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Johnson J2R4SUC 2007 Service Manual

2.5 hp 4 stroke
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Summary of Contents for Johnson J2R4SUC 2007

  • Page 3 DPL™ Lubricant QuikStart™ S.A.F.E.™ ® Evinrude ® ® S.L.O.W.™ Evinrude E-TEC ® ® Screw Lock™ Evinrude / Johnson XD30™ Outboard Oil ® ® SystemCheck™ Evinrude / Johnson XD50™ Outboard Oil ® ® ® Evinrude / Johnson XD100™ Outboard Oil Triple-Guard Grease Extreme Pressure Grease™...

  • Page 4: Table Of Contents

    CAUTION When replacement parts are required, use Evinrude/Johnson Genuine Parts or parts with Indicates a potentially hazardous situation equivalent characteristics, including type, strength which, if not avoided, MAY result in minor and material.

  • Page 5: Safety

    DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 6: Table Of Contents

    ABLE ONTENTS SECTION ........PAGE INTRODUCTION .
  • Page 7 INTRODUCTION INTRODUCTION CONTENTS MODELS COVERED IN THIS MANUAL ..........6 IDENTIFYING MODEL AND SERIAL NUMBERS .

  • Page 8: Models Covered In This Manual

    This manual covers service information on head. Johnson 2.5 HP 4-Stroke models. Use this man- ual together with the proper Parts Catalog for part numbers and for exploded views of the outboard, which are a valuable aid to disassembly and reas- sembly.

  • Page 9: Introduction

    INTRODUCTION MODEL DESIGNATION MODEL DESIGNATION STYLE: J = Johnson E = Evinrude MODEL RUN HORSEPOWER PREFIX 4-STROKE or SUFFIX J 2 R 4 SU MODEL YR: DESIGN FEATURES: I = 1 AP = Advanced Propulsion N = 2 B = Blue Paint...

  • Page 10: Typical Page - A

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

  • Page 11: Typical Page - B

    INTRODUCTION TYPICAL PAGE – B TYPICAL PAGE – B Section Title Section Title Subsection Title Section Title Model specific illustrations designated with image captions Products and Products and lubricants italicized lubricants italicized...

  • Page 12: Typical Page - C

    INTRODUCTION TYPICAL PAGE – C TYPICAL PAGE – C Title in italics indicates a procedure concerning a Denotes necessary particular model step or information to prevent damage or control correct Title indicates the procedure procedure specific to V4 Models is finished.

  • Page 13: Typical Page - D

    INTRODUCTION TYPICAL PAGE – D TYPICAL PAGE – D Illustration components Typical illustration for numbered to lower pulse hose of correspond to V4 or V6 Models image Cross references Cross references direct readers to direct readers to related topics related topics Section tabs allow for quicker reference when thumbing...

  • Page 14: Abbreviations Used In This Manual

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

  • Page 15: Product Reference And Illustrations

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

  • Page 16: Values

    INTRODUCTION SYMBOLS bol for ohm, the unit of measurement for resis- When “≥” precedes a value on the meter face, the tance. reading should be greater than, or equal to, the value shown. DR4205 DR4207 Values When “≤” precedes a value on the meter face, the reading should be less than, or equal to, the value shown.
  • Page 17 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SERVICE SPECIFICATIONS AND SPECIAL TOOLS TABLE OF CONTENTS TECHNICAL DATA ..............16 STANDARD TORQUE SPECIFICATIONS .

  • Page 18: Service Specifications And Special Tools

    87 AKI (R+M)/2 or 90 RON ® Fuel Conditioner, Fuel System Cleaner, Carbon Guard Use only Evinrude/Johnson recommended fuel additives. Additives The use of other additives may result in engine damage. See Fuel Requirements on p. 31 for additional information.

  • Page 19: Service Specifications And Special Tools

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS TECHNICAL DATA Thermostat opens 118 to 126°F (48 to 52°C) Type Transistorized RPM Limit 6500 RPM † CR6HSA @ 0.030 in. (0.76 mm) Spark Plugs Gap: 0.024 to 0.028 in. (0.6 to 0.7 mm) Ignition Timing 30°...

  • Page 20: Standard Torque Specifications

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS STANDARD TORQUE SPECIFICATIONS STANDARD TORQUE SPECIFICATIONS Tightening Torque – Important Fasteners THREAD TIGHTENING TORQUE ITEM DIAM. N·m kg-ft lb-ft Cylinder head cover bolt 5 mm Cylinder head bolt 6 mm Crankcase bolt 6 mm Connecting rod cap bolt 5 mm Valve adjusting lock nut 5 mm...

  • Page 21: Tightening Torque - General Bolt

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

  • Page 22: Special Tools

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS SPECIAL TOOLS Electrical / Ignition Digital multimeter DRC7265 CD Peak reading voltmeter 49799 Multimeter, analog 49793 Ohms resolution 0.01 P/N 507972 P/N 501873 Purchase through local supplier Ignition analyzer 49791 Spark checker 49798 Tachometer/timing light 49789 P/N 501890...

  • Page 23: Fuel And Oil

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Fuel and Oil Fuel/Oil pressure gauge 002275 Fuel vacuum tester 23286 Oil pressure test adapter 002623 P/N 5000902 P/N 390954 P/N 350930 Gearcase Gearcase filler 49790 Universal pinion bearing remover 33974 Installer handle 002575 P/N 501882 and installer kits P/N 5005927...

  • Page 24: Powerhead

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Powerhead Crankshaft holder 002587 Cylinder bore gauge 45303 Valve lifter adapter kit 002625 P/N 5034236 P/N 771310 P/N 5000899 Compression gauge adapter 005515 P/N 5037485 Tappet adjusting tool 38202 Valve spring compressor DRC50025 P/N 341444 P/N 346186 Crankshaft upper seal...

  • Page 25: Universal

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SPECIAL TOOLS Universal Puller Bridge P/N 432127 23146 Slide hammer P/N 391008 CO1577 Universal Puller Set P/N 378103 32885 Puller jaws (small) P/N 432131 23150 Slide hammer P/N 432128 15345 (replacement jaws P/N 437952) Puller jaws (large) P/N 432129 23148 Tie strap installation tool 18105...

