DOWNLOAD JOHNSON EVINRUDE REPAIR MANUALS
The Johnson-Evinrude Workshop manual downloads for the above listed models describes the service procedures for the complete vehicle. Follow the Maintenance Schedule recommendations to ensure that the outboard is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the outboard motor. All chapters in the Workshop Manual apply to the whole vehicle and illustrates procedures for removal/installation of components that are in detailed step-by-step fashion. Most all Workshop manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures.
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Fuel Pumps General Information Fuel Pump Description/Operation Testing Troubleshooting Fuel Pump Fuel Pump Components Fuel Pump Removal/Installation Fuel Pump Cleaning, Inspection, Disassembly and Reassembly Fuel Pump – Cleaning/Inspection Check Valve Reassembly Carburetion Fuel System Troubleshooting Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves Fuel System (Carburetor) Fuel System (Linkage) Carburetor Adjustments Initial Starting Adjustment Low Speed Mixture Adjustment Carburetor Float Adjustment Specification Sheet - WME Carburetors Carburetor Fastener Torques Settings Fuel Pump Specifications Fuel Pump Pressure Sealants Idle Speed Adjustment Main (High Speed) Jet Adjustment Rejetting Carburetors For High Altitude Operation Jet Orifice Size/Part Number Chart Carburetor Removal and Disassembly Carburetor Disassembly Cleaning and Inspection Carburetor Reassembly Idle Air Screw Enrichener System Enrichener Valve Hose Installation Enrichener Valve Test Acceleration Pump Fuel Flow Circuit Fuel Tank Fuel Tank Components Fuel Line and Primer Bulb Assembly Fuel Line Clamp Removal and Installation
Fuel Pumps General Information FUEL PUMP DESCRIPTION/OPERATION The fuel pump is a crankcase-pressure-operated, diaphragm- type pump. Crankcase pulsating pressure (created by the up-and-down movement of piston) is transferred to fuel pump by way of a passage (hole) between crankcase and fuel pump. When piston is in an upward motion, a vacuum is created in the crankcase, thus pulling in a fuel/air mixture (from carburetor) into crankcase. This vacuum also pulls in on the fuel pump diaphragm, thus the inlet check valve (in fuel pump) is opened and fuel (from fuel tank) is drawn into fuel pump. Downward motion of the piston forces the fuel/air mixture out of the crankcase into the cylinder. This motion also forces out on the fuel pump diaphragm, which, in turn, closes the inlet check valve (to keep fuel from returning to fuel tank) and opens the outlet check valve, thus forcing fuel to the carburetors. CHECKING FOR RESTRICTED FUEL FLOW CAUSED BY ANTI-SIPHON VALVES While anti-siphon valves may be helpful from a safety stand-point, they clog with debris, they may be too small, or they may have too heavy a spring. Summarizing, the pressure drop across these valves can, and often does, create operational problems and/or powerhead damage by restricting fuel to the fuel pump and carburetor(s). Some symptoms of restricted (lean) fuel flow, which could be caused by use of an anti-siphon valve, are: Loss of fuel pump pressure Loss of power High speed surging Preignition/detonation (piston dome erosion) Outboard cuts out or hesitates upon acceleration Outboard runs rough Outboard quits and cannot be restarted Outboard will not start Vapor lock Since any type of anti-siphon device must be located between the outboard fuel inlet and fuel tank outlet, a simple method of checking [if such a device (or bad fuel) is a problem source] is to operate the outboard with a separate fuel supply which is known to be good, such as a remote fuel tank. If, after using a separate fuel supply, it is found that the anti-siphon valve is the cause of the problem, there are 2 solutions to the problem; either (1) remove the anti-siphon valve or (2) replace it with a solenoidoperated fuel shutoff valve. Testing Install clear fuel hose(s) between fuel pump and carburetor( s). Run engine, and inspect fuel passing thru hose(s) for air bubbles. If air bubbles are found, see “Air Bubbles in Fuel Line,” below. If air bubbles are NOT found, see “Lack of Fuel Pump Pressure,” continued on next page. Troubleshooting Fuel Pump PROBLEM: AIR BUBBLES IN FUEL LINE Possible Cause Corrective Action Low fuel in fuel tank. Fill tank with fuel. Loose fuel line connection. Check and tighten all connections. Fuel pump fitting loose. Tighten fitting. A hole or cut in fuel line. Check condition of all fuel lines and replace any found to be bad. Fuel pump anchor screw(s) loose. Tighten all screws evenly and securely. Fuel pump gasket(s) worn out. Rebuild fuel pump. PROBLEM: LACK OF FUEL PUMP PRESSURE Possible Cause Corrective Action An anti-siphon valve. Read “Checking for Restricted Fuel Flow, Caused by Anti-Siphon Valves” preceding. Air in fuel line. “Air Bubbles in Fuel Line”, preceding. A dirty or clogged fuel filter. Clean or replace fuel filter. The fuel pickup in fuel tank clogged or dirty. Clean or replace pickup. Worn out fuel pump diaphragm. Rebuild fuel pump. Defective (hole or crack) check valve(s) in fuel pump (unlikely). Rebuild fuel pump. Broken check valve retainer. Rebuild fuel pump. Pulse hole plugged. Remove fuel pump and clean out hole.
