1971-1989 Johnson-Evinrude 1.25 thru 60 HP Service Manual

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Covers: 1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 Johnson Evinrude 1.5 thru 60 hp, 1 & 2-cylinder, 2-Stroke Models
Pages: 631
Format: PDF
Compatibility: Windows/Mac/Tablet

Topics covered in the 1971-1989 Johnson-Evinrude 1.25 thru 60 HP Service Manual:

SAFETY
INTRODUCTION
REED SERVICE
CLEANING, WAXING, POLISHING
Reed Valve Adjustment
CONTROLLING CORROSION
Cleaning and Service
PROPELLERS
FUEL SYSTEM
Installation
LOADING
BYPASS COVERS
HEAD SERVICE
HORSEPOWER
Installation
FLOTATION 1-10
EMERGENCY EQUIPMENT
EXHAUST COVER
COMPASS
Cleaning 3-12 ANCHORS 1-17 Installation 3-12 MISCELLANEOUS EQUIPMENT 1-18 TOP SEAL 3-13 BOATING ACCIDENT REPORTS 1-19 Removal 3-13 NAVIGATION 1-19 Installation 3-13
BOTTOM SEAL 3-14
Inspection 3-14
2 TUNING CENTERING PINS 3-15
MAIN BEARING BOLTS
INTRODUCTION 2-1 AND CRANKCASE SIDE BOLTS 3-15
TUNE-UP SEQUENCE 2-2 Installation 3-16
COMPRESSION CHECK 2-3 CRANKCASE COVER 3-16
SPARK PLUG INSPECTION 2-4 Removal 3-16
IGNITION SYSTEM 2-5 Cleaning and Inspection 3-16
SYNCHRONIZING 2-5
BATTERY SERVICE 2-6 CONNECTING RODS AND PISTONS 3-17
CARBURETOR ADJUSTMENTS 2-8 Removal 3-18
FUEL PUMPS 2-9 Disassembling 3-18
STARTER AND SOLENOID 2-10 Rod Inspection and Service 3-21
INTERNAL WIRING HARNESS 2-11 Piston and Ring Inspection
WATER PUMP CHECK 2-11 and Service 3-23
PROPELLERS 2-12 Assembling 3-25
LOWER UNIT 2-13 CRANKSHAFT 3-27
BOAT TESTING 2-14 Removal 3-27
Cleaning and Inspection 3-29
CYLINDER BLOCK SERVICE 3-30
3 POWERHEAD Honing Procedures 3-30
Assembling 3-32
INTRODUCTION 3-1 Piston and Rod Installation 3-32
Theory of Operation 3-1 Crankshaft Installation
CHAPTER ORGANIZATION 3-4 Needle Main and
POWERHEAD DISASSEMBLING 3-5 Rod Bearings 3-35
3 POWERHEAD (CONTI TYPEIV CARBURETOR 4-39
Removal 4-39
Crankshaft Installation Dis a sse mb ling 4-41
With Top Needle Main Brg. Cleaning and Inspecting 4-42
and Babbitt Ctr. & Bottom Assembling 4-46
With Top & Bottom Needle Installation 4-49
Brg. and Ctr. Babbitt Brg.
With All Babbitt Main Brgs. 3-38 FUEL PUMP SERVICE 4-51
Crankshaft Installation Removal and lnstalla tion 4-51
Babbitt Main and Cleaning and Inspecting 4-51
Rod Bearings 3-39
Crankcase Cover Installation 3-40 FUEL TANK SERVICE 4-53
Main Bearing Bolt and
Crankcase Side Bolt Instl. 3-41 ELECTRIC PRIMER CHOKE 4-55
Bottom Seal Installation 3-42
Reed Box Installation 3-43 MANUAL PRIMER CHOKE 4-55
Head Installation 3-44
BREAK-IN PROCEDURES 3-44 OIL INJECTION SYSTEMS 4-57
VRO Oil Inject. 4-57
AccuMix (AutoBlend) 4-62
4 FUEL
INTRODUCTION 4-1
GENERAL CARBURETION
INFORMATION 4-1
FUEL SYSTEM 4-3 5 IGNITION
TROUBLESHOOTING 4-4
Fuel Pump Tests 4-5 INTRODUCTION 5-1
Fuel Line Test 4-6 SPARK PLUG EVALUATION 5-2
Rough Engine Idle 4-8 POLARITY CHECK 5-3
Excessive Fuel Consumption 4-8 WIRING HARNESS 5-4
Engine Surge 4-9
FLYWHEEL MAGNETO IGNITION
JOHNSON/EVINRUDE 1.25 hp — 1987 & on
CARBURETORS 4-9 2 hp — 1971-86
TYPEI CARBURETOR 4-11 2.5 hp — 1987 & on
Removal 4-11 4 hp — 1971-84
Disassembling 4-12 6 hp — 1971-76
Cleaning and Inspecting 4-13 9.5 hp — 1971-73
Assembling 4-15 18 hp — 1971-73
Installation 4-18 20 hp –1971-72
25 hp — 1971-72
CHOKE SYSTEM SERVICE 4-19 40 hp — 1971-73 5-5
ALL ELECTRIC CHOKE REMOVAL 4-20
TYPE II CARBURETOR 4-21 TROUBLESHOOTING 5-6
Disassembling 4-21 Wiring Harness 5-8
Cleaning and Inspecting 4-23 Key Switch 5-8
Assembling 4-25 Compression 5-10
Adjustments 4-30 Condenser 5-11
Breaker Points 5-12
TYPE III CARBURETOR 4-31
Removal 4-31 SERVICING FLYWHEEL MAGNETO
Disassembling 4-32 IGNITION SYSTEM 5-13
Cleaning and Inspecting 4-33 Removal 5-13
Assembling 4-35 Cleaning and Inspecting 5-19
Installation 4-37 Assembling 5-20

