52138772-Johnson-6HP-1965-68
Contents
1. SERVICE MANUAL Evinrude amp Johnson 5 amp 6 HP EVINRUDE AND JOHNSON 5 AND 6 HP 1965 1968 EVINRUDE JOHNSON Year Produced 5 hp 6 hp Shp 6 hp PAGO cami yy siggy aewaldian en OES 5502 5503 6502 503 LD 10 LDL 10 CD 22 CDL 22 SEES Score mediantis th VRE SE RP 5602 5603 6602 6603 LD 11 LDL 11 CD 23 CDL 23 EST inci ae bot ind iw ake aaaee E T 5702 5703 6702 6703 LD 12 LDL 12 CD 24 CDL 24 1968 0 46555 ig als TEINAR Son ore hw CTE 6802 5803 6802 6803 LD 138 LDL 13 CD 25 CDL 25 CONDENSED SERVICE DATA TUNE UP OL 5 0 4000 6 0 4500 LUBRICATION Bore Inche s lt 26 64 6 o8eecaeees 14 144 The power head is lubricated by oil mixed with the fuel Use Ys pint of oil with each Stroke Inches z s srs i aoa i 1 gallon of regular automotive or white marine Number of Cylinders 2 2 gasoline A good quality Outboard Motor Displacement Cu In 8 84 8 84 Oil is recommended if outboard oil ie not Spark Pl available use Type MM SAE 30 Automotive elon Motor Oil Use double the recommended Champion sseeee0s jj JAJ amount of oil in the mixture with a new AC tease cere rene neees M42K M42K motor or after overhaul Mix oil and gaso Antolllo ibs ase os hres kas A21X A21X line thoroughly using a separate container Electrode Gap seeues 0 030 0 030 before pouring mixture into fuel tank Magneto The lower unit gears and bearings are Point Gap cceeceeus 0 020 0 020 lubr2. 17 Cam follower 18 Spring 19 Cam roller 20 Retalner 21 Bushing 22 Throttle shaft 23 Spring 24 Packing 25 Blow speed needle 26 Nut 27 Adjusting knob 28 Choke spring 29 Choke plate 30 Gasket age with throttle just ready to open at this time if it is not loosen the two screws secur ing synchronizing cam to armature plate then retighten with all slack removed To fur ther check the adjustment move speed con trol lever or grip to Fast position and check to make sure that throttle valve is fully open LEAF REED VALVES The inlet leaf valve unit is located between intake manifold and crankcase Refer to Fig OM4 3 Leaf petals 3 should seat very lightly against leaf plate 2 throughout their en tire length with the least possible tension Seating surface of plate 2 should be smooth and flat Make sure that leaf stop 4 is not bent or otherwise damaged Do not at tempt to straighten a bent valve leaf nor bend a leaf in an attempt to improve per formance if a valve leaf is bent or dam aged renew the leaf The crankcase bleeder valve can be checked as in the following paragraphs after leaf plate 2 Fig OM4 3 is removed CRANECASE BLEEDER VALVE All motors are equipped with a crankcase bleeder valve LV Fig OM4 4 designed to remove Fig OM4 3 Exploded view of inlet leaf valve plate and associated parts Gasket Leaf plate Leaf petal Leaf stop 5 Gasket ia Ga p
3. 1 Stern clamp 2 Tilting lever 3 Stern clamp 4 Reverse lock fi Swivel bracket 6 Adjusting screw T Friction block H Water tube u Grommet 10 Exhaust housing 11 0 ring 12 Liner li Swivel clamp 14 Liner 15 O ring 10 Thrust washer 17 Powerhead adapter 18 Grommet 19 Support 20 Steering handle Evinrude amp Johnson 5 amp 6 HP Sr mer Ep Fig OM4 19 Exploded view of exhaust housing stern clamps and associ ated parts used on hp models Stern clamp Reverse lock arm Adjusting screw Reverse lock Tilting lever Thrust washer O ring Bushing Stern bracket 10 Swivel bracket 11 Locking lever 12 Shift rod 13 Water tube 14 Lower mount 15 Liner 16 Friction block 17 Thrust washer 18 Pilot shaft 18 Rubber mount 20 Exhaust housing 21 Shift lever 22 Lever 23 Cover plate 24 Goar amp shaft Gear 26 Gear 27 Bushing 28 Gear amp shaft 29 Steering bracket 20 Lower mount T Go ee BS ee J 183 Copyright of Old Outboard Motor Service Manual 1st Editon is the property of Penton Media Inc Clymer and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder s express written permission However users may print download or email articles for individual use