Troubleshooting Fuel Pump (continued) PROBLEM: LACK OF FUEL PUMP PRESSURE Possible Cause Corrective Action Hole in pulse hose (1 pulse hose). Replace pulse hose. Loose pulse hose. Tighten connection. Boost diaphragm gasket distorted or out of place. Check seal between mating surfaces where “rib” divides pulse chamber – gasket must align with rib; check for distorted gasket. Align or replace gasket if necessary. Fuel Pump Components (Design 1) NOTE: In fuel pump reassembly, remember that respective diaphragms go against the mating surfaces of the fuel pump body, and respective gaskets are between the diaphragms and end caps. Gaskets should always be replaced on fuel pump assembly.
a - Fuel Pump Base b - Fuel Pump Body c - Chamber Plate d - Gasket, Base e - Fuel Filter – Inline f - Gasket, Pulse Chamber g - Diaphragm, Fuel Pump h - Retainer, Check Valve i - Check Valve j - Check Valve Rubber Disc k - Main Compression Spring End Cap l - Main Compression Spring m- Boost Diaphragm n - Boost Chamber Gasket o - Boost Compression Spring End Cap p - Boost Compression Spring q - Retainer, Check Valve r - Check Valve s - Check Valve Rubber Disc t - Check Valve Assembly
Carburetion Fuel System Troubleshooting Troubles, that are caused by items 1-thru-5, listed below, may give the impression that a problem exists in the fuel system: 1. Spark plugs 2. Ignition spark voltage 3. Cylinder compression 4. Reed valves 5. Ignition timing Troubleshooting Charts |
PROBLEM 1: ENGINE TURNS OVER BUT WILL NOT START OR STARTS HARD WHEN COLD Possible Cause Corrective Action Improper starting procedure. Check procedure, as outlined in “Operation and Maintenance Manual.” Fuel tank empty; improperly mixed fuel; contaminants (water, dirt, etc.) in fuel. Check fuel in fuel tank and replace or add. Fuel tank air vent closed or restricted. Air vent must be open and free from contaminants. A pinched or restricted fuel line. Check, and replace as needed. Dirty or restricted fuel filter. Check, replace or clean. Enrichener valve not operating. Check enrichener system. (Refer to “Enrichener System” following.) An inlet needle (in carburetor) that is stuck open or closed. (A needle stuck open, will cause a flooding condition. A needle stuck closed, will prevent fuel from entering carburetor.) Remove, clean, or replace. Anti-Siphon valve restricting fuel flow. Refer to “Checking for Restricted Fuel Flow caused by Anti-Siphon Valves”, following. See “Checking for Restricted Fuel Flow caused by Anti-Siphon Valves”, page 3A-1. PROBLEM: ENGINE FLOODS Possible Cause Corrective Action Dirt or foreign particles are preventing inlet needle from seating. Flush out inlet seat and clean inlet needle. Worn inlet needle. Replace. Punctured float. Replace. Incorrect float setting. Reset float. PROBLEM: ENGINE RUNS TOO LEAN Possible Cause Corrective Action Carburetor is loose. Air leaks past mixing chamber cover. Tighten bolts securely. Tighten cover or replace gasket. Fuel level too low. Reset float level. Clogged high speed jet. Check and clean. Restricted fuel flow to carburetor. Check fuel lines and filter(s) for restricted flow. Incorrect high speed jet. Refer to main jet chart and replace with proper jet. Idle mixture set too lean. Adjust to run richener. Air leakage into fuel system. Check fuel line connections, hose clamps, fuel pump, and fuel outlet tube (located in fuel tank) for loose fittings. Anti-Siphon valve restricting fuel flow. Refer to “Checking for restricted fuel flow caused by Anti-Siphon valves.” PROBLEM: ENGINE RUNS TOO RICH Possible Cause Corrective Action Fuel level too high. Reset float to correct level. Carburetor floods. See preceding “Engine Floods” Idle nozzle air holes plugged. Blow out with compressed air. Restricted air flow. Check cowl air inlet and carburetor for obstructions. Main Fuel Jet loose. Retighten Jet.
