1996 Johnson Evinrude "ED" 60 LV 90, 115, 150, 150C, 175 Service Repair Manual, P/N 507127

& Safety Warning

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

e Injure yourself or people around you elnjure the boat operator, boat passengers, or people around the boat

e Damage the outboard or its systems

Understand the following symbols before proceeding:

& Safety Warning

Important

Alerts you to the possibility of danger and identifies information that will help prevent injuries.

Identifies information that will help prevent damage to machinery.

Appears next to information that controls correct assembly and operation of the product.

This Service Manual is written for qualified, factorytrained service technicians familiar with the use of CIVIC Service Tools.

This Service Manual tells you how to correctly maintain and service the outboard and its systems. When correctly serviced, the outboard will be reliable and safe to operate.

When CIVIC Service Tools are called for, use them. Where mentioned, the tools are required to perform the service procedure.

If you use procedures or service tools that are not recommended in this manual, YOU ALONE must decide if your actions might injure people or damage the outboard.

Outboard Models Covered in This Service Manual

90 Models

E90ELED J90ELED

E90EXED J90EXED

E90SLED J90SLED

115 Models

E115ELED L115GLED J115ELED

E115GLED J115GLED

E115SLED J115SLED

E115SXED J115SXED

150 Models

E150ELED L 150GLED J150ELED

E150EXED J150EXED

E150NXED J150NXED

E150GLED J150GLED

E150JLED J150JLED

E150CXED J150CXED

E150SLED J150SLED

150 Comm. Models

150WTLD

150WTXD

150WTPLB

150WTPXB

150WCLD

175 Models

E175EXED J175EXED

E175GLED J175GLED

E175NXED J175NXED

E175CXED J175CXED

E175SLED J175SLED

General Information

Table of Contents

Carburetor Orifice Plug Chart.

Heli-Coillnserts and Installers

In General Safety Warnings

Before working on any part of the outboard, read the section called Safety at the end of this manual.

When replacement parts are required, use genuine OMC parts or parts with equivalent characteristics including type, strength, and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers.

To prevent possible eye injury, always wear SAFETY GLASSES while servicing the unit.

Always read and follow safety related precautions found on containers of hazardous substances like parts cleaners, primers, sealants, and sealant removers.

The timing wheel cover is a machinery guard. Use caution when conducting tests on running engines. Do not wear jewelry or loose clothing. Keep hair, hands, and clothing away from rotating parts.

Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak. Definite resistance to tightening must be felt when reusing a locking fastener. If replacement is indicated, use only authorized replacement or equivalent.

Service Specifications

Standard Torque Chart _____________________________

INotel These values apply only when a special torque for a specific fastener is not listed in the Special Torque Chart found at the beginning of each section.

INote I When tightening two or more screws on the same part, do not tighten screws completely, one at a time. To avoid distortion of the part, tighten all screws in sequence to one-third of torque value, then tighten to two-thirds of torque value, then tighten to full torque value.

Sealants and Lubricants Required __________________________

OMC Ultra-HPF ™Gearcase Lube

OMC Triple-Guard @Grease

Evinrude @Outboard Lubricant

Johnson @Outboard Lubricant

OMC 2+4 @Fuel Conditioner

OMC Carbon Guard ™ Fuel Additive

OMC Storage Fogging Oil

OMC Engine Tuner

OMC Electrical Grease

PCE0023

Introduction

This manual covers service information on all 60° V loopscavenged models.

Use this manual together with the proper Parts Catalog for part numbers and for exploded views which are a valuable aid to disassembly and reassembly.

This manual presents the English values and dimensions first and the metric values and dimensions second, inside parentheses ( ).

Good Service Practice

Service required for OMCengines is generally one ofthree kinds:

• Normal care and maintenance - which includes putting a new engine into operation, storing engines, lubrication, and care under special operating conditions such as salt water and cold weather. This includes engine servicing procedures to keep the engine in prime operating condition.

• Operating malfunctions - due to improper engine mounting, propeller condition or size, boat condition, or the malfunction of some part of the engine.

• Complete disassembly and overhaul - such as major service or rebuilding a unit.

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

When repairing a component, the most reliable way to ensure a good job is to do a complete overhaul on that component, rather than just replacing the bad part. Wear not readily apparent on other parts could cause malfunction soon after the repair job. Repair kits and overhaul kits contain all the parts needed to ensure a complete repair, to eliminate guesswork, and to save time.

