BRP 2995 Johnson User manual

Jah"SlflJn.
9.9 - 15 HP
4
Stroke Models

Bombardier Recreational Products Inc.
BRP us Inc.
Technical Publications
250 Sea Horse Drive
Waukegan, Illinois 60085 United States
tAMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of
Tyco International, Ltd.
t Amphenol is a registered trademark
of The Amphenol Corporation.
t Champion is a registered trademark
of Federal-Mogul Corporation.
t Deutsch is a registered trademark
of The Deutsch Company.
t Dexron is a registered trademark
of The General Motors Corporation.
t Fluke is a registered trademark
of The Fluke Corporation
t Frahm is a registered trademark
of James G. Biddle Co.
t Gasoila is a registered trademark
of The Federal Process Corporation.
t GE is a registered trademark
of The General Electric Company.
t GM is a registered trademark
of The General Motors Corporation.
t Loctite is a registered trademark
of The Henkel Group.
t Lubriplate is a registered trademark
of Fiske Brothers Refining Company.
t
NGK is a registered trademark of NGK Spark Plugs (U.S.A.) Inc.
t Oetiker is a registered trademark of Hans Oetiker AG Maschinen.
t Permatex is a registered trademark
of Permatex.
t Plastigage is a registered trademark
of The Dana Corporation.
t Sea-Lube is a registered trademark
of Wilcox Crittenden.
t STP is a registered trademark
of STP Products Company.
t Snap-on is a registered trademark
of Snap-on Technologies, Inc.
t ThreeBond is a registered trademark of Three Bond Co., Ltd.
• Bombardier logo is a registered trademark of Bombardier, Inc., used under license.
The following trademarks are the property of BRP US Inc. or its affiliates:
Evinrude®
Evinrude® E-
TECTM
Evinrude ® / Johnson® XD30™ Formula
Evinrude® / Johnson® XD50™ Formula
Evinrude ®/ Johnson ®
XD100™ Formula
FasTrak™
Gel-Seal WM
Hi-Vis™ Gearcase Lubricant
Johnson®
Moly Lube™
Printed in the United States.
© 2004 BRP US Inc. All rights reserved.
QuikStart™
S.LO . WTM
SpeedAdjusting Failsafe Electronics (S.A.F.E. TM)
SystemCheck™
Triple-Guard®Grease
Twist-Grip™
2+4® Fuel Conditioner
Ultra-HPFTM Gearcase Lubricant
Ultra™ 4-Stoke Oil
TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates.

SAFETY INFORMATION
Before working on any part of the outboard, read the SAFETY section at the end of this manual.
This manual is written for qualified, factory-trained
technicians who are already familiar with the use
of Evinrude®/Johnson® Special Tools. This man-
ual is not a substitute for work experience. It is an
organized guide for reference, repair, and mainte-
nance of the outboard(s).
This manual uses the following signal words iden-
tifying important safety messages.
6 DANGER 6
Indicates an imminently hazardous situa-
tion which, if not avoided, WILL result in
death
or serious injury.
6 WARNING 6
Indicates a potentially hazardous situation
which, if not avoided, CAN result in severe
injury or death.
6 CAUTION 6
Indicates a potentially hazardous situation
which, if not avoided, MAY result in minor
or moderate personal injury or property
damage. It also may be used to alert
against unsafe practices.
IMPORTANT: Identifies information that will help
prevent damage to machinery and appears next
to information that controls correct assembly and
operation
of the product.
These safety alert signal words mean:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
Always follow common shop safety practices. If
you have not had training related to common shop
safety practices, you should do
so to protect your-
self, as well as the people around you.
It is understood that this manual may be trans-
lated into other languages.
In the event of any dis-
crepancy, the English version shall prevail.
To reduce the risk of personal injury, safety warn-
ings are provided at appropriate times throughout
the manual.
DO NOT make any repairs until you have read the
instructions and checked the pictures relating to
the repairs.