4. Tap out the Fig OM4 10 The magneto armature plate can be lifted off after removing the four screws X 179 Evinrude amp Johnson 5 amp 6 HP Fig OM4 11 Exploded view of power head of the type used Speed control lever 22 amp 23 is used only on 6 hp models armature detent 24 through 28 only on 5 hp units 1 Tapered pin 10 Cylinder head 20 Gasket 2 Cap screw 11 Spark plug 21 Exhaust cover 3 Leaf stop 12 Gasket 22 Speed control 4 Bleeder valve 13 Thermostat shaft 5 Crankcase front 14 Seal 23 Pin half 15 Cover 24 Spacer Cylinder block 16 Retainer 25 Detent arm T Nipple 17 Support 2 Screw 8 Oll line 18 Gasket 27 Spring seat Head gasket 19 Inner cover 28 Spring tapered crankcase aligning pins 1 work ing from cylinder side of crankcase flange Remove the cap screws securing front crank case housing 5 to cylinder 6 and separate the crankcase halves NOTE Center main bearing cap screws CS Fig OM4 4 are accessible through intake ports and must first be removed Pistons rods and crankshaft are now ac cessible for removal and overhaul as out lined in the appropriate following para graphs When reassembling follow the pro cedures outlined in ASSEMBLY paragraph ASSEMBLY When reassembling the crankcase and intake manifold must be completely sealed against both vacuum and pressure Exhaust manifold and cylinder head must be sealed against water leakage and pre
5. certain that marks M on rod and cap are aligned OLD OUTBOARD MOTOR The mating surfaces of crankcase halves must be sealed during assembly by using a hardening cement such as Sealer 1000 Available from Marprox Corp P O Box 955 Sheboygan Wisconsin Make sure that all old cement is removed and that surfeces are flat and free from nicks and burrs Apply cement sparingly and evenly to cyl inder half of crankcase only then immed iately install front half Install the locating dowel pins then install the crankcase screws Tighten screws evenly to a torque of 60 80 inch pounds When installing gaskets check to make sure correct gasket is used and that ALL water passage holes are open and unob structed All gasket surfaces must be sealed using a non hardening cement such as Perfect Seal No 4 Use the non hardening sealer on all screw threads and tighten to the torques given in CONDENSED SERVICE DATA table or in table given in SERVICE FUNDAMENTALS section in front of manual The lip type seal used in place of oil slinger 13 Fig OM4 13 on 1967 and late 1966 motors should be installed after crank case is assembled Lip of seal should be down On all models install armature piate retainer 16 Fig OM4 11 with flat side up and tapered side down Thoroughly lubricate all friction surfoces during assembly Refer to Fig OM4 13 for exploded view of crankshaft piston and associated parts PISTONS RINGS P
6. drive 16 Gearcase head shaft 1905 17 Seal WL Snap ring 18 O ring 1966 amp up 19 Propeller a0 Upper drive 20 Nut ehaft 1065 30L Drive shaft 1966 amp up 40 Seal assembly 21 Drive pin 22 Inlet stralner 24 Upper gearcase Forward position and remove the gear case retaining capscrews Separate g ar case from exhaust housing far enough to remove either connector screw from shift lever clamp 30 then withdraw the gear case and drive shaft as an assembly When assembling gearcase use new seals gaskets and O rings Install new seal strip 12 in lower gearcase 10 and trim ends with a sharp knife to extend approximately y inch beyond ends of groove and form a tight butt jolnt against gearcase head 16 Use a small amount of hardening sealer Such as Sealer 1000 available from Marprox Corporation P O Box 955 Sheboygan Wisconsin on each end of sealing strip 12 and a thin line of sealer on housing flange Install immediately after sealer is applied Use a non hardening thread sealant on all cap screw threads STEERING TENSION Steering tension can be adjusted by turning the adjusting scew 6 Fig OM4 18 for 5 hp models or 3 Fig OM4 19 for 6 hp models Steering tension is correct when motor is easy to steer but will maintain a set course SERVICE MANUAL Fig OM4 18 Exploded view of exhaust housing stern clamps and associ ated parts used on 5 hp models
