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1971-1989 Johnson 1.25 hp-60 hp outboard engine service manual Preview image 1
1971-1989 Johnson 1.25 hp-60 hp outboard engine service manual Preview image 2
1971-1989 Johnson 1.25 hp-60 hp outboard engine service manual Preview image 3
1971-1989 Johnson 1.25 hp-60 hp outboard engine service manual Preview image 4
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1971-1989 Johnson 1.25 hp-60 hp outboard engine service manual Preview image 6

1971-1989 Johnson 1.25 hp-60 hp outboard engine service manual

Models covered in this manual:

1971-1989 Johnson Outboard Engines

  • 2 HP, 2.5 HP, 3 HP, 4 HP
  • Excel 4, Ultra 4, 4 HP Deluxe
  • 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
  • 28 HP, 30 HP, 35 HP, 40 HP
  • and Electrics, 1973 through 1990
  • 1991 to 1994
  • All models including Jet Drives & Sea Drives
  • 2.0 HP, 2.3 HP, 3.3 HP, 3 HP, 4 HP, 4 DELUXE,
  • 6 HP, 8 HP, 9.9 HP, 15 HP, 20 HP, 25 HP, 28 HP, 30 HP,
  • 35 HP, 40 HP, 48 HP, 50 HP, 60 HP, 70 HP, 65 HP, 80 HP,
  • 85 HP, 88 HP, 90 HP, 100 HP, 115 HP, 120 HP, 140 HP,
  • 150 HP (90 V6), 175 HP (90 V6), 150 HP (60 V6),
  • 175 HP (60 V6), 225 HP, 250 HP, 300 HP, 1.6 Sea Drive,
  • 2.0 Sea Drive, 3.0 Sea Drive, and 4.0 Sea Drive
  • 1995 to 2001
  • 5hp to 70hp
  • 4 stroke models
  • 1995 to 2003
  • All models 2 stroke & Jet Drive 2hp to 70hp
  • 2hp,3hp,3.3hp,3.5hp,4hp,4 Deluxe,
  • 6hp,8hp,9.9hp,15hp,18Jet,20 hp,
  • 25hp,28Special,28Jet,30hp,
  • 35hp,40hp,48Special,50Special,50hp,60hp and 70hp
  • 1.25R71, 1.5R71, 2R71, 2.5R71, 4R71, 4W71, 6R71, 6RL71, 9.5R71, 9.5RL71, 15R71, 15RL71, 25R71, 25RL71, 40R71, 40RL71, 50R71, 50RL71, 55R71, and 55RL71.

Production/model years: 1971, 1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989.

File specifications

File size: 140.07 MB
File type: ZIP
Language: English

Printable: Yes
Estimated download time: 2.87 Minutes
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Product Information

Table of Contents

1 Safety

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

2 Tuning

  1. Introduction
  2. Tune-Up Sequence
  3. Compression Check
  4. Cylinder Inspection
  5. Ignition System
  6. Ignition Timing
  7. Synchronizing Adjustments
  8. Fuel Pump
  9. Carburetor
  10. Idle Speed Adjustment
  11. Spark Plugs
  12. Starting and Running
  13. Boat Rigging

3 Powerhead

  1. Introduction
  2. Theory of Operation
  3. Chapter Organization
  4. Powerhead Disassembling
  5. Head Service
  6. Reed Service
  7. Bypass Covers
  8. Exhaust Cover
  9. Bottom Seal
  10. Intake Manifold
  11. Pan and Crankcase Side Bolts
  12. Crankcase Cover
  13. Connecting Rods and Pistons
  14. Crankshaft
  15. Reassembly

4 Fuel

  1. Introduction
  2. General Carburetion
  3. Fuel System
  4. Fuel Pump Service
  5. Fuel Tank Service
  6. Manual Primer Choke
  7. Electric Primer Choke
  8. Oil Injection Systems

5 Ignition

  1. Introduction
  2. Flywheel Magneto Ignition
  3. Synchronizing Flywheel
  4. Troubleshooting
  5. Servicing Flywheel Magneto Ignition System

6 Electrical

  1. Introduction
  2. Batteries
  3. Battery Testing
  4. Alternator Charging
  5. Circuit Service
  6. Choke Circuit Service
  7. Starter Motor
  8. Starter Drive Gear Service
  9. Bosch Starter Motor Service
  10. Starter Solenoid
  11. Troubleshooting

7 Remote Control

  1. Introduction
  2. Single Lever Shift
  3. Dual Lever Shift
  4. Single Lever Shift Box Service
  5. Pushbutton Type Shift Box Service
  6. Control Lever Service
  7. Cable and Fitting Installation

8 Lower Unit

  1. Introduction
  2. Propeller Shaft
  3. Water Pump
  4. Gearcase
  5. Lower Unit Assembly
  6. Gearcase Installation
  7. Lower Unit Removal
  8. Function Check
  9. Troubleshooting
  10. Lower Unit Service (Manual Shift)
  11. Lower Unit Service (Electric Shift)
  12. Lower Unit Service (Propeller Exhaust)

9 Specifications

  1. General Specifications
  2. Engine Specifications
  3. Gearcase Specifications
  4. Electrical Specifications

10 Wiring Diagrams

  1. Complete Wiring Diagrams
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