Be careful, and never rush or guess a service pro-
cedure. Human error
is caused by many factors:
carelessness, fatigue, overload, preoccupation,
unfamiliarity with the product, and drugs and alco-
hol use, to name a few. Damage to a boat and
outboard can be fixed in a short period oftime, but
injury or death has a lasting effect.
When replacement parts are required, use
Evinrude/Johnson Genuine Parts or parts with
equivalent characteristics, including type, strength
and material. Using substandard parts could result
in injury or product malfunction.
Torque wrench tightening specifications must be
strictly followed. Replace any locking fastener
(locknut or patch screw) if its locking feature
becomes weak. Definite resistance to turning
must
be felt when reusing a locking fastener. If
replacement is specified or required because the
locking fastener has become weak, use only
authorized Evinrude/Johnson Genuine Parts.
If you use procedures or service tools that are not
recommended in this manual, YOU ALONE must
decide if your actions might injure people or dam-
age the outboard.

~ DANGER ~
Contact with a rotating propeller is likely to result in serious injury or death. Assure the
engine and
prop area is clear of people and objects before starting engine or operating boat.
Do
not allow anyone near a propeller, even when the engine is off. Blades can be sharp and
the propeller can continue to turn even after the engine is off. Remove propeller before ser-
vicing and when running the outboard on a flushing device.
DO NOT run the engine indoors or without adequate ventilation or permit exhaust fumes to
accumulate in confined areas. Engine exhaust contains carbon monoxide which, if inhaled,
can cause serious brain damage or death.
~ WARNING ~
Wear safety glasses to avoid personal injury, and set compressed air to less than 25 psi (172
kPa).
The
motor cover and flywheel cover are machinery guards. Use caution when conducting
tests on running outboards. DO NOT wear jewelry or loose clothing. Keep hair, hands, and
clothing away from rotating parts.
During service, the
outboard may drop unexpectedly. Avoid personal injury; always support
the outboard's weight with a suitable hoist or the tilt support bracket during service.
To prevent accidental
starting while servicing, disconnect the battery cables at the battery.
Twist and remove all
spark plug leads. .
The electrical system presents a serious shock hazard. DO NOT handle primary or secondary
ignition components while outboard is running or flywheel is turning.
Gasoline is extremely flammable and highly explosive under certain conditions. Use caution
when working on any part of the fuel system.
Protect against hazardous fuel spray. Before
starting any fuel system service, carefully
relieve fuel system pressure.
Do
not smoke, or allow open flames or sparks, or use electrical devices such as cellular
phones in the vicinity of a fuel leak or while fueling.
Keep all electrical connections clean, tight, and insulated to prevent shorting or arcing and
causing an explosion.
Always
work in a well ventilated area.
Replace any locking fastener (locknut or patch screw) if its locking feature becomes weak.