7. inch pitch 3 blade propeller is used on 5 hp models an 8 inch diameter 7 inch pitch 2 blade propeller on all 6 hp units The propeller drive pin 17 Fig OM4 16 used on 5 hp models is x 1 inch stainless steel The drive pin 21 Fig OM4 17 or OM4 18 used on 6 hp models is 7 x 7a inch stainless steel REMOVE AND REINSTALL Most service on the lower unit can be performed by detaching the gearcase housing from ex haust housing When servicing lower unit pay particular attention to water pump and water tubes with respect to air or water leaks Leaky connections may interfere with Proper cooling of the motor Refer to the appropriate exploded views and to the special instructions following when service on gearcase or water pump is indicated 182 5 hp Models Refer to Fig OM4 16 for ex ploded view of gearcase and associated parts and to Fig OM4 18 for exhaust hous ing and support assembly Motor is equipped with full pivot steering and no neutral is provided for propeller shaft To remove the gearcase for service on the water pump or drive shaft remove the four cap screws retaining gearcase housing 9 Fig OM4 16 to exhaust housing and with draw gearcase and drive shaft as an assem bly Water tube 8 Fig OM4 18 will remain with exhaust housing Withdraw crankcase lower seal components 1 Fig OM4 16 from upper end of drive shaft to prevent loss To renew the drive shaft it is first necessary to unb
8. 015 0 0025 drained and renewed every 100 hours of Lower Main Bearing 0 001 0 002 0 001 0 002 SPExanon Crankpin srecsrescesssee Roller Bearing _ _ FUEL SYSTEM Crankshaft End Play 0 007 x ron ay 1 007 Max 0 007 Max CARBURETOR A float type carburetor is Piston Pin Diametral used refer to Fig OM4 1 for exploded view Clearance In Hod 9 0003 0 001 0 0003 0 001 Normal initial setting for slow speed mix ms ture needle 25 is two 2 tums open from TIGHTENING TORQUES closed position Major adjustment should All Values in Inch Pounds be made with knob 27 removed Clockwise Connecting Red 5 60 66 60 66 rotation of needle leans the mixture Make i final adjustment after motor has reached e Halves 60 80 60 80 operating temperature then reinstall knob Cylinder Head 60 80 60 80 27 with pointer down High speed mixture Exhaust Cover eee 24 36 24 36 is controlled with a fixed jet 2 and is not Flywheel Nut ees 480 540 480 540 eg A Oo se e carburetor float level first re Intake Manifold 24 36 24 36 move the carburetor then unbolt and re Spork Plug sssssessisssia 240 246 240 246 move float chamber 3 Invert the carbure 177 Evinrude amp Johnson 5 amp 6 HP tor body 16 and check the natural position of float with body inverted Upper surface of float 6 lower surface with body in verted should be le
9. A in spool is easily accessible then engage pinion 12 in teeth in flywheel ring gear and lock the assembly by inserting a suit able block or wedge between pinion and upper bearing head Refer to Fig OM4 14 Thread the rope through hole in anchor A Fig OM4 15 making sure rope is properly positioned behind rope guide 3 then re install the grip Remove the previously in stalled locking block and allow starter to slowly recoil Evinrude amp Johnson 5 amp 6 HP Retainer plate Bushing Rope guide Rope Intake manifold Recoil spring Retainer Bushing Spool Bearing head Spring Pinion Roll pin Ataching lug Pin hole Blot See oS SaaS os mo Fig OM4 15 Exploded view of recoil starter and associated parts Intake mani fold 5 contains the mounting bracket for starter unit OVERHAUL To overhaul the starter first disconnect starter rope as previously out lined for service and allow recoil spring to unwind Remove the two cap screws securing upper bearing head 10 OM4 15 fo intake manifold 5 and lift off items 6 through 13 as a unit Drive out roll pin 13 and separate the components Wash the parts in a suitable solvent and renew any which are worn damaged or questionable When assembling the starter lubricate recoil spring 6 with a light grease Pinion gear 12 and spool 9 should not be lubricated but installed dry to preve