PROBLEM 1: ENGINE IDLES ROUGH AND STALLS PROBLEM 2: ENGINE RUNS UNEVEN OR SURGES PROBLEM 3: ENGINE WILL NOT ACCELERATE Possible Cause Corrective Action Fuel tank air vent closed or restricted. Check - Air vent must be open all-the-way and free from restrictions. A pinched, cut or restricted fuel line; also loose fuel line connection. Check all fuel lines and replace as needed. Check and tighten all fuel line connections. A dirty or restricted fuel filter. Check, replace, or clean all fuel filters. Restricted filter in fuel tank. Clean by rinsing in clean lead-free gasoline or kerosene. Improperly mixed fuel; contaminants (water, dirt, etc.) in fuel. Check fuel and replace, if necessary. An inlet needle (in carburetor) that is either stuck open or closed. (A needle, that is stuck open, will cause a flooding condition. A needle, that is stuck closed, will prevent fuel from entering carburetor.) Remove and replace with new inlet needle. Incorrect idle mixture adjustment. Re-adjust. Damaged fuel pump diaphragm. Replace. Carburetor is loose. Tighten bolts securely. Chamber cover leaking air. Tighten or replace gasket. Off idle holes plugged. Blow out with compressed air. Main nozzle or idle nozzle air bleed holes plugged. Blow out with compressed air. Improper main jet or restricted jet. Clean or replace with proper jet (refer to “Main Jet Chart”). Damaged reed(s). Inspect reeds as outlined in Section 4A. A crack in the fuel pick-up outlet tube (located in fuel tank). Replace. A crack in the fuel outlet tube (located in fuel tank.) Replace. Anti-Siphon valve restricting fuel flow. Refer to “Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves,” following. PROBLEM: FUEL BLOW-BACK OUT OF CARBURETOR Possible Cause Corrective Action Chipped/Broken (reed-block) Reeds Replace Reeds. PROBLEM: ROUGH IDLE If related to reed-block, indicates excessive preload in reeds. Replace Reeds. PROBLEM: CAN’T REDUCE ENGINE RPM TO SLOW IDLE Multiple Chipped Reeds. Replace Reeds. Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves While anti-siphon valves are helpful from a safety standpoint, they clog, they may be too small, or they may have too heavy a spring. The pressure drop across these valves can, create operational problems and/or powerhead damage by restricting fuel. Some symptoms of restricted (lean) fuel flow, are: 1. Loss of fuel pump pressure 2. Loss of power 3. High speed surging 4. Preignition/detonation (piston dome erosion) 5. Outboard cuts out or hesitates upon acceleration 6. Outboard runs rough 7. Outboard quits and cannot be restarted 8. Outboard will not start 9. Vapor lock Any type of anti-siphon device must be located between the outboard fuel inlet and fuel tank outlet. A method of checking [if such a device (or bad fuel) is a problem source] is to operate the outboard with a separate fuel supply which is known to be good. If, it is found that the anti-siphon valve is the cause of the problem, either 1) replace the anti-siphon valve or 2) replace it with a solenoid-operated fuel shutoff valve. |
1973 1990 Johnson Evinrude 2 to 40 HP Service Manual Outboard
Johnson - Evinrude Service Manual Application: 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 Outboard For 2, 2.5, 4, 4.5, 5, 6, 7.5, 8, 9.5, 9.9, 15, 18, 20, 25, 28, 30, 35, 40 HP (Horsepower - Horse Power) Outboards Marine Engine Johnson/Evinrude 2Stroke 2-Stroke Two Stroke & 4Stroke 4-Stroke Four Stroke models.
