Johnson 15 2004 Service Manual Download Page 1

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http://motorka.org

Summary of Contents for 15 2004

Page 1: ...BOMBARDIER 7 http motorka org...

Page 2: ...re registered trademarks of The Henkel Group t Lubriplate is a registered trademark of Fiske Brothers Refining Company t Oetiker is a registered trademark of Hans Oetiker AG Maschinen t Permatex is a...

Page 3: ...tect your self as well as the people around you It is understood that this manual may be trans lated into other languages In the event of any dis crepancy the English version shall prevail To reduce t...

Page 4: ...CIAL TOOLS AND SERVICE SPECIFICATIONS 17 INSTALLATION AND PREDELIVERY 33 MAINTENANCE 57 ELECTRICAL 81 IGNITION 111 FUEL SYSTEM 137 POWERHEAD 169 MIDSECTION 225 GEARCASE 253 MANUAL STARTER 291 SAFETY S...

Page 5: ...4 E o u oj Qj i i E...

Page 6: ...PICAL PAGE A 8 TYPICAL PAGE B 9 TYPICAL PAGE C 10 TYPICAL PAGE D 11 ABBREVIATIONS USED IN THIS MANUAL 12 UNITS OF MEASUREMENT 12 LIST OF ABBREVIATIONS 12 ENGINE EMISSIONS INFORMATION 13 MANUFACTURER S...

Page 7: ...ough 30 HP 2 Stroke models Use this manual together with the proper Parts Catalog for part numbers and for exploded views of the outboard which are a valuable aid to disassembly and reassembly This ma...

Page 8: ...r Steering W Commercial Model V White Johnson Evinrude I 1 N 2 T 3 R 4 0 5 D 6 U 7 C 8 E 9 S O Ex SR 2004 MODEL LIST Model Number Start Shaft Steer Model Number Start J10RSRD Rope 15 Tiller J25TESRA E...

Page 9: ...ub canton threllds bnly _ _ 1_ _ ___ I U Tightening torque for ist lrDfj O l tq tI StJ HI lbS 6 8 9 5 N M a fastener ifd l ff1 111 1Jri 1 rr B l __ r _ JIQ 1zQ 1 uln lbs B 13 6 1fS3Nm Jl f f B f32 In...

Page 10: ...nectors Apply a light coat of I to the seal Push connec rs latched 1 Seal INTRODUCTION TYPICAL PAGE B a water pressure gauge is to be used install the water pressure hose fitting in the cylinder block...

Page 11: ...all between mounts Apply Nut Lock to retainer screw install the screw and torque to 15 to 20 ft Ibs 20 to 27 N m 1 Mount retainer screw 272 a procedure concerning a particular model Title indicates th...

Page 12: ...located in the oil injec tor manifold and reacts to changes in oil manifold pressure The EMM supplies and monitors electri cal current to the switch components numbered to The switch opens or correspo...

Page 13: ...EMM engine management module mm millimeter ICOMIA International Council of Marine N m Newton meter Industry Associations PIN part number MCA marine cranking amps psi pounds per square inch MWS modular...

Page 14: ...cribed certification standards The owner operator is not to and should not allow anyone to modify the outboard in any manner that would alter the horsepower or allow emis sions levels to exceed their...

Page 15: ...graphs and illustrations used in this man ual may not depict actual models or equipment but are intended as representative views for refer ence only Certain features or systems discussed in this manua...

Page 16: ...resis tance DR4205 Values When precedes a value on the meter face it indicates your reading must be less than or equal to the value shown O 3n Q ad DR4206 INTRODUCTION SYMBOLS When 2 precedes a value...

Page 17: ...INTRODUCTION NOTES NOTES Technician s Notes 16 Related Documents Bulletins Instruction Sheets Other...

Page 18: ...ABLE OF CONTENTS SPECIAL TOOLS AND SERVICE SPECIFICATIONS TABLE OF CONTENTS SPECIAL TOOLS 19 ELECTRICAL I IGNITION 19 FUEL 20 GEARCASE 21 POWERHEAD 23 STARTER 24 UNIVERSAL 24 SHOP AIDS 27 TECHNICAL DA...

Page 19: ...18...

Page 20: ...322698 3 3 Amphenol socket removal tool PIN 322699 Amphenol connectors jumper wire 73158 Analog multimeter PIN 501873 1 No 16 wire 8 in 200 mm 2 Pin PIN 511469 3 Socket PIN 581656 4 Shrink tube 510628...

Page 21: ...2 49791 Ignition coil terminal extender PIN 502054 23664 Float gauge PIN 324891 Orifice plug screwdriver PIN 317002 23611 Fuel vacuum tester PIN 390954 20 C03010 Spark checker PIN 508118 49798 Tachome...

Page 22: ...ICATIONS SPECIAL TOOLS 23218 Driveshaft bearing installer upper PIN 319931 9 9 15 HP 49790 Driveshaft bearing installer PIN 322923 25 30 HP o 49794 Driveshaft seal installer PIN 326554 9 9 15 HP 2050...

Page 23: ...PIN 335821 25 30 HPJ 22 Prop shaft bearing housing bearing installer PIN 339751 9 9 15 HPJ Prop shaft bearing housing bearing installer PIN 335820 25 30 HPJ Prop shaft bearing housing bearing remover...

Page 24: ...Crankshaft upper seal remover PIN 387780 25 30 HP 22428 Cylinder bore gauge PIN 771310 16718 Rod screw torque socket 000797 PIN 331638 23624 Ring compressor C03768 9 9 15 HP standard PIN 339754 25 30...

Page 25: ...e threading tool 23682 Starter spring winderlinstaller PIN 378774 PIN 392093 Universal a Drive handle PIN 311880 31932 Hose clamp wrench PIN 325043 24 1 2 23668 1 Wrist pin retaining ring driver DR164...

Page 26: ...ench PIN 334359 use with pullerjaws SPECIAL TOOLS AND SERVICE SPECIFICATIONS SPECIAL TOOLS 23150 Slide hammer PIN 391008 23148 Slide hammer PIN 432128 23149 Syringe PIN 346936 23147 Tie strap installa...

Page 27: ...JJJ f 000 Tilt tube service kit PIN 434523 33249 Twist Grip remover PIN 390767 COA6017 Universal Puller Set PIN 378103 Torque wrench extension PIN 912031 26 I o o 23656 Universal pinion bearing remov...

Page 28: ...9570 Engine Tuner PIN 775625 6 in 1 Multi Purpose Lubricant PIN 775782 Cleaning Solvent PIN 771087 Fuel System Cleaner PIN 775632 Adhesive Type M PIN 776964 D P L Spray PIN 776896 Gel Seal and Gasket...

Page 29: ...mpound PIN 772666 Gel Sealll PIN 327361 GMt Sealer Type B PIN 3853169 28 HI VIS Gearcase Lube PIN 772085 Locquic Primer PIN 772032 Lubriplatet 777 PIN 317619 Marine EP Wheel Bearing Grease PIN 508303...

Page 30: ...t Lock PIN 500421 Loctite Blue 242 Equivalent 3 Ultra Lock PIN 500423 Loctite Red 271 Equivalent SPECIAL TOOLS AND SERVICE SPECIFICATIONS SHOP AIDS Sea Lubet Needle Bearing Grease PIN 378642 Silicone...

Page 31: ...7874 in 19 98 to 19 99 mm 0 9842 to 0 9846 in 25 00 to 25 01 mm Rod Crankpin 0 8120 to 0 8125 in 20 63 to 20 64 mm 1 1823 to 1 1828 in 30 03 to 30 04 mm Piston Ring End Gap Both 0 005 to 0 015 in 0 1...

Page 32: ...h 90 Minutes Reserve Capacity or 90 Minutes Reserve Capacity or 50 Ampere Hour 50 Ampere Hour 5 A Non regulated 4 A Non regulated accessory Standard 25 30TE EL 5 Pulse I 10 pole 5 Pulse I 10 Pole with...

Page 33: ...ues apply only when a specific torque for a specific fastener is not listed in the appropri ate section When tightening two or more screws on the same part DO NOT tighten screws completely one at a ti...

Page 34: ...ING BATTERY AND CABLES INSTALLING BATTERY BATTERY CABLE REQUIREMENTS FUEL REQUIREMENTS MINIMUM OCTANE ADDITIVES FUEL SYSTEM REQUIREMENTS OVERViEW FUEL HOSE FUEL SYSTEM PRIMER FUEL FILTERS OUTBOARD FUE...

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Page 36: ...y from rotating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To p...

Page 37: ...s transom The width of the top edge of the transom should provide adequate clearance The transom must be flat and cannot have any protrusions The transom should meet ABYC Standards The boat s transom...

Page 38: ...he centerline of the boat transom as it relates to the hull bottom of the boat Use a straightedge to draw a line connecting the port and starboard chines The chines should be used as reference points...

Page 39: ...dified If you install and operate the outboard Lower than recommended Serious power head damage could result from water entry into the lower engine cover or overloading from an under revving propeller...

