Evinrude/Johnson 1.25–60 HP Outboard Repair Manual, 1971–1989 (P/N 1302)
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Johnson Models Covered & Key Technical Specifications
Models: 1.25 hp, 2 hp, 2.5 hp, 4 hp, 4.5 hp, 5 hp, 6 hp, 7.5 hp, 8 hp, 9.5 hp, 9.9 hp, 15 hp, 18 hp, 20 hp, 25 hp, 30 hp, 35 hp, 40 hp, 50 hp, 55 hp, 60 hp
Models & Model Codes:
1.25 hp — Johnson: JCO-CU, JCOCC
Evinrude: EJRCU, EJRCC
2 hp — Johnson: 2R-71, 2R-72, 2R-73, 2R-74, 2R-75, 2R-76, 2R-77, 2R-78, 2R-79, 2RCS, J2RCIB, J2RSV, J2RCN, J2RCT, J2RCR, J2RCO, J2RCD
Evinrude: 2102, 2202, 2302, 2402, 2502, 2602, 2702, 2802, 2902, E2RCS, E2RCIB, E2RSV, E2RCN, E2RCT, E2RCR, E2RCO, E2RCD
2.5 hp — Johnson: J3RCU, J3RCC
Evinrude: E3RCU, E3RCC
4 hp — Johnson: 4R-71, 4W-71, 4R-72, 4W-72, 4R-73, 4W-73, 4W-74, 4R-74, 4W-75, 4R-75, 4W-76, 4R-76, 4W-77, 4R-77, 4W-78, 4R-78, 4RL-78, 4W-79, 4R-79, 4RL-79, 4WCS, 4RLCS, J4BRCIC, J4BRLCIC, J4WCIC, J4WCN, J4BRCN, J4RLCN, J4RHCN, J4RHLCN, J4RSY, J4RSLY, J4BRCT, J4RLCT, J4RHCT, J4RHLCT, J4BRCO, J4BRLCO, J4BRHCO, J4BRHLCO, J4BRHCD, J4BRHLCD, J4RDHCD, J4RDHLCD, J4BRCR, J4RLCR, J4RHCR, J4RHLCR, J4RCU, J4RLCU, J4RDHCU, J4RDHLCU, J4RCC, J4RLCC, J4RDHCC, J4RDHLCC
Evinrude: 4106, 4136, 4206, 4236, 4306, 4336, 4406, 4436, 4506, 4536, 4606, 4636, 4706, 4736, 4806, 4836, 4837, 4904, 4932, 4933, E4WCS, E4RLCS, E4BRCIC, E4BRLCIC, E4WCIC, E4WCN, E4BRCN, E4RLCN, E4RHCN, E4RHLCN, E4RSY, E4RSLY, E4BRCT, E4RLCT, E4RHCT, E4RHLCT, E4BRCO, E4BRLCO, E4BRHCO, E4BRHLCO, E4BRHCD, E4BRHLCD, E4RDHCD, E4RDHLCD, E4BRCR, E4RLCR, E4RFHCR, E4RHLCR, E4BRHCU, E4RLCU, E4RDHCU, E4RDHLCU, E4BRHCC, E4RCC, E4RDHCC, E4RDHLCC
4.5 hp — Johnson: 5RCS, 5RLCS, 5RHCS, 5RHLCS, J5RCIC, J5RLCIC, J5RHCIC, J5RHLCIC, J5RCN, J5RLCN, J5RHCN, J5RHLCN, J5RCT, J5RHCT, J5RLCT, J5RHLCT, J4RDCO, J4RDLCO, J4RDHCO, J4RDHLCO, J4RDCR, J4RDLCR, J4RDHCR, J4RDHLCR
Evinrude: E5RCS, E5RLCS, E5RCIC, E5RLCIC, E5RHCIC, E5RHLCIC, E5RCN, E5RLCN, E5RHCN, E5RHLCN, E5RCT, E5RHCT, E5RLCT, E5RHLCT, E4RDCO, E4RDLCO, E4RDHCO, E4RDHLCO, E4RDCR, E4RDLSR, E4RDHCR, E4RDHLCR
5 hp — Johnson: J5RHCR, J5BFCR, J5BFLCR, J5RHCO, J5BFCO, J5BFLCO
Evinrude: E5RHCR, E5BFCR, E5BFLCR, E5RHCO, E5BFCO, E5BFLCO
6 hp — Johnson: 6R-71, 6RL-71, 6R-72, 6RL-72, 6R-73, 6RL-73, 6R-74, 6RL-74, 6R-75, 6RL-75, 6R-76, 6RL-76, 6R-77, 6RL-77, 6R-78, 6RL-78, 6R-79, 6RL-79, J6BFCN, J6BFLCN, J6RCN, J6RLCN, J6RSM, J6RSLM, J6BFCT, J6BACT, J6BFLCT, J6BALCT, J6RCT, J6RLCT, J6BACR, J6BALCR, J6BFCR, J6FLCR, J6RCR, J6RLCR, J6SLCR, J6BACO, J6BALCO, J6BFCO, J6RCO, J6BFLCO, J6RLCO, J6SLCO, J6RCD, J6RLCD, J6SLCD, J6RCU, J6RLCU, J6SLCU, J6RCC, J6RLCC, J6SLCC
