SERVICE MANUAL Evinrude & Johnson 5 & 6 HP

EVINRUDE AND JOHNSON 5 AND 6 HP(1965-1968)

EVINRUDE

Year Produced 5 hp 6 hp

1965 5502,5503 6502,6503

1966 5602,5603 6602,6603

1967 5702, 5703 6702, 67031968 5802, 5803 6802, 6803

CONDENSED SERVICE DATA

TUNE-UP

Hp @ rpm. 5.0 @ 4000 6.0@4500

Bore—Inches lfj Iff

Stroke—Inches V/i 1V&

Number of Cylinders 2 2

Displacement—Cu. In 8.84 8.84

Spark PlugChampion J4J J4JAC M42K M42KAutolite A21X A21XElectrode Gap 0.030 0.030

MagnetoPoint Gap 0.020 0.02O

CarburetorMake Own Own

Fuel—OU Ratio 50:1 50:1

SEES—CLEARANCES

Piston RingsEnd Gap 0.005-0.015 0.005-0.015Side Clearance 0.001-0.0035 0.0O1-O.0035

Piston Skirt Clearance O.0O18-O.0O3 0.0018-0.003

Crankshaft Bearings—DiameterTop Main Bearing 0.808-0.8085 0.808-0.8085Center Main Beariag 0.8075-0.808 0.8075-0.808Lower Main Bearing 0.808-0.8085 O.808-O.8OS5Crankpin 0.6685-0.6690 0.6685-0^6690

Crankshaft Bearings—Diametral ClearanceTop Main Bearing 0.001-0.002 0.001-0.002Center Main Bearing 0.0015-0.0025 0.0015-0.0025Lower Main Bearing 0.001-0.002 0.001-0.002Crankpin Roller Bearing

Crankshaft End Play 0.007 Max. 0.007 Max.

Piston Pin—Diametral

Clearance In Rod 0.0003-0.001 0.0003-0.001

TIGHTENING TORQUES

(AU Values in Inch Pounds)

Connecting Rod 60-66 60-66

Crankixtse Halves 60^80 60-80

Cylinder Head 60-80 60-80

Exhaujst Cover 24-36 24-36

Hywheel Nut 480-540 480-540

Intake Manifold 24-36 24-36

Spark Plug 240-246 240-246

JOHNSON5hp

LD-10, LDL-10

LD-11,LDL-11

LD-12, LDL-12LD-13, LDL-13

6hp

CD 22, CDL-22

CD 23, C0L-23

(JD-24, CDL-24

( :D-25 , C D L - 2 5

LUBRICATIONThe power head is lubricated by oil mixed

with the fuel Use Vs pint of oil with eachgallon of regular automotive or white marinegasoline. A good quality Outboard MotorOil is recommended; if outboard oil is notavailable, use Type l^M, SAE 30 AutomotiveMotor Oil. Use double the recommendedamount of oil in 1hi mixture with a newmotor or after overhaul. Mix oil and gaso-line thoroughly, using a separate container,before pouring mixture into fuel tank.

The lower unit gears and bearings arelubricated by oil contained in the gear case.Special "Outtoard Marine Corporation, TypeC Lubricant" should be used. This lubricantis supplied in a tube? and filling proceduresare as follows: Remove lower plug fromgear case and attach tube. Remove upper(vent) plug from case and, with motor in anupright position, fill gear case until lubri-cant reaches level of upper (vent) plug hole.Reinstall vent plug; then remove lubricanttube and reinstall lower plug. Tighten bothplugs securely, using new gaskets if neces-sary, to assure a water-tight seal. If OMCType C Lubricant is not available, gearcase may be temporarily filled with out-board motor oil thorough vent (top) plugopening. If outboard oil is used, drain andrefUl with OMC Type C Lubricant as soonas possible. Lower gear lubricant shouldbe maintained at level of vent plug, anddrained and renewed every 100 hours ofoperation.

