Home ▸ Johnson Evinrude ▸ BEST 1965 – 1978 Evinrude Johnson Outboard 1.5 – 35 Hp Service | Repair Manual ( 65 1966 1967 1968 1969 1970 1971 1972 1973 – 90741268

BEST 1965 – 1978 Evinrude Johnson Outboard 1.5 – 35 Hp Service | Repair Manual ( 65 1966 1967 1968 1969 1970 1971 1972 1973 – 90741268

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1965 – 1978 Evinrude Johnson Outboard 1.5 – 35 Hp ( 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP ) Service / Repair Manual – Production years 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978 Evinrude Outboard Manual ( 65 66 67 68 69 70 71 72 73 74 75 76 77 78 ) – Download !!

File Format: PDF

Compatible: All Versions of Windows & Mac

Downloadable: YES

Language: English

Requirements: Adobe PDF Reader

Description:

COVERS ALL MODELS & ALL REPAIRS A-Z

THIS IS NOT SOME GENERIC REPAIR INFORMATION. IT IS A VEHICLE SPECIFIC SERVICE MANUAL! THIS HIGHLY DETAILED SERVICE REPAIR MANUAL CONTAINS EVERYTHING YOU WILL EVER NEED TO SERVICE, REPAIR, RESTORE, MAINTAIN, REFURBISH OR EVEN REBUILD YOUR VEHICLE.

COMPLETE & EASY TO USE STEP-BY-STEP INSTRUCTIONS, ILLUSTRATIONS, DIAGRAMS, SPECIFICATIONS & WIRING SCHEMATICS WILL HELP ASSIST YOU TO PERFORM RIGHT FROM VERY SIMPLE REPAIRS TO COMPLEX ONES !!.

CLEAR PICTURES AND ZOOMABLE ILLUSTRATIONS HELP YOU PERFORM YOUR SERVICE REPAIR WITH UTMOST EASE! NO TECHNICAL EXPERTISE REQUIRED. YOU SEE IT AND YOU DO IT (DO-IT-YOURSELF MANUAL)

THIS IS THE SAME MANUAL THAT TECHNICIANS AND MECHANICS IN DEALERSHIPS & ELSEWHERE USE TO SERVICE & REPAIR YOUR VEHICLE! YOU CAN REFER THIS MANUAL RIGHT FROM YOUR PC/LAPTOP OR ONLY PRINT OFF THE PAGES THAT YOU REQUIRE FOR THE MOMENT.

SOME OF THE REPAIRS & CONTENTS INCLUDE:

INTRODUCTION Filling Lower Unit

CLEANING, WAXING, POLISHING Propeller Installation

CONTROLLING CORROSION SHIFT WITH NO DISCONNECT

PROPELLERS 4 DELUXE THRU 8 HP 1980-85

FUEL SYSTEM Description

LOADING Removal

HORSEPOWER 6 ELECTRICAL (CONT)

