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

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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