- mended. Keep rods and rod caps together as a set to ensure they will be installed as a pair and in the proper sequence.
Page 47 POWERHEAO the engine begins to run too hot. The light Many, but not all, heads have a thermo- stat installed. In addition to the thermo- on the dash can be checked by turning the stat, engine may have a thermostat ignition switch to the ON position, and then bypass valve.
Page 48 REED SERVICE or other wind instrument. At rest, the reed is closed and seals the opening to which it is attached. the case of an outboard engine, this opening is between the crankcase the carburetor. The reeds are mounted in the intake manifold, just behind the carbu- retor.
Page 49 POWERHEAD Close view showing the dimple on the reed plate. reed leaves must straddle dimple and be over centered the openings for proper operation. Reed stops centered over reeds. NEVER The reeds must be turned over in Reed Stops an attempt to correct a problem.
Page 50 REED SERVICE Back side the same plate shown the bottom Front view the reed box showing the Phillips the previous column. Notice how the reed stops are reeds. screws that must be removed before the box can centered over the removed from the plate.
Page 51 3-10 POWERHEAO Check the reed location over the reed block, or plate openings to be sure the reed is centered. The reed assemblies are then ready for installation. Small Engines Disassemble the reed block by first re- moving the screws securing the reed stops and reeds to the reed block, and then lifting the reed stops and reeds from the block.
Page 52 BYPASS COVERS 3-11 During a normal overhaul, the bypass the powerhead and be transferred to the covers should be removed, cleaned, and new exhaust housing. If the cover was the only gaskets installed. Identify the covers to item over the exhaust ports, they would ensure...
Page 53: Top Seal
3-12 POWERHEAD On powerheads equipped with the heat/- 3-8 TOP SEAL electric choke, a baffle is installed on the The top seal maintains vacuum and pres- inside surface of the inner plate. This sure in the crankcase at the top cylinder. baffle is heated from the engine exhaust...
Page 54: Bottom Seal
Johnson/- spring, another washer, and a snap ring. Evinrude bottom seal installed. Removal Seal Mounted on the Driveshaft To remove this seal from the lower end When the power head is removed, observe...
Page 55: Inspection
3-14 POWERHEAD Removing the quadrant seal and retainer from crankshaft. groove is not clean, the ring will snap out and the lower sealing qualities will be lost. If the groove is badly corroded, the crank- Using pair truarc pliers remove the snap ring shaft must be replaced.
Page 56: Centering Pins
3-10 CENTERING PINS All Johnson/Evinrude outboard engines have at least one, and in most cases two,...
Page 57: Main Bearing Bolts
3-16 POWERHEAD These bolts usually have a 7/16" head and all Once the crankshaft has been tapped, as must be removed before the crankcase cov- described, and the proper sound heard, the er can be removed. Remove the crankcase cover will be jarred loose and may be re- side bolts.
Page 58 ROD AND PISTONS 3-17 Rod and rod cap with the two alignment dimples Wrist pin of the rod with the pressed-in bearing shown. shown. The connecting rod and its cap on 15 to REMOVAL 40 hp engines are manufactured as a set --as a single unit.
Page 59 3-18 POWERHEAD Tap the piston out of the cylinder from the crankshaft side. Immediately attach the WORD proper rod cap to the rod and hold it in IILOOSE place with the rod bolts. The few minutes involved in securing the cap with the rod will ensure the matched cap remains with its mating rod during the cleaning and as-...
Page 60 RODS AND PISTONS 3-19 It may be necessary to heat the piston in a container of boiling water in order TRUARC press the wrist pin free. SNAP RING Remove the retaining clips from each end of the wrist pin. Some clips are spring wire type and may be worked free of the piston using a screwdriver.
Page 61 3-20 POWERHEAD TAKE CARE not to lose any of the bearings when the wrist pin is driven free of the piston. Alternate Removal Method If the piston does not have the "L" or the word LOOSE stamped, the wrist pin may be driven out in either direction.
Page 62 RODS AND PISTONS 3-21 Badly rusted and corroded crankshaft from sub- merged engine. This crankshaft is no longer fit Needle bearings and cages unfit for further service. service. the loss of bearing surface, and resembles ROD INSPECTION SERVICE flaking or chipping. The spalling condition will be most evident on the thrust portion of If the rod has needle bearings, the need-...
Page 63 3-22 POWERHEAD cylinder, the piston pushes the connecting rod with tremendous force, and this force is transferred to the connecting rod journal. Since there is little or no load on the crankshaft, it bounces away from the con- necting rod. The crankshaft then remains immobile for a split second, until the piston...
Page 64: And Pistons
RODS AND PISTONS 3-23 critical during inspection if the engine has been submerged. Carefully check each wrist pin to be sure it is not the least bit bent. If a wrist pin is bent, the pin and piston MUST be replaced as a set, because the pin will have damaged the boss when it was removed.
Page 65: Assembling
3-24 POWERHEAD Check the piston ring grooves for wear, burns, distortion or loose locating pins. During an overhaul, rings should be replaced to ensure lasting repair and proper engine performance after the work has been completed. Clean the piston dome, ring grooves and the piston skirt.
Page 66 RODS PISTONS 3-25 Therefore, the rod and piston MUST be assembled correctly in order for the sembly to be properly installed into the cylinder. Soak the piston in a container very water about minutes. Heating the piston will cause it to expand ever so slightly, but enough to allow the wrist...
Page 67 3-26 POWERHEAD First, soak the piston in a container very hot water for about ten minutes. Before pressing the wrist pin into place, hold the piston and rod near the cylinder block and check to be sure both will be facing in the right direction when they are installed.
Page 68: Crankshaft
CRANKSHAFT 3-27 Filling the inside of the piston protect the skirt from being struck by the rod before piston i'!stalled in the cylinder block. INSTALLATION Crankcase cover with the labyrinth seal area clearly visible. Piston and rod assembly installation pro- the locating pins in the cylinder block.
Page 69: Assembling
3-28 POWERHEAD marks, chatter marks, uneven wear or over- heating. Clean the crankshaft surfaces with crocus cloth. Clean crankshaft crankshaft bearing with solvent. Dry the parts, bearing, with compressed air. Check crankshaft surfaces a second time. Replace the crankshaft if the sur- faces cannot be cleaned properly for satis- Crankshaft with...
Page 70: Honing Procedures
CYLINDER BLOCK 3-29 carbon with a fine wire brush on a shaft HONING PROCEDURES attached to an electric drill or use a carbon remover solution. To ensure satisfactory engine perform- Use an inside micrometer or telescopic ance and long life following the overhaul gauge and micrometer to check the cylin-...
Page 71: Assembling
3-30 POWERHEAD bore. Now, turn the ring horizontal in the cylinder. It is now in its normal operating position, but without the piston. Next, use a feeler gauge and measure the distance (the gap) between the ends of the ring. maximum and minimum allowable ring gap is listed in the Specifications in the Appen-...
Page 72 CYLINDER BLOCK 3-31 the ring has a small cutout on the inside circumference. Now, visualize the ring in- stalled in the piston groove. The ring ends must straddle the pin installed in each pis- ton groove. As the ring is tightened around the piston, the ends will begin to come...
Page 73 3-32 POWERHEAD Checking the flexibility the rings through intake When installing the piston into small horsepower port. powerhead, is possible compress the ring with the fingers each hand, and then push the piston into the clamp is against the piston skirt. the cylinder with your thumbs.
Page 74: Crankshaft Installation
CYLINDER BLOCK 3-33 Crankshaft with the upper, lower, center main bearings installed. Notice the hole in each bearing. pins in index Matching the cylinder block must into these holes during crankshaft installation. Crankshaft installed into the cylinder block. CRANKSHAFT INSTALLATION LARGE HORSEPOWER ENGINES...
Page 75 3-34 POWERHEAD Rod and cap showing the alignment dimples. Installing needle bearing on each side crankshaft. side of the crankshaft. Put one needle bearing on each side of the crankshaft. Using needle bearing grease load the other cage and install the needle bearings into the cage.
Page 76: Crankshaft Installation Small Horsepower
CYLINDER BLOCK 3-35 push on each ring to be sure it has spring tension. It will be necessary to move the piston slightly, because all of the rings will not be visible at one time. If there is no spring tension, the ring was broken during installation.
Page 77 3-36 POWERHEAD If servicing the 9.5 hp or a 10 hp engine, the hole in the upper and lower main bearing MUST index into the pin in the cylinder block. Some engines may have a lining arrange- ment as listed in the heading of this section. The lining is made in two parts.
Page 78 CYLINDER BLOCK 3-37 Rod and cap with the alignment marks visible. Using hammers CRANKSHAFT INSTALLATION crankshaft. SMALL HORSEPOWER ENGINES BABBIT MAIN BEARINGS given in the Torque Table in the Appendix. BABBITT ROD BEARINGS Tighten the bolts to 1/2 the torque value on ALL 3.0 HP, 4.0 HP, AND 7.5 HP ENGINES the first round, to 3/4 the torque value on the second round, and to the full torque...
Page 79: Crankcase Cover Installation
3-38 POWERHEAD Repeat the "fitting" procedure for the other rod and cap. Once the installation procedure appears satisfactory and all work has been complet- ed, bend the bolt locking tabs upward to prevent the bolts from loosening. CRANKCASE COVER INSTALLATION First, check to be sure the mating sur- faces of the crankcase cover and the cylin- der block are clean.
Page 80: Main Bearing Bolt And Crankcase
CYLINDER BLOCK 3-39 Tighten the bolts to 1/2 the total torque SPECIAL NOTE Some model powerheads do not use the value on the first round, to 3/4 the total "spaghetti" seal. If the engine being ser- torque value on the second round, and to the viced does not use the seal, apply a coating full torque value...
Page 81: Exhaust Cover And Bypass
3-40 POWERHEAD Using pair truarc pliers install the truarc snap ring onto the crankshaft secure the bottom seal in place. EXHAUST COVER BYPASS COVER INSTALLATION Installing the intake bypass covers. already Coat both sides of a gasket with in place. 1000 Sealer, and then place the gasket in position on the exhaust side of the cylinder REED...
Page 82: Head Installation
CYLINDER BLOCK 3-41 Installing the gasket and reed plate power- head. HEAD INSTALLATION Installing the intake manifold over the reed plate. Place a head gasket in place on the Install all powerhead accessories includ- cylinder block. NEVER use automotive type flywheel, carburetor, magneto,...
Page 83 3-42 POWERHEAD CHECK to As soon as the engine starts, Mix gasoline and oil during the break- in period, total of 10 hours, at a ratio of be sure the water pump is operating. If the 50:!. water pump is operating, a water mist will be discharged from the exhaust relief holes d- While the engine is operating during...
Page 84 CYLINDER BLOCK 3-43 of a 1956 E:rp~oded drawing 3.0 hp powerhead -- and the 4.0 powerhead -- 1969-70, with principle parts identified. The 4.0' hp unit uses bearing and seal on the crankshaft instead the oil slinger.
Page 85 POWERHEAD 3-44 EXHAUST COVER LEVER of a Exploded drawing hp powerhead -- 1956-60, principle parts identified.
Page 86 CYLINDER BLOCK 3-45 GASKET FUEL PUMP GASKET Exploded drawing of powerhead, with principle parts identified for the following units: hp -- 1961-64; 5.0 hp-- 1965-68; 6.0 hp -- 1965-70. The 6.0 hp unit uses an oil slinger instead of the seal.
Page 87 3-46 POWERHEAD of a Exploded drawing hp powerhead -- 1956-58, with principle parts identified.
Page 88 CYLINDER BLOCK 3-47 HEAD GASKET RING...
Page 89 3-48 POWERHEAD HEAD BYPASS COVER 1956-63, Exploded drawing of powerhead -- with principle parts identified.
Page 90 CYLINDER BLOCK 3-49 THERMOSTAT EXHAUST COVER...
Page 91 3-50 POWERHEAD Exploded drawing the crankshaft and associated parts for the powerhead shown on the previous page.
Page 92 FUEL 4-1 INTRODUCTION mixture of about 8 parts air to 1 part fuel. At high speed or under heavy duty service, The carburetion and ignit ion principles the mixture may change to as much as 12 of two-cycle engine operation be un- MUST parts air to 1 part fuel.
Page 93 FUEL Typical fuel line with squeeze bulb quick- disconnect fitting at each end. These items purchased as assembled unit. On models produced from 1956 through different type fuel pumps with covers 1959, the fuel tank is equipped with a hand removed show the filter screen.
Page 94 FLOAT Choke valve location the carburetor venturi. Fuel [tow controlled the float typical carbu- choke valve on most Johnson/Evinrude carburetors retor. The inlet valve is opened and closed by move- located in front the venturi. ment the float in the carburetor bowl.