  • Page 26: Shop Aids

    SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS SHOP AIDS Cleaning Solvent P/N 771087 Engine Tuner P/N 777185 Anti-Corrosion Spray P/N 777193 “6 in 1” Multi-Purpose Lubricant P/N 777192 D.P.L. Spray P/N 777183 Silicone spray P/N 775630 Ultra 4-Stroke Outboard Oil, P/N 775594 4-Stroke Outboard Oil, P/N 775597 HPF PRO™...
  • Page 27 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Moly Lube P/N 175356 Needle Bearing Grease, P/N 378642 Starter Bendix Lube P/N 337016 Storage Fogging Oil Power Trim/Tilt and Power Steering Fluid Adhesive 847 P/N 776964 P/N 777186 P/N 775612 Lubriplate† 777 P/N 317619 Black Neoprene Dip P/N 909570 Electrical Grease P/N 504824 2 + 4™...
  • Page 28 SERVICE SPECIFICATIONS AND SPECIAL TOOLS SHOP AIDS Gasket Sealing Compound P/N 317201 † † ThreeBond 1104, P/N 351052 Permatex No. 2, P/N 910032 ThreeBond 1207B, P/N 351053 † Pipe Sealant with Teflon P/N 910048 Thermal Joint Compound P/N 322170 RTV Silicone Sealant P/N 263753 †...
  • Page 29 INSTALLATION AND PREDELIVERY INSTALLATION AND PREDELIVERY TABLE OF CONTENTS HULL PREPARATION ............. . . 28 .

  • Page 30: Hull Preparation

    INSTALLATION AND PREDELIVERY HULL PREPARATION HULL PREPARATION Top Edge of Transom or Bracket Transom thickness or off-sets must also be con- Maximum Capacity sidered. The top edge of the transom or bracket must provide a proper surface for stern brackets. WARNING The stern brackets must contact the flat surface of the transom or bracket.

  • Page 31: Installation And Predelivery

    INSTALLATION AND PREDELIVERY TRANSOM MEASURING AND DRILLING TRANSOM MEASURING Transom Heights Make sure the transom height is consistent with AND DRILLING the height of the outboard to be installed. • A 19 to 21 in. (48.3 to 53.3 cm) transom height Hull Centerline uses a 20 in.

  • Page 32: Lifting The Outboard

    INSTALLATION AND PREDELIVERY OUTBOARD MOUNTING Lifting the Outboard OUTBOARD MOUNTING Lift the outboard using the lift grips (NOT the tilt Fastening the Outboard to the Transom grip or steering handle) and place it in the center of the boat’s transom. WARNING The outboard must be correctly installed.

  • Page 33: Fuel And Oil

    Minimum Octane Evinrude/Johnson outboards are certified to oper- ate on unleaded automotive gasoline with an octane rating equal to or higher than: •...

  • Page 34: Oil Requirements

    IMPORTANT: During the initial 10-hour break-in cause corrosion of metallic parts in the fuel sys- tem. period, use Evinrude/Johnson 4-Stroke Outboard • Alcohol blended fuel can cause engine perfor- Oil or SAE 10W-40, API SE, SF, SG, SH, or SJ mance problems.

  • Page 35: Running Checks

    INSTALLATION AND PREDELIVERY RUNNING CHECKS RUNNING CHECKS IMPORTANT: DO NOT perform break-in using a flushing device. DO NOT start-up or run the engine out of water. DO NOT leave a running WARNING engine unattended. DO NOT run outboard without a water sup- During the break-in, check water pump operation ply to the outboard’s cooling system.

  • Page 36: Fuel System

    INSTALLATION AND PREDELIVERY RUNNING CHECKS Fuel System Water Pump Overboard Indicator Perform running checks of the fuel system by fol- A steady stream of water should flow from the lowing these steps: overboard indicator. • Start outboard. Visually inspect all oil hoses and connections and fuel hoses and connections.

  • Page 37: Propeller Selection

    INSTALLATION AND PREDELIVERY PROPELLER SELECTION PROPELLER SELECTION Procedure The propeller selection process is very important Refer to Propeller Hardware Installation on to the engine’s service life and to boat perfor- p. 36 before installing propeller. mance. Proceed carefully and thoroughly while considering the following points: The correct propeller, under normal load condi- •...

  • Page 38: Propeller Hardware Installation

    INSTALLATION AND PREDELIVERY PROPELLER SELECTION Propeller Hardware Installation WARNING When servicing the propeller, always shift the outboard to NEUTRAL, turn the key switch OFF, and twist and remove all spark plug leads so the engine cannot be started accidentally. Apply Triple-Guard grease to the entire propeller shaft before installing the propeller.
  • Page 39 MAINTENANCE MAINTENANCE TABLE OF CONTENTS INSPECTION AND MAINTENANCE SCHEDULE ......... 38 10-HOUR INSPECTION .

  • Page 40: Inspection And Maintenance Schedule

    MAINTENANCE INSPECTION AND MAINTENANCE SCHEDULE INSPECTION AND MAINTENANCE SCHEDULE Routine inspection and maintenance is necessary for all mechanized products. Periodic maintenance contributes to the product’s life span. The following chart provides guidelines for outboard inspection and maintenance to be performed by an authorized Dealer. IMPORTANT: Outboards used for rental operations, commercial applications, or other high hour use applications require more frequent inspections and maintenance.

  • Page 41: Maintenance

    (1) Also recommended at 10-Hour Inspection (2) Replace every 100 hours or annually if Ultra 4-Stroke oil is not used. (3) Emission-related component Evinrude/Johnson Anti-Corrosion Spray or Evinrude/Johnson “6 in 1” Multi-Purpose Lubricant HPF XR Gearcase Lubricant Power Trim/Tilt and Power Steering Fluid...

  • Page 42: 10-Hour Inspection

    10-HOUR INSPECTION 10-HOUR INSPECTION ANTI-CORROSION PROTECTION IMPORTANT: All Johnson outboard owners are encouraged to return their new engines to an authorized dealer for a mechanical check. Sacrificial Anodes Galvanic corrosion occurs in fresh or salt water. This check should be performed after approxi- Salt, brackish, and polluted water can accelerate mately 10 operating hours.

  • Page 43: Testing Procedure - Continuity

    MAINTENANCE ANTI-CORROSION PROTECTION For best anode performance: Metallic Component Protection • Replace all anodes that have eroded or disinte- Protect metal components on outboards from cor- grated to two-thirds of their original size. rosion. Use the following products to minimize •...

  • Page 44: Cooling System

    MAINTENANCE COOLING SYSTEM COOLING SYSTEM IMPORTANT: To prevent damage, do not run outboard above fast idle. Water must flow from Check the condition of cooling system compo- the water pump indicator. If it does not, shut off nents regularly. The outboard cooling system con- the outboard and repair as needed.

  • Page 45: Fuel System

    MAINTENANCE FUEL SYSTEM FUEL SYSTEM LUBRICATION Breather and Fuel Line Engine Oil If leakage, cracks, swelling, or other damage is Refer to INSPECTION AND MAINTENANCE found, replace the breather and/or the fuel line. SCHEDULE on p. 38 for oil change schedule. IMPORTANT: Engine oil should be changed while engine is warm.

