1958-1972 Johnson Evinrude Outboard 50HP to 125HP Motors Service Repair Manual ( Preview, Perfect for the DIY person!)

TABLE OF CONTENTS 1 SAFETY INTRODUCTION CLEANING, WAXING, AND POLISHING CONTROLLING CORROSION PROPELLERS FUEL SYSTEM LOADING HORSEPOWER FLOTATION EMERGENCY EQUIPMENT COMPASS STEERING ANCHORS MISCELLANEOUS EQUIPMENT BOATING ACCIDENT REPORTS NAVIGATION 2 N NING INTRODUCTION TUNE- UP SEQUENCE COMPRESSION CHECK SPARK PLUG INSPECTION IGNITION SYSTEM SYNCHRONIZING BATTERY SERVICE CARBURETOR ADJUSTMENTS FUEL PUMPS STARTER AND SOLENOID INTERNAL WIRING HARNESS WATER PUMP CHECK PROPELLER LOWER UNIT BOAT TESTING 3 POWERHEAD INTRODUCTION Theory of Operation CHAPTER ORGANIZATION POWERHEAD DISASSEMBLING HEAD SERVICE REED SERVICE Description Cleaning and Service Reed Assembling Installation EXHAUST COVER Cleaning TOP SEAL Removal - - V4 Engine Removal - - 3- Cylinder Engine BOTTOM SEAL Inspec tion CENTERING PINS MAIN BEARING BOLTS AND CRANKCASE SIDE BOLTS CRANKCASE COVER CONNECTING RODS AND PISTONS Removal Disassembling Rod Inspection and Service Piston and Ring Inspection and Service Cleaning and Inspecting Assembling CRANKSHAFT Removal Cleaning and Inspecting Assembling CYLINDER BLOCK SERVICE Honing Procedures POWERHEAD ASSEMBLING PISTON AND ROD ASSEMBLY INSTALLATION CRANKSHAFT INSTALLATION NEEDLE MAIN AND ROD BEARINGS CRANKCASE COVER BOTTOM SEAL INSTALLATION TYPE ATTACHED TO LOWER END OF CRANKCASE 3-43 ©eblue-dist 2007

EXHAUST COVER AND BYPASS COVER INSTALLATION 3-44 REED BOX INSTALLATION 3-44 HEAP INSTALLATION 3- 45 BREAK-IN PR.OCEDURES 3-46 4 FUEL INTPODUCTICPN 4 - 1 GENERAL CARBIJR ETIPN INFORMATION 4- 1 FUEL SYSTEM 4- 3 TROUBLESHOOTING 4 - 3 Fuel Pump Tests 4 - 5 Fuel Line Test 4-6 Rough Engine Idle 4-7 Excessive Fuel Consumption 4-7 Engine Surge 4-8 JOHNSCaW/EVINW UTPE CAFBURETQPS 4-8 TYPE IA CARPURETOR HBOWNCPRAFT, CaOUBLE BRL. WITH HIGFJ- APJD LOW- SPEED NEEDLE VALVES 50 HP -- 1958 AP'D IF39 1 60 HP -- 1964 ANC 1965 ) 4- 9 75 HP -- 1960 1 TYPE IB CARBURETQR SAME AS TYPE IA EXCEPT WITH FIGF-SPEED FIXED ORIFICE 60 WP - - 1366 ANP 1367 1 65 HP -- 196% 1 75 HP - - -1961 TVRU 1965 1 4- 9 80 IIP -- 1966 ANP 1967 1 85 MI? - - 196% 1 DESCRIPT1C)N REMOVAL CARBURETOR PISASSEMBLIP.'G 4-1 1 CLEANING AND IblSPECTIPJG 4-14 ASSEMBLING 4-17 TYPE I1 CARBURETOR 30 HP - - 1964 AND 1965 ) 4-22 100 I-?P -- 1966 TMRU 1968 1 DESCRIPTION Choke System REEK OVAL DISASSEMBLING CEOKE SYSTEF"SEFV1CE 4-3$ Peat/Electric Choke I? ernoval 4-35 Installation 4-37 All Electric Choke F emovall & Pisassembling It-?.? Assembling Water Choke Pescriptim P ernoval Installation ASSEhWPWG IVYFALLATION Fl EL PUVP SERVICE Trsubleshaot ing Removal an8 Repair Cleaninp and Inspecting Assernbline, and Installation FUEL TAWK SERVICE ©eblue-dist 2007