Evinrude: 6102, 6103, 6202, 6203, 6302, 6303, 6402, 6403, 6504, 6505, 6604, 6605, 6704, 6705, 6804, 6805, 6904, 6905, E6BFCN, E6BFLCN, E6RCN, E6RLCN, E6RSM, E6RSLM, E6BFCT, E6BACT, E6BFLCT, E6BALCT, E6RCT, E6RLCT, E6BACR, E6BALCR, E6BFCR, E6FLCR, E6RCR, E6RLCR, E6SLCR, E6BACO, E6BALCO, E6BFCO, E6RCO, E6BFLCO, E6RLCO, E6SLCO, E6RCD, E6RLCD, E6SLCD, E6RCU, E6RLCU, E6SLCU, E6RCC, E6RLCC, E6SLCC
7.5 hp — Johnson: 8RCS, 8RLCS, J8RCIC, J8RLCIC, J8BACIC, J8BALCIC, J8RCN, J8RLCN, J8BACN, J8BALCN, J8SRLCN, J8BACT, J8RCT, J8BALCT, J8RLCT, J8SRLCT
Evinrude: E8RCS, E8RLCS, E8RCIC, E8RLCIC, E8BACIC, E8BALCIC, E8RCN, E8RLCN, E8BACN, E8BALCN, E8SRLCN, E8BACT, E8RCT, E8BALCT, E8RLCT, E8SRLCT
8 hp — Johnson: J8RCR, J8RLCR, J8BACR, J8BALCR, J8SRLCR, J8RCO, J8RLCO, J8BACO, J8BALCO, J8SRLCO, J8RCD, J8RLCD, J8SRLCD, J8RCU, J8RLCU, J8SRLCU, J8RCC, J8RLCC, J8SRLCC
Evinrude: E8RCR, E8RLCR, E8BACR, E8BALCR, E8SRLCR, E8RCO, E8RLCO, E8BACO, E8BALCO, E8SRLCO, E8RCD, E8RLCD, E8SRLCD, E8RCU, E8RLCU, E8SRLCU, E8RCC, E8RLCC, E8SRLCC
9.5 hp — Johnson: 9R-71, 9RL-71, 9R-72, 9RL-72, 9R-73, 9RL-73
Evinrude: 9122, 9123, 9222, 9223, 9322, 9323
9.9 hp — Johnson: 10R-74, 10RL-74, 10E-74, 10EL-74, 10R-75, 10RL-75, 10E-75, 10EL-75, 10R-76, 10RL-76, 10E-76, 10EL-76, 10R-77, 10RL-77, 10E-77, 10EL-77, 10R-78, 10RL-78, 10EL-78, 10SL-78, 10R-79, 10RL-79, 10EL-79, 10SEL-79, 10RCS, 10RLCS, 10ELCS, 10SELCS, J10RCID, J10RLCID, J10ELCID, J10BACID, J10BALCID, J10SELCID, J10RCN, J10RLCN, J10BACN, J10BALCN, J10ELCN, J10RSW, J10RSLW, J10RCT, J10RLCT, J10BACT, J10BALCT, J10SELCT, J10RCR, J10RLCR, J10BACR, J10BALCR, J10SELCR, J10ELCR, J10RCO, J10RLCO, J10BACO, J10ECO, J10BALCO, J10SELCO, J10ELCO, J10RCD, J10RLCD, J10ECD, J10SELCD, J10ELCD, J10RCU, J10RLCU, J10ECU, J10SELCU, J10ELCU
Evinrude: 10424, 10425, 10454, 10455, 10524, 10525, 10554, 10555, 10624, 10625, 10654, 10655, 10724, 10725, 10754, 10755, 10824, 10825, 10835, 10855, 10924, 10925, 10935, 10955, E10RCS, E10RLCS, E10SELCS, E10ELCS, E10RCID, E10RLCID, E10ELCID, E10BACID, E10BALCID, E10SELCID, E10RCN, E10RLCN, E10BACN, E10BALCN, E10ELCN, E10RSW, E10RSLW, E10RCT, E10RLCT, E10BACT, E10BALCT, E10SELCT, E10RCR, E10RLCR, E10BACR, E10BALCR, E10SELCR, E10ELCR, E10RCO, E10RLCO, E10BACO, E10ECO, E10BALCO, E10SELCO, E10ELCO, E10RCD, E10RLCD, E10ECD, E10SELCD, E10ELCD, E10RCU, E10RLCU, E10ECU, E10SELCU, E10ELCU
