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1971 - 1989 EVINRUDE JOHNSON OUTBOARD (1hp - 60hp) Manual * CLICK HERE * DIY FACTORY SERVICE / REPAIR / MAINTENANCE MANUAL FOR PRODUCTION YEARS: (1971 1972 1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989) Evinrude Johnson Outboard Service Manual (71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89). Covers all 1 and 2 cylinder 2 stroke models. - SIMPLY THE BEST MANUAL OUT THERE FOR YOUR 1971 - 1989 EVINRUDE JOHNSON OUTBOARD (1hp - 60hp) - INSTANT DOWNLOAD - FULL DOWNLOAD SUPPORT PROVIDED AFTER PURCHASE 1. Downloadable: YES 2. Compatible: All Versions of Windows & Mac 3. Language: English 4. File Format: PDF 5. Requirements: Adobe PDF Reader & WinZip. 6. Pages: 632 DESCRIPTION: ========= COVERS ALL MODELS & ALL REPAIRS A-Z THIS IS NOT GENERIC REPAIR INFORMATION! IT IS VEHICLE SPECIFIC. THIS IS THE EXACT SAME MANUAL USED BY TECHNICIANS AT THE DEALERSHIPS TO MAINTAIN, SERVICE, DIAGNOSE AND REPAIR YOUR VEHICLE. COMPLETE STEP-BY-STEP INSTRUCTIONS, DIAGRAMS, ILLUSTRATIONS, WIRING SCHEMATICS, AND SPECIFICATIONS TO COMPLETELY REPAIR YOUR VEHICLE WITH EASE! YOU GET EVERYTHING YOU WILL EVER NEED ON ONE EASY-TO-USE PDF-MANUAL. NO MORE FLIPPING THROUGH BOOKS TO FIND WHAT YOU NEED. PRINT ONLY THE PAGES AND DIAGRAMS YOU REQUIRE. NO MORE GREASY PAGES OR TORN LOST PAPER MANUALS AGAIN. ALL PAGES ARE PRINTABLE, SO PRINT OFF WHAT YOU NEED & TAKE IT WITH YOU TO YOUR VEHICLE OR WORKSHOP. YOU CAN BLOW-UP IMAGES AND THEN PRINT OFF ENLARGED COPIES! FACTORY HIGHLY DETAILED REPAIR MANUALS, WITH COMPLETE INSTRUCTIONS AND ILLUSTRATIONS, WIRING SCHEMATICS AND DIAGRAMS TO COMPLETELY SERVICE AND REPAIR YOUR VEHICLE. ALL MANUALS ARE WINDOWS VISTA32 and 64, XP, ME, 98, NT, 2000 COMPATIBLE AND WORK WITH MAC! -------------------------------------------------------------------------------------- * INSTANT DOWNLOAD * NO SHIPPING COST * NO NEED TO WAIT FOR A CD-ROM SOME OF THE CONTENTS INCLUDE: ========================== INTRODUCTION Filling Lower Unit CLEANING, WAXING, POLISHING Propeller Installation CONTROLLING CORROSION SHIFT WITH NO DISCONNECT PROPELLERS 4 DELUXE THRU 8 HP 1980-85 FUEL SYSTEM Description LOADING Removal HORSEPOWER 6 ELECTRICAL (CONT) FLOTATION ALTERNATOR CHARGING EMERGENCY EQUIPMENT CIRCUIT SERVICE COMPASS Troubleshooting ANCHORS CHOKE CIRCUIT SERVICE MISCELLANEOUS EQUIPMENT STARTER MOTOR BOATING ACCIDENT REPORTS CIRCUIT SERVICE NAVIGATION Circuit Description 2 TUNING Starter Motor Description INTRODUCTION Testing TUNE-UP SEQUENCE STARTER DRIVE GEAR SERVICE COMPRESSION CHECK Disassembling Type I SPARK PLUG INSPECTION Cleaning and Inspecting IGNITION SYSTEM Assembling Type I SYNCHRONIZING Disassembling Type II BATTERY SERVICE Cleaning and Inspecting CARBURETOR ADJUSTMENTS Assembling Type II FUEL PUMPS BOSCH STARTER MOTOR SERVICE STARTER AND SOLENOID Removal INTERNAL WIRING HARNESS Disassembling Armature Testing WATER PUMP CHECK Cleaning and Inspecting Assembling PROPELLERS PRESTOLITE SERVICE LOWER UNIT Removal BOAT TESTING Disassembling 3 POWERHEAD Armature Testing Cleaning INTRODUCTION and Inspecting Theory of Operation Assembling STARTER MOTOR TESTING CHAPTER ORGANIZATION STARTER MOTOR INSTALLATION POWERHEAD DISASSEMBLING 7 REMOTE CONTROLS INTRODUCTION SHIFT BOXES 3 POWERHEAD (CONT) DOUBLE-LEVER SHIFT HEAD SERVICE BOX SERVICE REED SERVICE Troubleshooting Description Removal Reed Valve Adjustment