DUTBDARDS

& SAFETY WARNING

This Service Manual will alert you to certain proce-

dures that should Ье done very carefully. If you
ignore this information, you could ...

• Injure yourself or bystanders

• Injure the boat operator, passengers or
bystanders
• Damage the outboard or its accessories

~ This safety symbol appears next to informa-

ill tion that, if ignored, could result in injury to
you or others.

~ This information symbol appears next to in-

~ formation that, if ignored, could result in
damage to the outboard ог its accessories.

This Service Manual is written for qualified,

factory-trained service technicians familiar with the
use of оме Special Tools.

This Service Manual tells you how to correctly

maintain and service the outboard and its accesso-
ries. When correctly serviced, the outboard and its
accessories will Ье reliabIe and safe to use.

When ОМС Special Tools аге called for, use them.

Where mentioned, the tools аге required to рег­
form the service procedure.

If you use service procedures ог tools that аге not

recommended Ьу ОМС, YOU ALONE must decide if
your actions might injure people ог damage the
outboard ог its accessories.
 I dex
Gene а nformation
Fuel Syst m
Igni 10 System
Powerhead
idsection
Gearcase
Manua Starter
Е ectrical System
Safety

4С 1
 I х

Topic Service Manual Title Page

Air Bleed Orifices Carbuгetor Orifice Plug Reference Chart 1-47
Alcohol in gasoline Fuel Requirement Chart 1-24
Anodes Anodes - Testing and Replacement 1-35
Battery СаЫе Extensions Battery СаЫе Extension 8-3
Battery Cnarging Battery Specifications 8-4
Battery Recommendations Battery Specifications 8-4
Battery Testing Battery Specifications 8-4
Break-In Proceduгe Break-In Proceduгe 1-29
Compression Check Tune-up Proceduгe 1-33
Соге Plug Carbuгetor Servicing 2-16
DoubIe Firing Indexing Flywheel 3-27
Engine Weight Engine Specifications Section 1
Exhaust Housing Parallelism Cleaning and Inspection 5-5
Flywheel Nut Torque Flywheel Servicing 3-8
Fogging Engine Off-Season Storage 1-30
Fuel Filter In-Line Fuel Filter 2-7
Fuel Oil Mixtuгe FuellOil Ratios 1-22
Fuel Pump Pressuгe Fuel Pump - Functional Test 2-14
Full Throttle Operating Range Engine Specifications Section 1
Full Throttle Timing Synchronization and Linkage Adjustments Section 1
Galvanic Corrosion Anodes - Testing and Replacement 1-35
Gear Ratio Engine Specifications Section 1
Gearcase Capacity Engine Specifications Section 1
Heli-Coillnserts Heli-Coillnserts and Installers 1-49
High Altitude Operation Weather, Altitude and Engine Performance 1-28
High Performance Oil Ratios FuellOil Ratios 1-22
Idle АРМ Engine Specifications Section 1
Ignition Timing Synchгonization and Linkage Adjustments Section 1
Jet Chart Carbuгetor Orifice Reference Chart 1-47
Lubrication Chart Lubrication Chart Section 1
Maximum Spark Advance Synchгonization and Linkage Adjustments Section 1

2 4C/eng
 Topic Service Manual Title Page
Models Covered Models Covered Page 4
Motor Mounts Exhaust Housing Servicing Section 5
Octane Requirements Fuel Requirements Chart 1-24
Off-Season Storage Off-Season Storage 1-30
Operating Temperature Engine Temperature Check 4-5
Orifice Chart Carburetor Orifice Plug Reference Chart 1-47
Orifice P/ugs - Factory Installed See ОМС Paгts Cata/og •
Overheating Engine Temperature Check 4-5
Preseason Service Preseason Service 1-32
Pressure Test - Gearcase Gearcase Servicing - AssembIy Section 6
I
Propeller Selection Propeller Selection 1-26
АРМ Limit Engine Specifications Section 1
Severe Service Oil Ratios FuellOil Ratios 1-22
Spark Plugs Spark Plug Information 3-6
Spark Test Ignition Output Test Section 3
Starter Аоре Length Starter Servicing Section 7
Storage Mixture Off-Season Storage 1-30
Submerged Engines Submerged Engines 1-36
Summerize Preseason Service 1-32
Sync & Link ~ynchronization and Linkage Adjustments Section 1
Test Wheel АРМ Engine Specifications Section 1
Thermomelt Sticks Engine Temperature Check 4-5
Thermostat Powerhead Servicing - AssembIy Section 4
Timing Synchronization and Linkage Adjustments Section 1
Tune-up Procedures Tune-up Procedure 1-33
Vacuum Test - Gearcase Gearcase Servicing - AssembIy Section 6
Water Pump Water Pump Servicing Section 6
Wi nterization Off-Season Storage 1-30