5 IGNITION INTRODUCTION 5- 1 Ignition Systems 5- 2 SPARK PLUG EVALUATION 5- 3 Removal 5- 3 EXAMINATI@N 5-3 OTHER IGNITION PARTS 5- 5 Description 5-5 TYPE I IGNITION DISTRIRlJTOF VAGNETO 50 HP - - 1958 AND 1959 60 HP -- 1964 TVRIJ 1?66 ) 75 HP -- 196Q TI4RtI 1965 ) 80 HP -- 1966 1 Description TRCPUALESHOOTI1\?G SERVICING General Information Removal Servicing Cleaning: and Inspecting Installation BELT REPLACEMENT Engine M istimed TYPE I1 IGNITIQN DISTRIBUTOR BATTEP Y 75 HI? -- 1961 THRU 1965 ) 80 HP -- 1966 AND 1967 90 HP - - 1964 AND 1965 1 108 HP -- 1966 Description TROUBLESHOOTING SERVICING Removal - Cleaning and Inspecting Installation BELT REPLACEMENT Engine Mistimed Installation TYPE I11 IGNITION CAPACITOR lXSCHARGE (CLd) WITM SENSOR 100 MP - - 1967, 1968, AND 1972 ) 115 HP -- 1969 AND 1970 125 HP - - 1971 AND 1972 ) TROUBLESHOQTING 100 HP -- 1967 AND 1968 TROUBLESHOOTING 115 HP -- 1969 AND 1370 TROLJBLESHQOTHNG 108 HP -- 1972 125 HP -- 1971 AN@ 1972 COVPONENT REPLACEMENT Rotor Replacement 100 hp - - 1967 Sensor Replacement 100 hp -- 1967 Powerpack Replacement 100 hp -- 1967 COMPONENT REPLACEArENT IGNITION PARTS UNPEF FLY WHEEL: STATOR, CISTRIBUTOR CAP, EIST WIBUTOR ROTCW, SENSOR ROTOR, APE? SEE1% 100 MP - - 8968 ANC 1972 115 HP -- 8969 ANP 1970 125 HP -- 1971 ANE 1972 W emoval Cleaning and Inspecting Assembling CAPACITOR DISCWAR GE (CG) WITM BREAKER P(3IbT5 55 HP 3- CYL. -- 1968 AND 1969 60 HP 3-CYL. -- 1 978 AND 1971 6 5 MP V4 -- 19653 $5 EP V4 -- 1968 TEIRU 1972 100 MP V4 -- 197 1 Cescription Safety General Troubleshootiwe All CD Wodels Troubles hooting 55 hp - - 1968 and 1969 65 hp -- 1968 85 hp -- 1968 Troubles hooting 85 h~ -- 1969 thru 6972 100 hp -- 1971 Troubles hooting 40 hp - - 1970 and 197 1 CL IGNITION SYSTEV PARTS REPLACEWENT AND AEJUSTMENT 55 HP 3- CYL - - 1968 eC 1969 60 HP 3-CYL -- 1570 & 1571 65 HP V4 -- 1968 85 flP V4 -- 1968 THRU 1972 100 HP V4 -- 1971 Removal Cleaning and Inspecting ©eblue-dist 2007

