1998 Johnson Evinrude EC 50 thru 70 HP 3-Cylinder Service Repair Manual P/N 520208

Outboards covered this Service Manual designed, built, and equipped to comply with applicabIe regulations of the U.S. Environmental Protection Agency estabIished under the Federal Clean Air Act. The regulations affect the way you maintain and repair these outboards, particularly in the areas of emission-related components and their adjustments.

After you have serviced the outboard, it must continue to comply with the same regulations it was manufactured under. Therefore, if emissionrelated component these outboards requires repair, replacement, adjustment, you must use parts and repair procedures that meet specifications. Use this Service Manual as reference for repair procedures.

The regulations provide significant civil penalties for tampering that causes the engine to longer meet U.S. emission standards. Tampering include improper repair, replacement, adjustment of emission-related components.

& Safety Warning

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

• Injure yourself or people around you

• Injure the boat operator, boat passengers, or people around the boat

• 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

Identifies information that will help prevent damage to machinery.

Appears next to information that controls rect assembIy and operation of the product.

This Service Manual is written for qualified, factory-trained service technicians familiar with the use of Q\IIC Service Tools.

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

for, use them. Where mentioned, the tools required

tools that are not recommended in this manual, YOU might iniure people or damage the outboard.

Service Manual Title

50 Models

E50DTLEC

E50TTLEC

J50DTLEC

J50TTLEC

60 Models

E60TLEC

E60TTLEC

65 Models

65RSLD

65RSYD

65WMLD

65WMYD

70 Models

E70ELEC

E70TLEC

J60TLEC

J60TTLEC

J70ELEC

J70TLEC

General Information

of Contents

& General Safety Warnings

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

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

prevent possibIe injury, always wear SAFETY GLASSES while servicing the unit.

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

The engine cover is machinery guard. Use caution when conducting tests running engines. Do not wear jewelry or loose clothing. hair, hands, and clothing away from rotating flywheel.

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

Service Specifications

Standard Torque Chart ____________________________

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

INotel When tightening two screws the same part, do not tighten screws completely, at time. avoid distortion, first tighten all screws in sequence to one-third of torque value, then tighten to two-thirds of torque value, then tighten to full value

Sealants and Lubricants Required ________________________

U1tra-HPF ™Gearcase Lube Grease

Evinrude Outboard Lubricant

Johnson Outboard Lubricant

Guard Fuel Additive

2 + 4 @Fuel Conditioner

Storage Fogging Oil

Starter Pinion Lube

Engine Electrical Grease

Introduction

This manual covers service information 56.1 cU.in. (913 models. Some of the information might apply to previous models.

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

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

Good Service Practice

Service required for 0fIIIC engines is generally of three kinds:

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

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

• Complete disassembIy and overhaul - such as major service rebuilding unit.

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

When repairing component, the most reliabIe way to 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 overhaul kits contain the parts needed to 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 some cases, the use of substitute tools damage the part.

/Notel 00 not operate engine out of water, even momentarily. If operated in test tank, use test wheel. to do so 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 and engines. AII general covered in abbreviated form, mostly reference to illustrations . The specific which apply to this engine covered in fully-illustrated, detailed, step-bystep i nstructions.

Each of the manual sections contains detailed instructions for disassembIy, inspection, assembIy, testing, and operating adjustments of the various engine systems. These will help you service specific system completely overhaul the outboard.

Product Reference and Illustrations

Outboard reserves the right to make changes at time, without notice, in specifications and models and also to discontinue models. The right is also reserved to change specifications parts, at time, without obIigation to equip same models prior to date of such change. Specifications used based the latest product information availabIe at the time of pubIication.

The continuing of this manual cannot guaranteed.

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

Certain systems discussed in this manual might not found all models in all marketing areas.

