1972–1991 Johnson Evinrude 60–235 hp Outboard Motor Service Manual
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Johnson Models Covered & Key Technical Specifications
Models: 60 hp, 65 hp, 70 hp, 75 hp, 85 hp, 90 hp, 100 hp, 110 hp, 115 hp, 120 hp, 135 hp, 140 hp, 150 hp, 175 hp, 185 hp, 200 hp, 225 hp, 235 hp
Models & Model Codes:
60 hp — Johnson: J60ELCD, J60TLCD, J60ELCU, J60TLCU, J60ELCC, J60TLCC, J60ELCE, J60TLCE, J60TTLCE, J60ELES, J60TLES, J60TTLES
Evinrude: E60ELCD, E60TLCD, E60ELCU, E60TLCU, E60ELCC, E60TLCC, E60ELCE, E60TLCE, E60TTLCE, E60ELES, E60TLES, E60TTLES
65 hp — Johnson: 65ES, 65ESL-72, 65ESL, 65SLR-73
Evinrude: 65272-73, 65372-73
70 hp — Johnson: 70ES, 70ESL, 70ELR-74, 70ESL-75, 70EL-76, 70EL-77, 70EL-78, 70EL-79, 70ELCS, J70ELCIH, J70ELCIM, J70TLCIM, J70ELCNB, J70TLCNB, J70ELCT, J70TLCT, J70ELCR, J70TLCR, J70ELCO, J70TLCO, J70ELCD, J70TLCD, J70ELCU, J70TLCU, J70ELCC, J70TLCC, J70ELCE, J70TLCE, J70ELES, J70TLES
Evinrude: 70442-43, 70472-73, 70572-73, 70673, 70773, 70873, 70973, E70ELCS, E70ELCIH, E70ELCIM, E70TLCIM, E70ELCNB, E70TLCNB, E70ELCT, E70TLCT, E70ELCR, E70TLCR, E70ELCO, E70TLCO, E70ELCD, E70TLCD, E70ELCU, E70TLCU, E70ELCC, E70TLCC, E70ELCE, E70TLCE, E70ELES, E70TLES
75 hp — Johnson: 75ESR, 75ER, 75ESLR-75, 75ELR-76, 75ELR-77, 75EL-78, 75ELR-79, 75ERCS, 75ERLCS, 75TRLCS, J75ERCIH, J75ERCIM, J75ERLCIH, J75ERLCIM, J75TRLCIH, J75TRLCIM, J75ELCNB, J75ECNB, J75TLCNB, J75ELTC, J75ECT, J75TLCT, J75ELCR, J75ECR, J75TLCR, J75ELCO, J75ECO, J75TLCO
Evinrude: 75542-43, 75642-43, 75742-43, 75842, 75843, 75942, 75943, E75ERCS, E75ERLCS, E75ERCIH, E75ERCIM, E75ERLCIH, E75ERLCIM, E75TRLCIH, E75TRLCIM, E75ERLCNB, E75ERCNB, E75TRLCNB, E75ELCT, E75ECT, E75TLCT, E75ELCR, E75ECR, E75TLCR, E75ELCO, E75ECO, E75TLCO
85 hp — Johnson: 85ESL73, 85ESL74, 85ESLR-75, 85EL, 85ETLR-76, 85ETLR, 85TXLR-77, 85ML, 85TXLR-78, 85TL, 85TXL-79, 85MLCS, 85TLCS
Evinrude: 85393, 85493, 85593, 85693, 85790, 85793, 85799, 85890, 85895, 85899, 85990, 85995, 85999, E85MLCS, E85TLCS, E85TXCS
90 hp — Johnson: J90MLCIH, J90MLCIM, J90TLCIH, J90TLCIM, J90TXCIH, J90TXCIM, J90MLCNB, J90TLCNB, J90TXCNB, J90MLCT, J90TLCT, J90TXCT, J90MLCR, J90TLCR, J90TXCR, J90MLCO, J90TLCO, J90TXCO, J90MLCD, J90TLCD, J90TXCD, J90MLCU, J90TLCU, J90TXCU, J90TLCC, J90TLCE, J90TXCE, J90TLES, J90TXES
Evinrude: E90MLCIH, E90MLCIM, E90TLCIH, E90TLCIM, E90TXCIH, E90TXCIM, E90MLCNB, E90TLCNB, E90TXCNB, E90MLCT, E90TLCT, E90TXCT, E90MLCR, E90TLCR, E90TXCR, E90MLCO, E90TLCO, E90TXCO, E90MLCD, E90TLCD, E90TXCD, E90MLCU, E90TLCU, E90TXCU, E90TLCC, E90TLCE, E90TXCE, E90TLES, E90TXES
100 hp — Johnson: 100ML, 100TLR, 100TXLR-79, 100MLCS, 100TRLCS, 100TRXCS
