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Evinrude 4906B 4HP 1969, Owner'S Manual

The Evinrude 4906B 4HP 1969 is a reliable outboard motor perfect for small boats. Ensure smooth sailing by reading the Owner's Manual available for free download on manualshive.com. This comprehensive manual provides all the information you need to properly maintain and operate your Evinrude motor.

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APPENDIX

DRILL SIZE CONVERSION CHART

SHOWING

MILLIMETER SIZES, FRACTIONAL AND

DECIMAL INCH SIZES AND NUMBER DRILL SIZES

Milli·

Dec.

Frac-

Num·

Milli·

Dec.

Frae-

Num-

Milli·

Dec.

Frac-

Num·

Milli·

Dec.

Frae-

Num·

Milli·

Dec.

Frae-

Meter

Equiv.

tional

ber

Meter

Equiv.

tional

ber

Meter

Equiv.

tional

ber

Meter

Equiv.

tional

ber

Meter

Equiv.

tional

.1

.0039

1.75

.0689

....

.1570

22

6.8

.2677

10.72

.4219

27/64

.15

.0059

....

.0700

50

4.0

.1575

6.9

.2716

11.0

.4330

.2

.0079

1.8

.0709

....

.1590

21

. ...

.2720

I

11.11

.4375

7/16

.25

.0098

1.85

.0728

....

.1610

20

7.0

.2756

11.5

.4528

.3

.0118

....

.0730

49

I

4.1

.1614

. ...

.2770

J

11.51

.4531

29/64

....

.0135

80

1.9

.0748

4.2

.1654

7.1

.2795

11.91

.4687

15/32

.35

.0138

....

.0760

48

.

...

.1660

19

.

...

.2811

K

12.0

.4724

....

.0415

79

1.95

.0767

4.25

.1673

7.14

.2812

9/32

. ...

12.30

.4843

31/64

.39

.0156

1/64

....

1.98

.0781

5/64

. ...

4.3

.1693

7.2

.2835

12.5

.4921

.4

.0157

....

.0785

47

. ...

.1695

18

7.25

.2854

12.7

.5000

1/2

....

.0160

78

2.0

.0787

4.37

.1719

11/64

. ...

7.3

.2874

13.0

.5118

.45

.0177

2.05

.0807

....

.1730

17

.

...

.2900

L

13.10

.5156

33/64

....

.0180

77

. ...

.0810

46

4.4

.1732

7.4

.2913

13.49

.5312

17/32

.5

.0197

....

.0820

45

..

,-

.1770

16

....

.2950

M

13.5

.5315

....

.0200

76

2.1

.0827

4.5

.1771

7.5

.2953

13.89

.5469

35/64

....

.0210

75

2.15

.0846

. ...

.1800

15

7.54

.2968

19/64

.

...

14.0

.5512

.55

.0217

....

.0860

44

4.6

.1811

7.6

.2992

14.29

.5624

9/16

....

.0225

74

2.2

.0866

.

...

.1820

14

. ...

.3020

N

14.5

.5709

.6

.0236

2.25

.0855

4.7

.1850

13

7.7

.3031

14.68

.5781

37/64

....

.0240

73

.

...

.0890

43

4.75

.1870

7.75

.3051

15.0

.5906

....

.0250

72

2.3

.0905

4.76

.1875

3/16

.

...

7.8

.3071

15.08

.5937

19/32

.65

.0256

2.35

.0925

4.8

.1890

12

7.9

.3110

15.48

.6094

39/64

....

.0260

71

"

.

0935

42

.

...

.1910

11

7.94

.3125

5/16

. ...

15.5

.6102

....

.0280

70

2.38

.0937

3/32

..,

.

4.9

.1929

8.0

.3150

15.88

.6250

5/8

.7

.0276

2.4

.0945

....

.1935

10

. ..

.3160

0

16.0

.6299

....

.0292

69

. ...

.0960

41

.

...

.1960

9

8.1

.3189

16.27

.6406

41/64

.75

.0295

2.45

.0964

5.0

.1968

8.2

.3228

16.5

.6496

....

.0310

68

... .

.0980

40

.

...

.1990

8

. ..

.3230

P

16.67

.6562

21/32

.79

.0312

1/32

....

2.5

.0984

5.1

.2008

8.25

.3248

17.0

.6693

.8

.0315

....

.0995

39

. ...

.2010

7

8.3

.3268

17.06

.6719

43/64

...

.

.0320

67

..,

.

.1015

38

5.16

.2031

13/64

...

.

8.33

.3281

21/64

..

.

.

17.46

.6875

11/16

....

.0330

66

2.6

.1024

. ...

.2040

6

8.4

.3307

17.5

.6890

.85

.0335

...

.

.1040

37

5.2

.2047

....

.3320

0.

17.86

.7031

45/64

...

.

.0350

65

2.7

.1063

....

.2055

5

8.5

.3346

18.0

.7087

.9

.0354

....

.1065

36

5.25

.2067

8.6

.3386

18.26

.7187

23/32

,

...

.0360

64

2.75

.1082

5.3

.2086

....

.3390

R

18.5

.7283

...

.

.0370

63

2.78

.1094

7/64

...

. ...

.2090

4

8.7

.3425

18.65

.7344

47/64

.. 95

.0374

... .

.1100

35

5.4

.2126

8.73

.3437

11/32

....

19.0

.7480

...

.

.0380

62

2.8

.1102

...

.2130

3

8.75

.3445

19.05

.7500

3/4

... .

.0390

61

....

.1110

34

5.5

.2165

8.8

.3465

19.45

.7656

49/64

1.0

.0394

... .

.1130

33

5.56

.2187

7/32

...

.

....

.3480

S

19.5

.7677

....

.0400

60

2.9

.1141

5.6

.2205

8.9

.3504

19.84

.7812

25/32

..

,-

.0410

59

... .

.1160

32

....

.2210

2

9.0

.3543

20.0

.7874

1.05

.0413

3.0

.1181

5.7

.2244

....

.3580

T

20.24

.7969

51/64

.. .

-

.0420

58

....

.1200

31

5.75

.2263

9.1

.3583

20.5

.8071

_

...

.0430

57

3.1

.1220

... .

.2280

1

9.13

.3594

23/64

....

20.64

.8125

13/16

1.1

.0433

3.18

.1250

1/8

....

5.8

.2283

9.2

.3622

21.0

.8268

1.15

.0452

3.2

.1260

5.9

.2323

9.25

.3641

21.04

.8218

53/64

... .

.0465

56

3.25

.1279

....

2340

A

9.3

.3661

21.43

.8437

27/32

1.19

.0469

3/64

... .

.1285

30

5.95

.2344

15/64

....

. ...

.3680

U

21.5

.8465

.. .

1.2

.0472

3.3

.1299

6.0

.2362

9.4

.3701

21.83

.8594

55/64

1.25

.0492

3.4

.1338

....

.2380

B

9.5

.3740

22.0

.8661

1.3

.0512

...

.

.1360

29

6.1

.2401

9.53

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3/8

....

22.23

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7/8

..

,

.

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55

3,5

.1378

... .

.2420

C

....

.3770

V

22.5

.8858

1.35

.0513

....

.1405

28

6.2

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9.6

.3780

22.62

.8906

57/64

....

.0550

54

3.57

.1406

9/64

.

...

6.25

.2460

0

9.7

.3819

23.0

.9055

1.4

.0551

36

.1417

6.3

.2480

9.75

.3838

23.02

.9062

29/32

1.45

.0570

....

.1440

27

6.35

.2500

1/4

E

9.8

.3858

23.42

.9219

59/64

1.5

.0591

3.7

.1457

6.4

.2520

....

.3860

W

23.5

.9252

....

.0595

53

. ...

.1470

26

6.5

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9.9

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15/16

1.55

.0610

3.75

.1476

...

.

.2570

F

9.92

.3906

25/64

....

24.0

.9449

1.59

.0625

1/16

.

. . .

....

.1495

25

6.6

.2598

10.0

.3937

24.21

.9531

61/64

1.6

.0629

3.8

.1496

.. .

.2610

G

....

.3970

X

24.5

.9646

... .

.0635

52

.

...

.1520

24

6.7

.2638

....

4040

y

24.61

.9687

31/32

1.65

.0649

B.9

.1535

6.75

.2657

16/64

... .

10.32

.4062

13/32

...

25.0

.9843

1.7

.0669

...

.

.1540

23

6.75

.2657

.

_

..

.4130

Z

25.03

.9844

63/64

....

.0670

51

3.97

.1562

5/32

. ...

.

...

.2660

H

10.5

.4134

25.4

1.0000

1

Summary of Contents for 4906B 4HP 1969

Page 1: ...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 I...

Page 2: ...ICAL 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 Adj...

Page 3: ...tions TROUBLESHOOTING MANUAL SHIFT PROPELLER REMOVAL 8 1 8 1 8 2 8 2 8 7 DRAINING LOWER UNIT LOWER UNIT SERVICE 1 5 hp to 4 0 hp NO SHIFT Lower Unit Removal Water Pump Removal Disassembling Cleaning a...

Page 4: ...31 9 32 9 34 9 34 9 37 9 39 9 39 Removal 9 40 Disassembling 9 40 Cleaning and Inspecting 9 42 Assembling 9 43 Rope Installation 9 43 Starter Installation 9 46 10 MAINTENANCE INTRODUCTION ENGINE SERIAL...

Page 5: ......

Page 6: ...ver 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...

Page 7: ...DIAMETER 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 c...

Page 8: ...peller 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 b...

Page 9: ...AVITATION BURN o Cavitation air bubbles formed at the propeller Manufacturers are constantly fighting this problem as explained in the text from your boat and engine Therefore take time to make the pr...

Page 10: ...good working condition and through proper maintenance and lubr i cation Vibration can also be reduced in some cases by increasing the number of blades For this reason many racers use Rubber hub remove...

Page 11: ...rmance when for ward and rotational speed is high and or the propeller breaks the surface of the water Progressive pitch starts low at the lead ing edge and progressively increases to the trailing edg...

Page 12: ...protection against leakage Re inforced flexible sections should be installed in fuel lines where there is a lot of motion such as at the engine connection The flaring of copper tubing should be anneal...

Page 13: ...arpet and then touch a metal object All of these actions cause an elec trical charge In most cases static electri city is generated during very dry weather conditions but when you are filling the fuel...

Page 14: ...operly grounded to prevent static electricity Static electricity could be extremely dan gerous when taking on fuel LOADING 1 9 opening the fill pipe deck fitting One way to ground yourself is to dip y...

Page 15: ...buoyancy NEVER use them for cushions or other purposes 5 Coast Guard Approved equipment is equipment which has been approved by the Commandant of the U S Coast Guard and has been determined to be in c...

Page 16: ...urn its wear er in a vertical or slightly backward position in the water The turning action is not as pronounced as with a Type I The device will not turn as many different type persons under the same...