Disassembling Cleaning and Service Cleaning and Inspecting Installation Assembling BYPASS COVERS ELECTRIC GEAR BOXES AND Installation SINGLE LEVER CONTROL EXHAUST COVER Troubleshooting Cleaning SINGLE LEVER SHIFT BOX SERVICE Installation JOHNSON UNITS ONLY TOP SEAL Disassembling Removal Cleaning and Inspecting Installation Assembling BOTTOM SEAL PROPELLER EXHAUST Inspection MECHANICAL SHIFT 35 HP 1978 CENTERING PINS 20 HP 1974 & on 25 HP 1986 & on MAIN BEARING BOLTS Water Pump Disassembling AND CRANKCASE SIDE BOLTS Lower Unit Disassembling Installation Cleaning and Inspecting CRANKCASE COVER Lower Unit Assembling Removal Water Pump Installation Cleaning and Inspection Lower Unit Installation CONNECTING RODS AND PISTONS Functional Check Removal TROUBLESHOOTING Disassembling MANUAL SHIFT 6.0 to 40 HP Rod Inspection and Service ALL MODELS EXCEPT 35 HP Piston and Ring Inspection WITH PROPELLER EXHAUST and Service LOWER UNIT SERVICE MANUAL Assembling SHIFT 6.0 HP CRANKSHAFT 1979 9.5 HP to 20 HP Removal 1977 25 HP 1978 Cleaning and Inspection Shift Rod Disconnect CYLINDER BLOCK SERVICE Lower Unit Removal Honing Procedures Water Pump Removal Assembling Lower Unit Disassembling Piston and Rod Installation Cleaning and Inspecting Crankshaft Installation Lower Unit Assembling Needle Main and Water Pump Installation Rod Bearings Lower Unit Installation Crankshaft Installation Functional Check With Top Needle Main Brg. LOWER UNIT SERVICE and Babbitt Ctr. & Bottom MANUAL SHIFT 40 HP THRU 1976 With Top & Bottom Needle Brg. Lower Unit Removal and Ctr. Babbitt Brg. Water Pump Removal With All Babbitt Main Brgs. Lower Unit Disassembling Crankshaft Installation Babbitt Cleaning and Inspecting Main and Rod Bearings Lower Unit Assembling Crankcase Cover Installation Water Pump Installation Main Bearing Bolt and Crankcase Lower Unit Installation Side Bolt Instl. Functional Check Bottom Seal Installation PROPELLER EXHAUST Reed Box Installation MECHANICAL SHIFT 9.9 HP Head Installation 1974 & on15 HP 1974 & on BREAK-IN PROCEDURES Description TYPE IV CARBURETOR Troubleshooting Removal Lower Unit Removal Disassembling Cleaning and Water Pump Removal Inspecting Assembling Installation Lower Unit Disassembling FUEL PUMP SERVICE Cleaning and Inspecting Removal and Installation Lower Unit Assembling Cleaning and Inspecting Water Pump Installation FUEL TANK SERVICE Lower Unit Installation ELECTRIC PRIMER CHOKE Functional Check MANUAL PRIMER CHOKE 30 HP 1981 & on OIL INJECTION SYSTEMS Description VRO Oil Inject. Troubleshooting AccuMix (AutoBlend) Lower Unit Removal 5 IGNITION Water Pump Removal INTRODUCTION Lower Unit Disassembling SPARK PLUG EVALUATION Cleaning and Inspecting POLARITY CHECK Lower Unit Assembling WIRING HARNESS Water Pump Installation FLYWHEEL MAGNETO IGNITION 1.25 hp Lower Unit Installation 1987 &on 2 hp- 1986 2.5 hp Functional Check 1987 on 4 hp-1984 6 hp - 1976 ELECTRIC SHIFT 9.5 hp-19773 18 hp - 19773 20 hp TWO SOLENOIDS 1971 -72 25 hp - 1972 40 hp-1973 50 HP 1977 TROUBLESHOOTING Description Wiring Harness Troubleshooting Key Switch Lower Unit Removal Compression Water Pump Removal Condenser Frozen Propeller Shaft Breaker Points Cleaning and Inspecting SERVICING FLYWHEEL MAGNETO Lower Unit Assembling IGNITION SYSTEM Water Pump Installation Removal Lower Unit Installation Cleaning and Inspecting Functional Check Assembling MECHANICAL SHIFT 4 FUEL HYDRAULIC