FLOTATION ALTERNATOR CHARGING

EMERGENCY EQUIPMENT CIRCUIT SERVICE

COMPASS Troubleshooting

ANCHORS CHOKE CIRCUIT SERVICE

MISCELLANEOUS EQUIPMENT STARTER MOTOR

BOATING ACCIDENT REPORTS CIRCUIT SERVICE

NAVIGATION Circuit Description

2 TUNING Starter Motor Description

INTRODUCTION Testing

TUNE-UP SEQUENCE STARTER DRIVE GEAR SERVICE

COMPRESSION CHECK Disassembling Type I

SPARK PLUG INSPECTION Cleaning and Inspecting

IGNITION SYSTEM Assembling Type I

SYNCHRONIZING Disassembling Type II

BATTERY SERVICE Cleaning and Inspecting

CARBURETOR ADJUSTMENTS Assembling Type II

FUEL PUMPS BOSCH STARTER MOTOR SERVICE

STARTER AND SOLENOID Removal

INTERNAL WIRING HARNESS Disassembling Armature Testing

WATER PUMP CHECK Cleaning and Inspecting Assembling

PROPELLERS PRESTOLITE SERVICE

LOWER UNIT Removal

BOAT TESTING Disassembling

3 POWERHEAD Armature Testing Cleaning

INTRODUCTION and Inspecting

Theory of Operation Assembling STARTER MOTOR TESTING

CHAPTER ORGANIZATION STARTER MOTOR INSTALLATION

POWERHEAD DISASSEMBLING 7 REMOTE CONTROLS

INTRODUCTION

SHIFT BOXES

3 POWERHEAD (CONT) DOUBLE-LEVER SHIFT

HEAD SERVICE BOX SERVICE

REED SERVICE Troubleshooting

Description Removal

Reed Valve Adjustment Disassembling

Cleaning and Service Cleaning and Inspecting

Installation Assembling

BYPASS COVERS ELECTRIC GEAR BOXES AND

Installation SINGLE LEVER CONTROL

EXHAUST COVER Troubleshooting

Cleaning SINGLE LEVER SHIFT BOX SERVICE

Installation JOHNSON UNITS ONLY

TOP SEAL Disassembling

Removal Cleaning and Inspecting

Installation Assembling

BOTTOM SEAL PROPELLER EXHAUST

Inspection MECHANICAL SHIFT 35 HP 1978

CENTERING PINS 20 HP 1974 & on 25 HP 1986 & on

MAIN BEARING BOLTS Water Pump Disassembling

AND CRANKCASE SIDE BOLTS Lower Unit Disassembling

Installation Cleaning and Inspecting

CRANKCASE COVER Lower Unit Assembling

Removal Water Pump Installation

Cleaning and Inspection Lower Unit Installation

CONNECTING RODS AND PISTONS Functional Check

Removal TROUBLESHOOTING

Disassembling MANUAL SHIFT 6.0 to 40 HP

Rod Inspection and Service ALL MODELS EXCEPT 35 HP

Piston and Ring Inspection WITH PROPELLER EXHAUST

and Service LOWER UNIT SERVICE MANUAL

Assembling SHIFT 6.0 HP

CRANKSHAFT 1979 9.5 HP to 20 HP

Removal 1977 25 HP 1978

Cleaning and Inspection Shift Rod Disconnect

CYLINDER BLOCK SERVICE Lower Unit Removal

Honing Procedures Water Pump Removal

Assembling Lower Unit Disassembling

Piston and Rod Installation Cleaning and Inspecting

Crankshaft Installation Lower Unit Assembling

Needle Main and Water Pump Installation

Rod Bearings Lower Unit Installation

Crankshaft Installation Functional Check

With Top Needle Main Brg. LOWER UNIT SERVICE

and Babbitt Ctr. & Bottom MANUAL SHIFT 40 HP THRU 1976

With Top & Bottom Needle Brg. Lower Unit Removal

and Ctr. Babbitt Brg. Water Pump Removal

With All Babbitt Main Brgs. Lower Unit Disassembling

Crankshaft Installation Babbitt Cleaning and Inspecting

Main and Rod Bearings Lower Unit Assembling

Crankcase Cover Installation Water Pump Installation

Main Bearing Bolt and Crankcase Lower Unit Installation

Side Bolt Instl. Functional Check

Bottom Seal Installation PROPELLER EXHAUST

Reed Box Installation MECHANICAL SHIFT 9.9 HP

Head Installation 1974 & on15 HP 1974 & on

BREAK-IN PROCEDURES Description

TYPE IV CARBURETOR Troubleshooting

Removal Lower Unit Removal

Disassembling Cleaning and Water Pump Removal

Inspecting Assembling Installation Lower Unit Disassembling

FUEL PUMP SERVICE Cleaning and Inspecting

Removal and Installation Lower Unit Assembling

Cleaning and Inspecting Water Pump Installation

FUEL TANK SERVICE Lower Unit Installation

ELECTRIC PRIMER CHOKE Functional Check

MANUAL PRIMER CHOKE 30 HP 1981 & on

OIL INJECTION SYSTEMS Description

VRO Oil Inject. Troubleshooting

AccuMix (AutoBlend) Lower Unit Removal

5 IGNITION Water Pump Removal

INTRODUCTION Lower Unit Disassembling

SPARK PLUG EVALUATION Cleaning and Inspecting

POLARITY CHECK Lower Unit Assembling

WIRING HARNESS Water Pump Installation

FLYWHEEL MAGNETO IGNITION 1.25 hp Lower Unit Installation