Page 17: ...during daytime sunrise to sunset for Recrea tional boats less than 16 ft 5 meters in length Boats participating in organized events such as races regattas or marine parades Open sailboats not equippe...

Page 18: ...Coast Guard Approved pyrotechnic de vices carry an expiration date This date can NOT exceed 42 months from the date of An adequately stocked first aid kit should be on board for the safety of crew and...

Page 19: ...one or more of the following conditions as a boat of closed construction subject to fire extinguisher regulations A suitable fire extinguisher should be mounted close to the helmsman for emergency use...

Page 20: ...ill not knowingly accept a cheap parachute A good boater should not accept a bargain in lifejackets fire ex tinguishers or compass Take the time and spend the few extra dollars to purchase a compass t...

Page 21: ...one of non magnetic ma terial test to determine whether it is merely magnetic a small piece of iron or steel or some magnetized steel Bring the north pole of the compass near the object then shift an...

Page 22: ...an alum inum can was placed on one side and the compass read as 204 degrees a good 14 degrees off Next the full can was moved to the opposite side of the compass and again a reading was observed This...

Page 23: ...lf Bilge Pumps Automatic bilge pumps should be equip ped with an overriding manual switch They should also have an indica tor in the opera tor s position to advise the helmsman when the pump is operat...

Page 24: ...r and operator If the operator cannot file the report for any reason each person on aboard MUST notify the authorities or determine that the report has been filed 1 15 NAVIGATION Buoys In the United S...

Page 25: ...in any way as covering the entire subject Powered boats must yield the right of way to all boats without motors except when being overtaken When meeting an other boat head on keep to starboard un les...

Page 26: ...properly no matter how much time and expense is spent on the tune up Poor Damaged piston probably caused by inaccurate fuel mixture or improper point setting compression must be corrected or the tune...

Page 27: ...r fine adjustments The time effort and expense of a tune up will not restore an engine to satisfactory performance if the pistons are damaged Major Tune up Remove head Clean carbon from pistons and cy...

Page 28: ...y also be caused by running the engine out of the water For unknown reasons many opera tors have formed a bad habit of running a small engine without the lower unit being submerged Such a practice wil...

Page 29: ...e damaged the head should be removed and and a Hell coil insert installed If an at tempt is made to drill out the opening with the head in place some of the filings may fall into the cylinder and caus...

Page 30: ...nd synchronization are essential for proper engine operation An engine may be in apparent excellent me chanical condition but perform poorly un less the points and synchronization have been adjusted p...

Page 31: ...sion If the battery has remained under charg ed check for high resistance in the charging circuit If the battery appears to be using too much water the battery may be defec tive or it may be too small...

Page 32: ...tor Specifi cations in the Appendix With a fully charged battery the ammeter reading will be a bit lower because of the self regulating characteristics of the generating systems A 40 hp engine with a...

Page 33: ...tion of the idle and high speed adjustments Notice the pressure type fuel con nector CAUTION Water must circulate through the lower unit to the engine any time the en gine is run to prevent damage to...

Page 34: ...starting a cold engine It is better to have the adjustment on the rich side rather than on the lean side Stating it another way do not make the adjustment A 3 0 hp engine with the low and high speed a...

Page 35: ...y first removing the cap then the filter element cleaning the parts and drying them with compressed air and finally installing them in their original position A fuel pump pressure test should be made...

Page 36: ...ed INTERNAL WIRING 2 11 wire to a cutout switch on top of the engine This cutout switch provides a safety to break the ground to the solenoid in the event the engine starts at a high rpm Therefore the...

Page 37: ...ical connec tor should be inspected and cleaned each season This connector is exposed and vulnerable to dampness and corrosion Resistance Test See the Wiring Diagram in the Appendix Use a magneto anal...

Page 38: ...entering the power head by way of the drive shaft housing and the exhaust ports during the flush It will also prevent residual water from being trap ped in the drive shaft housing and other passagewa...

Page 39: ...commercial applications The higher rpm is recommended for light fast boats The wide rpm range will result in greater satisfaction because of maximum performance and greater fuel economy If the engine...

Page 40: ...AIN ING GEAR Oil The gear oil in the lower unit should be checked on a daily basis during the season of operation The oil should be drained and replenished with new oil every 100 hours of operation BO...

Page 41: ...drastically hampered if the bottom is damaged the center the bow will be light and the boat will plane more efficiently For this test the boat must be operated in a body of water Check the engine rpm...

Page 42: ...ivered to the combustion chamber 2 The complete lubrication system 3 In most cases the ignition system 4 The frequency of the power stroke These differences will be discussed briefly and compared with...

Page 43: ...MOSPHERIC AIR PRESSURE Air flow principle for a modern carburetor with each revolution of the crankshaft Compare this system with a four cycle en gine A stroke of the piston is required to accomplish...

Page 44: ...nd the fresh fuel charge is compressed inside the combustion chamber DEFLECTOR INTAKE COMPRESS ION INTRODUCTION 3 3 Pressure in the crankcase decreases as the piston moves upward and a fresh charge of...

Page 45: ...ifferent type of crankshaft installa tions The illustrations accompanying the text are from different size units and the cap tions clearly identify which model is cover ed Exploded drawings showing pr...

Page 46: ...in salt water or has not had proper maintenance or shelter or any number of other factors then separating the powerhead from the exhaust housing may not be a simple task An air hammer may be required...

Page 47: ...k plug opening if the threads have been damaged On many engines a sending unit is in stalled in the head to warn the operator if Removing the thermostat from the head the engine begins to run too hot...

Page 48: ...storted If the reed is broken the loose piece MUST be located and removed before the engine is returned to service The piece of reed may have found its way into the crankcase behind the bypass cover I...

Page 49: ...the reed tip and the reed plate Close view showing the dimple on the reed plate The reed leaves must straddle the dimple and be centered over the openings for proper operation The reeds must NEVER be...

Page 50: ...y used with a pressure fuel tank REED SERVICE 3 9 Back side of the same plate shown at the bottom of the previous column Notice how the reed stops are centered over the reeds reed from the front side...

Page 51: ...reeds unless they are to be replaced AL WAYS replace reeds in sets NEVER turn used reeds over to be used a second time Lay the reeds on a flat surface and measure all the reed stops If there is a grea...

Page 52: ...S COVERS 3 11 the powerhead and be transferred to the exhaust housing If the cover was the only item over the exhaust ports they would become so hot from the exhaust gases they might cause a fire or a...

Page 53: ...Block Service under Bypass Cover and Exhaust Cover Installation The exhaust area of the powerhead open for inspec tion and cleaning 3 8 TOP SEAL The top seal maintains vacuum and pres sure in the cran...

Page 54: ...sing the proper tools to install the top seal BOTTOM SEAL 3 13 is installed through the driveshaft and holds the seal upward and in place As the powerhead is lowered down over the driveshaft during in...

Page 55: ...crankshaft where the truarc ring fits If the Quadrant ring installed in its retainer at the bottom seal Removing the quadrant seal and retainer from the crankshaft groove is not clean the ring will s...

Page 56: ...od hard forceful blow DO NOT keep beating on the end of the pin because such action would round the pin head until it would not be possible to drive it out of the cover Centering pins are the first it...

Page 57: ...f the cover is distorted it will fail to make a proper seal when it is installed Cylinder block after the crankcase cover has been removed Once the crankshaft has been tapped as described and the prop...

Page 58: ...ice the hole in the rod near where the wrist pin passes through the piston On many rods there is also a hole in the rod at the crank end These two holes MUST AL WAYS face upward during installation Ro...

Page 59: ...of the cylinder and the sharp edge toward the intake side during installation When the rod is installed to the piston the relationship of the rod can only be one way The rod holes must face upward and...

Page 60: ...n must be driven out FROM the loose side This may not seem reason able but there is a very simple explanation By placing the piston in the arbor press cradle with the tight side down and the arbor ram...

Page 61: ...above your knees Set the piston between your legs with the LOOSE side of the piston facing upward Now drive the wrist pin free using a drift pin with a shoulder The drift pin will fit into the hole th...

Page 62: ...ring surface being subjected to water contamination which causes etching The etching re sembles the size of the bearing as shown in the accompanying illustration Inspect the bearing surface of the rod...

Page 63: ...Align the etched marks on the knob side of the connecting rod with the etched marks on the connecting rod cap b Tighten the connecting rod cap at taching bolts securely Installing the rod cap onto th...

Page 64: ...ring may break but if it is difficult to remove it MUST be replaced OBSERVE the pin in each ring groove of the piston The ends of the ring MUST straddle this pin The pin prevents the ring from rotatin...

Page 65: ...on ring locating pins to be sure they are tight There is one locating pin in each ring groove If one locating pin is loose the piston must be replaced Never attempt to replace the pin it is NEVER succ...

Page 66: ...ugh the piston and rod Continue to press the wrist pin through until the groove in the wrist pin for the lock ring is visible on both ends of the pin Remove the assembly from the arbor press Install t...

Page 67: ...through the wrist pin and the shoulder will ride on the end of the wrist pin Use sharp hard blows with a hammer Your legs will absorb the shock without damaging the piston If this method is used on a...

Page 68: ...e Crankshaft with the upper center and lower main bearings ready to be removed CRANKSHAFT 3 27 Crankcase cover with the labyrinth seal area clearly visible the locating pins in the cylinder block The...

Page 69: ...to remove the seal A crankshaft cleaned and ready for installation Crankshaft with a badly corroded throw This crankshaft is unfit for further service from the top main bearing If the same type of sea...

Page 70: ...cating during the honing operation b Pump a continuous flow of honing oil into the work area If pumping is not practical use an oil can Apply the oil generously and frequently on both the stones and w...

Page 71: ...for the do i t yourselfer working at home without the advantage of special tools First purchase a special hose clamp with a strip of metal inside the clamp as shown Checking the ring gap clearance by...

Page 72: ...ermitted to rotate at one point the opening between the ring ends would align with either the intake or ex haust port in the cylinder the ring would expand very slightly catch on the edge of the port...

Page 73: ...ough intake port the clamp is against the piston skirt At this point the ring ends will be together and the cutout on each ring end will be against the pin Tap the piston with the end of a wooden tool...

Page 74: ...e block and at the same time align the hole in each bearing to enable the pin in the block to Bearing locating pins in the cylinder block Each pin must index into a hole in the bearing shown in the il...

Page 75: ...tight and then just a bit more Use a scratchall pick or similar tool and move it back and forth on the outside surface of the rod and cap Make the movement across the mating line of the rod and cap T...

Page 76: ...on slightly because all of the rings will not be visible at one time If there is no spring tension the ring was broken during installation The piston must be removed and a new ring installed Repeat th...

Page 77: ...lled in the rod cap This pin will index into a hole in the rod for proper alignment Tighten the rod cap bolts alternately and evenly in three rounds to the torque value given in the Specifications in...