FUEL SYSTEM

CARBURETOR. A float type carburetor isused; refer to Fig. OM4-1 for exploded view.Normal initial setting for slow speed mix-ture needle (25) is ATO (2) turns open fromclosed position. Major adjustment shouldbe made with knob (27) removed. Clockwiserotation oi needle leans the mixture. Makefinal adjustment after motor has reachedoperating temperatuie; then reinstall knob(27) with pointer dov/n. High speed mixtureis controlled with a fixed jet (2) and is notadjustable.

To set the carbur&tor iloat level, first re-move the carburetor; then unbolt and re-move float chamber (3). Invert th© carbxire-

177

Evinrude & Johnson 5 & 6 HP OLD OUTBOAF^D MOTOR

tor body (16) and check the natural positionof float with body inverted. Upper surfaceof float (6) (lower surface with body in-verted) should be level and flush withgasket surface of carburetor body. If it isnot, carefully bend float lever; then checkafter assembly to be sure float does notbind or rub.

Refer to Fig. OM4-1 when disassemblingor reassembling the carburetor. High speednozzle (9) can be removed with a bladescrewdriver after float chamber (3) is re-moved. Needle valve (10) and seat (11) canbe renewed after removing the float. Renewall gaskets and packing whenever carbure-tor is disassembled.

SPEED CONTROL LINKAGE. The speedcontrol lever rotates the magneto armatureplate to advance the timing. The throttlevalve is synchronized with the plate to openthrottle the proper amount as timing isadvanced.

To synchronize the linkage, remove the topcowl and move speed control lever or grip un-til index mark on cam is aligned with centerof cam follower roller on models prior to 1968as shown in Fig. OM4-2. On 1968 models aligncam follower leading edge with throttle cammark. All slack should be removed from link-

Fig. 0M4.1—Explodedview of carburelor ond

ossoeiated parts.

1. Plug2. High-speed Jet3. Float chamber4. Gasket5. Chok© knob6. Float7. Float shaft8. Choke shaft9. Nozzle

10. Inlet needle11. Needle seat12. Throttle lever13. Follower lever14. Link15. Throttle plate16. Body17. Cam follower18. Spring19. Cam roller20. Retainer21. Bushing22. Throttle shaft23. Spring24. Packing25. Slow speed needle26. Nut27. Adjusting knob28. Choke spring29. Choke plate30. Gasket

age, with throttle just ready to open at thistime; 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 checkto make sure that throttle valve is fully open.

LEAF (REED) VALVES. The inlet leaf valveunit is located between intake manifoldand crankcase. Refer to Fig. OM4-3.

Leaf petals (3) should seat very lightlyagainst leaf plate (2) throughout their en-tire length with the least possible tension.Seating surface of plate (2) should be smoothand flat. Make sure that leaf stop (4) is notbent or otherwise damaged. Do not at-tempt to straighten a bent valve leaf norbend a leaf in an aittempt to improve per-formance; if a valve leaf is bent or dam-aged, renew the leaf.

The crankcase bleeder valve can bechecked as in the foUowing paragraphsafter leaf plate (2—Fig. OM4-3) is removed.

CRANKCASE BLEEDER VALVE. AU motorsare equipped with a crankcase bleedervalve (LV—Fig. OM4-4), designed to remove

Fig. OM4-4—View of cninkcose with in-foke monifold removed. The reed-rypecronkcose bleeder voive (LV) ond stop(RS) con be removed for service, «¥irhmonifoid off. The two center moin beoringscrews (CS) must be removed before crank«

cose con be disosiiembled.

any liquid fuel or oil whicb might builc upin crankcases. The bleeder valve thus pro-vides smoother operation at all speeds 3tndlessens the possibility of s])ark plug foulingduring slow-speed operation. The bleedervalve is covered by intake manifold 3ndmay be inspected when iinlet leaf va>esare being serviced.

A small passage leads from the bottom oleach erankcase to the bleeder valve. Anycondensed liquid thus accumulates in thebleeder pocket until the piston travels itsdownward stroke, at whicli time the a cu-mulated liquid is blown into the exh<:aiBtpassage.