ASSIST INTRODUCTION SHIFT DISCONNECT UNDER GENERAL CARBURETION LOWER CARBURETOR INFORMATION 50 HP 1977 FUEL SYSTEM Description TROUBLESHOOTING Trouble shoot ing Fuel Pump Tests Lower Unit Removal Fuel Line Test Water Pump Removal Rough Engine Idle Frozen Propeller Shaft Excessive Fuel Consumption Cleaning and Inspecting Engine Surge Lower Unit Assembling JOHNSON/EVINRUDE Water Pump Installation CARBURETORS Lower Unit Installation TYPE I CARBURETOR Functional Check 171 Removal MECHANICAL SHIFT Disassembling SHIFT DISCONNECT UNDER Cleaning and Inspecting LOWER CARBURETOR Assembling 40 HP 1977 & on Installation 50 HP 1977 CHOKE SYSTEM SERVICE 50 HP 1975 and 1980 & on ALL ELECTRIC CHOKE REMOVAL 55 HP 1978 TYPE II CARBURETOR 60 HP 1980 & on Disassembling Description Cleaning and Inspecting Troubleshooting Assembling LOWER UNIT (CONT) Adjustments Lower Unit Removal TYPE III CARBURETOR Water Pump Removal Removal Frozen Propeller Shaft Disassembling Cleaning and Inspecting Cleaning and Inspecting Lower Unit Assembling Assembling Water Pump Installation Installation Lower Unit Installation Flywheel Removal FROZEN PROPELLER Armature Plate Removal Starter Disassembling Armature Plate Installation Cleaning and Inspecting Charge or Sensor Coil Removal Assembling Charge or Sensor Coil Installation Installation Adjustment Charge or Sensor Coil TYPE V MOUNTED ATOP Adjustment FLYWHEEL WITH NO Flywheel Installation RETURN SPRINGS Power Pack Replacement 40 HP- 1977 & 1988 Timing Check Adjustment Removal SYNCHRONIZATION FUEL Cleaning and Inspecting AND IGNITION SYSTEMS Assembling Primary Pickup Adjustments Rope Installation and Locations Starter Installation The No. A Location TYPE VI MOUNTED ATOP FLYWHEEL The No. B Location WITH ONE OR TWO NYLON PAWLS The No. C Location COLT, JUNIOR, The No. D Location & ULTRA 1986 & on 2 HP 19785 2.5 HP The No. E Location 1987 & on 4 HP 1980 & on 18 HP 6 ELECTRICAL 1973 20 HP 1977, 1985 & on 25 HP INTRODUCTION 1971 & on 35 HP 1978 BATTERIES Starter Removal Marine Batteries Disassembling Battery Construction Cleaning and Inspecting Battery Ratings Starter Assembling Battery Location Rope Installation Battery Service Starter Installation Jumper Cables TYPE VII MOUNTED ATOP FLYWHEEL Storage WITH LARGE PAWL PLATE Dual Battery Installation Starter Removal GAUGES AND HORNS Disassembling Constant Voltage System Cleaning and Inspecting Temperature Gauges Starter Assembling Warning Lights Starter Installation Thermomelt Sticks 9 HAND STARTERS FUEL SYSTEM INTRODUCTION Fuel Gauge Emergency Starting Fuel Gauge Hookup TYPE I STARTER Fuel Gauge Troubleshooting CYLINDER WITH PINION GEAR All TACHOMETER ]HP All 6 HP All 7.5 HP All 8 HP HORNS Starter Rope Replacement ELECTRICAL SYSTEM Removal GENERAL INFORMATION Installation GENERATING CHARGING Starter Removal CIRCUIT SERVICE Disassembling Troubleshooting Cleaning and Inspecting Removal and Disassembling Assembling Armature Testing TYPE II STARTER Cleaning and Inspecting CYLINDER WITH PINION GEAR Assembling All 9.5 HP LOW TENSION FLYWHEEL Rope Removal MAGNETO IGNITION SYSTEM Rope Installation 9.9 hp - 1976 Starter Removal 15 hp-1976 Cleaning and Inspecting 18 hp- 1973 Assembling 20 hp - 1973 Installation 25 hp - 19776 TYPE III STARTER 35 hp - 1976 COIL SPRING WITH SWING ARM 40 hp - 1976 VERTICAL MOUNT 4 HP 19778 40 hp Comm. - 1983 4 HP DELUX 1982 & on 4.5 HP Description 1980-84 Theory of Operation