Page 78: ...washers Bring the bolts up fingertight and then just a bit more Tighten the rod cap bolts alternately and evenly in three rounds to the torque value Tightening the rod cap bolts to the proper torque...

Page 79: ...ylinder block in stallation work should be performed WITH OUT interruption Do not begin the work if a break in the sequence is expected coffee lunch whatever The sealer will begin to set almost immedi...

Page 80: ...gh the crank case cover into the cylinder block CYLINDER BLOCK 3 39 Tighten the bolts to 1 2 the total torque value on the first round to 3 4 the total torque value on the second round and to the full...

Page 81: ...ion on the cylinder block Install the bypass covers and secure them in place with the attaching hardware If a fuel pump is used be sure the same bypass cover is installed in the position from which it...

Page 82: ...ee rounds to the torque value specified in the Appen dix Tighten the bolts to 1 2 the torque value on the first round to 3 4 the total torque value on the second round and to the full torque value on...

Page 83: ...e at any speed after 2 hours BUT NOT at sustained full throttle until another 8 hours of operation Testing a 35 horsepower unit with a pressure fuel tank c Mix gasoline and oil during the break in per...

Page 84: ...BLOCK 3 43 AIR E rp oded drawing of a 3 0 hp powerhead 1956 and the 4 0 hp powerhead 1969 70 with principle parts identified The 4 0 hp unit uses a bearing and seal on the crankshaft instead of the oi...

Page 85: ...3 44 POWERHEAD EXHAUST COVER I LEVER Exploded drawing of a 5 5 hp powerhead 1956 60 principle parts identified...

Page 86: ...45 GASKET FUEL PUMP GASKET Exploded drawing of a powerhead with principle parts identified for the following units 5 5 hp 1961 64 5 0 hp 1965 68 6 0 hp 1965 70 The 6 0 hp unit uses an oil slinger ins...

Page 87: ...3 46 POWERHEAD Exploded drawing of a 7 5 hp powerhead 1956 58 with principle parts identified...

Page 88: ...CYLINDER BLOCK 3 47 HEAD GASKET RING...

Page 89: ...3 48 POWERHEAD HEAD BYPASS COVER Exploded drawing of a 10 hp powerhead 1956 63 with principle parts identified...

Page 90: ...CYLINDER BLOCK 3 49 THERMOSTAT EXHAUST COVER The...

Page 91: ...Exploded drawing of the crankshaft and associated parts for the powerhead shown on the previous page 3 50 POWERHEAD...

Page 92: ...r under heavy duty service the mixture may change to as much as 12 parts air to 1 part fuel Float Systems A small chamber in the carburetor serves as a fuel reservoir A float valve admits fuel into th...

Page 93: ...fuel tank arrangement the filter is actually an intergral part of the fuel pickup Obsolete pressure type fuel tank used extensively until about 1958 The system was replaced by the squeeze bulb arrang...

Page 94: ...needle valves are installed On late model engines the high speed needle valve was replaced with a high speed orifice There is no adjustment with the orifice type These needle valves are used to compe...

Page 95: ...mobile using regu lar gasoline If a sudden increase in gas consumption is noticed or if the engine does not perform Commercial additives such as Sta bii may be used to keep the fuel in the tank fresh...

Page 96: ...he carburetor The ONLY guaranteed method of removing ALL fuel is to take the time to remove the carburetor and drain the fuel Secondly if the engine is operated with the fuel supply shut off until it...

Page 97: ...edle or to a defective float which would cause an extra high level of fuel in the bowl and overflow into the intake mani fold FUEL PUMP TESTS CAUTION Gasoline will be flowing in the engine area during...

Page 98: ...el line connec tor into the engine 4 Defective fuel pump 5 The line from the fuel tank to the fuel pump may be plugged the line may be leaking air or the squeeze bulb may be defective 6 Defective fuel...

Page 99: ...orked to pump fuel to the engine After engine start air pressure forces fuel from the tank to the engine situation simply immerse the ends of the hose in boiling water for a few minutes to soften the...

Page 100: ...periods and then shuts down from lack of fuel the problem may be lack of air pressure in the tank To check for air pressure after the engine has run for just a short period open the fill cap very sli...

Page 101: ...principle parts with important comments for satisfac tory service A set of points unfit for service due to oxidation ROUGH ENGINE IDLE If an engine does not idle smoothly the most reasonable approach...

Page 102: ...the owners pride of ownership and good care While you are checking the bottom take note of the propeller condition A bent blade or other damage will definitely cause poor boat performance If the hull...

Page 103: ...the horsepower and model engines equipped with each CARBURETOR INSTALLATIONS Type I Single barrel front draft with adjustable low speed and high speed needle valves 1 5 hp 3 0 hp 5 0 hp 5 5 hp 1968 70...

Page 104: ...s and then remove the copper fuel line between the shut off valve and the carburetor 4 On engines utilizing a separate fuel tank remove the tie strap or clamp secur ing the rubber hose connecting the...

Page 105: ...igh speed orifice and covered with a plug in approximately the same location in the carburetor as the high speed needle valve Therefore if there is a plug instead of the high speed needle valve remove...

Page 106: ...tween the bowl and the carburetor showing the opening to allow fuel to leave the bowl and enter the idle passage of the carburetor CLEANING AND INSPECTING NEVER dip rubber parts plastic parts diaphrag...

Page 107: ...alled on the carburetor being serviced check the orifice for cleanliness The orifice has a stamped number This number represents a drill size Check the orifice with the shank of the proper size drill...

Page 108: ...AF AIR SILENCER Exploded vtew of a Type I carburetor installed on small Johnson Evinrude engines This carburetor is used with the old style pressure type fuel tank Therefore the filter bowl is incorpo...

Page 109: ...4 18 FUEL Exploded view of a Type I carburetor installed on small Johnson Evinrude engines equipped with the fuel tank attached to the engine The filter on these units is in the tank...

Page 110: ...arburetor Check to be sure the float is square with the carburetor cavity one side is not further away than the other 16 Place the bowl gasket in position on the carburetor and then position the bowl...

Page 111: ...o allow the needle valves to be installed 22 Install the high speed needle valve into the bottom cavity by rotating it CLOCKWISE Allow the needle valve to sea t LIGHTLY then back it out COUNTER CLOCKW...

Page 112: ...gasket material Place a NEW gasket in position on the intake manifold 27 Connect the fuel line to the carbu retor or on engines equipped with a self contained fuel tank replace the line be tween the s...

Page 113: ...ust the high speed by rotating the high speed needle valve CLOCKWISE until the number of rpm begins to drop then rotate the high speed valve COUNTERCLOCK WISE until the highest rpm is reached Re turn...

Page 114: ...erform one of the fol lowing three procedures depending on the choke system installed on the carburetor of the engine being serviced CHOKE SYSTEM 4 23 HEA T ELECTRIC CHOKE REMOVAL 1 Observe the compre...

Page 115: ...r Remove the solenoid and take care to retain the spring inside the solenoid Remove the choke solenoid gasket LEVER SPRING 6 Using a pair of needle nose pliers reach inside the choke base and remove t...

Page 116: ...ing the clamp to the carburetor Remove the choke solenoid from the carburetor The choke solenoid CANNOT be serviced The boot should be in good condition It may be re moved by sliding it off the soleno...

Page 117: ...em A check valve and orifice is installed in the water system to prevent flooding of the diaphragm when the manifold pressure fluc tuates during slow speed operation A punc ture or other damage to the...

Page 118: ...through the chamber 4 After the cover has been removed it is not necessary to remove the choke base from the carburetor Remove the four screws securing the choke head and then remove the head 5 Notice...

Page 119: ...the carburetor being ser viced has a front shield installed remove the top screw 2 Remove the two screws on the front side of the carburetor cover Remove the cover from the front of the carburetor 3...

Page 120: ...eedle valve 7 Loosen the packing nut securing the high speed needle valve to the carburetor bowl Turn the high speed needle valve COUNTERCLOCKWISE until it is free then remove it from the carburetor b...

Page 121: ...eed nozzle Remove the high speed nozzle from the carburetor using the proper size screwdriver to prevent possible damage to the nozzle If difficulty is experienced in removing the high speed nozzle le...

Page 122: ...ges in the castings with compressed air Check all of the parts TYPE II CARBURETOR 4 31 GOOD Compare this new needle valve with the worn needle to the left and passages to be sure they are not dogged o...

Page 123: ...rrs which might cause a leak Check the float for deterioration Check to be sure the float spring has not been stretched If any part of the float is damaged the unit must be replaced Check the float ar...

Page 124: ...askets are contained TYPE II CARBURETOR 4 33 In the kit V ost repair kits contain more parts and gaskets than are needed because the kit may be used to service a wide range of carburetor models 1 Inst...

Page 125: ...r the nozzle Force the gasket down onto the carburetor stem 5 Place a NEW gasket in position on the the carburetor base NEVER attempt to install a used gasket at this location As the gasket is used th...

Page 126: ...s not level use a pair of needle nose pliers and CAREFULLY bend the foat tab SQUARELY until the float is in the correct position level with the carbu retor Check to be sure the float is square with th...

Page 127: ...d by hand but with just a little difficulty 13 Install the high speed orifice into the carburetor bowl using the proper size screwdr iver 14 Install a NEW drain plug gasket and then thread the drain p...

Page 128: ...stall a NEW gasket and screen onto the front of the carburetor 19 If a front cover is used on the unit being serviced install the front cover and secure it in place with the two attaching screws 20 In...

Page 129: ...ger and spring by hooking the spring into the choke lever 2 Insert a NEW gasket into the cavity of the choke base 3 Insert the spring into the bore of the choke solenoid 4 Work the choke solenoid up t...

Page 130: ...buretor Connect the choke quick disconnect on the choke wire leading to the dash Install the starter and genera tor if the engine being serviced is equipped with these two units 8 Connect the heat tub...

Page 131: ...d and into the lever attached to the carburetor Install the washer and cotter pin 4 Clean the surface of the intake mani fold thoroughly Check to be sure all old gasket material has been removed Place...

Page 132: ...PHRAGM TYPE II CARBURETOR 4 41 4 Lower the stem down through the spring and diaphragm and onto the base 5 Install the cover and secure it in place with the attaching screws Tighten the screws ALTERNAT...

Page 133: ...CARBURETOR ADJUSTMENTS GOOD WORD Under all conditions the ignition and fuel system MUST be synchronized before the fine adjustments to the carburetor are made See Chapter 5 After the synchroni zation...

Page 134: ...the car buretor On later models the reeds were removed from this location and installed between the engine block and the intake manifold TYPE III CARBURETOR 4 43 The early model idle needle valves ex...

Page 135: ...The O ring may be discarded 4 Remove the five screws securing the carburetor to the intake manifold Notice that four of the screws have slots and one is a countersunk screw Lift the carburetor from th...