When engine is overhauled, bleed pas-sages should be blown out with compressedair. The valve leaf (LV) should exert slightpressure against its seat. S^aating surface oncrankcase should be smooth and flat. Vclveleaf should be renewed if broken, crack:ed,warped, rusted or bent. Qoarance betweenstop (RS) and leaf valve (LV) should be0.023-0.039 inch. Stop (RS) should be tentto set the correct clearance.

FUEL PUMP AND FILTER. The diaphrogmtype fuel pump (2—Fig. O1 4-5) attaches toside of cylinder block and is actuated bypressure and vacuum puUations in upper

EARLY

CAMFOLLOWER

Fig. OM4-2—View of index mork on syn-chronizer com oligned with center of com

foiiower roiler.178

Fig. OM4-3—Exploded view of inlet leofvoive plote ond ossocioted ports.

1. Gasket2. Leaf plate3. Leaf petal4. Leaf stop5. Gasket

Fig. OM4-5—Fuel pump, fuel fitter ondossocioted ports. Eorly fyp€> pump is shown

ot fop.1. Inlet fuel line2. Fuel pump3. Gasket4. Filter

5. Cover6. Washer7. Giiskit8. Ov tlet fuel line

SERVICE MANUAL Evinrude & Johnson 5 & 6 HP

Fig. OM4-6—View of mofor with rimifigfixture (TF) instaiied. Breoker points shouidfust open when pointer is centered between

timing morics (TM) on armatun^ plate.

crankcase. The luel pump (2) is avcdlableonly as cm asseinbly and mcludes thefilter unit.

If fuel pump problems are encountered,first remove and clean the filter and blowthrough fuel lines to be sure they are openand clean; then, if trouble is not corrected,renew the fuel pump assembly.

IGNITION SYSTEM

Breaker point gap should be 0.020 andboth sets of points should be set to openexactly 180° apart. Flywheel must be re-moved for breaker point adjustment orinspection.

The recommended method of breaker pointadjustment is by using the special timing fix-ture ((3MC Tool 383602) as shovm in Fig.OM4-6 and a timing test light. Any test lightor meter which indicates an open and closedcircuit is satisfactory.

To adjust the points using the specialtools, disconnect condenser and magnetocoil leads from both points and install thetiming fixture (TF—Fig. OMi4-6) over crank-shaft and flywheel key. Tum crankshaftuntil either end of pointer is aligned midwaybetween the timing marks (TM) on armatureplate. Attach the test light or meter to asuitable ground and to the terminal on theopening set of points; then adjust the gapuntil the points just open as indicated bytest lamp going out. Turn crankshaft 180°until opposite leg of pointer is midway be-tween timing marks (TM) on armcuture plateand adjust the other set of points in theBame manner.

To adjust the points without the specialtools, adjust each gap to exactly 0.020 whenflywheel key is aligned with rub block onmovable point.

Except for the permanent magnet built intothe flywheel the ignition system consists ofa separate coil, condenser, point set andwiring for each cylinder. When ignitiontroubles are encountered, check point con-dition and gap adjustment; check also forloose or corroded connections, dctmaged in-sulation and broken wires. The three endsof the laminated coii core shoulid be flushwith 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 upsetmark down as ahown in Fig. OM4-7.

Fig. OM4-7—When instaiiing breaiter pointcam and fiywheei drive icey, make certainthat the upset mark (M) is down as shown.

COOLING SYSTEM

WATER PUMP. All motors are cooled bya rubber impeller type water pump whichis mounted on and driven by the lower unitdrive 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 the displacement principle.As speed increases, the blades curve back-ward and coolant delivery becomes partiallycentrifugal, thus maintaining a relativelyconstant coolant flow regardless of enginespeed.

When cooling system problems are en-countered, first check water inlet for plug-ging or pKirtial stoppage. Check the therma-stat on models so equipped. If the difficultyis not thus corrected, remove the lower unitgearcase 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. Themain water inlet is located in the lowerunit gearcase housing below the anti-cavi-tation plate; at sides of housing and aheodof propeller on 5 hp models, and below theexhaust outlet above and behind the pro-peller on 6 hp units.