5 IGNITION (CONT) SYWCFRCNIZING C"ISTRIBUT0R ANC CARBURETOR hvP,Gh'FTQ IGNITION MGPELS 50 tiP 1958 ANL" 1959 5- 92 SYNCH-'RCNIZING CISTRIBUTOR AND CARBURETOR BATTERY IGNITION NAGNETQ IGNITION 60 HP -- 1964 THRU 1966 75 PI? -- 1960 THRU 6963 $0 HI' -- 1906 ANI3 1967 90 IF? -- 3964 ANE 1965 100 E? -- 1966 ANC 1967 6 ELECTRICAL INTROIPUCTICPJ 6-1 BATTEPIES 6- 1 Jumper Cables 6-5 Pual Battery Installatic\n 6-5 GAUGES AND FORPS 6-7 FUEL SYSTEbb Fuel Gauge 6-8 Fuel Gauge Poskup 6-8 Fuel Gauge Troubleshooting 6-9 TACFOPJETER 6-10 KOWNS 6-10 ELECTRICAL SYSTEM GENERAL IPIF(?Ri?4ATI@N 6-1 1 GENER ATCF CPARGIFG CIRCIJIT Troubleshooting 6-12 Generator Service 6-10 Cleaning and Inspecting 6-18 Assemhli ng 6-20 ALTER NATPR CpAP GIPG CIRCUIT Pperation 6- 22 Troubleshooting 6-24 ALTERblATOFs WIW PATTER Y IGb'.'ITI[ON WC9PEkS 190 1 THR tJ 1967 6- 25 ALTER PIPTOP VJITF" CP IGWITION 100 FP -- 1907 AND ALL cp IGPIITIC\P. 1968 TPFelir 1972 6- 27 Troubleshootinp 6- 27 CYPKE CIRCUIT SERVICE 6- 31 STAP TEP FVTCP CIPCIJIT SEPVICE Circuit Pescription 6-31 Starter P'otor Description 6-32 Tr~ubleshsstin 6-34 Testim 6-34 STAP T E PCTCP, rmvE G E A R Starter Removal All \'hts 1958 Thru 1958 6- 37 Starter Crive Removal 6-37 Cleanine and Inspecting 6-38 Installation 6-38 STARTEFF PRIVE GEAR SEW VICE 55 HE ' 3-CYLIIWPEP 1968 AFT 1965 1 60 WP 3-CXLIP.!@ER 1970 AND lQ71 1 85 HP W4 -- lQ49 TFRU 1972 ) 6-39 115 HP V4 -- 1969 ANT31 1870 ) 125 VP Yk - - 1971 AND 1972 ) R ernoval 6- 39 Pisassemblinp 6-40 Cleaning and Inspecting 6-41 Assembling 6-41 ©eblue-dist 2007

PELCO-W EF4Y SERVICE R ernoval 64 1 Disassembling 6-k2 Armature Testing 6- 43 Cleaning and Inspecting 6- 44 Assembling 6- 45 AUTOLITE SERVICE Removal 6- 47 Disassembling 6-48 Armature Testing 6-48 Cleaning and Inspecting 6-50 PR ESTOLITE SER VICE Removal from Starboard Installation with Separate Drive Gear 6-52 Removal from Port Side Installation with Drive Gear on Armature Shaft 6-52 Disassembling 6-53 Armature Testing 6- 53 Cleaning and Inspecting 6- 55 Assembling 6- 56 STARTER MOTOR TESTIP'G 6- 57 STARTER MOTOR INSTALLATION 6- 57 7 ACCESSORIES DESCRIPTION 7- 1 SHIFT BOXES 7 - 1 OLD- STYLE DOUBLE LEVER Troubleshooting 7 - 3 h)isassembling 7-4 Cleaning and Inspecting 7- 5 Assembling 7 - 5 NEW-STYLE SWIFT LEI'EF. Troubleshooting 7 - 6 Removal 7 - 8 Disassembling 7- 8 Cleaning and Inspecting 7-0 Assembling 7- 10 ELECTRIC GEAR BOXES AbJD SINGLE LEVER CONTROL JOHNSON I JNITS 7- 12 Troubleshooting 7-12 Disassembling 7- 15 Cleaning and Inspecting 7-16 Assembling 7- 17 PUSHBUTTON SHIFT BOX EVINRUDE UNITS Ob'LY 7 - 1" Troubleshooting 7-20 Disassembling 7-22 Cleaning and Inspecting 7-24 Assembling 7-74 Troubleshooting 7-26 Disassembling 7- 29 clean in^ and inspect in^ 7-31 Assembling 7-32 CABLE ENP FITTIPIG IPJSTALEPTION AT EWGIF'E EFT" 7-34 8 LOWER UNIT DESCRIPTICN 8 - 11 CPAPTER COVERAGE 8- 1 ILLUSTRATIONS 8-2 PROPELLER SERVICE 8-2 Propeller with Shear Pin Removal 8-2 Installation 8- 3 Exhaust Propeller 8-3 Removal 8-4 Installation 8-4 WATER PUMP REMOVAL 8-1 8 Lower Unit Pisassemblinp 8- 1 E Cleaning and Inspectinn $- Lower Unit Assembling: 8-16 WATER PUMP INSTALLATIQN 8- 19 Lower Unit %nstallatio 8-20 ©eblue-dist 2007