15 hp — Johnson: 15R-74, 15RL-74, 15E-74, 15EL-74, 15R-75, 15RL-75, 15E-75, 15EL-75, 15R-76, 15RL-76, 15E-76, 15EL-76, 15R-77, 15RL-77, 15E-77, 15EL-77, 15R-78, 15RL-78, 15E-78, 15EL-78, 15R-79, 15RL-79, 15E-79, 15EL-79, 15RCS, 15RLCS, 15ECS, 15ELCS, J15RCIS, J15RLCIS, J15ECIS, J15BACIS, J15BALCIS, J15RCN, J15RLCN, J15ECN, J15BACN, J15ALCN, J15RSP, J15RSLP, J15RCT, J15RLCT, J15ECT, J15ELCT, J15BACT, J15BALCT, J15RCR, J15RLCR, J15ECR, J15ELCR, J15BACR, J15BALCR, J15RCO, J15RLCO, J15ECO, J15ELCO, J15BACO, J15BALCO, J15RCD, J15RLCD, J15ECD, J15ELCD, J15RCU, J15RLCU, J15ECU, J15ELCU, J15RCC, J15RLCC, J15ECC, J15ELCC
Evinrude: 15404, 15405, 15454, 15455, 15504, 15505, 15554, 15555, 15604, 15605, 15654, 15655, 15704, 15705, 15754, 15755, 15804, 15805, 15854, 15855, 15904, 15905, 15954, 15955, E15RCS, E15RLCS, E15ECS, E15ELCS, E15RCIS, E15RLCIS, E15ECIS, E15BACIS, E15BALCIS, E15RCN, E15RLCN, E15ECN, E15BACN, E15ALCN, E15RSP, E15RSLP, E15RCT, E15RLCT, E15ECT, E15ELCT, E15BACT, E15BALCT, E15RCR, E15RLCR, E15ECR, E15ELCR, E15BACR, E15BALCR, E15RCO, E15RLCO, E15ECO, E15ELCO, E15BACO, E15BALCO, E15RCD, E15RLCD, E15ECD, E15ELCD, E15RCU, E15RLCU, E15ECU, E15ELCU, E15RCC, E15RLCC, E15ECC, E15ELCC
18 hp — Evinrude: 18102, 18103, 18202, 18203, 18304, 18305
20 hp — Johnson: 22R-71, 22RL-71, 20R-72, 20RL-72, 20R-73, 20RL-73, J20CRCIM, J20CRLCIM, J20BFCIM, J20BFLCIM, J20CRCN, J20CRLCN, J20BFCN, J20BFLCN, J20CRCT, J20CRLCT, J20BECT, J20BELCT, J20BTCT, J20BFCT, J20BFLCT, J20BICT, J20BILCT, J20CRCR, J20CRLCR, J20BFCR, J20BFLCR, J20BICR, J20BILCR, J20CRCO, J20CRLCO, J20ELCO, J20ECO, J20BECO, J20BELCO, J20BFCO, J20BFLCO, J20BICO, J20BILCO, J20CRCD, J20CRLCD, J20ELCD, J20ECD, J20CRCU, J20CRLCU, J20ELCU, J20ECU, J20CRCC, J20CRLCC, J20ECC, J20ELCC, J25BECR, J25BELCR, J25BFCR, J25BFLCR, J25BFCO, J25BFLCO
Evinrude: E20CRCIM, E20CRLCIM, E20BFCIM, E20BFLCIM, E20CRCN, E20CRLCN, E20BFCN, E20BFLCN, E20CRCT, E20CRLCT, E20BECT, E20BELCT, E20BTCT, E20BFCT, E20BFLCT, E20BICT, E20BILCT, E20CRCR, E20CRLCR, E20BFCR, E20BFLCR, E20BICR, E20BILCR, E20CRCO, E20CRLCO, E20ELCO, E20ECO, E20BECO, E20BELCO, E20BFCO, E20BFLCO, E20BICO, E20BILCO, E20CRCD, E20CRLCD, E20ELCD, E20ECD, E20CRCU, E20CRLCU, E20ELCU, E20ECU, E20CRCC, E20CRLCC, E20ECC, E20ELCC, E25BECR, E25BELCR, E25BFCR, E25BFLCR, E25BFCO, E25BFLCO