THERMOSTAT. Six horsepower models areequipped with a thermostat which controlsengine temperature. Cylinder heads areinterchangeable on all models, but thethermostat is not n^mally installed on5 hp units. NOTE: Thermostat may be in-stalled, and is recommended if motor isextensively used in water 50** F. or below.

The thermostat is calibrated to controlcoolant temperature within the range of 145°-150° F. Thermostat can be removed for in-

Fig. OM4-9—On 6 lip modeis, the powerhead is attached to iower unit with sevencap screws (S). Two of the screws are on

other side.

spection or renewal by first removing uppermotor cover; then removing thermostat hous-ing cover located on upper side of cylinderhead. Refer to Fig. OM4-11 for explodedview of power head castings showing ther-mostat and associateii parts.

POWEII HEAD

R&R AND DISASSEMBLE. To overhaul thepower head, clamp the motor on a stand,remove the upper motor cover and discon-nect choke control. Remove the starter as-sembly as outlined iri the STARTER section.On 5 hp models, disconnect the link con-necting speed control lever to armatureplate and remove cap screws (S—Fig.OM4-8) and nuts (N). On 6 hp models, dis-connect armature link from speed cx>ntrolshaft (22—Fig. OM4-11), remove clamp fromupper end of shaft and lift shaft (22) andpin (23) out of lower cover. Remove theseven cap screws C3—Fig. OM4-9) attach-ing power hcKid to exhaust housing. On allmodels, lift power head straight up off oflower unit.

Intake manifold and carburetor can beremoved 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 armatureplate can be lifted off. Remove support(17—Fig. OM4-11) and armatiue plate re-tainer (18). Remove cylinder head (10) andexhaust covers (19 & 21). Tap out the

Fig. OM4-8—On 5 hp modeis. the powerhead is attached to the adaptor housingwith three cap screws (S) and four nuts(N) . Two of the screws are on other side.

Fig. OM4-10—The magneto armature platecan be iifted off alFter removing the four

screws (X). |

179

Evinrude & Johnson 5 & 6 HP OLD OUTBOARD MOTOR

Fig. Oi^4-11—Exploded view of power head of fhe fype used. Speed confrol lever (22 &23) is used only on 6 hp models; armafure defenf (24 fhrough 28) only on 5 hp unlfs.

1. Tapered pin2. Cap screw3. Leaf stop4. Bleeder valve5. Crankcase front

half6. Cylinder block7. Nipple8. Oil line9. Head gasket

10. Cylinder head11. Spark plug*12. Gasket13. Thermostat14. S&al15. Cover16. Retainer17. Support18. Gasket19. Inner cover

20. Gasket21. Exhaust cover22. Speed control

shaft23. Pin24. Spacer25. Detent arm26. Screw27. Spring: seat28. 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 separatethe crankcase halves. NOTE: Center mainbearing cap screws (CS—Fig. OM4-4) areaccessible through intake ports and mustfirst 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, thecrankcase and intake manifold miist becompletely sealed against both vacuumand pressure. Exhaust manifold cmd cylinderhead must be sealed against water leokageand pressure. Mating surfaces of water in-take and exhaust areas between powerhead and lower unit must form a tight seal.

Whenever the power head is disassem-bled, it is recommended that all gasketsurfaces and the mating surfaces oi crank-case halves be carefully checked for nicksand buns or warped surfaces which mightinterfere with a tight seal. The cylinderhead, head end of cylinder block, or matingsurfaces of manifold and crankcase maybe checked and lapped, if necessary, toprovide a smooth surface. Do not removeany more metal than is necessary.

Mating surfaces of crankcase halves maybe checked on the lapping block, and highspots or nicks removed, but surface must

180

not be lowered. If extreme care is used, aslightly damaged crankcase may be sal-vaged in this manner. In case of doubt,renew the crankcase assembly.