4Cleng 3
 Outboard Models Covered in This Service Manual

2.3, 3.3 Models

HE2REN HJ2REN
HE2RSH HJ2RSH
НЕЗRЕN НJЗRЕN
НЕЗRSН НJЗRSН

3 Models
ЕЗRЕN JЗRЕN

4 Models

E4BREN E4BRLEN J4BREN J4BRLEN

E4REN E4RLEN J4REN J4RLEN
E4RDHEN E4RDHLEN J4RDHEN J4RDHLEN

5 Models

E5DREN E5DRLEN J5DREN J5DRLEN

6 Models
E6DREN E6DRLEN J6DREN J6DRLEN
E6REN E6RLEN J6REN J6RLEN
E6SLEN J6SLEN

6.5 Models

7RSG
7RSLG

8 Models

E8REN E8RLEN J8REN J8RLEN

E8SRLEN J8SRLEN

4 4C/eng
 General Infor
ТаЫе of Contents

General Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 2

Service Specifications ............................. 1- 3
Introduction .................................... 1- 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 7
Engine Specifications
2.3,3.3 ....... . ........... . ... . ............ . .. 1- 8
3,4 ................ . . ...... ...... .. .. .. . .... 1-10
4 Deluxe ..... . ..... . .................... . .... 1-12
5 thru 8 ................... . ...... . ........... 1-14
Gearcase Lubrication ............................. 1-17
Lubrication Chart
2.3, 3.3, 3, 4 .. . .. ........ . . ..... .. .... ... . . .... 1-18
4 Deluxe thru 8 .... . .. . ....... . .. . . .. . . . ...... . 1-20
Fuel/Oil Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-22
Fuel Requirements ......................... . ..... 1-24
New Engine Pre-Delivery Checks .................... 1-25
Propeller Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-26
Weather, Altitude, and Engine Performance ............ 1-28
Break-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-29
Off-Season Storage ............................... 1-30
Preseason Service ...... . ......................... 1-32
Tune-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Anodes - Testing and Replacement. . . . . . . . . . . . . . . . . .. 1-35
Submerged Engines .............................. 1-36
Synchronization and Linkage Adjustments
3, 4 ........ .. .. . ................ .. ...... .. . . 1-38
4 Deluxe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-40
5 thru 8 .. ........... . ........... . ... . ... . ... . 1-42
20-Hour Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-45
Drill Size Conversion Chart. . . . . . . . . . . . . . . . . . . . . . . .. 1-46
Carburetor Orifice Plug Chart ....................... 1-47
Heli-Coillnserts and Installers . . . . . . . . . . . . . . . . . . . . .. 1-49
Checking Propeller Hub Slippage - 4 Deluxe thru 8 . . . . .. 1-50

4C1eng 1-1
 & General Safety Warnings

Before working оп апу part of the outboard, read the section

called Safety at the end of this manual.

When replacement parts are required, use genuine оме parts or

parts with equivalent characteristics including type, strength,
and material. Failure to do so mау result in product malfunction
and possibIe injury to the operator and/or passengers.

То prevent possibIe еуе injury, always wear SAFETV GLASSES

while servicing the unit.

Always read and follow safety related precautions found оп

containers of hazardous substances like parts cleaners, primers,
sealants, and sealant removers.

The engine cover is а machinery guard. Use caution when

conducting tests оп running engines. Do not wear jewelry or
loose clothing. Кеер hair, hands, and clothing away from rotat-
ing flywheel.

