0209815 JOHNSON OWNER'S MANUAL, Evinrude

Table 1
Required Tools
Tool Part Number Part Description Qty
A 342-9516 Line Socket 1
B 4C-5597 Anti-Seize Compound -
C 195-4609 Seal Pick 1
D - Isopropyl Alcohol -
E 5P-4996 Plug 2 Start By:
Remove the Exhaust Elbow.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
Illustration 1 g02324314
Loosen clamp assembly (1).Note: Place locating marks on each tube assembly and the clamp assemblies prior to disassembly.
Remove bolt and clamp assembly (2).
Remove three bolts (4) and position tube assembly (3) out of the way.
Illustration 2 g02481317
Remove bolt (6) and the ground strap. Disconnect cable assembly (5).
Remove allen bolt (7), remove the hold down clamp, and disconnect cable assembly (7a).
Use Tooling (A) to disconnect the flame detection sensor (8).
Illustration 3 g02325353Note: Cap all tube assemblies and fittings that are disconnected to prevent fluid loss. This action will also keep contaminants out of the systems.
Disconnect tube assemblies (9) and (10).
Disconnect tube assemblies (11) and plug with Tooling (E).
Illustration 4 g02325434
Remove nuts (16) and remove combustion head (15).
Remove gasket (14), tube assembly (13), and gasket (12).Note: The gaskets are one time use only. Replace with new gaskets upon installation.
If required, remove studs (17).
Illustration 5 g02325454
Remove fittings (20) and (21).
Remove spark plug (19) and remove fittings (18).
Illustration 6 g02481319
Use Tooling (C) to remove O-ring seals (22) and (23) from cable assembly (7a). Discard the O-ring seals.Installation Procedure
Install combustion head (16) in reverse order of removal.
Apply Tooling (B) onto the threads of the studs (17). Tighten studs (17) to a torque of 17 2 N m (150 18 lb in).
Tighten nuts (16) in a crisscross pattern to a torque of 23 3 N m (17 2 lb ft). Tighten nuts (16) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft). Tighten nuts (16) again in a crisscross pattern to a torque of 28 3 N m (21 2 lb ft).
Use caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
Lubricate new O-ring seals (22) and (23) with Tooling (D) prior to installation.
Tighten fittings (20) and (21) to a torque of 60 6 N m (44 4 lb ft).
Tighten fittings (18) to a torque of 30 2 N m (22 1 lb ft).
Tighten spark plug (19) to a torque of 57.5 4 N m (42 3 lb ft).
Apply Tooling (B) to the threads of flame detection temperature sensor (8) and install the sensor. Use Tooling (A) to tighten flame detection temperature sensor (8) to a torque of 45 5 N m (33 3 lb ft).
Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.
Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".