Page 136: ...ip rubber parts plastic parts nylon parts diaphragms or pump plungers in carburetor cleaner These parts should be cleaned ONLY in solvent and then blown dry with compressed air Place all metal parts i...

Page 137: ...4 46 FUEL LEVER AND LOW SPEED...

Page 138: ...replace any that have developed a groove GOOD WORN WORN GOOD Needle and seat arrangement showing a worn and new needle for comparison TYPE III CARBURETOR 4 47 Parts included in a carburetor repair kit...

Page 139: ...ding condi tion in the carburetor 4 Apply just a drop of oil into the seat and then insert the inlet needle into seat 5 Position a NEW float over the needle and then slide a NEW hinge pin into place 6...

Page 140: ...gasket mater ial Place a NEW gasket in position on the manifold Set the carburetor into place on the manifold and secure it with the five TYPE III CARBURETOR 4 49 attaching screws OBSERVE that one of...

Page 141: ...arm to operating temperature Adjust the low speed idle by turning the low speed needle valve CLOCKWISE until the engine begins to misfire or the rpm drops noticeably From this point rotate the needle...

Page 142: ...anges will be identified in the text All other fuel pumps must be replaced as a unit However the pump cover can be SEAT DIAPHRAGM INLET VALVE OUTLET VALVE Functional diagram to illustrate operation of...

Page 143: ...to removing the cover and cleaning the screen from the engine operate the squeeze bulb in the fuel line until it is firm and then to carefully observe the end of the vacuum hose to detect any fuel le...

Page 144: ...all disc washer because it will be used again 6 Some model pumps may have a small disc washer and long spring installed under the diaphragm Other models may have a large nylon washer and spring DISCAR...

Page 145: ...internal parts necessary to rebuild the pump including diaphragm check valves gaskets etc will be included in the pump repair kit At one time these kits were available from the local O l C dealer at...

Page 146: ...o attaching screws 5 Install the NEW LONG spring over the boss of the retainer and then place the nylon disc washer on top of the spring that was provided in the kit NEVER use the small disc on top of...

Page 147: ...hion the vacuum im pulses from the engine 8 Ease the fuel pump cover down over the diaphragm and then thread the six cover attaching screws into the pump body As each screw is started pull on the edge...

Page 148: ...LINE SERVICE The procedures outlined in this section cover service of or iginal equipment produc ed by Johnson Evinrude Pressurized Fuel System A pressure type fuel tank was used with the early model...

Page 149: ...xtending its ull length the cylinders Installation of new hoses to the carburetor is not a difficult or expensive task The accompanying illustration clearly shows the two hoses connected to the fuel t...

Page 150: ...rom inside of the fuel cap The chain may hang free inside the fuel tank 4 If the chain cannot be disconnected from the cap by removing the retaining screw then remove the cotter pin from inside the ta...

Page 151: ...check valve should allow air to pass up through the tube but prevent the movement of air in the opposite direction If the check valve fails the tests clean the assembly in carburetor cleaner and then...

Page 152: ...because highly flam able fumes dre present and the danger of fire or explosion is present Demand and observe NO SMOKING or open flame in the work area Clean the tank in the out of doors Wash the inter...

Page 153: ...4 62 FUEL Exploded view of a pressure tyoe fuel tank with major parts identified...

Page 154: ...wn through the spring and the housing with the dia phragm seated on the housing Install the relief spring and washer into the housing and hole of the diaphragm 7 Install the spring over the top of the...

Page 155: ...ith the matching holes in the gasket and tank 13 Securing the pump in place with the attaching screws Use NEW tiny gaskets on each screw to prevent fuel linkage through the screw holes 14 Slide the pu...

Page 156: ...catch fuel being discharged from the end of the hose Fuel Line Service The only service work to be performed on the fuel lines is replacement of the 0 rings in the fuel line connectors and re placemen...

Page 157: ...4 66 fUEL...

Page 158: ...the screen for damage It is possible to bend a new piece of screen material around the pickup and solder it in place without purchasing a complete new unit Attach the fuel gauge to the new pickup unit...

Page 159: ...t may have become hardened causing difficulty in working it over the check valve To remedy this situation simply immerse the ends of the hose i boiling water for a few minutes to soften the rubber and...

Page 160: ...uld be started and run per iodicall y up on an outboard motor If you have any doubts concerning your understanding of two cyle engine operation it would be best to study the operation theory section i...

Page 161: ...or of the porcelain which is an indication this plug has been running at the correct tempera ture This means the plug is one with the correct heat range and also that the air fuel mixture is correct R...

Page 162: ...Wear Electrode wear results in a wide gap and if the electrode becomes carbonized it will form a high resistance path for the spark to jump across Such a condition will cause the engine to misfire du...

Page 163: ...nnector side the polarity is reversed 3 The firing end of a used spark plug can give a clue to coil polarity If the ground electrode is dished it may mean polarity is reversed 5 4 WIRING HARNESS CRITI...

Page 164: ...k the engine DOES NOT mean the engine is equipped with a battery type igni tion system A magneto system uses the battery only to crank the engine Once the engine is running the battery has absolutely...

Page 165: ...he spark plug s and continue through the system until the source of trou ble is located Remember a magneto system is a self contained unit Therefore if the engine has a key switch and wire harness rem...

Page 166: ...en the boat is operating in the water If the propeller is released from the TROUBLESHOOTING 5 7 shaft because of an accident striking an underwater object whatever the engine would then be operating u...

Page 167: ...L WORDS These next two paragraphs may well be the most important words in this chapter Misuse of the wiring harness is the most single cause of electri cal problems with outboard power plants A wiring...

Page 168: ...rk plug s by hand This is a rough test to determine if the plug is tightened properly You should not be able to remove the plug without using the proper socket size tool Remove the spark plug s and ke...

Page 169: ...ngs are not stuck in the piston fail to expand properly Therefore it is essential that any compres sion problem be corrected before proceeding with the tune up procedure See Chapter 3 If the power hea...

Page 170: ...ondition Condenser In simple terms a condenser is composed of two sheets of tin or aluminum foil laid TROUBLESHOOTING 5 11 ALTERNATE LAYERS OF INSULATION WAXED PAPER ALTERNATE LAYERS OF FOIL TI N OR A...

Page 171: ...e crankshaft Both points are constructed with a steel base and a tungsten cap fused to the base To properly diagnose magneto spark problems the theory of electricity flow must be understood The flow o...

Page 172: ...wheel type magnetos REMOVAL 1 Remove the hood or enough of the engine cover to expose the flywheel Dis connect the battery connections from the SERVICING 5 13 battery terminals if a battery is used to...

Page 173: ...couple from the sides showing the wiring and ar rangement of parts Breaker Points Condenser Service The armature plate does not have to be removed to service the magneto If it is necessary to remove t...

Page 174: ...d down screw secur ing the non moveable half of the point set to the armature plate 11 Remove the hold down screw securing the condenser to the armature plate Ob serve how the condenser sets into a re...

Page 175: ...Replacement of the top seal on a John son E vinrude engine is NOT a difficult task with the proper tools a seal remover and seal installer NEVER attempt to remove the seal with screwdrivers punch pic...

Page 176: ...tly with the wrong side up SERVICING 5 17 Slide the cam down the crankshaft with the word TOP facing upward Continue working the cam down the crankshaft until it is in place over the Woodruff key or p...

Page 177: ...5 18 IGNITION FLYWHEEL Exploded drawing of a typical magneto system Only one coil and set of points is shown...

Page 178: ...dence the seal has been leaking it MUST be re placed as outlined earlier in this section A coil burned where the high tension lead enters the coil on the bottom side Arcing caused the damcge CLEANING...

Page 179: ...ee screws through the laminated core into the armature plate but DO NOT tighten them If the engine being serviced has a second coil install the other coil in the same manner 4 Check to be sure the spa...

Page 180: ...Armature Plate Installation 8 Slide the armature plate down over the crankshaft and onto the engine Align the screw holes in the armature plate with the holes in the power head retainer After the arm...

Page 181: ...the spring arm to the inside of the post of the base points Continue to work the points on down into the base 13 Observe the points The points should be together and the spring part of the moveable ar...

Page 182: ...n ed at the factory and does not require adjustment Once the point set is properly installed all should be well In most cases breaker contact and alignment will not be necessary If a slight alignment...

Page 183: ...he key in the crankshaft key way Check to be sure the inside taper of the flywheel and the taper on the crankshaft are clean of dirt or oil to prevent the flywheel from walking on the crankshaft while...

Page 184: ...to the torque value given in the following table Connect the battery leads to the battery terminals if a battery is used with a starter motor to crank the engine This particular engine differs from t...

Page 185: ...pendix two numbers will be obtained One for the location of the primary adjustment and the other indicating the method of making the adjustment GOOD WORDS When making the synchronization adjust ment i...

Page 186: ...ctual adjustment is accomplished by ONLY ONE method depending on the engine being ser viced Check the Appendix for the ad justment to be performed The reference numbers are listed in the Appendix unde...

Page 187: ...ced is to be adjusted until pickup is at the proper location and the throttle shaft just begins to move 7 Movement of the shaft can be exag gerated by attaching a short piece of stiff wire to an allig...

Page 188: ...e clip to the throttle shaft as shown The wire jiggling will instantly indi cate movement of the shaft The actual adjustment is accomplished by ONLY ONE of two means depending on the engine being serv...

Page 189: ...n The wire jiggling will instantly indi cate movement of the shaft The actual adjustment is accomplished by ONLY ONE of three means depending on the engine being serviced Check the Appendix for the ad...

Page 190: ...mp for a bait tank Because of its job and the consequences failure to perform in an emergency the best advice is to purchase a well known brand with an extended warranty period from a reputable dealer...

Page 191: ...ting at OOF This second figure indicates the cranking load capacitv and is referred to as the Peak Wa tt Rating of a battery This Peak Watt Rating PWR has been developed to measure the cold cranking a...

Page 192: ...evel should drop below normal the lower tip of the rod is exposed and the upper end glows as a warn ing to add water Such a device is only necessary on one cell cap because if the electrolyte is low i...

Page 193: ...ertically and suck up liquid only until the float is free and floating A pair of pliers should be used to tighten the wingnuts when they are used Securing the wingnuts by hand is not adequate the conn...

Page 194: ...ance at the connections Such corrosion places a strain on all electrically operated devices on the boat and causes hard engine starting BATTERY SERVICE 6 5 attention rr ust be giver to the battery to...

Page 195: ...s and the advantage of the dual installation is lost The switch may be dosed intentionally to take advantage of Schematic drawing for a two battery one engine hookup Sche matic drawing for Q two batte...

Page 196: ...cons tant voltage system is used to reduce the 12 14 volts of the electrical system to an average of 5 vol ts This steady 5 vol ts ensures the gauges will read accurately un der varying conditions fr...