Page 95 FUEL When this choke valve is closed, a very rich fuel mixture is drawn into the engine. The throat of the carburetor is usually referred to as the "barrel." Carburetors installed on engines covered in this manual all have a single metering jet with a single throttle and choke plate.
Page 96 TROUBLESHOOTING fuel pump, or by a leak in the line from the trapped in the float chamber and other passages and in the line leading to the fuel tank to the fuel pump. Aged fuel left in the carburetor and the formation of var- carburetor.
Page 97 FUEL If the choke should stick in the open position, the engine will be hard to start. If the choke should stick in the closed position, the engine will flood making VERY diffi- cult to start. In order for this raw fuel to vaporize enough to burn, considerable air must be added to lean out the mixture.
Page 98 TROUBLESHOOTING If there is no fuel discharged from the line, the check valve in the squeeze bulb may be defective, or there may be a break or obstruction in the fuel line. If there is a good fuel flow, then crank the engine.
Page 99 FUEL situation, simply immerse the ends of the hose in boiling water for a few minutes to soften the rubber. The hose will then slip onto the check valve without further prob- lems. After the lines on both sides have been installed, snap the camps in place to secure the line.
Page 100 TROUBLESHOOTING Next, drill the appropriate size hole for a suitable fitting to pickup the cylinder vacu- um. Install the cover plate with the tting in place. Mount the fuel pump in a conven- ient location, and then connect the vacuum hose.
Page 101 4-10 FUEL VENT FILTER due to A set points unfit for service oxidation. Sectional view of a engine mounted fuel tank show- ing the filter inside the tank and the external shut-off valve. ROUGH ENGINE IDLE remedy is replacement. The cost is very modest and this one area is thus eliminated If an engine does not idle smoothly, the as a problem source.
Page 102 TROUBLESHOOTING 4-11 A clean engine reflecting owners "pride ownership", and good care. While you are checking the bottom take note of the propeller condition. A bent blade or other damage will definitely cause poor boat performance. Carburetor installed most 35 hp 40 hp If the hull and propeller are in good...
Page 103 Type I cedures fuel pump are given Single barrel, front draft, Section 4-9. with adjustable low-speed needle valve with special packing. 4-5 JOHNSON/EVINRUDE CARBURETORS High-speed is fixed or ifice in float bowl. This section provides complete detailed procedures for removal,...
Page 104 CARBURETORS 4-13 FilTER SHUTOFF VALVE rubber hose from the carburetor. Remove nuts securing the carburetor to the 4-6 TYPE I CARBURETOR crankcase. The carburetor may have to moved slightly forward as the nuts are loos- ened in order to obtain clearance for the REMOVAL DISASSEMBLING...
Page 105 4-14 FUEL 8- If installed, remove the high-speed or ifice, using the proper size screwdriver. 9- Turn the carburetor upside down. If a filter bowl assembly is installed, loosen the 6- Observe how both the low-speed nee- hinge and swing it to one side. Remove the glass bowl.
Page 106 J/E CARBURETORS 4-15 Gasket used between the bowl and the carburetor showing the opening allow fuel leave the bowl and enter the idle passage the carburetor. 11- Remove the five attaching screws, CLEANING INSPECTING and then lift the bowl free of the carbure- tor.
Page 107 INLET NEEDLE FLOAT GOOD WORN WORN GOOI!) Cross-section the needle and seat arrangement Johnsori/Evinrude carburetors, showing worn and new needle for comparison. Move the throttle shaft back-and-forth to check for wear. If the shaft appears to be too loose, replace the complete throttle...
Page 108 CARBURETORS 4-17 LEAF SILENCER vtew Exploded Type I carburetor installed small Johnson/Evinrude engines. This carburetor is used with the tank. old style pressure-type fuel Therefore, the filter bowl is incorporated in the carburetor.
Page 109 4-18 FUEL Exploded view of a Type I carburetor installed on small Johnson/Evinrude engines equipped with the fuel tank attached to the engine. The filter on these units is in the tank.
Page 110 CARBURETORS 4-19 17- If a filter is used in the float bowl, slip the filter down over the center post in the bowl. Slide the gasket into place in float bowl. Install and tighten secu ring the filter in place. 18- Place the glass float bowl in position and slip the spring over the edge of the on top of the gasket.
Page 111 4-20 FUEL New type packing used for the low-speed needle valve. A packing nut is not used to hold the needle in adjustment. 20- Place a white plastic washer into the high- and low-speed cavities. If a high- speed orifice is used, install the orifice with the proper size screwdirver until the orifice just BARELY seats.
Page 112 J/E CARBURETORS 4-21 29- Connect the manual choke lever and the front cover onto the carburetor. Thread knobs onto low- and high-speed needle valves. 24- Install the high-speed orifice, if one is used, into the float bowl. ALWAYS take time to use the proper size screwdr iver to prevent damaging the orifice.
Page 113 4-22 FUEL Check the synchronization of the fuel and ignition systems according to the procedures outlined in Chapter 5. Mount the engine in a body of water. Connect the fuel line to a fuel source. Prime the engine. If the engine is equipped with a self-contained fuel tank, open the fuel shut-off valve and allow the carburetor to fill with fuel.
Page 114 HEA T /ELECTRIC CHOKE - REMOVAL 4-7 CHOKE SYSTEM SERVICE FIRST THESE WORDS 1- Observe the compression nut under Johnson/Evinrude carburetors may be the plate securing the heat tube to the identified by the type of choke system used. exhaust manifold.
Page 115 4-24 FUEL 6- Using a pair of needle-nose pliers, reach inside the choke base and remove the spring from the choke lever. Lower the through the tube and around the spring, the spring and plunger from the carburetor. spring expands and releases its pressure on Further disassembly of the...
Page 116 ALL ELECTRIC CHOKE 4-25 ALL ELECTRIC CHOKE - REMOVAL The electric choke is mounted on the bottom side of the carburetor. 1- Disconnect the electrical wire from the choke solenoid. Disconnect the fuel line from the carburetor. Remove the two nuts securing the carburetor to the intake mani- fold.
Page 117 4-26 FUEL not necessary. If the choke is to be assem- diaphragm when the manifold pressure fluc- bled without rebuilding the carburetor, pro- tuates during slow speed operation. A punc- ceed directly to Section 4-8. If the carbure- ture, or other damage, to the diaphragm will tor is to be rebuilt at this time, proceed to cause the choke to be held in the closed Section 4-7.
Page 118 WATER CHOKE 4-27 6- Remove the small valve and seat lo- cated under the spring. Further disassembly of the water choke valve is not necessary. If the choke is to be 2- Observe the mark on the choke cover assembled without rebuilding the carbure- and a matching mark on the choke base.
Page 119 4-28 FUEL ADJUSTING KNOB needle valve. If the carburetor being ser- viced has a front shield installed, remove the top screw. 2- Remove the two screws on the front side of the carburetor cover. Remove the 4-8 TYPE CARBURETOR cover from the front of the carburetor. 3- Remove the small screen and gasket.
Page 120 TYPE II CARBURETOR 4-29 6- Remove the 7/16" nut from the bowl at the bottom of the carburetor. Using the proper size screwdriver, remove the high- speed needle valve from the bowl. GOOD WORDS: The following steps are to be performed the carburetor being serviced has an ad- justable high-speed needle valve.
Page 121 4-30 FUEL 10- If the carburetor has an attaching fuel filter bowl, turn the locking disc hold- ing the glass bowl to the carburetor COUN- TERCLOCKWISE, and then move the hanger clear of the bowl. Remove the bowl. 11- Remove center screw, washer,...
Page 122 TYPE II CARBURETOR 4-31 GOOD Compare this new needle valve with the worn needle A worn needle valve unfit for further service. the left. and passages to be sure they are not dogged CLEANING INSPECTING or contain any deposits. NEVER use a piece NEVER dip rubber parts, plastic parts, of wire or any type of pointed instrument to diaphragms, or pump plungers in carburetor...
Page 123 4-32 FUEL WORN GOOD WORN GOOD of a Comparison of a worn new needle valve. Cross-section drmving allow comparison needle and seat (left), with one badly worn (right). top needle is unfit further service. burrs which might cause a leak. Check the If a high-speed orifice is installed on the float for deterioration.
Page 124 TYPE II CARBURETOR 4-33 number. This number represents a drill size. In the kit. !V;ost repair kits contain more Check the orifice with the shank of the parts and gaskets than are needed because proper size drill to verify the proper orifice the kit may be used to service a wide range is used.
Page 125 4-34 FUEL the nozzle seats in the bowl of the carbure- tor and burrs on the nozzle will result in fuel leakage, or the bowl will NOT fit prop- er ly onto the carburetor. Install a NEW gasket over the nozzle. Force the gasket down onto the carburetor stem.
Page 126 TYPE II CARBURETOR 4-35 6- If the carbureotor being serviced has a filter bowl attached to the carburetor, install a NEW filter bowl gasket, NEW filter, washer and screw at this time. 7- Place the fitler bowl over the filter and secure it in place with the clamp.
Page 127 4-36 FUEL Installing new type packing. A packing nut etit: used hold the needle adjustm opening. Continue threading it into the opening until it barely seats. After needle valve seats, back it out 1-1/2 turns COUNTERCLOCKWISE. Now, tighten packing nut until there is drag on the needle valve, but the valve may still be rotated by hand, but with just a little difficulty.
Page 128 TYPE II CARBURETOR 4-37 17- Thread the high-speed needle valve into the high-speed opening. Continue to thread it into place until it BARELY seats. After the needle valve seats, back it out 3/4 turn COUNTERCLOCKWISE. Now, tighten the packing nut until there is drag on the needle valve, but the valve may still be rotated hand, but with just a little diffi-...
Page 129 4-38 FUEL Heat/Electrical Choke Installation 1- Install the choke plunger and spring by hooking the spring into the choke lever. 2- Insert a NEW gasket into the cavity of the choke base. 3- Insert the spring into the bore of the choke solenoid.
Page 130 TYPE II CARBURETOR 4-39 7- Clean the surface of the intake mani- fold thoroughly. Check to be sure all old gasket material has been removed. Place a gasket over the studs and into place on the manifold. Slide the carburetor down over the studs and secure it in place with the two nuts.
Page 131 4-40 FUEL ALL Electric Choke Installation 1- Install the rod extending from the the manifold. Slide the carburetor onto the upper choke assembly to the lower hinge of intake manifold studs and secure it in place the choke. Secure the rod in place with a with the attaching nuts.
Page 132 TYPE II CARBURETOR 4-41 Water Choke Installation 4- Lower the stem down through 1- Install the check valve support into spring and diaphragm and onto the base. the head. 5- Install the cover and secure it in 2- Install the small diaphragm into the place with the attaching screws.
Page 133 4-42 FUEL 7- Align the mark on the cover with the wa ter will be injected into the cylinder mark on the body, and then secure the cover when the engine is cranked, resulting in a in this position with the three attaching ser ies of horrendous problems.
Page 134 TYPE III CARBURETOR 4-43 justrnent, Return the engine to idle speed. The early model idle needle valves ex- If the engine coughs and operates as if the tended out of the carburetor with an O-ring, fuel is too lean, but the idle and high-speed spring, and E-clip.
Page 135 4-44 FUEL SPECIAL NOTE: As the needle valve being removed, BOWL take care to retain the washer, a-ring, spr ing installed between the E-r ing on the valve and the carburetor. The washer and spring will be used again. The O-ring may be discarded.
Page 136 Place all metal parts in a screen-type l\lajor parts carburetor installed tray and dip them in carburetor cleaner Johnson/Evinrude horsepower engine. until they appear completely clean, then blow them dry with compressed air. Blowout all passages...
Page 137 4-46 FUEL LEVER AND LOW-SPEED...
Page 138 Parts included carburetor repair kit for are NOT available. Johnson/Evinrude horsepower engine. Inspect the main body, airhorn, and ven- If a high-speed or ifice is installed on the turi cluster gasket surfaces for cracks and carburetor being serviced, check the orifice burrs which might cause a leak.
Page 139 4-48 FUEL Any damage to the orifice will result fuel leakage and poor engine performance. 2- Install the drain plug with a gasket and tighten it securely with a 7/16" wrench. 3- Install the inlet needle seat and gas- ket. TAKE CARE to use the proper size screwdriver to install the seat.
Page 140 TYPE III CARBURETOR 4-49 8- Lower the float bowl down over the top of the carburetor body and secure it in place with the four attaching screws. attaching screws. OBSERVE that one of the SPECIAL WORDS screws is a countersunk type.
