1985 Johnson/Evinrude 2 thru V-6 models service repair manual - final edition P/N 507508

&SAFETY WARNING

This Service Manual will alert you to certain procedures that should done very carefully. If you ignore this information, you could ...

• Injure yourself or bystanders

• Injure the boat operator, passengers or bystanders

• Damage the outboard or its accessories

& This safety symbol appears next to information that, if ignored, could result in injury to you or others.

INotel This information symbol appears next to information that, if ignored, could result in damage to the outboard or its accessories.

This Service Manual tells you how to correctly maintain and service the outboard and its accessories. When correctly serviced, the outboard and its accessories will reliabIe and safe to use.

When special service tools are called for, use them. Special tools are MUST to ' do the job correctly.

If you use service procedures or tools that are recommended YOU ALONE must decide if your actions might injure people or damage the outboard or its accessories.

Recreat iona l Outboard Service Manual 2 thru

V-6 Models

Section 1 - General Information

of Contents

After Storing - Before Using 1-56

Arrangement of Service Manual 1-6

Break - In ..... ....

1-47

Carburetor Orifice Plug Reference Chart 1-51

Checking Propeller Hub Slippage - 4 Deluxe thru 30 1-50

Dr i ll Size Conversion Chart 1-53 Engine Fuel and Lubricant . . .......... ... 1-44

Gearcase Lubrication - 2 1-25

Gearcase Lubrication - 4 thru V-6 1-25

General Specifications 1-24 Good Service Practice 1-6 Heli-Coil ® Inserts and Installers 1-60 I ntroduction 1-6 Lubrication 1-24

Lubrication Chart - 2 and 4 . 1-26

Lubrication Chart - 4 Deluxe, 4 5, 5, 6 and 8 . ...

. ......... . 1-28

Lubrication Chart - 9.9 and 15 . . . 1-30

Lubrication Chart - 20, 25 and 30 ... . . . ... 1-32

Lubrication Chart - 40, 50 and 60 (Remote Control Models) 1-34

Lubrication Chart - 40 Rope, 45CR and 55CR . 1-36

Lubrication Chart - 70 and 75 1-38

Lu brication Chart - 90, 115 and V -6 1-40

Lu brication Chart - 120 and 140 1-42

New Motor Preparation . ......... . . ..... 1-62

Off-Season Storage ..................... 1-54

Outooard Models Covered in This Service Manual 1-2 , 1-3, 1-4

Outboard Motor Nomenclature . 1-8

Parts Catalog 1-7

Trim and Tilt Reservoir

Remote Control Warning Test (At Control) ' -57

Parts and Product Reference '-7

Policy

Service Tools .......

1-7 Spec ifica tions - 2 and 4 1-1 1-11 Sp ec ifications - 4 Deluxe thru 8 1-12,1 - 13

Spe c ifications -9 9 and 15 1-14,1-15 Specifications - 20 thru 30 ,. 1-16,1 - 17

Specifications - 40 thru 75 1-18, 1-19

Specifications - 90, 115 and V-6 1-20, 1-21

Specifications - 120 and 140 1-22, 1-23

Steering System Lubrication - Remote lectric Models 1-25

Submerged Motors 1-58

Synchronization and Linkage Adjustments2 thru 15 Models 1-64

Synchronization and Linkage Adjustments20 thru 30 Models . .. . . .. ..... . ... . ... 1-68