25 hp — Johnson: 25R-71, 25RL-71, 25R-72, 25RL-72, 25E-72, 25EL-72, 25R-73, 25RL-73, 25E-73, 25EL-73, 25R-74, 25RL-74, 25E-74, 25EL-74, 25R-75, 25RL-75, 25E-75, 25EL-75, 25R-76, 25RL-76, 25E-76, 25EL-76, 25R-77, 25RL-77, 25E-77, 25EL-77, 25R-78, 25RL-78, 25E-78, 25EL-78, 25R-79, 25RL-79, 25E-79, 25EL-79, 25RCS, 25RLCS, 25TECS, 25TELCS, J25ECIM, J25ELCIM, J25RCIM, J25RLCIM, J25BACIM, J25BALCIM, J25TECIM, J25TELCIM, J25BFCIM, J25BFLCIM, J25BECIM, J25BELCIM, J25RSA, J25RSLA, J25RWCIM, J25RWLCIM, J25RCN, J25RLCN, J25ECN, J25ELCN, J25BACN, J25BALCN, J25TECN, J25TELCN, J25BFCN, J25BFLCN, J25BECN, J25BELCN, J25RSK, J25RSLK, J25RWCN, J25RWLCN, J25RCT, J25RLCT, J25ECT, J25ELCT, J25BACT, J25BALCT, J25TECT, J25TELCT, J25RWCTE, J25RWLCTE, J25RCR, J25RLCR, J25BACR, J25ECR, J25TECR, J25TELCR, J25ELCR, J25RCO, J25RLCO, J25BACO, J25ECO, J25BALCO, J25TECO, J25TELCO, J25ELCO, J25RCD, J25RLCD, J25ECD, J25ELCD, J25TECD, J25TELCD, J25RCU, J25RLCU, J25ECU, J25ELCU, J25TECU, J25TELCU, J25RCC, J25RLCC, J25ECC, J25ELCC, J25TECC, J25TELCC
Evinrude: 25102, 25103, 25202, 25203, 25252, 25253, 25302, 25303, 25352, 25353, 25402, 25403, 25452, 25453, 25502, 25503, 25552, 25553, 25602, 25603, 25652, 25653, 25702, 25703, 25752, 25753, 25802, 25803, 25852, 25853, 25904, 25905, 25952, 25953, E25RCS, E25RLCS, E25TCS, E25TELCS, E25ECIM, E25ELCIM, E25RCIM, E25RLCIM, E25BACIM, E25BALCIM, E25TECIM, E25TELCIM, E25BFCIM, E25BFLCIM, E25BECIM, E25BELCIM, E25RSA, E25RSLA, E25RWCIM, E25RWLCIM, E25RCN, E25RLCN, E25ECN, E25ELCN, E25BACN, E25BALCN, E25TECN, E25TELCN, E25BFCN, E25BFLCN, E25BECN, E25BELCN, E25RSK, E25RSLK, E25RWCN, E25RWLCN, E25RCT, E25RLCT, E25ECT, E25ELCT, E25BACT, E25BALCT, E25TECT, E25TELCT, E25RWCTE, E25RWLCTE, E25RCR, E25RLCR, E25BACR, E25ECR, E25TECR, E25TELCR, E25ELCR, E25RCO, E25RLCO, E25BACO, E25ECO, E25BALCO, E25TECO, E25TELCO, E25ELCO, E25RCD, E25RLCD, E25ECD, E25ELCD, E25TECD, E25TELCD, E25RCU, E25RLCU, E25ECU, E25ELCU, E25TECU, E25TELCU, E25RCC, E25RLCC, E25ECC, E25ELCC, E25TECC, E25TELCC
30 hp — Johnson: J30ECR, J30ELCR, J30RCO, J30RLCO, J30ECO, J30ELCO, J30BACO, J30BALCO, J30TECO, J30TELCO, J30RCD, J30RLCD, J30ECD, J30ELCD, J30TECD, J30TELCD, J30RCU, J30RLCU, J30ECU, J30ELCU, J30TECU, J30TELCU, J30RCC, J30RLCC, J30ECC, J30ELCC, J30TECC, J30TELCC
Evinrude: E30ECR, E30ELCR, E30RCO, E30RLCO, E30ECO, E30ELCO, E30BACO, E30BALCO, E30TECO, E30TELCO, E30RCD, E30RLCD, E30ECD, E30ELCD, E30TECD, E30TELCD, E30RCU, E30RLCU, E30ECU, E30ELCU, E30TECU, E30TELCU, E30RCC, E30RLCC, E30ECC, E30ELCC, E30TECC, E30TELCC
35 hp — Johnson: 35R-76, 35RL-76, 35E-76, 35EL-76, 35R-77, 35RL-77, 35E-77, 35EL-77, 35R-78, 35RL-78, 35E-78, 35EL-78, 35R-79, 35RL-79, 35E-79, 35EL-79, 35RCS, 35RLCS, 35ECS, 35ELCS, J35RCIG, J35RLCIG, J35ECIG, J35ELCIG, J35BACIG, J35BALCIG, J35RCN, J35RLCN, J35ECN, J35ELCN, J35BACN, J35BALCN, J35RCT, J35RLCT, J35ECT, J35ELCT, J35TELCT, J35BACT, J35BALCT
