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(PDF) Johnson Evinrude Outboard Service Manual - 1 HP to HP - - About Free Johnson Outboard Motors Manuals
T he 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. 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. 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.
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. 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. 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. 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. Air in fuel line. 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. Defective hole or crack check valve s in fuel pump unlikely. Broken check valve retainer. Pulse hole plugged. Remove fuel pump and clean out hole. Replace pulse hose. Loose pulse hose. Tighten connection. Boost diaphragm gasket distorted or out of place. 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. 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. 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. 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.
Flush out inlet seat and clean inlet needle. Worn inlet needle. Punctured float. Incorrect float setting. Reset float. 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. Reset float to correct level. Carburetor floods.
Blow out with compressed air. Restricted air flow. Check cowl air inlet and carburetor for obstructions. Main Fuel Jet loose. Retighten Jet. 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. 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.
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