Page 197: ...UGE The fuel gauge is intended to indicate the quantity of fuel in the tank As the experienced boatman has learned the gauge reading is seldom an accurate report of the fuel available in the tank The...

Page 198: ...nections are on a negative grounded system If the pointer fails to move from the FULL position the problem could be one of three faul ts 1 The tank sending unit is not properly grounded 2 Improper con...

Page 199: ...ter readings range from 0 to 6 000 rpm in increments of 100 Tachome ters have solid state electronic circuits which eliminates the need for relays or Maximum engine performance can only be obtained th...

Page 200: ...es are still started only by pulling on a rope On the larger hp engines an electric starter motor coupled with a mechanical gear mesh between the cranking motor and the engine flywheel similar to the...

Page 201: ...0 watts and a radio rated at 30 watts Amps 48 Watts 12 volts 4 Amps In this case if all the lights are on and the radio is being used the total draw on the battery would be 4 amps If the engine is run...

Page 202: ...re the engine MUST be mounted in a body of water to prevent a RUNAWAY condition and serious damage to internal parts or destruction of the unit NEVER attempt to operate the engine above idle speed wit...

Page 203: ...rator will run wild If the amp meter registers a high reading while the generator field is grounded the circuit has a broken wire or the voltage regulator is defective If the amp meter reading does no...

Page 204: ...When a new voltage regulator is instal led the generator must be polarized BE FCRE the cover is installed CHARGING CIRCUIT 6 15 3 Polarize the new regulator by first connecting the posi tive lead to...

Page 205: ...ewdriver or other similar tool and pry the puller up and free of the generator shaft Hold the generator and at the same time remove the nuts from the top of the generator support bracket and the gener...

Page 206: ...IT 6 17 between the commutator bars on the arma ture Perform the test again If the hack saw blade still vibrates during the test the armature has a short and MUST be replaced Testing for a Ground 7 Ob...

Page 207: ...meter indicates continuity the positive terminal insulation through the generator frame is broken down and MUST be replac ed Positive Brush Test for Ground 11 Using a test lamp or ohmmeter make contac...

Page 208: ...THRU BOLT UPPER HEAD ARMATURE BEARING FRAME CHARGING CIRCUIT 6 19 Exploded view of a typical generator showing arrangement of major parts BRUSH 2 LOWER HEAD...

Page 209: ...n the commutator bars should be 1 3 4 This undercut must be the full width of the insulation and flat at the bottom A triangular groove is NOT satisfactory After the undercut work is completed the slo...

Page 210: ...t personal INJURY or damage to the generator 1 Connect a jumper wire between the field terminal and a good ground on the case Connect a second jumper wire be tween the positive battery terminal and th...

Page 211: ...h to connect or disconnect the starter from the battery The operator controls the switch with a pushbutton or key switch A cutout switch is installed in the sys tem to prevent starting the engine if t...

Page 212: ...ill strike the splin es and the rubber cushion will not absorb the shock STARTER MOTOR 6 23 The sound of the motor during cranking is a good indication of whether the starter motor is operating proper...

Page 213: ...harged b Throttle advanced too far beyond fast idle speed Typical Bendix spring arrangement on a starter motor A small amount or 011 on the Shaft in the spring area will prolong satisfactory operation...

Page 214: ...6 to identify exactly where the connection or test is to made Starter Motor Turns Slowly a Battery charge is low Charge the battery to full capacity b Electrical connections corroded or loose Clean an...

Page 215: ...jump er wire at No 8 the starter solenoid and the other lead to a good ground Connect a second jumper wire at No 2 the positive terminal of the battery to No 6 the starter solenoid The voltmeter shou...

Page 216: ...E GEAR 6 27 CASTELLATED NUT Two different type drive nuts used on outboard starter motors The nut on the left is a self locking type and the right one is a castellated nut with a cotter pin Type I Dri...

Page 217: ...e sta rter motor pro ceed directly to Section 6 16 To install the starter motor onto the engine if no further work is to be perform ed proceed directly to Section 6 17 DISASSEMBLING Type II Drive Gear...

Page 218: ...CO REM Y STARTER 6 29 the three 7 16 bolts or nuts in some cases securing the starter motor bracket to the engine Remove the starter motor and bracket together G X D NEWS If the only motor repair nece...

Page 219: ...nuity the arma ture is grounded and MUST be replaced Checking the Commutator Bar 5 Check between or check bar to bar as shown in the accompanying illustration The test light should light or the meter...

Page 220: ...ter frame If the meter does not indicate continuity the brush or brush retainer is not grounded to the frame If the unit being tested has a double set of negative and positive brushes move the test le...

Page 221: ...this chapter for detailed procedures to test the starter motor ASSEMBLING THE DELCO REMY Negative Brushes and Retainer The following procedures apply to brush es mounted to the field frame assembly 1...

Page 222: ...in the right position to reach the brush holders Do not Installing the negative brush into the frame assemb ly A new bolt and washer is provided in the replace ment kit DELCO REMY STARTER 6 33 overhea...

Page 223: ...engine proceed directly to Section 6 17 6 14 AUTOLITE STARTER MOTOR SERVICE REMOVAL 1 Before beginning any work on the starter motor disconnect the positive lead from the battery terminal Remove the...

Page 224: ...ly Remove the positive brush from its holder ARMATURE TESTING Testing for a Short 5 Position the armature on a growler then hold a hacksaw blade over the arma ture core Turn the growler switch to the...

Page 225: ...mmeter Connect one lead of the meter to the end of the brush and the other lead to the terminal The ohmmeter MUST indicate continuity between the brush and the terminal If the meter indi cates any res...

Page 226: ...ny suspect ed defective part according to the pro cedures outlined ear lier in this Section Check the commutator for run out In spect the armature shaft and both bearings for scoring Turn the commutat...

Page 227: ...cap over the frame assembly Install the positive brush into the retainer and push the brush backward until the spring part of the retain er is on the side of the brush 2 Work the cap over the end of...

Page 228: ...ement of the brushes the drive gear does not have to be removed All starter motors have thru bolts securing the upper and lower cap to the field frame assembly In all cases both caps have some type of...

Page 229: ...from their holders and then remove the brush springs Lift the white plastic retainer free from the frame Observe the location of the notch on the retainer in relation to the frame The retainer must be...

Page 230: ...ion and flat at the bottom A triang ular groove is not satisfactory After the under cutting work is completed clean out the slots carefully to remove dirt and cop per dust Sand the commutator lightly...

Page 231: ...d CLEANING AND INSPECTING Clean the field coils armature commu tator armature shaft brush end plate and drive end housing with a brush or compress ed air Wash all ot her parts in solvent and blow them...

Page 232: ...ough the cut a way in the plate 2 Install the spring into the retainer Push the negative brush into its retainer and then wrap a fine piece of wire around the front side of the brush and the back side...

Page 233: ...ook up to test an assembled starter motor motor NEVER make the momemtary con tact with the positive lead to the terminal because any arcing at the terminal may damage the terminal threads and the nut...

Page 234: ...updated manual shift electr ic shift and the push button shift mechanism These shift boxes are all considered original Johnson Evinrude equipment 7 2 SHIFT BOXES DESCRIPTION Undoubtedly the most used...

Page 235: ...rip on the lever handle without the throttle changing position An idle stop is also built into the shift box This feature prevents the throttle from being retracted past normal idle to the point where...

Page 236: ...ever moves smoothly without difficulty the problem is immediately isolated to the Connecting ruon with adjustable trun DOUBLE SHIFT LEVER 7 3 engine Attempt to identify if the problem is in the thrott...

Page 237: ...mechanism jumping a tooth and loosing its timing DISASSEMBLING Removing Single and Double Lever Shift Boxes 1 Remove the attaching hardware se curing the shift box to the side of the boat Once the shi...

Page 238: ...te the inner wires To lubricate the inner wire remove the casing guide from TRUNNION SHIFT HANDLE DOUBLE SHIFT LEVER 7 5 the cable at both ends Attach an electric drill to one end of the wire Momentar...

Page 239: ...t ratchet in position in side the shift half of the box Place the shift lever down over the top of the ratchet with the last tooth on the lever rocker engaged with the last tooth of the slider Apply a...

Page 240: ...Normally this type of problem is the result of improper shift box installation This area includes connection of the shift and throttle cables in the shift box If the stainless steel inner wire was no...

Page 241: ...ift side of the box does not have any adjustments except for the low idle stop Observe how the shift lever pivots at the bottom and the throttle lever pivots at the top DISASSEMBLING Throttle Half 2 R...

Page 242: ...which the screws were attached Push out the center square button and then remove the rack from the shift lever CLEANING AND INSPECTING Check the nylon wear block on the end of the anti friction cap Th...

Page 243: ...a bluish appearance it has been heated at an earlier date and the temper removed The temper MUST be removed to permit the holding screw to make a crimp in the wire to hold an adjustment If the wire ha...

Page 244: ...mine if the temper has been removed If the end has a bluish appearance it has been heated at an earlier date and the temper removed The temper MUST be removed to permit the holding screw to make a cri...

Page 245: ...performing the work 1 Difficult Shift Operation Many times this type of problem is the result of incorrect cable installation the NO SLACK SLACK 1 f cable is not the proper length or there are too man...

Page 246: ...circuit If the results of this test indicate a short in the cirucit the lower unit must be disassembled and inspected See Chapter 8 4 Testing Shift Switch Forward To test the switch for the FORWARD po...

Page 247: ...BLING GOOD WORDS On Johnson units a friction screw is installed in the bottom side of the shift box This screw allows friction adjustment of the throttle handle This arrangement prevents the throttle...

Page 248: ...idle link as an assembly 5 Remove the screws from the end of the sleeve on the end of the cable and then pull the throttle cable free of the link and sleeve 6 If the switch fails to check out as desc...

Page 249: ...p in the wire THROTTLE CD to hold an adjustment If the wire has not been tempered heat the end but not enough to melt the wire Tighten the top screw in the sleeve until the screw makes a crimp in the...

Page 250: ...ts SHOULD ALWAYS BE USED because a loose shift box during high speed operation could be extremely dangerous Connect the shift wire under the dash SINGLE LEVER SHIFT BOX 7 17 EXTREME OPPOSITE pas ITION...

Page 251: ...ockwise one half turn Move the auxiliary throttle to the START position and then turn the ignition switch to the START position again If the starter still fails to crank the engine with the warm up le...

Page 252: ...button for the FORWARD position and then for the REVERSE posi tion Note how much the ammeter reading increased each time a shift button was de pressed If the reading was more than 2 5 amperes for eit...

Page 253: ...ple or red lead and to the reverse terminal blue lead with the other probe Again depress the FORWARD NEUTRAL and RE VERSE pushbuttons The meter should indicate continuity or the test light come on for...