Page 141 Idle adjustment linkage Johnson/Evinrude and ignition systems. horsepower engines. On engines with the flexible low-speed extension to the front of the engine, the spring maintains tension on the needle and adjustment will not be lost because of vibra- tion during operation.
Page 142 4-11 FUEL PUMP SERVICE A considerable number of fuel pump de- signs and sizes have been installed on the larger Johnson/Evinrude engines covered in this manual. Only one can be rebuilt and detailed procedures with illustrations PRESSURE given in this section.
Page 143 4-52 FUEL from the engine, operate the squeeze bulb in the fuel line until it is firm, and then to carefully observe the end of the vacuum hose to detect any fuel leakage. The smal- lest amount of fuel from the hose indicates a damaged diaphragm.
Page 144 FUEL PUMP 4-53 4- Shift the pump position in the vise, as shown. Remove the six screws securing the pump cover. 5- Remove the cover. Take care not to lose the disc washer and spring from the top of the diaphragm. Remove the disc washer, spring and diaphragm.
Page 145 4-54 FUEL 8- CAREFULLY observe how one check valve is facing downward and the other valve is facing upward. Also notice groove in the fuel pump body. A small boss on the retainer fits into the groove as a prevention against installing the retainer...
Page 146 FUEL PUMP 4-55 Parts included fuel pump repair kit for those model pumps that can be rebuilt. 3- Position the other check valve on top of the gasket facing UPWARD. Slide the retainer down over the check valves with the boss on the retainer in the groove of the pump body.
Page 147 4-56 FUEL GOOD WORD: The following steps may only be properly accomplished by exercising patience and a Iitt le time. 6- Mount the pump in a vise in a vertical position, as shown. Lay the diaphragm over the top of the nylon disc washer and onto the pump body.
Page 148 13- ~."ount the fuel pump onto the engine cover service of or iginal equipment produc- and secure it with the two screws on top and ed by Johnson/Evinrude. CARE- one behind the fuel inlet nipple, FULLY connect...
Page 149 4-58 FUEL The primer pump is operated until the car- the cylinders. Installation of new hoses to buretor is full of fuel. The engine is then the carburetor is not a difficult or expensive started. Once the engine is operating, even task.
Page 150 FUEL TANK AND LINE 4-59 2- Check to be sure the proper hose is connected to the correct fitting at the car- buretor. The hose on the left in the accom- panying illustration is the air pressure line and the hose on the right is the fuel supply line.
Page 151 4-60 FUEL FUEL PICKUP COVER 7- Remove the retaining scews from a- round the pump housing. Take care to save 12- Remove the eight screws from the the washer on each screw for use during pump body and lift the body free of the installa tion.
Page 152 FUEL TANK AND LINE 4-61 14- Lift the diaphragm free of the pump body with the pump plunger passing out Pickup and filter screen used in pressure-type fuel through the housing. tank. The screen should be cleaned regularily with Remove the spring from the housing air.
Page 153 4-62 FUEL Exploded view of pressure-tyoe fuel tank with major parts identified.
Page 154 FUEL TANK AND LINE 4-63 the plunger and tighten it just snugly. NOT overtighten the nut, to prevent possible damage to the diaphragm. 3- Insert the small disc washer into the center hole of the housing. 4- Insert the glass sight gauge in the housing and check to be sure it is properly seated.
Page 155 4-64 FUEL 10- Place the pickup check valve sembly in position, and then start the com- pression nut BY HAND to prevent cross- threading. Tighten the nut securely with the proper size wrench. Position gasket in place around the fuel pump opening on the tank. 12- Lower the complete assembly into the fuel tank.
Page 156 FUEL TANK AND LINE 4-65 16- Install the fuel cap and chain. If the chain and cap were removed, use a cotter pin through the flange in the tank to secure the chain in place. 17- Install the fuel cap. If only the cap was removed, attach the chain to the cap...
Page 157 4-66 fUEL...
Page 158 FUEL TANK AND LINE 4-67 5- Clean the old gasket material from fuel tank and old pickup unit (if the old pickup unit is to be installed for further 4-13 LATE MODEL FUEL TANK SERVICE service). Work the float arm down through the fuel tank opening, and at the same time 1- Late model fuel tanks (since about the fuel pickup tube into the tank.
Page 159 4-68 FUEL An arrow is clearly visible on the squeeze bulb to indicate the direction fuel flow. The sqeeze bulb be instal- MUST 8- Use two ice picks or similar tool, and led correctly in the line because the check push down the center plunger of the connec- valves in each end of the bulb will allow fuel tor and work the O-ring out of the hole.
Page 160 The ONLY ignition system used on all the engine should be operating every 3 to 4 Johnson/Evinrude engines covered in this weeks throughout the year. manual is a flywheel magneto system. The carburetion...
Page 161 IGNITION 5-2 SPARK PLUG EVALUA TION Removal: Remove the spark plug wires by pulling and twisting on only the molded cap. NEVER pull on the wire or the connec- tion inside the cap may become separated the boot damaged. Remove the spark plugs and keep them in order.
Page 162 POLARITY CHECK shown in this illustration. Overheating pre-ignition are usually caused by improper point gap adjustment; detonation from using too-Iow an octane rating fuel; an excessive- ly lean air-fuel mixture; or problems in the cooling system. Electrode Wear: Electrode wear results in a wide gap and if the electrode becomes carbonized...
Page 163 IGNITION The needle should swing upscale. If the needle swings downscale, polarity reversed. The spark plug gap should always be checked before installing used spark plugs. 2- If a voltmeter not available, pencil may be used in the following manner: Disconnect a spark plug wire and hold the metal...
Page 164 FLYWHEEL MAGNETO A wiring harness is used between the key switch and the engine. This harness seldom contains wire of sufficient size to allow connecting accessories. Therefore, anytime a new accessory is installed, wiring should be used between the battery and the accessory.
Page 165 IGNITION may be cranked manually and the engine I APHRAGl1 started. The flywheel-type magneto unit consists of an armature plate, and a permanent mag- TO MAGNETO net built into the flywheel. ignition coil, condenser breaker points mounted on the armature plate. As the pole pieces of the magnet pass over the heels of the coil, a magnetic field...
Page 166 TROUBLESHOOTING shaft, because of an accident, striking an ignition system. The switch is actuated underwater object, whatever, engine vacuum from the cylinder. When a high would then be operating under a no-load vacuum pull is exerted against the switch, condition. The vacuum switch will shut during engine operation in gear without the...
Page 167 IGNITION WIRING HARNESS CRITICAL WORDS: These next paragraphs may well be the most important words in this chapter. Misuse of the wiring harness is the most single cause of electri- cal problems with outboard power plants. A wiring harness is used between key switch and the engine.
Page 168 TROUBLESHOOTING Spark Plugs 1- Check the plug wires to be sure they are properly connected. Check the entire length of the wire/s from the plug/s to the magneto under the armature plate. If the wire is to be removed from the spark plug, ALWAYS use a pulling and twisting motion as a precaution...
Page 169 5-10 IGNITION not available, hold the plug wire about 1/4- Therefore, it is essential that any compres- inch from the engine. Turn the flywheel sion problem be corrected before proceeding with a pull starter or electrical starter with the tune-up procedure. See Chapter 3. check for spark.
Page 170 TROUBLESHOOTING 5-11 Checking Compression ALTERNATE LAYERS 4- Remove spark plug wires. INSULATION -- WAXED PAPER ALWAYS grasp the molded cap and pull it ALTERNATE LAYERS OF FOIL loose with a twisting motion to prevent TI N OR ALUM I NUH damage to the connection.
Page 171 5-12 IGNITION bracket and does not move. The other point is attached to a movable mount. A spring is used to keep the points in contact with each other, except when they are separated the action of a cam built into the flywheel or machined on the crankshaft.
Page 172 4- Install the proper flywheel puller us- ply to all Johnson/Evinrude high speed fly- ing the same screw holes in the flywheel wheel-type magnetos. REMOVAL 1- Remove the hood or enough of the engine cover to expose the flywheel.
Page 173 5-14 IGNITION that are used to secure the ratchet plate removed in Step 2. NEVER attempt to use a puller which pulls on the outside edge of the flywheel or the flywheel may be damaged. After the puller is installed, tighten center screw onto the end of the crankshaft.
Page 174: Of Points
SERVICING 5-15 9- Lif t the moveable side of the points free of the other half of the set. 10- Remove the hold-down screw secur- ing the non-moveable half of the point set to the armature plate. 11- Remove the hold down screw securing the condenser to the armature plate.
Page 175: The Armature Plate
The tools are usually available at the local John- the crankshaft. son/Evinrude dealer at reasonable cost. 14- To remove the seal, first, work the point cam up and free of the dr iveshaft.
Page 176: The Armature
SERVICING 5-17 Slide the cam down the crankshaft with word TOP facing upward. Continue working the cam down the crankshaft until it is in place over the Woodruff key, or pin. If the coil is not to be removed, proceed directly to Step 25.
Page 177 5-18 IGNITION FLYWHEEL of a Exploded drawing typical magneto system. Only one coil points is shown.
Page 178 CLEANING AND INSPECTING 5-19 "' ..,' .. BLOW, ~~Oll A coil destroyed when the side blew out. This damage caused when 12-volts was connected magneto circuit the key switch. 20- Hold the armature plate and separ- ate the coils from the plate. As the coil is Test the armature plate to verify it is...
Page 179 5-20 IGNITION ASSEMBLING Coil to Armature Plate 1- To install a new coil, first turn the armature plate over, and loosen the spark plug lead wires, and push them through the armature plate. Now, work the leads into the coil. 2- After the leads are into the coil, work the small boot up onto the coil.
Page 180: Tighten The
ASSEMBLING 5-21 6- If a special ring tool is not available, and in a emergency, hold a straight edge against the boss on the armature plate and bring the heel of the laminated core out square against the edge of the boss on the armature plate.
Page 181 5-22 IGNITION Point Set Install the condensers and secure them in place with their hold-down screws. 11- Hold the base side of the points and slide it down over the anchor pin onto the armature plate. Install the wavy washer and hold-down screw to secure the point base to the armature plate.
Page 182 ASSEMBLING 5-23 CRITICAL WORDS As the coil, condenser, and "kill" switch wire are being attached to the point set, take the following precautions and adjust- ments: a- The wire between the coil and the points should be tucked back under the coil and as far away from the crankshaft possible.
Page 183 5-24 IGNITION contact any part of the magneto or the revolution and again check the gap adjust- wir mg, 21- Thread the flywheel nut onto the ment. After the crankshaft has been turned and the points are on the high point of the crankshaft and tighten it to the torque value given in the Appendix.
Page 184: Plate Installed On Some Engines Covering
ASSEMBLING 5-25 Plate installed some engines covering the inspec- tion hole in the flywheel. The plate is clearly marked indicate which side is face upward during installa- tion. SPARK PLUG side. When installing this plate, check to be YEAR sure the word UP is facing upward. TORQUE 23- After the ratchet...
Page 185: Attaching The
5-26 IGNITION and the locations numbered 5 thru 9. The number to be used is taken from the table by following across from first column for the engine being serviced to the column titled Primary Pickup Location the column titles Primary P/U Adjustment Note.
Page 186 SYNCHRONIZATION 5-27 shown. The wire jiggling will instantly in- dicate movement of the shaft. The actual adjustment is accomplished by ONLY ONE The No.5 Location method, depending on the engine being ser- 1- The pickup location for the No.5 viced. Check the Appendix for the ad- location is PORT side of the mark.
Page 187 5-28 IGNITION one side of the clip; and then attaching clip to the throttle shaft, as shown. wire jiggling instantly indicate move- will m ent of the shaft. The actual adjustment accomplished by ONLY ONE method, gardless of the engine being serviced for the No.6 location.
Page 188 SYNCHRONIZATION 5-29 The No. 8 Location Per Note 1 in the Appendix, loosen 10- Engines referenced to the No.8 the two screws under the armature plate cation are to be adjusted with the cam and move the primary pickup inward or out- follower midway between the two marks on ward to meet the follower.
Page 189 5-30 IGNITION The No.9 Location Engines referenced to the No.9 lo- cation have a pointer attached to the intake manifold. Synchronization is made by ad- vancing the magneto until the mark on the is aligned with the pointer on the intake manifold.
Page 190: The Plate
ELECTRICAL 6-1 INTRODUCTION Do not consider a battery of less than 70-ampere hour capacity. If in doubt as to The battery, gauges and horns, charging how large your boat requires, make a liberal system, and the cranking system are all estimate and then purchase the one with the considered subsystems of the electrical...