MAGNETO IGNITION SYSTEM Armature Plate Removal 5-65
9. 9 hp — 1974-76 Armature Pia te Installation 5-65
15 hp — 1974-76 Charge or Sensor Coil Removal 5-66
1~ hp — 1973 Charge or Sensor Coil
20 hp — 1973 Installation 5-67
25 hp — 1973-76 Charge or Sensor Coil
35 hp — 1976
40 hp — 1974-76 Adjustment 5-67
40 hp Comm. — 1981-83 5-26 Flywheel Installation 5-68
Description 5-26 Power Pack Replacement 5-69
Theory of Operation 5-27 Timing Check Adjustment 5-69
Troubleshooting 5-27
Removal 5-32 SYNCHRONIZATION FUEL
Cleaning and Inspecting 5-36 AND IGNITION SYSTEMS 5-70
Assembling 5-36 Primary Pickup Adjustments
and Locations 5-70
TYPE I CAPACITOR DISCHARGE The No. A Location 5-71
(CD) FLYWHEEL MAGNETO The No. B Location 5-71
WITH TIMER BASE The No. C Location 5-72
50 hp — 1971-75 The No. D Location 5-74
55 hp — 1976-77 5-41 The No. E Location 5-75
Description 5-41
Theory of Operation 5-41
Troubleshooting 5-42 6 ELECTRICAL
Servicing 5-48
Stator and Charge Coil INTRODUCTION 6-1
Replacement 5-48 BATTERIES 6-1
Timer Base and Sensor Marine Batteries 6-1
Assembly Replacement 5-49 Battery Construe tion 6-2
Power Pack Replacement 5-50 Battery Ratings 6-2
Timing Check and Adjustment 5-51 Battery Location 6-2
Battery Service 6-2
TYPE II CD FLYWHEEL MAGNETO Jumper Cables 6-5
IGNITION WITH SENSOR COIL Storage 6-5
2.5 hp — 1987 & on Dual Battery lnstalla tion 6-5
4 hp Dlx. — 1984 & on GAUGES AND HORNS 6-7
4.5 hp — 1 980-85 Constant Voltage System 6-7
5 hp — 1984-85 Temperature Gauges 6-7
6 hp — 1977-79 Warning Lights 6-7
6 hp — 1 98 2 & on Thermomelt Sticks 6-8
7.5 hp — 1980-85 FUEL SYSTEM 6-8
8 hp — 1984 & on Fuel Gauge 6-8
9. 9 hp — 1 977 & on Fuel Gauge Hookup 6-8
15 hp — 1 977 & on Fuel Gauge Troubleshooting 6-9
20 hp — 1981 & on TACHOMETER 6-10
2 5 hp — 1977 & on HORNS 6-10
30 hp — 1 985 & on
35 hp — 1977-84 ELECTRICAL SYSTEM
40 hp — 1 984 & on GENERAL INFORMATION 6-11
50 hp — 1 97 8 & on GENERATING CHARGING
55 hp — 1978-83 CIRCUIT SERVICE 6-12
60 hp — 1980-85 5-51 Troubleshooting 6-13
Description 5-51 Removal and Disassembling 6-16
Theory of Operation 5-52 Armature Testing 6-17
Troubleshooting 5-54 Cleaning and Inspecting 6-18
Checking Type II System 5-55 Assembling 6-20