  • Page 46: Gearcase Lubricant

    Always check the fill level of the gearcase lubricant prior to removing drain/fill plug. Recommended oil: A tie strap can be used to check lubricant level. • Evinrude/Johnson Ultra 4-Stroke oil, or • SAE 10W-40, API classification SE, SF, SG, SH, SJ. Oil amount: •...

  • Page 47: Linkages And Fittings

    MAINTENANCE LUBRICATION Linkages and Fittings Apply Triple-Guard grease to the points shown. Throttle cable Swivel bracket Clamp screws Propeller shaft WARNING When servicing the propeller, always shift the outboard to NEUTRAL position, and twist and remove all spark plug leads so the engine cannot be started accidentally.

  • Page 48: Spark Plug

    MAINTENANCE SPARK PLUG SPARK PLUG VALVE CLEARANCE The spark plug should be removed and examined Measurement periodically. Replace worn, fouled or damaged Remove engine cover. spark plug. • Remove spark plug and inspect condition. Remove recoil starter. Refer to starter REMOVAL •...

  • Page 49: Adjustment

    MAINTENANCE VALVE CLEARANCE Use a feeler gauge to measure clearance Adjustment between valve stem end and valve adjusting Loosen the valve adjusting lock nut while holding screw on rocker arm. the valve adjusting screw. valve clearance Turn valve adjusting screw using to bring valve clearance within specification.

  • Page 50: Idle Speed

    MAINTENANCE IDLE SPEED Tighten the four cylinder head screws to 5 ft. lbs. Untie the knot in grip holder and remove the grip (7 N·m). holder and starter grip. 1. Screw (4) 005896 005942 IMPORTANT: Completely remove the engine cover. re-use gasket once...

  • Page 51: Ignition Timing

    MAINTENANCE IGNITION TIMING IGNITION TIMING Start and warm the engine. Engine idle speed: IMPORTANT: Before checking ignition timing, • 1800 to 2000 RPM make sure idle speed is adjusted within specifica- tion. IMPORTANT: Check and/or adjust idle speed after the engine speed has stabilized. Start and warm the engine.

  • Page 52: Storage

    Failure to check for fuel leakage could p. 38. allow a leak to go undetected, resulting in fire or explosion. Use Evinrude/Johnson Storage Fogging Oil to prevent corrosion of internal engine components during periods of storage. Remove spark plugs and spray a liberal amount of Evinrude/Johnson Storage Fogging Oil into the spark plug hole.

  • Page 53: Pre-Season Service

    MAINTENANCE PRE-SEASON SERVICE PRE-SEASON SERVICE SUBMERGED ENGINES If the outboard was removed from the boat for Once an outboard has been submerged in fresh storage, make certain it has been reinstalled with or salt water, it must be serviced within three (3) factory specified hardware.
  • Page 54 MAINTENANCE SUBMERGED ENGINES Disconnect fuel supply hose from outboard. Drain and clean all fuel hoses, filters, and fuel tanks. Refill fuel tank with fresh fuel. Inject a small amount of outboard lubricant into spark plug holes and install new spark plugs. Reinstall all removed or disconnected parts.
  • Page 55 IGNITION AND ELECTRICAL IGNITION AND ELECTRICAL TABLE OF CONTENTS SERVICE CHART ..............54 OPERATION .

  • Page 56: Service Chart

    IGNITION AND ELECTRICAL SERVICE CHART SERVICE CHART 1. Flywheel 2. Ignition coil 3. Bolt 4. Nut 5. Key 6. Cap, spark plug 7. Seal, spark plug 8. Seal, high tension cord 9. Switch assembly, emergency 10. Plate, lock 11. Nut 12.

  • Page 57: Operation

    IGNITION AND ELECTRICAL OPERATION OPERATION The outboard uses a transistorized ignition circuit. The ignition system consists of a flywheel magneto, an igniter unit, a spark plug and an emergency stop switch. Igniter Flywheel unit magneto Spark plug Emergency stop switch...
  • Page 58 IGNITION AND ELECTRICAL OPERATION When the recoil starter is pulled, the flywheel is turned. An electromotive force generated in the primary winding (n ) of the ignition coil makes the transistor (TR ) conduct through the resistor (R ) and forms the primary circuit (indicated by dashed lines).

  • Page 59: Troubleshooting

    IGNITION AND ELECTRICAL TROUBLESHOOTING TROUBLESHOOTING Perform the following ignition system tests when engine is hard to start to determine if the cause is in the ignition or other system. The cause is not in the ignition START system Check ignition timing by Sparks Check spark condition.

  • Page 60: Ignition Tests

    IGNITION AND ELECTRICAL IGNITION TESTS IGNITION TESTS Spark Plug Cap Resistance Test Igniter Unit Measure spark plug cap resistance. Resistance Test Spark plug cap resistance: Ω Remove the spark plug cap from the high-tension • 8 to 12 k cord. Connect Ohmmeter test probes to igniter unit coils as shown: Tester probe connection...

  • Page 61: Component Servicing

    IGNITION AND ELECTRICAL COMPONENT SERVICING COMPONENT Use strap-type flywheel holder, P/N 507976, or equivalent to loosen the flywheel nut. SERVICING IMPORTANT: Do not remove the flywheel nut. It prevents damage to the crankshaft when using Igniter Air Gap flywheel remover tools. Use a thickness gauge to measure the air gap between the flywheel and the igniter unit: •...

  • Page 62: Installation

    IGNITION AND ELECTRICAL COMPONENT SERVICING Remove the flywheel nut, starter pulley, flywheel, Igniter Unit and key. Install the igniter unit with an air gap of 0.02 in. (0.5 mm) between both core ends and the fly- wheel. Check the gaps as shown. 005955 Tighten igniter unit bolts to 7.0 ft.
  • Page 63 FUEL SYSTEM FUEL SYSTEM TABLE OF CONTENTS SERVICE CHART ..............62 REMOVAL .

  • Page 64: Service Chart

    FUEL SYSTEM SERVICE CHART SERVICE CHART 1. Carburetor 2. Nozzle, main 3. Jet, main (68) Jet, main (70) Jet, main (72) 4. Valve, needle 5. Float 6. Pin, float 7. Spring 8. Gasket 9. Chamber, float 10. Gasket 11. Screw 12.

  • Page 65: Fuel System

    FUEL SYSTEM 1. Tank, fuel 2. Bracket, fuel tank 3. Cap assembly, fuel tank 4. Gasket, tank cap 5. Cushion 6. Grommet, fuel tank 7. Rubber, fuel tank grommet 8. Valve assembly, fuel 9. Clip, fuel hose 10. Hose, fuel (valve to carb) EPC4224...