10. Fig OM4 5 Fuel pump fuel filter ond associated parts Early type pump is shown at top 1 Inlet fuel line 5 Cover 2 Fuel pump 6 Washer 3 Gasket 7 Gaskit 4 Filter 8 Ovtlet fuel line SERVICE MANUAL Fig OM4 6 View of motor with timing fixture TF installed Breaker points should just open when pointer is centered between timing marks TM on armature plate crankcase The fuel pump 2 is available only as an asseinbly and includes the filter unit If fue pump problems are encountered first remove and clean the filter and blow through fuel lines to be sure they are open and clean then if trouble is not corrected renew the fuel pump ossembly IGNITION SYSTEM Breaker point gap should be 0 020 and both sets of points should be set to open exactly 180 apart Flywheel must be re moved for breaker point adjustment or inspection The recommended method of breaker point adjustment is by using the special timing fix ture OMC Tool 383602 as shown in Fig OM4 6 and a timing test light Anv test light or meter which indicates an open and closed circuit is satisfactory To adjust the points using the special tools disconnect condenser and magneto coil leads from both points and install the timing fixture TF Fig OM4 6 over crank shaft and flywheel key Turn crankshaft until either end of pointer is aligned midway between the timing marks TM on armature plate Attach the test light or meter to a s
11. INS AND CYLINDERS Before detaching connecting rod caps from crankshaft make certain that rod and cap are properly marked for correct assembly to each other and in the correct cylinder Each aluminum piston is fitted with three rings which are interchangeable and may be installed either side up Pistems and rings are available in standard size and 0 020 over size The recommended piston ring end gap is 0 005 0 015 Recommended ring to groove clearance is 0 001 0 0035 Suggested piston to cylinder wal clearance is 0 0018 0 003 Renew pistons rings and or cylinder assem bly if clearances are excessive The piston pin is a loose fit in piston boss mark L refer to Fig OM4 12 and a tight fit in other boss Piston pin should have 0 0003 0 001 clearance in unbushed rod SERVICE MANUAL When assembling observe the following Piston should have long sloping side of head EX Fig OM4 12 toward exhaust side of cylinder and oil hole H in con necting rod should be up Piston pin should be installed from the loose L side of piston Ends of piston rings must engage pins P in grooves NOTE Only two pins are shown pin for center ring is on other side of piston CONNECTING RODS BEARINGS AND CRANESHAFT Before detaching connecting rod from crankshaft make sure that rod and cap are properly marked for correct assembly to each other and in the proper cylinder The crankshaft end of each connecting rod contai
12. a ee OLD OUTBOARD MOTOR Fig OM4 4 View of crankcase with in take manifold removed The reed type crankcase bleeder valve LV and RS can be removed for service w manifold off The two center main beoring screws CS must be removed before crank case can be disassembled any liquid fuel or oil which might build up in crankcases The bleeder valve thus pro vides smoother operation at all speeds and lessens the possibility of spark plug fouling during slow speed operation The bleeder valve is covered by intake manifold and may be inspected when inlet leaf valves are being serviced A small passage leads from the bottom ol each crankcase to the bleeder valve Any condensed liquid thus accumulates in the bleeder pocket until the piston travels its downward stroke at which time the accu mulated liquid is blown into the exhaust passage When engine is overhauled bleed pas sages should be blown out with compressed air The valve leaf LV should exert slight pressure against its seat Seating surface on crankcase should be smooth and flat Valve leaf should be renewed if broken cracked warped rusted or bent Clearance between stop RS and leaf valve LV should be 0 023 0 039 inch Stop RS should be bent to set the correct clearance FUEL PUMP AND FILTER The diaphragm type fuel pump 2 Fig OM4 5 attaches to side of cylinder block and is actuated by pressure and vacuum pulsations in upper EARLY