6 ELECTRICAL (CONT) PUSHBUTTON TYPE SHIFT BOX
SERVICE– EVINRUDE ONLY 7-14
ALTERNATOR CHARGING Troubleshooting 7-15
CIRCUIT SERVICE 6-22 Disassembling 7-17
Trqubleshooting 6-22 Cleaning and Inspecting 7-18
CHOKE CIRCUIT SERVICE 6-26 Assembling 7-18
STARTER MOTOR SINGLE-LEVER REMOTE
CIRCUIT SERVICE 6-26 CONTROL SHIFT BOX 7-20
Circuit Description 6-26 Troubleshooting 7-21
Starter Motor Description 6-26 Disassembling 7-22
Testing 6-28 Assembling 7-23
SHIFT BOX REPAIR 7-26
STARTER DRIVE GEAR SERVICE 6-30 Disassembling 7-26
Disassembling Type I 6-30 Cleaning and Inspecting 7-27
Cleaning and Inspecting 6-31 Assembling 7-27
Assembling Type I 6-32
Disassembling Type II 6-32 CABLE END FITTING INSTALLATION
Cleaning and Inspecting 6-32 AT THE ENGINE END FOR ALL
Assembling Type II 6-32 SHIFT BOXES EXCEPT SINGLE
LEVER REMOTE CONTROL 7-29
BOSCH STARTER MOTOR SERVICE6-33
Removal 6-33 8 LOWER UNIT
Disassembling 6-34
Armature Testing 6-34 DESCRIPTION 8-1
Cleaning and Inspecting 6-35 Chapter Coverage 8-2
Assembling 6-37 Illustrations 8-3
PROPELLER SERVICE 8-3
PRESTOLITE SERVICE 6-40 Propeller with Shear Pin 8-3
Removal 6-40 Removal 8-3
Disassembling 6-41 Exhaust Propeller 8-4
Armature Testing 6-42 Removal 8-5
Cleaning and Inspecting 6-44 Propeller with Shear Pin
Assembling 6-44 Installation 8-5
STARTER MOTOR TESTING 6-45 Exhaust Propeller Installation 8-6
STARTER MOTOR INSTALLATION 6-46 LOWER UNIT LUBRICATION 8-7
Draining 8-7
7 REMOTE CONTROLS Filling 8-8
INTRODUCTION 7-1 NO SHIFT LOWER UNIT SERVICE
SHIFT BOXES 7-1 1.25 to 4.0 HP 1971 & on 8-8
DOUBLE-LEVER SHIFT Description 8-8
BOX SERVICE 7-3 Troubleshooting 8-9
Troubleshooting 7-3 Removal 8-9
Removal 7-4 Water Pump Removal 8-10
Disassembling 7-5 Lower Unit Disassembling 8-10
Cleaning and Inspecting 7-6 Cleaning and Inspecting 8-11
Assembling 7-6 Assembling 8-13
ELECTRIC GEAR BOXES AND Water Pump Installation 8-14
SINGLE LEVER CONTROL 7-8 Lower Unit Installation 8-15
Troubleshooting 7-8 Filling Lower Unit 8-16
Propeller Installation 8-16
SINGLE LEVER SHIFT BOX SERVICE
JOHNSON UNITS ONLY 7-10 SHIFT WITH NO DISCONNECT
Disassembling 7-10 4 DELUX THRU 8 HP 1980-’85 8-17
Cleaning and Inspecting 7-11 Description 8-17
Assembling 7-12 Removal 8-18