8 LOWER UNIT (CONTI TYPE H I L@lVJE hThTIT SEPVICE VAPJUAL SFWT SIPfGEE ENCLOSEI" RQLJSIIPJG 48 PP -- 1964 TERU BQR7 1 65 I-'P -- 1068 75 PF -- 1968 TFRU 1965 ) 8- 22 80 PP -- 1066 ANP 1967 'B 85 EP - - l"68 ) WATER PUMP REMOVAL 8- 24 Lower 1Jnit Pisassembliw p-sk clean in^ and Inspecting 8-3" kewer (Init Assemhline 8-31 WATER PUMP INSTALLATION P-36 Lower [!nit Installatio P- ?P Pescription Type I11 and Type IV Units 8- 40 Troubles hooting Type I11 and Type IV Units 8- 48 Removal Type III Units 8-43 WATER PUMP REMOVAL 8-Sg Pisassembling 8-44 Cleaninp an8 Inspectinp $-50 Assembling 8- 52 WATER PUMP INSTALLATION 8-60 Lower llnit lInstallaticm 8- 6 1 TYPE 1IV LCYUER UP1.'IT EkECTROKATIlr BOO FB -- 1906 TPR P_I 11968 8-62 Troubleshooti~ 8- 63 WATER PUMP REMOVAL 8-64 Lower Unit Pisassembling 8-h@ CBeanin and Inspecting 8-Go Lower ifnit Asse~blinp 8-7 1 WATER PUMP INSTALLATICN 8- 80 Lower Unit Installation 8-8 1 Description Troubleshooting Lower Unit Removal WATER PUMP REMOVAL 8-86 Lower Unit Pisassembling 8- 87 "Frozen'Tropeller Shaft 8- 83 Cleaning and Inspecting 8-93 Lower Unit Assembling 8- 95 WATER PUMP INSTALLATION 8- 105 Lower Unit Ynstallation 8-108 'FFFOZEf."T!?OPEkkER Description 8-1 18 P emaval 8-1 10 9 HAND STARTER 10 MAINTENANCE ©eblue-dist 2007

APPENDIX A-4 A- 8 A- 10 A-IC A-P B 75 hp V4 with Papnets, Generator, and Standard Shift -- 1 O6 1 75 hp thru 90 hp V4 with Electric Shift 1961 thru 1965 80 hrz V4 with Generator -- 1966 88 hp V4 -- 1367 80 hp V4 with Electric Shift -- 1?67 85 hp V4 -- 15568 85 hp V4 with Electric Shift -- 1?68 $5 hp V4 with PJternator %?69 and 1970 85 hp Y4 with Alternator -- 1972 $5 hp and 100 hp Vk with Alternator -- 1.971 100 hp V4 with CD Ignition I967 and 1968 100 hp V4 and 125 hp V4 with Alternator -- 1972 1 15 hp V4 -- 1969 and 1970 125 hp Y4 -- 1971 ©eblue-dist 2007

SAFETY 1-1 INTRODUCTION Your boat probably represents a sizeable investment for you. In order to protect this investment and to receive the maximum amount of enjoyment from your boat it must be cared for properly while being used and when it is out of the water. Always store your boat with the bow higher than the stern and be sure to remove the transom drain plug and the inner hull drain plugs. If you use any type of cover to protect your boat, plastic, canvas, whatever, be sure to allow for some movement of air through the hull. Proper ventilation will assure evaporation of any condensation that may form due to changes in temperature and humidity. 1- 2 CLEANING, WAXING, AND POLISHING An outboard boat should be washed with clear water after each use to remove sur - face dirt and any salt deposits from use in salt water. Regular rinsing will extend the time between waxing and polishing. It will also give you " pride of ownership" , by having a sharp looking piece of equipment. Elbow grease, a mild detergent, and a brush Whenever the boat is stored, for long or short periods, the bow should be slightly higher than the stern and the drain plug in the transom removed to ensure proper drainage of rain water. will be required to remove stubborn dirt, oil, and other unsightly deposits. Stay away from harsh abrasives or strong chemical cleaners. A white buffing com- pound can be used to restore the original gloss to a scratched, dull, or faded area. The finish of your boat should be thoroughly cleaned, buffed, and polished at least once each season. Take care when buffing or polishing with a marine cleaner not to over - heat the surface you are working, because you will burn it. A small outboard engine mounted on an aluminum boat should be removed from the boat and stored separately. Under all cir - cumstances, any outboard engine must AL- WAYS be stored with the powerhead higher than the lower unit and exhaust system. This position will prevent water trapped in the lower unit from draining back through the exhaust ports into the powerhead. Lower unit badly corroded because the zinc was not replaced. Once the zinc is destroyed, more costly parts will be damaged. Attention to the zinc condition is extremely important during boat operation in salt water. ©eblue-dist 2007