Evinrude: 35602, 35603, 35652, 35653, 35752, 35753, 35802, 35803, 35852, 35853, 35902, 35903, 35952, 35953, E35RCS, E35RLCS, E35ECS, E35ELCS, E35RCIG, E35RLCIG, E35ECIG, E35ELCIG, E35BACIG, E35BALCIG, E35RCN, E35RLCN, E35ECN, E35ELCN, E35BACN, E35BALCN, E35RCT, E35RLCT, E35ECT, E35ELCT, E35TELCT, E35BACT, E35BALCT
40 hp — Johnson: 40R-71, 40RL-71, 40E-71, 40EL-71, 40R-72, 40RL-72, 40E-72, 40EL-72, 40R-73, 40RL-73, 40E-73, 40EL-73, 40R-74, 40RL-74, 40E-74, 40EL-74, 40R-75, 40RL-75, 40E-75, 40EL-75, 40R-76, 40RL-76, 40E-76, 40EL-76, J40RSD, J40RSLD, J40RSR, J40RSLR, J40RWCIS, J40RWLCIS, J40RWCN, J40RWLCN, J40RWCTR, J40RWLCTR, J40RCV, J40RCLV, J40TACR, J40TALCR, J40ECR, J40ELCR, J40TELCR, J40RCO, J40RLCO, J40BACO, J40ECO, J40BALCO, J40ELCO, J40TECO, J40TELCO, J40RCD, J40RLCD, J40ECD, J40ELCD, J40TECD, J40TELCD, J40RCU, J40RLCU, J40ECU, J40ELCU, J40TECU, J40TELCU, J40TLCU (PT/T), J40RCC, J40RLCC, J40ECC, J40ELCC, J40TECC, J40TELCC, J40TLCC (PT/T)
Evinrude: 40102, 40103, 40152, 40153, 40202, 40252, 40253, 40304, 40305, 40354, 40355, 40404, 40405, 40454, 40455, 40504, 40505, 40554, 40555, 40604, 40605, 40654, 40655, E40RSD, E40RSLD, E40RSR, E40RSLR, E40RWCIS, E40RWLCIS, E40RWCN, E40RWLCN, E40RWCTR, E40RWLCTR, E40RCV, E40RCLV, E40TACR, E40TALCR, E40ECR, E40ELCR, E40TELCR, E40RCO, E40RLCO, E40BACO, E40ECO, E40BALCO, E40ELCO, E40TECO, E40TELCO, E40RCD, E40RLCD, E40ECD, E40ELCD, E40TECD, E40TELCD, E40RCU, E40RLCU, E40ECU, E40ELCU, E40TECU, E40TELCU, E40TLCU (PT/T), E40RCC, E40RLCC, E40ECC, E40ELCC, E40TECC, E40TELCC, E40TLCC (PT/T)
50 hp — Johnson: 50ES-71, 50ESL-71, 50R-72, 50RL-72, 50ES-72, 50ESL-72, 50ES-74, 50SL-74, 50ES-75, 50ESL-75, 50MR-78, 50MRL-78, 50R-79, 50RL-79, 50ES, 50ESL, 50ECS, 50ELCS, J50BECIC, J50BELCIC, J50BECN, J50BELCN, J50BECT, J50BELCT, J50TELCT, J50BECR, J50BELCR, J50TELCR, J50TLCR, J50BECO, J50BELCO, J50TELCO, J50TLCO, J50BECD, J50BELCD, J50TELCD, J50TLCD, J50BECU, J50BELCU, J50TELCU, J50TLCU, J50BECC, J50BELCC, J50TELCC, J50TLCC, J50TLCU (PT/T), J50TLCC (PT/T)
Evinrude: 50172, 50173, 50202, 50203, 50272, 50273, 50302, 50303, 50372, 50373, 50442, 50443, 50472, 50473, 50572, 50573, 50542, 50543, 50802, 50803, 50902, 50903, E50BECIC, E50BELCIC, E50BECN, E50BELCN, E50BECT, E50BELCT, E50TELCT, E50BECR, E50BELCR, E50TELCR, E50TLCR, E50BECO, E50BELCO, E50TELCO, E50TLCO, E50BECD, E50BELCD, E50TELCD, E50TLCD, E50BECU, E50BELCU, E50TELCU, E50TLCU, E50BECC, E50BELCC, E50TELCC, E50TLCC, E50TLCU (PT/T), E50TLCC (PT/T)
