1984 johnson evinrude 2 thru v 6 service manual pn 394607

Service Manual 2 thru V-6 Models Part No. 394607

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Š OUT BOAR D MAR IN E COR PORA TI ON

1983

Litho U.S.A.

OMC Recreational Outboard Service Manual 2 thru V-6 Models Section 1 - General Information Table of Contents After Stori ng - Before Usi ng . . . . . . . . . . . . . . . .. 1·74 Arrangement of Service Manual .. .. .. . . . .. . ... , 1-6 Break·ln .. .. . ........... .. ... ... .. ... . 1-62 Carburetor Orifice Plug Reference Chart . . . . . . . .. 1-65 Checking Propeller Hub Slippage - 4 Deluxe thru 35 . 1-64 Drill Size Conversion Chart . . . . . . . . . . . . . . . . .. 1-66 Engine Fuel and Lubricant . . . . . . . . . . . . . . . . .. 1-60 Engine Synchronization and Adjustments · All Models ..... . . ... ... .. ..... . ...... 1·80 Engine Synchronization and Adjustments 2 thru 15 .. .. .... . . . . . . . . . . . . . . . . . . . 1-80 Engine Synchronization and Adjustments· 20 thru 35 ......... . . . .... .... . .... . , 1-82 Engine Synchronizations and Adjustments · 40 and 50 Tiller Electric and Rope Start Models. . . . . . . 1·84 Engine Synchronization and Adjustments· 40 thru V-6 Remote Control Models. . . . . . . . . . . . 1·88 General Specifications .. .. .. .... . ... . ..... . 1-42 Good Service Practice . . ...... ..... .... . . .. 1-6 Gearcase Lubrication - 2 . . .. ..... ..... . .... 1-43 Gearcase Lubrication · 4 thru V·6 . . ... .. .... .. 1-43 Heil-Coil®lnserts and Installers .... . ... .. . . .. . 1-76 I nstallation of Remote Control Cables on Motor ... , 1-88 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Lubrication . . ... .. . ...... . . ... .. ...... , 1-42 Lubrication Chart - 2 and 4 .. . . . . . . . . . . ... .. 1-44 Lubrication Chart· 4 Deluxe, 4.5, 5,6 and 8 .. . .. , 1-46 Lubrication Chart· 9.9 and 15 ...... . . . ... .. . 1-48 Lubrication Chart· 20, 25,30 and 35 . . . . . . . . . . . 1-50 Lubrication chart· 40, 50 and 60 (Remote Control Models) ... .. .. .. .. . .... ... . . . . . . . . . . 1·52 Lubrication Chart· 40 Rope, 40TE and 50TE .. ... 1-54 Lubrication Chart - 70 and 75 . .. .. . .. ... .... , 1-56 Lubrication Chart - V-4 and V·6 . . . . . . . . . . . . .. 1-58 Motor Installation· 40thru V-6 .. ....... ..... 1-68 New Motor Preparation . . . . . . . . . . . . . . . . . . .. 1-78 Off-Season Storage . . . . . . . . . . . . . . . . . . . . . .. 1·73 Outboard Models Covered in This Service Manual .... 1-2 Outboard Motor Nomenclature . . . . . . . . . . . . . . . . 1·8 Overheat Warning Horn Test (At Control) ........ 1·75 Parts Catalog .. . . . . . . . . . . . . . . . . . . . . . . . . . . 1·7 Power Trim and Tilt Reservoir .. ... .... . . . . .. 1-42 Propeller Selection . . . . . . . . . . . . . . . . . . . . . .. 1-62 Reference Views 2 and 4 Models. . . . . . . . . . . . . . . . . . . . . . .. 1-98 4 Deluxe and 4.5 Models . .. .. ........ . ... 1-99 5,6 and 8 Models . . . . . . . . . . . . . . . . . . . . . 1-100 6 and 8 Sail Models .... .. .. .. . . .. . .... 1-101 Part No. 394607-1

