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    1978 Johnson 175 200 235 HP Outboard Service Manual PDF

    Uploaded by

    ChrisStainton
    This service manual provides information needed to service 1978 Johnson 175 HP, 200 HP, and 235 HP outboard motors. It includes specific procedures for these models that apply primarily or only to them. General procedures are covered briefly, often through references to illustrations. Chapters cover introduction, general service information, fuel system, ignition system, power head, lower unit, electrical system, remote control, and power trim and tilt. The manual is intended for use by technicians and includes all information specific to these 1978 Johnson outboard models.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    1978 Johnson 175 200 235 HP Outboard Service Manual PDF

    Uploaded by

    ChrisStainton
    2K views6 pages
    This service manual provides information needed to service 1978 Johnson 175 HP, 200 HP, and 235 HP outboard motors. It includes specific procedures for these models that apply primarily or only to them. General procedures are covered briefly, often through references to illustrations. Chapters cover introduction, general service information, fuel system, ignition system, power head, lower unit, electrical system, remote control, and power trim and tilt. The manual is intended for use by technicians and includes all information specific to these 1978 Johnson outboard models.

    Original Title

    1978.Johnson.175.200.235.HP.Outboard.Service.Manual.pdf

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    © © All Rights Reserved

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    This service manual provides information needed to service 1978 Johnson 175 HP, 200 HP, and 235 HP outboard motors. It includes specific procedures for these models that apply primarily or only to them. General procedures are covered briefly, often through references to illustrations. Chapters cover introduction, general service information, fuel system, ignition system, power head, lower unit, electrical system, remote control, and power trim and tilt. The manual is intended for use by technicians and includes all information specific to these 1978 Johnson outboard models.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2K views6 pages

    1978 Johnson 175 200 235 HP Outboard Service Manual PDF

    Uploaded by

    ChrisStainton
    This service manual provides information needed to service 1978 Johnson 175 HP, 200 HP, and 235 HP outboard motors. It includes specific procedures for these models that apply primarily or only to them. General procedures are covered briefly, often through references to illustrations. Chapters cover introduction, general service information, fuel system, ignition system, power head, lower unit, electrical system, remote control, and power trim and tilt. The manual is intended for use by technicians and includes all information specific to these 1978 Johnson outboard models.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 6
    At a glance
    Powered by AI
    The documents provide instructions for adjusting timing and troubleshooting ignition systems on outboard engines.

    The steps include checking the timing on each cylinder, selecting the cylinder with the highest advance, and adjusting the full advance screw so that cylinder indicates 28 ± 1/2 degrees BTDC.

    Tips include making sure connections are clean and tight, using proper test equipment, and not removing potting in power packs.

    INTRODUCTION

    GENERAL

    SlIVIOE
    tNPOIfM:ATfON

    LOWER
    UNIT

    200 HP models

    ELECTRICAL

    SYSTEM

    REMOTE
    CONTROL

    ITEM' NO. JM -7810

    OUTBOARD MARINE CORPORATION 1977

    LITHO U .S.A .

    II

    II
    II
    II
    II

    TROUBLESHOOTING THE MAGNETO


    C.D. IGNITION SYSTEM

    UtIill1NOTE
    Read through first before attempting to
    troubleshoot the ignition system.

    INTRODUCTION

    1. Advance screw
    2. Locknut

    The magneto "C . D." ignition is a Simple system to


    troubleshoot. It requires the use of:

    3. Timing pointer
    4. 3/8 - 7/16"
    (9.5 - 11.1 mm)

    1. Two needle point spark checkers, gaps set to


    7/16" (11 mm).

    Figure 4-7. Spark Advance Stop Screw

    2. S- 80 or M80 neon test light.


    3. Ohmmeter.

    Make initial adjustment of full advance stop screw.


    See Figure 4-7. This is just an initial starting
    dimension.

    4. Timing Light.

    With the timing light connected to No. 1 spark plug


    lead, start the engine and set engine speed to 4300
    to 4600 rpm (in gear). Observe the degrees of advance indicated by the timing pOinter (timing grid
    #1 cylinde r). Stop engine, and connect timing light
    to #2 spark plug lead. Start and run engine at 4300
    to 4600 rpm in gear. Observe the degrees of advance indicated by the timing pOinter (timing grid
    #2 cylinder). Stop motor. Select the cylinder with
    the highest indicated degrees of advance and adjust
    full advance screw so the higher reading cylinder
    indicates 28 1/2 degrees B. T.D.C. Move advance
    stop adjustment screw to obtain proper setting. One
    turn clockwise retards timing about 10. One turn
    counterclockwise advances timing about 10.