Removal Troubleshooting Disassembling Removal Cleaning and Inspecting Cleaning and Inspecting Assembling Assembling TYPE IV STARTER COIL SPRING WITH SLIDING GEAR TYPE I CAPACITOR DISCHARGE HORIZONTAL MOUNT (CD) All 9.9 HP FLYWHEEL MAGNETO WITH All 15 HP TIMER BASE 50 hp Removal - 1977 55 hp - 1977 Starter Rope Replacement Description 10 POWER TRIM/TILT Theory of Operation SYSTEM DESCRIPTION Troubleshooting FILLING SYSTEM Servicing TROUBLESHOOTING Stator and Charge Coil SERVICING Replacement ELECTRICAL MOTOR SERVICE Timer Base and Sensor Cleaning & Inspecting Assembly Replacement Testing Power Pack Replacement II MAINTENANCE Timing Check and Adjustment INTRODUCTION TYPE II CD FLYWHEEL MAGNETO IGNITION ENGINE SERIAL NUMBERS WITH SENSOR COIL 2.5 hp 1987 & on FIBERGLASS HULLS 4 hp Dlx. 1984 & on 4.5 hp-1980-85 ALUMINUM HULLS 5 hp - 1985 BELOW WATERLINE SERVICE 6 hp - 1979 SUBMERGED ENGINE SERVICE 6 hp - 1982 & on WINTER STORAGE 7.5 hp -1980-85 LOWER UNIT SERVICE 8 hp 1984 &on Propellers 9.9 hp 1977 & on BATTERY STORAGE 15 hp- 1977 & on PRESEASON PREPARATION 20 hp - 1981 & on APPENDIX 25 hp - 1977 & on METRIC CONVERSION CHART 30 hp 1985 & on DRILL SIZE CONVERSION CHART 35 hp - 19784 TORQUE SPECIFICATIONS 40 hp 1984 & on TUNE-UP SPECIFICATIONS 4 to 17 50 hp - 1978 & on POWERHEAD SPECIFICATIONS 55 hp - 1983 OIL/FUEL MIXTURE 60 hp - 1980-85 GEAR OIL CAPACITIES Description STARTER MOTOR SPECS. Theory of Operation REGULATOR SPECIFICATIONS Troubleshooting GENERATOR SPECIFICATIONS Checking Type II System CONDENSER SPECIFICATIONS PUSHBUTTON TYPE SHIFT BOX STARTER ROPE SPECIFICATIONS SERVICE - EVINRUDE ONLY WIRE IDENTIFICATION DRAWINGS Troubleshooting Typical I-cylinder pwhd. Disassembling 2.5 hp, Excel, Ultra, & 4 hp Cleaning and Inspecting -1984 & on Assembling 4 Delux thru 55 hp w/CD 2ign., SINGLE-LEVER REMOTE w/manual start; CONTROL SHIFT BOX Also models equipped Troubleshooting with A.C. lighting Disassembling 9.9 hp and 15 hp Assembling w / electrlc start - 1976 SHIFT BOX REPAIR 9.9 hp and 15 hp Disassembling w/electrlc start - 1978 Cleaning and Inspecting 9.9 hp and 15 hp Assembling w/electric start 1986 & on 27 CABLE END FITTING INSTALLATION I8 hp, 20 hp, & 25 hp AT THE ENGINE END w / electric start - 1971 -7 2 FOR ALL SHIFT BOXES EXCEPT SINGLE 28 18 hp, 20hp,& 25 hp LEVER REMOTE CONTROL w/electric start - 1976 8 LOWER UNIT 35 hp w/electric start - 1976 DESCRIPTION 25 hp and 35 hp-19778 Chapter Coverage 20 hp thru 90 hp w/std. shift Illustrations & w/electric start 19783 PROPELLER SERVICE 40 hp w/generator, w/std. shift Propeller with Shear Pin & w/electric start 1973 Removal 40 hp w/alternator, w/std. shift Exhaust Propeller & w/electrlc start - 1976 Removal 30 hp w / alternator Propeller with Shear Pin 4 w/electric start - 1972 Installation 50 hp w/alternator Exhaust Propeller Installation & w/electrlc start - 1977 LOWER UNIT LUBRICATIN Also 55 hp with no Draining thermo switch 1977 Filling 50 hp w/manual Start 1980-83 NO SHIFT LOWER UNIT SERVICE 55 hp w/electric start - 1977 1.25 to 4.0 HP 1971 & on 50 hp & 53 hp Description w/electric start 1978 Troubleshooting 50 hp - 1979, 55 hp - 1983, Removal & 60 hp - 1980-81 Water Pump Removal all w/electric start Lower Unit Disassembling 20 hp, 23 hp, 30 hp, 33 hp, Cleaning and Inspecting 40 hp, 30 hp, and 60 hp RELATED KEYWORDS: =============== boat evinrude motor part, boat johnson motor part, boat johnson