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

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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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