1973-1990 Johnson Evinrude Service Manual 48 235 HP Outboard & Sea Drives
Johnson - Evinrude Service Manual Application: 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 Outboard & Sea Drive (Sea Drives) For 48 50 55 60 65 70 75 85 88 90 100 110 115 120 135 140 150 175 185 200 225 & 235 HP (Horsepower - Horse Power) Outboard & Sea Drive Marine Engine Johnson/Evinrude 2Stroke 2-Stroke Two Stroke & 4Stroke 4-Stroke Four Stroke models.
1973-1991 Johnson Evinrude Outboard 60 HP-235 HP Workshop Manual 2-STROKE
1973-1991 Johnson Evinrude Service Repair Manual Application: 60 Hp, 3 cyl 1986-1991 - 65 Hp, 3 cyl 1973 - 70 Hp, 3 cyl 1974-1991 - 75 Hp, 3 cyl 1975-1985 - 85 Hp, V4 1973-1980 - 90 Hp, V4 1981-1991 - 100 Hp, V4 1979 1980 - 115 Hp, V4 1973-1984 - 115 Hp, V4 1990 1991 - 120 Hp, V4 1985-1991 - 135 Hp, V4 1973-1976 - 140 Hp, V4 1977-1991 - 150 Hp, V6 1978-1991 - 175 Hp, V6 1977-1983 - 175 Hp, V6 1986-1991 - 185 Hp, V6 1984 1985 - 200 Hp, V6 1976-1983 - 200 Hp, V6 1986-1991 - 225 Hp, V6 1986-1991 - 235 Hp, V6 1978-1985
1990-2001 Johnson-Evinrude 1 HP To 70 HP Service Manual 2-Stroke & 4 Stroke
Johnson - Evinrude Service Manual Application: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Outboard For 1-Hp, 2-HP, 2.3-HP, 3.3-Hp, 3.5-HP, 4-HP, 5-HP, 6-HP, 6.5-HP, 8-HP, 9.9-HP, 10-HP, 14-HP, 15-HP, 18 JET, 20-HP, 25-HP, 25D, 28-HP, 30-HP 35-HP, 40-HP, 45-HP, 50-HP, 55-HP, 60-HP, 65-HP, 70-HP (Horsepower - Horse Power) Outboards Marine Engine Johnson/Evinrude 2Stroke 2-Stroke Two Stroke & 4Stroke 4-Stroke Four Stroke 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 models.
1992-2001 Johnson Evinrude 65-300 HP Service Manual Application:
4-CYLINDER ENGINE/MOTOR MODELS/YEARS COVERED: 65HP-65 HP Jet 1992, 1993, 1994 & 1995 - 80HP-80 HP Jet 1992, 1993, 1994, 1995, 1996 & 1997 - 85HP-85 HP 1992 to1995 - 88HP-88 HP 1992, 1993, 1994, 1995 & 1996 - 90HP-90 HP 1992, 1993, 1994, 1995, 1996, 1997 & 1998 - 100HP-100 HP 1992 to 1997 - 112HP-112 HP SPL 1994 to 1996 - 115HP-115 HP 1992, 1993, 1994, 1995, 1996, 1997 & 1998 - 75HP-75 HP 2001 - 80HP-80 HP JET 1998, 1999, 2000 & 2001 - 90HP 90 1995, 1996, 1997, 1998, 1999, 2000 & 2001 - 100HP 100 1998 to 2001 - 105HP 105 Com 1997 to 2001 - 115HP 115 1995 to 2001 - 120HP 120 1992 to 1994 - 130HP 130 1994 to 2000 - 135HP 135 2001 - 140Hp 140 1992 to 1994
6-CYLINDER ENGINE/MOTOR MODELS/YEARS COVERED: - 105HP 105 JET 1992-2001 - 135HP 135 2001 - 150HP 150 1992-2001 - 175HP 175 1992-2001 - 185HP 185 1992-1994 - 200HP 200 1992-2001 - 225HP 225 2001 - 250HP 250 1999-2001
8-CYLINDER ENGINE/MOTOR MODELS/YEARS COVERED: 250HP 250 1992-1998 - 300HP 300 1992-1995
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