1956-1970 Johnson-Evinrude 1.5 thru 40 HP Service Manual

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Covers: 1956 1957 1958 1959 1960 1961 1962 1963 1964 1965 1966 1967 1968 1969 1970 Johnson-Evinrude 1.5 hp through 40 hp 2-stroke models

1.5HP 3HP 4HP 5HP 5.5HP 6HP 7.5HP 9.5HP 10HP 15HP 18HP 20HP 25HP 28HP 30HP 33HP 35HP 40HP

Pages: 422
Format
: PDF
Compatibility: Windows/Mac/Tablet

This PDF service manual contains all the necessary instructions needed for any repair your outboard motor may require from top to bottom. This is the same manual Mercury technicians use to diagnose and repair your outboard. Whether it’s routine maintenance, such as tune-ups and fuel system service, or more extensive repairs involving engine and pump disassembly, this manual provides the most accurate information to perform the job.

Topics covered in this Service Manual:

1 SAFETY TOP SEAL 3-12
Removal 3-12
INTRODUCTION 1-1 BOTTOM SEAL 3-13
CLEANING, WAXING, Inspection 3-14-
AND POLISHING 1-1 CENTERING PINS 3-15
CONTROLLING CORROSION 1-2
PROPELLERS 1-2 MAIN BEARING BOLTS
FUEL SYSTEM 1-7 AND CRANKCASE SIDE BOLTS 3-15
LOADING 1-9 CRANKCASE COVER 3-16
HORSEPOWER 1-10 Removal 3-16
FLOTATION 1-10 Cleaning and Inspecting 3-16
EMERGENCY EQUIPMENT 1-12 CONNECTING RODS
COMPASS 1-15 AND PISTONS 3-16
STEERING 1-17 Removal 3-17
ANCHORS 1-17 Disassembly 3-18
MISCELLANEOUS EQUIP MENT 1-18 Rod Inspection
BOATING ACCIDENT REPORTS 1-19 and Service 3-21
NAVIGATION 1-19 Piston and Ring Inspection
and Service 3-22
2 TUNING Assembling 3-24-
CRANKSHAFT 3-27
INTRODUCTION 2-1 Removal 3-27
TUNE-UP SEQUENCE 2-2 Cleaning and Inspection 3-27
COMPRESSION CHECK 2-3 Assembling 3-28
SPARK PLUG INSPECTION 2-4-
IGNITION SYSTEM 2-4- CYLINDER BLOCK SERVICE 3-28
SYNCHRONIZING 2-5 Honing Procedures 3-29
BATTERY SERVICE 2-5 Assembling 3-30
CARBURETOR ADJUSTMENTS 2-7 Piston and Rod Assembly
FUEL PUMPS 2-9 Installation 3-30
STAR TER AND SOLENOID 2-10 Crankshaft Installation
INTERNAL WIRING HARNESS 2-11 Large Horsepower Engines
WATER PUMP CHECK 2-12 15 hp to 4-0hp 3-33
PROPELLER 2-13 Crankshaft Installation
LOWER UNIT 2-14- Small Horsepower Engines
BOAT TESTING 2-15 1.5 hp, 5.0 hp, 5.5 hp,
6.0 hp, 9.5 hp 3-35
3 POWERHEAD Crankshaft Installation
Small Horsepower Engines
INTRODUCTION 3-1 3.0 hp, 4-.0hp, 7.5 hp 3-37
Theory of Operation 3-1 Crankcase Cover Installation 3-38
CHAPTER ORGANIZATION 3-4- Main Bearing Bolt and Crankcase
POWERHEAD DISASSEMBLING 3-5 Side Bolt Installation 3-39
HEAD SERVICE 3-5 Bottom Seal Installation
REED SERVICE 3-6 15 hp to 4-0hp Engines 3-39
Description 3-6 Exhaust Cover and Bypass
Reed Valve Adjustment 3-8 Cover Installation 3-4-0
Cleaning and Service 3-9 Reed Box Installation 3-4-0
BYPASS COVERS 3-10 Head Installation 3-4-1
EXHAUST COVER 3-11 BREAK-IN PROCEDURES 3-4-1
Cleaning 3-11 EXPLODED DRAWINGS 3-4-2 – 3-50
FUEL SYNCHRONIZA TION FUEL AND
IGNITION SYSTEMS 5-26
INTRODUCTION 4–1 Primary Pickup Adjustments
GENERAL CARBURETION and Locations 5-26
INFORMATION 4–1
FUEL SYSTEM 4–4- 6 ELECTRICAL
TROUBLESHOOTING 4–4-
Fuel Pump Tests 4–6 INTRODUCTION 6-1
Fuel Line Test 4–7 BATTERIES 6-1