55 hp — Johnson: 55E-76, 55EL-76, 55E-77, 55EL-77, 55E-78, 55EL-78, 55E-79, 55EL-79, 55RCS, 55RLCS, J55RCIM, J55RLCIM, J55RCN, J55RLCN, J55RSJ, J55RSLJ, J55RCTE, J55RLCTE
Evinrude: 55672, 55673, 55642, 55643, 55772, 55773, 55874, 55875, 55974, 55975, E55RCS, E55RLCS, E55RCIM, E55RLCIM, E55RCN, E55RLCN, E55RSJ, E55RSLJ, E55RCTE, E55RLCTE
60 hp — Johnson: 60ECS, 60ELCS, J60ECIH, J60ECIA, J60ELCIH, J60ELCIA, J60TLCIA, J60ECN, J60ELCN, J60TLCN, J60ECT, J60ELCT, J60TLCT, J60ECR, J60ELCR, J60TLCR, J60ECO, J60ELCO, J60TLCO
Evinrude: E60ECS, E60ELCS, E60ECIH, E60ECIA, E60ELCIH, E60ELCIA, E60TLCIA, E60ECN, E60ELCN, E60TLCN, E60ECT, E60ELCT, E60TLCT, E60ECR, E60ELCR, E60TLCR, E60ECO, E60ELCO, E60TLCO
Sub-models / Variants: 2-Stroke, 1-Cylinder, 2-Cylinder, Deluxe, Commercial, VRO, AccuMix
Model Years: 1971–1989 (1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989)
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Piston ring gap: 0.005–0.015 inch (4 hp)
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System voltage: 12 volts
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Cylinder bore wear limit: 0.003–0.004 inch (0.076–0.102 mm)
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Cylinder head bolt torque: 60–80 in-lbs (4 hp)
Johnson Manual Features & Selected Content Preview
The Seloc Johnson/Evinrude Outboards 1971–89 Repair Manual (P/N 1302) covers 1.25–60 HP, 1- and 2-cylinder 2-stroke models. Service procedures are grouped by horsepower, model year, and hardware design.
Printable PDF and Limited Bookmark Navigation
Search, navigation, and wiring detail: PDF text search is unavailable. Embedded bookmarks provide limited file-part navigation, and one bookmark has no working destination. Small wiring labels require zooming.
The ZIP contains one printable PDF with 632 pages: one cover, seven contents pages, 578 chapter pages, and a 46-page appendix. All are included in that total.
Powerhead, Ignition, and Lower-Unit Service
These selected topics outline the repair coverage; additional sections address fiberglass and aluminum hull care.
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Powerhead overhaul: Step-by-step disassembly, inspection, cylinder-block honing, piston and crankshaft installation, reassembly, and break-in procedures.
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Fuel and oil injection: Carburetor service, fuel-pump and fuel-line tests, primer systems, and VRO and AccuMix/AutoBlend service coverage.
