Service Manual Johnson Evinrude 48 – 235 HP 1973 – 1989 (includes Sea Drives)

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Service Manual Johnson Evinrude 48 – 235 HP 1973 – 1989 (includes Sea Drives)

Contents – Quick Reference Data ………… IX – Chapter One – General Information ………… 1 – Manual Organization ………… 1 – Notes, Cautions and Warnings ………… 1 – Torque Specifications ………… 2 – Engine Operation ………… 2 – Fasteners ………… 2 – Lubricants ………… 8 – Gasket Sealant ………… 10 …

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Service Manual Johnson Evinrude 48 – 235 HP 1973 – 1989 (includes Sea Drives)

Contents

Quick Reference Data ………… IX

Chapter One

  • General Information ………… 1
  • Manual Organization ………… 1
  • Notes, Cautions and Warnings ………… 1
  • Torque Specifications ………… 2
  • Engine Operation ………… 2
  • Fasteners ………… 2
  • Lubricants ………… 8
  • Gasket Sealant ………… 10
  • Galvanic Corrosion ………… 11
  • Protection From Galvanic Corrosion ………… 12
  • Propellers ………… 14

Chapter Two

  • Tools and techniques ………… 21
  • Safety first ………… 21
  • Basic hand tools ………… 21
  • Test equipment ………… 26
  • Service hints ………… 28
  • Special tops ………… 30
  • Mechanic’s techniques ………… 31

Chapter Three

  • Troubleshooting ………… 33
  • Operating requirements ………… 34
  • Starting System ………… 34
  • Charging System ………… 39
  • Ignition System ………… 45
  • 1973-1977 CD 2 Ignition Troubleshooting ………… 46
  • 1978-1984 CD 2 Ignition Troubleshooting ………… 55
  • 1985-1988 CD 2 Ignition Troubleshooting ………… 60
  • 1989 CD2USL Ignition Troubleshooting ………… 65
  • 1973-1978 CD 3 Ignition Troubleshooting ………… 69
  • 1976-1978 CD 6 Ignition Troubleshooting ………… 75
  • 1979-1984 CD 3 and 1979-1984 CD 6 Ignition Troubleshooting ………… 82
  • 1985-1988 CD 3 Ignition Troubleshooting ………… 87
  • 1989 CD 3 Ignition Troubleshooting ………… 94
  • 1973-1977 CD 4 Ignition Troubleshooting ………… 100
  • 1978-1984 CD 4 Ignition Troubleshooting ………… 109
  • 1985-1987 90 HP, 1985 115 HP AND 1986-1987 110 HP CD 4 Ignition Troubleshooting ………… 115
  • 1988 90 HP AND 110 HP CD 4 Ignition Troubleshooting ………… 121
  • 1989 90 HP AND 110 HP CD 4 Ignition Troubleshooting ………… 126
  • 1985-1987 120 AND 140 HP CD 4 Ignition Troubleshooting ………… 130
  • 1988-1989 120 AND 140 HP CD 4 Ignition Troubleshooting ………… 135
  • 1985 V6 AND 1986-1988 150-175 HP CD 6 Ignition Troubleshooting ………… 143
  • 1989 150 AND 175 HP CD 6 Ignition Troubleshooting ………… 148
  • 1986-1987 200-225 HP Cd Ignition Troubleshooting ………… 161
  • 1988-1989 200-225 CD Ignition Troubleshooting ………… 167
  • Ignition AND Neutral Start Switch ………… 176
  • Neutral Start Switch ………… 177
  • Fuel System ………… 177
  • Engine Temperature And Overheating ………… 180
  • Engine ………… 182

Chapter Four

  • Lubrification, Maintenance And Tune-UP ………… 193
  • Lubrication ………… 193
  • Storage ………… 200
  • Complete Submersion ………… 202
  • Anti-Corrosion maintenance ………… 203
  • Engine Flushing ………… 203
  • Tune-Up ………… 204

Chapter Five

  • Engine Synchronization And Linkage Adjustments ………… 217
  • Engine timing ………… 217
  • Synchronizing ………… 217
  • Required Equipment ………… 217
  • 1973-1988 50 HP (tiller models) ………… 219
  • 1973-1988 48, 50, 55 AND 60 HP (2-cylinder remote control models) ………… 223
  • 1989 48 And 50 HP models ………… 227
  • 60, 65, 70 AND 75 HP (3-cylinder models) ………… 230
  • 65 HP (3-cylinder tiller models) ………… 234
  • V4 Engines (Except 1985-on 120-140 HP And 1986-on 88-110 HP) ………… 238
  • V4 Engines (1986-on 90-110 HP) ………… 243
  • V4 Engines (1985-on 120-140 HP) ………… 246
  • V6 Engines (1975-1985) ………… 252
  • V6 Engines (1986-on 150-175 HP) ………… 257
  • V6 Engines (1986-on 200-225 HP) ………… 259

Chapter Six

  • Fuel System ………… 265
  • Fuel pump ………… 265
  • Carburetors ………… 268
  • Carburetor (48-75 HP) ………… 271
  • V4 And V6 Carburetor (except 1985-on 120-140 Hp And 1986 200-225 HP) ………… 275
  • V4 And V6 Carburetor (1985-on 120-140 HP And 1986-on 200-225 HP) ………… 281
  • Choke And Primer Solenoid Service ………… 284
  • Anti-Siphon devices ………… 286
  • Fuel tank ………… 286
  • Fuel line and primer bulb ………… 286

Chapter Seven

  • Ignition And Electrical Systems ………… 292
  • Battery ………… 292
  • Battery Charging System ………… 299
  • Electric Starting System ………… 302
  • Start Motor ………… 302
  • Ignition System ………… 306

Chapter Eight

  • Power Head ………… 317
  • Engine serial number ………… 318
  • Fasteners And Torque ………… 319
  • Gaskets And Sealants ………… 319
  • Flywheel ………… 319
  • Power Head ………… 320
  • Reed Block Service ………… 364
  • Thermostat Service ………… 365

Chapter Nine

  • Gearcase ………… 375
  • Propeller ………… 375
  • Water pump ………… 376
  • Gearcase removal/installation (all models) ………… 379
  • Hydro-mechanical gearcase ………… 381
  • Mechanical gearcase (except 1989 48 And 50 HP) ………… 397
  • Pressure And Vacuum test ………… 409

Chapter Ten

  • Power Trim And Tilt Systems ………… 412
  • External Power trim and tilt system ………… 413
  • Internal power trim and tilt system ………… 419
  • Trim and tilt motor testing ………… 437
  • System removal/installation ………… 437

Chapter Eleven

  • Oil Injection Systems ………… 440
  • OMC Economixer ………… 440
  • OMC VRO System ………… 447

Chapter Twelve

  • Sea Drives ………… 453
  • SelectTrim/Tilt (1983-1989 1.6L) ………… 453
  • SelectTrim/Tilt (1987-1988 1.8L, 1989 2.0L, 1984-1985 2.5L [S-type], 1984-1985 2.6L [S-type], 1986-1988 2.6L, 1987-1988 2.7L And 1988 3.0L) ………… 461

Index ………… 467

Wiring Diagrams ………… end of book

Service Manual Johnson Evinrude 48 - 235 HP 1973 - 1989 (includes Sea Drives)

 

 

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