Definite resistance
to tightening must be felt when reusing a locking fastener. If replacement
is indicated, use only authorized replacement or equivalent. E
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TABLE
OF
CONTENTS
SECTION ..................................... PAGE-
INTRODUCTION ................................... 5
1 SERVICE SPECIFICATIONS AND SPECIAL TOOLS
.. 15
2 INSTALLATION AND PREDELIVERY
.............. 27
3 MAINTENANCE
............................... 45
4 ELECTRICAL
................................. 65
5 IGNITION SYSTEM ............................. 93
6 FUEL SYSTEM ............................... 107
7 POWERHEAD ................................ 127
8 MIDSECTION
................... . ............. 175
9 GEARCASE
................................. 195
10 MANUAL STARTER ........................... 217
11 WIRE/HOSE ROUTING ........................ 225
SAFETY .................. . .................... S-1
INDEX ...................................... lndex-1
4

INTRODUCTION
INTRODUCTION
CONTENTS
MODELS COVERED IN THIS MANUAL .................................................. 6
IDENTIFYING MODEL AND SERIAL NUMBERS . . . . . • . . . . • . • . . . . . . . . • . . • • . . • • . . . . . . . • . • . . . .. 6
MODEL DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 7
TYPICAL PAGE - A ........................................................... " ..... 8
TYPICAL PAGE - B ................................................................. , 9
TYPICAL PAGE - C ................................................................. 10
TYPICAL PAGE - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.. 11
ABBREVIATIONS USED IN THIS MANUAL .............................................. 12
UNITS OF MEASUREMENT • . . . . . . . . . . . . . . . . . • • . • . . . . . . . • . • . . . . . . • . . . . • . . . . . . . • • . . • .. 12
LIST OF ABBREVIATIONS • . . . . . . . • . . . • . . . . . . . . . . . . . • . . . . • • • . • . . . . . . • • . . . . . . . . . . . . . .. 12
PRODUCT REFERENCE AND ILLUSTRATIONS
.......................................... 13
SyMBOLS ........................................................................ 13
ELECTRICAL . . . . . • . . . . . • • . . . . . . . . . . • . . • . . . . . . . • • . . . . . . . • • . . • . . . . . . • • • . . . . . . • . • .. 13
VALUES ......•................•............•.•.....•.........•.•......•.•..... 14
5

INTRODUCTION
MODELS COVERED
IN THIS MANUAL
MODELS COVERED IN
THIS MANUAL
This manual covers service information on
Johnson 9.9 and 15 HP 4-Stroke models. Use this
manual together with the proper Parts Catalog for
part numbers and for exploded views of the out-
board, which are a valuable aid to disassembly
and reassembly.
Model Number
Start Shaft Steer
J10R4S0A
Rope
15 in. Tiller
J10RL4S0A Rope
20 in.
Tiller
J10TE4S0A Electric 15
in.
Tiller
J10TEL4S0A Electric
20 in.
Tiller
J10TBL4S0B Electric 20 in. Tiller
J10EL4S0R Electric
20 in. Remote
J15R4S0A
Rope 15
in.
Tiller
J15RL4S0A Rope
20 in.
Tiller
J15TE4S0A Electric 15 in. Tiller
J15TEL4S0A Electric
20 in. Tiller
J15EL4S0S Electric
20 in.
Remote
(Europe only)
6
Identifying Model and Serial
Numbers
Outboard model and serial numbers are located
on the starboard stern bracket and on the power-
head.
1_--:in-ITTI
Starboard Stern Bracket
004351
1. Model and serial number
1
Powerhead 004352
1. Serial number
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INTRODUCTION
MODEL DESIGNATION
MODEL DESIGNATION
STYLE:
J =Johnson
E =Evinrude
LENGTH:
L =20" Long
I PREFt I " I HORSEPOWER I ,I 4-SiROKE I
B J 15 R L 4 SO
~_----1t_------, t
MODEL YR:
DESIGN FEATURES:
AP =Advanced Propulsion
B =Blue Paint
C =Counter Rotation
D =Evinrude E-TECTM
E = Electric Start w/Remote Steering
F = Direct-Injection
G =Graphite Paint
H =High Output
J = Jet Drive
M =Military
P =Power Trim and Tilt
R =Rope Start wlTiller Steering
S = Saltwater Edition
T =Tiller Steering
TE =Tiller Electric
V =White Paint
W = Commercial Model
I =1
N=2
T =3
R=4
0=5
D=6
U=7
C=8
E =9
S=O
Ex: SO = 2005
MODEL RUN
or SUFFIX
7
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INTRODUCTION
TYPICAL PAGE - A
TYPICAL PAGE - A
GEARCASE
SERVICE CHART
Subsection title
indicates beginning of
the subsection.
Italic subheading
above Service Chart
indicates pertaining
models.