Page 40: ...ALLATION AND PREDELIVERY STEERING SYSTEM OUTBOARD MOUNTING rn WARNING m The outboard must be correctly installed 2 Failure to correctly install the outboard could result in serious injury death or pro...

Page 41: ...g bolts screws or other fasteners use Evinrude Johnson Genu ine Parts or parts of equivalent strength and material 40 WARNING m The remote control used must have the start in gear prevention feature T...

Page 42: ...ntrol cables and wiring harnesses Proper type and quality of cables and wiring harnesses Correct routing of cables and harnesses Adequate length and appropriate slack in front of the outboard for remo...

Page 43: ...Control Cable Casing Guides DR2067 1 Retracted 2 Extended to midpoint 42 Throttle Cable Installation Position the remote control handle in NEUTRAL Be sure the throttle cable is retracted IDLE 9 9 15...

Page 44: ...ed to IDLE position and shift cable is at mid point of travel Position shift linkage of outboard in NEUTRAL Make sure gearcase is in NEUTRAL INSTALLATION AND PREDELIVERY OUTBOARD RIGGING PROCEDURE 9 9...

Page 45: ...be adjusted properly or oper ator may lose control of direction and engine speed The remote control cable trunnion provides adjustment for the throttle cable and the shift cable Adjust by turning the...

Page 46: ...9 15 Model 35545 1 Solenoid terminal 2 Ground terminal 25 30 Model 42358 1 Solenoid terminal 2 Ground terminal Secure the battery negative cable to the pow erhead ground terminal Apply Black Neoprene...

Page 47: ...D PREDELIVERY OUTBOARD RIGGING PROCEDURE Install electrical bracket cover and secure with Install clamp and secure with screws screw Install battery cables and electrical cable into grommet 1 Grommet...

Page 48: ...Installation IMPORTANT Connect the battery positive cable to the battery positive post FIRST Con nect the battery negative cable to the battery 2 negative post LAST Install a starwasher on the threade...

Page 49: ...Minimum Octane 87 R M 2 AKI or 90 RON Evinrude Johnson outboards have been designed to operate using the above fuels however be aware of the following The boat s fuel system may have different require...

Page 50: ...ps on perma nently installed fuel hoses routed below decks Multi outboard applications require separate fuel tank pickups Install separate fuel hoses from the fuel tank to the outboards in multi out b...

Page 51: ...070 Outboard Fuel System Requirements Chart Component 25 HP 130 HP Models 135 HP 250 HP Models Fuel tank pickup tube 5 16 in 7 9 mm min 1 0 3 8 in 9 5 mm min 1 0 Fuel fittings 1 4 in 6 4 mm min 1 0 9...

Page 52: ...ns 3 U S Gallons 1 Liter 50 1 16 fl oz oil 8 fl oz oil 20 ml oil 25 1 32 fl oz oil 16 fl oz oil 40 ml oil INSTALLATION AND PREDELIVERY OIL REQUIREMENTS INITIAL RUNNING CHECKS WARNING DO NOT run outboa...

Page 53: ...t damage Find and correct the cause before continuing Change engine RPM often Avoid holding a throt tle setting longer than 15 minutes 52 First 10 minutes of operation Operate the outboard in gear at...

Page 54: ...unctional start in gear prevention Start outboard and shift outboard into FORWARD Turn outboard OFF while lever is in FORWARD Attempt restarting the outboard Outboard should not start Pull shift lever...

Page 55: ...rief periods of time to check full throttle RPM Use an accurate tachometer to determine the engine s full throttle RPM while testing various propellers Select a propeller that suits the customer s app...

Page 56: ...NG To prevent accidental starting while ser vicing twist and remove all spark plug leads INSTALLATION AND PREDELIVERY TRIM TAB ADJUSTMENT If the boat pulls to the left or right when its load is evenly...

Page 57: ...INSTALLATION AND PREDELIVERY NOTES NOTES Technician s Notes 56 Related Documents Bulletins Instruction Sheets Other J o o Qj Qj...

Page 58: ...66 67 67 68 68 FUEL SYSTEM 69 FUEL FILTER 69 AIR SILENCER 69 HOSES AND CONNECTIONS 69 SPARK PLUGS 69 SYNCHRONIZATION AND LINKAGE ADJUSTMENTS 9 9 15 70 PRELIMINARY ADJUSTMENTS 70 CAM FOLLOWER PICKUP P...

Page 59: ...t run lever shaft tilt shaft lubricate l J 0 Every 60 days Every 30 in Saltwater Swivel br 9ket tilt support bracket 0 Every 60 days Every 30 in Saltwater lubricate 1 Shift lever Sh and detent shallow...

Page 60: ...iveshaft splines inspect and lubricate Water pump inspect and replace 1 Also recommended at lO Hour Inspection 2 Emission related component 3 Do not use light duty penetrating lubricants MAINTENANCE I...

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Page 62: ...m rotating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To preven...

Page 63: ...unctioning properly IMPORTANT Anodes that are not eroding may indicate that the anodes are not properly grounded Anodes and the mounting screws must be clean and tight for effective corrosion protec t...

Page 64: ...NT The outboard must be located in a well ventilated area with appropriate ground drainage during the flushing procedures Keep water inlet pressure between 20 to 40 psi 140 to 275 kPa Flushing Outboar...

Page 65: ...the plug from the flushing port Install flushing device and garden hose Turn water supply ON 64 Flush outboard for at least five minutes Turn off water supply Remove garden hose and flushing device R...

Page 66: ...Steering cable DR29S46 2 Wiper nut Midsection Lubricate the tilt tube tilt shaft grease fittings clamp screws tilt lever shaft grease fittings and swivel bracket with Triple Guard grease Apply grease...

Page 67: ...icate the throttle linkage shift linkage starter lockout mechanism and carburetor linkage with Triple Guard grease Refer to the following dia grams IMPORTANT Check proper throttle and shift function 9...

Page 68: ...lity may be affected with continued use IMPORTANT The recommended gear lubri cants include special additives for marine applica tions Do not use any automotive gear lubricants 2 stroke or 4 stroke eng...

Page 69: ...rior to disas sembly Disconnect battery negative cable first and the battery positive cable last Clean all terminals battery posts and connectors with a solution of baking soda and water Use a wire br...

Page 70: ...rea Periodically clean the air silencer to remove any accumulations MAINTENANCE FUEL SYSTEM Hoses and Connections Check condition of all hoses and connections related to the fuel system Visually inspe...

Page 71: ...adjustment knob counterclockwise to the full SLOW position Turn the connector clockwise until it seats Turn counterclockwise no more than one half turn to align it with the throttle lever Install the...

Page 72: ...Cam Follower Pickup Point Connect a throttle shaft amplifier to the carburetor throttle shaft as shown Advance the throttle until the tip of the amplifier begins to move At this point the center of t...

Page 73: ...restrained The 1 boat must not be tied to a dock or trailer 1 Stop screw WOT 34778 Open throttle to WOT position and make sure the throttle shaft pin is vertical If adjustment is required turn the cam...

Page 74: ...propeller shaft and move the shift lever to NEUTRAL position SYNCHRONIZATION AND LINKAGE ADJUSTMENTS 25 30 IMPORTANT Synchronization and linkage pro cedures MUST be followed in sequence and be I perf...

Page 75: ...r marks 1 1 Indicator marks To adjust loosen the screw retaining the adjust ment lever to the throttle shaft Slide the adjust ment lever up or down to make the adjustment 1 74 1 2 3 1 Pivot block 4510...

Page 76: ...turn clock wise retards the timing about 1 one turn counter clockwise advances timing about 10 Tighten the nut and recheck the timing adjust ment Idle Speed The boat must be in the water under normal...

Page 77: ...ight cause accelerated wear of shift sys tem components and high shifting effort Install the throttle cable trunnion cover and tighten cover screw to 60 to 84 in Ibs 7 to 9 N m 76 IMPORTANT All Johnso...

Page 78: ...of storage Remove all spark plugs and spray a liberal amount Evinrude Johnson Storage Fogging Oil into the spark plug holes MAINTENANCE STORAGE Turn the flywheel in a clockwise direction to dis tribu...

Page 79: ...ced within three 3 hours of recovery Immediate service can mini mize the corrosive affect that air has on the pol ished surfaces of the crankshaft connecting rods and internal powerhead bearings IMPOR...

Page 80: ...edures as Engine Dropped Overboard Not Running However if there is any binding when the flywheel is rotated it may indicate a bent connecting rod and no attempt should be made to start the outboard Po...

Page 81: ...MAINTENANCE NOTES NOTES Technician s Notes 80 Related Documents Bulletins Instruction Sheets Other E o u oj Qj i i E I...

Page 82: ...COIL RESISTANCE TESTS 88 TACHOMETER CIRCUIT TEST 89 ELECTRIC STARTER TESTS 90 START SWITCH TEST 90 START CIRCUIT VOLTAGE TEST 90 VOLTAGE DROP TESTS 96 STARTER SOLENOID TEST 97 NO LOAD CURRENT DRAW TE...