  • Page 66: Removal

    FUEL SYSTEM REMOVAL REMOVAL Remove the two bolts securing the carburetor. WARNING Gasoline is extremely flammable and highly explosive under certain conditions. Use caution when working on any part of the fuel system. Do not smoke, or allow open flames or sparks, or use electrical devices such as cellular phones in the vicinity of a fuel leak or while fueling.

  • Page 67: Carburetor

    FUEL SYSTEM CARBURETOR CARBURETOR Remove the pilot jet. Disassembly Remove the idle adjusting screw and the four screws securing the plate. 1. Pilot jet 005975 Remove the bolt and the float chamber. 1. Idle adjusting screw 005973 2. Screw (4) 3.

  • Page 68: Cleaning And Inspection

    FUEL SYSTEM CARBURETOR Remove the needle valve from the float. Cleaning and Inspection Clean carburetor components thoroughly with cleaning solvent and compressed air before inspection. WARNING Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172 kPa).

  • Page 69: Reassembly

    FUEL SYSTEM CARBURETOR Needle Valve Install the main nozzle to the carburetor body before installing the main jet. Inspect the needle valve. If broken tip or wear is found, replace the valve. 1. Main nozzle 005986 2. Main jet 005987 005984 Install the float with needle valve.

  • Page 70: Installation

    FUEL SYSTEM INSTALLATION IMPORTANT: INSTALLATION After installing float, inspect for smooth movement of float. Installation is reverse order of removal with spe- cial attention to the following steps. 1. Spring 005978 Checking Float Height Measure the float height. 005970 • Float height: 10 ±...

  • Page 71: Leakage Check

    FUEL SYSTEM INSTALLATION Leakage Check Throttle Adjustment Twist the air-vent screw on the fuel tank cap coun- Fully close the throttle control grip. terclockwise to open the vent. Turn the idle adjusting screw counterclockwise until the screw does not touch the stopper plate. 005966 1.

  • Page 72: Fuel Tank

    FUEL SYSTEM FUEL TANK FUEL TANK Remove the fuel tank. Removal Remove the motor cover. Remove the recoil starter. Refer to MANUAL STARTER on p. 139. 1. Fuel tank 005995 Loosen the connecting screw and remove the fuel cock from the fuel tank. 1.

  • Page 73: Installation

    FUEL SYSTEM FUEL TANK Inspect the fuel tank. If crack, leakage, or deterio- Installation ration is found, replace the tank. Installation is reverse order of removal with spe- cial attention to the following steps. If water or other contamination is found, drain and clean the tank.

  • Page 74: Notes

    FUEL SYSTEM NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 75 POWERHEAD POWERHEAD TABLE OF CONTENTS SPECIFICATIONS ..............74 COMPRESSION TESTING .

  • Page 76: Specifications

    POWERHEAD SPECIFICATIONS SPECIFICATIONS Data Item Unit 2.5 HP CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Cam height mm (in) 28.480 – 28.680 (1.1213 – 1.1291) IN, EX Limit mm (in) 28.180 (1.1094) Rocker arm shaft hole mm (in) 4.015 –...

  • Page 77: Powerhead

    POWERHEAD SPECIFICATIONS Data Item Unit 2.5 HP CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) Piston to cylinder mm (in) 0.018 – 0.033 (0.0007 – 0.0013) clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 48.000 –...

  • Page 78: Compression Testing

    POWERHEAD COMPRESSION TESTING COMPRESSION TESTING IMPORTANT: The values shown are guidelines only, not absolute service limits. Start and run outboard until it achieves operating Cylinder Compression Test temperature, then shut OFF. 137 to 199 psi Standard (960 to 1400 kPa) Remove spark plug.

  • Page 79: Removal

    POWERHEAD REMOVAL REMOVAL Detach the powerhead and lower cover. Remove the four lower cover bolts, then detach Before removing the powerhead: the powerhead from the lower cover. • Drain the engine oil. Refer to Engine Oil on p. 43. • Shift into “NEUTRAL”...

  • Page 80: Cylinder Head

    POWERHEAD CYLINDER HEAD CYLINDER HEAD Remove the valve adjusting lock nuts, then the valve adjusting screw. Remove the rocker arm shaft and the rocker arms. Disassembly Remove the two bolts, intake manifold, and insu- lator. 1. Lock nut (2) 006012 2.
  • Page 81 POWERHEAD CYLINDER HEAD Remove the retainers. Remove the intake valve and exhaust valve. 1. Retainer (2) 006023 1. Intake valve 006026 2. Exhaust valve IMPORTANT: To remove the retainer, move it Remove the valve stem seals. in the direction shown, and force it off the valve shaft.

  • Page 82: Cleaning And Inspection

    POWERHEAD CYLINDER HEAD Cleaning and Inspection Cylinder Head Distortion Using a straightedge and thickness gauge, mea- IMPORTANT: If any excessive wear, cracks, sure the gasket surface of the cylinder head at six defects, or other damage is found on any compo- locations as shown.
  • Page 83 POWERHEAD CYLINDER HEAD Water Jacket Rocker arm shaft hole diameter: • 0.1581 to 0.1585 in. (4.015 to 4.027 mm) Inspect the water jacket for clogs or obstructions. Clean the water jackets if necessary. 006034 006032 Measure the rocker arm shaft diameter. Rocker Arm and Shaft Rocker arm shaft outside diameter: Inspect the rocker arms and shaft for wear, bends,...
  • Page 84 POWERHEAD CYLINDER HEAD Valve and Valve Guide If the measurement exceeds the service limit, replace the valve and/or the cylinder head. Using a micrometer and a small bore gauge, mea- sure the diameters on the valve stems and the If unable to measure the valve guide inside diam- guides in order to check the guide to stem clear- eter, measure the valve stem deflection.
  • Page 85 POWERHEAD CYLINDER HEAD Valve Stem Runout Valve Head Thickness Measure the valve stem runout. Measure the thickness of the valve head. 006041 Valve stem runout: Valve head thickness: • • 0.002 in. (0.05 mm) IN / EX: 0.02 in. (0.5 mm) If the measurement exceeds the service limit, If the measurement exceeds the service limit, replace the valve.

  • Page 86: Assembly

    POWERHEAD CYLINDER HEAD Measure the valve seat contact width. If the measurement exceeds the service limit, replace the valve spring. Valve Spring Preload Measure the valve spring preload. 1. Valve seat contact area 006045 Valve seat contact width: • IN / EX: 0.03 to 0.04 in. (0.8 to 1.0 mm) 006048 If measurement exceeds specification, repair valve seat.
  • Page 87 POWERHEAD CYLINDER HEAD Apply engine oil to the valve guide bore and valve the retainer, and let it slide sidewise into the cen- stem. ter hole. Install the valves in the valve guides. 1. Side hole 006052 1. Valve (2) 006050 Make sure the retainers are properly seated in groove.