Evinrude: 100990, 100993, 100999, E100MLCS, E100TLCS, E100TXCS
110 hp — Johnson: J110MLCD, J110TLCD, J110MLCU, J110TLCU, J110MLCC, J110TLCC, J110TXCC, J110TLCE, J110TXCE
Evinrude: E110MLCD, E110TLCD, E110MLCU, E110TLCU, E110MLCC, E110TLCC, E110TXCC, E110TLCE, E110TXCE
115 hp — Johnson: 115ESL-73, 115ESL, 115ETL-74, 115ETL-75, 115EL, 115ETL-76, 115ETL, 115TXL-77, 115ML, 115TXL-78, 115TL, 115TXL-79, 115LMCS, 115TLCS, 115TXCS, J115TLCIH, J115TLCIM, J115MLCIH, J115MLCIM, J115TXCIH, J115TXCIM, J115MLCNB, J115TLCNB, J115TXCNB, J115MLCT, J115TLCT, J115TXCT, J115MLCR, J115TLCR, J115TXCR, J115TLES, J115TXES
Evinrude: 115393, 115493, 115593, 115693, 115790, 115793, 115799, 115890, 115893, 115899, 115990, 115993, 115999, E115MLCS, E115TLCS, E115TXCS, E115TLCIH, E115TLCIM, E115MLCIH, E115MLCIM, E115TXCIH, E115TXCIM, E115MLCNB, E115TLCNB, E115TXCNB, E115MLCT, E115TLCT, E115TXCT, E115MLCR, E115TLCR, E115TXCR, E115TLES, E115TXES
120 hp — Johnson: J120TLCO, J120TXCO, J120TLCD, J120TXCD, J120TLCU, J120TXCU, J120TLCC, J120TXCC, J120TLCE, J120TXCE, J120TLES, J120TXES
Evinrude: E120TLCO, E120TXCO, E120TLCD, E120TXCD, E120TLCU, E120TXCU, E120TLCC, E120TXCC, E120TLCE, E120TXCE, E120TLES, E120TXES
135 hp — Johnson: 135ESL73, 135ESL, 135ETL-74, 135ETL-75, 135EL, 135ETL-76
Evinrude: 135383, 135443, 135483-89, 135583, 135643, 135683
140 hp — Johnson: 140ML, 140TL, 140TXL-77, 140TXL-78, 140TXL-79, 140MLCS, 140TLCS, 140TXCS, J140TLCIH, J140TLCIM, J140MLCIH, J140MLCIM, J140TXCIH, J140TXCIM, J140MLCNB, J140TLCNB, J140TXCNB, J140MLCT, J140TLCT, J140TXCT, J140MLCR, J140TLCR, J140TXCR, J140TLCO, J140TXCO, J140TLCD, J140TXCD, J140TLCU, J140TXCU, J140TLCC, J140TXCC, J140CXCC, J140TLCE, J140TXCE, J140TLES, J140TXES
Evinrude: 140740, 140743, 140783, 140840, 140843, 140883, 140940, 140943, 140983, E140MLCS, E140TRLCS, E140TRXCS, E140TRLCIH, E140TRLCIM, E140MLCIH, E140MLCIM, E140TRXCIH, E140TRXCIM, E140MLCNB, E140TRLCNB, E140TRXCNB, E140MLCT, E140TLCT, E140TXCT, E140MLCR, E140TLCR, E140TXCR, E140TLCO, E140TXCO, E140TLCD, E140TXCD, E140TLCU, E140TXCU, E140TLCC, E140TXCC, E140CXCC, E140TLCE, E140TXCE, E140TLES, E140TXES
150 hp — Johnson: 150TL-78, 150TL, 150TXL-79, 150TLCS, 150TXCS, J150TLIH, J150TLIA, J150TXCIH, J150TXCIA, J150TLCNM, J150TXCNM, J150TLCT, J150TXCT, J150TLCR, J150TXCR, J150STLCR, J150TLCO, J150TXCO, J150STLCO, J150TLCD, J150TXCD, J150TLCU, J150TXCU, J150TLCC, J150TXCC, J150CXCC, J150TLCE, J150TXCE, J150CXCE, J150TLES, J150TXES, J150CXES
Evinrude: 150849, 150940, 150949, E150TRLCS, E150TRXCS, E150TRLCIH, E150TRLCIA, E150TRXCIH, E150TRXCIA, E150TRLCNM, E150TRXCNM, E150TLCT, E150TXCT, E150TLCR, E150TXCR, E150STLCR, E150TLCO, E150TXCO, E150STLCO, E150TLCD, E150TXCD, E150TLCU, E150TXCU, E150TLCC, E150TXCC, E150CXCC, E150TLCE, E150TXCE, E150CXCE, E150TLES, E150TXES, E150CXES