Replace апу locking type fastener (locknut or patch screw) if its

locking feature becomes weak. Definite resistance to tightening
must Ье felt or locking fastener is not suitabIe for continued use.
Replace only with authorized replacement part or equivalent.

1-2 4C1eng
 Service Specifications

Standard Torque Chart •• =-___.-________.._______________

Size In. Lbs. Ft. Lbs. N'm

NO.6 7-10 • 0,8-1,2

NO.8 15-22 • 1,6-2,4

NO.10 25-35 2-3 2,8-4,0

NO.12 35-40 3-4 4,0-4,6

1f4 in. 60-80 5-7 7-9

5116 in. 120-140 10-12 14-16

3/8 in. 220-240 18-20 24-27

7116 in. 340-360 28-30 38-40

РСЕОО23

~ These values only apply when а special torque for а specific

~ fastener is not listed in the Special Torque Chart found at
the beginning of each section.

ГN='J When tightening two ог тоге screws оп the same part, do

~ not tighten screws completely, ог опе at а time . То avoid
distortion, first tighten all screws in sequence to one-third of
torque value, then tighten to two-thirds of torque value, then
tighten to full value.
Sealants and Lubricants Required _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ._1118_ __

оме Hi-Vis @Gearcase Lubricant

оме Тгiрlе-GuаГd@ Grease
Evinrude@Outboard Lubricant
Johnson @Outboard Lubricant
оме 2+4@Fuel Conditioner
оме Storage Fogging Oil
оме Engine Типег

4C1en g 1-3
Introduction

This manual covers service information оп 2.3 thru 8 models.

Some of the information might apply to previous models.

Use this manual together with the ргорег Parts Catalog for part
numbers and exploded views which аге а valuabIe aid to service.

This manual presents the English values and dimensions first and
metric values and dimensions second, inside parentheses ( ).

Good Service Practice

Service required for OMCengines is generally опе ofthree kinds:

• Normal care and maintenance - which includes putting а

new engine into operation , storing engines, lubrication,
and саге under special operating conditions such as salt
water and cold weather.

• Operating malfunctions - due to improper engine

mounting, propeller condition ог size, boat condition, ог
the malfunction of some part of the engine. This includes
engine servicing proceduгes to keep the engine in prime
operating condition.

• Complete disassembIy and overhaul - such as major

service ог rebuilding а unit.

It is important to you as the service person to determine, before

disassembIy, just what the troubIe is and how to correct it quickly,
with minimum expense to the owner.

When repairing а component, the most reliabIe way to ensuгe а

good job is to do а complete overhaul оп that component, rather
than just replacing the bad part. Wear not readily apparent оп
other parts could cause а malfunction soon after the repair job.
Repair kits and overhaul kits contain а" the parts needed to
ensuгe а complete repair, to eliminate guesswork, and to save
time.

Repair time сап also Ье minimized Ьу the use of special tools.

оме special tools speed repair work so it сап Ье done within flat
rate time. 'П some cases, the use of substitute tools сап damage
the part.

r::=J 00 по operate engine out of water, even momentarily. If

~ operated in test tank, use ргорег test wheel . Failure to do so
сап result in damage to water pump and engine overheating!

1-4 4C1eng
Arrangement of Service Manual

This Service Manual includes the specific information you will

need to service Evinrude and Johnson engines. AII general
proceduгes аге covered in abbreviated form, mostly Ье reference
to proceduгal iIIustrations. The specific procedures which apply
to this engine аге covered in fully-illustrated, detailed, step-by-
step instructions.

Each of the manual sections contains detailed instructions for

disassembIy, inspection, assembIy, testing, and operating adjust-
ments of the various engine systems. These procedures will help
you service а specific system ог completely overhaul the out-
board.

Product Reference and lIIustrations

Outboard Marine Corporation reserves the right to make changes

at апу time, without notice, in specifications and models and also
to discontinue models. The right is also reserved to change апу
specifications ог parts, at апу time, without incurring апу obIiga-
tion to equip same оп models manufactured prior to date of such
change. Specifications used аге based оп the latest product
information availabIe at the time of pubIication.

The continuing accuracy of this manual cannot Ье guaranteed.