  • Page 88: Installation

    POWERHEAD CYLINDER HEAD Installation Install the push rods onto the cam rocker arms. Insert the dowel pins and place a new cylinder head gasket into position on cylinder. 1. Push rod (2) 006019 2. Cam rocker arms 006020 Install the rocker arms and the rocker arm shaft. 1.

  • Page 89: Cylinder/Crankcase/Piston

    POWERHEAD CYLINDER/CRANKCASE/PISTON CYLINDER/CRANKCASE/ Remove the thrust washer. PISTON Disassembly Remove the powerhead. Refer to REMOVAL on p. 77. Remove the cylinder head. Refer to CYLINDER HEAD on p. 78. Remove the bolt and the under oil seal plate. 1. Thrust washer 006056 Remove the cam rocker arm, washer, cam rocker arm, spring, washer, and shaft.
  • Page 90 POWERHEAD CYLINDER/CRANKCASE/PISTON Remove the two connecting rod bolts and the con- Remove the circlips, the piston pin, the connecting necting rod cap. rod, and the piston rings from the piston. 1. Bolt (2) 006059 1. Circlips 006062 2. Connecting rod cap 2.

  • Page 91: Inspection

    POWERHEAD CYLINDER/CRANKCASE/PISTON Remove the four bolts and the thermostat cover. Remove a screw and the reed valve. 1. Thermostat cover 006065 1. Screw 006068 2. Reed valve Remove the thermostat. Inspection IMPORTANT: If excessive wear, crack, defec- tive or other damage is found on any component, replace.
  • Page 92 POWERHEAD CYLINDER/CRANKCASE/PISTON Inspect the camshaft gear for wear or other dam- Cylinder distortion: age. Replace, if necessary. • Service limit: 0.002 in. (0.05 mm) If the measurement exceeds the service limit, resurface or replace the cylinder. 006070 Cam Rocker Arm 006073 Inspect the cam rocker arm for wear or other dam- age.
  • Page 93 POWERHEAD CYLINDER/CRANKCASE/PISTON Measure the cylinder bore in the thrust and axial Cylinder bore: directions at the three position depths. • 1.8898 to 1.8904 in. (48.000 to 48.015 mm) Piston skirt diameter: • 1.8888 to 1.8894 in. (47.975 to 47.990 mm) Oversize piston and piston rings are marked as shown.
  • Page 94 POWERHEAD CYLINDER/CRANKCASE/PISTON IMPORTANT: Measure the piston ring end gap with the piston The piston grooves must be ring in the lowest position of the cylinder bore. clean, dry and free of carbon before checking clearance. Fit the piston ring into the piston groove, and mea- sure the clearance between the ring and the ring groove using the thickness gauge.
  • Page 95 POWERHEAD CYLINDER/CRANKCASE/PISTON Piston Pin Clearance Connecting Rod Big End Side Clearance To check the clearance, measure: Measure the clearance with the connecting rod • installed on the crank pin as shown in the figure. Piston pin outside diameter in the thrust and axial directions.
  • Page 96 POWERHEAD CYLINDER/CRANKCASE/PISTON Crank pin outside diameter difference (out-of- Remove the connecting rod and the connecting round and taper): rod cap from the crank pin. Measure the clear- • ance. Service limit – 0.0004 in. (0.010 mm) Connecting rod big end oil clearance: If the out-of-round or the taper exceeds the ser- •...
  • Page 97 POWERHEAD CYLINDER/CRANKCASE/PISTON Visually check the crankshaft upper bearing for Drive the oil seal down into position as shown. pitting, roughness, or other damage. Inside crankcase 1. Crankshaft upper oil seal 006099 006100 006096 If no damage is found on the oil seals or bearing, do not remove either.

  • Page 98: Assembly

    POWERHEAD CYLINDER/CRANKCASE/PISTON Assembly Make sure that the connecting rod is installed in the direction shown. Install the circlips with a gap Assembly is reverse order of disassembly with facing either up or down as shown. special attention to the following steps. If the original components are not replaced, each Mark piston, piston pin, and connecting rod is to be...
  • Page 99 POWERHEAD CYLINDER/CRANKCASE/PISTON IMPORTANT: Ring Gap Direction When installing the spacer, do not allow the ends to overlap in the groove. Position the piston rings so the ring gaps are stag- gered at approximately 90 degree angles. incorrect Mark correct 006108 1.
  • Page 100 POWERHEAD CYLINDER/CRANKCASE/PISTON Insert the piston/connecting rod assembly into the Install the connecting rod cap in the direction cylinder bore from the cylinder head side using a shown. piston ring compressor. 006119 Apply engine oil lightly to the connecting rod bolts. 006116 Tighten the two connecting rod bolts in two steps: •...
  • Page 101 POWERHEAD CYLINDER/CRANKCASE/PISTON While aligning each mark on the camshaft gear IMPORTANT: Be sure the cam rocker arms are and the crankshaft gear, install the camshaft. positioned as shown. Mark Mark 006122 006125 Cam Rocker Arm Oil Pump Apply engine oil to the cam rocker arm shaft. Apply engine oil to the inner rotor and the outer Install the washer and the spring on the shaft as rotor.
  • Page 102 POWERHEAD CYLINDER/CRANKCASE/PISTON Install the oil pump shaft. Apply engine oil to the crankcase bearing, the crankshaft lower oil seal and the driveshaft oil seal. 1. Oil pump shaft 006128 Crankcase to Cylinder 006130 006131 Clean the mating surfaces of the cylinder block and the crankcase.

  • Page 103: Thermostat

    POWERHEAD THERMOSTAT THERMOSTAT Breather Plate and Thermostat Install the reed valve on the cylinder block and Removal secure with a screw. Remove the recoil starter assembly. Refer to MANUAL STARTER on p. 139. Remove the four bolts and thermostat cover. 1.

  • Page 104: Installation

    POWERHEAD THERMOSTAT Insert a length of thread between the thermostat Apply silicone sealant to both surfaces of thermo- valve/body and suspend the thermostat in a con- stat cover gasket (as shown in shaded areas). tainer filled with water. Place the thermometer in the container and heat water.

  • Page 105: Installation

    POWERHEAD INSTALLATION INSTALLATION Secure the powerhead to the lower cover and tighten the four bolts to the specified torque: • 6.0 ft. lbs. (8 N·m) Installation is reverse order of removal with spe- cial attention to the following steps. Install the two dowel pins and gasket on the drive- shaft housing.

  • Page 106: Flywheel

    POWERHEAD INSTALLATION Flywheel Final Assembly Check Install the flywheel magneto. Refer to Flywheel Perform the following checks in order to ensure on p. 60. proper and safe operation of the outboard. • All parts removed have been returned to the Tighten the flywheel nut to the specified torque: original positions.

