1965 - 1978 Evinrude Johnson Outboard 1.5 - 35 Hp ( 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP ) Service / Repair Manual - Production years 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 Evinrude Outboard Manual ( 65 66 67 68 69 70 71 72 73 74 75 76 77 78 ) - Download !! File Format: PDF Compatible: All Versions of Windows & Mac Downloadable: YES Language: English Requirements: Adobe PDF Reader DESCRIPTION: ========= COVERS ALL MODELS & ALL REPAIRS A-Z THIS IS NOT SOME GENERIC REPAIR INFORMATION. IT IS A VEHICLE SPECIFIC SERVICE MANUAL! THIS HIGHLY DETAILED SERVICE REPAIR MANUAL CONTAINS EVERYTHING YOU WILL EVER NEED TO SERVICE, REPAIR, RESTORE, MAINTAIN, REFURBISH OR EVEN REBUILD YOUR VEHICLE. COMPLETE & EASY TO USE STEP-BY-STEP INSTRUCTIONS, ILLUSTRATIONS, DIAGRAMS, SPECIFICATIONS & WIRING SCHEMATICS WILL HELP ASSIST YOU TO PERFORM RIGHT FROM VERY SIMPLE REPAIRS TO COMPLEX ONES !!. CLEAR PICTURES AND ZOOMABLE ILLUSTRATIONS HELP YOU PERFORM YOUR SERVICE REPAIR WITH UTMOST EASE! NO TECHNICAL EXPERTISE REQUIRED. YOU SEE IT AND YOU DO IT (DO-IT-YOURSELF MANUAL) THIS IS THE SAME MANUAL THAT TECHNICIANS AND MECHANICS IN DEALERSHIPS & ELSEWHERE USE TO SERVICE & REPAIR YOUR VEHICLE! YOU CAN REFER THIS MANUAL RIGHT FROM YOUR PC/LAPTOP OR ONLY PRINT OFF THE PAGES THAT YOU REQUIRE FOR THE MOMENT. -------------------------------------------------------------------------------------- SOME OF THE REPAIRS & 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 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP - 1973 Installation 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP - 19776 TYPE III STARTER 35 hp - 1976 COIL SPRING WITH SWING ARM 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP - 1976 VERTICAL MOUNT 4 HP 19778 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 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 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 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP Cleaning and Inspecting 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP -------------------------------------------------------------------------------------- PLEASE NOTE: ========= 1) Looking for someother Service manual, please check: (for massive collection of service manuals.) 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