Johnson Evinrude 1.25 HP–60 HP Outboard Motor Manual 1971–1990 (P/N 1302)

• 631-page PDF covering Johnson and Evinrude one- and two-cylinder two-stroke outboards from 1.25 through 60 hp, with model and tune-up tables spanning 1971-1990 and engine-family-specific service year ranges.
• Takes powerhead repair through disassembly, cleaning, inspection, cylinder honing, and reassembly, including reeds, bypass and exhaust covers, crankshaft seals, pistons, connecting rods, main bearings, and crankcase installation.
• Covers Type I-IV carburetor service, fuel-pump and fuel-line testing, manual and electric primer systems, rough-idle and engine-surge diagnosis, plus VRO and AccuMix/AutoBlend oil-injection systems.
• Separates flywheel magneto, low-tension magneto, Type I timer-base CD, and Type II sensor-coil CD ignition systems, with component testing, timing checks, and fuel/ignition synchronization procedures.
• Details Johnson and Evinrude remote controls, Bosch and Prestolite electric starters, charging systems, and no-shift, manual-shift, electric-shift, and hydraulic-assist lower-unit configurations.
• Supplies model-specific exploded drawings and wiring schematics, along with torque tables, tune-up and powerhead specifications, gear-oil capacities, electrical test data, and identified OMC service tools.

This is a Seloc cross-model repair guide, not a single-model OMC factory service manual. It is suited to experienced DIY owners and working mechanics who can identify the exact engine configuration, interpret electrical tests, and use pullers, meters, torque tools, and press equipment where the repair calls for them.

Coverage is not identical across every horsepower and model year. The tables include Colt, Junior, Ultra, Excel, Deluxe, Commercial, tiller-control, remote-control, manual-start, and electric-start configurations. The 55 hp service listings extend through 1983 and the 60 hp listings through 1985, while the combined 1989-1990 tune-up table covers engines through 50 hp. Model-number and serial-tag identification information helps place an engine in the correct year and service section before parts or procedures are selected.

Powerhead, Fuel, and Ignition Systems

The powerhead chapter distinguishes the earlier cross-flow designs from the loop-scavenged 40 hp engines used from 1983 onward and the related 50, 55, and 60 hp families. Separate assembly coverage addresses needle-bearing and Babbitt-bearing crankshaft arrangements, different lower-seal designs, reed adjustment, piston and rod inspection, cylinder-block service, and final powerhead installation.

Carburetor coverage is divided by actual design rather than treated as one generic procedure: Type I units for the smaller engines, Type II for many 18-40 hp applications, the Type III used on 9.5 hp models, and Type IV assemblies fitted to 50-60 hp engines. Fuel diagnosis covers pump output, line leakage, restricted flow, excessive consumption, rough idle, and surge. The oil-injection section explains VRO testing and repair as well as the separate AccuMix/AutoBlend tank and warning system.

Ignition work ranges from breaker-point magnetos to timer-base and sensor-coil capacitor-discharge systems. Test sequences cover wiring harnesses, key and cutout switches, condensers, coils, charge and sensor coils, stators, power packs, and ignition timing. The electrical chapters add generator and alternator troubleshooting, starter-solenoid circuits, armature testing, starter-drive repair, battery arrangements, temperature warning equipment, fuel gauges, tachometers, and horns.

Controls, Lower Units, and Trim/Tilt

Remote-control sections cover double-lever boxes, Johnson single-lever controls, Evinrude pushbutton shift boxes, cable-end installation, neutral-start functions, and control adjustment. Lower-unit repair is organized by gearcase design, including non-shifting units, shift-with-no-disconnect models, conventional mechanical shift, the two-solenoid electric-shift 50 hp unit, the 50 hp hydraulic-assist system, and later shift-disconnect arrangements located below the lower carburetor. Procedures address gearcase removal, water-pump service, internal disassembly, bearing and seal work, reassembly, frozen propeller shafts, installation, and functional checks.

The trim/tilt chapter covers both Prestolite and Calco systems, fluid filling and air purging, mechanical and electrical troubleshooting, unit removal, and electric-motor repair. The hydraulic pump itself is non-serviceable, and deeper high-pressure hydraulic work is outside the manual’s repair scope.

Diagrams, Specifications, and Service Cautions

Representative illustrations include the 40/50/55/60 hp powerhead assembly, Type IV carburetor variants, the 1971-1972 electric-shift 50 hp lower unit, 1982-1985 remote-electric-start wiring for 20-60 hp engines, 1986-and-later 40/50 hp tiller and remote-start circuits, and the 1989 20-30 hp tiller and remote-start schematics. The wiring appendix runs from A-22 through A-46.

Referenced tools include OMC P/N 387780 for crankshaft-seal removal, OMC 317001 for ignition-coil alignment, OMC 378103 for flywheel and bearing-carrier pulling, and design-specific gearcase bearing installers and removers. The ignition section warns that an outside-edge flywheel puller can damage the flywheel, while hammering the puller bolt can damage the lower seal or bearing. The Type VI hand-starter section also explains how uncontrolled rope return can overtravel the recoil spring and bend its end.

Because the repair work involves fuel, high-voltage ignition, rotating flywheels, press operations, hydraulic components, and heavily loaded recoil springs, the manual’s safety precautions and specified service equipment should be followed throughout.