Repair time can also be minimized by the use of special tools. OMC special tools speed repair work so it can be done within flat rate time. In some cases, the use of substitute tools can damage the part.

\Notel Do not operate engine out of water, even momentarily. If operated in test tank, use proper test wheel. Failure to do so can result in damage to water pump and engine overheating!

Arrangement of Service Manual

This Service Manual includes the specific information you will need to service Evinrude @and Johnson @ engines. All general procedures are covered in abbreviated form, mostly by reference to procedural illustrations. The specific procedures which apply to this engine are covered in fully-illustrated, detailed, step-bystep instructions.

Each of the manual sections contains detailed instructions for disassembly, inspection, assembly, testing , and operating adjustments ofthe various engine systems. These procedures will help you service a specific system or completely overhaul the outboard.

Product Reference and Illustrations

Outboard Marine Corporation reserves the right to make changes at any time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change any specifications or parts, at any time, without incurring any obligation to equip same on models manufactured prior to date of such change. Specifications used are based on the latest product information available at the time of publication .

The continuing accuracy of this manual cannot be guaranteed.

All photographs and illustrations used in this manual may not depict actual models or equipment, but are intended as representative views for reference only.

Certain features or systems discussed in this manual might not be found on all models in all marketing areas .

When servicing an outboard which is within its normal warranty period or covered by the OMC Extend™ Service Contract, make repairs using only genuine OMC replacement components or parts.

If OMC genuine replacement components or parts are not used, OMC might refuse subsequent warranty claims involving that engine.

& When replacement parts are required, use genuine OMC parts or parts with equivalent characteristics, including type, strength, and material. Failure to do so may result in product malfunction and possible injury to the operator and/or passengers.

When reference is made to a brand name product or specific tool , an equivalent product may be used in place of the referenced product. Substitute products used must have equivalent characteristics, including type, strength, and material. You must determine if incorrect substitution could result in product malfunction and possible injury to the operator and/or passengers.

Whether within or following the warranty period, OMC has a constant interest in its products. It is OMC's policy to provide dealers with service information so they can give the professional service demanded by today's consumer. The OMC Training Centers, frequent mailings of Service Bulletins and Advisories, OMC Special Tools, and this Service Manual represent some of OMC's efforts to assist dealers in giving consumers the best service possible.

The Service Manual covers all phases of servicing outboards. However, new situations sometimes arise in servicing an engine. If a service question does not appear to be answered in this manual, you are invited to write to the Service Department for additional help. Always be sure to give complete information, including engine model number and serial number.

Be sure that you are familiar with OMC warranty policies.

Special Service Tools

OMC has specially designed tools to simplify some of the disassembly and assembly operations These tools are illustrated in this Service Manual, in many cases in actual use. Refer to the OMC Special Tool Guide for a description and ordering instructions for these tools. Individual purchasers of Service Manuals must order Special Tools through an authorized dealer

Outboard Engine Nomenclature

Sometimes the words "right" and "left" are very confusing when referring to the sides of an outboard Therefore, the sides are referred STARBOARD means on the right PORT means left.

Symbols

Throughout this service manual, symbols are used to interpret electrical troubleshooting results or to assign values in drawings.

Electrical

OJ This symbol indicates continuity or very low resistance.

rn This symbol indicates no continuity or very high resistance.

Use an ohmmeter calibrated on high ohms scale, or a continuity light, to test continuity.

rn When "00" shows on the meter face, no continuity, or very high resistance, is indicated. The symbol is referred to as infinity.

W When "V" follows a value on the meter face, the procedure is measuring voltage.

rn When lin" follows a value on the meter face, the procedure is measuring resistance. 0. is the symbol for ohm, the unit of measurement for resistance.

Values

[]] When liS" precedes a value on the meter face, it indicates your reading should be less than, or equal to, the value shown.

rn When "?!" precedes a value on the meter face, it indicates your reading should be greater than, or equal to, the value shown.