  • Page 107: Water Cooling System

    POWERHEAD WATER COOLING SYSTEM WATER COOLING SYSTEM The water cooling system consists of the water pump (in the midsection), the water tube (between the midsection and the powerhead) and the thermostat (in the cylinder). This system cools both the power- head and the exhaust.

  • Page 108: Engine Lubrication System

    POWERHEAD ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM A camshaft driven trochoid-type pump provides lubrication to all required powerhead components. Crankshaft upper bearing Cylinder head Valve train Cylinder block · Connecting rod · Piston · Timing gear · Lower bearing Oil pump Lower crankcase (Oil pan) ENGINE OIL...
  • Page 109 MIDSECTION MIDSECTION TABLE OF CONTENTS SERVICE CHART ..............108 REMOVAL .

  • Page 110: Service Chart

    MIDSECTION SERVICE CHART SERVICE CHART ILLER ANDLE AND RIVESHAFT OUSING 1. Handle, tiller 2. Grip, throttle 3. Spacer, tiller handle 4. Bushing, tiller handle 5. Mount, tiller handle 6. Washer, tiller handle 7. Bolt, handle pivot 8. Knob, throttle adjust 9.

  • Page 111: Midsection

    MIDSECTION SERVICE CHART SERVICE CHART TERN RACKET AND WIVEL RACKET 1. Bracket, clamp 2. Handle, clamp 1. Bracket, swivel port 3. Plate, clamp 2. Bracket, swivel starboard 4. Cap, clamp screw 3. Bushing, steering upper 5. Spacer, tilt lock 4. Bolt, swivel bracket 6.

  • Page 112: Removal

    MIDSECTION REMOVAL REMOVAL Remove the swivel shaft nut and swivel shaft washer. Remove the powerhead. Refer to POWERHEAD on p. 73. Remove the gearcase. Refer to GEARCASE on p. 119. Remove the water tube with the grommet upside. 1. Nut 006148 2.

  • Page 113: Clamp Bracket

    MIDSECTION REMOVAL Remove the starboard side clamp bracket, the tilt Take out the steering adjuster plate with the steer- friction washer and the swivel shaft bolt. ing adjuster rubber. 1. Side clamp bracket – starboard 006162 1. Adjuster plate 006165 2.

  • Page 114: Tiller Handle

    MIDSECTION REMOVAL Take out the upper steering bushings from the Remove the igniter unit bolt and ground lead of driveshaft housing. the emergency/engine stop switch. Remove the plus lead of the emergency/engine stop switch from the igniter unit. 1. Upper steering bushing (2) 006168 Tiller Handle 1.
  • Page 115 MIDSECTION REMOVAL Remove the washer, two tiller handle bushings, Take out the throttle lower case and the throttle tiller handle mount, and tiller handle spacer from upper case from the tiller handle. the tiller handle. 1. Lower case 006194 2. Upper case 1.

  • Page 116: Inspection

    MIDSECTION INSPECTION INSPECTION Steering Upper Bushing Inspect the upper bushings. IMPORTANT: If excessive wear, crack, defec- tive or other damage is found on any component, replace. Driveshaft Housing If crack or other damage is found, replace. 006171 Stopper Bracket/Stopper Spring Inspect the stopper bracket and the stopper spring.

  • Page 117: Assembly

    MIDSECTION ASSEMBLY ASSEMBLY Swivel Shaft Bolt Inspect the swivel shaft bolt. Reassembly is reverse order of disassembly with special attention to the following steps. Swivel Bracket After completing reassembly of the midsection, apply Triple-Guard grease through grease nipple. Apply Triple-Guard grease to the following parts: •...

  • Page 118: Clamp Bracket

    MIDSECTION ASSEMBLY Install the steering adjuster rubber with the steer- Install the thrust block with the lower thrust mount ing adjuster plate. and the tilt lock bolt. 1. Adjuster rubber 006178 1. Thrust block 006181 2. Adjuster plate 2. Bolt Install the swivel port bracket.

  • Page 119: Lubrication

    MIDSECTION ASSEMBLY Install the tilt lock spacer and the tilt lock wing nut. Install the throttle handle spacer and the throttle Install the tilt lock pin to the tilt lock bolt. handle bushings. 1. Spacer 006184 1. Spacer 006198 2. Wing nut 2.
  • Page 120 MIDSECTION ASSEMBLY Install throttle cable to the throttle cable holder. Install throttle cable to the carburetor. 1. Throttle cable 006201 2. Holder 3. Carburetor 4. Choke rod connector 5. Choke rod Check that the throttle control operates smoothly from the fully closed position to the fully opened position.
  • Page 121 GEARCASE GEARCASE TABLE OF CONTENTS SERVICE CHART ..............120 PROPELLER .

  • Page 122: Service Chart

    GEARCASE SERVICE CHART SERVICE CHART EARS EARCASE 1. Shaft, drive 2. Bush, Drive shaft 3. Pinion 4. Shim (10X16X1.8) Shim (10X16X1.9) Shim (10X16X2.0) Shim (10X16X2.1) Shim (10X16X2.2) 5. E-ring, pinion 6. Gear, forward 7. Shim (17X23X0.3) Shim (17X23X0.4) Shim (17X23X0.5) Shim (17X23X0.6) 8.

  • Page 123: Gearcase

    GEARCASE SERVICE CHART SERVICE CHART ATER 1. Case, water pump 2. Seal, water pump case 3. Sleeve, water pump case 4. Grommet, water pump case 5. Impeller, water pump 6. Pin, pump case impeller 7. Panel, pump case under 8. Gasket, pump case panel 9.

  • Page 124: Propeller

    GEARCASE PROPELLER PROPELLER LUBRICANT Inspection Draining Carefully check the propeller and outboard for the WARNING following conditions: • Damaged blades and signs of propeller cavita- Gearcase lubricant may be under pressure tion and/or hot. If plug is removed from a •...

  • Page 125: Filling

    GEARCASE LEAK TEST LEAK TEST Inspection Inspect the lubricant for water contamination. Check for leakage of the oil seals and O-ring Water in the lubricant can cause a milky appear- when applying the specified pressure inside of the ance, however normal aeration can also cause gearcase.

  • Page 126: Removal

    GEARCASE REMOVAL REMOVAL Remove the two bolts. Separate the gearcase assembly from the driveshaft housing. WARNING To prevent accidental starting while ser- vicing, twist and remove all spark plug leads. During service, the outboard may drop unexpectedly. Avoid personal injury; always support the outboard’s weight with a suitable hoist or the tilt support bracket during service.
  • Page 127 GEARCASE REMOVAL Pull out the shift rod. Remove the two bolts securing the propeller shaft bearing housing. 1. Shift rod 006209 1. Bolt (2) 006212 Remove four pump case bolts and pump case. Remove the propeller shaft bearing housing. 1. Bolt (4) 006210 2.