Water Pump Disassembling
Lower Unit Disassembling
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Func tiona! Check
TROUBLESHOOTING
MANUAL SHIFT 6.0 to 40 HP
ALL MODELS EXCEPT 35 HP
WITH PROPELLER EXHAUST
LOWER UNIT SERVICE
MANUAL SHIFT
6.0 HP 1971-79
9.5 HP to 20 HP — 1971-73
25 HP 1971-85
Shift Rod Disconnect
Lower Unit Removal
Water Pump Removal
Lower Unit Disassembling
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Functional Check
LOWER UNIT SERVICE
MANUAL SHIFT 40 HP THRU 1976
Lower Unit Removal
Water Pump Removal
Lower Unit Disassembling
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Func tiona! Check
PROPELLER EXHAUST
MECHANICAL SHIFT
9.9 HP 1974 &: on
15 HP 1 97 4 &: on
Description
Troubleshooting
Lower Unit Removal
Water Pump Removal
Lower Unit Disassembling
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Functional Check

PROPELLER EXHAUST
MECHANICAL SHIFT
35 HP 1976-84
20 HP 1 974 &: on
25 HP 1986 &: on
30 HP 1981 &: on
Description
Troubleshooting
Lower Unit Removal
Water Pump Removal
Lower Unit Disassembling
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Func tiona! Check
ELECTRIC SHIFT
TWO SOLENOIDS
50 HP 1971-72
Description
Troubleshooting
Lower Unit Removal
Water Pump Removal
“Frozen” Propeller Shaft
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Functional Check
MECHANICAL SHIFT
HYDRAULIC ASSIST
SHIFT DISCONNECT UNDER
LOWER CARBURETOR
50 HP 1973-74
Description
Troubleshooting
Lower Unit Removal
Water Pump Removal
“Frozen” Propeller Shaft
Cleaning and Inspecting
Lower Unit Assembling
Water Pump Installation
Lower Unit Installation
Func tiona! Check
MECHANICAL SHIFT
SHIFT DISCONNECT UNDER
LOWER CARBURETOR
40 HP 1977 &: on
50 HP 1972-73
50 HP 197 5 and 1980 &: on
55 HP 1975-83
60 HP 1 980 &: on
Description
Troubleshooting
8 LOWER UNIT (CONTI Starter Disassembling 9-27
Cleaning and Inspecting 9-29
Lower Unit Removal 8-173 Assembling 9-29
Water Pump Removal 8-175 Installation 9-30
“frozen” Propeller Shaft 8-178 Adjustment 9-31
Cleaning and Inspecting 8-182
Lower Unit Assembling 8-185 TYPE V MOUNTED A TOP
Water Pump Installation 8-193 FLYWHEEL WITH NO
Lower Unit Installation 8-196 RETURN SPRINGS
“FROZEN” PROPELLER 8-197 40 HP — 1971-76 & 1981-85 9-32
Removal 9-33
9 HAND STARTERS Cleaning and Inspecting 9-34
Assembling 9-36
INTRODUCTION 9-1 Rope Installation 9-37
Emergency Starting 9-3 Starter Installation 9-39
TYPE I STARTER
CYLINDER WITH PINION GEAR TYPE VI MOUNTED A TOP FLYWHEEL
All 5 HP WITH ONE OR TWO NYLON PAWLS
All6 HP COLT, JUNIOR,
All 7.5 HP & ULTRA 1986 & on
All8 HP 9-4 2 HP 1971-85
Starter Rope Replacement 9-4 2.5 HP 1987 & on
Removal 9-4 4 HP 1980 & on
Installation 9-5 18 HP 1971-73
Starter Removal 9-5 20 HP 1971-73, 1985 & on
Disassembling 9-7 25 HP 1971 & on
Cleaning and Inspecting 9-7 35 HP 1976-84 9-41
Assembling 9-8 Starter Removal 9-41
Disassembling 9-41
TYPE II STARTER Cleaning and Inspecting 9-43