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9.9 and 15 - Manual Start Models ..... . ... . _ 1-1 02 9.9 and 15 - Electric Start Models ... . .. .. .. 1-103 20 and 25 - Manual Start Models . . . . . . . . . .. 1-104 25 and 35 - Tiller Electric Models ... .. . . . .. 1-105 20, 25, 30 and 35 - Electric Start Models. . . . .. 1-106 40 - Manual Start. . . . . . . . . . . . . . . . . . . .. 1-1 07 40 and 50 - Tiller Electric Start Models . ...... 1-108 40, 50 and 60 - Remote Electric Start Models . , 1-109 70and75Models .. . . . . . . . . . . . . . ...... 1-11 0 V-4Models . . . . . . . . . . . . . . . . . . . . . 1-111,1-112 V-6Models . . ... .... .. . . . . . . . . . . 1-113,1 -114 Replacement Parts and Product Reference ..... . . " 1-7 Safety Part A Marine Products and Safety of People Who Use Them ...... . ... .. .... 1-9 Outboard Emergency Stop System and Persons Safety . . . . . . . . . . . . . . . .. 1-20 Outboard , Fuel, Electrical System and Persons Safety . . . . . . . . . . . . . . . .. 1-14 Outboard Hydraulic Tilt/Trim Shock Absorption System and Persons Safety . . .. 1- 19 Outboard Mounting System and Persons Safety . . . . . . . . . . . . . . . . . . .. 1-17 Outboard Shift System and Persons Safety ... 1-10 Outboard Speed Control System and Persons Safety . . . . . . . . . . . . . . . . . . .. 1-11 Outboard Steering System and Persons Safety 1-12 Part B Gasolinel Handle With Care ... . . . . . . . . . . 1-27 Handling Lead/Acid Batteries ..... .. ..... 1-26 Handling Motors . . . . . . . . . . . . . . . . . . . . . 1-23 Hazardous Products . .. ....... . . .... . . 1-28 Marine Products and the Safety of People * Who Fix Them . ... . . . . . . . . . . . . .... 1-23 Service Policy .. .. .. ... .. .. ...... . ..... .. 1-7 Special Service Tools .... . . . . . . . . . . . . . . . . . . . 1-7 Specifications - 2 and 4 . . . . . . . . . . . . . . . . 1-30, 1-31 Specifications - 4 Deluxe thru 8. . . . . . . . . . . 1-32, 1-3 3 Specifications - 9.9 and 15 . . . . . . . . . . . . .. 1-34, 1-35 Specifications - 20 thru 35 ........ . . . . .. 1-36, 1-37 Specifications - 40 thru 75 . . . . . . . . . . . . . . 1-38,1-39 Specifications - V-4 and V-6 . . . . . . . . . . . .. 1-40, 1-41 Submerged Motors . , ...... . . . . . . . . . . . . . . . 1-75 Trouble Check Chart .. ... ....... " 1-95, 1-96, 1-97 Tune-Up Procedure . . .... . . . . . . . . . . . . . . . . . 1-77 Weather Altitude and Engine Performance. . . . . . .. 1-79

©OUTBOARD MARINE CORPORATION 1983 ALL RIGHTS RESERVED

Litho U.S.A.

Outboard Models Covered in This Service Manual

E2RCR

••

2 thru V-6 Models

2 Models

•

J2RCR

4 Models E4BRCR E4BRLCR

E4BRHCR E4BRHLCR

E4RDCR E4RDLCR

E4RDHCR E4RDHLCR

J4BRCR J4BRLCR

J4BRHCR J4BRHLCR

4 Deluxe Models J4RDCR J4RDLCR

J4RDHCR J4RDHLCR

5 Models J5RHCR J5BFCR J5BFLCR

E5RHCR E5BFCR E5BFLCR

6 Models E6BACR E6BALCR E6BFCR E6BFLCR

E6RCR E6RLCR E6SLCR

J6BACR J6BALCR J6BFCR J6BFLCR

J6RCR J6RLCR J6SLCR

8 Models E8RCR E8RLCR E8BACR

E8BALCR E8SRLCR

J8RCR J8RLCR J8BACR

J8BALCR J8SRLCR

9.9 Models E10RCR E10RLCR E10BACR

E10BALCR E10SELCR E 10ELCR

J10RCR J10RLCR J10BACR

J10BALCR J 10SELCR J10ELCR

15 Models E15RCR E15RLCR E15ECR

E15ELCR E 15BACR E15BALCR

E20CRCR E20CRLCR E25BECR E25BELCR E20BFCR E20BFLCR

E25BFCR E25BFLCR E20BICR E20BILCR

J15RCR J15RLCR J15ECR

J15ELCR J15BACR J15BALCR

20 Models

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J20CRCR J20CRLCR J25BECR J25BELCR J20BFCR J20BFLCR 1-2

J25BFCR J25BFLCR J20BICR J20BILCR