I--2 SAFETY A new zinc prior to installation. This inexpensive item will save corrosion on more valuable parts. Most outboard engines have a flat area on the back side of the powerhead. When the engine is placed with the flat area on the powerhead and the lower unit resting on the floor, the engine will be in the proper altitude with the powerhead higher than the lower unit. 1-3 CONTROLLING CORROSION Since man first started out on the water, corrosion on his craft has been his enemy. The first form was merely rot in the wood and then it was rust, followed by other forms of destructive corrosion in the more modern materials. One defense against cor - rosion is to use similar metals throughout the boat. Even though this is difficult to do in designing a new boat, particularily the undersides, similar metals should be used whenever and wherever possible. A second defense against corrosion is to insulate dissimilar metals. This can be done by using an exterior coating of Sea Skin or by insulating them with plastic or rubber gaskets. Using Zinc The proper amount of zinc attached to a boat is extremely important. The use of too much zinc can cause wood burning by plac - ing the metals close together and they be - come "hot". On the other hand, using too Diameter and pitch are the two basic dimensions of a propeller. The diameter is measured across the circumference of a circle scribed by the propeller blades, as shown. small a zinc plate will cause more rapid deterioration of the metal you. are trying to protect. If in doubt, consider the fact that is is far better to replace the zincs than to replace planking or other expensive metal parts from having an excess of zinc. When installing zinc plates, there are two routes available. One is to install many different zincs on all metal parts and thus run the risk of wood burning. Another route, is to use one large zinc on the tran - som of the boat and then connect this zinc to every underwater metal part through internal bonding. Of the two choices, the one zinc on the transom is the better way to go- Small outboard engines have a zinc plate attached to the cavitation plate. Therefore, the zinc remains with the engine at all times. 1-4 PROPELLERS As you know, the propeller is actually what moves the boat through the water. This is how it is done. The propeller oper - ates in water in much the manner as a wood screw does in wood. The propeller " bites " into the water as it rotates. Water passes between the blades and out to the rear in the shape of a cone. The propeller " biting" through the water in much the same manner as a wood auger is what propels the boat. Propeller and associated parts in order, washer, snear-pin, and nut, ready for installation. ©eblue-dist 2007

PROPELLERS 1 - 3 Arrangement of propeller and associated parts, in order, for a small horsepower engine. Diameter and Pitch Only two dimensions of the propeller are of real interest to the boat owner: the diameter and the pitch. These two dimen - sions are stamped on the propeller hub and always appear in the same order: the diameter first and then the pitch. For instance, the number 15 - 19 stamped on the hub, would mean the propeller had a diameter of 15 inches with a pitch of 19. The diameter is the measured distance from the tip of one blade to the tip of the other as shown in the accompanying illus- tration. The pitch of a propeller is the angle at which the blades are attached to the hub. This figure is expressed in inches of water travel for each revolution of the propeller. In our example of a 15 - 19 propeller, the propeller should travel 19 inches through the water each time it revolves. If the propel - ler action was perfect and there was no slippage, then the pitch multiplied by the propeller rpms would be the boat speed. Most outboard manufacturers equip their units with a standard propeller with a diameter and pitch they consider to be best suited to the engine and the boat. Such a propeller allows the engine to run as near to the rated rpm and horsepower (at full throt - tle) as possible for the boat design. The blade area of the propeller deter - mines its load - carrying capacity. A two- blade propeller is used for high- speed run - ning under very light loads. Shear-pin installed behind the propeller instead of in front of the propeller. A four - blade propeller is installed in boats intended to operate at low speeds under very heavy loads such as tugs, barges, or large houseboats. The three - blade propeller is the happy medium covering the wide range between the high performdnce units and the load carrying work horses. Propeller Selection There is no standard propeller that will do the proper job in very many cases. The list of sizes and weights of boats is almost endless. This fact coupled with the many boat - engine combinations makes the propel - ler selection for a specific purpose a diffi - cult job. In fact, in many cases the propel - ler is changed after a few test runs. Proper selection is aided through the use of charts set up for various engines and boats. These charts should be studied and understood when buying a propeller. However, bear in mind, the charts are based on average boats Diagram to explain the pitch dimension through the water if there was no slippage. 1- 21" -1 of a propeller. The pitch is the theoretical distance a propeller would travel ©eblue-dist 2007

1958-1972 Johnson Evinrude Outboard 50HP to 125HP Motors Service Repair Manual ( Preview, Perfect for the DIY person!)

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