CYLINDER WITH PINION GEAR Starter Assembling 9-44
All 9.5 HP 9-11 Rope Installation 9-4′-J.
Rope Removal 9-11 Starter Installation 9-48
Rope Installation 9-12
Starter Removal 9-12
Cleaning and Inspecting 9-14 TYPE VII MOUNTED ATOP FLYWHEEL
Assembling 9-15 WITH LARGE PAWL PLATE
Installation 9-15 Starter Removal 9-48
Disassembling 9-48
TYPE III STARTER Cleaning and Inspecting 9-49
COIL SPRING WITH SWING ARM Starter Assembling 9-49
VERTICAL MOUNT Starter Installation 9-50
4 HP 1971-78
4 HP DELUX 1982 & on
4.5 HP 1980-84 9-17
Removal 9-17
Disassembling 9-18
Cleaning and Inspecting 9-19 10 POWER TRIM/TILT
Assembling 9-20
SYSTEM DESCRIPTION 10-1
TYPE IV STARTER FILLING SYSTEM 10-2
COIL SPRING WITH SLIDING GEAR TROUBLESHOOTING 10-2
HORIZONTAL MOUNT SERVICING 10-3
All 9.9 HP
All 15 HP 9-23 ELECTRICAL MOTOR SERVICE 10-3
Removal 9-23 Cleaning &:: Inspecting 10-4
Starter Rope Replacement 9-24 Testing 10-4
11 MAINTENANCE
INTRODUCTION 11-1
ENGINE SERIAL NUMBERS 11-2
FIBERGLASS HULLS 11-3
ALUMINUM HULLS 11-3
BELOW WATERLINE SERVICE 11-4
SUBMERGED ENGINE SERVICE 11-5
WINTER STORAGE 11-7
LOWER UNIT SERVICE 11-9
Propellers 11-9
BATTERY STORAGE 11-14
PRESEASON PREPARATION 11-15
APPENDIX
METRIC CONVERSION CHART A-1
DRILL SIZE CONVERSION CHART A-2
TORQUE SPECIFICATIONS A-3
TUNE-UP SPECIFICATIONS A-4 to A-17
POWERHEAD SPECIFICATIONS A-18
OIL/FUEL MIXTURE A-19
GEAR OIL CAPACITIES A-19
STARTER MOTOR SPECS. A-20
REGULA TOR SPECIFICATIONS A-20
GENERATOR SPECIFICATIONS A-20
CONDENSER SPECIFICATIONS A-21
STARTER ROPE SPECIFICATIONS A-21
WIRE IDENTIFICATION DRAWINGS
Typical l-ey linder pwrhd. A-22
2.5 hp, Excel, Ultra, &. 4 hp —
1984 &. on A-23
4 Delux thru 55 hp w/CD II Ign.,
w /manual start; Also models
equipped with A.C. lighting A-24
9.9 hp and 15 hp
w/electric start– 1974-76 A-25
9.9 hp and 15 hp
w I electric start — 1977-85 A-26
9.9 hp and 15 hp
w/electric start — 1986 &. on A-27
18 hp, 20 hp, &. 25 hp
w I electric start — 1971-72 A-28
18 hp, 20 hp, &. 25 hp
w/e1ectric start — 1973-76 A-29
35 hp w/electric start– 1976 A-30
25 hp and 35 hp — 1977-78 A-31
20 hp thru 40 hp w/std. shift
&. w I electric start 1979-85 A-32
40 hp w/generator, w/std. shift
&. w/electric start– 1971-73 A-33
40 hp w/alternator, w/std. shift
&. w/electric start– 1974-76 A-34
50 hp w I altern a tor
&. w/electric start– 1971-72 A-35
50 hp w I alternator
&. w/electric start– 1973-77
Also 55 hp with no
thermo switch – 1977 A-36
50 hp w/manual Start– 1980-85 A-37
55 hp w/electric start– 1977 A-38
50 hp &. 55 hp
w/electric start– 1978 A-39
50 hp — 1 979, 55 hp — 1979-83,
&. 60 hp — 1 980-81
all w I electric start A-40
20 hp, 25 hp, 30 hp, 35 hp,
40 hp, 50 hp, and 60 hp
w/remote electric start–
1982-85 A-41
40 hp &. 50 hp w I tiller
electric start — 1986 &. on A-42
40 hp &. 50 hp w/remote
electric start — 1986 &. on A-43
Remote Control Box A-44

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

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