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Page 84: ...rom rotating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prev...

Page 85: ...ywheel contains permanently charged magnets The magnets supply energy to power the stator windings The magnets must be at their original design strength for full alternator output 32278 Stator The alt...

Page 86: ...en beginning this test Connect the battery cables and run the outboard in a test tank Refer to the output curve to determine the correct out put to RPM ratio If there is no output or the output is not...

Page 87: ...ter leads between yellow blue and one yellow gray lead Ohmmeter must show 1 5 to 1 7 ohms To check stator for a grounded condition connect one meter lead to a clean engine ground and the other lead al...

Page 88: ...note the reading Perform the same procedure on the yellow and yellow blue rectifier leads Note the readings A high reading in one direction and a low read ing in the other direction indicates the dio...

Page 89: ...eter leads between yellow gray and yellow blue stator leads Meter must show 1 21 0 02 ohms DR4160 Calibrate ohmmeter on high ohms scale Connect one lead to a clean engine ground Probe each of the conn...

Page 90: ...and black circuits engine fuse key switch and the battery con nections STEP 3 With the engine NOT running and the key switch ON check for battery voltage between the instru ment harness gray lead and...

Page 91: ...shows 12 V go to STEP 3 If the voltmeter shows 0 V test the negative battery cable 90 STEP 3 Move the voltmeter red lead to the start switch connection Check the voltage between the start switch conn...

Page 92: ...ery positive 2 Battery negative 3 Rectifier terminal ground 4 Start switch connection 5 Powerhead ground 6 Start switch output lead 7 Start button 8 Starter terminal 9 Pinion ELECTRICAL ELECTRIC START...

Page 93: ...onnect the voltmeter between solenoid connec tion B and ground Press the start button Check voltage at solenoid connection B If the voltmeter shows 12 V go to STEP 4 If the voltmeter shows 0 V test st...

Page 94: ...1 Starter terminal 2 Start button 3 Solenoid connection A 4 Solenoid connection B 5 Yellowlred lead 6 Neutral start switch 7 Solenoid connection C ELECTRICAL ELECTRIC STARTER TESTS DR6187 E o U Qj Qj...

Page 95: ...94 IMPORTANT Remote control must be in NEU TRAL for neutral safety switch to be closed STEP 4 Connect voltmeter between key switch connector pin S and ground Turn key to START position Check voltage...

Page 96: ...enoid connection A 3 Solenoid connection B 4 Key switch connector pin S 5 Neutral start switch 6 Key switch connector pin B 7 Solenoid connection C 8 Solenoid connection D 9 Starter terminal ELECTRICA...

Page 97: ...s only while the engine is cranking or dam age to the voltmeter can occur STEP 2 Remove voltmeter positive lead from starter solenoid and stop cranking engine DRC4030 STEP 3 Connect voltmeter positive...

Page 98: ...ring must be discon nected from the solenoid before proceeding STEP 1 Connect one ohmmeter lead to terminal A and the other lead to terminal 8 Ohmmeter must show a high reading If ohmmeter shows a low...

Page 99: ...el MT110 or EETA501 and various other ammeters should be available through your local tool suppliers Attach or hold a vibration tachometer such as a Frahm Reed tachometer to the starter Complete the c...

Page 100: ...t source and use an oil that has a flashpoint above 300 F 150 C such as a 4 cycle motor oil Separate the connector and remove the tempera ture switch from the cylinder head Using a continuity light or...

Page 101: ...the vertical throttle shaft clamp screws and clamp Remove the screws and washers retaining the starter bracket to the side of the powerhead Note that the ground lead attaches to the lower screw and ha...

Page 102: ...and washer from the armature 1 Pinion nut 2 Spacer 3 Spring 4 Pinion 5 Washer 6 Armature rr 5 6 e 4 g _ 3 o 2 0 1 32983 ELECTRICAL ELECTRIC STARTER SERVICING 25 30 MODELS Gently pry bottom of protect...

Page 103: ...commutator with 300 grade emery cloth If commutator surface is unevenly worn or pitted turn on a lathe Remove any trace of oil or metal dust from commutator Check the armature on a growler for shorted...

Page 104: ...The cleaning agent could drain into the starter washing dirt from the drive into the bearings and commutator After disassembling clean each part with a grease solvent and inspect If the pinion does n...

Page 105: ...ure shaft 1_ I O o o o o O ___ 2 o 0 to 40 in Ibs 3 4 to 4 6 N m Apply Black Neo 1 Washer 38288 prene Dip to the seams between the end caps and 2 Drive end cap frame and magnet assembly Assemble the p...

Page 106: ...notch and rib A suitable tool for holding brushes in place can be made from a putty knife Put a drop of oil on thru bolts before assembling starter motor Install thru bolts Torque thru bolts 95 to 10...

Page 107: ...y Black Neoprene Dip to con nection IMPORTANT When tightening the terminal nut make sure the starter lead and terminal does not turn into a position where the lead and terminal could contact the start...

Page 108: ...procedures if it is necessary to remove any of the following accessory components Primer Solenoid Rectifier Electrical bracket Removal ELECTRICAL ACCESSORY COMPONENTS Disconnect the black and purple w...

Page 109: ...at may be required for installation Install bracket with coil on powerhead Torque screws 48 to 96 in Ibs 5 4 to 10 8 N m Install the fuse and connect the gray and tan wires Install the rectifier with...

Page 110: ...4 in 6 mm insulation from wire and crimp new terminal onto wire with crimping pliers 1 _ Pick the proper tool for the service being per formed Refer to SPECIAL TOOLS on page 19 in SPECIAL TOOLS AND SE...

Page 111: ...yl alcohol to the terminal cavity Place connectors against solid surface Hold tip of tool securely against shoulder of terminal while inserting terminal Push terminal into connector until step of inse...

Page 112: ...ROUBLESHOOTING 119 FLYWHEEL INDEXING 119 IGNITION SYSTEM TESTS 120 TOTAL IGNITION OUTPUT TEST 120 STOP CIRCUIT TESTS 120 CHARGE COIL TEST 122 SENSOR COIL TEST 123 POWER PACK CRANKING OUTPUT 124 POWER...

Page 113: ...112 J o u iii Qj...

Page 114: ...ating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent acc...

Page 115: ...voltage is supplied to the power pack to operate the ignition system 1 1 Charge coil 114 Sensor Coil The sensor coil contains many windings of wire wrapped around a metal lamination Once the fly whee...

Page 116: ...1 1 Stop button 24331 2 Emergency stop switch IGNITION COMPONENTS When the clip and lanyard assembly is removed the emergency stop device is in the STOP posi tion When the clip and lanyard assembly i...

Page 117: ...coil has primary and secondary terminal connec tions and a ground plate 1 25130 Model 17127 1 Single ignition coils Through mutual induction the ignition coil trans forms the ignition module output to...

Page 118: ...81 Stevens Number CO 77 Electro Specialties Number PRV 1 Ohmmeter IGNITION TEST EQUIPMENT Used for various resistance measurements and must be capable of reading low and high ranges Various models ava...

Page 119: ...Ignition coil terminal extender 23600 Amphenol Connector Adapter A jumper wire used for performing ignition output tests can be made locally using the following Number 16 wire 8 in 200 mm length Pin...

Page 120: ...rratically or continuously To trouble shoot this Situation determine if each cylinder is firing at the correct time and no more than once per revolution Disconnect the spark plug leads and remove both...

Page 121: ...arc route tester leads at least 2 in 51 mm from any metal surface 120 If equipped install the clip onto the emergency stop switch Crank the engine Spark should jump each tester gap alternately If test...

Page 122: ...ween the power pack and ignition plate Calibrate ohmmeter on appropriate scale Con nect meter leads between ignition plate end of connector terminal E and a clean engine ground Key OFF meter must show...

Page 123: ...und or replace charge coil If no reading is indicated go to STEP 2 DR4619 122 STEP 2 Set peak reading voltmeter to 9 9 15 NEG and SOD 25130 pas and SOD Attach voltmeter black lead to ignition plate co...

Page 124: ...CD 77 meter Alternately connect voltmeter between ignition plate connector terminals B C and a clean engine ground Crank engine and observe meter at each connection Any reading indicates sensor coil o...

Page 125: ...ack lead to a clean engine ground If Stevens Number PL 88 is not available an adapter can be made using a 10 ohm 10 watt resistor Radio Shack Number 271 132 or equiva lent Connect peak reading voltmet...

Page 126: ...esting number 1 ignition coil test the num ber 2 ignition coil If either cylinder shows less than specified out put test charge coil Refer to Charge Coil Test on p 122 If charge coil tests good replac...

Page 127: ...s vary 126 Ignition Coil Analyzer Tests IMPORTANT When conducting these tests to the coil do not exceed its maximum specified amperage Magneto C D Coil Specifications Operating Merc O Tronic Stevens A...

