Evinrude Johnson Outboard Repair Manual 48-235 HP 1973-1990

1. Disconnect the spark plug leads. Remove the spark plugs.



2. Install piston stop tool No. 384887 in the No. 1 spark plug hole (Figure 24).



3. Rotate the flywheel clockwise until the TDC mark is approximately 1 « in. beyond the pointer. Depress the piston stop plunger until it touches the piston and then tighten the locknut.



4. Mark the flywheel rim directly under the point. This is point ?A?, Figure 25.



5. Continue rotating the flywheel clockwise until the piston contacts the piston stop tool again. Mark the flywheel again directly under the pointer. This is point ?B?, Figure 25.



6. Remove the piston stop tool and measure the distance between the marks made in Step 4 and Step 5. The mid-point between the 2 marks (point ?C?, Figure 25) should fall directly on the TDC mark cast into the flywheel if timing pointer alignment is correct.



7. If the mid-point does not fall on the flywheel TDC mark, the pointer is out of alignment. Rotate the flywheel to align the mid-point with the timing pointer.
   
   Hold the flywheel in this position and loosen the pointer screws. Move the pointer to align with the TDC mark cast into the flywheel and tighten the pointer screws.

Johnson and Evinrude fuel pumps are self-contained, remote assemblies. Fuel pump design is extremely simple and reliable in operation. Diaphragm failures are the most common problem, although the use of dirty or improper fuel-oil mixtures can cause check valve problems.

Repair kits are available to overhaul a defective pump.

V6 engines use dual fuel pumps mounted in series. Under certain operational conditions, a V6 engine may exhibit symptoms such as stalling when coming back from a full throttle position or surging with the throttle at a high setting.

The symptoms point to a lack of fuel, yet the pumps may check out satisfactorily when pressure tested (Chapter Three).

• General information
• Tools and techniques
• Troubleshooting
• Lubrication, maintenance and tune-up
• Engine synchronization and linkage adjustments
• Fuel system
• Ignition and Electrical systems
• Power head
• Gearcase
• Power trim and tilt system
• Oil injection systems
• Sea Drives
• Wiring diagrams