Evinrude Johnson Outboard Repair Manual 1.5-125 HP 1956-1972

• Evinrude Johnson 1.5 hp | 2 hp | 3 hp | 4 hp | 5 hp | 5,5 hp | 6 hp | 7.5 hp



• Evinrude Johnson 9.5 hp | 10 hp | 15 hp | 18 hp | 20 hp | 25 hp | 28 hp



• Evinrude Johnson 30 hp | 33 hp | 35 hp | 40 hp | 50 | 55 hp | 60 hp | 65 hp



• Evinrude Johnson 75 hp | 80 hp | 85 hp | 90 hp | 100 hp | 115 hp | 125 hp

SPARK PLUG INSTALLATION

Improper installation of spark plugs is one of the most common causes of poor spark plug performance in outboard engines.

The gasket on the plug must be fully compressed against a clean plug seat in order for heat transfer to take place effectively. This requires close attention to proper tightening during installation.

1. Inspect the spark plug hole threads and clean them with a thread chase (Figure 38). Wipe cylinder head seats clean before installing the new plugs.



2. Screw each plug in by hand until it seats. Very little effort is required. If force is necessary, the plugis cross-threaded. Unscrew it and try again.



3. Tighten the spark plugs. If you have a torque wrench, tighten to 17-20 ft.-lb. (24-27 N.m). If not, seat the plug figher-tight on the gasket, then tighten an additional 1/4 turn with a wrench.



4. Inspect each spark plug wire before reconnecting it to its cylinder. If insulation is damaged or deteriorated, install a new plug wire. Push wire boot onto plug terminal and make sure it seats fully.

A faulty water pump or one that performs below specifications can result in extensive engine damage. Thus, it is a good idea to replace the water pump impeller, seals and gaskets once a year or whenever the lower drive is removed for service. See Chapter Nine.

The fuel pump does not generally require service during a tune-up. Fuel pump diaghragms are fragile and one that is defective often produces symptoms that are diagnosed as an ignition system problem. A common malfunction results from a tiny pinhole or crack in the diaphragm caused by an engine backfire.

This defect allows gasoline to enter the crankcase and wet-foul the spark plug at idle speed, causing hard starting and engine stall at low rpm. The problem disappears at higher speeds, as fuel quantity is limited. Since the plug is not fouled by excess fuel at higher speeds, it fires normally.

BREAKERLESS DISTRIBUTOR (FLYWHEEL CD IGNITION)

REMOVAL/INSTALLATION

1. Remove the flywheel as described in this chapter.
   
   
2. Disconnect the yellow stator leads at the connector, remove the stator attaching screws and remove the stator from the distributor cap.
   
   
3. Disconnect the coil and spark plug leads from the distributor cap.
   
   
4. Remove the distributor cap assembly from the base plate.
   
   
5. Remove the wave washer from inside the distributor rotor. See Figure 12. Remove the rotor.
   
   
6. Carefully pry sensor rotor from crankshaft as shown in Figure 13.

• General information
• Tools and techniques
• Troubleshooting
• Lubrication, maintenance and tune-up
• Engine synchronization and linkage adjustments
• Fuel system
• Electrical systems
• Power head
• Gearcase
• Automatic rewind starters
• Power tilt system
• Wiring diagrams