Page 128: ...nnect temperature switch tan red lead Install correct test propeller Start outboard in test tank and run at 3500 RPM Touch engine harness tan red lead to a clean engine ground If engine speed slows to...

Page 129: ...Use a Flywheel Holding Tool and three screws PIN 307641 from Univer sal Puller Set PIN 378103 or Flywheel Holder PIN 771311 IMPORTANT Use of non suppression spark Flywheel Holding Tool 32927 plugs wil...

Page 130: ...flywheel key with its outer edge parallel to taper of crankshaft I j I I DR2115 25 30 MODELS Install the flywheel key with its outer edge parallel 3 to centerline of crankshaft and single upset mark...

Page 131: ...art Model Ft lb N m 9 9 15 45 to 50 60 to 70 25 30 100 to 105 135 to 140 130 IGNITION PLATE SERVICING Removal m WARNING m To prevent accidental starting while ser vicing twist and remove all spark plu...

Page 132: ...h washers from the powerhead 1 1 1 Screws 47303 IGNITION IGNITION PLATE SERVICING Installation 9 9 15 MODELS Place the retainer plate then the support plate on the powerhead Align support plate with f...

Page 133: ...Refer to SYNCHRONIZATION AND LINKAGE ADJUST MENTS 9 9 15 on p 70 Check for sufficient slack on ignition component leads during full advance movement of the ignition plate 132 25 30 MODELS Place the r...

Page 134: ...LINKAGE ADJUST MENTS 25 30 on p 73 Check for sufficient slack on ignition component leads during full advance movement of the ignition plate IGNITION CHARGE COIL AND SENSOR COIL CHARGE COIL AND SENSO...

Page 135: ...all the new ignition component on the ignition plate Connect and route the leads from the spiral wrap and from the ignition component IMPORTANT All component leads must be routed through the clamp and...

Page 136: ...55 IGNITION IGNITION COIL 4 2 1 3 2 5 4 2 3 tr 2 1nIt j 11IIrIl n 4 25 30 Model DR5741 1 Fiber washer 2 Flat washer 3 Ignition coil ground strap 4 Starwasher 5 J clamp 6 Stop switch ground lead Remove...

Page 137: ...IGNITION NOTES NOTES Technician s Notes 136 Related Documents Bulletins Instruction Sheets Other...

Page 138: ...ESSURE TEST 145 PRIMER SOLENOID REMOVAL DISASSEMBLY ASSEMBLy INSTALLATION PRIMER PUMP DISASSEMBLY CLEANING AND INSPECTION ASSEMBLy FUEL PUMP GENERAL DISASSEMBLY CLEANING ASSEMBLy CARBURETOR EMISSIONS...

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Page 140: ...otating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent a...

Page 141: ...p directly to the carburetor and or the intake manifold Primer Pump 25 TE AND 25 30 R MODELS Fuel mixture enrichment for cold starting and warm up is provided by a manually operated primer pump Pull t...

Page 142: ...ginal factory fuel mixture calibrations beyond the limits allowed by the tamper resistant device is a violation of federal law Any carburetor adjustments beyond preset limits become the responsibilty...

Page 143: ...CESSIVE OIL USE STALLS ON ACCELERATION SURGES AT HIGH SPEED RUNS RICH AT HIGH SPEED LOSS OF W O T RPM CARBURETOR FUELSPITBACK 32CFTCENR http SelfFixer Com_ FUEL SYSTEM TROUBLE CHECK CHART CARBURETOR 1...

Page 144: ...2 Remove primer hose from intake or carburetor fit ting Connect a 1 8 in I D clear vinyl hose between the fitting and a syringe PIN 346936 filled with isopropyl alcohol Press lightly on the syringe R...

Page 145: ...t is functional No affect on speed check primer operation Proceed to next step STEP 2 Remove primer hose s from intake or carburetor fitting s Connect a 1 8 in I D clear vinyl hose between the fitting...

Page 146: ...imer pump housing under the small nipple should allow fuel to come out in one direction and close in the other direction The fuel inlet check valve allows fuel into the end of the plunger and out thro...

Page 147: ...When assembling solenoid back out screws in their holes to engage original threads and tighten securely DR1417 Installation Install solenoid and bracket with screws Position ground lead under rear br...

Page 148: ...tches replace the plunger Inspect plunger where cross hole intersects inside hole Any burrs around cross hole will accelerate FUEL SYSTEM PRIMER PUMP wear of O rings Remove any protruding burrs and po...

Page 149: ...ill the plunger housing Alcohol should flow freely out of the small nipple indicating no obstructions 001008 If no flow is indicated replace primer pump hous ing Assembly Position the spring and washe...

Page 150: ...ure to check for fuel leakage could allow a leak to go undetected resulting in fire or explosion Before replacing a suspect fuel pump remove and clean the fuel filter and install a new filter ele ment...

Page 151: ...resistance is felt 150 CARBURETOR Emissions Compliance Johnson 9 9 15 models for model year 2004 are manufactured in accordance with United States of America Environmental Protection Agency EPA stand...

Page 152: ...two retaining screws and remove air Remove the cam follower O ring silencer 1 1 1 O ring 35010 1 Screws 32957 Loosen two mounting nuts and remove carburetor Remove the choke lever Cut tie strap securi...

Page 153: ...ic starter bracket if equipped and set it aside Remove primer hose from nipple Push throttle link out of cam follower 152 Remove carburetor mounting nuts Remove carburetor from manifold Remove and dis...

Page 154: ...djustable within a limited range If the needle is turned for any reason it should be returned to its original location HR Models Only Remove the low speed needle and spring from the carburetor body co...

Page 155: ...uretor Assembly Cleaning and Inspection 154 Cleaning and Inspection IMPORTANT Do not clean carburetor or its components by submerging in strong carburetor cleaner or hot soaking tank Strong cleaners m...

Page 156: ...excessive throttle shaft play Check for throttle valve misalignment If necessary remove the calibration pocket core plug to inspect the pocket for damage or restric tions Drive a small punch not more...

Page 157: ...build kit inspect gaskets and compare to origi nal gaskets to ensure all holes are correctly punched Also inspect new gaskets for any loose fibers or particles of gasket material IMPORTANT Before proc...

Page 158: ...ning of the inlet needle and is critical to correct operation of the carburetor With carburetor body in normal running position the float must drop open from base of carburetor body to setting shown F...

Page 159: ...uretor calibration and function Turn carburetor body upside down and hold so gasket surface is horizontal The weight of the float will close the float valve needle Rest Float Gauge PIN 324891 on gaske...

Page 160: ...tie strap Position a new gasket on the intake manifold Install the carburetor Tighten two retaining nuts securely FUEL SYSTEM CARBURETOR Install cam follower on post Position O ring on the post to se...

Page 161: ...N 323716 38517 Position a new carburetor base gasket on the intake manifold studs Do not use sealer on the gasket Secure the carburetor to the intake manifold 160 Connect the throttle link to the cam...

Page 162: ...idle speed adjustment knob counterclockwise to lowest SLOW speed position FUEL SYSTEM CARBURETOR MIXTURE ADJUSTMENT Run the engine at slow speed 700 to 800 RPM and adjust the low speed needle until th...

Page 163: ...h the engine will be rough and unsteady Do the following procedure Note the reference mark and turn the needle 1 8 revolution clockwise Wait 15 seconds after each adjustment and repeat this procedure...

Page 164: ...INTAKE MANIFOLD Follow steps listed in CARBURETOR Removal on page 150 Remove pin from end of throttle control rod 1 1 Pin 14504 2 Throttle control rod Remove tie strap and disconnect oil recirculation...

Page 165: ...or chipped The leaf stops must not be distorted or loose Test leaf plate screw tightness If loose tighten using Screw Lock The check valve disk must be intact and free to move inside the valve The ch...

Page 166: ...es 6 When disassembled keep the stops shims and leaf valves separated by assembly IMPORTANT The 9 9 and 15 leaf valves are not interchangeable The thickness of the valves is not the same 25 30 MODELS...

Page 167: ...shim if required and leaf stop Install screws finger tight Center the leaf valves on the plate using index 12321 marks IMPORTANT Used leaf valves must not be turned over for reuse Leaf valve may brea...

Page 168: ...s with light pressure valve is acceptable If not inspect leaf plate for high spots or burrs IMPORTANT Do not lap leaf plate If plate is too smooth the leaf valves may stick closed after off season sto...

Page 169: ...e rod in pivot pin on throttle lever Align the gasket with the manifold and install man ifold screws Tighten screws evenly and securely Install wire retainer in throttle rod 2 1 12335 1 Wire retainer...

Page 170: ...9 15 DISASSEMBLY 25 30 CLEANING INSPECTION ALL MODELS 9 9115 MODELS 25 30 MODELS ASSEMBLY 9 9 15 ASSEMBLY 25 30 INSTALLATION 9 9 15 INSTALLATION 25130 POWERHEAD VIEWS 9 9 15 PORT STARBOARD VIEW MANUA...