Remove crankcase bleeder valve (4—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 twotapered dowel pins (1). Check to make surethat the dowels are not bent, nicked ordistorted, and that dowel holes are cleanand true. When installing dowel pins, makesure they are fully seated, but do not useexcessive force.

The mating surfaces of tn'ankcase ha vesmust be sealed during asisembly by usinga hardening cement such as "Sealer l(>O0"(Available from Marprox ( orp., P. O. Box955, Sheboygan, WisconsiniL Make sure thatall old cement is removed and that surfc.:ceflare flat and free from nicks and biArrs.Apply cement sparingly and evenly to cyl-inder half of crankcase only; then immed-iately install front half. Iruttall the locatingdowel pins; then install the crankcasescrews. Tighten screws evt nly to a tori ueof 60-80 inch pounds.

When installing gaskets, check to makesure conect gasket is used and that ALLwater passage holes are open and unob-structed. All gasket surfaceii must be seeled,using a non-hardening cement such as"Perfect Seal No. 4." Use the non-hccrdeiingsealer on all screw threads and tighter tothe torques given in CONE»ENSED SERVICEDATA table or in table given in SERVICEFUNDAMENTALS section in front of man lal.

The lip type seal used in place of oilslinger (13—Fig. OM4-13) on 1967 and ate1968 motors should be instctUed after crank-case is assembled. Up of seal should bedown. On cdl models, instaU armature picrteretainer {l&~Fig. OM4-11) with flat sideup and tapered side down.

Thoroughly lubricate all friction suifcceBduring assembly. Refer to Fig. OM4-13 forexploded view of crankshaft, piston mdassociated parts.

PISTONS, RINGS, PINS ifJfD CYLINDERS.Before detaching connectintj rod caps fromcrankshaft, make certain tliat rod and :apare properly marked for correct asseir.blyto each other and in the correct cylincier.

Each aluminum piston is fitted with threerings which ai9 interchangeable and may beinstalled either side up. Pistcois and rings areavailable in standard size and 0.020 o 'er-size. The recommended piston ring end qapis 0.005-0.015. Recommende<l ring to gro>veclearance is 0.001-0.0035. £;uggested pi»tonto cylinder wall clearance is 0.0018-0.rK)3.Renew pistons, rings and/or cylinder assem-bly if clearances are excessive. The pistonpin is a loose fit in piston boss mark X"(refer to Fig. OM4-12) and a tight fit in otierboss. Piston pin should have 0.0003-0.LK)1clearance in unbushed rod.

Fig. OM4-12 — Pisfonmusf be eorrecfly otsem-bled fo rod wifh long,sloping side of pisfonhead foword exhousf (EX)ond oil hole (H) in rodup. When Insfolling rodcop, make cerfaln fhafmarks (M) on rod and

cap are aligned.

SERVICE MANUAL Evinrude & Johnson 5 & 6 HP

12

10

When assembUng, observe the following:Piston should have long, sloping side ofhead (EX—Fig. OM4-12) toward exhaustside oi: cylinder and oil hole (H) in con-necting rod should be up. Piston pin shoulcjbe installed from the loose (L) side of piston.Ends of piston rings must engage pins (P)in grooves. NOTE: Only two pins areshown, pin for center ring is on other sideof piston.

CONNECTING RODS, BEARINGS ANDCRANKSHAFT. Before detaching connectingrod from crankshaft, make sure that rodand cap are properly marked for correctassenittly to e<2ch other and in the propercylinder.

The crankshaft end of each connecting rodcontains 30 loose needle rollers which ridein a renewable split race in connecting rodand use the hardened, machined crankpinas the inner race. Piston end of connectingrod is unbushed; the rod should be renewedif clearance is exc^sive. If clearance isexcessive between crankshaft main journalsand bores in crankcase, renew crankshaftand/or crankcase. Refer to CONDENSEDSERVICE DATA for recommended clearancesand torque values.

When reassembling, make certain dowels(4—Fig. OM4-13) aro correctly positionedand 30 bearing needles (6) are in each race.Marks (M—Fig. OM4-12) on connecting rodand cap should be aligned. All friction sur-faces should be lubricated during assem-bly.