1987 &on 2 hp- 1986 2.5 hp Functional Check

1987 on 4 hp-1984 6 hp – 1976 ELECTRIC SHIFT

9.5 hp-19773 18 hp – 19773 20 hp TWO SOLENOIDS

1971 -72 25 hp – 1972 40 hp-1973 50 HP 1977

TROUBLESHOOTING Description

Wiring Harness Troubleshooting

Key Switch Lower Unit Removal

Compression Water Pump Removal

Condenser Frozen Propeller Shaft

Breaker Points Cleaning and Inspecting

SERVICING FLYWHEEL MAGNETO Lower Unit Assembling

IGNITION SYSTEM Water Pump Installation

Removal Lower Unit Installation

Cleaning and Inspecting Functional Check

Assembling MECHANICAL SHIFT

4 FUEL HYDRAULIC ASSIST

INTRODUCTION SHIFT DISCONNECT UNDER

GENERAL CARBURETION LOWER CARBURETOR

INFORMATION 50 HP 1977

FUEL SYSTEM Description

TROUBLESHOOTING Trouble shoot ing

Fuel Pump Tests Lower Unit Removal

Fuel Line Test Water Pump Removal

Rough Engine Idle Frozen Propeller Shaft

Excessive Fuel Consumption Cleaning and Inspecting

Engine Surge Lower Unit Assembling

JOHNSON/EVINRUDE Water Pump Installation

CARBURETORS Lower Unit Installation

TYPE I CARBURETOR Functional Check 171

Removal MECHANICAL SHIFT

Disassembling SHIFT DISCONNECT UNDER

Cleaning and Inspecting LOWER CARBURETOR

Assembling 40 HP 1977 & on

Installation 50 HP 1977

CHOKE SYSTEM SERVICE 50 HP 1975 and 1980 & on

ALL ELECTRIC CHOKE REMOVAL 55 HP 1978

TYPE II CARBURETOR 60 HP 1980 & on

Disassembling Description

Cleaning and Inspecting Troubleshooting

Assembling LOWER UNIT (CONT)

Adjustments Lower Unit Removal

TYPE III CARBURETOR Water Pump Removal

Removal Frozen Propeller Shaft

Disassembling Cleaning and Inspecting

Cleaning and Inspecting Lower Unit Assembling

Assembling Water Pump Installation

Installation Lower Unit Installation

Flywheel Removal FROZEN PROPELLER

Armature Plate Removal Starter Disassembling

Armature Plate Installation Cleaning and Inspecting

Charge or Sensor Coil Removal Assembling

Charge or Sensor Coil Installation

Installation Adjustment

Charge or Sensor Coil TYPE V MOUNTED ATOP

Adjustment FLYWHEEL WITH NO

Flywheel Installation RETURN SPRINGS

Power Pack Replacement 40 HP- 1977 & 1988

Timing Check Adjustment Removal

SYNCHRONIZATION FUEL Cleaning and Inspecting

AND IGNITION SYSTEMS Assembling

Primary Pickup Adjustments Rope Installation

and Locations Starter Installation

The No. A Location TYPE VI MOUNTED ATOP FLYWHEEL

The No. B Location WITH ONE OR TWO NYLON PAWLS

The No. C Location COLT, JUNIOR,

The No. D Location & ULTRA 1986 & on 2 HP 19785 2.5 HP

The No. E Location 1987 & on 4 HP 1980 & on 18 HP

6 ELECTRICAL 1973 20 HP 1977, 1985 & on 25 HP

INTRODUCTION 1971 & on 35 HP 1978

BATTERIES Starter Removal

Marine Batteries Disassembling

Battery Construction Cleaning and Inspecting

Battery Ratings Starter Assembling

Battery Location Rope Installation

Battery Service Starter Installation

Jumper Cables TYPE VII MOUNTED ATOP FLYWHEEL

Storage WITH LARGE PAWL PLATE

Dual Battery Installation Starter Removal

GAUGES AND HORNS Disassembling

Constant Voltage System Cleaning and Inspecting

Temperature Gauges Starter Assembling

Warning Lights Starter Installation

Thermomelt Sticks 9 HAND STARTERS

FUEL SYSTEM INTRODUCTION

Fuel Gauge Emergency Starting

Fuel Gauge Hookup TYPE I STARTER

Fuel Gauge Troubleshooting CYLINDER WITH PINION GEAR All

TACHOMETER ]HP All 6 HP All 7.5 HP All 8 HP

HORNS Starter Rope Replacement

ELECTRICAL SYSTEM Removal

GENERAL INFORMATION Installation

GENERATING CHARGING Starter Removal

CIRCUIT SERVICE Disassembling

Troubleshooting Cleaning and Inspecting

Removal and Disassembling Assembling

Armature Testing TYPE II STARTER

Cleaning and Inspecting CYLINDER WITH PINION GEAR

Assembling All 9.5 HP

LOW TENSION FLYWHEEL Rope Removal

MAGNETO IGNITION SYSTEM Rope Installation

9.9 hp – 1976 Starter Removal

15 hp-1976 Cleaning and Inspecting

18 hp- 1973 Assembling

1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP – 1973 Installation

1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP – 19776 TYPE III STARTER

35 hp – 1976 COIL SPRING WITH SWING ARM

1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP – 1976 VERTICAL MOUNT 4 HP 19778