~
n ~~~1uln " b '
! ! l1 / (13.6. 1tJ .3 N-m)
! / 6--! B
B
~f{-"
I " '~ _ ./
, D ,~~ 0 ,
\~ :@,-----
! t -- f -
! 1<:.;:::::)'
I 1
24--361n /bs / C
(2 ' 7" " H~ ~
~/nlbs ~ '
(6.8-" .5 No m)
t:t
I I I
-. -I I
~
.: :
SeeWat$l'Pump C-o A I _. _ :
As s embly Instructlo~ I ". l
B - ~ I '
A - ~ ;~~.
A-o :'
C-o i'~
~l: G ····
B - n~ ~ t!J
~ , ( "5'
'"" J ~ f 3540 Ft . lb • . )
... . ", _! @-100-110Ft.j S. (47. 54N -m) i
,-- " ! (13tj.140N-)
!
... ~---1 __ .....L ___ ~ - t8p4t(mu st d. el u n and dry . !"_
" ~ ..... U sa Geaf'C 8L.Ubricantonthre . dllbnIY ,.
A -- ~-1 U"-
tI ...... Sf)..U In . lb • .
8
Tightening torque for '.jj {} r~ 'lC}"- , -.
~'- ~ __ _ (, .B-9., N'm)
a fastener. ~ f:;' r::,.'
- " '- {~/ ~ ((j)@
corresponding to
applicable letter in
exploded view of the
DSSl33 Service Chart.
.., Page Number
Triple-Guard Gl'ItBse
GasketSealing Compound
Adhealve If Ses/anl
lfo/yLubs
R«I Ultra Lock
Blue Nut Lock
Sea Lube Bearing Lubrlc8nt
Bold letter indicates
liquid product to be
applied to a surface
Pay attention to
torque specifications.
Some units appear
as in. Ibs. Use
Exploded view of
Service Chart assists
in identifying parts
and positions
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TYPICAL PAGE - B
Section Title
Cable, Hose, and Wire Rou 1n9
Route all hoses, control cables, and wiring
through a protective sleeve or conduit into
the
boat and through the grommet.
Refer to the following diagram to ensure proper
positioning of rigging components
in grommet.
1. Fuel supply hose
2. Oil return hose
3. Oil supply hose
4. Battery cables
5.
Ma in wire harness (MWS)
6. Throttle cable
7. Shift cable
8. Oil tank sending unit harness
9. Water pressure hose
10. Accessory charge wire
Model specific
illustrations
designated with
image captions
000084
Connect outboard main wire harness to boat
wire harness.
Before installing electrical connectors, check
the seal is in place. Clean Off !!l! d ! irt ! fr ~ o ! m ~!!
nectors. Apply a light coat of
to the seal. Push connectors
latched.
1. Seal
INTRODUCTION
TYPICAL PAGE -B
a water pressure gauge is to be used, install the
water pressure hose fitting
in the cylinder block.
Use Pipe Sealant with Teflon (PIN 910048) on the
threads of the hose fitting. Refer to installati on
instructions supplied with gauge.
Route the water pressure hose through cover
grommet with oil tank sending unit harness.
Route
hose along battery cables toward the back of the
powerhead. Use tie straps to fasten in place.
pressure fitting l oca t io n: top, sta rb oa rd side
of cylinder/crankcase assembl
y, below t hr ottle
p os iti on sen so r.
If temperature gauge is to be used, route sending
unit wire through grommet
with hose for wa t er
pressure gauge. Follow the path of battery cables.
Provide adequate length to reach cylinder head.
Refer to installation instructions supplied
with
gauge.
47
9

INTRODUCTION
TYPICAL PAGE -C
TYPICAL PAGE - C
POWERHEAD
INSTALLATION
motor mount, washer, and INSTALLAT .............. -----.
sfl~ic:ed as an assembly. Do not disas- Titlein italics indicates
10
39820
Installation
Place mount assemblies in position, with flats fac-
ing away from each other.
49557
Apply Extreme Pressure Grease to all sides of
retainer and install between mounts.
Apply Nut Lock to retainer screw, install the screw,
and torque to 15
to 20 ft . Ibs . (20 to 27 N· m).