Fig. OM4-14—The sfarter pinion can beblocked up as shown for removing sfarter

rope.

Fig. OM4-T3—When at-taching connecting rod tocrankshaft, make certainthat dowels (4) are posi-tioned correctiy and 30bearing needies (6) arein each race. A lip typeseal is used in place ofslinger (13) on 1967 and

fate 1966 motors.

1. Cap screw2. Ix>ck.1. Rod cap4. Dowel5. CrankshaftCK Bearing needle7. Bearing race8. Connecting rod9. Piston pin

10. Retainer11. Piston12. Piston rings13. Oil slinger14. Breaker cam

MANUAL STARTER

Refer to Fig. OM4-15 for an exploded viewof starter assembly. Starter mounts on intakemanifold as shown, and rope (4) extendsthrough Iower motor cover. The suggestedprocedure for rope renewal differs slightlyfrom that required for other service; proceedas outlined for the type of service contem-plated.

R&R STARTED ROPE. To RENEW a wombut still usable starter rope, remove uppermotor cover and disconnect both spaTk plughigh tension leads. Pull starter rope untilalmost fuJly extended. With rope-end inspool (9—Fig. OM4-15) accessible, blockpinion into engagement with flywheel, thuslocking 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 reversingthe removal procedure. With rope securedat both ends, remove the wedge and allowstarter to recoil. If rope is broken or dis-connected, assemble as outlined for serviceremoval.

To disconnect starter rope for SERVICEremoval of starter, intake manifold or powerhead, pull out starter rope about a foot andtie a slip knot in rope to prevent completerecoil. Pry rope anchor from grip and re-move the grip. Remove ^knot and allowrope to slowly enter hole in cover untilrecoil spring is fully unwound. Starter cannow be removed.

To renew a broken rope or reconnectstarter rope after service, proceed as fol-lows: Insert a heavy-duty screwdriver orbrace with screwdriver bit through top ofpinion (12—Fig. OM4-15) and spool (9) andinto slot (S) in top of spring retainer (7). Turnscrewdriver or brace counter-clockwise ap-proximately 16 2 turns until anchor (A) inspool is easily accessible; then engagepinion (12) in teeth in flywheel ring geaiand lock the assembly by inserting a suit-able block or wedge between pinion andupper bearing head. Refer to Fig, OM4-14.Thread the rope through hole in anchor (A—Fig. OM4-15), making sure rope is properlypositioned behind rope guide (3); then re-install the grip. Remove the previously in-stalled locking block and allow starter toslowly recoil.

1. Retainer plate2. Bushing.3. Rope guide4. Rope5. Intake manifoldf\. Recoil spring7. Retainer8. Bushing9. Spool

10. Bearing head11. Spring12. Pinion13. Roll pinA. Ataching lugP. Pin hoieS. Slot

D—'

Fig. OM4-15—Exploded view of recoilstarter and associat< d parts. Intake mani-foid (5) contains the mounting bracket

for stai-ter unit.

OVERHAUL. To overhaul the starter, firstdisconnect starter rope as previously out-lined for service, and allow recoil springto unwind. Remove the two cap screwssecuring uppor bearmg head (10—OM4-15)to intake manifold (5) and lift off items(6 through 13) as a unit. Drive out roll pin(13) and separate the components.

Wash the prarts in a suitable solvent andrenew any which o re wom, damaged orquestionable. When assembling the starter,lubricate recoil spring (6) with a light grease.Pinion gear (12) and spool (9) should not belubricated, but installed dry to prevent dustaccumulation. Align holes (P) in spring re-tainer (7) and spool (9) and slots in piniongear (12). and tap the pin (13) through theholes and slots. Upi)er bearing head (10),spring (11) and upper bushing (8) must beproperly positioned l)eforo installing pinion.Make sure slot in lc wer end of spring re-tainer (7) engages imier end of recoil spring(6) and enters bushing (2). Install rope andadjust recoil spring tension as outlined inthe previous paragraph.