Page 191 ELECTRICAL plate is securely anchored within the bat- BATTERY RATINGS tery case to ensure extended life. The caps of marine batteries are "spill Two ratings are used to classify batter- ies: one is a20-hour rating at 80°F and the proof" to prevent acid from spilling into the bilges when the boat heels to one side in a other is a cold rating at OOF.
Page 192 BATTERY SERVICE 3- Using more electrical power than the tip of the rod is immersed in the electrolyte generator or al ternator can replace resul t- when the level is correct. If the level ing in an undercharged condition. should drop below normal, the lower tip of 4- A defect in the charging system.
Page 193 ELECTRICAL resistance to the charging circuit. This 5- ALWAYS hold the hydrometer at eye resistance will cause the voltage regulator level and take the reading at the surface of to register a fully charged battery, and thus the liquid with the float free and floating. cut down on the alternator output adding to Disregard the...
Page 194: To Use A
BATTERY SERVICE attention rr-ust be giver, to the battery JUMPER CABLES prevent complete discharge or possible darr-- If booster batt er ies are usee for starting age to the terminals and wiring. Before an engine the jumper cables must be con- putting the boat in storage, disconnect nected correctly...
Page 195 ELECTRICAL ·0 ·0 "'1'1'111111111" 111111.1 ••• 11111.'1 "11'1""111'1111 111 ••••• 11 •••••••• 11I.111I11t ••••••• ••••••••••••••• .,1111111 • ., ••• " 11111111111 ••••• ••••••••••• 1111111. •• 111 •••••••• 1111 • • Schematic drawing of three battery, two engine Sche matic drawing for two battery, two engine hookup.
Page 196 GAUGES AND HORNS this arrangement can be a disadvantage TEMPERATURE GAUGES since it will draw a load from the starting battery while cranking the engine. One way The body of temperature gauges must be to avoid such a condition is to connect the grounded and they must be supplied with 12 relay coil to the ignition switch accessory volts.
Page 197 ELECTRICAL lamp on the dash should light. If it does not 6-5 FUEL SYSTEM light, check for a burned-out bulb or a break in the wiring to the light. FUEL GAUGE The fuel gauge is intended to indicate THERMOMEL T STICKS the quantity of fuel in the tank.
Page 198 FUEL SYSTEM the dash. Connect one end of a second black wire 3- The wire from the gauge to the igni- to the fuel gauge terminal marked GRD and tion switch is connected at the wrong term- other end to a good ground. It is inal.
Page 199 6-10 ELECTRICAL H Gauge Reads Full: batter ies and contributes to their accuracy. 1- Connect a known good tank sending The electronic parts of the tachometer sus- unit to the tank feed wire and the ground ceptible to moisture are coated to prolong lead.
Page 200 ~FORMATION faulty insulation, or poor ground. Check the GENERAL resistor with an ohmmeter, or test the con- Probably 75-80% of all Johnson/Evinrude denser for capacity, ground, and leakage. engines covered in this manual are started Inspect the diaphragm for cracks.
Page 201 6-12 ELECTRICAL switch to carry the heavy current from the The volts will always be 12. Accessories battery to the starter motor. The solenoid will usually be given in watts. If the obso- is actuated by turning the ignition key to lete measurement of candle power is used, the START...
Page 202 CHARGING CIRCUIT 6-13 Most amp-meters have a 20-amp scale. Therefore, it is only necessary for the scale to register in the 10-amp area, while the engine is operating above 1500 rpm, to indi- ca te satisfactory performance a- The 4-amp or 20-amp fuse in the junction box may have burned, opening the circuit.
Page 203 6-14 ELECTRICAL GENERATOR ENGINE GROUND STARTER SWITCH GROUND TO LOWER HOTOR COVER the cover and cannot be completely remov- it-amp or 20-amp fuse with a continuity light, or install a new fuse and check the ed, only released from the junction box.
Page 204 CHARGING CIRCUIT 6-15 3- "Polarize" the new regulator by first connecting the posi tive lead to the battery, and then using a sm all jumper wire to make a MOMENTARY connection between battery terminal and the arm ature terminal 2- Place the junction box cover on its of the regulator.
Page 205 6-16 ELECTRICAL ARMATURE TERMINAL 2- Remove the generator belt from the pulley. Use a screwdriver or other similar tool and pry the puller up and free of the generator shaft. Hold the generator, and at the same time remove the nuts from the top of the generator support bracket, and the...
Page 206 CHARGING CIRCUIT 6-17 between the commutator bars on the arma- ture. Perform the test again. If the hack- saw blade still vibrates during the test, the armature has a short and MUST be replaced. 5- Remove the end cap from the gener- ator.
Page 207 6-18 ELECTRICAL Positive Brush Test for Ground 11- Using a test lamp or ohmmeter, make contact with one probe lead to the positive or insulated brush holder. Make the field insulation is not broken. Using a contact with the other probe lead to a good test lamp or ohmmeter, make contact with...
Page 208 CHARGING CIRCUIT 6-19 UPPER HEAD ARMATURE BEARING FRAME BRUSH (2) THRU -.., BOLT LOWER HEAD Exploded view of typical generator showing arrangement of major parts.
Page 209 6-20 ELECTRICAL CORRECT INCORRECT Armature segments properly cleaned (left) and im- properly cleaned (right). the turn the upper cap on the shaft with the other hand. The cap and shaft should turn freely with no sign of binding. If either of these tests are not successful, the bear ing MUST be replaced.
Page 210 GENERATOR SERVICE 6-21 Testing Rotating the Armature Performing this test will also "polarize" the new or rebuilt generator. If this test is not performed, the new or rebuilt generator MUST still be "polarized" following installa- tion. "Polarization" at that time is ac- complished by first connecting the battery to the system in the normal manner,...
Page 211 STARTER MOTOR DESCRIPTION Delco-Remy, Autolite, and Prestolite starter motors are used on the Johnson/ Evinrude engines covered in this manual. Any of the three may be installed on a or 40 hp engine. The early model starters (especially...
Page 212 STARTER MOTOR 6-23 The sound of the motor during cranking for more than 3D-seconds without allowing the motor to cool for at least three minutes. is a good indication of whether the starter Actually, this time can be spent in making motor is operating properly or not.
Page 213 6-24 ELECTRICAL handy instruments use in checking motor generating circuit (left) and starter circuit (right). These meters do not require any wire connec- tions. A reading will be obtained by simply placing the meter on the line. checks outlined in the previous paragraph should be performed.
Page 214 STARTER MOTOR 6-25 correlated with numbers on the accompany circuit diagram on Page 26, to identify exactly where the connection or test is to made. Starter Motor Turns Slowly a- Battery charge is low. Charge the battery to full capacity. Electrical connections corroded...
Page 215 6-26 ELECTRICAL b- If voltage is present-at No.6, connect present, the starter solenoid is defective a voltmeter at No.3 and to No.7. Connect and MUST be replaced. one end of a jumper wire to No.2, Testing Throttle Advance Cut-out Switch positive terminal of the battery MENTARIL Y...
Page 216 Two types of drive gear arrangements cotter pin. The drive mechanism is now are used on Johnson/Evinrude outboard star- ready to be removed in the following se- ter motors covered in this manual. Both quence: pinion stop, anti-drift...
Page 217: Exploded Drawings
6-28 ELECTRICAL flexible and has not become distorted. cracks, or a broken tooth. Check the spline spect the rubber cushion for cracks and for inside the drive gear for burrs and to be sure signs of oil on the cushion. Clean the drive gear moves freely on the armature armature shaft with crocus cloth.
Page 218 DELCO-REM Y STARTER 6-29 illustration will be most helpful in assemb- the three 7/16" bolts (or nuts in some cases) ling the parts in the proper sequence. securing the starter motor bracket to the First, slide the cushion retainer down engine.
Page 219 6-30 ELECTRICAL Testing for a Ground 4- Obtain a test lamp or continuity me- ter. Make contact with one probe lead on the armature core and the other probe lead on the commutator bar. If the lamp lights, or the meter indicates continuity, the arma- ARMATURE TESTING ture is grounded and MUST be replaced.
Page 220 DELCO-REMY STARTER 6-31 Positive Brushes 7- The positive brush or brushes can always be identified as the brushes connect- ed to the field coil. Obtain an ohmmeter. Connect one lead of the meter to the end of the brush and the other lead to the terminal.
Page 221 6-32 ELECTRICAL Turn the commutator in a lathe if it is out-of-round by more than 0.005". Check the springs in the brush holder to be sure none are broken. Check the spring tension and replace if the tension is not 32- 4-0 ounces.
Page 222 DELCO-REMY STARTER 6-33 A new negative brush brush hotcter it appears when removed from the package. Replacement brush sets available and usually contain the following parts: One insulated brush, with flexible lead attached. overheat the leads, because the solder will One ground brush holder with brush and run onto the lead and the lead will loose its lead attached.
Page 223 6-34 ELECTRICAL the frame, and thread them into the starter bracket. Tighten the thru-bolts securely. To test the complete starter motor, pro- ceed directly to Section 6-16. To install the starter motor onto the engine, proceed directly to Section 6-17. 6-14 AUTOLITE STARTER...
Page 224 AUTOLITE STARTER 6-35 the hacksaw blade vibrates, the armature commutator has a short. Clean the grooves DISASSEMBLING between the commutator bars on the arma- ture. Perform the test again. If the hack- 2- Observe the caps and find the identi- saw blade still vibrates during the test, the fying mark or boss on each.
Page 225 6-36 ELECTRICAL or the meter indicates continuity, the arma- ture is grounded and MUST be replaced. Checking the Commutator 7- Check between or check bar-to-bar CORRECT as shown in the accompanying illustration. The test light should light, or the meter should indicate continuity.
Page 226 AUTOLITE STARTER 6-37 position to reach the brush holders. Do not overheat the leads, because the solder will run onto the lead and the lead will loose its flexibility. Check to be sure none of the soldered connections are touching the frame.
Page 227 6-38 ELECTRICAL against the brush built into the re tainer • Therefore, a separate brush spring required. With one brush attached to the end cap and the other to the frame assem- bly, positioning the brushes properly with the easiest task, but it can be done patience.
Page 228 PRESTOLITE STARTER 6-39 6-15 PRESTOLITE SERVICE REMOVAL 1- Before beginning any work on the starter motor, disconnect the positive lead from the battery terminal. Remove the engine hood. Disconnect the red cable at the starter motor terminal. Remove the 1/2" bolt securing the starter bracket. This bolt is located on the starboard side of the engine just above the carburetor.
Page 229 6-40 ELECTRICAL DISASSEMBLING 2- Observe the caps and find the identi- fying mark or boss on each. If the marks are not visible, make an identifying mark prior to removing the thru-bolts as an essen- tial aid during asembling. Remove the thru- bolts from the bracket and the starter tor.
Page 230 PRESTOLITE STARTER 6-41 TEST LEADS CORRECT INCORRECT the brushes are harder than the insulation. Undercut the insulation between the com- mutator bars 1/32" to the full width of the insulation and flat at the bottom. A triang- ular groove is not satisfactory. After the under-cutting work is completed,...
Page 231 6-42 ELECTRICAL Obtain an ohmmeter. Make contact with one test lead to the negative brush and make contact with the other lead to the starter frame. If the meter does not indi- cate continuity, the field coils are open and MUST be replaced.
Page 232 PRESTOLITE STARTER 6-43 Turn the commutator in a lathe if it is out-of-round by more than 0.005". Check the springs in the brush holder to be sure none are broken. Check the spring tension and replace if the tension is not 32- 40 ounces.
Page 233 6-44 ELECTRICAL motor. NEVER make the momemtary con- tact with the positive lead to the terminal, because any arcing at the terminal damage the terminal threads and the nut may not take to the damaged threads. motor should turn rapidly. If the starter motor fails to rotate,...
Page 234 These shift boxes are all considered original Johnson/Evinrude equipment. 7-2 SHIFT BOXES DESCRIPTION Undoubtedly, the most used accessory on Single lever electric Shift box used only on the any boat is the the shift control box.
Page 235 FRICTION ADJUSTMENT the updated mechanical shift box. This new Single lever electric shift box installed with Evinrude units. This box incorporates pushbuttons box still uses the two lever principle for the Shift control, an idle adjustment the front, throttle and shift.
Page 236 DOUBLE SHIFT LEVER SHIFT engine. Attempt to identify if the problem NOT ADJUSTABLE is in the throttle or the shift side of the shift box. The problem may be in the tower shaft between the connector of the throttle and the armature plate or the armature...