Page 171: ...m 60 to 84 in Ibs 7 to 9 N m Use Rod Cap Alignment Fixture PIN 396749 25130 Lubricant 30 to 32 ft Ibs Apply Evinrude Johnson 40 to 43 N m Outboard Lubricant to threads 60 to 84 in Ibs Apply Gasket Se...

Page 172: ...otating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent a...

Page 173: ...proce dure for each cylinder Return throttle to idle position and reconnect power pack connector Replace spark plugs Taper Pin Tool 11 2 In 13 mml 9 32 In 7 mml Hole for Storage Scale FULL SIZE __ 1...

Page 174: ...ads Start outboard and run at 3000 RPM for at least five minutes POWERHEAD ENGINE TEMPERATURE CHECK Reduce engine speed to 900 RPM At 900 RPM the digital pyrometer or Temperature Gun should indicate 1...

Page 175: ...e holding remover installer body turn press ing screw PIN 342227 and remove seal r 3 2 1 L 1 Tip C01556 2 Remover installer body 3 Pressing screw 25 30 MODELS Use Seal Remover PIN 387780 Thread remove...

Page 176: ...180 Remove the clip and drive pin from shift handle 32338 Remove the screw retaining the shift handle 32337 Remove the lockout rod POWERHEAD SHIFT LINKAGE Remove the choke lever and grommet 32333 Rem...

Page 177: ...red for installation Install the two shift arm bushings Install the pin and shift lever and secure with cotter pin Install the shift arm and spacer Position lock tab on shift arm and install screw sec...

Page 178: ...actuator cam 47175 2 Lockout lever Tighten the shift lever screws and torque 60 to 84 in Ibs 7 to 9 N m Refer to NEUTRAL START PROTECTION on p 178 to adjust the neutral start switch Start Switch 9 9 1...

Page 179: ...t as required 178 NEUTRAL START PROTECTION Manual Starter Manual start outboards are equipped with starter lockout mechanisms Check operation of starter and lockout Manual starter must NOT operate whe...

Page 180: ...outboard in NEUTRAL the light or ohmmeter should show continuity While rotating the propeller shaft shift the out board into FORWARD then REVERSE The light or ohmmeter should NOT show continuity in ei...

Page 181: ...cator hose and remove the screw from the lower rear of the lower engine cover 180 Remove the two screws from the top front of the lower engine cover Remove the screw and nut from the lower front of th...

Page 182: ...nt accidental starting of engine while servicing twist and remove all spark plug leads On electric start models dis connect battery cables at the battery Dis connect battery positive cable first and t...

Page 183: ...O ring inside 1 Cover 001007 Remove the overboard water indicator hose from fitting on exhaust cover Remove the hose from J Remove the primer hose from the carburetor and the primer hose from the inta...

Page 184: ...oard retaining nut and washer POWERHEAD REMOVAL 25 30 47174 Remove the four screws retaining the powerhead to the exhaust housing 1 Screws 20984 Move the powerhead sideways to break the gas ket loose...

Page 185: ...ust cover screws If necessary tap the exhaust cover edge with a rawhide mallet Remove the inner and outer exhaust covers care fully separate the pieces IMPORTANT Check the inner exhaust cover for pitt...

Page 186: ...Pin Tool 32382 POWERHEAD DISASSEMBLY 9 9 15 Remove the four crankcase flange screws and six main bearing screws Turn the powerhead so the intake manifold sur face faces up Using a rawhide mallet ligh...

Page 187: ...rod screws Remove the rod caps and bearing retainers 186 Lift the crankshaft out of the cylinder block Replace the connecting rod caps on the rods Ori ent them exactly as they were before you removed...

Page 188: ...e of the piston skirt during han dling Remove the piston rings using an appropriate ring expander DO NOT try to save the rings Install a complete set of new rings at reassembly TYPICAL 22153 POWERHEAD...

Page 189: ...y Gasket Sealing Compound to outside diameter of the grommet Align tab of the grommet with hole in the housing and install grommet 188 Using diagonal or end cutters gently pry out and remove the flywh...

Page 190: ...Carefully separate the inner and outer exhaust covers Clean all gasket surfaces 1418 POWERHEAD DISASSEMBLY 25 30 IMPORTANT Check the inner exhaust cover for pitting and flatness If pitting exists or t...

Page 191: ...m the cylinder block 190 IMPORTANT Pistons connecting rods rod bearings and bearing retainers are wearing parts and seat with the operation of the engine Because of this it is essential to maintain th...

Page 192: ...the condition of the piston by packing paper towels between the connecting rod and piston Do not allow the con necting rod to contact the inside of the piston skirt during handling POWERHEAD DISASSEMB...

Page 193: ...of new rings at reassembly 22153 Using Retaining Ring Pliers or equivalent remove the wrist pin retaining rings Discard the rings 192 The fit between the wrist pin to bosses of the pis ton is loose o...

Page 194: ...and Gasket Remover POWERHEAD CLEANING Use Gel Seal and Gasket Remover to remove all traces of gaskets adhesives and Gel Seal II from the cylinder block and crankcase Carefully remove any carbon accumu...

Page 195: ...piece of bar stock or machinist s straightedge and a feeler gauge set Cylinder head warpage must not exceed 0 004 in 0 10 mm per inch ot measurement Replace head it warpage exceeds this dimen sion Us...

Page 196: ...no more than 0 002 in 0 05 mm 0 ____ L __ LiIIIIIII t C03082 Place each ring separately in its respective bore Use a piston to square the ring in the cylinder Use a feeler gauge to measure the ring en...

Page 197: ...ndition Make your measure ments 1 8 to 1 4 in 3 2 to 6 4 mm above the bot tom edge of the piston skirt Piston side view C03082 Measure the diameter of the pistons as follows The major diameter of the...

Page 198: ...ing fully seated in its groove make several checks around the pis ton The side clearance must not exceed 0 004 in 0 10 mm 1529 POWERHEAD INSPECTION Use a machinist s straightedge to check clearance on...

Page 199: ...opposite notch in the piston 2 1 1 Gap of retaining ring COB1132 2 Notch in piston 198 Using the piston cradle and wrist pin driver oil and start the wrist pin into the piston wrist pin boss opposite...

Page 200: ...on in Ring Compressor PIN 339754 PIN 339755 for oversize pistons Make certain that the rings are correctly positioned in their grooves with respect to the dowel pins Damaged pistons and broken rings m...

Page 201: ...eeves together with the retaining ring 1 COB1144 Remove the rod caps from connecting rods Place one retainer half and bearings on each rod 1 1 I I 1 Retainer half 32405 200 Place crankshaft in positio...

Page 202: ...Solvent and let air dry Apply Locquic Primer to the mating flange of the crankcase and let air dry POWERHEAD ASSEMBLY 9 9 15 Apply a thin coat of Gel Seal II to the cylinder block flange Coating must...

Page 203: ...ts the head Use the opposite side of the tool to install the large diameter seal Lip of this seal must face away from large diameter of the tool When installed both seal lips will face toward 202 each...

Page 204: ...n Install the cylinder head screws dry Do not use sealant on threads 3 4 2 1 6 5 Torque Sequence 32448 POWERHEAD ASSEMBLY 9 9 15 Install the thermostat assembly and temperature switch if equipped in t...

Page 205: ...cut or abrade wire insulation 204 ASSEMBLY 25 30 IMPORTANT Proceed slowly Make no forced assemblies unless a pressing operation is called for All internal components must be perfectly clean and light...

Page 206: ...Install the wrist pin through the piston and con necting rod pushing the tool out through the pis ton 24442 Using Cone PIN 318600 and Driver PIN 318599 install new wrist pin retaining rings in both w...

Page 207: ...the crankshaft Use Crankshaft BearinglSleeve Installer PIN 339749 to install bearing Support the crankshaft between the two lower counter weights and press against the lettered side of the bearing Ins...

Page 208: ...591 PIN 330223 for oversize with outboard lubricant Center connecting rod in piston and locate piston rings on their dowel pins Slide one piston assem bly into the respective cylinder bore while guidi...

Page 209: ...cause permanent damage to the connecting rod and crankshaft To maintain accurate torque values keep torque wrench extension length to a minimum 208 Install Rod Cap Alignment Fixture PIN 396749 before...

Page 210: ...cing screw to a torque of 14 to 16 in Ibs 1 6 to 1 8 N m 34432 1 IMPORTANT Make sure that frame is squarely in position and that rod and cap are aligned Test at least three corners of the rod and cap...

Page 211: ...f the six main bearing screws with Gel Seal II Install the screws finger tight When the crankcase is seated install and firmly seat the crankcase taper pin Install crankcase flange screws finger tight...

Page 212: ...m POWERHEAD ASSEMBLY 25 30 Place the thermostat and the seal in the cavity provided in the cylinder head Set the spring on top of the thermostat 3 __ I 1 _ _ _ 2 1 Thermostat 2 Seal 3 Spring COA1452 A...

