Evinrude Johnson 1.5–40 hp Outboard Workshop Manual (1956–1972)

This workshop manual covers service and repair of the Evinrude and Johnson 1.5–40 hp outboards listed above, with coverage organized by horsepower, model and equipment configuration across 1956–1972.

PDF Search, Bookmarks and Diagram Detail

Text access and readability: The main chapters have searchable text, with embedded bookmarks for the contents, chapters and appendix. Many wiring-diagram labels are not searchable. Small wiring labels require zooming, and some diagrams benefit from rotation. Some appendix tables contain distorted characters or overlapping entries.

One printable, English-language 422-page PDF, including four contents pages, one blank page and one Notes & Numbers page.

Powerhead, Fuel, Ignition and Gearcase Service

These selected coverage highlights outline the principal workshop sections. Additional topics include propeller selection and fiberglass and aluminum hull care.

• Powerhead repair: Step-by-step disassembly and assembly procedures, cylinder-head and reed service, piston and connecting-rod inspection, cylinder honing and crankshaft installation.

• Fuel systems: Type I, II and III carburetor rebuilding, choke service, fuel-delivery diagnosis, pressure-tank repairs and overhaul of the serviceable fuel-pump design.

• Ignition and tune-up: Compression checks, spark-plug evaluation, flywheel-magneto troubleshooting, breaker-point service and fuel-to-ignition synchronization.

• Electrical systems: Charging-circuit diagnosis, generator service, starter-solenoid testing and separate Delco-Remy, Autolite and Prestolite starter-motor repair procedures.

• Lower units and cooling: Non-shifting, mechanical-shift and Electromatic gearcase service, water-pump rebuilding, seal and bearing inspection, and shift-system troubleshooting.

• Controls and hand starters: Double-lever and single-lever controls, Evinrude pushbutton shift boxes, cable adjustments and Type I, II and III recoil-starter service.

• Seasonal maintenance: Winter storage, preseason preparation, battery care and distinct service considerations for engines recovered from fresh or salt water.

The manual is suited to experienced owners and mechanics who understand two-cycle operation and can carry out the mechanical measurements and electrical tests described.

Powerhead Inspection and Assembly References

The powerhead chapter explains two-cycle operating principles before addressing internal repairs. Crankshaft installation is separated by bearing arrangement, including babbitt-bearing and needle-bearing configurations. Inspection material addresses rod alignment, bearing-surface damage, piston-ring locating pins and cylinder wear.

Model-specific illustrations and exploded powerhead drawings support component identification during teardown. The appendix adds bore and piston-clearance data, ring-end-gap specifications, tune-up tables, gear-oil capacities and metric and drill-size conversion charts.

Torque-table limitation: Appendix page A-3, “Torque Specifications,” is missing from the PDF. Several connecting-rod, main-bearing and cylinder-head assembly procedures refer to that table; individual torque values elsewhere in the service chapters do not replace it.

Carburetor Types, Chokes and Fuel-Pump Limits

Carburetor sections distinguish adjustable-needle and fixed-orifice arrangements, with needle-and-seat inspection and float-setting information. Choke coverage separates heat/electric, all-electric and water-operated systems.

The fuel-pump overhaul procedure applies to the illustrated three-connection pump. Other pump designs are treated as replacement units, apart from permitted filter-screen and cover-gasket service. Pressure-tank troubleshooting and the functional pressure-tank system diagram explain the separate air and fuel circuits.

A Type I carburetor exploded view distinguishes the pressure-tank arrangement from the version with an engine-mounted fuel tank.

Magneto Diagnosis and Starting Circuits

The troubleshooting sections distinguish faults in the wiring harness, key switch and vacuum cutout from problems within the magneto. This provides a practical way to identify which part of the ignition system needs attention before disassembly.

The ignition section warns that an automotive-type key switch can expose the magneto circuit to battery voltage and destroy the coil.

A typical magneto exploded drawing, numbered starter-circuit test diagram and generator-equipped wiring drawings support electrical diagnosis. Starter repair extends to armature, commutator, field-coil and brush checks, with separate procedures for the three starter manufacturers.

Gearcase Differences and Remote Controls

Separate lower-unit sections account for different shift-disconnect arrangements, bearing layouts and water-pump installations. The Electromatic section adds shift-coil and current-draw checks, clutch-spring and hub inspection, and installation references for bearing tool 308104 and forward-coil tool 379230.

Manual-shift and electric-shift exploded drawings show the different internal assemblies. The instructions also flag shift-rod coupler misalignment, which can strip the retaining-bolt threads and allow the rod to pull free.

Control-box sections distinguish mechanical linkage problems from electrical shift faults. Hand-starter coverage separates pinion-gear, swing-arm and flywheel-mounted designs, including return-spring and nylon-pawl versions.

Selected Reed and Ignition Settings

The reed inspection section specifies a maximum resting clearance of 0.010 inch between the reed tip and its base plate. This is a reed inspection limit, not a four-cycle intake-valve setting.

The tune-up appendix lists a breaker-point gap of 0.020 inch and a spark-plug gap of 0.030 inch for the engines covered. These accompany the point-service and spark-plug inspection material.

Working on marine engines involves pressurized fuel lines and high-voltage ignition systems. Follow the manual’s precautions and consult a qualified marine technician if the work exceeds your experience.