hp Comm. – 1983 4 HP DELUX 1982 & on 4.5 HP

Description 1980-84

Theory of Operation Removal

Troubleshooting Disassembling

Removal Cleaning and Inspecting

Cleaning and Inspecting Assembling

Assembling TYPE IV STARTER

COIL SPRING WITH SLIDING GEAR

TYPE I CAPACITOR DISCHARGE HORIZONTAL MOUNT

(CD) All 9.9 HP

FLYWHEEL MAGNETO WITH All 15 HP

TIMER BASE 50 hp Removal

– 1977 55 hp – 1977 Starter Rope Replacement

Description 10 POWER TRIM/TILT

Theory of Operation SYSTEM DESCRIPTION

Troubleshooting FILLING SYSTEM

Servicing TROUBLESHOOTING

Stator and Charge Coil SERVICING

Replacement ELECTRICAL MOTOR SERVICE

Timer Base and Sensor Cleaning & Inspecting

Assembly Replacement Testing

Power Pack Replacement II MAINTENANCE

Timing Check and Adjustment INTRODUCTION

TYPE II CD FLYWHEEL MAGNETO IGNITION ENGINE SERIAL NUMBERS

WITH SENSOR COIL 2.5 hp 1987 & on FIBERGLASS HULLS

4 hp Dlx. 1984 & on 4.5 hp-1980-85 ALUMINUM HULLS

5 hp – 1985 BELOW WATERLINE SERVICE

6 hp – 1979 SUBMERGED ENGINE SERVICE

6 hp – 1982 & on WINTER STORAGE

7.5 hp -1980-85 LOWER UNIT SERVICE

8 hp 1984 &on Propellers

9.9 hp 1977 & on BATTERY STORAGE

15 hp- 1977 & on PRESEASON PREPARATION

20 hp – 1981 & on APPENDIX

25 hp – 1977 & on METRIC CONVERSION CHART

30 hp 1985 & on DRILL SIZE CONVERSION CHART

35 hp – 19784 TORQUE SPECIFICATIONS

40 hp 1984 & on TUNE-UP SPECIFICATIONS 4 to 17

50 hp – 1978 & on POWERHEAD SPECIFICATIONS

55 hp – 1983 OIL/FUEL MIXTURE

60 hp – 1980-85 GEAR OIL CAPACITIES

Description STARTER MOTOR SPECS.

Theory of Operation REGULATOR SPECIFICATIONS

Troubleshooting GENERATOR SPECIFICATIONS

Checking Type II System CONDENSER SPECIFICATIONS

PUSHBUTTON TYPE SHIFT BOX STARTER ROPE SPECIFICATIONS

SERVICE – EVINRUDE ONLY WIRE IDENTIFICATION DRAWINGS

Troubleshooting Typical I-cylinder pwhd.

Disassembling 2.5 hp, Excel, Ultra, & 4 hp

Cleaning and Inspecting -1984 & on

Assembling 4 Delux thru 55 hp w/CD 2ign.,

SINGLE-LEVER REMOTE w/manual start

CONTROL SHIFT BOX Also models equipped

Troubleshooting with A.C. lighting

Disassembling 9.9 hp and 15 hp

Assembling w / electrlc start – 1976

SHIFT BOX REPAIR 9.9 hp and 15 hp

Disassembling w/electrlc start – 1978

Cleaning and Inspecting 9.9 hp and 15 hp

Assembling w/electric start 1986 & on 27

CABLE END FITTING INSTALLATION I8 hp, 20 hp, & 25 hp

AT THE ENGINE END w / electric start – 1971 -7 2

FOR ALL SHIFT BOXES EXCEPT SINGLE 28 18 hp, 20hp,& 25 hp

LEVER REMOTE CONTROL w/electric start – 1976

8 LOWER UNIT 35 hp w/electric start – 1976

DESCRIPTION 25 hp and 35 hp-19778

Chapter Coverage 20 hp thru 90 hp w/std. shift

Illustrations & w/electric start 19783

PROPELLER SERVICE 40 hp w/generator, w/std. shift

Propeller with Shear Pin & w/electric start 1973

Removal 40 hp w/alternator, w/std. shift

Exhaust Propeller & w/electrlc start – 1976

Removal 30 hp w / alternator

Propeller with Shear Pin 4 w/electric start – 1972

Installation 50 hp w/alternator

Exhaust Propeller Installation & w/electrlc start – 1977

LOWER UNIT LUBRICATIN Also 55 hp with no

Draining thermo switch 1977

Filling 50 hp w/manual Start 1980-83

NO SHIFT LOWER UNIT SERVICE 55 hp w/electric start – 1977

1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP

Description w/electric start 1978

Troubleshooting 50 hp – 1979, 55 hp – 1983,

Removal & 60 hp – 1980-81

Water Pump Removal all w/electric start

Lower Unit Disassembling 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP

Cleaning and Inspecting 1.5 2 3 4 5 6 9.5 9.9 15 18 25 33 35 HP

FULL VALUE FOR MONEY! GET YOUR REPAIRS DONE BY TODAY !!

Tags: * best * 1965 – 1978 evinrude johnson outboard 1.5 – 35 hp service | repair manual ( 65 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 78 ) download !, evinrude johnson outboard 1965 1966 1967 1968 1969 1970 1971 1972 1973 1974 1975 1976 1977 1978

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