Page 213: ...ate Do not use sealer on the gasket Apply Gel Seal to the threads of the flat head screw then install and tighten the screw 1 Flat head screw 1427 Install a new intake manifold gasket over the crankca...

Page 214: ...r tube and the short water tube as shown prior to installing the powerhead on the exhaust housing Guide the long water tube into the water tube opening in the exhaust housing and the short water tube...

Page 215: ...the water tube enters the inner exhaust housing Rotate the powerhead slightly back and forth to align the crankshaft and the driveshaft splines Install four powerhead retaining screws and torque 192...

Page 216: ...hten pivot screw to 60 to 84 in Ibs 7 to 9 N m Remove the pin securing the plunger 2 1 1 Screw 47176 2 Washer POWERHEAD INSTALLATION 25 30 Rotate the propeller shaft and shift the engine into REVERSE...

Page 217: ...bushing on the stud of the throttle control lever Engage the armature plate link on the stud Place the washer over the stud and engage the spring 1 Throttle control rod 21579 2 Pin 3 Armature plate li...

Page 218: ...Port Starboard View Manual Start POWERHEAD POWERHEAD VIEWS 9 9 15 217...

Page 219: ...POWERHEAD POWERHEAD VIEWS 9 9 15 Rear View Manual Start 218 E o u iii Qj C...

Page 220: ...Port Starboard View Manual Start POWERHEAD POWERHEAD VIEWS 25 30 E o U Qj Qj ii 219 E...

Page 221: ...POWERHEAD POWERHEAD VIEWS 25 30 Rear View Manual Start 220 E o u oj Qj i i E I...

Page 222: ...Port Starboard View Tiller Electric Start POWERHEAD POWERHEAD VIEWS 25 30 I E o U Qj Qj ii 221 E...

Page 223: ...POWERHEAD POWERHEAD VIEWS 25 30 Rear View Tiller Electric Start 222 E o U Qj Qj ii E...

Page 224: ...Port Starboard View Remote Electric POWERHEAD POWERHEAD VIEWS 25 30 223 E o U Qj Qj ii E...

Page 225: ...POWERHEAD POWERHEAD VIEWS 25 30 Rear View Remote Electric 224 E 0 1 o Qj i i E...

Page 226: ...SEMBLY 230 INSPECTION 231 ASSEMBLY 232 INSTALLATION 234 EXHAUST HOUSING 237 DISASSEMBLY 237 CLEANING AND INSPECTION 241 GENERAL 241 ASSEMBLY 242 SWIVEL BRACKET 246 DISASSEMBLY 246 ASSEMBLY 248 ADJUSTM...

Page 227: ...18 to 20 ft Ibs 24 to 27 N m 60 to 84 in Ibs 7 to 9 N m 18 to 20 ft Ibs 24 to 27 N m 60 to 84 in Ibs 7 to 9 N m 50 to 54 ft Ibs 68 to 73 N m 48 to 60 in Ibs 5 to 7 N m 25 30 Lubricant Nut Lock 144 to...

Page 228: ...rotating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent...

Page 229: ...throttle cable anchor to the powerhead Remove the cable end connector and throttle cable anchor from the cable Cut tie strap and separate the 5 pin Amphenol connector Remove the stop button black wire...

Page 230: ...arate the 5 pin Amphenol connector Remove the stop button lead from the plug using Socket Removal Tool PIN 322699 45034 30386 MIDSECTION STEERING HANDLE TILLER MODELS Remove the stop button ground lea...

Page 231: ...ng the idle adjustment knob clockwise 1 __ 2 3 1 Twist Grip Remover 32290 2 Screw 3 Idle adjustment knob Remove the helix halves rollers and guides 1 2 3 2 1 1 Helix halves COA2674 2 Rollers 3 Guides...

Page 232: ...eplace it Using a punch and mallet drive the steel pin that retains the inner handle from the steering handle 24285 Remove the plastic inner handle from the metal outer handle by driving the outer han...

Page 233: ...l plate on outer handle 25 30 MODELS Install the throttle cable seal in inner handle If removed apply Loctite Depend 300 adhesive to inner handle at areas shown 232 1 2 in 12mm 20849 Install the metal...

Page 234: ...ooves and inner handle guide slot with Moly Lube Place the guides over the roller pin and into the slots of the inner handle Place the rollers on the ends of the roller pin Assemble helix halves on th...

Page 235: ...y IMPORTANT Make sure the protective sleeves are on the throttle cable and stop switch wires Apply Triple Guard grease to the steering handle sleeve and place the sleeve into the steering bracket 9 9...

Page 236: ...Pin Insert Tool PIN 322697 to install the stop button black wire into the 5 pin Amphenol plug 35279 Connect the Amphenol connector Secure the connector to the ignition coil post with a tie strap Posi...

Page 237: ...cable housing 2 in 50 mm plus or minus one turn from the end of the cable sleeve Secure anchor in place with shoulder screw and spacer Next thread the con nector onto the cable end 2 in 50 mm 50174 P...

Page 238: ...disengage the shift rod from the shift arm and remove the rod MIDSECTION EXHAUST HOUSING Remove the five screws and lift the lower engine cover support off the exhaust housing Remove the two lower mou...

Page 239: ...mmet Refer to Cleaning and Inspection on p 241 238 25 30 MODELS Remove the following Powerhead refer to Powerhead REMOVAL 25 30 on p 181 Gearcase refer to Gearcase REMOVAL AND INSTALLATION on p 260 RE...

Page 240: ...shift rod lever 2 1 1 Clip COA2522 2 Screw 3 Shift rod lever MIDSECTION EXHAUST HOUSING Remove the adjustment lever and shaft retainer with a small screwdriver Hold the shift rod lever and the upper...

Page 241: ...r side mount 2 240 Remove the nut and the washer from the upper front mount Separate the exhaust housing from the swivel bracket assembly 1 1 Nut and washer 17392 2 Upper front mount Remove the two sc...

Page 242: ...Install a new swivel plate with screw and tighten securely Exhaust Housing Before checking the exhaust housing for distor tion thoroughly clean the top and bottom mating surfaces and remove all seale...

Page 243: ...the threads on the two upper mount to steering bracket screws Apply Nut Lock to threads of screws Position the swivel bracket assembly on the exhaust housing Install the two upper mount screws and ti...

Page 244: ...e exhaust housing and torque the five screws to 60 to 84 in Ibs 7 to 9 N m MIDSECTION EXHAUST HOUSING Lubricate the upper shift rod with Triple Guard grease Install the shift rod into the shift arm a...

Page 245: ...xhaust housing Apply Adhesive M to the seal 244 surface of the exhaust housing Position a new exhaust housing to lower engine cover seal 1 1 Seal lower engine cover 001019 Apply Gasket Sealing Compoun...

Page 246: ...the adjusting lever and shaft comes through the exhaust hous ing install the shift rod lever Snap the shift shaft retainer into place Place a new shift rod lever clip over the shift rod lever Install...

Page 247: ...e adjustment lever and shaft with two screws plate spacer and nuts Torque screws to 60 to 80 in Ibs 7 to 9 N m 1 Shift lever 2 Spacer ALL MODELS Install the following Gearcase refer to Gearcase REMOVA...

Page 248: ...2 If necessary service the components of the stern brackets o om I O 0 TYPICAL 32471 MIDSECTION SWIVEL BRACKET If the tilt bolt is removed tighten the bolt to a torque of 60 to 84 in Ibs 7 to 9 N m wh...

Page 249: ...et 1 Liner 6295 2 Friction block Remove the upper front mount from the steering bracket Disassemble the steering bracket from the pilot shaft by removing the four screws 1 Upper front mount 2 Screws 2...

Page 250: ...2 Liner 1 2 1 32479 MIDSECTION SWIVEL BRACKET Install the upper thrust washer on the swivel bracket 1 Upper thrust washer 32481 1 Friction adjustment screw Apply Triple Guard grease to the lower bushi...

Page 251: ...f the four steering bracket to pivot shaft screws thoroughly Apply Screw Lock to the threads Apply Ultra Lock to top mating flange of the pilot shaft Assemble the pilot shaft to the steering bracket T...

Page 252: ...ck 001017 MIDSECTION SWIVEL BRACKET Install the upper thrust washer Slide the pilot shaft into the swivel bracket 6296 Lubricate and slide the lower bushing O ring and lower thrust washer on the pilot...

Page 253: ...ndle Turning the knob clockwise increases idle speed turning it counterclockwise decreases idle speed Make certain that throttle is in SLOW position and the outboard is at normal operating temperature...

Page 254: ...0 BEARING AND SEAL REMOVAL 273 DRIVESHAFT SEALS 273 DRIVESHAFT BEARING 273 PINION BEARINGS 274 FORWARD BEARING 274 SHIFT ROD BUSHING AND O RING 275 9 PROP SHAFT BEARING HOUSING SEALS AND O RING 275 PR...