4

Opera

Full Throttle Operating Range

Power

Power Rated @

Idle RPM in Gear

Test Propeller

Minimum Test RPM Weight

Engine Specifications

90, 115 EL, SL, SX - 4500 to 5500 RPM

115 GL - 5000 to 6000 RPM

90 - 90 HP (67,2 kw)

115 - 115 HP (85,8 kw)

90, 115 EL, SL, SX - 5000 RPM

115 GL - 5500 RPM

See Page 1-33

OMC PI N 382861

115SX - 387388

90 - 4500

115 - 4800

EL, GL, SL - 319 Ibs. (145 kg)

EX, SX - 336 Ibs. (152 kg)

Power he a d ________________________________

Type

Displacement

Bore

Stroke

Standard Bore *

Crankshaft Dimensions:

Top Journal

Center Journal

Bottom Journal

Rod Crankpin

Piston Ring End Gap, Both

60 ° V, 4-Cylinder

105.4 cu. in (1726 cm 3 )

3.600 in. (91,44 mm)

2.588 in. (65,74 mm)

3.5995 -3 .6005 in. (91,43-91,45 mm)

2.1870-2.1875 in. (55,55 - 55,56 mm)

2.1870-2.1875 in. (55,55-55,56 mm)

1.5747-1 .5752 in. (40,0-40,01 mm)

1.3757-1 3762 in (34,94-34,96 mm)

0.011 -0 023 in. (0,28-0 , 58 mm)

* To bore oversize, add piston oversize dimension to standard bore.

Gearcase ....................................................................

Gear Ratio

Lubricant Capacity

Shift Rod Height, L Models

Shift Rod Height, X Models

Shift Cable Stroke

Ignition System

Type

Firing Order

Ignition Features

Power Pack RPM limit Models 90 115

EL, GL, SL - 13:26 (.500)

EX, SX - 12:27 (.44)

0I'v'K: Ultra-HPF Gearcase Lube

EL, GL, SL - 26 flo oz. (770 ml)

EX, SX - 33 flo oz. (980 ml)

21114 ± 1/32 in. (539,8 ± 0,8 mm)

26114 ± 1/32 in. (666,8 ± 0,8 mm)

See Page 6-4

Magneto Powered Capacitor Discharge

1-2-3-4

5.L.0. W. ™and Quik5tart™ 6400

Spark Plug, Champion CD

Recommended Extended Idle

OL82YC@

OL87YC @ 0.030 in. (0,8 mm) 0.030 in. (0,8 mm)

CD Use of non-suppression spark plugs will cause ignition problems.

Electrical System

Battery, Minimum Recommendation

Alternator

Tachometer Setting

Engine Fuse (20 Amp)

Warning Signals

Fuel System

Fuel/Oil Ratio

Fuel Requirements

Carburetion

Calibration

In itia I Low-speed Setti ng ®

Starting Enrichment

Carburetor Float Level Setting

Carburetor Float Drop Setting

Vapor

Vapor

12-Volt, 360 CCA (465 MCA) with 90 Minutes Reserve Capacity (50 Ampere-Hours)

20-Amp, Fully Regulated

6

0I'v'K: PI N 514021

No Oil, Low Oil, Water Temperature

See Page 1-14

See Page 1-16

Two Dual-Throat Carburetors

Adjustable low speed, fixed intermediate and high speed

5% Turns

Electric Primer Solenoid

Level with gasket surface ± 0.03 in. (0,8 mm), chamber inverted 11/ 16 -1% in . (17-28 mm)

-Parallel with Separator Body 1114-111/32 in. (32-34 mm)

® Adjustment.

Engine Specifications

150, 175

Operation ________________________________

Full Throttle Operating Range

Power

Power Rated @

Idle RPM in Gear

Test Propeller

Minimum Test RPM

Weight

Powerhead

Type

Displacement

Bore Stroke

Standard Bore*

Crankshaft Dimensions:

Top Journal

Center Journals

Bottom Journal

Rod Crankpin

Piston Ring End Gap , Both

Gearcase

Gear Ratio

Lubricant Capacity

4500 to 5500 RPM

150 - 150 HP (112 kw)

175 - 175 HP (131 kw)

5000 RPM

See Page 1-33

OMC PI N 387388

150NX, ex; 175NX, ex - OMC PI N 398673

150 - 4500

175 - 4800

150L, 175L - 370 Ibs. (168 kg)

150X, 175X - 375 Ibs. (170 kg)

60° V, 6-Cylinder

158 cu. in. (2589 cm 3 )

3.600 in. (91,44 mm)

2.588 in. (65,74 mm)

3.5995-3.6005 in . (91,43-91,45 mm)

2.1870-2.1875 in. (55,55-55,56 mm)

2.1870-2.1875 in. (55,55-55,56 mm)

1.5747-1.5752 in. (40,0-40,01 mm)

1.3757-1.3762 in. (34,94-34,96 mm)

0.011 -0.023 in. (0,28-0,58 mm)

14:26 (.540)

OMC Ultra-HPF Gearcase Lube

33 fl. oz. (980 ml)

* dimension to standard bore.