1. Mount retainer screw 49556
272
a procedure
concerning a
particular model
Title indicates the
matex
procedure specific to inner
V4 Models is
finished. From this
from this point.
All Models
a new are concerned ensure
proper sealing, clean
and free of oil, grease, and foreign matter.
23497
Coat the driveshaft splines with Moly Lube. Do not
apply lubricant to end of driveshaft.
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TYPICAL PAGE - D
Two pulse hoses connect the pump to pulse fit-
tings
on the front of the cylinder/crankcase.
• V4 Models -cylinders 1 and 3
• V6 Models -cylinders 1 and 4
r-Manifold
distributes the oil sup-
oil lift pump. A pressure-sensing
oil injection pressure.
Oil Injector-Manifold Cpal.D.CI.D.CILDn~----,
• 40 V oil injector Cross references
• Oil distribution manifold direct readers to
related topics
• Oil pressure switch
• Pressure regulator (oil return hose)
• Oil distribution hoses
• Oil to fuel check valve
3 3
2
1 4
TYPICAL 000722
1. Oil injector
2. Oil distribution manifold
3. Oil distribution hoses
4. Oil
to fuel check valve
INTRODUCTION
TYPICAL PAGE -0
OILING SYSTEM
COMPONENTS
Oil Pressure Switch
The oil pressure switch is located in the oil injec-
tor-manifold and reacts to changes in oil manifold
pressure. The EMM supplies and monitors electri-
cal current to the switch.
components
numbered
to
The switch opens or correspond to
oil manifold pressures: image
53 psi (365 kPa) (nominal) to close
43 psi (296 kPa) (nominal)
to reopen
Service Code 38
A faulty electrical circuit or an inoperative pres-
sure switch activates service code
38 (no oil sen-
sor feedback or lack of oil pressure) and the EMM:
Service Code 39
quicker reference
when thumbing
through manual
If no oil pressure is detected during startup, the
EMM initiates an oil injector "recovery mode" to
pressur iz e the system. If inadequate oil pressure
is still detected after the recovery mode is com-
pleted, the EMM:
Activates the System Check "NO OIL" light
Stores a service code
Initiates S.L.O.w.
209
11
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1NTRODUCT10N
SYMBOLS
bol for ohm, the unit of measurement for resis-
tance.
DR4205
Values
When " :::;" precedes a value on the meter face, the
reading should
be less than, or equal to, the value
shown.
14
~O.3n
Q) CD
DR4206
When "~" precedes a value on the meter face, the
reading should be greater than, or equal to, the
value shown.
~O.3n
Q) CD
DR4207
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.1: '

SERVICE SPECIFICATIONS AND SPECIAL TOOLS
SERVICE SPECIFICATIONS AND
SPECIAL TOOLS
TABLE OF CONTENTS
TECHNICAL DATA ................................................................. 16
TORQUE SPECiFiCATIONS .......................................................... 18
TIGHTENING TORQUE -IMPORTANT FASTNERS ................................................. 18
TIGHTENING TORQUE -GENERAL BOLT ........................................................ 19
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20
ELECTRICAL I IGNITION ...................................................................... 20
FUEL AND OIL ......................................................................... . .... 21
GEARCASE ......................... .. .................................................... " 21
POWERHEAD ............................................................................... 22
STARTER .................................... . ............................................. 22
UNIVERSAL ............................................................................... " 23
SHOP AIDS ....................................................................... 24
15
I

SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TECHNICAL DATA
TECHNICAL DATA
HP 9.9
15
Full Throttle 4900-5500 5400-6000
Operating Range RPM
Power 9.9 HP
(7 .3 kw) @ 5000 RPM 15 HP
(11 kw) @ 5700
Idle RPM
in Gear 820 to 920
(R) Models: 97 Ibs. (44 kg)
(Rl) Models: 99 Ibs. (45 kg)
ILl Weight (TE) Models: 1061bs. (48 kg)
~
(TEL) Models : 1081bs. (49 kg)
Cl
(El) Models: 106 Ibs. (48 kg)
Gl
Evinrude/Johnson Ultra 4-Stroke outboard oil
Lubrication Refer to
Oil Requirements on p. 40.