Synchronization and Linkage Adjustments40 and 50R and Models 1-70

Synchronization and Linkage Adjustmentsthru V6 (Except 120, 140 Models) 1-74

Synchronization and Linkage Adjustments120 and 140 Models 1-82

Testing Anti-Corrosion Anodes - AII Models .. 1-47

TroubIe Check Chart 1-88' 1-89, 1-90

Tune-Up Procedure 1-61

Weather, Altitude and Engine Performance " ' -63

E4BRLCO

E4RDCO

E4RDLCO

Outboard Models Covered

2 thru V-6 Models

2 Models

4 Models

J2RCO

J4BRCO J4BRHCO

E4BRHLCO J4BRLCO J4BRHLCO

4 Deluxe Models

E4RDHCO J4RDCO J4RDHCO

E4RDHLCO J4RDLCO J4RDHLCO

5 Models

J5RHCO

E5BFCO J5BFCO

E5BFLCO

E6BALCO

6 Models J5BFLCO

J6BACO J6RCO

E6RLCO J6BALCO J6RLCO

E6BFCO E6SLCO J6BFCO J6SLCO

E6BFLCO J6BFLCO

8 Models

E8BALCO

E8RLCO

J8RCO J8BALCO

E8SRLCO J8RLCO J8SRLCO

J8BACO

9.9 Models

E10BALCO J10RCO J1OBALCO

E10RLCO E10SELCO J10RLCO J1OSELCO J10BACO J1OECO

E1OELCO J10ELCO

15 Models

E15RCO

E15ELCO J15RCO J15ELCO

E15RLCO J15RLCO J15BACO

E15BALCO J15ECO J15BALCO

20 Models

E25BFCO J20CRCO J25BFCO

E20CRLCO

E25BFLCO J20CRLCO J25BFLCO

E20BICO J20ECO J20BICO J20ELCO J20BfLCO

J25BECO J25BELCO

J20BFCO

J20BFLCO

Outboard Models Covered in This Service Manual

2 thru V-6 Models

25 Models

J25RCO J25TECO

E25RLCO E25TELCO J25RLCO J25TELCO

J25BACO J25ECO

E25BALCO E25ELCO J25BALCO J25ELCO

30 Models

J30RCO J30BACO

E30RLCO E30BALCO J30RLCO J30BALCO J30ECO J30TECO

E30ELCO E30TELCO J30ELCO J30TELCO

40 Models

J40RCO J40ECO

E40RLCO E40ELCO J40RLCO J40ELCO J40BACO J40TECO

E40BALCO E40TELCO J40BALCO J40TELCO

50 Models

E50TELCO J50BECO J50TELCO

E50BELCO E50TLCO J50BELCO J50TLCO

60 Models

J60ECO

E60ELCO J60ELCO E60TLCO J60TLCO

70 Models

E70ELCO J70ELCO E70TLCO J70TLCO

75 Models

E75ELCO J75ELCO J75ECO E75TLCO J75TLCO

2 thru Models

90 Models

E90MLCO

E90TLCO

E115MLCO

E115TLCO

E120TLCO

E140TLCO

E150STLCO

E150TLCO

E150ANCO

E175TLCO

E185TLCO

E235TLCO

E235STLCO

J90MLCO

J90TLCO

J90TXCO

115 Models

J115MLCO

J115TLCO

120 Models

J120TLCO

J120TXCO

140 Models

J140TLCO

J140TXCO

Models

J150TLCO

J150TXCO

J150STLCO

J175TLCO

J175TXCO

J185TLCO

J185TXCO

J235TLCO

J235TXCO

J235STLCO

Introduction

This manual covers Service 1nformation current models 2 thru V-6. Much of the information also applies to previous models.

Use this manual together with the Parts Catalog for part numbers and for exploded views which valuabIe aid to disassembIy and reassembIy.

This manual presents the metric dimension first and the English dimension in parentheses ( ). When referring to the metric dimension, is used to represent decimal point which is standard printing practice in Europe.

Good Service Practice

When repairing component, the most reliabIe way to assure good job is to do complete overhaul that component, rather than just replacing the bad part. Wear not readily apparent other parts could cause malfunction soon after the repair job. Repair kits and overhau 1 kits contain the parts needed to assure complete repair, to eliminate guesswork, and to save time. Repair time also minimized the use of special tools. special tools speed repair work so it done within flat rate time. 1n some cases the use of substitute tools actually damage the part.

•

• prevent possibIe injury always wear SAFETY GLASSES while servicing motor. When testing adjusting running engine with the motor cover removed: keep hands, hair, and clothing away from rotating flywheel do not touch electrical system parts. Reaction to electrical shock could result in contact with rotating flywheel.