Page 255: ...I A 1 I 60 to 84 in b 7 to 9 N m F I B C D A Triple Guard Grease B Gasket Sealing Compound C Adhesive M Sealant o MolyLube I I I 0 0 I 1 I I I I I I I I I I I I I I I I I I I I I 48 to 84 In lb 5to 9N...

Page 256: ...S A Triple Guard Grease B Gasket Sealing Compound C Adhesive M Sealant o MolyLube F Blue Nut Lock GEARCASE SERVICE CHART 192 to 216 in lb 22 to 25 N m I I I I I I I I I fr J ftl I I I I J gJJ c i J EP...

Page 257: ...256...

Page 258: ...g parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent acciden...

Page 259: ...y aligning splines and pushing until seated on the thrust bushing Install the spacer engaging the propeller shaft splines 3 4 2 1 TYPICAL C02443 1 Thrust bushing 2 Thrust washer 3 Cotter pin 4 Propell...

Page 260: ...ttle for a minimum of one hour to deter mine if there is an abnormal amount of water in the oil Some gearcase lubricants are designed to mix with a small amount of water from normal water vapor conden...

Page 261: ...stall vacuum test gauge Apply 3 to 5 in of vac uum 76 to 127 mm Hg with pump Check for leakage If leakage occurs apply oil around suspected seal If leak then stops or oil is drawn in that seal is defe...

Page 262: ...both water intake screens GEARCASE REMOVAL AND INSTALLATION IMPORTANT Remove any paint from the upper shift rod before disassembling the shift rod con nectors Disengage the shift rods using two open e...

Page 263: ...mmet and see that the driveshaft engages the crank shaft Rotate the flywheel if necessary Make sure the upper shift rod enters the shift rod connector 262 Align the groove in the lower shift rod with...

Page 264: ...driveshaft in the crankshaft Coat upper shift rod with Triple Guard grease GEARCASE REMOVAL AND INSTALLATION Temporarily install the upper shift rod connector on the gearcase lower shift rod Install...

Page 265: ...1 Water intake holes Install the propeller Refer to PROPELLER on p 258 Confirm proper shift control operation 264 RAND TE MODELS Adjust the shift lever actuator cam and the neu tral start switch Refer...

Page 266: ...emove the impeller drive pin and impeller plate 1 2 1 Drive pin 16307 2 Impeller plate Remove and discard the water tube grommet D ring and seal in the impeller housing 25 30 MODELS Pull up on the dri...

Page 267: ...rommet with Tri ple Guard grease 1 housing 1 Grommet 16308 1 1 Seal 16312 Apply Adhesive M to the impeller housing O ring and install it on the housing 1 1 O ring Apply Adhesive M to outside surface o...

Page 268: ...nstall the shift rod bushing into the impel ler housing 1 Shift rod bushing 21223 Apply Triple Guard grease to the two impeller housing O rings Install the small thick shift rod 0 ring Position the la...

Page 269: ...e the impeller housing down the driveshaft Engage the impeller with the cam 1 EJ c _____ 2 1 Driveshaft rotation C02995 2 Drive cam IMPORTANT Confirm the impeller is oriented properly and engages the...

Page 270: ...ing Housing Puller 32534 2 Propeller nut Remove the propeller shaft with thrust washers and reverse gear components If forward thrust washer is not on propeller shaft check for it in the relieved area...

Page 271: ...NING m Wear safety glasses to avoid personal injury and set compressed air pressure to less than 25 psi 172 kPa IMPORTANT Clean and inspect all components during disassembly Replace all damaged compo...

Page 272: ...g is under extreme pressure during removal and installation After the retaining ring is removed far enough from the gearcase to clear the housing release the pli ers while retaining ring is still arou...

Page 273: ...72 Using a magnetic tool locate and remove the two shifter detent balls and one detent spring from the gearcase 1 Magnetic tool 21619 Use long nose pliers to remove the clutch dog and shifter lever as...

Page 274: ...it must be replaced Driveshaft Seals Use Puller Bridge PIN 432127 and Small Puller Jaws PIN 432131 to remove the two driveshaft seals Discard the seals 32545 GEARCASE BEARING AND SEAL REMOVAL Drivesha...

Page 275: ...326582 C03125 2 Pilot Plate PIN 326583 3 Remover and Installer PIN 326577 4 114 20 x 112 in hex head screw 5 114 20 x 1114 in hex head screw 6 1 in 0 0 flat washer Place the tool in gearcase using a...

Page 276: ...been removed from the gearcase examine the bushing for damage If damaged replace the bushing on reassembly Remove and discard the O ring s and washer from the bushing lIinr i _ 1 F 9I l IWI 3 2 1 Ada...

Page 277: ...bearing L _ 1 1 Bearing remover 32554 Using Puller Bridge PIN 432127 and Bearing Puller PIN 432130 remove the larger propeller shaft bearing located in the front of the bearing housing Discard the be...

Page 278: ...l threaded holes must be free of corrosion and sealer Gearcase anode if anode has been reduced to two thirds of its original size it must be replaced Refer to Anode Testing Procedure Continuity on p 6...

Page 279: ...ion installer against the lettered side of bearing Install new front bearing large from the forward end of bearing housing Use Bearing Installer PIN 339751 Position installer against the lettered side...

Page 280: ...rd grease to new bearing hous ing a ring Place a ring in groove GEARCASE SEAL AND BEARING INSTALLATION 25 30 MODELS Install new seals back to back in aft end of the propeller shaft bearing housing usi...

Page 281: ...5 30HP models only 9 9 15 Model 1 2 3 25130 Model COA3319 1 Bushing 2 Washer 3 a ring outer groove Use a mallet to drive the bushing into the gear case housing 280 Forward Bearing Remove the gearcase...

Page 282: ...ntil washer contacts spacer Install upper pinion bearing Assemble tool using long spacer PIN 339753 25 30 MODELS Install lower pinion bearing Assemble tool using short spacer PIN 330067 and removerlin...

Page 283: ...ips after installing 9 9 15 MODELS Use Seal Installer PIN 326554 Install the inner seal with lip of the seal facing into the gearcase then the outer seal with lip of the seal facing out of 21887 the g...

Page 284: ...ring and the shift lever should be located in the slot at the bottom of the gearcase 1 32557 Position one pinion thrust washer on the pinion Oil and install the thrust bearing Install the other thrust...

Page 285: ...se pliers place the clutch dog in the cradle Groove on the clutch dog must face the forward gear Hold propeller shaft in place and move shift rod to NEUTRAL position Apply Needle Bearing Assembly Grea...

Page 286: ...To complete gearcase servicing refer to LEAK TEST PROCEDURE on p 260 WATER PUMP on p 265 REMOVAL AND INSTALLATION on p 260 PROPELLER on p 258 GEARCASE ASSEMBLY 25 30 ASSEMBLY 25 30 IMPORTANT Make no d...

Page 287: ...eads of the pin Align hole of shifter lever with hole in gearcase Install and tighten pivot pin to a torque of 48 to 84 in Ibs 5 to 9 N m end of clutch dog must face forward gear end of 1 Pivot pin CO...

Page 288: ...whide mallet to seat detent assembly GEARCASE ASSEMBLY 25 30 Remove detent tool Slide the reverse gear down the propeller shaft and into the gearcase 1 2 1 Reverse gear COB3051 2 Bushing Coat the reve...

Page 289: ...ner plate down the propeller shaft and into the gearcase with tab facing down 1 1 Tab retainer plate COA3238 288 WARNING Wear safety glasses and proceed with care to avoid unsnapping the ring from the...

Page 290: ...sket Sealing Compound to the O rings and threads of the screws L 1 1 Screws COA3243 Install one screw in the bearing housing Remove the guide pin and install the second screw Tighten screws to 60 to 8...

Page 291: ...GEARCASE NOTES NOTES Technician s Notes 290 Related Documents Bulletins Instruction Sheets Other...

Page 292: ...STARTER TABLE OF CONTENTS SAFETY INFORMATION 293 GENERAL 294 STARTER ROPE LENGTH 294 TORQUE CHART 294 REMOVAL 294 ROPE REPLACEMENT 9 9 15 296 DISASSEMBLY 296 CLEANING AND INSPECTION 298 ASSEMBLY 299...

Page 293: ...292...

Page 294: ...ating parts During service the outboard may drop unexpectedly Avoid personal injury always support the outboard s weight with a suitable hoist or the tilt support bracket during service To prevent acc...

Page 295: ...nd Nut 144 REMOVAL 9 9 15 MODELS WARNING Avoid accidental starting of engine while servicing twist and remove all spark plug leads IMPORTANT Use of Starter Spring Installer Kit PIN 342682 is required...

Page 296: ...ntal starting of engine while servicing twist and remove all spark plug leads Remove the three starter housing retaining screws Lift starter housing from engine 22095 Using a screwdriver apply pressur...

Page 297: ...knot in rope end and install in pulley channel Insert rope into handle tie knot at end of rope install handle cap Hold rope taut and pull stop tool out Allow rope to slowly wind into starter DISASSEM...