outboard motor part, evinrude johnson part, evinrude motor part, evinrude outboard motor part, evinrude outboard part, evinrude part, evinrude propeller, johnson boat part, johnson motor part, johnson outboard motor part, johnson outboard part, johnson part, johnson propeller, omc cobra part, omc engine part, omc marine engine part, omc outdrive part, omc part, omc propeller, omc sterndrive part, omc stern drive part, marine parts, boat parts, evinrude-johnson, sierra marine parts, sierra interchange, sierra switch, sierra electrical products, shields marine hose, sierra accessories, sierra parts for chris-craft, sierra parts for chrysler outboards, sierra parts for force, sierra parts for chrysler inboards, sierra parts for crusader, sierra parts for honda, sierra parts for indmar, sierra parts for jabsco pump, sierra parts for johnson evinrude, sierra parts for johnson pump, sierra parts for mallory, sierra parts for marine power, sierra parts for mcculloch, sierra parts for mercruiser, sierra parts for mercury, sierra parts for mariner, sierra parts for nissan tohatsu, sierra parts for oberdorfer, sierra parts for omc sterndrive, sierra parts for omc cobra, sierra parts for perkins marine, sierra parts for pleasurecraft, sierra parts for prestolite, sierra parts for sherwood pump, sierra parts for suzuki, sierra parts for volvo penta, sierra parts for yamaha, sierra parts for yamaha sterndrive, mercury marine, bombardier marine parts, volvo penta parts, yamaha marine parts, yamaha outboard parts, yamaha sterndrive parts mercruiser boat part, mercruiser engine part, mercruiser marine part, mercruiser outdrive part, mercruiser part, mercruiser sterndrive part, mercury marine, mercury marine catalog, mercury marine control, mercury marine engine part, mercury marine inflatable boat, mercury marine lubricant, mercury marine outboard part, mercury marine paint, mercury marine part, mercury marine propeller, mercury marine rigging, mercury marine smartcraft, mercury outboard part, mercury part, mercury marine gauge, mercury marine fuel, mercury marine engine accessory, mercury marine boat, mercury marine boat accessory, 1971 - 1989 Evinrude Johnson Outboard Service Manual 1hp - 60hp Years maintenance, johnson, evinrude, manual, outboard service, outboard repair, outboard, evinrude outboard service manual, 1965-1989 JOHNSON EVINRUDE OUTBOARD SERVICE REPAIR MANUAL, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 1971 to 1989 Evinrude Johnson Outboard Service repair workshop manual 1hp - 60hp, service, repair, problems fix it troubleshooting, parts --------------------------------------------------------------------------------------- PLEASE NOTE: ========= 1) Looking for someother Service manual, please check: http://pecno1.TBTBTB/files.php/1003 (for massive collection of service manuals.) GET THIS MANUAL NOW! COMPLETE YOUR REPAIRS BY TODAY! FULL VALUE FOR MONEY GUARANTEED!! THANKS FOR VISITING THIS PAGE. NOW HAVE A GREAT DAY THERE !! Tags: 1971 - 1989 evinrude johnson outboard service manual 1hp - 60hp years maintenance, outboard service, outboard repair, outboard, evinrude outboard service manual, 1965-1989 johnson evinrude outboard service repair manual, 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 1971 to 1989 evinrude johnson outboard service repair workshop manual 1hp - 60hp, service, repair, problems, fix it, troubleshooting, parts