181

Evinrude & Johnson 5 & 6 HP OLD OUTBOARD MOTOR

19 17

Fig. OiM4-16—Expioded view of iower unitgearcase, water pump and associated parts

used CHI 5 hp modeis.

1. Seal assembly2. Drive shaft.'1. Grommet4. Pump housingr>. Impeller6. Plate7. Seal8. Vent plug9. Gearcase

10. Drain plusU. Pinion12. Bushing13. Propeller shaft14. **O" ring

15. Gearcase headin. Seal17. Drive pin18. Propeller19. Washer20. Nut21. Cap22. Gasket23. Rivet24. Exhaust cover25. Extension26. Ring dowelH. Hole

LOWER UKIT

PROPELLER AND DRIVE PIN. Cushioningprotection of propeller and drive unit is builtinto propeller hub on aU 5 hp models and1966 and later 6 hp models. Cushioning pro-tection for 1965, 6 hp motor is provided bya shock absorber built into lower drive shaft.Service consists of renewing propeller onmodels with cushioning hub. The pinionshaft clutch on 1965, 6 hp units should re-lease at an applied torque of 155-225 inchpounds.

An 8 inch diameter, IVi inch pitch, 3blade propeller is used on 5 hp models;an 8 inch diameter, IV^ inch pitch, 2 bladepropeller on all 6 hp units.

The propeller drive pin (17—Fig. OM4-16)used on 5 hp models is Vi x IV4 inchstainless steel. The drive pin (21—Fig. OM4-17 or OM4-18) used on B hp models is 1^ x8 inch stainless steel.

REMOVE AND REINSTALL. Most serviceon the lower unit can be performed bydetaching the geaTcase housing from ex-haust housing. When servicing lower unit,pay particular attention to water pump andwater tubes with respect to air or waterleaks. Leaky connections may interfere withproper cooling of the motor. Refer to theappropriate exploded views and to thespecial instructions following, when serviceon gearcase or water pump is indicated.

182

5 hp Models* Refer to Fig. OM4-18 lor ex-ploded view of gearcase and assodortedparts and to Fig. OM4-18 for exhaust hous-ing and support assembly. Motor is equippedwith full pivot steering and no neutral isprovided for propeller shaft.

To remove the gearcase for service on thewater pump or drive shaft, remove the fourcap 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 remainwith exhaust housing. Withdraw crankcaselower seal components (1—Fig. OM4-16) fromupper end of drive shaft to prevent loss. Torenew the drive shaft, it is first necessary tounbolt water pump housing (4) from gear-case, then remove either of the two roll pinsin driveshaft before pump housing can bewithdrawn. Propeller shaft and gearcasehead can be withdrawn from gearcase afterremoving retaining cap screw. Drive pinion(11) is free to fall from its bore after pro-peller shaft and gear is withdrawn. Frontpropeller shaft thrust bushing (12) is alsofree and may be withdrawn with shaft. Theexhaust cover (24) is retained by rivet (23)and sealed by gasket (22) which is avail-able in thicknesses of 1/32 and 3/64 inchfor service installation. Exhaust cover neednot be removed unless loose or damaged, orservice is indicated. To remove the cover,file off peened portion and remove the rivet,then lift off the cover. When installing, usethe thinnest gasket which will compressslightly when rivet holes are aligned. Coatboth sides of the selected gasket with anon-hardening gasket cement and peen rivetslightly aifter installation. NOTE: Only onegasket should be installed.

When reassembling the gearcase, coatthe parts lightly with gearcase lubricant.Use new seals and gaskets. Invert thegearcase so drive pinion can be properlypositioned. Install pinion in housing and slipthrust bushing (12) over end of propellershaft; then install shaft in housing withoutthe gearcase head (15). Install gearcasehead with shaft oil hole (H) up (towardpower head) and install and tighten the re-taining cap screws.

When reinstalling gearcase on exhatisthousing, make sure drive shaft upper sealassembly (1) is properly installed. Coat IDof water pump outlet grommet with lubri-cant, and carefully guide water tube intoposition in piimp housing as parts areassembled. Tum propeller shaft if necessary,to align upper drive shaft splines.

