1971-1989 Johnson Outboards 1 hp - 60 hp outboard motor service manual

Product Information

Table of Contents

1. SAFETY

1. Introduction
2. Cleaning, Waxing, Polishing
3. Controlling Corrosion
4. Propellers
5. Fuel System
6. Loading
7. Mooring
8. Flotation
9. Emergency Equipment
10. Compass
11. Anchors
12. Miscellaneous Equipment
13. Boating Accident Reports
14. Navigation

2. TUNING

1. Introduction
2. Tune-Up Checklist
3. Compression Check
4. Cylinder Inspection
5. Spark Plug Inspection
6. Ignition System Check
7. Carburetor Adjustments
8. Synchronizing Adjustments
9. Fuel Pump Service
10. Starter and Solenoid
11. Drive Shaft Housing
12. Gear Housing
13. Water Pump
14. Gear Lubrication
15. Boat Hull

3. POWERHEAD

1. Introduction
2. Chapter Organization
3. Powerhead Disassembling
4. Head Service
5. Reed Service
   • Description
   • Clearance Adjustment
   • Cleaning and Inspecting
6. Bypass Covers
   • Installation
7. Exhaust Cover
   • Cleaning and Inspecting
8. Thermostat
   • Removal
   • Cleaning and Testing
   • Installation
9. Bottom Seal
   • Anti-Corrosion Pins
   • Can Crankcase Side Bolts
10. Crankcase Cover
    • Cleaning and Inspection
    • Cleaning
    • Honing
11. Connecting Rods and Pistons
    • Description
    • Cleaning and Inspecting
12. Crankshaft
    • Cleaning and Inspecting
    • Assembly
13. Cylinder and Crank Service
    • Cleaning and Inspecting
    • Replacement
    • Assembly
14. Break-In Procedures

4. FUEL

1. Introduction
2. General Carburetion Information
3. Carburetion System Service
4. Type I Carburetor
   • Description
   • Removal
   • Cleaning and Inspecting
   • Assembling
   • Installing
5. Type II Carburetor
   • Description
   • Removal
   • Cleaning and Inspecting
   • Assembling
   • Installing
6. Type IV Carburetor
   • Description
   • Removal
   • Cleaning and Inspecting
   • Assembling
   • Installing
7. Fuel Pump Service
   • Description
   • Removal and Installation
   • Cleaning and Inspecting
8. Fuel Tank Service
9. Electric Primer Choke
10. Manual Primer Choke
11. Oil Injection Systems
    • VRO Oil Injection
    • AccuMix

5. IGNITION

1. Introduction
2. Spark Plug Inspection
3. Polarity Check
4. Wiring Harness
5. Flywheel Magneto Ignition System
   • Description
   • 1.5 hp to 60 hp
   • Removal
   • Cleaning and Inspecting
   • Assembly
6. Troubleshooting
   • Description
   • Synchronizing
   • Service Tool
7. Synchronizing Flywheel Magneto Ignition
   • Synchronizing
   • Inspection
8. Type III Flywheel Magneto Ignition System
   • 2 hp to 60 hp
   • Description
   • Cleaning and Inspecting
   • Removal
   • Assembly

6. ELECTRICAL

1. Introduction
2. Batteries
3. Alternator Charging
4. Circuit Service
5. Choke Circuit Service
6. Starter Motor
   • Description
   • Removal and Installation
   • Cleaning and Inspecting
   • Assembly
7. Starter Drive Gear Service
   • Bosch Starter Motor Service
8. Solenoid and Wiring Harness
   • Testing
9. Starter Motor Installation
   • Alternator Testing
10. Starter Motor Assembly

7. REMOTE CONTROLS

1. Introduction
2. Remote Shift
   • Service
   • Cleaning and Inspecting
   • Assembling
3. Single Lever
   • Shift Box Service
4. Pushbutton Type Shift Box Service
   • Description
   • Troubleshooting
   • Cleaning and Inspecting
   • Assembling
5. Single Lever Shift Box
   • Description
   • Assembling
   • Installation
6. Cable End Fitting Installation
7. Remote Control Units
   • Installation
   • Adjustment

8. LOWER UNIT

1. Introduction
2. Gearcase
   • Cleaning and Inspecting
   • Propeller Shaft
   • Gearcase
   • Water Pump
   • Gear Lubrication

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