1965–1978 Evinrude 1.5–35 HP Outboard Service & Repair Handbook

This Clymer service and repair handbook covers 1965–1978 Evinrude 1.5–35 HP outboards, with an integrated 1976–1978 service supplement. This PDF has gaps in the service text, including electrical and lower-unit procedures.

• Power head repair: Removal, disassembly, piston and cylinder inspection, decarbonization, bearing checks, reassembly, and model-specific clearance and torque tables.

• Fuel system: Carburetor overhaul, float adjustment, reed-valve inspection, throttle-linkage synchronization, fuel-pump testing, and tank and fuel-line service.

• Ignition and starting diagnosis: Static and strobe timing, coil and stator checks, rectifier testing, safety-switch adjustment, and starter-circuit fault tracing.

• Lower unit and cooling: Gearcase and exhaust-housing removal, shift adjustment, alignment checks, pressure testing, and standard and weedless gearcase illustrations.

• Manual starters: Rope replacement, lockout adjustment, and small-engine recoil-starter disassembly, with limits on spring service for larger models.

• Later-model updates: Serial-specific water-pump corrections, armature-plate bearing changes, piston-ring checks, and additional wiring diagrams in the 1976–1978 supplement.

The handbook is suited to owners comfortable with mechanical disassembly and electrical testing; it directs advanced gearcase work and several recoil-spring repairs to properly equipped shops.

Power Head Inspection and Reassembly

The engine chapter separates removal and disassembly by horsepower group. Bore/stroke and crankshaft-journal data accompany ring-clearance and flywheel/cylinder-head torque tables.

Cylinder-wall measurements, bearing and connecting-rod checks, and gasket-surface inspection support overhaul decisions. The Piston and Crankshaft view for 9.9–15 HP engines identifies the related components.

Some complex engine operations are expressly omitted. The supplement also warns that incorrectly machined replacement rings on 9.9 and 15 HP engines can protrude from their grooves and damage the pistons and cylinders.

Carburetors, Reed Valves, and Fuel Delivery

Separate carburetor sections distinguish adjustable high-speed needles from fixed-jet designs. Float settings, inlet-needle and seat inspection, recirculating valves, and choke-solenoid checks accompany the Carburetor Assembly view for 1.5–6 HP engines. Fuel mixing and altitude-related adjustments are also addressed.

Fuel-pump coverage combines delivery-pressure testing with filter service and pump replacement; it does not describe rebuilding the pump's individual parts. Accessory remote-control installation is also outside the handbook's scope.

Ignition Tests and Wiring Coverage

Breaker-point timing, carburetor-to-magneto synchronization, shift-lock stops, and neutral-start switch adjustment are covered. Static timing references fixture No. 376969. Battery inspection and charging guidance include a reference table labeled 6N6-3B.

The Wiring Diagram—9.9–15 HP with Electric Starter and Motor and Instrument Cables views support circuit tracing. Separate diagrams cover manual-start arrangements and the larger electric-start motors, including generator and regulator connections.

Missing electrical service text: The magneto removal/installation and electric-starter service sections referenced in the index are absent from this PDF. The troubleshooting chapter also contains a break in its text.

The supplement addresses armature-plate wobble and unstable timing. It explains how incorrect lubrication of the Delrin bearing and plate pilot can damage the armature plate and cylinder/crankcase assembly.

Gearcases, Water Pumps, and Build Changes

Lower-unit material covers mounting components, propeller service, steering-handle gears, and Centri-matic pump operation. Gearcase views, including the 6 HP assembly, accompany inspection and removal information.

Lower-unit limits: The text is interrupted within the shift-adjustment and gearcase-removal material. Internal gearcase work requires specialized equipment; this is not a complete gearcase rebuilding guide.

The supplement's serial-number cutoffs identify which 1978 35 HP motors the low-idle water-pump update applies to. That distinction helps match impeller-housing and gasket corrections to the affected build.

Early 1976 S-suffix 35 HP motors use three pump-housing screws; later G-suffix builds use four.

Recoil Starters and Electric-Motor Controls

Small recoil starters receive disassembly and assembly instructions; several larger units receive rope-replacement and lockout-adjustment coverage, with spring work referred to a dealer.

A separate electric-motor chapter covers steering-cable replacement and motor-tube angle adjustment, supported by a Cable and Pedal Group view. Most internal electric-motor repairs are left to a specialist.

Follow the handbook's precautions for fuel vapors, ignition voltage, and stored recoil-spring tension.

A Sample of Fuel-Pressure and Ignition Test Data

These examples show a small selection of the handbook's diagnostic specifications.

For the 3–33 HP fuel-pump test, the pressure table lists 1.5 psi at 2,500–3,000 rpm, with the motor operated in a test tank or on the boat in the water.

The 1976–1978 specification table for 9.9 and 15 HP engines lists charge-coil resistance of 575 ± 75 ohms for rope-start versions and 475 ± 75 ohms for electric-start versions.

PDF Bookmarks and Wiring-Label Legibility

Search, section access, and diagram detail: PDF text search is not available. Embedded bookmarks open the available sections, supplement, and index. Small wiring and connector labels vary in clarity; some remain blurred when enlarged.

One printable, 202-page PDF, including the 25-page 1976–1978 supplement, two cover pages, one maintenance-log page, and one repeated wiring-diagram page. These are already included in the total.