Page 237 ACCESSORIES NEUTRAl Inner shift wire after has been removed showing the proper type crimp necessary to hold the adjustment. stainless steel inner wire was not heated and the clamp did not hold the inner cable (wire), the wire could slip inside the sleeve thus shortening the cable.
Page 238 Throttle Cable Lubrication 1- On some shift and throttle cables not 6- If the throttle or shift cables are not manufactured by Johnson/Evinrude, the in- to be replaced, now is an excellent time to ner cable is made of stainless steel. When lubricate the inner wires.
Page 239 ACCESSORIES TRUNNION SHIFT HANDLE Shift Half Assembling 4- Lay the shift ratchet in position in- MUST wire pass through the hole and pro- side the shift half of the box. Place the trude out the end of the ratchet. Work the shift lever down over the top of the ratchet, ratchet onto the end of the shift cable.
Page 240 NEW SHIFT LEVER SPEED RANGE NEUTRAL FAST Connecting throttle cable with adjustable trun- nion. engine. The problem may be in the tower shaft between the connector of the throttle and the armature plate. The armature plate may be "frozen", unable to move properly. If the problem with shifting is at the engine, the first place to check is the area...
Page 241 ACCESSORIES REMOVAL Removing Double Lever Shift Box 1- Remove the attaching hardware se- curing the shift box to the side of the boat. Once the shift box is free, the service work may be performed in the boat. The cables may remain as routed.
Page 242 NEW SHIFT LEVER 5- Loosen the two screws securing the gear rack to the end of the throttle cable and remove the end of the cable from the throttle lever. Take care not to lose the small sleeve from the end of the rack to which the screws were attached.
Page 243 7-10 ACCESSORIES has a bluish appearance, it has been heated at an earlier date and the temper removed. The temper MUST be removed to permit the holding screw to make a crimp in the wire to hold an adjustment. If the wire has net been tempered, heat the end, but not enough to mel t the wire.
Page 244 NEW SHIFT LEVER 7-1 , ~quare n~lon plu& ~ith the holes in the plug In a ver tical pOSItIOnto permit the cable to slide through. Two different size screws are used on each end of the sleeve. Install the short screw into the bottom of the sleeve to prevent the sleeve from rubbing on the shift box.
Page 245 Johnson single lever shift box with the warm-up lever to the rear and the Evinrude single lever pushbutton shift box operation. The procedures and suggestions are key- ed by number to matching numbered illus- trations as an aid in performing the work.
Page 246 ELECTRIC GEAR BOXES 7-13 amp gauge for the test. Replace the wires after the test is completed. Disconnect the shift leads at the rear of the engine. Temporarily lay a piece of cloth or other insulating material under the wires to prevent them from shorting out during the following tests.
Page 247 7-14 ACCESSORIES DISASSEMBLING GOOD WORDS On Johnson units, a friction screw is installed in the bottom side of the shift box. This screw allows friction adjustment of the throttle handle. This arrangement prevents the throttle handle from "creeping" after the operator releases his grip on the handle. The box has a maximum advance screw.
Page 248 SINGLE LEVER SHIFT BOX 7-15 SCREW AND WASHER EXTREME OPPOSITE FRONT POSITION HOUSING IDLE POSITION NEUTRAL POSITION observe the screw and the concave washer. The washer must be installed with the con- cave side toward the screw to allow the screw to seat properly.
Page 249: To This
7-16 ACCESSORIES THROTTLE to hold an adjustment. If the wire has not been tempered, heat the end, but not enough Interior view of used shift box showing the results to melt the wire. improper installation. The inner wire was not Tighten the top screw in the sleeve until crimped hold the adjustment.
Page 250 SINGLE LEVER SHIFT BOX 7-17 EXTREME OPPOSITE ITION " IDLE POSITION 4- AL WAYS TAKE CARE when as- sembling the shift box, not to damage .the remote-control unit. The arm on the switch 7- The tension of the throttle lever is MUST lay in the cut-out portion...
Page 251 START position. 7-6 PUSHBUTTON SHIFT BOX SERVICE EVINRUDE UNITS ONL Y GOOD WORDS A friction screw is installed in the bot- tom side of the shift box. This screw allows friction...
Page 252 Evinrude single lever pushbutton shift box Again operate the shift buttons and note operation. the current loss. If the current draw is still The procedures and suggestions are key- more than 2.5 amperes,...
Page 253 7-20 ACCESSORIES 3- Testing Shift Switch - Forward To test the switch for the FORWARD position, make contact with one probe of a continuity meter (or a test light) to the terminal (purple or red lead) and to the forward (green lead) terminal with the other probe.
Page 254 PUSJ-IBUTTONSHIFT BOX 7-21 1/4- more than forward, the cutout switch attached to the armature plate will open the circuit to the starter solenoid. If the crank- ing system fails to operate the starter prop- erly when the throttle lever is in the IDLE position, check the 20-ampere fuse between the ingition switch...
Page 255 7-22 ACCESSORIES CLEANING AND INSPECTING off to rotate the wire and at the same time Clean the box halves thoroughly inside allow lubricant to flow into the cable, as and out with solvent and blow them dry with shown. compressed air. Apply a thin coat of engine oil on all metal parts.
Page 256 PUSH3UTTON SHIFT BOX 7-23 Adjustment Temporarily install the side plate, and then move the throttle hand forward CRITICAL WORDS until the boss mark on the bottom of the If the throttle adjustment is not properly throttle hand aligns with the mark on the performed, the circuit to the starter sole-...
Page 257 7-24 ACCESSORIES Check the end of the cable to determine selector bracket. Move the bracket forward or aft until the buttons can be depressed. if the temper has been removed. If the end has a bluish appearance, it has been heated To adjust the friction knob under the shift at an earlier date and the temper removed.
Page 258 CABLE END FITTING 7-25 Detailed draWing the shift trunnion the engine. in the casting guide, tighten the top screw until a definite crimp is made in the cable. If the screw is not tightened enough, the inner wire will slip during operation and the adjustment will be lost.
Page 259 7-26 ACCESSORIES TRUNNION SHIFT CRITICAL WORDS NOT ADJUSTABLE Check the end of the cable to determine if the temper has been removed. If the end has a bluish appearance, it has been heated at an earlier date and the temper removed. The temper be removed to permit the MUST...
Page 260 LOWER UNIT 4- The lower unit does not have shifting DESCRIPTION capabilities, therefore, removal of the unit The lower unit is considered as that part is not an invol ved procedure. of the outboard below the exhaust housing. To determine the proper procedures follow, simply check the Appendix for the The unit contains...
Page 261 LOWER UNIT except for the type of bearings installed and therefore slightly different assembling procedures. fourth type units, presented Section 8-8, lower units with electric shift. Water pump service work is by far the most common reason for removal of the lower unit.
Page 262 TROUBLESHOOTING Arrangement propeller shaft parts used on most to 4 1.5 hp hp engines. Unable to Shift into Forward or Reverse Remove the propeller and check to de- termine if the shear pin has been broken. If the unit being serviced has the shear pin at rear of the propeller,...
Page 263 LOWER UNIT Cut-a-way view of propeller showing the propel- unit, View of a badly corroded lower liater entered ler, rubber hUb, and metal hub. and was allowed remain over extended period of time causing extensive damage. propeller and the rubber hub.
Page 264 TROUBLESHOOTING with shift cable disconnected, problem must be in the lower unit. verify the problem is in the lower unit, have an assistant turn the propeller and at the same time move the shift cable back-and- forth. Determine if the clutch engages properly.
Page 265 LOWER UNIT requirmg If the engine is the type lower unit to be lowered slightly to gain Powerhead low horsepower engine removed exposing interior of the exhaust housing. This access to the shift rod: Lower the lower bellcrank is quite different than the one shown unit slightly, and then hold the shift rod previous page.
Page 266 PROPELLER REMOVAL to connect the upper shift with lower rod. If the coupler has not been installed properly, any shifting will be diffi- cult. Parts in the lower unit are worn from extended use. Frozen Power head This condition is suggested when the operator unsuccessfully...
Page 267 LOWER UNIT 8-4 DRAINING LOWER UNIT Position a suitable container under the lower unit, and then remove the FILL screw and the VENT screw. CRITICAL WORD The Phillips screw securing the shift fork in place located very dose to the vent screw.
Page 268 SERVICE NO SHIFT 1- Disconnect the spark plug wire from Lower unit with propeller in place prior service the plug. Remove the retaining bolts secur- work. ing the lower unit to the exhaust housing. The seal may be replaced by first remov- CAREFULLY pull directly downward,...
Page 269 8-10 LOWER UNIT SPECIAL WORDS LOWER UNIT DISASSEMBLING On the Weedless type lower unit, thrust bearing is installed under the pinion 4- Remove the gearcase head and the gear. This thrust bearing can only be re- two screws. Pull on the propeller shaft or moved by tapping it out in the following tap on the gear case head to separate manner:...
Page 270 SERVICE NO SHIFT 8-1 I CLEANING INSPECTING Clean all water pump parts with solvent, and then dry them with compressed air. Inspect the water pump cover and base for cracks and distortion, possibly caused from overheating. Inspect the face plate water pump insert for grooves and/or rough surfaces.
Page 271 8-12 LOWER UNIT PROPELLER Exploded drawing of the "Weedless" lower unit gear case, with major parts identified.
Page 272: These Items Must Be
SERVICE r-JO SHIFT 8-13 nicked, chipped, or the edges rounded, the operator performing shift operation improperly. These items MUST be replaced if they are damaged. LOWER UNIT ASSEMBLING 1- Tap a NEW seal into place on top of the lower unit housing. 2- Tap a NEW seal into place in the gear case head.
Page 273 8-14 LOWER UNIT soft-headed mallet and tighten the screws EVENLY ALTERNATELY. CRITICAL WORDS If the screws are not tightened evenly, or the driven gear and pinion gear teeth are not fully and properly engaged, the gearcase head will be thrown out of line just whisker, and the ears through...
Page 274 SERVICE NO SHIFT 8-15 9- ALWAYS rotate driveshaft CLOCKWISE while the screws are tightened to prevent damaging the impeller vanes. impeller is not rotated, housing could damage or cut the end of the vanes as the screws are brought up tight. The rota- tion allows them to spring back in a natural position.
Page 275 8-16 LOWER UNIT PROPELLER INSTALLATION FIRST, THESE GOOD WORDS The propellers used on the outboards covered in this section have a removable clutch ring and a clutch hub, and bushing. Under normal conditions, these items are NOT removed from the propeller. However, if they have been removed for any number of reasons, they should be coated with OMC...
Page 276 MANUAL SHIFT 5 HP TO 25 HP 8-'17 Type A - No Shift Unit This type is used on the direct drive engines, without a reverse gear. The engine is rotated with the steering lever to move the boat sternward. Because a shift rod is not used, naturally there is no re-...
Page 277 8-18 LOWER UNIT BELLCRANK View into the exhaust housing after the powerhead has been removed. The bellcrank part of the upper mechanical shift mechanism is clearly visible. Removing the bolt through the shift connector after the shift lever. Remove the attaching bolts, [rott: the lower unit has been separatec...
Page 278 MANUAL SHIFT 5 HP TO 25 HP 8-19 UNIT LOWER REMOVAL 1- After the shift rod has been discon- nected, as described in the previous para- graphs, remove the bolts securing the lower unit to the housing. Some units may have an additional bolt on each side and one at the rear of the engine.
Page 279: Take Time
8-20 LOWER UNIT ADVICE If the only work to be performed service of the water pump, be extremely CAREFUL to prevent the driveshaft from being pulled up and free of the pinion gear in the lower unit. NEVER carry the lower unit by the driveshaft.
Page 280 MANUAL SHIFT 5 HP TO 25 HP 8-21 Lower W1it with the cap removed exposing internal parts before disassembling. have been made to the lower unit over the years. Therefore, the positioning of the gears, shims, bearings, and other parts may vary slightly from one unit to the next.
Page 281 8-22 LOWER UNIT Bearing carrier prior removal. The two screws carrier shown are used align the with the gasket during installation. stubborn bearing carrier is to heat the lower unit housing while attempting to remove the carrier. this method employed, TAKE CARE not to overheat the lower unit.
Page 282 8-23 MANUAL SHIFT 5 HP TO 25 HP A new Shift cradle (right) compared with one badly and unfit for service (left). Worn clutch dog ears. This clutch dog must be replaced. Inspect the impeller side seal surfaces and the ends of the impeller blades for cracks, tears, and wear.
Page 283 8-24 LOWER UNIT Badly worn water pump impeller. The impeller should be inspected thoroughly. The best practice replace the impeller each time the lower unit is disas- sembled for service. clutch dog and drive gear arrangement sur- Badly worn pinion gear from lower unit.