Page 254: ...er 2 Notice the screw and retainer at the forward end of the casing guide and just below the throttle lever Remove the screw and retainer Pull the throttle cable and casting guide free of the shift bo...

Page 255: ...he drill on and off to rotate the wire and at the same time allow lubricant to flow into the cable as shown ASSEMBLING Switch Installation 1 Position the switch box inside the shift box underneath the...

Page 256: ...he selector bracket Move the bracket forward or aft until the buttons can be depressed Tighten the screws to secure the bracket in the proper position 7 Install the shift box cover and secure it in pl...

Page 257: ...onds without water will damage the water pump Now adjust the slide yoke to allow the pushbuttons to be depressed at 700 rpm but not at 750 rpm If it is not possible to depress the buttons at 700 rpm r...

Page 258: ...e throttle cable into the trunnion at the engine end CABLE END FITTING 7 25 Detailed draWing of the shift trunnion at the engine in the casting guide tighten the top screw until a definite crimp is ma...

Page 259: ...n earlier date and the temper removed The temper MUST be removed to permit the holding screw to make a crimp in the wire to hold an adjustment If the screw is not tightened to this degree the wire wil...

Page 260: ...uple inches and the shift coupler removed Non shift lower unit with the drive gear cap and propeller shaft shown 4 The lower unit does not have shifting capabilities therefore removal of the unit is n...

Page 261: ...wer unit or metal particles are discovered in the gear lubricant the lower unit should be com pletely disassembled cleaned and inspected Gear arrangement used on the 40 hp manual Shift lower unit Gear...

Page 262: ...indow must be removed Hold the shift rod with a pair of pliers and at the same time attempt to move the shift lever on the starboard side of the engine If it is possible to move the shift lever the be...

Page 263: ...ustration at the top of this column The propeller should be removed frequently and debris removed from the rpropelier shaft to prevent such costly repairs Cut a way view of a propeller showing the pro...

Page 264: ...finally the unit will not stay in gear for even a short time The following areas must be checked to locate the cause 1 Check the bellcrank under the power head This is accomplished by first checking i...

Page 265: ...r cable should slip on the end cable guide the adjustment would be lost 3 Move the shift lever at the engine into the neutral position and the shift lever at the control box to the neutral position No...

Page 266: ...the lower unit If the attempt to crank the engine is still unsuccessful the problem is in the powerhead 8 3 PROPELLER REMOVAL The shear pin on most outboard units is installed through the propeller s...

Page 267: ...to its proper location Allow the gear lubricant to drain into the container As the lubricant drains catch some with your fingers from time to time and rub it between your thumb and finger to determin...

Page 268: ...the driveshaft installed SERVICE NO SHIFT 8 9 1 Disconnect the spark plug wire from the plug Remove the retaining bolts secur ing the lower unit to the exhaust housing CAREFULLY pull directly downwar...

Page 269: ...ss type lower unit a thrust bearing is installed under the pinion gear This thrust bearing can only be re moved by tapping it out in the following manner Turn the lower unit so the propeller shaft ope...

Page 270: ...ears and wear Check for a glazed or melted appearance caused from operat ing without sufficient water If any ques tion exists and as previously stated install a new impeller if at all possible Clean a...

Page 271: ...8 12 LOWER UNIT PROPELLER Exploded drawing of the Weedless lower unit gear case with major parts identified...

Page 272: ...splines on the shaft to index with the splines in the gear SPECIAL WORDS After the drives haft is installed care must be exercised NOT to allow the drive shaft to slip out of position in the pinion ge...

Page 273: ...when the head is install ed WATER PUMP INSTALLATION 5 Lay down a bead of sealer No 1000 onto the lower unit surface Slide the water pump plate down the driveshaft and onto the lower unit surface 6 In...

Page 274: ...o the grommet in the water pump housing as a further aid to installation This tube is very small in size and will bend easily during installation if it has even a little difficulty passing through the...

Page 275: ...from the propeller However if they have been removed for any number of reasons they should be coated with OMC Type A lubricant prior to installation The bushing is installed first then the clutch hub...

Page 276: ...the direct drive engines without a reverse gear The engine is rotated 1800 with the steering lever to move the boat sternward Because a shift rod is not used naturally there is no re quirement to dis...

Page 277: ...inch and then remove the bottom bolt in the shift Window removed from a lower unit to gain access to the shift connector as explained in the text The detail drpwing upper left illustrates the relatio...

Page 278: ...t piece of 211 x 6 wood to accommodate the lower unit with the cavitation plate resting on top of the wood Clamp the wood in a vise and service work may then be performed with the lower unit erect On...

Page 279: ...will not come free it is the type with the key and keyway Therefore the driveshaft will be removed later when the lower unit is disassembled If the driveshaft comes free remove it at this time 6 Turn...

Page 280: ...in the slot during installation With the reverse gear some bearing heads have a hole and a matching pin installed in the housing indexes in this hole Some other reverse gears have a tab protruding fro...

Page 281: ...t A special tapered punch is required to remove the bushing from the lower unit housing Obtain the special punch and then remove the bushing and the O ring Using a slide hammer to pull the bearing car...

Page 282: ...per and finish with No 180 Check the water intake screen and pas sages by removing the bypass cover if one is used Inspect the clutch dog drive gears pinion gear and thrust washers Replace these items...

Page 283: ...e the prongs are not worn or rounded Dam age or wear to the prongs indicates the lever must be replaced C aged ball bearing set destroyed due to lack of lubrication vibration corrosion metal particles...

Page 284: ...o the hole and make another test Continue to drop solder into the hole and test until the pin is flush with the housing when it is installed If more soldered is inserted into the hole than necessary t...

Page 285: ...8 26 LOWER UNIT Exploded drawing of a lower unit with a window for access to the shift connector...

Page 286: ...MANUAL SHIFT 5 HP TO 25 HP 8 27 Exploded drawing of a lower unit requiring the powerhead to be removed to gain access to the shift disconnect...

Page 287: ...e the clutch dog onto the propel ler shaft splines Apply a light coating of lubricant to the washer and then insert it into the center of the forward gear Slide the forward gear onto the end of the pr...

Page 288: ...the gear case 6 Slide the propeller shaft assembly in to the lower unit housing Check to be sure the slot in the forward gear bearing indexes with the pin in the lower unit and the protrusion on the...

Page 289: ...If the cap and shift lever are not aligned exactly the screw will seek and make the alignment as it passes through However do not make a long point or the screw will not have enough support and would...

Page 290: ...rop of sealer to the threads and then tighten the screw securely 15 Turn the lower unit rightside up Install a NEW gasket onto the upper surface of the lower unit MANUAL SHIFT 5 HP TO 25 HP 8 31 16 In...

Page 291: ...the driveshaft CLOCKWISE as the wa ter pump housing is lowered to allow the impeller blades to assume their natural and proper position inside the housing Continue to rotate the drives haft and work...

Page 292: ...stalled the cutout area on the shift rod MUST be aligned in such a manner to allow the bolt to be properly installed Therefore as the lower unit is mated with the exhaust hous ing exercise patience as...

Page 293: ...ge of the shift handle Install the power head 25 Check to be sure the water pickup tube is clean smooth and free of any corrosion Coat the water pickup tube and grommet with lubricant as an aid to ins...

Page 294: ...e vent plug MANUAL SHIFT 5 HP TO 25 HP 8 35 A FEW GOOD WORDS The propeller washer if used and drive pin play an extremely important role When shifting gears during normal operation or if the propeller...

Page 295: ...sed NEVER oper ate the engine above an idle speed because the no load condition on the propeller would allow the engine to RUNA WAY resulting in Location of the shear pin through the propeller shaft j...

Page 296: ...ing It is not uncommon for the water tube s to be stuck in the water pump making separation of the lower unit from the exhaust housing diffi cult However with patience and persist ence the tube s will...

Page 297: ...screw heads to break off when an attempt to remove them is made If this should happen use a chisel and breakaway the water pump housing from the lower unit EXERCISE CARE not to damage the lower unit h...

Page 298: ...ke time to make a sketch or take Q photograph showing the arrangement of parts as en assist during the installation work years Therefore the positioning of the gears shims bearings and other parts may...

Page 299: ...The babbitt side MUST face toward the reverse gear during installation The washer also has two dog ears one facing upward and the other downward By taking note at this time of these items and exactly...

Page 300: ...er unit housing These two items prevent water from entering the lower unit A special tapered Caged ball bearing set installed on some newer model lower units instead of the babbitt bearing MANUAL SHIF...

Page 301: ...aft if the splines are worn Inspect the gearcase and exhaust housing for dam age 1 0 the machined surfaces Remove any nicks and refurbish the surfaces on a surface plate Start with a No 120 Emery pape...

Page 302: ...dutch dog The sides of the The web area indicated should be inspected careful ly for the slightest sign of a hairline crack The smallest evidence of a crack is cause to replace the housing because ex...

Page 303: ...ed on 35 hp and 40 hp engines Two propeller shafts are shown The second shaft with the two balls and spring may be installed as a conversion This new type shaft arranqment holds the shift dog more sec...

Page 304: ...typical manual shift lower unit installed on late mode 40 hp engines This lower unit is almost identical to the one shown on Page 8 44 except the water pump has a two line recirculating system The pr...

Page 305: ...heck to be sure the shift rod is clean and smooth free of any burrs or corrosion Coat the shift rod and the 0 ring with oil as an aid to installation Slide the shift rod down through the a ring and bu...

Page 306: ...in MUST index into the hole in the retainer when the propeller shaft is instal led If the pin is not seated properly in the hole the seal retainer will work part way out of the housing and the lubrica...

Page 307: ...mmer If the caged needle bearing is installed tap on the numbered side of the bearing 14 Coat the outside edge of a NEW seal with No 1000 sealer and then tap the seal into place in the top of the uppe...

Page 308: ...face of the water pump with light weight oil 18 Lower the water pump housing down the driveshaft and over the impeller Ro tate the driveshaft CLOCKWISE as the wa ter pump housing is lowered to allow t...

Page 309: ...to allow the bolt to be properly installed Therefore as the lower unit is mated with the exhaust housing exercise patience as the two units come together to enable the bolt to be installed at the prop...

Page 310: ...Words just before Step 20 before MANUAL SHIFT 28 HP TO 40 HP 8 51 making this connection After the bolt is in place install and secure the window with the attaching hardware Start the bolts securing t...

Page 311: ...ive pin Slide the propeller cap into place and secure it with the cotter pin 27 Final adjustment for remote control units Shift the lower unit into NEUTRAL gear At the shift box move the shift lever t...

Page 312: ...used on the 40 hp electromatic shift lower unit ELECTROMATIC SHIFT 8 53 generator to maintain battery amperage and voltage for efficient operation of the shift mechanism When the key is in the ON posi...

Page 313: ...ing the full length of the hub Hold the shaft from turning and then rotate the propeller 1 4 turn to position the grooves over the drive pin holes The propeller can then be pulled straight off the sha...

