1965-1978 Johnson Evinrude 1.5 hp - 235 hp outboard motor service repair handbook

Table of Contents

Chapter One: General Information

• Identification
  • Model Numbers
  • Serial Number Locations
• Specifications
  • Engine Specifications
  • Fuel and Oil Recommendations
• Tools and Materials
  • Special Tools
  • Standard Tools

Chapter Two: Lubrication, Periodic Maintenance, and Tune-up

• Lubrication
  • Lubrication Points
  • Types of Lubricants
• Periodic Maintenance Schedule
  • Monthly Checks
  • Annual Checks
• Engine Tune-up Procedures
  • Spark Plug Maintenance
  • Carburetor Adjustment
  • Timing Adjustment

Chapter Three: Troubleshooting

• Engine Will Not Start
  • Fuel System Check
  • Ignition System Check
• Engine Misfires
  • Spark Plug Check
  • Ignition Coil Check
• Poor Performance
  • Carburetor Issues
  • Compression Check
• Electrical Problems
  • Battery Issues
  • Wiring Check
• Fuel System Problems
  • Fuel Pump Check
  • Fuel Line Inspection
• Cooling System Problems
  • Water Pump Check
  • Thermostat Check

Chapter Four: Fuel System

• Carburetor Adjustment
  • Idle Speed Adjustment
  • Mixture Adjustment
• Fuel Pump
  • Fuel Pump Disassembly
  • Fuel Pump Assembly
• Fuel Lines
  • Inspection and Replacement
• Fuel Tank
  • Cleaning and Maintenance

Chapter Five: Electrical System

• Ignition System
  • Points and Condenser
  • Electronic Ignition
• Charging System
  • Alternator Check
  • Regulator/Rectifier Check
• Battery Maintenance
  • Battery Charging
  • Battery Replacement
• Wiring Diagrams
  • Color Codes
  • Schematic Diagrams

Chapter Six: Engine Repair and Overhaul

• Cylinder Head Removal and Installation
  • Cylinder Head Torque Sequence
  • Gasket Replacement
• Piston and Connecting Rod Removal and Installation
  • Piston Ring Installation
  • Connecting Rod Bolt Torque
• Crankshaft Removal and Installation
  • Main Bearing Inspection
  • Crankshaft End Play Adjustment
• Engine Block Disassembly and Reassembly
  • Block Cleaning
  • Reassembly Tips

Chapter Seven: Lower Unit

• Lower Unit Removal and Installation
  • Propeller Shaft Removal
  • Gearcase Seal Replacement
• Water Pump Maintenance
  • Impeller Replacement
  • Water Pump Housing Inspection
• Gearcase Disassembly and Reassembly
  • Gear Inspection
  • Bearing Replacement

Chapter Eight: Manual Starter

• Starter Rope Replacement
  • Rope Routing
  • Recoil Spring Tension
• Recoil Spring Replacement
  • Spring Installation
  • Lubrication Points

Chapter Nine: Electric Motors

• Electric Motor Troubleshooting
  • Common Issues
  • Diagnostic Procedures
• Electric Motor Maintenance
  • Brush Replacement
  • Armature Inspection

Chapter Ten: Supplement 1976-1978 Service Information

• Model Changes and Updates
  • New Specifications
  • Updated Parts
• Updated Specifications
  • Engine Changes
  • Performance Improvements
• Revised Maintenance Procedures
  • New Lubrication Points
  • Updated Service Intervals

Index

• Page 209

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