Page 284 8-25 MANUAL SHIFT 5 HP TO 25 HP water Standard pump (left) new type (right). newer pump only used with updated lower a forward gear Indent mark on bearing indicating unit. the unit was not assembled properly. The pin in the housing caused this damage.
Page 285 8-26 LOWER UNIT of a Exploded drawing lower unit with window for access the shift connector.
Page 286 MANUAL SHIFT 5 HP TO 25 HP 8-27 of a to be Exploded drawing lower unit requiring the powerhead removed gain access the shift disconnect.
Page 287 8-28 LOWER UNIT ASSEMBLING 4- Apply a light coating of lubricant to the washer, and then insert it into the 1- Place the lower unit on the work center of the reverse gear. Slide the re- bench with the water pump recess facing verse gear onto the propeller shaft from the upward.
Page 288 8-29 MANUAL SHIFT 5 HP TP 25 HP O-RING An assembled bearing head without the index hole. This bearing has a protrusion which indexes with cutout in the lower unit housing. the cradle. Check to be sure the dutch dog in the forward gear bearing.
Page 289 8-30 LOWER UNIT Two shift lever screws. The right screw has been ground assist installation, explained in the text. 10- Place a NEW seal in the lower cap and hold the seal in the groove with sealer. Apply a small amount of silicone sealer on each side of the bearing gear case head.
Page 290 MANUAL SHIFT 5 HP TO 25 HP 8-31 16- Install the bearing housing and bear- ing assembly by sliding a couple bolts through the housing to align the base gasket. 13- If the screw-type cap is used, with the Phillips screw in the side of the cap, use a flashlight and align the hole in the cap WATER PUMP...
Page 291 8-32 LOWER UNIT 21- ALWAYS rotate driveshaft CLOCKWISE while the screws are tightened to prevent damaging the impeller vanes. impeller is not rotated, housing could damage or cut the end of the vanes as 18- If the unit being serviced, uses the the screws are brought up tight.
Page 292 MANUAL SHIFT 5 HP TO 25 HP 8-33 23- If the lower unit being serviced uses a pin on the top of the driveshaft, install the pin at this time. Shift the lower unit into FORWARD gear and at the same time ro- tate the propeller shaft CLOCKWISE.
Page 293 8-34 LOWER UNIT SPECIAL WORDS If the unit being serviced uses the shift rod coupler arrangement, then the coupler must be connected to the shift rod BEFORE the lower unit is fully mated with the ex- haust housing, as described in the previous step and the "Good Words".
Page 294 MANUAL SHIFT 5 HP TO 25 HP 8-35 A FEW GOOD WORDS Shift rod connected on lower unit requiring The propeller washer, if used, and drive powerhead be removed gain access the con- pin play an extremely important role. When nection.
Page 295 8-36 LOWER UNIT If the unit being serviced has a propeller using the rear-type shear pin arrangement: Install the shear pin and then coat the propeller shaft with anti-corrosion grease. Install the propeller, propeller nut, and then the cotter pin. 29- Final adjustment for remote control units: Shift the lower unit into...
Page 296 MANUAL SHIFT 28 HP TO 40 HP LOWER UNIT REMOVAL Type D - Window Removal to Gain Access 1- Remove the metal plate from port side of the engine. Access to the shift coupler is gained through opening. Disconnect the shift rod from the exhaust housing by removing the bottom bolt from the shift coupler.
Page 297 8-38 LOWER UNIT performed with the lower unit erect (in its normal position), or inverted (upside down). In both positions, the cavitation plate is the supporting surface. 3- Remove DISCARD the O-ring from the top of the drives haft. GOOD NEWS WATER PUMP REMOVAL If the only work to be performed...
Page 298 MANUAL SHIFT 28 HP TO 40 HP 8-39 Lower unit with the cap removed exposing internal parts. Take time make a sketch take photograph showing the arrangement parts as assist during the installation work. with the skeg attached. Remove the Phil- years.
Page 299 8-40 LOWER UNIT Arrangement of parts after the propeller shaft has been removed. Also observe the seal retainer on the propel- ler end of the propeller shaft. Now, notice the matching pin in the lower unit housing. During the installation work, the retainer MUST be installed...
Page 300 MANUAL SHIFT 28 HP TO 40 HP 8-41 punch is required to remove the bushing from the lower unit housing. Obtain the special punch, and then remove the bushing, and the O-ring. CLEANING AND INSPECTING Using slide hammer remove the seals bear- vrater ings from underneath...
Page 301 8-42 LOWER UNIT of a View badly corroded lower unit. Water entered and was allowed remain over an extended period Eabbitt bearing unfit for further service. This type time causing extensive damage. bearing must not show any signs wear. Inspect the impeller side seal surfaces and the ends of the impeller blades for...
Page 302 MANUAL SHIFT 28 HP TO 40 HP 8-43 shift cradle (right) compared with one badly worn and unfit for service (left). Check the water intake screen and pas- sages by removing the bypass cover, if one is used. Inspect the dutch dog, drive gears, pinion gear, and thrust washers.
Page 303 8-44 LOWER UNIT of a Exploded drawing typical manual shift lower unit installed 35 hp and 40 hp engines. Two propeller shafts shown. The second shaft with the two balls and spring may be installed conversion. This new type shaft parts are separate arranqment...
Page 304 MANUAL SHIFT 28 HP TO 40 HP 8-45 HUU~INu shift Exploded drawing a typical manual lower unit installed late mode hp engines. This lower unit is almost water 8-44, identical the one shown on Page except the pump has two-line recirculating system.
Page 305 8-46 LOWER UNIT the babbitt side TOWARDS the reverse gear. ASSEMBLING Install the snap ring, the bearing. Check to be sure a NEW seal and a-ring has been 1- Place the lower unit on the work installed into the seal retainer, and then bench with the water pump recess facing install the retainer.
Page 306 MANUAL SHIFT 28 HP TO 40 HP 8-47 6- Slide the clutch dog onto the propel- ler shaft splines. Apply a light coating of 7- Slide the propeller shaft assembly in- lubricant to the washer and then insert it to the lower unit housing. Check to be sure into the center of the forward gear.
Page 307 8-48 LOWER UNIT -.-._--- ..the shift rod to move it up or down until the clutch dog is in the center between forward and reverse gears. 9- Lay down a bead of No. 1000 Sealer screw will "seek" and make the alignment as into the groove of the cap in preparation it passes through.
Page 308 MANUAL SHIFT 28 HP TO 40 HP 8-49 WATER PUMP INSTALLATION 15- Apply a coating of sealer to the upper surface of the lower unit. Install the water pump base plate. Slide the driveshaft into the lower unit, and then rotate the shaft very slowly. When the splines of the driveshaft...
Page 309 8-50 LOWER UNIT damage or cut the end of the vanes as the screws are brought up tight. The rotation allows them to spring back in a natural position. Place grommets into the water pump housing for the water pickup. If a new Shift rod connector with the clear hole through the connector and shift rod, indicating the rod.
Page 310 MANUAL SHIFT 28 HP TO 40 HP 8-51 21- Check to be sure the water pickup tubes are clean, smooth, and free of any corrosion. Coat the water pickup tubes and grommets with lubricant as an aid to instal- lation. Guide the lower unit up into the exhaust housing with the water tube sliding making this connection.
Page 311 8-52 LOWER UNIT plug. Remove the gear lubricant tube, and gear. At the shift box, move the shift lever install the drain/fill plug. to the NEUTRAL position. If the pin on the 25- After the lower plug has been instal- end of the shift cable, does not align with led, remove the vent plug again and using a the shift handle, move the adjusting...
Page 312 ELECTROMATIC SHIFT 8-53 Start the engine and observe the tattle- generator to maintain battery amperage and tale flow of water from relief in the voltage for efficient operation of the shift idle exhaust housing. The water pump installa- mechanism. When the key in the tion work is verified.
Page 313 8-54 LOWER UNIT completely disassembled, inspected, cause of the problem determined, and then propeller has been removed, file the drive corrected. pin holes on both sides of the shaft 2- Check for a broken shear pin by re- remove the burrs. moving the propeller.
Page 314 ELECTROMATIC SHIFT 8-55 4- Battery Check: Begin with a thor- ough check of the battery. Measure the gravity of the electrolyte in each cell by withdrawing only enough to lift the float. Take the reading at eye level. A fully charged battery cell should read 1.280;...
Page 315 8-56 LOWER UNIT leading to the ignition switch and from the switch for 12 volts. If the reading is less than 12 volts, the key switch is defective and should be replaced. 8- Shift Coil Tests: Disconnect Box and the blue and green shift wires at the rear of engine.
Page 316 ELECTROMATIC SHIFT 8-57 Pull the shift wire down through exhaust cover. Apply oil or soap onto the cable and remove the inner plate from the cable. 4- If the lower unit being serviced lower unit, force a wide blade chisel, stiff the 6-inch extension above the lower unit, remove the screws from the bottom side of...
Page 317 8-58 LOWER UNIT Remove the screws attaching water pump to the lower housing. If the screws are stubborn and refuse to release, or if they break off due to corrosion, it may be necessary to actually chisel the water pump free of the housing. Lift the water pump and impeller up off the driveshaft.
Page 318 ELECTROMATIC SHIFT 8-59 Separating the upper and lower portions the lower unit after the retaining bolts have been cut. 12- Clamp the lower unit by the skeg in sides, as shown. The lower housing can then a vise equipped with soft jaws, as shown. be separated from the upper housing.
Page 319 8-60 LOWER UNIT out and at the same time feed the reverse WARNING coil blue wire down into the recess in the The next step involves a dangerous pro- lower unit. Continue working the coil out cedure and should be executed with care and down the propeller shaft...
Page 320 ELECTROMATIC SHIFT 8-61 Using slide hammer to remove forward bearing race from the lower unit. professional mechanics use heat and drive the seal out. This method is very effective and adjacent parts are not harmed. Remove the O-ring f rom the bear ing case head. WORD OF ADVICE Professional mechanics...
Page 321 8-62 LOWER UNIT center of the bearing and determine if the new gear case head should be purchased and needles roll freely and smoothly. If there is installed. The new head will have a new no evidence of binding or roughness, bearing, O-ring, and seal installed...
Page 322 ELECTROMATIC SHIFT 8-63 bearing and the hub knurled to provide more positive engagement. The reverse gear assembly uses needle bearings and the hub is smooth. The greatest percentage motor operation in forward gear with the reverse gear turning in the opposite direc- tion, the needle bearings are used in the reverse gear hub for more satisfactory...
Page 323 8-64 LOWER UNIT of a Exploded drawing typical electric shift lower on 40 unit installed hp engines, with major parts identified.
Page 324 ELECTROMA TIC SHIFT 8-65 CLEANING INSPECTING Clean the parts with solvent and blow them dry with compressed air. Remove all seal and gasket material from mating sur- faces. Blow all water and oil passages, and screw holes clean with air. After the parts are clean and dry, apply a coating of light engine oil to the bearings and bright mating surfaces of the shafts and...
Page 325 8-66 LOWER UNIT Check the water pickup screen on the upper housing. Blow air through the screen to dislodge any debris. Clean the area behind the screen. Inspect the propeller for cracks, gouged, bent, or broken blades. Replace all bent, worn, corroded, or damaged parts.
Page 326 ELECTROMATIC SHIFT 8-67 WARNING in the slot of the bevel gear. The spacer MUST be positioned This next step can be dangerous. to encircle the cupped snap ring is placed under tremendous tension area in the opposite direction to the normal with the Truarc pliers while it is being...
Page 327 8-68 LOWER UNIT 7- TAKE NOTE of the ring at the top of the reverse hub used to retain the needle bear ings. The needle bearings are held in a cage. The correct number of needles will fill the cage. This ring is the only visible difference between the forward and reverse...
Page 328 ELECTROMATIC SHIFT 8-69 the square hole on top of the lower unit and also with the wire coming out the hole. 17- Lower the forward gear, hub, and spring assembly into the lower unit and over the forward coil. IS- Position the pinion gear into its re- No.
Page 329 8-10 LOWER UNIT placed into the groove. Therefore, wear SAFETY GLASSES exercise care prevent the snap ring from slipping out of the pliers. If the snap ring should slip out, it GOOD WORDS would travel with incredible speed and cause accompanying photographs were...
Page 330 ELECTROMATIC SHIFT 8-71 Bearing head screw with O-ring. A NEW O-ring should be installed each time the screw is removed during service work. The recess in the screw head must cleaned allow the O-ring seat properly. If the ring is left exposed, when the screw is tightened, "_l\~\ '-:::/ head...