• Refer to solvent manufacturer's caution regarding use and storage of solvent.

fN=t;1 00 not operate motor out of water even momentarily. If operated in test tank use test wheel. Failure to do so result in damage to water pump and motor overheating.

Arrangement of Service Manual

This Service Manual includes the specific information you will need to service Outboards. general procedures covered in abbreviated form mostly reference to procedural illustrations. The specific procedures wh ich apply only, primarily, to each motor covered in fully-illustrated, detailed, step-by-step instructions as required.

The General Service Information section will help you diagnose malfunctioning outboard. It includes specifications and lubrication procedures. Clearances and torque values also included for quick reference during servicing operations. Each of the following sections, Fuel System, Ignition System, Powerhead, Mid-Section, Gearcase, Manual Starter, Electrical System, Tilt, gives detailed instrucreassembIy, and operating procedures will help you completely overhaul the models.

Parts Catalog

The Parts Catalogs contain exploded views illustrating the correct sequence of all parts as well as complete listing of the parts for replacement. This catalog of considerabIe help as reference during disassembIy and reassembIy. Use the current Parts Catalog for the specific model outboard you working as you use this Service Manual.

Replacement Parts and Product Reference

'" When replacement part5 are required, use genuine ill parts or part5 with equivalent characteristic5 including type, 5trength, and material. Failure to do 50 result in product malfunction and p055ibIe injury to the operator and/or passenger5.

When reference is made to brand product specific tool, equivalent product used in place of the referenced product . Substitute products used must have equivalent characteristics, including type, strength, and material. Incorrect substitution result in product malfunction and possibIe injury to the operator and/or passengers.

AII photographs and illustrations used not necessarily depict actual models equipment, but intended only for reference Specifications used based the latest product information availabIe at the time of pubIication.

Service Policy

Whether within following the warranty period, has constant interest in its products.

It is OMC's policy to provide dealers with service knowledge so they give professional service demanded today's sumer. The Training Centers, frequent mailings of Service Bulletins, Letters and Promotions, Special Tools and this Service Manual represent OMC'S efforts to assist dealers in giving sumers the best and most prompt service possibIe. The Service Manual covers all phases of servicing motors. However, new situations sometimes arise in servicing motor. 1f service question does not to answered in this manual, you invited to write to the Service Department for additional help Always sure to give complete information, including motor model number and serial number. sure that you familiar with the Warranty.

Special Service Tools

has specially-designed tools to simplify some of the disassembIy and reassembIy operations. These tools illustrated in this Service Manual, in cases in actual use. Refer to the Special Tool Catalog for description and ordering instructions for these tools. 1ndividual purchasers of Service Manuals authorized dealer.

Outboard Motor Nomenclature

Sometimes the words "right" and "Ieft" very confusing when referring to the sides of outboard motor. Therefore, the sides referrea to as STARBOARD PORT sides. STARBOARD means the right hand while facing the bow (F of the boat; PORT means left hand.

Service required for motors is generally of three kinds

1. Normal and Maintenance - which includes putting new motor into operation, storing motors, lubrication, and under special operating conditions such as salt water and cold weather.

2. Operating Malfunctions - due to improper motor mounting, propeller condition size, boat condition, the malfunction of some of the motor. This includes motor tune·up procedures to keep the motor in prime operating condition.

3. Complete DisassembIy and Overhaul - such as inspecting motor that has submerged, rebuilding trade·in units.

It is important to you as the service person to determine before disassembIy just what the troubIe is, and how to correct it quickly and with minimum expense to the owner.

determine size for oversize pistons, add oversize dimension to standard size

Ignit ion Syste m

Fuel System

Clearance Chart Powerhead

Torque Chart

Powerhead

Fuel System

Clearance Chart

Torque Chart

Powerhead

Gearcase

Mounting Screws

determine correct size for oversize pistons, add over size dimen sion to standard

Ignition System

determine size for overs i ze pistons, add oversize dimension to standard size.

System