13. amp Johnson 5 amp 6 HP Fig OM4 9 On 6 hp models the power head is attached to lower unit with seven cap screws 5 Two of the screws are on other side spection or renewal by first removing upper motor cover then removing thermostat hous ing cover located on upper side of cylinder head Refer to Fig OM4 11 for exploded view of power head castings showing ther mostat and associated parts POWER HEAD R amp R AND DISASSEMBLE To overhaul the power head clamp the motor on a stand remove the upper motor cover and discon nect choke control Remove the starter as sembly as outlined in the STARTER section On 5 hp models disconnect the link con necting speed control lever to armature plate and remove cap screws S Fig OM4 8 and nuts N On 6 hp models dis connect armature link from speed control shaft 22 Fiq OM4 1 remove clamp from upper end of shaft and lift shaft 22 and pin 23 out of lower cover Remove the seven cap screws S Fig OM4 9 attach ing power head to exhaust housing On all models lift power head straight up off of lower unit Intake manifold and carburetor can be removed as an assembly Remove flywheel breaker point cam and key from crank shaft After the four screws X Fig OM4 10 are removed the magneto armature plate can be lifted off Remove support 17 Fig OM4 11 and armature plate re tainer 16 Remove cylinder head 10 and 19 amp exhaust covers 21
14. e displacement principle As speed increases the blades curve back ward and coolant delivery becomes partially centrifugal thus maintaining a relatively constant coolant flow regardless of engine speed When cooling system problems are en countered first check water inlet for plug ging or partial stoppage Check the therma stat on models so equipped If the difficulty is not thus corrected remove the lower unit gearcase as outlined in the appropriate sec tion and check the condition of water pump water passages gaskets and sealing sur faces Refer to Fig OM4 16 or OM4 17 The main water inlet is located in the lower unit gearcase housing below the anti cavi tation plate at sides of housing and ahead of propeller on 5 hp models and below the exhaust outlet above and behind the pro peller on 6 hp units THERMOSTAT Six horsepower models are equipped with a thermostat which controls engine temperature Cylinder heads are interchangeable on all models but the thermostat is not normally installed on 5 hp units NOTE Thermostat may be in stalled and is recommended if motor is extensively used in water 50 F or below The thermostat is calibrated to control coolant temperature within the range of 145 150 F Thermostat can be removed for in Fig OM4 8 On 5 hp models the power head is attached to the adaptor housing with three cap screws 5 and four nuts N Two of the screws are on other side Evinrude
15. icated by oil contained in the gear case Carb Special Outboard Marine Corporation Type E C Lubricant should be used This lubricant Make TELELE ICET Toe we oe oe Own Own is supplied in a tube ond filling procedures Fuel Oil Ratio ce 0ce 50 1 50 1 are as follows Remove lower plug from gear case and attach tube Remove upper SIZES CLEARANCES vent plug from case and with motor in an Piston Hings cad a a teat ot ciate deni alas ia End GOP woe ee cece eee e eee 0 005 0 015 0 005 0 015 Reinstall vent plug then remove lubricant Side Clearance sees 0001 00035 0 001 0 0035 tube and reinstall lower plug Tighten both Piston Skirt Clearance 0 0018 0 003 0 0018 0 003 plugs securely using new gaskets if neces