Page 331 8-72 LOWER UNIT OMC needle bearing lubricant into the pin- ion gear race. Install the needle bearings in 30- Check to be sure the shift cable the outer race. retaining fork is over the hole as the stud 28- Coat the O-ring groove around the passes through retainer...
Page 332 ELECTROMATIC SHIFT 8-73 assume their natural and proper position inside the housing. Continue to rotate crivesbaf t and work the water pump housing 33- Install the Woodruff key into the recess in the driveshaft. Some models may downward until it is seated on the lower unit upper housing.
Page 333 8-74 LOWER UNIT O-RING GOOD WORDS Clean both lower unit water tubes with sandpaper. These tubes should be clean and shiny as an aid to mating the lower unit to the vent plug. Remove the gear lubricant the exhaust housing. If these tubes are not tube, and install the drain/fill plug.
Page 334 ELECTROMATIC SHIFT 8-75 lift the lower unit into place with the drive- shaft indexing wi th the crankshaft splines and the water tubes entering the exhaust housing grommets. It may be necessary to have an assistant rotate the flywheel ever so slowly and to pull the elec- CLOCKWISE...
Page 335 8-76 LOWER UNIT 44- Coat the propeller shaft with an anti-corrosion grease. Install the propeller with the drive pin holes aligned. Install the washer and drive pin. Slide the propeller the no-load condition on the propeller would cap into place and secure it with the cotter allow the engine to RUNAWAY resulting in pin.
Page 336 Once the engine starts the drive gear Three different type hand starters automatically disengages. Service proce- dures for both models of this starter be installed on the Johnson/Evinrude out- board engines covered in this manual. Each presented in Sections 9-2 and 9-3. type starter...
Page 337 30 hp, hp, and 40 hp Three models of this type starter may be engines. installed on various Johnson/Evinrude gines covered in this manual. OPERATION The first model contains pawls with re- turn springs, a center cone, and a...
Page 338 PINION GEAR 5 & 6 HP Three causes contribute to starter fail- The rewind spring made of spring ure. Two may be prevented, third steel. Depending on the model and the cannot. power head, from 6 feet to 12 feet of spring The most common problem is the result length is wound into about a 4- inch diame-...
Page 339 HAND STARTERS STARTER ROPE REPLACEMENT REMOVAL 1- Disconnect high-tension leads from the spark plugs. Ground the high- tension leads. Pull the starter rope out until it is fully Now, allow the rope to extended, retract just a little, until the knot end on the spool is facing the port side of the engine.
Page 340 PINION GEAR 5 & and at the same time remove pliers from under pinion gear. Allow the starter rope to rewind in a normal manner. After rope is fully wound onto starter spool, the rope handle should be up tight against the engine cowling.
Page 341 HAND STARTERS 2- The rope may be removed now, or 4- Remove the two retaining bolts on later. To remove the rope now, first pull top of the starter. the rope all the way out. Slide the handles 5- Loosen, DO NOT remove bolts on the bottom and on each side of the...
Page 342 PINION GEAR 5 & 6 HP DISASSEMBLING 6- Remove the pin in the piruon gear, and then remove the pinion gear from the collar. Slip the bearing head off the spool. Remove the retainer, installed under the pinion gear, from the starter. 7- Remove the spring retainer (the long tube) from the center of the spool.
Page 343 HAND STARTERS spring retainer. Work the spring upward until the inner spring tang engages the slot on t he bottom of the retainer. 2- Align the hole in the retainer with the hole in the spool sleeve. 3- Slip the bearing head and pinion gear down over the spool shaft.
Page 344 PINION GEAR 5 & 6 HP 6- Place the starter assembly in position on the engine and start two upper screws through the upper bearing support. Check to be sure the guide is in place in the bottom and top retainers. Tighten the two bottom retainer screws.
Page 345 9-10 HAND STARTERS 4A- Lower the spool assembly down over the spring and engage the spring retainer into the tang of the inner spring. Start the two upper screws through the upper bearing support. Check to be sure the guide is in place in the bottom and top retainers.
Page 346 PINION GEAR ALL 9.5 HP 9-11 TYPE I STAR TER CYLINDER WITH PINION GEAR 9- Bring the short end of the rope ALL 9.5 HP ENGINES through the loop just formed. Work the short end back through the This gear-drive starter is a new design anchor, as shown.
Page 347 9-12 HAND STARTERS engaged with the ring gear, and at the same time, slide the handles of a pair of pliers under the pinion gear to lock the pinion gear with the ring gear, as shown. 2- Remove the handle from the end of the starter rope.
Page 348 PINION GEAR ALL 9.5 HP 9-13 time, slide the handles of a pair of pliers under the pinion gear to lock the pinion gear with the ring gear, as shown. the block or come with the starter retainer 2- Remove the handle from the end of as the starter is removed.
Page 349 9-14 HAND STARTERS 8- Notice the cap on the bottom of the spool secured with a set screw. Remove the set screw from the cap, and then pull the cap and bushing from the spring. 9- Remove the spring retainer and outer Check the rope condition.
Page 350 PINION GEAR ALL 9.5 HP 9-15 4- Rotate inner spring until "hook" on the end of the spring seats in the groove of the spring retainer. Insert the assembled springs and re- tainer from Step 4, into the bottom of the spool.
Page 351 9-16 HAND STARTERS 9- Lower the spool assembly down into place on the side of the engine with the lower spring retainer indexed over the pin in the bottom portion of the housing. 10- Install the two bolts securing bearing head to the power head. Rope Purchase Instructions The length and diameter of the starter...
Page 352 SWING ARM DRIVE GEAR 9-17 The starter must be disassembled to re- place the rope. WARNING The rewind spring is under tremendous tension and is a potential hazard. There- fore, SAFETY GLASSES should be worn and extrem e CARE exercised to follow the pro- cedures carefully during disassembling...
Page 353 9-18 HAND STARTERS 5- Hold the starter together with one hand, and at the same time LOOSEN large bolt from the center of the starter. DO NOT remove this bolt at this time. Remove the starter from the engine. 2- Remove the knot tied in the rope in 6- If the starter is only removed in order Step 1.
Page 354 SWING ARM DRIVE GEAR 9-19 DISASSEMBLING 7- Remove idler gear arm, idler gear, and the idler gear arm spring. SAFETY WORDS The next step could be dangerous. moving the pulley from the cup MUST be done with care to prevent personal injury. 8- Lift the pulley SLIGHTLY and then...
Page 355 9-20 HAND STARTERS CLEANING INSPECTING Wash all parts except the rope in solvent and then blow them dry with compressed air. Remove any trace of corrosion and wipe all metal parts with an oil dampened cloth. Inspect the starter spring end loops. Re- place the spring if it is weak, corroded cracked.
Page 356 SWING ARM DRIVE GEAR 9-21 5- If the spring was NOT removed from the cup, lower the pulley down over the spring and insert the end of the spring into the spring anchor post of the pulley. If the spring removed from the cup, hook the end of the spring into the pulley and then allow the spring to come out the slot in the...
Page 357 9-22 HAND STARTERS 8- Install the screw through the idler down into the cup. If the rope becomes arm and into the exhaust manifold. DO NOT fully extended, before the spring is installed tighten this screw at this time. Apply a into the cup, allow the rope to rewind onto light coating of OMC Type A lubricant the pulley as far as possible and then wind...
Page 358 ATOP FLYWHEEL WITH SPRINGS 9-23 out, then feed it through the cowling at the front of the engine. Continue to pull the rope until about two feet is extending out through the cowling. Tie a slip knot in the rope. 11- Install the rubber bumper and handle onto the rope.
Page 359 9-24 HAND STARTERS STARTER REMOVAL 1- Disconnect any linkage between the hand starter and the carburetor. Remove the compression release linkage between the starter and the engine head. Move the linkage out of the way. Remove the starter leg retaining screws, and then lift...
Page 360 ATOP FLYWHEEL WITH SPRINGS 9-25 4- Lay the starter on its back on a work surface. Remove the three screws securing the pawl retainers to the pulley. Remove the three pawl springs, as shown. In the illustration, two springs have already been removed and the third is being removed.
Page 361 9-26 HAND STARTERS make contact with the floor, release grip on the pulley. The pulley will fall and the spring will be released from the housing, but the three legs will contain the spring and prevent from traveling across the room.
Page 362 ATOP FLYWHEEL WITH SPRINGS 9-27 STAR TER ASSEMBLING spring into the housing. Patience and time are required to work the spring completely into the housing. After the last portion is in GOOD WORDS place, bend the end of the spring towards The accompanying illustration shows a...
Page 363 9-28 HAND STARTERS A spring properly installed and seated on the spindle shoulder. 3- Slide the equalizer cup onto spindle. Work the spring around the outside diameter of the spindle. Lower the spindle assembly down through the pulley and index the pin into the hole in the housing.
Page 364 ATOP FLYWHEEL WITH SPRINGS 9-29 on the shoulder and the spindle installed COUNT- again. Rotate the pulley slightly ERcLocKwIsE and then release it to be sure there is proper engagement with the spr ing and pulley good spring tension. 5- Install the three pawls onto the three pins with the end of the pawls indexed in the three cutouts of the equalizer cup.
Page 365 9-30 HAND STARTERS ® pulley and housing in Step 8. Maintain some tension on the rope, remove the pin, and allow the spring to SLOWLY wind the rope onto the pulley. Check the bolt through the After three complete turns have been made, spindle to be sure it is tight.
Page 366 ATOP FLYWHEEL NO RETURN SPRINGS 9-31 9-6 TYPE III MOUNTED ATOP FLYWHEEL MODEL WITH NO RETURN SPRINGS 28 HP 1964 33 HP 1965-70 40 HP 1964-70 WARNING As with other types of hand starters, rewind spring is a potential hazard. spring is under tremendous tension when it is wound -- a real tiger in a cage.
Page 367 9-32 HAND STARTERS permit it to turn and thus allow the rope to wind back onto the pulley SLOWLY. Contin- ue to allow the spring in the pulley unwind SLOWLY until all tension has been released. 3- Remove the center bolt nut from the STARTER REMOVAL top side of the starter.
Page 368 ATOP FLYWHEEL NO RETURN SPRINGS 9-33 WARNING The rewind spring is a potential hazard. The spring is under tremendous tension when it is wound -- a real tiger in a cage. If the spring should accidentally be released, vere personal injury could result from being struck by the spring with force.
Page 369 9-34 HAND STARTERS Inspect the starter spring end loops. Re- will fall and the spring will be released from place the spring if it is weak, corroded or the housing, but the three legs will contain the spring and prevent it from traveling cracked.
Page 370 ATOP FLYWHEEL NO RETURN SPRINGS 9-35 A safe method is for one person remove hog rings while an assistant holds the spring. After the rings have been removed, both persons work to unwrap the spring, one coil at-a-time. 1- Slide the spring onto the outer and then start the spring from the outside edge of the housing and insert...
Page 371 9-36 HAND STARTERS 5- Install the nylon bushing onto the spindle with the protrusions on the bushing indexed into the slots in the spindle. Notice the pin protruding from the bottom of the spindle. This pin MUST drop into the hole in starter housing.
Page 372 ATOP FLYWHEEL NO RETURN SPRINGS 9-37 pulley slightly COUNTERCLOCKWISE, then release it to be sure the spring is properly engaged with the pulley and that the pulley has good spring tension. ROPE INSTALLATION Rope Purchase Instructions The length and diameter of the starter rope required will vary depending...
Page 373 9-38 HAND STARTERS the special tool is not available take a stiff piece of wire; insert it through the handle; thread it through the rope; apply just a little oil to the rope; then pull the wire and rope through the handle. Work the end of the rope into the handle anchor.
Page 374 ATOP FLYWHEEL WITH NYLON PAWL 9-39 wrong time. Such action would be a STARTER INSTALLATION BAD SCENE, a very BAD SCENE, because ser ious personal injury could result. 17- Position the starter over the fly- wheel with the three legs aligned over the The starter rope should NEVER be re-...
Page 375 9-40 HAND STARTERS marks on the engine. What is actually happening, is the engine is stopping with either the top piston at TOC (top dead center) or the bottom piston at the TOC position. Now, assume the engine has been operat- ing at idle speed and then suddenly stops for any number of reasons.
Page 376 ATOP FLYWHEEL WITH NYLON PAWL 9-41 the knot in the rope, and then hold the disc pulley, but permit it to turn and thus allow rope wind back onto pulley SLOWL Y. Continue to allow the spring in the pulley to unwind SLOWLY until all ten- sion has been released.
Page 377 9-42 HAND STARTERS make contact with the floor, release your grip. The pulley will fall and the spring will be released from the housing, but the three legs will contain the spring and prevent from traveling across the room. If the spring was not released from the housing, the only safe method...