6 hp ModeU. Refer to Fig. OM4-17 iotr anexploded view of gearcase and associatedparts and to Fig. OM4-19 for an explodedview of exhaust housing and support as-sembly. Six horsepower models are equippedwith a full gear shift.

The propeller shaft (13—Fig. OM4-17) anddrive gears (3 & 14) can be removed afterfirst draining lubricant from gear housing,removing pivot screw (8), then unbolting andremoving gearcase lower housing (10).

To separate gearcase assembly from ex-haust housing, place the gear shift lever in

.r-" »'"M !

Fig. OiM4.17—Expioded view of iower unitgearcase, water pump and associated parts

used on 6 hp models.

1. Bushing:2. Pinion3. Forward gear4. Thrust washer5. Clutch dog<i. Cradle7. Shift fork8. Pivot screw9. Drain plug

10. Lower gearcase11. Dowel12. Seal strip13. Propeller shaft14. Reverse gear15. Bushing16. Gearcase head17. Seal18. "O" ring19. Propeller20. Nut21. Drive pin22. Inlet strainer23. Upper gearcase

24. ]3ushing25. "O" ring2(5. <:!over27. Vent plug28. Detent29. !3hlft rod30. Connector31. Grommet32. I'ump housing33. Impeller34. l^late35. fSeal^6. ]3earlng houslnjt:37. (basket.38. Ijower drive

shaft (1965)38L. Snap ring

(1966 & up)39. Upper drive

ehaft (1965)S9L.. Drive shaft

(1966 & up)40. Seal assembly

"Forward" position and romove the g«ar-case retaining capscrews. Separate g*Kzr-case from exhaust housing far enough toremove either connector screw from nhiitlever damp (30); then wittidraw the g«ar-case and drive shaft as cm assembly.

When assembling gearcase, use i ewseabj gaskets and "O" riigs. Install rewseal strip (12) in lower gearcase (10), mdtrim ends with a sharp knife to extondapproximately ^ inch beyond ends ofgroove and form a tight Isutt-joint agauistgearcase head (18). Use a small amountof hardening sealer (Such as Sealer lt)OO,available from Marprox C<»rporatioiw P. O.Box 955, Sheboygan, Wisconsin) on eadiend of sealing strip (12) and a thin line ofsealer on housing flange. Iruitall immediatelyafter sealer is applied. Use a non-hardei^lngthread sealant on all cap screw three ds.

STEERING TENSION. Steering tension :xciibe adjusted by tiiming the adjusting screw(6—Fig. OM4-18) for 5 hp models or (3—Fig.OM4-19) for 6 hp models. Staering tension. Iscorrect when motor is easy to steer but willmaintain a set course.

SERVICE MANUAL Evinrude & Johnson 5 & 6 HP

Fig. OM4-18 —Expiodedview of exhaust housing,stem damps and associ-ated parrs used on 5 hp

modeis.

1719 20

stern clampTilting leverStem clampReverse lockSwivel bracketAdjusting screwFriction blockWater tubeGrommetExhaust housing"O" ringI^inerSwivel clampLiner"O" ringThrust washerI'owerhead adapterGronnmetSupportSteering handle

10

Fig. OM4.19 —Expiodedview of exhaust housing,stern ciamps and associ-ated parts used on 6 hp

modeis.

1. stem clamp2. Reverse lock arm3. Adjusting screw4. Reverse lock5. Tilting lever6. Thrust washer7. "O" ringr8. BuBhin r9. Stem bracket

10. Swivel bracket11. Locking lever12. Shift rod13. Water tub©14. Lower mount15. Liner16. Frtctlon block17. Thrust washer18. Pilot shaft19. Rubber mount20. Exhaust housing21. Shift lever22. Lever23. Cover plate24. Gear & shaft25. Gear26. Gear27. Bushing28. Gear & ehaft29. Steering bracket30. Lower mount

183