Page 314: ...m eter is not installed on the dash one must be temporarily connect ed to the system for this test by first removing the wire marked BAT from the key switch and then connecting the ammeter in ELECTROM...

Page 315: ...switch OFF move the shift lever to the NEUTRAL position and connect one lead of an ohmmeter to the green forward wire leading from the rear of the engine to the lower unit and the other lead to a goo...

Page 316: ...haust housing or extension The water tubes may be stuck in the water pump Therefore if difficul ty is encountered in freeing the ELECTROMATIC SHIFT 8 57 lower unit force a wide blade chisel stiff scra...

Page 317: ...damaged Use a 9 16 deep well socket and remove the lower unit gear case stud nuts then the washers and shift cable retainer DISCARD the nuts because they are the self locking type and MUST NOT be use...

Page 318: ...er portions of the lower unit after the retaining bolts have been cut 12 Clamp the lower unit by the skeg in a vise equipped with soft jaws as shown Remove the retainer screw and washer then lift the...

Page 319: ...other suitable container before releasing the pliers 15 Obtain a pair of Truarc pliers In sert the tips of the pliers into the holes of the retaining ring Now CAREFULLY re move the retaining ring fro...

Page 320: ...ired After the housing is heated grasp the studs with a gloved hand and at the same time tap the housing on a board The forward coil and bearing race will be released from the hous ing If the tools ar...

Page 321: ...s can be made to determine the condition of the bearing One is to feel the driveshaft in the area where it passes through the bearing If the shaft is smooth with no indication of roughness the bearing...

Page 322: ...he clutch has been slipping the modest cost of the spring and hub is justi fied in eliminating this area as a possible source of shifting problems 26 Obtain and wear a pair of SAFETY GLASSES while wor...

Page 323: ...8 64 LOWER UNIT Exploded drawing of a typical electric shift lower unit installed on 40 hp engines with major parts identified...

Page 324: ...turns freely without any evi dence of rough spots or binding Inspect the rollers and balls for any sign of pits or flat spots Lower unit with a broken stud This type of damage is usually the result of...

Page 325: ...te direction to the normal winding of the spring coils Place the spring in the gear with the spring key beside the spacer key Now shift both keys to the side of the slot against which they will pull 2...

Page 326: ...ith its key ELECTROMATIC SHIFT 8 67 in the slot of the bevel gear The spacer MUST be positioned to encircle the cupped area in the opposite direction to the normal winding of the spring coil Install t...

Page 327: ...seal was removed press a new seal into the head The seal can be installed using a block of wood and a mallet If the bearing was removed install a new bearing from the back side of the head A special b...

Page 328: ...o the bearing race Naturally the tapered end of the bear ing enters the race first 15 Install the forward coil in the hous ing using special tool No 379230 Feed the coil wire into the groove in the bo...

Page 329: ...e feed the blue lead through the opening in the lower housing The lead on the back side of the coil MUST be on TOP WARNING This next step can be dangerous The snap ring is placed under tremendous tens...

Page 330: ...e four screws alternately and evenly Rotate the propeller shaft and check to be sure it turns without excessive drag 25 Set the wires into the retainer and secure them in place with the screw and wash...

Page 331: ...er the hole as the stud passes through the retainer washer Continue to lower the upper housing and at the same time work the shift wires up into the cavity of the upper housing to prevent the wires fr...

Page 332: ...driveshaft CLOCKWISE as the water pump housing is lowered to allow the impeller blades to Comparison of a new left water pump impeller with one unfit for service right ELECTROMATIC SHIFT 8 73 assume...

Page 333: ...O ring onto the top of the driveshaft just below the splines O RING GOOD WORDS Clean both lower unit water tubes with sandpaper These tubes should be clean and shiny as an aid to mating the lower unit...

Page 334: ...the rear housing cover with the exhaust relief boot fitting into the re cess of the cover Secure the cover in place with the attaching hardware 42 Position the outer exhaust cover in place on the por...

Page 335: ...tank in a body of water or with a flush attachm ent connected to the lower unit If the flush attachment is used NEVER oper ate the engine above an idle speed because the no load condition on the prope...

Page 336: ...lon drive gear Starter installation on the 5 hp and 6 hp engines This starter is similar in operation to an automotive type starter slides upward and engages the flywheel ring gear Once the engine sta...

Page 337: ...turn springs a center cone and a set of spring release dogs that engage with the Ilywheel ring gear when the starter rope is pulled Service procedures are presented in Section 9 5 The second model do...

Page 338: ...ard con tinues to perform year after year the age of the spring steel will finally take its toll This single pawl starter may be installed on 3 hp to 25 hp engines PINION GEAR 5 6 HP 9 3 The rewind sp...

Page 339: ...ending on the size horsepower engine being serviced Therefore check the Hand Starter Rope Specifications in the Appendix and then purchase a quality nylon piece of the proper length and diameter size...

Page 340: ...r the starter spring is weak and should be replaced STARTER REMOVAL AUTHOR S NOTE For photographic clarity the accomp anying pictures were taken servicing a star ter from a powerhead removed from the...

Page 341: ...the pliers and allow the spool to slip a little at a time until the spring is completely unwound 4 Remove the two retaining bolts on top of the starter 5 Loosen but DO NOT remove the bolts on the bot...

Page 342: ...e the starter is disassembled Inspect the teeth of the pinion gear The teeth will show some signs of normal wear A broken tooth or excessive wear on one side of the teeth is justification for replace...

Page 343: ...on the engine HELPFUL WORD As an assist to installation first soak the bushing in hot water for about ten minutes and then lubricate it with just a drop of outboard oil 5 The tang on the outer spring...

Page 344: ...ng into the bottom collar on the engine HELPFUL WORD As an assist to installation first soak the bushing in hot water for about ten minutes and then lubricate it with just a dorp of outboard oil 2A In...

Page 345: ...wo bottom retainer screws 7 Insert a large size screwdriver into the top of the spool and then rotate the spool by count exactly 16 1 2 complete turns Lift the pinion gear to engage the flywheel ring...

Page 346: ...YPE I STAR TER CYLINDER WITH PINION GEAR ALL 9 5 HP ENGINES This gear drive starter is a new design employing the principle of an automotive type starter motor When the starter rope is pulled the star...

Page 347: ...fused and while they are still hot use a piece of cloth as protection and pull the end out flat to prevent a glob from forming 3 Tie a figure 8 knot in one end of the new rope Feed the rope through th...

Page 348: ...starter Lift the starter assembly from the power head OBSERVE As the starter is removed take special note of how the upper bearing retainer ex tends over a hole in the powerhead This hole is a water...

Page 349: ...these parts will attract dirt causing the gear to bind on the spool Lubricate the upper and lower spool bearing surfaces with just a drop of outboard lubricant Apply outboard oil to the spring on the...

Page 350: ...ear down over the spool shaft 7 Align the hole in the upper spring retainer with the hole in the starter spool and with the slot in the pinion gear INSTALLA TION AUTHOR S WORD For the following illust...

Page 351: ...of cloth as protection and pull the end out flat to prevent a glob from forming 11 Insert a large screwdriver blade into the top of the spool and then rotate the spool COUNTERCLOCKWISE by count 20 1 2...

Page 352: ...arefully during disassembling and asembling work with the starter SAFETY WORDS Work on the starter can be very danger ous Because approximately 12 feet of spring steel is tightly wound into about a 4...

Page 353: ...r of needle nose pliers and then pull the spring out as far as possible to relieve tension on the spring 4 Remove the 3 8 bolt from the brac ket between the starter and the exhaust housing 5 Hold the...

Page 354: ...rope from the pulley Notice how the rope unwinds from t he pulley COUNTERCLOCKWISE 9 Remove the bushings from the idler gear arm A bushing is installed on each side of the pulley 10 Two different meth...

Page 355: ...e horsepower engine being serviced Therefore check the Hand Starter Rope Specifications in the Appendix and then purchase a quality nylon piece of the proper length and diameter size Only with the pro...

Page 356: ...ly The remainder of the spring will be installed later 6 Assemble the idler gear with the shoulder against the idler gear arm Install the idler gear arm and spring to the pulley and cup with the stop...

Page 357: ...f the engine pull on the rope and the idler gear will engage with the flywheel ring gear Continue to pull the rope and at the same time work the spring down into the cup If the rope becomes fully exte...

Page 358: ...he Appen dix ATOP FLYWHEEL WITH SPRINGS 9 23 9 5 TYPE In MOUNTED ATOP FLYWHEEL MODEL WITH RETURN SPRINGS 28 HP 1962 63 30 HP 1956 35 HP 1957 59 40 HP 1960 63 This type starter is installed as original...

Page 359: ...t Work the rope anchor out of the rubber covered handle then remove the rope f rom the anchor Remove the handle from the rope Untie the knot in the rope and then hold the disc pulley but permit it to...

Page 360: ...n a cage If the spring should accidently be released severe personal injury could result from being struck by the spring with force Therefore the following step MUST be performed with care to prevent...

Page 361: ...ppears to be weak or frayed If the rope is The rope on this unit broke causing the spring to rewind with incredible speed The end of the spring was bent back in the wrong direction New pawl return spr...

Page 362: ...direction Work the first turn into the housing and then hold the spring down with one hand and continue to wind the ATOP FLYWHEEL WITH SPRINGS 9 27 spring into the housing Patience and time are requir...

Page 363: ...indle housing and then install the bolt through the washer into the housing Tighten the bolt securely Housing left with the spring properly installed and the spring end bent toward the center The pin...

Page 364: ...sepower engine being serviced Therefore check the Hand Starter Rope Specifications in the Appendix and then purchase a quality nylon piece of the proper length and diameter size Only with the proper r...

Page 365: ...e handle thread it through the rope apply just a little oil to the rope then pull the wire and rope through the handle 10 Work the end of the rope into the handle anchor Secure the rope in place by pu...

Page 366: ...th force Therefore the service instructions MUST and we say again MUST be followed closely to prevent release of the spring at the wrong time Such action would be a BAD SCENE a very BAD SCENE because...

Page 367: ...thus allow the rope to wind back onto the pulley SLOWLY Contin ue to allow the spring in the pulley to unwind SLOWLY until all tension has been released 3 Remove the center bolt nut from the top side...

Page 368: ...hers in the area If the spring should be accidently released at the wrong time such action would be a BAD SCENE a very BAD SCENE because serious personal injury could result 8 Lift the pulley straight...

Page 369: ...incredible speed The end of the spring was bent back in the wrong direction Inspect the starter spring end loops Re place the spring if it is weak corroded or cracked Check the spring pin located at...

Page 370: ...ng After the last portion is in place bend the end of the spring towards the center of the housing This position will allow the pulley pin to align with the loop in the end of the spring when the pull...

