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TABLE OF CONTENTS


JOHNSON / EVINRUDE POWERHEAD COMPONENTS

Johnson / Evinrude Johnson / Evinrude
Pistons Section 9 Carburetor Kits and Fuel Pumps Section 13

Engine Designs (60° vs. 90°) V4/V6 ........................................... 114 Carburetor Service Kits ............................................................. 148
GLM Exclusive Marine Pistons .................................................. 114 Needles and Seats ..................................................................... 148
Piston Designs (Crossflow, Loopcharged & Four-Stroke) ........ 115 Carburetor Service Kits / Needle and Seats Applications ....... 149
2-Cylinder Crossflow Pistons ..............................................116-117 Carburetor Parts & Gaskets ...................................................... 150
2-Cylinder Loopcharged Pistons ................................................ 118 Gaskets ....................................................................................... 151
3-Cylinder Loopcharged Pistons ........................................ 119-121 Fuel Pump Kits and Applications .............................................. 152
V4 90° & V6 90° Crossflow Pistons ........................................... 122 Kit Components .......................................................................... 152
V6 90° Crossflow Pistons ........................................................... 123 Fuel Filters and Kits ................................................................... 153
V4 60° & V6 60° Loopcharged Pistons ............................... 124-125 Low Pick-up Water / Fuel Separator Mounting Bracket ........... 154
V4 90° / V6 90° / V8 Loopcharged Pistons ......................... 126-127 How to Choose the Correct Water / Fuel Separator ................. 155
V6 90° Loopcharged Pistons ...................................................... 128 Stainless Steel Brackets / Die Cast Aluminum Brackets ........ 155
2-Cylinder Four-Stroke Pistons ................................................. 129 Water Separating Fuel Filter Kits .............................................. 156
Piston Kits and Rings Applications .................................... 130-131 Johnson / Evinrude
Powerhead Gaskets Section 14
Johnson / Evinrude
Powerhead Bearings and Seals Section 10 1 & 2-Cylinder Head Gaskets .................................................... 158

Powerhead Bearings ............................................................ 134-135 3-Cylinder & V4 Head Gaskets.................................................. 159
Main Bearings ............................................................................. 134 V6 & V8 Head Gaskets............................................................... 160
Center Bearings .......................................................................... 134 Head Gaskets Applications ....................................................... 161
Center Split Sleeve ..................................................................... 134 Powerhead Gasket Kits ....................................................... 162-165
Center Bearing Kits .................................................................... 134 Powerhead Gasket Kits Applications ........................................ 165
Connecting Rod Bearings - Small End ...................................... 135 Powerhead Mounting Gaskets ............................................ 166-167
Connecting Rod Bearings - Big End .......................................... 135 Intermediate Housing Exhaust Gaskets ................................... 167
Seals - Exhaust Housing ........................................................... 167
Bearing Applications ........................................................... 136-137
Crankshaft Seals Applications .................................................. 138 Powerhead Exhaust Gaskets ..................................................... 168
Powerhead Water Passage Cover Gaskets ............................. 169
Johnson / Evinrude
Thermostats Section 11 Powerhead Transfer Port Gaskets - Crossflow Engines .......... 169
Carburetor to Intake Manifold Gaskets..................................... 170
Thermostat Kits .......................................................................... 140 Intake Manifold Gaskets / Reed Plate Gaskets ....................... 171
2-Cyl. 25/35 HP Thermostat Assembly (1996-2001) ............... 141 Air Silencer Gaskets .................................................................. 172
2 & 3-Cyl. & V4 Loopcharged Thermostat Assembly (1992-2000) ........... 141
V4 Crossflow Assembly ............................................................. 141 Johnson / Evinrude
V6 Crossflow Assembly ............................................................. 142 Oil Seals & O-Ring Size Charts Section 15
Thermostats ................................................................................ 142 Oil Seals Shaft & Bore Size ....................................................... 174
Thermostat Covers & O-ring ...................................................... 142 O-Ring Size Chart ...................................................................... 175
Thermostat & Valve Springs ...................................................... 143
Thermostat Housing Components ............................................. 143
Thermostat Gaskets................................................................... 144 WARRANTY
Thermostat Cover Gaskets ........................................................ 144
Notes .................................................................................... 176-177
Johnson / Evinrude Limited Warranty ........................................................................ 178
Ignition and Electrical Section 12
Warranty Service Procedure ...................................................... 179
Point Sets & Condenser ............................................................. 146 Warranty Claim Application ....................................................... 180
Power Trim Relay ........................................................................ 146
Rectifiers ..................................................................................... 146
Point Sets & Condenser Application ......................................... 146
Power Trim Relay Application .................................................... 146
Rectifier Application ................................................................... 146
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