Page 298: ...m uncoil ing spring Turn starter housing over and jar on bench to remove spring 25 30 MODELS MANUAL STARTER DISASSEMBLY WARNING Wear safety glasses while disassembling and assembling manual starters t...

Page 299: ...r the starter housing against a bench to dislodge the rewind spring and pulley 298 CLEANING AND INSPECTION Wash metal components in solvent and dry with compressed air Inspect the rewind spring for br...

Page 300: ...ousing with shield over mandrel and route hook end of spring through housing open ing MANUAL STARTER ASSEMBLY Place pulley over mandrel and secure with pulley retainer taper toward pulley and left han...

Page 301: ...eat knot in handle Install starter handle cap Route rope through housing into pulley Tie knot in rope end and install in pulley channel Insert rope into handle tie knot at end of rope install handle c...

Page 302: ...Insert the pin of the crank and pin assembly into the inner loop of the rewind spring Secure the crank and pin assembly to the starter winder base with the crank retainer screw 2 1 3 1 Inner loop of r...

Page 303: ...ith the inner loop of the rewind spring and install the pulley in the starter housing 2 1 1 Inside loop 2679 2 Pin Lightly apply Trip e Guard grease or Lubrip ate 777 to the spindle bushing and pawl p...

Page 304: ...rope Using Starter Rope Threading Tool PIN 378774 thread the starter rope through the handle Press the starter rope into the channel of the rope anchor with end of starter rope butting firmly against...

Page 305: ...ounts 12303 304 Insta the starter lockout cable into the starter housing Position the starter assembly onto the outboard Insta the three starter housing retaining screws The short screw is installed o...

Page 306: ...FUEL ELECTRICAL SYSTEM AND SAFETY S 8 OUTBOARD MOUNTING SYSTEM AND SAFETY S 11 OUTBOARD HYDRAULIC TILTITRIM SHOCK ABSORPTION SYSTEM AND SAFETy 8 13 OUTBOARD EMERGENCY STOP SYSTEM AND SAFETY S 14 SUMM...

Page 307: ...8 2...

Page 308: ...oal manu facturers are careful to make sure Product user is informed and Products are safe and reliable It is up to you the people who Rig boats Fix machinery and Maintain equipment to keep the produc...

Page 309: ...NEUTRAL or REVERSE shift linkage must match control lever position boat will move opposite to direction wanted by operator How can loss of shift control be minimized Read understand and follow manufac...

Page 310: ...o STOP propeller SAFETY If Operator cannot slow down the outboard or shift into NEUTRAL gear stop propeller Operator could panic and lose control of boat How can loss of speed control be minimized Rea...

Page 311: ...wheeL and ends here at the trim tab on the outboard If steering system comes apart boat might turn suddenly and circle Persons thrown into the water could be hit If steering jams operator may not be...

Page 312: ...ilt outboard into boat then turn it transom mounted steerer to Be aware that raising or lowering outboard on transom can change a set up which was OK earlier If moved up or down even one half inch run...

Page 313: ...Can Fire and Explosion Be Minimized Read understand and follow manufacturer s instructions Follow warnings marked closely Do not substitute fuel or electrical systems parts with other parts which may...

Page 314: ...in manual Screws Nuts Washers Tighten firmly these keep clamps in position and ends of wires from sparking Where lock washers are called for use them Spark Plug Boots Not torn or cracked Fully pushed...

Page 315: ...unning I_U Squeeze until bulb feels hard Check for leaks under engine cover I Whenever possible remove hose from outboard and from tank Store hose around ears of tank This way gasoline is trapped in t...

Page 316: ...ng solid and does not stay on the transom boat occupants may be injured from the outboard or its parts entering the boat How Can Loss of Mounting Be Minimized Read understand and follow manufacturer s...

Page 317: ...ied with outboard They are usually special and will not rust or weaken s If owner tells you I hit something really hard Check for a high speed blow to the lower unit 8 12 Use only or smaller Mount on...

Page 318: ...n too far may dive boat under water or spin it around How can possible conditions be minimized Read understand and follow manufacturer s instructions Follow warnings marked closely Test your work when...

Page 319: ...and ends here in the ignition system on the powerhead The emergency stop system must STOP the engine when the clip is removed or the lanyard pulled from the emergency stop key switch What could happen...

Page 320: ...w can failure of the emergency stop system be minimized Read understand and follow manufacturer s instructions Follow warnings marked closely When Assemble parts carefully SAFETY rigging Inspect lanya...

Page 321: ...erstanding instructions Re reading warnings marked A Putting parts together correctly Making correct adjustments Testing your work And making sure Worn or damaged parts are replaced Replaced parts are...

Page 322: ...xed lift bracket bolted to the powerhead Because outboard will want to hang like this when off the floor Center of gravity ____ If engine does not have fixed lifting bracket and you use Universal Pull...

Page 323: ...handling a hot electrical part or near the propeller Outboard starting at the wrong time When you do things that turn the flywheel like Off season storage fogging oiling of outboard Removing propeller...

Page 324: ...rious brain damage or death Whenever running the engine assure there is proper ventilation to avoid the accumulation of carbon monoxide CO which is odorless colorless and tasteless and can lead to unc...

Page 325: ...near a propeller even when the engine is off Blades can be sharp and the propeller can continue to turn even after the engine is off Always shut off the engine when near people in the water Eye prote...

Page 326: ...l ventilated area Charging causes acid solution to give off hydrogen gas through the vents in the caps Make sure vents are open If clogged pressure inside may build Battery may EXPLODE Battery gas is...

Page 327: ...ressure relief valve in pour spout Fill portable tanks outside of boat Spillage will collect in bottom of boat Use fuel as fuel ONLY not for a cleaner or degreaser If fumes are smelled in shop basemen...

Page 328: ...use How to give First Aid Have recommended First Aid materials on hand should an emergency arise How to dispose of can It s all on the back of the can or bottle label And remember Little children are...

Page 329: ...ety section in par ticular contain essential information to help prevent personal injury to yourself and your customers as well as prevent damage to equipment 6 Have you received training related to c...

Page 330: ...r Shaft Bearing Housing 276 Blocking Diode Test 127 Break In Fuel Oil Ratio 52 Procedure 52 INDEX c _________________________ Cable Hose and Wire Routing 45 Cables Battery Cables 45 Cam Follower Picku...

Page 331: ...281 Removal 273 Driveshaft Seals 2 Installation 282 Removal 273 E _ ____________ Electric Starter Adjustment 178 Assembly 103 Cleaning and Inspection 102 Disassembly 100 Installation 106 Lubrication...

Page 332: ...260 Lubricant 67 Lubricant Replacement 259 Removal 260 Seal Installation 278 Removal 273 INDEX H _________________________ Hoses Fuel System 49 50 Grommet 45 Maintenance 69 Idle Speed Adjustment 25 30...

Page 333: ...298 Disassembly 9 9 15 296 Installation 25 30304 Installation 9 9 15303 Removal 25 30 295 297 Removal 9 9 15 294 Rope Length 294 Rope Replacement 296 Torque Chart 294 Model Designation 7 Models Cover...

Page 334: ...earing Installation 278 Bearing Removal 276 Removal 269 Seal Installation 279 Seal Removal 275 INDEX R _________________________ Rectifier 84 Description 84 Resistance Tests 87 Remote Control Installa...

Page 335: ...n 76 Control Rod Adjustment 25 30 74 Friction Adjustment 252 Wide Open Throttle Adjustment 9 9 15 72 Tilt Friction Adjustment 252 Timing Pointer 119 Tools 19 Ball Hex Screwdriver PIN 32762271 Bearing...

Page 336: ...PIN 322700 183 Starter Rope Threading Tool PIN 378774 303 Starter Spring Installer Kit PIN 342682 294 296 299 INDEX Starter Spring Winder and Installer PIN 392093301 Syringe PIN 346936 143 144 Taper P...

Page 337: ...Water Flow Diagram 9 9 15HP t I I I 1 1 1 1 DR4698...

Page 338: ...Water Flow Diagram 25 30HP DRlt81...

Page 339: ...MWS Instrument Wiring Harness A _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ I l DRC6 165 R...

Page 340: ...Lanyard Switch Emergency Stop Circuits Single Outboard Dual Outboards 000705...

Page 341: ...MWS Key Switch and Neutral Safety Switch B I il r 1 M C OFF 14 5 6 3 2 1 M B I ON B M A f i START M B J M CHOKE PRIMER 000954...

Page 342: ...MWS DASHBOARD TM SYSTEM CHECK TACHOMETER SPEEDOMETER VOLTMETER WATER PRES FUEL FUEL TANK SENDER LIGHT SWITCH TO OUTBOARD DRC6278R...

Page 343: ...N to t a o...

Page 344: ...N N lO o o l Cl c o o M Ln N...

Page 345: ...o II W l ll N...

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Johnson 15 2004, Service Manual

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Summary of Contents for 15 2004

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