Page 371: ...index the pin into the hole in the housing 7 Place the washer inside the spindle housing and then install the bolt through the washer into the housing Tighten the bolt securely 8 Install the three pa...

Page 372: ...een fused and while they are still hot use a piece of doth as protection and pull the end out flat to prevent a glob from forming 11 Tie a figure g knot in one end of the rope Settheropeaside but hand...

Page 373: ...ightly pull on the rope to relieve tension on the pin installed through the pulley and housing in Step 12 Maintain some tension on the rope remove the pin and allow the spring to SLOWLY wind the rope...

Page 374: ...ause ser ious personal injury could result The starter rope should NEVER be re leased from the extended position Such action would allow the spring to wind with incredible speed resulting in serious d...

Page 375: ...able for starting AND that one of the pistons will return to TOC when the pull is completed if the engine fails to start If an excessive amount of pull is necessary before the fly wheel begins to rota...

Page 376: ...bolt lockwasher and washer from the center of the pulley spin dle Lift the spindle out of the pulley and ATOP FLYWHEEL WITH NYLON PAWL 9 41 at the same time hold the pulley firmly together with the ho...

Page 377: ...ext illustration clearly shows a spring end properly positioned in the housing Wash all parts except the rope in solvent and then blow them dry with compressed air Remove any trace of corrosion and wi...

Page 378: ...used and while they are still hot use a piece of cloth as protection and pull the end out flat to prevent a glob from forming Knot tied in the end of the starter rope to prevent the rope from being pu...

Page 379: ...ee end of the spring around the coiled portion 3A CAREFULL Y lower the coiled spring into the starter housing with the loop on the free end of the spring indexed over the peg in the housing and the sp...

Page 380: ...nylon pawl onto the starter hub The friction spring fits into a groove in the spindle Pull just a little on the pawl and set it over the stud on the flywheel pulley 6 Snap the E clip over the top of t...

Page 381: ...r E for Evinrude On the Evinrude engines the arrow must fall between the two marks on the pulley If the arrow is not properly aligned the starter rope is not the proper length It is either too long or...

Page 382: ...long life and satisfactory performance at mini mum cost Many times if an outboard is not per forming properly the owner will nurse it through the season with good intentions of working on the unit on...

Page 383: ...r is the stern and the direction is aft Manufacturer s identification plate installed be tween the transom brackets the right side when facing forward is the starboard side and the left side is the po...

Page 384: ...f this type boat will probably carry it atop his vehicle and be saved the expense and trouble of tro ilering to the water the hull sustains a severe blow the impact will be either absorbed by deflecti...

Page 385: ...ull and a leak develops the only emer gency action possible is to make an attempt to reduce the amount of water being taken on by stuffing any type of available material into the opening until the boa...

Page 386: ...d after the following procedures have been performed the engine should be disas sembled cleaned assembled using new gas kets seals and Oeririzs and then st2 rted as soon as possible Submerged engine t...

Page 387: ...gine in a horizontal position with the spark plug holes DOWN and then cranking the engine with the rewind starter or with a socket wrench on the flywheel nut 6 Alcohol will absorb water There fore pou...

Page 388: ...is used to describe a boat that has filled with rain water and ruined the interior because the plug was not removed or the bow was not high enough to allow the water to drain properly Proper storage f...

Page 389: ...e of additive will maintain the fuel in a fresh condition for up to a full year 3 Clean the with benzol see pair Section carburetor fuel filter s Chapter 4 Carburetor Re Rust preventative to be used w...

Page 390: ...h the lower unit down If hanging is not practical lay the outboard on its back This will place the lower unit below the power head Adding lubricant to the lower unit on a small horsepower engine The l...

Page 391: ...nd cause burrs on the hole These burrs may make removing the propeller difficult To overcome this Propeller installation with a washer and shear pin The cotter pin is installed through the propeller n...

Page 392: ...ant drains Draining lubricant from a lower I1nit TAKE CARE not to remove the Phillips screw by mistake This screw secures the Shift fork in position LOWER UNIT 10 11 catch some with your fingers from...

Page 393: ...vent hole A squirt type oil can must be used to allow the trapped air in the lower unit to escape at the same time the final lubricant is added Once the unit is com pletely full install and tighten t...

Page 394: ...ndicates the battery is in satisfactory condition If the reading is 1 150 or in the red band the battery needs to be charged Observe the six safety points given in the text when using a hydrometer PRE...

Page 395: ...the fuel vias not drained at the end of the previous season make a careful inspection for gum formation If a six gallon fuel tank is used Method of removing an O ring from a connector The connector is...

Page 396: ...ump Check the idle exhaust port for water discharge At idle speed only a fine water mist will be visible Check for leaks Check operation of the thermostat After the engine has reached operating temper...

Page 397: ...e type that cannot cause an explosive mixture to ignite ONE FINAL WORD Before putting the boat in the water TAKE TIME to VERIFY the drain plugs are installed Countless number of boating ex cursions ha...

Page 398: ...ec2 m S2 X 0 0254 metres sec2 m s2 foot pounds calories Btu watt hours kilowatt hr s ENERGY OR WORK watt second joule newton metre X 1 3558 X 4 187 X 1055 X 3500 X 3 600 joules j joules j joules j jou...

Page 399: ...7 0 6693 8 0315 0995 39 2010 7 8 3 3268 17 06 6719 43 64 0320 67 1015 38 5 16 2031 13 64 8 33 3281 21 64 17 46 6875 11 16 0330 66 2 6 1024 2040 6 8 4 3307 17 5 6890 85 0335 1040 37 5 2 2047 3320 0 17...

Page 400: ...0015 0 0030 9 5 1968 1 81 2 31 0 020 0 004 5 0 0030 9 5 1969 70 1 81 2 32 0 020 0 0050 0 0035 10 1956 63 1 875 2 37 N A 0 0035 0 0030 15 1956 2 50 2 37 N A 0 0035 0 0030 18 1957 64 2 25 2 50 0 025 0...

Page 401: ...935 0 0925 0 015 0 005 7 5 1956 57 0 0035 0 0010 0 015 0 005 9 5 1968 0 0035 0 0010 0 0935 0 0925 0 017 0 007 9 5 1969 70 0 0035 0 0010 0 0935 0 0925 0 017 0 007 10 1956 63 0 0015 0 0030 0 017 0 007 1...

Page 402: ...ll 7522 2 7 5 12 4 4000 J6J B C 7 1 QO 18 10014 2 10 16 6 4000 J6J 0 7 1 FD FDE l1 15020 15922 2 18 22 0 4500 J4J 0 7 1 RO ROE RJE 19 25028 25930 25532 2 35 40 5 4500 J4J 0 9 1 1958 1958 1958 JW 14 3...

Page 403: ...J4J D 7 1 FD 15 15034 2 18 22 4500 J4J D 7 1 RD RDS 23 35022 35524 2 40 43 9 4500 J4J D 9 3 1962 1962 1962 JW 17 3042 3044 2 3 5 28 4000 J6J A 7 1 CD 19 5524 2 5 5 8 84 4000 J6J B C 7 1 QD 23 10024 2...

Page 404: ...4500 J4J D 7 1 RX RXW 13BE 33502 52 2 33 40 5 4500 J4J D 9 3 RD RDS RK AM 27 40502 52 40562 72 2 40 43 9 4500 J4J D 9 4 1966 1966 1966 JW JWL JH JHL 21 3602 03 3612 32 3G33 2 3 5 28 4000 J6J A 7 1 LD...

Page 405: ...8 84 4500 J6J B E 6 1 MQ MQL 14 9822 23 2 9 5 15 2 4500 J4J E 7 2 18802 03 2 18 22 0 4500 J4J 0 8 1 FO FOL 22 2 20 22 0 4500 J4J 0 8 1 RX RXL RXE RXEL 16 33802 03 33852 53 2 33 40 5 4500 J4J 0 9 3 RD...

Page 406: ...J4J D 9 4 lIOES 40ESL 70 GENERAL NOTES All engines flywheel magneto Top cylinder No 1 Bottom cylinder No 2 All points 020 All spark plugs 030 Timing NOT adjustable SPECIAL NOTES Primary Pickup Locati...

Page 407: ...18 hp 20 hp 25 hp 28 hp 30 hp 33 hp 35 hp 40 hp ltOE hp MODEL 1968 70 1956 70 1969 70 1969 70 1965 68 1956 6lt 1965 70 1956 58 1961t 70 1956 63 1956 1956 70 1966 68 1969 70 1962 65 1956 1965 68 1957...

Page 408: ...tage Ground Polarity Armature Air Gap Circuit Breaker Voltage Reg Current Regulator Current Regulator Setting Amps GENERATOR SPECI FICATIONS VRU 610lA 12 Negative Generator GJG 4 001M GJG 4 002M Rot D...

Page 409: ...2 5 5 hp All 580321 18 22 6 0 hp All 580321 18 22 7 5 hp All 580321 18 22 9 5 hp All 580321 18 22 10 hp All 580321 18 22 15 hp All 580321 18 22 18 hp 1957 61 580321 18 22 30 hp All 580321 18 22 35 hp...

Page 410: ...2 71 1 2 6 0 hp 1965 67 0 130 64 6 0 hp 1968 70 0 130 56 7 5 hp 1956 5 5 32 70 9 5 hp 1964 70 5 32 71 1 2 10 hp 1956 61 7 32 70 3 16 10 hp 1962 63 7 32 75 3 4 15 hp 1956 7 32 70 3 16 18 hp 1957 61 7 3...

Page 411: ...GREEN CHOKE SWITCH BLACK WIRE RED WIRE o BLACK BATTERY CABLE NEG SWITCH CABLE RED BATTERY CABLE POS SOLENOID TO GROUND RED CARBURETOR CHOKE SOLENOID WHITE GREEN PORT MOTOR BRACKET LOWER SCREW GROUND W...

Page 412: ...A 16 APPENDIX Wire Identification 33 hp with Generator 1965 67...

Page 413: ...APPENDIX A 17 o C...

Page 414: ...Wire Identification 33 hp with Generator 1969 70...

Page 415: ...APPENDIX A 19 Wire Identification 35 hp 1957 59...

Page 416: ...A 20 APPENDIX Wire Identification 40 hp Standard Shift with Generator 1960 66...

Page 417: ...APPENDIX A 21 UJ cc b Wire Identification 40 hp Standard Shift with Generator 1967 68...

Page 418: ...A 22 APPENDIX ee I U Vl Z Z o U I I Wire Identification 40 hp Standard Shift With Generator 1969 10...

Page 419: ...APPENDIX Wire Identification 40 hp Electric Shift with Generator 1961 66 A 23...

Page 420: ...A 24 APPENDIX C 00 Wire Identification 40 hp Electric Shift with Generator 1967 68...

Page 421: ...Wire Identification 40 hp Electric Shift with Generator 1969 70...

Page 422: ...NOTES NUMBERS...

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