AII photographs and illustrations used in this manual тау not

depict actual models ог equipment, but аге intended as represen-
tative views for reference only.

Certain featuгes of systems discussed in this manual might not Ье

found оп all models in all marketing areas.

4CJe ng 1-5
Service Pol icy

When servicing ап outboard which is within its normal warranty

period ог covered Ьу the ОМС 1+2@Extended Protection Plan,
make repairs using only genuine ОМС replacement components
ог parts.

If ОМС genuine replacement components ог parts аге not used,

ОМС might refuse subsequent warranty claims involving that
engine.

'" When replacement parts аге required, use genuine оме

~ parts or parts with equivalent characteristics, including
type, strength, and material. Failure to do so mау result in
product malfunction and possibIe injury to the operator and/or
passengers.

When reference is made to а brand пате product ог specific tool,

ап equivalent product тау Ье used in place of the referenced
product. Substitute products used must have equivalent chara-
cteristics, including type, strength, and material. You must deter-
mine if incoгrect substitution could result in product malfunction
and possibIe injuгy to the operator and/or passengers.

Whether within ог following the warranty period, ОМС has а

constant interest in its products. It is OMC's policy to provide
dealers with service information so they сап give the professional
service demanded Ьу today's consumer. The ОМС Training
Centers, frequent mailings of Service Bulletins and Advisories,
ОМС Special Tools, and this Service Manual represent some of
OMC's efforts to assist dealers in giving consumers the best
service possibIe.

The Service Manual covers all phases of servicing outboards.

However, new situations sometimes arise in servicing ап engine.
If а service question does not арреаг to Ье answered in this
manual, you аге invited to write to the Service Department for
additional help. Always Ье suгe to give complete information,
including engine model number and serial number.

Ве suгe that you аге familiar with ОМС warranty policies.

Special Service Tools

ОМС has specially designed tools to simplify 50те of the

disassembIy and assembIy operations. These tools аге illustrated
in this Service Manual, in тапу cases in actual use. Refer to the
ОМС Special Tool Guide for а description and ordering instruc-
tions for these tools. Individual puгchasers of Service Manuals
must order Special Tools through ап authorized dealer.

Outboard Engine Nomenclature

Sometimes the words "right" and "Ieft" аге very confusing when
referring to the sides of ап outboard. Therefore, the sides аге
referred to as STARBOARD ог РОRт. STARBOARD means оп the
right hand while facing the bow (FRONT) of the boat; PORT
means left hand.

& Safety Related 1-6 4C/eng

 1 DR2065
2 DR2066
3
1-":~·_---------=D=R4=20~Э

Symbols

Throughout this service manual, symbols аге used to interpret

electrical troubIeshooting results ог to assign values in drawings.

Electrical

ш This symbol indicates continuity ог very low resistance.

4
~ This symbol indicates по continuity ог very high resistance. DR4204

Use an ohmmeter calibrated оп high ohms scale, ог а continuity

light, to test continuity.

fЗl
When "00" shows оп the meter face, по continuity, ог very high
~ resistance, is indicated. The symbol is referred to as infinity.

г4l
When "'1"
follows а value оп the meter face, the procedure is
~ measUГlng voltage.

г5l
When "О" follows а value оп the meter face, the proceduгe is 5
~ measuгing resistance. О is the symbol for ohm, the unit of DR4205

measurement for resistance.

Values

г61
When "$." precedes а value оп the meter face, it indicates
~ your reading should Ье less than, ог equal to, the value shown.

г7lWhen "~" precedes а value оп the meter face, it indicates

~ youг reading should Ье greater than, ог equal to, the value
shown. 6
DR4206

7
DR4207
4C1eng 1-7
 Engine Specifications
2.3, 3.3
Operation EIIIIiI_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

Full Throttle Operating Range 2.3 - 4200 to 5200 RPM

3.3 - 4300 to 5000 RPM

Power 2.3 - 2.3 HP (1,7 kw)

3.3 - 3.3 HP (2,5 kw)

Power Rate @ 4700 RPM

Idle RPM in Gear 1200 ± 100

Test Propeller 2.3 - оме P/N 115297

3.3 - оме P/N 115306

Minimum Test RPM 2.3 - 4800

3.3 - 4900

Weight 27 Ibs. (12,3 kg)

Powerhead . . . . . .E8. . . . . . . . . . . . . . . .aa. .~~~. . . . . . . ._ _. ._ _ _ _ _. .. .