    A troubleshooting step chart is provided. It is deSigned to be an aid in determining which component


    is causing the trouble and whether it is good or bad.
    Magneto C.D. ignition system Do's and Do Not's.
    1. Do make sure that connections are clean and tight
    on all wiring, especially all ground connections.

    2. Do make sure the plug-in connections are fully


    engaged and all terminals are free of corrosion.

    IIlul1UNOTE

    3. Do make sure all wlrmg is located properly so


    that it will not rub against any metal edges. Vibration will eventually wear through the insulation and
    result in a service problem that may be difficult to
    locate.

    If the timing pOinter or the intake manifold


    have been disturbed, check the top dead center
    timing pOinter alignment. See paragraph
    "TIMING POINTER ADJUSTMENT," page
    4-25.

    4. Do make sure accurate test equipment is us ed


    when troubleshooting the system.
    5. Do use proper tools when installing system
    components.
    DO NOT
    1. Do not attempt to remove potting in Power Packs,
    as this will void any warranty.

    I.jn

    NOTE

    OMC liquid neoprene (Gaco) Part No. 315417


    must be applied to all electrical connections
    except ground stud, nut and terminal motor
    cable to by-pass cover.

    Figure 4-8. Motor Running at 28 Advance


    Timing B. T. D. C.

    o
    u

    :;j
    ><

    Qj
    E,JV6

    4-7

    i::i.

    c. Insert tilt tube bushings in swivel bracket. Lubricate tilt tube with OMC Anti-Corrosion Lube.
    Place washer on tilt tube and install port side tilt
    tube and stern bracket.
    d. Place washer on starboard end of tilt tube.
    Install starboard stern bracket. Attach power trim
    and tilt manifold to port and starboard stern brackets. Torque screws to specifications in Section 2.
    e. Thread tilt tube nut onto tilt tube and torque to
    24-26 ft.-Ibs. (32-36 N.m), then back off 1/ 8 to 1/4
    turn after torquing. See Figure 6-112.

    1. Steering arm
    2. Pivot shaft keepers
    3. Mount bracket
    63542

    Figure 6-113. Steering Arm Installed

    63664

    Figure 6-112. Torquing Tilt Tube Nut

    f. Install thrust rod and spring.

    g. If removed, install bushing in swivel bracket.


    Install new upper and lower seals with lips facing
    out.

    1. Pivot shaft nut


    2. Steering arm
    3. Mount bracket

    h. Lubricate steering arm and pivot shaft assembly


    with OMC Anti-Corrosion Lube. Place upper thrust
    washer on shaft, and install shaft in swivel bracket.
    See Figure 6-113 .

    63543

    Figure 6-114. Pivot Shaft Nut

    REASSEMBLY OF EXHAUST HOUSING


    AND ADAPTER

    i. Place lower thrust washer and pivot shaft keepers


    on pivot shaft. Install mount bracket in alignment
    with steering arm as shown in Figure 6-114. Apply
    OMC Gasket Sealing Compound to threads of nut.
    Torque nut to specifications in Section 2 (130 to
    150 ft.-Ibs. (180-200 Nm) .

    a. Install lower rubber mounts in exhaust housing


    and secure with lower mount covers. Torque screws
    to specifications in Section 2.
    6-38

    E , JV 6

    1978 Johnson 175, 200, 235 HP


    Outboard Service Manual
    This Service Manual includes the specific information you will need to Buy this Manual
    service the Johnson motor.
    All general procedures are covered in abbreviated form, mostly by reference to procedural
    illustrations.
    The specific procedures which apply only, or primarily, to this motor are covered in fully
    illustrated, detailed, step-by-step instructions.
    Item No. JM-7810
    Manual covers the following 1978 Johnson outboard models:
    175 HP models
    175TL78
    175TXL78
    200 HP Models
    200TL78
    200TXL78
    235 HP Models
    235TL78
    235TXL78
    Manual Chapters:
    - INTRODUCTION
    - GENERAL SERVICE INFORMATION
    - FUEL SYSTEM
    - IGNITION SYSTEM
    - POWER HEAD
    - LOWER UNIT
    - ELECTRICAL SYSTEM
    - REMOTE CONTROL
    - POWER TRIM AND TILT
    Unlike aftermarket repair manual this is the Original service manual which includes all
    information specific to 1978 175 HP, 200 HP, 235 HP Johnson Outboards.
    This is NOT a Seloc or Clymer repair manual.

    Buy this Manual

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