sary to assure a water tight seal If OMC Crankshaft Becrings earings Diameter Type C Lubricant is not available gear ae eee A EREA 0 808 0 8085 0 808 0 8085 case may be temporarily filled with out enter n Bearing 0 8075 0 808 0 8075 0 808 board motor oil through vent top plug Lower Main Bearing 0 808 0 8085 0 808 0 8085 opening If outboard oil is used drain and Crankpin 2 020 accesses 0 6685 0 6690 0 6685 0 6690 refill with OMC Type C Lubricant as soon Crankshaft Bearings Diametral Clearance as possible Lower gear lubricant should Top Main Bearing 0 001 0 002 0 001 0 002 be maintained at level of vent plug and Center Main Bearing 0 0015 0 0025 0 0
16. installing gearcase on exhaust housing make sure drive shaft upper seal assembly 1 is properly installed Coat ID of water pump outlet grommet with lubri cant and carefully guide water tube into position in pump housing as parts are assembled Turn propeller shaft if necessary to align upper drive shaft splines 6 hp Models Refer to Fig OM4 17 for an exploded view of gearcase and associated parts and to Fig OM4 19 for an exploded view of exhaust housing and support as sembly Six horsepower models are equipped with a full gear shift The propeller shaft 13 Fig OM4 17 and drive gears 3 amp 14 can be removed after first draining lubricant from gear housing removing pivot screw 8 then unbolting and removing gearcase lower housing 10 To separate gearcase assembly from ex haust housing place the gear shift lever in OLD OUTBOARD MOTOR el ay y i e 5 J6 37 24 25 Fig OM4 17 Exploded view of lower unit gearcase water pump and associated parts used on 6 hp models 1 Busting 24 Bushing 2 Pinion 44 O ring 3 Forward gear 2 Cover 4 Thrust washer 27 Vent plug i Clutch dog 28 Detent ti Cradle 29 Shift rod 7 Shift fork 30 Connector 8 Pivot screw 31 Grommet 9 Drain plug 32 Pump housing 10 Lower gearcase 3J Impeller 11 Dowel 4 Plate 12 Seal atrip 35 Seal 13 Propeller shaft 36 Bearing housing i4 Reverse gear a7 Gasket 15 Bushing 38 Lower
17. newal differs slightly from that required for other service proceed as outlined for the type of service contem plated R amp R STARTED ROPE To RENEW a worm but still usable starter rope remove upper motor cover and disconnect both spark plug high tension leads Pull starter rope until almost fully extended With rope end in spool 9 Fig OM4 15 accessible block pinion into engagement with flywheel thus locking the recoil mechanism Refer to Fig OM4 14 With starter securely locked dis connect from rubber grip and lug A Fig OM4 15 Install a new rope by reversing the removal procedure With rope secured at both ends remove the wedge and allow starter to recoil If rope is broken or dis connected assemble as outlined for service removal To disconnect starter rope for SERVICE removal of starter intake manifold or power head pull out starter rope about a foot and tie a slip knot in rope to prevent complete recoil Pry rope anchor from grip and re move the grip Remove knot and allow rope to slowly enter hole in cover until recoil spring is fully unwound Starter can now be removed To renew a broken rope or reconnect starter rope after service proceed as fol lows Insert a heavy duty screwdriver or brace with screwdriver bit through top of pinion 12 Fig OM4 15 and spool 9 and into slot S in top of spring retainer 7 Turn screwdriver or brace counter clockwise ap proximately 16 turns until anchor