175 hp — Johnson: 175TL, 175TXL-77, 175TXL-78, 175TXL-79, 175TLCS, 175TXCS, J175TLCIH, J175TLCIM, J175TXCIH, J175TXCIM, J175TLCNB, J175TXCNB, J175TLCT, J175TXCT, J175TLCD, J175TXCD, J175TLCU, J175TXCU, J175TLCC, J175TXCC, J175TLCE, J175TXCE, J175STLCE, J175TLES, J175TXES, J175STLES
Evinrude: 176740, 176749, 175840, 175849, 175940, 175949, E175TRLCS, E175TRXCS, E175TRLCIH, E175TRLCIM, E175TRXCIH, E175TRXCIM, E175TRLCNB, E175TRXCNB, E175TLCT, E175TXCT, E175TLCD, E175TXCD, E175TLCU, E175TXCU, E175TLCC, E175TXCC, E175TLCE, E175TXCE, E175STLCE, E175TLES, E175TXES, E175STLES
185 hp — Johnson: J185TLCR, J185TXCR, J185TLCO, J185TXCO
Evinrude: E185TLCR, E185TXCR, E185TLCO, E185TXCO
200 hp — Johnson: 200TL, 200TXL-76, 200TXL-77, 200TXL-78, 200TXL-79, 200TLCS, 200TXCS, J200TLCIH, J200TLCIB, J200TXCIH, J200TXCIB, J200TLCNE, J200TXCNE, J200TLCT, J200TXCT, J200TXCD, J200TXCU, J200TXCC, J200SCLCC, J200CXCC, J200STLCE, J200TXCE, J200CXCE, J200STLES, J200TXES, J200CXES
Evinrude: 200640, 200649, 200740, 200749, 200840, 200849, 200940, 200949, E200TRLCS, E200TRXCS, E200TRLCIH, E200TRLCIB, E200TRXCIH, E200TRXCIB, E200TRLCNE, E200TRXCNE, E200TLCT, E200TXCT, E200TXCD, E200TXCU, E200TXCC, E200SCLCC, E200CXCC, E200STLCE, E200TXCE, E200CXCE, E200STLES, E200TXES, E200CXES
225 hp — Johnson: J225TLCD, J225TXCD, J225PTLCD, J225PTXCD, J225TLCU, J225TXCU, J225PTXCU, J225TLCC, J225TXCC, J225CLCC, J225PLCC, J225PXCC, J225CXCC, J225TLCE, J225TXCE, J225CXCE, J225PLCE, J225PXCE, J225SCXCE, J225STLCE, J225SPLCE, J225SPXCE, J225TLES, J225TXES, J225CXES, J225PLES, J225PXES, J225SCXES, J225STLES, J225SPLES, J225SPXES
Evinrude: E225TLCD, E225TXCD, E225PTLCD, E225PTXCD, E225TLCU, E225TXCU, E225PTXCU, E225TLCC, E225TXCC, E225CLCC, E225PLCC, E225PXCC, E225CXCC, E225TLCE, E225TXCE, E225CXCE, E225PLCE, E225PXCE, E225SCXCE, E225TLES, E225TXES, E225CXES, E225PLES, E225PXES, E225SCXES
235 hp — Johnson: 235TL, 235TXL-78, 235TXL-79, 235TRLCS, 235TXCS, J235TLCIH, J235TLCIB, J235TXCIH, J235TXCIB, J235TLCNE, J235TXCNE, J235TLCT, J235TXCT, J235TLCR, J235TXCR, J235STLCR, J235TLCO, J235TXCO, J235STLCO
Evinrude: 235840, 235849, 235940, 235949, E235TRLCS, E235TRXCS, E235TRLCIH, E235TRLCIB, E235TRXCIH, E235TRXCIB, E235TRLCNE, E235TRXCNE, E235TLCT, E235TXCT, E235TLCR, E235TXCR, E235STLCR, E235TLCO, E235TXCO, E235STLCO
Sub-models / Variants: 3-cylinder (jet-drive application chart: L60, L60L, L60C, L60CL, L60L-89, L60CL-89), V4 (jet-drive application chart: M85-73, M135-73, R85, R140), V6 (jet-drive application chart: R6)
