1977

SERVICE MANUAL
2

hp
INTRODUCTION

model
GENERAL
SERVICE
INFORMATION

FUEL
SYSTEM
IGNITION
SYSTEM
POWER
HEAD
LOWER
UNIT
MANUAL
STARTER

HATIONAL
OF SERVICE MAHAGEAS
MrMlfll

. ' -'"

fJ

EI
11

5-2

The power head consists of one cylinder, piston, rod, crankshaft, and
crankcase. The cylinder is horizontally mounted in vertical plane and
delivers one power impulse
crankshaft revolution. See Figure 5-1 .
FUEL INTAKE AND EXHAUST

THEORY OF

39397

COMPRESSION STROKE-UP

FUEL-AIR
MIXTURE
ENTERS

Two-cycle engines used

outboard motors require only two piston
strokes - one
one down, to effect crankshaft revolution and to
complete the exhaust-intake-compression-ignition sequence that
duces power. In two-cycle engine, ignition of the fuel-air mixture
occurs as the piston reaches the top of each stroke. The explosion
drives the piston downward. Toward the end of the downward stroke,
ports which lead to the exhaust system
uncovered. The exhaust
gases flow into these ports, thus reducing the pressure in the cylinder.
At almost the same time, intake ports
opened. These ports connect
with the crankcase where fuel and air mixture has been induced
carburetion. The downward motion of the piston compresses this mixture in the crankcase and forces it through the intake ports into the
cylinder. The inrushing charge of the fuel-air mixture helps in ejecting
the last of the exhaust gases from the cylinder. See Figure 5-1, Fuel
Intake and Exhaust.
As the piston begins its upstroke, it closes the intake and exhaust ports
and begins to compress the fuel and air mixture trapped in the cylinder.
The upward travel of the piston also reduces the pressure in the crankcase compartment. The resulting suction opens leaf valves which admit
additional air and fuel from the carburetor into the crankcase, thus
paring the next cylinder charge. See Figure 5-1,
Compression
Stroke.
At the top of the piston stroke, the compressed fuel-air mixture is ignited
timed spark and the cycle begins anew. In an outboard motor
engine running at full throttle, this cycle

repeated 4000
times every minute. See Figure 5-1, Power Stroke.
PISTON

36527

POWER STROKE-DOWN

The function of the piston in two-cycle engine is to receive the force of

combustion and to transfer it through the connecting rod to the crankshaft, and to control the flow of fuel vapor and exhaust gases covering
and uncovering the ports in the cylinder.
Since the piston, with the piston rings, receives the force of combustion
in the cylinder head, it is necessary that both the piston and piston rings

properly fitted to form seal between the piston head and cylinder
wall.
retain maximum power within the cylinder head, the cylinder
must
perfectly round and the piston rings correctly seated in their
grooves.

EXPLODING
FUEL-AIR

AND BEARINGS

The connecting rod provides linkage between the piston and crankshaft.
The force of combustion, applied to the piston in reciprocating straight
line thrust, is converted to rotating power at the crankshaft through the
linkage of the connecting rod . The crankshaft is supported caged
needle lower main bearing and caged needle
main bearing.

LEAF VALVE
(CLOSED)

ROD,

COOLING SYSTEM
36557

Figure 5-1. The Two Stroke

Cycle

The power head is water cooled. water

driven the driveshaft, forces water through channels in the power head. Heated wate r
is discharged through the exhaust tube.
2/4

5-7
UPPER MAIN BEARING AND OIL SEAL
Instal1 upper main bearing through bottom of crankcase. Press against
1ettered side of bearing case until bearing is recessed 1/ 16" (1.5
be10w finish thrust face of crankcase . Avoid 10ss of need1es in upper
main bearing.

Instal1

NOTE

sea1, lip down until flush with top of c rankcase.

PISTON INST ALLATION

Coat piston and cylinder bore with
and instal1 piston and connecting
rod assembly through crankcase. Push piston through cylinder until
piston
grooves are exposed. The intake side of the piston deflector
must p1aced toward the intake port.
Figure 5-19 .
PISTON RINGS

Figure 5-19. Correct Piston

Instal1ation

Instal1 the piston rings piston. Spread each ring with ring expander
just enough to slip it over the head of the piston and down into p1ace .

Figure 5-20.
sure
rings fit free1y in the piston ring grooves.
The ring grooves are pinned I secure the position of the rings primar
to prevent ends of the
from catching the edges of the ports
in the cylinder, but a1so to
sure staggering of the ring gaps . Careful1y press piston and
into cylinder bore
head of piston is
flush with top of cylinder .
NOTE
Do not press beyond this
at
of cylinder

or 10wer ring will 10ck into recess

Damaged piston and broken piston rings

result from imperfect

of the ring groove and the piston dowe1 pins. Remove

necting rod
CONNECTING ROD

If removed, rep1ace

43027

Figure 5-20. Illstalling Rings

Piston
Connecting rod

not
correct assembly, smal1
sides of rod and

When rep1acing need1e

when the connecting rod and

App1y coat of
to cOllnecting rod liner,
Figure 5-21.

turned end for end.

ments are provided
5-18.

inserts,
match.

assist
matching

sure dove tail ends match

Figure 5-18.

Bearing Grease (Part Number 378642)

p1ace 14 need1es in cOnllectillg rod.

in crallkcase careful1y to avoid disturbing

upper bearing sea1.
Figure 5-22.

need1es in

BOSS
MARKS

Figure 5-18.
2/7

4 30 4 5

Figure 5-21. Install 14 Need1es

in Rod

1977 Johnson 2HP Outboards Service

Manual
Original Johnson service manual covers 2HP Outboard motors.

Buy this Manual

Manual covers the following Johnson 2HP outboard model: 2R77

Manual covers detailed maintenance and repair procedures. It includes hi-resolution
diagrams and detailed step-by-step instructions.
Item #: 7702
Manual chapters:
- Introduction
- General Service Information
- Fuel System
- Ignition System
- Power head
- Lower Unit
- Manual Starter
PDF file is indexed and searchabe.

Buy this Manual

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