Engine Type 4-Stroke SOHC 2-cylinder
Displacement 18.4 cu.
in . (302 cm3)
Bore 2.28in. (58 mm)
Stroke 2.24
in . (57 mm)
Compression ratio 9.0:1
Carburetion One single-throat carburetor, float feed
Main Jet #70 #115
Pilot Jet #38 #40
Low-Speed Setting PRE-SET PRE-SET
(1-7/8 ± 1/2 turns) (2-7/8 ± 1/2 turns)
:::E
(R) Models: Manual
~
Starting Enrichment (E) Models: Automatic
~
Float Level Setting 13.5 ± 2 mm
CI)
m Preferred Fuel Regular unleaded, plus grade unleaded, premium unleaded gasolines
~
Acceptable Fuel Any
of the above gasolines with 10% Ethanol or 5% Methanol with 5% co-solvents
u..
Minimum Octane
87 AKI (R+M)/2 or 90 RON
2+4 ® Fuel Conditioner, Fuel System Cleaner, Carbon Guard
Additives Use only Evinrude/Johnson recommended fuel additives.
The use of other additives may result
in engine damage.
See Fuel Requirements
on p. 39 for additional information.
16
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HP
Alternator
....
~
Battery
-Minimum Recommendation
e:
(.)
Tachometer Setting
LIJ
Lit
(Requires Battery Charging)
Fuse
(!)
~
....
Thermostat opens
0
0
(.)
~
Type
0 RPM Limit
j:::
~
Spark Plugs
(!) Ignition Timing
-
LIJ
Gear Ratio
CI)
~
Lubricant
a::
~
Capacity
(!)
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TECHNICAL DATA
9.9 l 15
7 Amp, Regulated
12 Volt, 360 CCA (465 MCA) with
90 Minutes Reserve Capacity or
50 Ampere-Hour
6 Pulse/12 Pole
20 A (Electric start models)
136 to 144°F (58 to 62°C)
Digital Capacitor Discharge
6500 RPM
NGKt BKR6E @ 0.030 in . (0 .76 mm)
5° ATDC @ 1000 RPM
12:25 (2.08:1)
Ultra-HPF Gearcase Lube
5.7 fl. oz. (170 ml)
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SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Tightening Torque -Important Fastners
ITEM THREAD
DIAM.
Cylinder head cover bolt
6mm
Cylinder head bolt
Bmm
Crankcase bolt
6mm
Bmm
Conrod cap bolt
7mm
Oil pump bolt
6mm
Oil pump gallery bolt 6mm
Intake manifold bolt
Bmm
Carburetor mounting bolt
6mm
Fuel pump bolt
6mm
Thermostat cover bolt
6mm
Valve adjusting lock nut 5mm
Timing pulley nut 26mm
Flywheel nut 14 mm
Spark plug -
Power unit mounting bolt and nut Bmm
Driveshaft housing bolt Bmm
Oil pressure switch -
Oil regulator
14 mm
Camshaft pulley bolt
6mm
Engine oil drain plug 12 mm
Upper mount bolt Bmm
Upper mount bracket bolt Bmm
Lower mount cover bolt
Bmm
Lower mount bolt Bmm
Clamp bracket shaft nut 7/B-14 UNF
Shallow drive arm bolt
10 mm
Tiller handle cover bolt
Bmm
Water pump case bolt
Bmm
Gearcase bolt Bmm
Propeller nut 12 mm
Propeller shaft bearing housing bolt 6mm
18
TIGHTENING TORQUE
N·m kg-ft Ib-ft
10 1.0 7.0
27 2.7 20.0
14
1.4 10.0
25 2.5
1B.O
12 1.2
B.5
14
1.4 10.0
14 1.4 10.0
23 2.3 16.5
10 1.0 7.0
10
1.0 7.0
10 1.0 7.0
11
1.1 7.9
50 5.0 36.0
7B.4 B.O 57.9
27 2.7 19.5
23 2.3 16.5
23 2.3 16.5
13 1.3 9.5
27 2.7 19.5
10 1.0 7.0
13 1.3 9.5
23 2.3 16.5
23 2.3 16.5
23 2.3 16.5
23 2.3 16.5
43 4.3
31 .0
25 2.5
1B.0
17 1.7 12.3
1B 1.B 13.0
23 2.3 16.5
1B
1.B 13.0
B O.B 6.0

SERVICE SPECIFICATIONS AND SPECIAL TOOLS
TORQUE SPECIFICATIONS
Tightening Torque -General Bolt
IMPORTANT: These values apply only when a specific torque for a specific fastener is not listed in the
appropriate section. When tightening two or more screws
on the same part, DO NOT tighten screws
completely, one at a time.