Gearcase Variants: Electric shift with two solenoids (65 hp, 1972); mechanical shift with hydraulic assist (65–135 hp, 1973–1975; 85–200 hp, 1976–1977); mechanical shift (70 hp, 1976–1977; 75 hp, 1975–1977; all covered units from 1978)
Model Years: 1972–1991 (1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991)
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Cylinder head bolt torque: 228 in-lbs final torque; staged tightening required
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Flywheel nut torque: 100 ft-lbs (60–140 hp); 145 ft-lbs (150–235 hp)
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Reed tip clearance (max, reed at rest): 0.010 inches
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Alternator output: 6–10 amps standard; accessory installations up to 35 amps
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Alternator charging cut-in speed: 800–1000 RPM with a partially discharged battery
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Lower unit capacity: 26.6 ounces (90 hp and 100 hp)
Johnson Manual Features & Content Preview
Service and repair coverage for 1972–1991 Johnson Evinrude 60–235 hp outboards with 3-cylinder, V4, and V6 powerheads. The manual separates procedures by ignition system, carburetor design, and lower-unit configuration.
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Powerhead repair: Disassembly, cylinder inspection and honing, piston and crankshaft service, bearing installation, reassembly, and break-in procedures.
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Fuel and VRO systems: Type I–IV carburetor service, primer choke diagnosis, fuel-pump testing, and Variable Ratio Oil circuit checks.
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CD ignition: Type I and Type II flywheel magneto troubleshooting, stator and timer-base replacement, power-pack tests, and ignition synchronization.
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Electrical service: Charging-system diagnosis, rectifier and regulator tests, Prestolite and American Bosch starter overhaul, and model-specific wiring diagrams.
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Lower units and controls: Gearcase rebuilding, water-pump replacement, Hydro-Electric Shift Box service, mechanical shift controls, and throttle-cable adjustment.
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Power tilt/trim: Hydraulic fault diagnosis, cylinder and valve service, electrical circuit checks, and trim-motor testing and repair.
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Outboard Jet Drive: Driveshaft and bearing service, impeller shimming, reverse-gate adjustment, water-pump assembly, and lubrication coverage.