U S. Emission Information

Outboard warrants that this marine engine conforms to all applicabIe U.S. Emission Regulations . Please read the complete warranty statement in the engine's operator's manual authorized dealer will repair replace emission-related part at cost to the customer the warranty period. The customer have non-warranty service performed repair estabIishment that uses certified parts. The regulations provide significant civil penalties for tampering that causes this marine engine to longer meet U.S . standards.

If you have questions about this information the emission warranty statement, write to the U.S Engine Compliance 401 Street SW, Washington, 20460.

When servicing outboard which is within its normal warranty period make repairs using only genuine replacement ponents parts .

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

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

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 . You must determine if incorrect substitution could result in product malfunction and possibIe to the operator and/or passengers.

Whether within following the warranty period, has constant interest in its products. It is policy to provide dealers with service information so they give the professional service demanded today's consumer. The Training ters, frequent mailings of Service Bulletins and Advisories, Special Tools, and this Service Manual represent some of 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 engine. If service question does not to answered in this manual, you invited to write to the Service Department for additional help. Always to give complete information, including engine model number and serial number

that you familiar with warranty policies.

Special Service Tools

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

Outboard Engine Nomenclature

Sometimes the words "right" and "Ieft" confusing when to the sides of outboard. Therefore, the sides STARBOARD means the means left hand.

Symbols

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

Electrical

This symbol indicates continuity very low resistance

This symbol indicates continuity very high resistance.

Use ohmmeter calibrated high ohms scale , continuity light, to test continu i ty.

When " 00 " shows the meter face, continuity, very high resistance, is indicated. The symbol is referred to as infinity.

When "V " follows value the meter face, the is measuring voltage.

When follows value the meter face, the procedure is measuring resistance. n is the symbol for ohm, the unit of measurement for resistance.

Values

When "5, " precedes value the meter face, it indicates reading should less than, equal to, the value shown.

When precedes value the meter face, it indicates reading should greater than, equal to, the value shown .

Engine Specifications

50 thru 70

Operation ________________________________

Full Throttle Operating Range

Power Power Rated @

Idle RPM in Gear

Test Propeller

Minimum Test RPM

Weight:

Powerhead

50, 60, 70 - 5000 to 6000 RPM

65 - 4500 to 5500 RPM

50 - 50 HP (37,3 kw)

60 - 60 HP (44,8 kw)

65 - 65 HP (46,2 kw)

70 - 70 HP (52,5 kw)

50,60, 70 - 5500 RPM

65 - 5000 RPM

Remote Control Models - See Page 1-36

Tiller Handle Models - See Page 1-40

50 - 4600

60 - 5000 65 - 5550 70 - 5700

EL, RS, WML - 237 Ibs. (108 kg)

TL, TTL - 250 Ibs. (114 kg) - 242 Ibs. (109,8 kg)

In-line 3-Cylinder

Displacement

dimension to standard

Lubricant

Capacity

Shift Rod Height, L Models

Shift Rod Height, Models

Shift Rod Height, Models

Shift Stroke

Ignition System

Firing Order

12:29 (0.414)

U1tra-HPF Gearcase Lube 22 fl. oz. (650 ml)

See Page 6-3

Alternator

Tachometer Setting Engine Fuse Model Warning Signals 12-Volt, 360 (465 with 90 minutes Reserve Capacity 50 Fully Regulated 65 WM - Non-Regulated 6 P/ N 514021 100 Watts No Oil, Low Oil, Water Temperature

FuellOil Ratios

Fuel Requirements

Carburetion

Calibration

Initial Low-Speed Setting *

Starting Enrichment

Float Level Setting

Float Setting

See Page 1- 16

See Page 1- 18

Three Single-Throat Carburetors, Float Feed

AdjustabIe Low Speed, Fixed Intermediate and High Speed

50 - 1% Turns

60, 65, 70 - 2 3/4 Turns

Remote Electric - Electric Primer Rope, Tiller Electric - Manual Primer

OrV1C Float Gauge, P/ N 324891 in (28-41

*Refer to Section 2, Carburetor Mixture Adjustment.