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Ignition diagnosis: Conventional and low-tension flywheel magnetos, Type I and Type II CD systems, timing checks, and fuel/ignition synchronization.
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Electrical service: Battery, gauge, horn, charging-circuit, and starter diagnosis, with armature tests and starter-motor repair procedures.
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Lower-unit repair: Gearcase and water-pump service, bearing and seal installation, driveshaft/pinion shimming, and functional checks for distinct shift designs.
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Hand starters and trim/tilt: Recoil-starter repair, trim/tilt troubleshooting, system filling, and electric-motor testing and service.
Suited to mechanically experienced owners and technicians with gauges and electrical test equipment; internal powerhead and gearcase work also calls for the specified special tools.
Powerhead Inspection and Assembly
Two-stroke operating explanations distinguish cross-fuel-flow deflector-piston designs from loop-scavenged powerheads used on 40 HP models from 1983 and on 50, 55, and 60 HP engines.
Powerhead work includes head and reed-box service, bypass and exhaust covers, top and bottom seals, connecting rods, and crankcase assembly. Separate crankshaft procedures account for different combinations of needle and Babbitt main bearings.
Piston inspection covers ring locating pins, groove condition, oversize pistons, and cylinder wear. The appendix separates piston ring gap and piston-to-cylinder clearance by horsepower and model year. Turning a used reed over reverses its flex direction and can cause it to break.
Carburetors, Fuel Delivery, and Oil Injection
Fuel diagnosis addresses rough idle, excessive consumption, and surge through pump and line tests. OMC Type I through Type IV carburetors have separate service procedures. Type IV coverage distinguishes adjustable- and fixed-orifice versions on later 40, 50, 55, and 60 HP engines.
Tank service and electric and manual primer chokes are included. For the non-serviceable fuel pumps shown, coverage is limited to screen/gasket service and complete pump replacement.
VRO checks: Fuel-and-oil delivery testing specifies 5–15 psi near full throttle, with the engine in gear under load; the fuel-line vacuum test allows no more than 7 in. Hg at idle. A defective VRO pump is replaced as an assembly.