This manual suits readers who understand two-stroke carburetion and ignition and can use the meters and test equipment specified for the work.
Powerhead Inspection and Reassembly
The powerhead chapter explains reed-valve operation and loop scavenging before covering internal engine work. Inspection includes cylinder condition, piston fit, wrist pins, connecting rods, needle-bearing cages, and crankshaft bearings.
Separate instructions distinguish the 3-cylinder crankshaft's labyrinth seals from the sealing rings used in V4 and V6 engines. Powerhead exploded drawings show component relationships, while the assembly sections address bypass covers, exhaust-cover gaskets, reed boxes, and crankcase sealing.
The manual warns that V4 and V6 crankshaft sealing rings are brittle and can break if twisted during removal or installation.
Carburetors and VRO Diagnosis
Carburetor coverage distinguishes single-barrel and double-barrel designs, fixed-orifice arrangements, float inspection, and linkage adjustment. Type IV sections address the individual carburetors used on the 120/140 hp V4 and 200/225 hp V6 configurations.
VRO troubleshooting includes fuel-and-oil circuit checks, oil-line vacuum testing, and warning-horn diagnosis. A defective VRO pump is replaced as an assembly; the manual does not provide an internal pump overhaul procedure. Its pulse-hose cautions explain how a misplaced spark arrestor can damage the pump.
V4 and V6 primer-choke hose-routing drawings support reconnection after powerhead work. Fuel-system service requires battery disconnection and precautions against igniting fuel or fumes.
Ignition, Charging, and Starter Testing
Type I power packs use external terminals; Type II units use sealed packs with multipin connections. Separate tests for 3-cylinder, V4, and V6 systems help match a no-spark diagnosis to the installed ignition before a power pack is condemned.
Illustrations include 3-cylinder Power Pack Terminal Identification and the 65 hp alternator Wire Identification drawing. Synchronization sections cover throttle pickup, timing-pointer adjustment, and the differing V6 linkage arrangements.
Charging tests distinguish stator, rectifier, and regulator faults. Starter service covers armature and commutator inspection, brush replacement, and bench testing for the Prestolite and American Bosch designs.
Gearcases, Trim Hydraulics, and Jet Drives
The lower-unit chapter separates electric-shift, hydraulically assisted mechanical-shift, and fully mechanical gearcases. Each has its own troubleshooting and rebuilding instructions, including bearings, seals, gear alignment, water-pump work, and functional checks. It also addresses frozen propeller shafts and seized propellers.
Power tilt/trim coverage includes hydraulic functional diagrams, pump and valve diagnosis, Prestolite and Showa tilt-cylinder service, and the separate early V4 arrangement. Tool references include OMC Trim Cylinder End Cap Remover 324958 and Tilt Cylinder End Cap Remover 326485.
The jet-drive exploded view identifies the bearing housing, impeller, spacers, and intake grille. Adjustment coverage extends to cable alignment, neutral stop, and trim. Maintenance chapters also cover winter storage, submerged-engine service, steering checks, and propeller selection, including progressive-pitch designs.
A Preview of VRO Test Data and Jet Impeller Clearance
These examples are a small selection of the manual's fuel-system test data and jet-drive adjustment specifications.
For the VRO fuel-and-oil circuit test, pump discharge pressure is 5–15 psi at near full throttle. The isolated oil-pickup-to-hose-end circuit is checked for its ability to hold 7 inHg of vacuum.
The jet-drive section specifies approximately 1/32 inch (0.8 mm) between the impeller edge and the intake-housing cone, with coverage of the related shim adjustment.
PDF Access and Diagram Detail
Text search and wiring labels: PDF text search and embedded bookmarks are not available. Small labels in ignition test drawings and V4/V6 wiring diagrams are best read with zoom.
One printable, 403-page PDF contains 370 chapter pages and a 27-page appendix. The total also includes one Engine Finder page and five table-of-contents pages; these six preliminary pages are already included in the 403 pages.
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