ITEM THREAD TIGHTENING TORQUE
DIAM. N·m
~
~
5mm
2-4
6mm
4-7
8mm 10 -16
(Conventional or "4" marked bolt) 10 mm 22-35
~
~
5mm
2-4
6mm 6 -10
8mm 15 -20
(Stainless steel bolt) 10 mm 34 -41
~
~
5mm 3-6
6mm 8 -12
8mm 18-28
(7 marked or --'-.. marked bolt)
10 mm
40-60
A WARNING 6
Torque wrench tightening specifications
must be strictly adhered to. Replace any
locking fastener (locknut or patch screw)
if its locking feature becomes weak. Defi-
nite resistance to turning must be felt
when reusing a locking fastener.
If replacement is specified or required
because the locking fastener has become
weak, use only authorized Evinrudel
Johnson Genuine Parts.
kg-ft Ib-ft
0.2 -0.4 1.5 - 3.0
0.4 -0.7 3.0 -5.0
1.0
-1.6 7. 0-11.5
2.2- 3.5 16.0 -25.5
0.2 -0.4 1.5 -3.0
0.6
-1.0 4.5 -7.0
1.5 - 2.0 11.0-14.5
3.4 - 4.1
24.5 -29.5
0.3-0.6 2.0 -4.5
0.8-1.2
6.0 - 8.5
1.8 - 2.8 13.0 - 20.0
4.0- 6.0 29.0 -43.5
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SERVICE SPECIFICATIONS AND SPECIAL TOOLS
SPECIAL TOOLS
SPECIAL TOOLS
Electrical/Ignition
CD Peak reading voltmeter
PIN 507972
Digital multimeter
PIN 500003
Multimeter. analog
PIN 501873
o
49799 Flywheel holder
PIN 5034227
Ignition analyzer
PIN 501890
49793 Wire harness adapterleads
PIN 342228
•
Flywheel removal screws 002570 Deutsch connector tool
PIN 5034235 PIN 342667
20
-
002605 Spark checker
PIN 508118
49791 Tachometerltiming light
PIN 507980
40269 6-Pin connectortest cord
PIN 5034231
42004
49798
49789
002550
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Fuel and Oil
FuellOil pressure gauge
PIN 5000902
Gearcase
Gearcase filler
PIN 501882
Gearcase pressure tester
PIN 507977 (Stevens PIN S-34)
Gearcase vacuum tester
PIN 507982 (Stevens PIN
V-34)
SERVICE SPECIFICATIONS AND SPECIAL TOOLS
SPECIAL TOOLS
002275 Fuel vacuum tester
PIN 390954
49790 Dial Indicator set
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49794 Universal pinion bearing remover
and installer kits PIN 5005927
and PIN 5005928
23286 Oil pressure test adapter
PIN 350930
Gearcase fillidrain adaptor
PIN 772269
33974 Installer handle
PIN 345822
Prop shaft remover
PIN 5034237
002623
48642
002575
002630
21
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