Page 378 ATOP FLYWHEEL WITH NYLON PAWL 9-43 The end of the spring should be bent back toward the coil of the spring. Inspect the paw I for wear and that the edges are not rounded. Check the friction spring and link to be sure they are not distorted.
Page 379 9-44 HAND STARTERS with one hand and continue to wind the spring into the housing. Patience and time are required to work the spring completely into the housing. After the last portion is in place, bend the end of the spring towards the center of the housing.
Page 380 ATOP FLYWHEEL WITH NYLON PAWL 9-45 5- Install the friction spring and link and to be sure the pulley will rotate smoothly the nylon pawl onto the starter hub. and does not bind on the spindle. Rotate the friction spring fits into a groove in the...
Page 381 Further up on the pulley you will notice letter E (for Evinrude), On the Evinrude engines, the arrow must fall between the two marks on the pulley. If the arrow is not properly aligned the starter rope is not the proper length.
Page 382 MAl NTENANCE It is critical for an outboard engine to be 10-1 INTRODUCTION run at least once a month, preferably, in the The authors estimate 75% of engine re- water. At the same time, the shift mecha- pair work can be directly or indirectly nism should be operated through the full...
Page 383 10-2 MAINTENANCE lake. The outboard is carried only as a last the right side, when facing forward, is the resort -- in case the wind fails completely, starboard side; and the left side is the port or in an emergency situation. side.
Page 384 FIBERGLASS AND ALUMINUM HULLS 10-3 owner An aluminum boat ready for an engine. this type boat will probably carry it atop his vehicle saved the expense and trouble tro.ilering the water. I.UVn. the hull sustains a severe blow, the impact Simple drawing illustrate two types of possible...
Page 385 10-4 MAINTENANCE One of the advantages of an aluminum soaking covering until the growth hull is the easy maintenance program loosened. An easy alternate method, course, is to return the boat to the water, if quired, and the ability of the material resist corrosion.
Page 386 SUBMERGED ENGINE 10-5 If barnacles or other crustaceans have attached themselves to the hull, extra work will be required to bring the bottom back to a satisfactory condition. First, if practical, put the boat into a body of fresh water and allow it to remain for a ew days.
Page 387 10-6 MAINTENANCE Submerged While Running carburetor throat and, at the same time, crank the engine to distribute oil throughout Special Instructions If the engine was running when it was the crankcase. submerged, the chances of internal engine 9- With the engine still in a horizontal damage is greatly increased.
Page 388 WINTER STORAGE 10-7 13- If the engine fails to start, determine and melted snow to drain from the boat and the cause, electrical or fuel, correct prevent "trailer sinking". This term is used problem, and again attempt to get it run- to describe a boat that has filled with rain ning.
Page 389 10-8 MAINTENANCE Standard OMC fuel tank. During periods of storage the tank should be empty and the cap "cracked" open allow the tank "breathe tr • the fuel tank containing fuel to be stored for more than a month, a commercial addi- ve such as Sta-Bil should be added to the fuel.
Page 390 LOWER UNIT 10-9 4- Drain, and then fill the lower unit with OMC Lower Unit Gear Lubricant, outlined in Section 10-8. 5- Lubricate the throttle and shift link- age. Lubricate the swivel pin and the tilt tube with Multipurpose Lubricant, or equiv- alent.
Page 391 10-10 MAINTENANCE Propeller installation with shear pin and cotter pin extending through the propeller shaft. A rubber cap covers both pins. Propeller Removal Propeller with slot for the shear pin. The pin is On some model engines, the shear pin is inserted first, then the propeller is installed...
Page 392 LOWER UNIT 10-11 catch some with your fingers, from time-to- problem, the propeller hub has two grooves time, and rub it between your thumb and running the full length of the hub. Hold the finger to determine if any metal particles shaft from turning,...
Page 393 10-12 MAINTENANCE season will be used in the next or the one after. A small inexpensive pump can be be purchased to move the lubricant from the large container to the lower unit. Position drive unit approximately vertical and without a list to either port or starboard.
Page 394 PRE-SEASON PREPARATION 10-13 10-9 BATTERY STORAGE Remove the batteries from the boat and keep them charged during the storage peri- Clean the batteries thoroughly of any dirt or corrosion, and then charge them to full specific gravity reading. After they are fully charged, store them in a clean cool dry place where they will not be damaged knocked over.
Page 395 If a six-gallon fuel tank is used, by first removing the vent screw on the port side just above the anti-cavitation plate. Method of removing an O-ring from connector. OMC lubricants for Jor.nson/Evinrude outboards. The connector is also replaceable.
Page 396 PRE-SEASON PREPARA TION 10-15 Insert a short piece of wire into the hole and check the level. Fill the lower unit accord- ing to procedures outlined in Section 10-8. 4- Close all water drains. Check and replace any defective water hoses. Check to be sure the connections do not leak.
Page 397 10-16 MAINTENANCE 7- Check all electrical parts on the en- gine and electrical fixture or connections in the lower portions of the hull inside the boat to be sure they are not of a type that could cause ignition of an explosive atmosphere. Rubber caps help keep spark insulators clean and reduce the possibility of arcing.
Page 398 APPENDIX METRIC CONVERSION CHART LINEAR ENERGY OR WORK (watt-second - joule - newton- X 25.4 inches :: millimetres (mm) metre) feet X 0.3048 metres (rn) X 1.3558 .: joules (j) foot-pounds yards X 0.9144 :: metres (rn) calories :: joules (j) X 4.187 X 1.6093 miles...
Page 399 APPENDIX DRILL SIZE CONVERSION CHART SHOWING MILLIMETER SIZES, FRACTIONAL AND DECIMAL INCH SIZES AND NUMBER DRILL SIZES Frac- Milli· Dec. Milli· Dec. Num· Frae- Num- Milli· Dec. Frac- Num· Milli· Dec. Frae- Num· Milli· Dec. Frae- Equiv. tional Meter Equiv. tional Meter Equiv.
Page 400 APPENDIX POWERHEAD SPECIFICATIONS BORE BORE BORE PISTON TO CYL YEAR STROKE OVERSIZE OVERSIZE CLEARANCE 1.56 0.0025 0.0013 1968 1.37 0.020 1.56 0.004-3 1969 1.37 0.020 0.0055 0.004-3 0.020 0.0055 1970 1.37 1.56 1.37 0.002 1.56 0.020 0.0013 1956-67 0.0025 0.0013 1968 1.37 1.56...
Page 401 APPENDIX POWERHEAD SPECIFICATIONS PISTON RING YEAR PISTON RING GROOVE WIDTH OF RING 0.0925 0.015 0.005 1968 0.0035 0.0010 0.0935 0.0010 0.0625 0.0615 0.015 0.005 1969 0.0035 9170 0.0040 0.0020 0.0625 0.0615 0.015 0.005 0.015 0.005 1956-67 0.0035 0.0010 0.005 1968 0.0035 0.0010 0.0935...
Page 402 TUNE-UP SPECIFICATIONS 1> PAGE A-lO SEE GENERAL AND SPECIAL NOTES APPENDIX > " ' C JOHNSON MODEL EVINRUOE MODEL CU IN W T SPARK SHIFT PRIMARY PRIMARY PIU DISPL RPM PLUG REMOVAL PICKUP ADJUSTMENT Z TYPE NOTE LOCATION NOTE 1956 1956 1956 5.28...
Page 403 TUNE-UP SPECIFICATIONS SEE GENERAL AND SPECIAL NOTES APPENDIX PAGE A-I0 JOHNSON MODEL EVINRUDE MODEL CU IN W 0 T SPARK SHIFT PRIMARY PRIMARY Plu DISPL PLUG REMOVAL PICKUP ADJUSTMENT TYPE NOTE LOCATION NOTE 1960 1960 1960 3034-3036 JW-16 4000 5.28...
Page 404 TUNE-UP SPECIFICATIONS 1> SEE GENERAL AND SPECIAL NOTES APPENDIX PAGE A-lO JOHNSON MODEL EVINRUDE MODEL CU IN W 0 T SPARK SHIFT PRIMARY PRIMARY PIU » DISPL PLUG REMOVAL PICKUP ADJUSTMENT '"'0 TYPE NOTE LOCATION NOTE '"'0 1964 1964 1964 JW,JH-19 3402-12;...
Page 405 TUNE-UP SPECIFICATIONS SEE GENERAL AND SPECIAL NOTES APPENDIX PAGE A-IO JOHNSON MODEL EVINRUDE MODEL CU IN W 0 T SPARK SHIFT PRIMARY PRIMARY Plu DISPL PLUG REMOVAL PICKUP ADJUSTMENT TYPE NOTE LOCATION NOTE 1967 (Continued) 1967 (Continued) 1967 (Continued) 18702-03...
Page 406 1> TUNE-UP SPECIFICATIONS SHIFT PRIMARY PRIMARY PIU JOHNSON MODEL EVINRUDE MODEL NO. HP CU IN W 0 T SPARK » DISPL PLUG RElvl0VAL PICKUP ADJUSTMENT NOTE "'0 TYPE NOTE LOCATION "'0 1970 1970 1970 2.6l~ 1R-70 1002 4000 4R,4W-70 4006; 4036 5.28...
Page 407 APPENDIX A-I I GEAR OIL CAPACITIES MODEL ENGINE CAPACITY OUNCES SIZE 1.5 hp 1968-70 3.0 hp 1956-70 4.0 hp 1969-70 3.lt 4.0W hp 1969-70 5.0 hp 1965-68 1956-6lt 5.5 hp 6.0 hp 1965-70 7.5 hp 1956-58 1961t-70 9.5 hp 10 hp 10.0 1956-63 15 hp...
Page 408 A-12 APPENDIX STARTER MOTOR SPECIFICATIONS Brush Spring Armature Tension Model End Play Min. Max. Max. Min. (Inches) (Ounces) Volts Volts Lbs. Ft. Number Amperes Amperes MDO-O 4-2-66 0.005 min. 10.0 10,000 MDO-l 4-2-66 .010-.035 10.0 10,000 4-.0 MDW-O 4-2-66 .010-.035 10.0 8,500 4-.0...
Page 409 APPENDIX A-13 CONDENSER SPECIFICATIONS ENGINE CONDENSER MODEL OMC PART NO. CAPACITY SIZE 1.5 hp 580321 18-22 3.0 hp 580321 18-22 4.0 hp 580321 18-22 5.0 hp 580321 18-22 5.5 hp 580321 18-22 6.0 hp 18-22 580321 7.5 hp 580321 18-22 9.5 hp 580321 18-22...
Page 410 A-14 APPENDIX STARTER ROPE SPECIFICATIONS ENGINE SIZE MODEL DIAMETER LENGTH INCHES INCHES 1.5 hp 1968-70 382712 Note 2 3.0 hp 65-1/4- 1956-61 5/32 3.0 hp 1962-67 5/32 71-1/2 3.0 hp 0.130 1968 4-.0 hp 1969-70 0.130 5.0 hp 1965-67 0.130 5.0 hp 1968 0.130...
Page 411 APPENDIX A-15 WHITE SWITCH BLACK BLACK GREEN CHOKE SWITCH BLACK WIRE WIRE BLACK BATTERY CABLE (-NEG) SWITCH BATTERY CABLE CABLE (+POS.) CARBURETOR CHOKE SOLENOID WHITE GREEN PORT MOTOR BRACKET LOWER SCREW SOLENOID GROUND GROUND Wire Identification - and 25 hp - 1911-12...
Page 412 APPENDIX A-16 Wire Identification - hp with Generator - 1965-67...
Page 413 APPENDIX A-17 <C <.:::>...
Page 414 Wire Identification - 33 hp with Generator - 1969-70...
Page 415 APPENDIX A-19 Wire Identification - hp - 1957-59...
Page 416 A-20 APPENDIX Wire Identification - 40 hp Standard Shift with Generator - 1960-66...
Page 417 APPENDIX A-21 <:> Wire Identification - 40 hp Standard Shift with Generator - 1967-68...
Page 418 A-22 APPENDIX Wire Identification - 40 hp Standard Shift With Generator -1969-10...
Page 419 APPENDIX A-23 Wire Identification - Electric Shift with Generator - 40 hp 1961-66...
Page 420 A-24 APPENDIX <C '" • • Wire Identification - 40 hp Electric Shift with Generator - 1967-68...
Page 421 Identification - with Generator - Wire 40 hp Electric Shift 1969-70...
Page 422 NOTES & NUMBERS...

Evinrude 4906B 4HP 1969 Owner's Manual

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