18. ns 30 loose needle rollers which ride in a renewable split race in connecting rod and use the hardened machined crankpin as the inner race Piston end of connecting rod is unbushed the rod should be renewed if clearance is excessive If clearance is excessive between crankshaft main journals and bores in crankcase renew crankshaft and or crankcase Refer to CONDENSED SERVICE DATA for recommended clearances and torque values When reassembling make certain dowels 4 Fig OM4 13 are correctly positioned and 30 bearing needles 6 are in each race Marks M Fig OM4 12 on connecting rod and cap should be aligned All friction sur faces should be lubricated during assem bly Fig OM4 14 The starter pinion can be blocked up as shown for removing starter rope Fig OM4 13 When at taching connecting rod to crankshoft make certain that dowels 4 are posi tioned correctly and 30 bearing needles 6 are in each race A lip type seal is used in place of slinger 13 on 1967 and late 1966 motors ow a Cap screw Lock Rod cap Dowel Crankshaft Bearing needle Bearing race Connecting rod H Piston pin 10 Retalner 11 Piaton 12 Piston rings 13 OIL slinger 14 Breaker cam Se oo MANUAL STARTER Refer to Fig OM4 15 for an exploded view of starter assembly Starter mounts on intake manifold as shown and rope 4 extends through lower motor cover The suggested procedure for rope re
19. nt dust accumulation Align holes P in spring re tainer 7 and spool 9 and slots in pinion gear 12 and tap the pin 13 through the holes and slots Upper bearing head 10 spring 11 and upper bushing 8 must be properly positioned before installing pinion Make sure slot in lower end of spring re tainer 7 engages inner end of recoil spring 6 and enters bushing 2 Install rope and adjust recoil spring tension as outlined in the previous paragraph 181 Evinrude amp Johnson 5 amp 6 HP Fig OM4 16 Exploded view of lower unit gearcase water pump and associated parts used on 5 hp models 1 Seal assembly 15 Gearcase head 2 Drive shaft id Seal 4 Grommet 17 Drive pin 4 Pump housing 18 Propeller fi Impeller 19 Washer Plate 20 Nut T Soni 21 Cap B Vent plug 22 Gasket H Gearcase 43 Rivet 10 Drain plug 24 Exhaust cover 11 Pinion 26 Extension 12 Bushing 26 Ring dowel 13 Propeller shaft H Hole 14 LT i ahd ring LOWER UNIT PROPELLER AND DRIVE PIN Cushioning protection of propeller and drive unit is built into propeller hub on all 5 hp models and 1966 and later 6 hp models Cushioning pro tection for 1965 6 hp motor is provided by a shock absorber built into lower drive shatft Service consists of renewing propeller on models with cushioning hub The pinion shaft clutch on 1965 6 hp units should re lease at an applied torque of 155 225 inch pounds An 8 inch diameter 74
20. olt water pump housing 4 from gear case then remove either of the two roll pins in driveshaft before pump housing can be withdrawn Propeller shaft and gearcase head can be withdrawn from gearcase after removing retaining cap screw Drive pinion 11 is free to fall from its bore after pro peller shaft and gear is withdrawn Front propeller shaft thrust bushing 12 is also free and may be withdrawn with shaft The exhaust cover 24 is retained by rivet 23 and sealed by gasket 22 which is avail able in thicknesses of 1 32 and 3 64 inch for service installation Exhaust cover need not be removed unless loose or damaged or service is indicated To remove the cover file off peened portion and remove the rivet then lift off the cover When installing use the thinnest gasket which will compress slightly when rivet holes are aligned Coat both sides of the selected gasket with a non hardening gasket cement and peen rivet slightly after installation NOTE Only one gasket should be installed When reassembling the gearcase coat the parts lightly with gearcase lubricant Use new seals and gaskets Invert the gearcase so drive pinion can be properly positioned Install pinion in housing and slip thrust bushing 12 over end of propeller shaft then install shaft in housing without the gearcase head 15 Install gearcase head with shaft oil hole H up toward power head and install and tighten the re taining cap screws When re