  • Page 128: Propeller Shaft

    GEARCASE REMOVAL Pull out the driveshaft. Propeller Shaft Separate the following parts: • Bearing housing • Washer • Propeller shaft assembly 006215 Remove the pinion gear and pinion gear backup shim. 1. Bearing housing 006218 2. Washer 3. Propeller shaft assembly Remove the clutch dog.

  • Page 129: Water Pump

    GEARCASE INSPECTION INSPECTION Water Pump Separate the following parts: IMPORTANT: If excessive wear, crack, defec- • Water pump case seal tive or other damage is found on any component, • Water pump case sleeve replace. • Water pump case Propeller •...
  • Page 130 GEARCASE INSPECTION Pinion Gear Inspect the return spring. If excessive wear or other damage is found, replace. Inspect the teeth of the forward gear and pinion gear. If excessive wear, chip or other damage is found, replace. 006227 Inspect the propeller shaft. If excessive wear, twist 006225 or other damage is found, replace.
  • Page 131 GEARCASE INSPECTION Propeller Shaft Bearing Housing When replacing the propeller shaft bearing hous- ing oil seal, use a screwdriver to remove oil seals. Inspect the housing. If crack or other damage is found, replace the housing. Visually check the oil seal and O-ring. If cut, nick, excessive wear or other damage is found, replace the oil seal.
  • Page 132 GEARCASE INSPECTION Water Pump Driveshaft Oil Seals Inspect the impeller. If cut, tear or excessive wear Visually check the oil seals. If cut, nick, excessive is found, replace the impeller. wear or other damage is found, replace the oil seal. Inspect the pump case, the inner sleeve and the under panel.

  • Page 133: Assembly

    GEARCASE ASSEMBLY ASSEMBLY Apply Triple-Guard grease to the seal lips. Reassembly and installation is reverse of removal and disassembly with special attention to the fol- lowing steps. IMPORTANT: • Make sure that all parts used in assembly are clean and lubricated. •...

  • Page 134: Propeller Shaft

    GEARCASE ASSEMBLY Pinion Gear Install the driveshaft. Apply gear lubricant to the following parts: • Pinion gear backup shim • Pinion gear 1. Driveshaft 006247 Install the E-ring. 1. E-ring 006248 1. Forward gear backup shim 006243 006249 2. Pinion gear 006244 Propeller Shaft Driveshaft...

  • Page 135: Water Pump

    GEARCASE ASSEMBLY Insert push rod into the propeller shaft. Install the propeller shaft/housing assembly to the gearcase and tighten the two bolts to torque of 6.0 ft. lbs. (8 N·m). 1. Push rod 006251 Propeller Shaft Assembly and Bearing 1. Bolt (2) 006254 Housing Water Pump...

  • Page 136: Shift Rod

    GEARCASE ASSEMBLY Apply ThreeBond 1207B sealant on the outer sur- Install the water pump case while rotating the face of water pump sleeve. driveshaft clockwise in order to flex the impeller vanes in the correct direction. Tighten the water Install the water pump sleeve into the water pump pump case bolts to torque of 3.5 ft.

  • Page 137: Installation

    GEARCASE INSTALLATION INSTALLATION GEAR SHIMMING AND ADJUSTMENT Apply Moly Lube to the driveshaft splines. Install the gearcase assembly. Apply Gasket If the gearcase has been rebuilt or has had com- Sealing Compound to the gearcase retaining bolts ponents replaced, shimming for correct gear con- and tighten the bolts to a torque of 6.0 ft.

  • Page 138: Forward Gear/Pinion Gear

    GEARCASE GEAR SHIMMING AND ADJUSTMENT Forward Gear/Pinion Gear Push the propeller shaft inward and hold in posi- tion. Backlash Adjustment To check the gear backlash of the pinion and for- ward gear, hold the pinion gear by hand, then gently rock forward gear back and forth by hand. Gear backlash: •...

  • Page 139: Propeller Shaft Thrust Play

    GEARCASE GEAR SHIMMING AND ADJUSTMENT A shim adjustment may be necessary in order to Correction measures: obtain the optimum tooth contact pattern. • Increase the thickness of the forward gear shim. • Slightly decrease the pinion gear shim thick- Approx. 1/3 of ness.

  • Page 140: Notes

    GEARCASE NOTES NOTES Technician’s Notes Related Documents Bulletins Instruction Sheets Other...
  • Page 141 MANUAL STARTER MANUAL STARTER TABLE OF CONTENTS SERVICE CHART ..............140 REMOVAL .

  • Page 142: Service Chart

    MANUAL STARTER SERVICE CHART SERVICE CHART 1. Starter assembly, recoil 2. Reel 3. Ratchet set 4. Spring, spiral 5. Grip set 6. Rope 7. Pulley, starter 8. Bolt 9. Bolt 10. Decal, S.I.G.P. Triple-Guard Grease EPC4222 Blue Nut Lock...

  • Page 143: Removal

    MANUAL STARTER REMOVAL REMOVAL Remove the knot from grip holder. Remove the grip holder and starter grip. Completely remove the motor cover. WARNING Avoid accidental starting of engine while servicing, twist and remove all spark plug leads. Wear safety glasses while disassembling and assembling manual starters to avoid personal injury caused by rewind spring tension.

  • Page 144: Disassembly

    MANUAL STARTER DISASSEMBLY DISASSEMBLY Remove the spring and the ratchet. WARNING Because of the coiled tension in the recoil spring, wear safety glasses and hand pro- tection when winding or unwinding this component. Turn the reel clockwise in order to release the coiled tension in the recoil spring.

  • Page 145: Inspection

    MANUAL STARTER INSPECTION INSPECTION ASSEMBLY AND INSTALLATION IMPORTANT: If excessive wear, crack, defec- tive or other damage is found on any component, replace. Reassembly is the reverse order of disassembly with special attention to the following steps. Inspect the ratchet and the all springs. If exces- sive wear or other damage is found, replace.
  • Page 146 MANUAL STARTER ASSEMBLY AND INSTALLATION Install the reel and the recoil spring to the recoil Install the friction plate. Apply Screw Lock to case aligning the inner end of the spring with the threads of screw then tighten the screw. boss cutaway on the case.
  • Page 147 WIRE/HOSE ROUTING WIRE/HOSE ROUTING TABLE OF CONTENTS WIRING DIAGRAM ..............146 WIRE ROUTING .