Testing with Pressure Tank 4–8 Mar ine Batteries 6-1
Rough Engine Idle 4–10 Battery Construction 6-2
Excessive Fuel Consumption 4–11 Battery Location 6-2
CARBURETORS 4–12 Battery Service 6-2
TYPE I CARBURETOR 4–13 Jumper Cables 6-5
Removal and Disassembling 4–13 Dual Battery Installation 6-5
Cleaning and Inspecting 4–15 GAUGES AND HORNS 6-7
Assembling 4–16 Constant-Voltage System 6-7
CHOKE SYSTEM SERVICE 4–23 SERVICE PROCEDURES 6-7
Heat/Electric Choke 4–23 Temperature Gauges 6-7
All Electric Choke 4–25 Warning Lights
Water Choke 4–26 Thermomelt Sticks 6-8
TYPE II CARBURETOR 4–28 FUEL SYSTEM 6-8
Disassembling 4–28 Fuel Gauge 6-8
Cleaning and Inspecting 4–31 Fuel Gauge Hookup 6-8
Assembling 4–33 Troubleshooting 6-9
ASSEMBLING CHOKES TO TACHOMETER 6-10
TYPE II CARBURETORS 4–38 HORNS 6-10
Adjustments 4–42 ELECTRICAL SYSTEM GENERAL
TYPE III CARBURETORS 4–43 INFORMA TION 6-11
Removal 4–4-3 CHARGING CIRCUIT SERVICE 6-12
Cleaning and Inspecting 4–45 Troubleshooting 6-12
Assembling 4–47 Generator Service 6-16
Adjustments 4–50 Armature Testing 6-17
FUEL PUMP SERVICE 4–51 Cleaning and Inspecting 6-18
Troubleshooting 4–52 Assembling 6-20
Removal and Repair 4–52 CHOKE CIRCUIT SERVICE 6-22
Cleaning and Inspecting 4-54- STARTER MOTOR CIRCUIT
Assembling and Installation 4–54- SERVICE 6-22
FUEL TANK AND LINE SERVICE 4–57 Circuit Description 6-22
Disassembling 4–58 Starter Motor Description 6-22
Cleaning and Inspecting 4–61 Troubleshooting 6-24
Assembling 4–61 Testing 6-25
LATE MODEL FUEL TANK STARTER DRIVE GEAR SERVICE 6-26
SERVICE 4–67 Starter Removal 6-26
5 IGNITION Drive Gear Disassembling 6-27
Cleaning and Inspecting 6-27
INTRODUCTION 5-1 Assembling Type I Drive 6-28
SPARK PLUG EVALUATION 5-2 Disassembling Type II 6-28
POLARITY CHECK 5-3 Cleaning and Inspecting 6-28
WIRING HARNESS 5-4- Assembling Type II Drive 6-28
FLYWHEEL MAGNETO IGNITION 5-5 DELCO-REMY SERVICE 6-29
TROUBLESHOOTING 5-6 Removal 6-29
SERVICING FLYWHEEL MAGNETO
IGNITION SYSTEM 5-13 Disassembling 6-29
Removal 5-13 Armature Testing 6-30
Cleaning and Inspecting 5-19 Cleaning and Inspecting 6-31
Assembling 5-20 Assembling 6-32
6 ELECTRICAL (CONT)
AUTOLITE STARTER MOTOR
SERVICE 6-34
Removal 6-34
Disassembling 6-35
Armature Testing 6-35
Cleaning and Inspecting 6-37
Assembling 6-37
PRESTOLITE STARTER MOTOR
SERVICE 6-39
Removal 6′:’39
Disassembling 6-40
Armature Testing 6-40
Cleaning and Inspecting 6-42
Assembling 6-43
STARTER MOTOR TESTING 6-44
STARTER MOTOR
INSTALLATION 6-44
7 ACCESSORIES
INTRODUCTION
SHIFT BOXES
Description
OLD-STYLE DOUBLE LEVER
Troubleshooting
Disassembling
Cleaning and Inspection
Assembling
NEW-STYLE SHIFT LEVER
Troubleshooting
Removal
Disassembling
Cleaning and Inspecting
Assembling
ELECTRIC GEAR BOXES AND
SINGLE LEVER CONTROL 7-12
Troubleshooting 7-12
Disassembling 7-14
Cleaning and Inspecting 7-15
Assembling 7-16
PUSH BUTTON SHIFT BOX SERVICE
EVINRUDE UNITS ONLY 7-18
Troubleshooting 7-19
Disassembling 7-21
Cleaning and Inspecting 7-22
Assembling 7-22
CABLE END FITTING INSTALLATION
AT THE ENGINE END 7-24
8· LOWER UNIT
7-1
7-1
7-1
7-3
7-3
7-4
7-5
7-5
7-6
7-6
7-8
7-8
7-9
7-10
DESCRIPTION
Chapter Coverage