Туре Single Cylinder

Displacement 4.75 cu . in. (78 сm З )

Ваге 1.8898 (48 тт)

Stroke 1.6929 (43 тт)

Standard Ваге 1.8890 - 1.8906 in. (48.00 - 48.02 тт)

Crankshaft Dimensions

Тор Jouгnal 0.7875 - 0.7878 in . (20,002 - 20,010 тт)

Bottom Jouгnal 0.5906 - 0.5910 in. (15,001 - 15,011 тт)

Rod Crankpin 0.6299 - 0.6301 in. (16,00 - 16,005 тт)

Piston Diameter, Standard 1.8868 - 1.8873 in. (47,9247 - 47,9374 тт)

Piston Ring End Gap 0.0059 - 0.0138 in. (0,15 - 0,35 тт)

Piston Ring Groove Side Clearance 0.0026 in. (0,066 тт) maximum

1-8 4C1eng
Gearcase ........................................................aa. . . . . . . .. .

Gear Ratio 13:24 (O.54)

Lubricant OMC Hi-Vis Gearcase Lubricant

Capacity 3 fl. oz. (90 ml)

Ignition System .............._ _ _ _ _. ._ _IiIIlI:I. . . . ._ _ _ _ _ _IllClIIIIiIII_ _ _ _IlIIII. .

Type Flywheel Magneto

Breaker Point Gap 2.3 - 0.014 in (O,35 mm)

3.3 - 0.020 in. (O,5 mm)

Spark Plug, Champion

Model Recommended
Alternate

QL77JC4 @ L77JC4 @
2.3,3.3
0.030 in . (O,8 mm) 0.030 in . (0,8 mm)

PCE0037

FueISvstem ...........................m. . . . . . . . . . . . . . . .Bm. . . . . .~am-=..=zBB33

Fuel/Oil Ratios See Page 1-22

Fuel Requirement See Page 1-24

Carburetion One Single-Throat Carburetor, Float Feed

Calibration Adjustable, Low Speed

Starting Enrichment Manual Choke

Float Level Setting See Section 2

4C/eng 1-9
 Engine Specifications
3,4
Operation 1lllll1IIiIII_ _ _ _ _ _ _ _ _ _IllllllIIIIIIIi_ _ _ _ _. ._ _ _ _ _. . ._ _ _ _ _ __

Full Throttle Operating Range 4500 to 5500 RPM

Power 3 - 3 HP (2,2 kw)

4 - 4 HP (3 kw)

Power Rated @ 5000 RPM

Idle RPM in Gear 750 ± 50

Test Propeller оме P/N 317738

Minimum Test RPM 4400

Weight R - 33 Ibs. (15,0 kg)

RL - 35 Ibs. (16,0 kg)

Роwегhеаd . . . ._ _. . . ..а. . . . . .ви. .вж~~~~28. . . .аа. .mв~. . . .~_. ._ . . . . .

Туре In-line 2-Cylinder

Displacement 5.28 cu. in. (87 сm З )

Воге 1.565 in. (39,7 тт)

Stroke 1.374 in. (34,9 тт)

Standard Воге * 1.5643-1.5650 in. (39,74-39,75 тт)

Crankshaft Dimensions

Тор Journal 0.7515-0.7520 in. (19,08-19,10 тт)

Center Journal 0.6685-0.6690 in. (16,98-16,99 тт)

Bottom Journal 0.6691-0.6695 in. (17,00-17,01 тт)

Rod Crankpin 0.6695-0.6700 in. (17,01-17,02 тт)

Piston Diameter, Standard 1.5625-1.5631 in . (39,69-39,70 тт)

Piston Ring End Gap, Both 0.005-0.015 in. (0,13-0,38 тт)

Piston Ring Groove Side Clearance, Both 0.004 in. (0,10 тт) maximum

* То Ьоге oversize, add piston oversize dimension to standard Ьоге.

1-10 4 C1eng