Some of the smaller motors use a lever that is pulled outward to release the cover. But, even given the best of conditions, components in a motor begin wearing the first time the motor is started and will continue to do so over the life of the powerhead. It compensates for the initial wear that occurs during the life of the outboard motor. Bold figure number help you quickly match illustrations with instructions. Learn about maintaining two-stroke motors and four-stroke motors properly. But, in some cases, if the leak was caught in time, and there is no significant wear, damage or corrosion in the gearcase, the propeller shaft seal can usually be replaced with the gearcase still installed to the outboard. If necessary for service or overhaul, drain the gear oil from the To install: 7.
Similarly, proper tune-ups that help maintain proper airlfuel mixture ratios and prevent pinging, knocking or other potentially damaging operating conditions are the next best way to preserve your motor. And, water, mixing with or replacing the oil in the gearcase will wreak havoc with the shafts and gears contained within the housinq. If you suspect water in the gearcase, start by draining and closely inspecting the fluid refer to the procedures found in the Maintenance and Tune-Up section. Subject: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001 Johnson Evinrude Outboard 1. Follow the Maintenance Schedule recommendations to ensure that the outboard is in peak operating condition.
The cover should come off before and after each use in order to perform these basic safety checks. In doing so, the powerhead is the equivalent of the engine and the gearcase is the equivalent of your drivetrain the the power necessary to move the'vehicle, while the gearcask is thk assembly that transmits that power via gears, shafts and a propeller instead of tires. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. A machinist is naturally going to be more experienced with the procedures. Fully bookmarked and hyperlinked with a master index for easy use.
Numbered table of contents easy to use so that you can find the information you need fast. Thoroughly inspect the gearcase and exhaust housing for signs of damage. If a complete powerhead overhaul is necessary on your outboard, we recommend that you find a local machine shop that has both an excellent reputation and that specializes in marine work. The subsequent pages give detailed procedures. Careful break-in or a properly overhauled motor will ensure many years of service for the trusty powerhead. Perfect for do-it-yourselfers, professional mechanics, or students.
The complexity of the job will vary with 2 major factors. You will not be dissatisfied. Fully bookmarked and hyperlinked with a master index for easy use. Step-by-step photos and illustrations lay out the whole process of disassembling and reassembling Evinrude Johnson outboard engines. The second most important task for proper gearcase maintenance is checkinq and maintainina the oil inside the case.
Remove any sand, silt or dirt that could potentially damage seals or clog passages. These days, many professionals will leave portions of machine work from cylinder block and piston disassembly, clean and inspection to honing and assembly up to a machinist. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Enlarged inset helps you identify and examine parts in detail. To be honest, a complete overhaul is recommended, because corrosion and damage may have occurred if moisture was in the gearcase long enough.
Once a major overhaul is completed, refer to the section on Powerhead Break-In for details on how to ensure the rings set properly without damage or scoring to the new cylinder wall or the piston surfaces. Book Excerpt: 1990-2001 Johnson Evinrude Outboard Repair Manual 1. It is an assembly of long-life components that are protected through proper maintenance. Simply print out the pages you need or print the entire manual as a whole. Water entering the gearcase will usually cause the oil to turn a slightly milky-white color. Detailed substeps expand on maintenance and repair procedure information Notes, cautions and warnings throughout each chapter pinpoint critical information.
The lower covers of most motors are screwed or bolted together by fasteners found around the perimeter of one or both sides of the cover. A few of the very small 2-strokes and the largest 4-strokes use over-center latches that hook onto tabs on the top cover, these are normally released by pulling at the base of the latch. Not onlv is it im~ortantto make sire the oil is at t k proper level not above or below , but it is important to check the oil for signs of contamination from moisture. Perfect for do-it-yourselfers, professional mechanics, or students. However, the vast majority of motors covered by this manual utilize a rotating lever that is twisted 45-90ø in order to release the top cover. Install the gearcase, while carefully aligning the water tube in the arommet and the driveshaft s~linesto the crankshaft shaft.
In these cases, you can usually remove the powerhead from the gearcase and deliver the entire unit to the shop for disassembly, inspection, machining and assembly. If oil can get out, then water can get in. Detailed substeps expand on maintenance and repair procedure information Notes, cautions and warnings throughout each chapter pinpoint critical information. Keep in mind that anytime pistons, rings and bearings have been replaced, the powerhead must be broken-in again, as if it were a brand-new motor. Numbered instructions guide you through every repair procedure step by step. Eventually, all powerheads will require some repair.
No matter what design is used, be certain that the cover is fully seated and mounted tightly to the lower cases in order to prevent the possibility of it coming loose in service. This can be especially helpful if the overhaul or rebuild is going to take place over an extended amount of time. This is not because they are not capable of the task, but because that's what a machinist does day in and day out. The Johnson-Evinrude Workshop manual downloads for the above listed models describes the service procedures for the complete vehicle. Numbered instructions guide you through every repair procedure step by step. The lower covers do not need to be removed nearly as often, but on models where they are easily removed, they should be removed at least seasonally for service and inspection procedures. No tools are necessary to remove the cover itself.