  • Page 148: Wiring Diagram

    WIRE/HOSE ROUTING WIRING DIAGRAM WIRING DIAGRAM Igniter unit Spark plug Flywheel Magneto Wire color B: Black EMERGENCY STOP SWITCH → Emergency stop switch: Lock plate IN → Lock plate OUT STOP → Button PUSHED STOP 006298...

  • Page 149: Wire/Hose Routing

    WIRE/HOSE ROUTING WIRE ROUTING WIRE ROUTING 006299...
  • Page 150 WIRE/HOSE ROUTING FUEL HOSE ROUTING FUEL HOSE ROUTING • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tabs to avoid contact with other parts. • Check that hoses do not contact rods and levers during either engine operation or standstill. •...
  • Page 151 SAFETY SAFETY TABLE OF CONTENTS MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO USE THEM ..... S–3 ..........S–4 OUTBOARD SHIFT SYSTEMS AND SAFETY .
  • Page 152 S–2...

  • Page 153: Marine Products And The Safety Of People Who Use Them

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

  • Page 154: Outboard Shift Systems And Safety

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

  • Page 155: Outboard Speed Control System And Safety

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

  • Page 156: Outboard Steering Control System And Safety

    SAFETY Outboard Steering Control System and Safety The outboard steering system starts here at the steering wheel..and ends here at the trim tab on the outboard. What is most important? The steering system: • Must not come apart; • Must not jam;...
  • Page 157 SAFETY How can loss of steering control be minimized? • Use a steering system recommended by the outboard manufacturer which meets Marine Industry Safety Standards (ABYC). • Read, understand, and follow manufacturer’s instructions When • Follow warnings marked “ ” closely. rigging •...

  • Page 158: Outboard Fuel, Electrical System, And Safety

    SAFETY Outboard Fuel, Electrical System, and Safety The electrical system begins The fuel system here at the battery... starts here at the fuel tank..and ends here at the fuel injector..and ends here on the powerhead. What is most important? •...
  • Page 159 SAFETY If electrical parts are replaced or even removed from the outboard, check the following: Wire and high voltage lead routing • As shown in service manual • Away from moving parts which could cut wires or wire insulation • Away from engine cover latches which can catch and cut insulation from high voltage spark plug leads Sleeves, boots, shields •...
  • Page 160 SAFETY After repair on any part of the fuel system, pressure test engine portion of fuel system as shown: When Storing: Squeeze until bulb feels hard GASOLINE Check for leaks under engine cover GASOLINE Whenever possible, remove hose from outboard and from tank.

  • Page 161: Outboard Mounting System And Safety

    SAFETY Outboard Mounting System and Safety The mounting system includes: • outboard parts • bolts, nuts, and washers • boat’s transom What is most important? • Outboard must stay in position on boat’s transom. What could happen? Outboard may Outboard may S...L...I...D...E on transom T...I...L...T on transom Boat may turn and be hard...

  • Page 162: If Weakened, Parts Could Fail Later On The Water, When Not Expected

    SAFETY If weakened, parts could fail later on the water, when not expected If boat plate shows... Use only or smaller When rigging or fixing any boat, if transom looks weak, tell the owner. Mount on flat surface only. If transom is Use shims to make surface flat.

  • Page 163: Outboard Hydraulic Tilt/Trim Shock Absorption System And Safety

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

  • Page 164: Outboard Emergency Stop System And Safety

    SAFETY Outboard Emergency Stop System and Safety The emergency system begins here at the clip and lanyard..and ends here in the ignition system on the powerhead. What is most important? • The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop / key switch.
  • Page 165 SAFETY What could happen? If lanyard is cut or frayed..lanyard or clip may break when pulled... If engine does NOT stop when lanyard is pulled, an operator thrown from the boat could be hit as boat circles area. Or, boat may not turn but leave area as a runaway.

  • Page 166: Summing Up

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

  • Page 167: Marine Products And The Safety Of People Who Fix Them

    SAFETY MARINE PRODUCTS AND THE SAFETY OF PEOPLE WHO FIX THEM The first part of this Safety section talked about safe boating and how you, the technician, can help keep it safe for the boater. But what about you? Technicians can be hurt while: •...
  • Page 168 SAFETY Running outboard with engine cover removed Engine cover is a guard. When you remove cover/guard to work on the outboard, remember: loose clothing (open shirt sleeves, neckties), hair, jewelry (rings, watches, bracelets), hands and arms can be caught by the spinning flywheel. Handling high voltage parts like spark plugs and coils can shock...
  • Page 169 SAFETY Running outboard too fast (Overspeeding) • “Too fast” means running faster than outboard normally runs on boat. Running too fast can happen when: 1) Using a flushing device... Turn on water before starting outboard. Keep engine speed below 2000 RPM. With no load, outboard will run too fast very easily.
  • Page 170 SAFETY Running outboards: Propellers DANGER Contact with a rotating propeller is likely to result in serious injury or death. Assure the engine and prop area is clear of people and objects before starting engine or operating boat. Do not allow anyone near a propeller, even when the engine is off. Blades can be sharp and the propeller can continue to turn even after the engine is off.

  • Page 171: Handling Lead/Acid Batteries

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

  • Page 172: Gasoline - Handle With Care

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

  • Page 173: Hazardous Products

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

  • Page 174: Safety Awareness Test

    6) Have you received training related to common shop safety practices to protect your- self and others around you? 7) When replacement parts are required, will you use Evinrude /Johnson Genuine ® ® Parts or parts with equivalent characteristics, including type, strength and material?
  • Page 175 INDEX INDEX Operating Temperature 17, 34 Turbulence 28 Abbreviations 12 Corrosion Adjustment Anodes 40 Backlash 136 Exterior Finishes 41 Gear Shimming 135 Internal Engine Treatment 50 Propeller Shaft 137 Metallic Components 41 Throttle 69 Winter Storage 50 Adjustments Crankcase Idle Speed 48 Assembly 100 Ignition Timing 49 Disassembly 87...
  • Page 176 INDEX Fuel System Removal 141 Carburetor 65 Minimum Octane 16 Fuel Cock 64 Model Number Location 6 Fuel Requirements 31 Mounting the Engine 30 Minimum Octane 31 Storage 50 Neutral Start Protection 34 Gearcase Assembly 131 Oiling System Inspection 127 Engine Lubricant 32 Installation 135 Requirements 32...
  • Page 177 INDEX Safety S–1 Valve Clearance Serial Number Location 6 Adjustment 47 Shimming 135 Spark Plugs Recommended 17, 46 Water Intake Screen 42 Replacement Schedule 39 Water Pump Specifications 16 Overboard Indicator 34 Powerhead 74 Winterizing 50 Starter Assembly and Installation 143 Disassembly 142 Inspection 143 Removal 141...

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