Illustrations
TROUBLESHOOTING
MANUAL SHIFT
PROPELLER REMOVAL
8-1
8-1
8-2
8-2
8-7
LOWER UNIT
LOWER UNIT SERVICE
1.5 hp to 4.0 hp — NO SHIFT
Lower Unit Removal
Water Pump Removal
Disassembling
Cleaning and Inspecting
Assembling
Water Pump Installation
Lower Unit Installation
Filling the Lower Unit
Propeller Installation
LOWER UNIT SERVICE
MANUAL SHIFT — 5 HP
TO 25 HP
Removal
Water Pump Removal
Disassembling
Cleaning and Inspecting
Assembling
Water Pump Installation
Lower Unit Installation
LOWER UNIT SERVICE
MANUAL SHIFT — 28 HP
TO 40 HP
Removal
Water Pump Removal
Disassem bling
Cleaning and Inspecting
Assembling
Lower Unit Installation
ELECTROMA TIC LOWER UNIT
Description
Troubleshooting
Removal
Disassembling
Cleaning and Inspecting
Assembling
Water Pump Installation
Lower Unit Installation
9 HAND STARTERS
INTRODUCTION
Operation
TYPE I STAR TER
CYLINDER WITH PINION GEAR
5 HP and 6 HP ENGINES
Starter Rope Replacement
Removal
Installation
Starter Removal
Disassembling
Cleaning and Inspecting
Assembling
9 HAND STARTERS (CONT
– TYPE I STARTER
CYLINDER WITH PINION GEAR
ALL 9.5 HP ENGINES 9-11
Starter Rope Replacement 9-11
Removal 9-11
Installation 9-12
Starter Removal 9-12
Cleaning and Inspecting 9-14
Assembling 9-14
Installation 9-15
TYPE II STARTER
COIL SPRING WITH SWING ARM
DRIVE GEAR
3HP1968
4 HP 1969-70
Removal
Disassembling
Cleaning and Inspecting
Assembling
TYPE III STARTER
MOUNTED ATOP FL YWHEEL
MODEL WITH RETURN SPRINGS
28 HP 1962-63
30 HP1956
35 HP 1957-59
40 HP 1960-63
Removal
Cleaning and Inspecting
Assembling
Rope Installation
Starter Installation
TYPE III STARTER
MOUNTED ATOP FLYWHEEL
MODEL WITH NO RETURN SPRINGS
28HP1964
33 HP 1965-70
40 HP 1964-70
Removal
Cleaning and Inspecting
Assembling
Rope Installation
Starter Installation
TYPE III STARTER
MOUNTED ATOP FLYWHEEL
MODEL WITH ONE NYLON PAWL
3 HP 1956-68
5.5 HP 1956-64
7.5 HP 1956-58
10 HP 1956-63
15 HP 1956
18 HP 1956-70
20 HP 1966-70
25 HP 1969-70
Disassembling 9-40
Cleaning and Inspecting 9-42
Assembling 9-43
Rope Installation 9-43
Starter Installation 9-46
10 MAINTENANCE
INTRODUCTION
ENGINE SERIAL NUMBERS
FIBERGLASS HULLS
ALUMINUM HULLS
BELOW WATERLINE SERVICE
SUBMERGED ENGINE SERVICE
WINTER STORAGE
LOWER UNIT SERVICE
Propeller
BATTERY STORAGE
PRESEASON PREPARATION
APPENDIX
METRIC CONVERSION CHART
DRILL SIZE CONVERSION CHART
TORQUE SPECIFICATIONS
POWERHEAD SPECS
TUNE-UP SPECS
GEAR OIL CAPACITIES
STARTER MOTOR SPECS
REGULA TOR SPECS
GENERATOR SPECS
CONDENSER SPECS
STAR TER ROPE SPECS
WIRE INDENTIFICATION ORA WINGS
20 hp and 25 hp — 1971-72 A-15
33 hp with Generator — 1965-67 A-16
33 hp with Generator — 1968 A-17
33 hp with Generator — 1969-70 A-18
35hp–1957-59 A-19
40 hp Standard Shift
with Generator — 1960-66 A-20
40 hp Standard Shift
with Generator — 1967-68 A-21
40 hp Standard Shift
with Generator — 1969-70 A-22
40 hp Electric Shift
with Generator — 1961-66 A-23
40 hp Electric Shift
with Generator — 1967-68 A-24
40 hp Electric Shift
with Generator — 1969-70 A-25

This is a complete service manual that contains detailed procedures, photos and specifications.

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