21. ssure Mating surfaces of water in take and exhaust areas between power head and lower unit must form a tight seal Whenever the power head is disassem bled it is recommended that all gasket surfaces and the mating surfaces of crank case halves be carefully checked for nicks and burrs or warped surfaces which might interfere with a tight seal The cylinder head head end of cylinder block or mating surfaces of manifold and crankcase may be checked and lapped if necessary to provide a smooth surface Do not remove any more metal than is necessary Mating surfaces of crankcase halves may be checked on the lapping block and high spots or nicks removed but surface must 180 not be lowered If extreme care is used a slightly damaged crankcase may be sal vaged in this manner In case of doubt renew the crankcase assembly Remove crankcase bleeder valve 4d Fig OM4 11 oil line 8 and blow out oil pass ages while crankcase is disassembled The crankcase halves are positively lo cated during assembly by the use of two tapered dowel pins 1 Check to make sure that the dowels are not bent nicked or distorted and that dowel holes are clean and true When installing dowel pins make sure they are fully seated but do not use excessive force Fig OM4 12 Piston must be correctly assem bled to rod with long sloping side of piston head toward exhaust EX and oil hole H in rod up When installing rod cap make
22. uitable ground and to the terminal on the opening set of points then adjust the gap until the points just open as indicated by test lamp going out Turn crankshaft 180 until opposite leg of pointer is midway be tween timing marks TM on armature plate and adjust the other set of points in the same manner To adjust the points without the special tools adjust each gap to exactly 0 020 when flywheel key is aligned with rub block on movable point Except for the permanent magnet built into the flywheel the ignition system consists of a separate coil condenser point set and wiring for each cylinder When ignition troubles are encountered check point con dition and gap adjustment check also for loose or corroded connections damaged in sulation and broken wires The three ends of the laminated coil core should be flush with machined bosses on armature stator plate The side of ignition cam marked TOP should face up The cam and fly wheel key should be installed with upset mark down os shown in Fig OM4 7 Fig OM4 7 When Installing breaker point cam and flywheel drive key make certain that the upset mark M is down as shown COOLING SYSTEM WATER PUMP All motors are cooled by a rubber impeller type water pump which is mounted on and driven by the lower unit drive shaft At slow speeds the flexible im peller blades follow the contour of the ec centric housing and the pump delivers cool ing water by th
23. vel and flush with gasket surface of carburetor body If it is not carefully bend float lever then check after assembly to be sure float does not bind or rub Refer to Fig OM4 1 when disassembling or reassembling the carburetor High speed nozzle 9 can be removed with a blade screwdriver after float chamber 3 is re moved Needle valve 10 and seat 11 can be renewed after removing the float Renew all gaskets and packing whenever carbure tor is disassembled SPEED CONTROL LINEAGE The speed control lever rotates the maqneto armature plate to advance the timing The throttle valve is synchronized with the plate to open throttle the proper amount as timing is advanced To synchronize the linkage remove the top cowl and move speed control lever or grip un til index mark on cam is aligned with center of cam follower roller on models prior to 1968 as shown in Fig OM4 2 On 1968 models align cam follower leading edge with throttle cam mark All slack should be removed from link CAM r FOLLOWER ROLLER _ ae Fig OM4 2 View of index mark on syn chronizer cam aligned with center of cam follower roller 178 Fig OM4 1 Exploded view of carburetor and associated parts Plug High speed jet Float chamber Gasket Choke knob Float Float shaft Choke shaft Nozzle 10 Inlet needle 11 Needle seat 12 Throttle lever 13 Follower lever 14 Link 15 Throttle plate Bod Pe rae ot go po a Y
Download Pdf Manuals
Related Search
52138772 Johnson 6HP 1965 68