AccuMix/AutoBlend: The tank-mounted system is described as metering a 100:1 fuel/oil ratio regardless of engine rpm. Coverage centers on canister and filter service; it does not provide an internal pump overhaul or a dedicated manufacturer troubleshooting test sequence.
Ignition and Electrical Fault Tracing
Type I capacitor-discharge ignition with a timer base applies to 50 HP 1971–75 and 55 HP 1976–77 engines. Type II CD ignition uses a sensor coil across many later 2.5–60 HP applications.
Procedures include polarity checks, breaker-point and condenser testing, stator/charge-coil replacement, timer-base and sensor service, power-pack replacement, and timing adjustment.
Electrical coverage separates generator and alternator charging circuits, choke circuits, starter testing, and armature checks, with Bosch and Prestolite starter-motor service. Feeding accessory power into the magneto circuit can destroy the ignition coil; an automotive-style key switch is not a suitable substitute.
Remote Controls and Gearcase Variants
Remote-control service covers double-lever manual boxes, electric-shift controls, Evinrude push-button units, Johnson single-lever units, and later single-lever remote controls.
Lower-unit sections separate no-shift, manual-shift, propeller-exhaust mechanical-shift, two-solenoid electric-shift, and hydraulic-assist designs. The 50 HP 1971–72 electric-shift unit differs from the 50 HP 1973–74 hydraulic-assist arrangement with its shift disconnect under the lower carburetor. These distinctions help identify the matching disassembly and shimming procedures before opening the gearcase.
Frozen propeller-shaft work receives separate treatment. Incomplete gear engagement or uneven tightening can misalign the gearcase head and break its mounting ears.
Special tools: OMC 378103 is identified for flywheel removal, 315767 for driveshaft/pinion shimming, and 316612 for pinion-nut service. Tools 319875, 319876, and 319877 cover bearing-carrier bearing and seal work.
Recoil Starters and Power Trim/Tilt
Hand-starter sections distinguish pinion-gear, swing-arm, sliding-gear, and flywheel-mounted designs, with rope replacement, spring service, reassembly, and applicable lockout adjustments.
Prestolite and Calco trim/tilt units have filling, troubleshooting, removal, and electric-motor repair coverage. Specified fluids are OMC Power Trim/Tilt Fluid or GM Dexron II ATF. The hydraulic pump is replaced if defective; further hydraulic disassembly is directed to a shop equipped for high-pressure hydraulic work.
Specifications, Drawings, and Seasonal Care
The appendix supplies torque, tune-up, powerhead, oil/fuel, gear-oil-capacity, starter-motor, regulator, generator, condenser, and starter-rope specifications. Plug-gap notes distinguish 0.030 in. for 1971–81 engines and all 2/4 HP models from 0.040 in. for 4.5–60 HP engines from 1982 onward.
Illustrations include the 9.9/15 HP 1974-and-on crankshaft assembly, Type IV fixed-orifice carburetor, typical generator, and 50 HP 1973 lower-unit exploded views. Wiring examples include the 40/50 HP remote electric-start drawing for 1986 and on and the 1989 Johnson/Evinrude 20–30 HP remote-start diagram.
Maintenance covers engine identification, the post-1979 OMC “INTRODUCES” year-coding system, submerged-engine service, winter storage, lower-unit care, battery storage, and preseason preparation. Boat-testing guidance uses full-throttle rpm to assess propeller pitch and load.
Working on these outboards involves ignition, fuel, hydraulic trim/tilt, and rotating machinery. Follow the manual's isolation, ventilation, water-circulation, and load precautions during testing; brief dry running can damage the water pump, and high-speed no-load operation can cause engine runaway.
Examples of Reed and Compression Inspection Limits
Reed inspection gives a maximum at-rest tip clearance of 0.010 in. (0.254 mm) between the reed and base plate. The powerhead chapter pairs this check with reed condition and seating inspection.
Compression diagnosis emphasizes cylinder-to-cylinder balance. A difference greater than 5 psi indicates a possible piston, ring, or cylinder problem, even when an individual reading appears satisfactory.
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