1958–1971 Evinrude 50–125 HP 3-Cylinder & V4 Outboard Repair Manual (P/N 395166-1500)

This Seloc repair manual (No. 1306) covers 1958–1972 Johnson and Evinrude 50–125 HP outboards with three-cylinder and V4 two-stroke engines.

• Powerhead repair: Removal and installation, cylinder inspection and honing, piston and connecting-rod service, crankshaft bearings, reed assemblies, and crankshaft seals.

• Fuel system: Carburetor overhaul and float adjustment, fuel-pump tests, fuel-line troubleshooting, and heat/electric, all-electric, and water-choke service.

• Ignition and tuning: Distributor magneto, battery ignition, and capacitor-discharge troubleshooting, with component replacement, distributor-belt timing, and fuel-system synchronization.

• Starting and charging: Bendix drive assemblies, Delco-Remy, Autolite, and Prestolite starter service, generator overhaul, and alternator, regulator, and rectifier tests.

• Lower units and controls: Manual-shift, Electromatic, and Hydro-Electric diagnosis, gearcase overhaul, water-pump rebuilding, shift-box service, and control-cable adjustment.

• Workshop references: Model-specific torque tables, powerhead clearances, gear-oil capacities, electrical test specifications, exploded drawings, and wiring diagrams.

This manual is suited to mechanics and experienced owners who understand two-stroke operation; its CD ignition diagnosis also requires the specified electrical test equipment.

Powerhead Rebuilding and Cooling Service

The powerhead chapter follows internal service through crankcase separation, connecting-rod and crankshaft inspection, needle-bearing assembly, and reinstallation. It distinguishes piston orientation and bearing arrangements for the different engine configurations. An exploded three-cylinder powerhead drawing shows how the major assemblies fit together.

Head service includes the staged tightening sequence, thermostat and bypass-valve inspection, and attention to corroded water passages. Water-pump removal, inspection, and rebuilding appear within the relevant lower-unit sections.

Carburetor Overhaul and Fuel Delivery

The fuel chapter separates adjustable-needle and fixed-orifice carburetors, including the four-barrel Type II and the individual Type III carburetors used on the covered three-cylinder engines. Its exploded Type II carburetor drawing and float-adjustment instructions specify OMC tool No. 380546.

Fuel-pump coverage distinguishes rebuildable pumps from nonserviceable units, whose maintenance is limited to the filter and gasket. The 65 HP three-cylinder engine is referred to Volume IV for engine service; this volume identifies its Type III carburetor application.

Ignition Diagnosis and Electrical Repair

CD troubleshooting separates sensor-triggered systems from breaker-point systems and ties numbered tests to the applicable diagrams. The 115 HP ignition-system test diagram supports component checks, while the charging sections address generator and alternator circuits separately.

The rotor illustrations distinguish similar-looking magneto and battery-ignition parts: installing the wrong rotor can prevent the engine from developing full power. The manual also includes precautions for fuel-vapor ignition and electrical testing; follow the safety instructions for the system being serviced.

Gearcase Variants and Shift Controls

The lower-unit chapter distinguishes split and enclosed manual-shift housings, the smaller Type III Electromatic assembly, the heavier Type IV unit, and the hydraulically operated Type V electric-shift unit.

Separate shift-box and gearcase tests help distinguish control or wiring faults from internal lower-unit problems before teardown. The Hydro-Electric shift-circuit troubleshooting schematic supports these checks; wire-identification drawings cover configurations such as the 85 HP V4 electric-shift system and the 125 HP V4.

The lubrication section warns that mistaking the Phillips shift-fork retaining screw for a lubricant plug can displace the fork and require lower-unit disassembly.

Hand-starter service, submerged-engine care, winter storage, and preseason preparation are also included.

Examples of Shift-Coil Tests and Gear-Oil Capacities

These are a small selection of the electrical test values and lubricant quantities in the manual.

For Type V electric-shift lower units, the specified resistance from each disconnected green or blue lower-unit lead to engine ground is 5–7 ohms.

The gear-oil table lists 17.4 ounces for the 1962–1965 75 HP electric-shift unit and 34.8 ounces for the 1964–1965 75 HP HD unit, keeping those gearcase applications distinct.

PDF Search, Bookmarks, and Page Breakdown

Search and wiring detail: OCR text supports searches through much of the manual, but some table entries and an ignition-test diagram are not searchable. Embedded bookmarks cover the contents, all ten chapters, the appendix, and wiring diagrams. Small labels in dense wiring diagrams require zooming.

One printable, English-language PDF contains 526 pages total: 488 chapter pages, a 30-page appendix, seven contents pages, and one cover page. All are included in the total.