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Johnson Service Bulletins

- Thru May, 1980

Currently, only a few bulletins are posted. There are so many other aspects of this site that need to be worked on; there is no reason to spend the time and effort to publish bulletins nobody will ever read.
If you need a bulletin, please use the “Contact” link above, and I will gladly post it. Be sure to include the Bulletin Number!

FUEL SYSTEM AND LUBRICATION
Bulletin # Subject Date
1232 Improving idle characteristics on 1970 - 3 cyl. 1/70
1242 Adjusting slow speed needles on 1970 - 3 cyl. & V-4 8/70
1255 Orifice plugs and inlet needles for 1963 thru 1971 models 2/71
1260 Minimum recommended fuel pump pressures 4/71
1265 Causes of poor idle on 1971 - 50 7/71
1283 Improve high speed - Orifice change on 1972 - 65 2/72
1298 Replace air silencer screws when base removed on 50 thru 125 6/72
1311 Orifice plugs & float valve & seat for 1972 & 73 - 6 thru 135 12/72
1322 Poor idle or hard starting characteristics on 1973 - V-4's 7/73
1328 Low speed knob grommet restricting air flow on 1974 - 9.9 & 15 10/73
1330 Change in carburetor choke valves on 1974 - 2, 9.9 & 15 11/73
1331 Rev. 1 New idle adjustment stop on 1974 - 9.9 & 15 1/74
1336 Spark plug fouling on 1974 - 9.9 & 15 2/74
1342 Piston failures on 1973 & 74 - 135 5/74
1354 Testing fuel pump pressure on 1974 to date - 4 thru 25 9/74
1385 Rev. 1 Recommended fuel for all to date - 2 thru V-6 9/75
1388 New idle speed control knob on 1974 & 75 - 9.9 & 15 8/75
1392 Permanently installed fuel tanks on 1976 to date - V-6's 10/75
1399 Change in carburetor orifice for 1976 - 55 & 75 12/75
1412 Change in choke linkage on 1976 - V-4's 4/76
1415 Throttle cam adjustment tool on all models to date 4/76
1422 Hard starting in cold weather on 1976 - V-6's 6/76
1427 Permanently installed fuel systems on dual V-4, single or dual V-6 8/76
1429 Mid range improvement on 1976 - 70 & 75 9/76
1438 HP restrictor kit on 1969 thru 1978 - 25 reduced to 20 6/77
1441 Lower to upper fuel pump hose on 1977 - V-6's 7/77
1453 Carburetor jet sizes on all recent models 1/78
1462 Carburetor improvements on 1978 - V-6's 4/78
1464 100:1 two cycle lubricants not approved for any models to date 5/78
1465 Lean won't idle - Missing idle air bleeds on 1978 - 140 5/78
1475 Loosening choke clevis due to wear on 1978 - V-4's 7/78
1479 Surging loss of power - Orifice change on 1978 - 150 8/78
1487 Loose choke butterfly screws on 1972 thru 1978 - 50 12/78
1491 Lean idle - Orifice change on 1979 - 175 2/79
1492 Engine not turning up - air bleed change on 1979 - 150 2/79
1493 Look alike float chamber gaskets on 1978 to date, V-4's & V-6's 4/79
1501 Recommended anti-siphon valves and fuel filter for all V-6's 6/79
1503 Eliminating insects from float bowl, add vent screen on 20 thru V-6 to date 8/79
1509 Rev. 1 Use of gasahol 1978 to date on all models 11/79
1514 Carburetor jet change 1979 - 55 1/80
1515 Hand starting cold engines on 1979 - 25 & 35 3/80
1516 Rev. 1 Carburetor Jet Change 3/80
1523 Revised fuel octane recommendation on 1976 to date - V-6's 3/80
1524 Fuel line vacuum tester on V-4's & V-6's to date 3/80
1528 Eliminating stalling after prolonged idle on 1980 - 50 and 1979 & 80 - 3 cyl. 4/80
1529 Fuel economy improvement on 1980 - 235 4/80
1532 List of available high, intermediate and low speed orifices - all fixed jet models 5/80
     
ELECTRICAL AND IGNITION SYSTEMS
Bulletin # Subject Date
1229  Testing clipper circuit on 1970 3 cyl. & V-4's  2/70
1237  New screw for anti-reverse contact & insulator on 1969-70 3 cyl. & V-4's  4/70
1239  Cleaning distributor caps on 1968 thru 1972-55 thru V-4  4/70
1249  Stator leads damaged by flywheel on 1970-50  12/70
1256  Short spark plug life due to charge coil or connector leakage on 1971-50  3/71
1261  Purpose of reverse cut-off spring. Do not remove from 55 thru V-4  5/71
1265  Causes of poor idle on 1971-50  7/71
1277  New throttle cam prevents starting in gear on 1972-40  10/71
1279  Servicing OMC CD system and new spark plug boots  1/72
1282  Erratic idle - Relieve back pressure - Adjust carburetor on 1972 - 20 & 25  1/72
1284  Supplement to 1282  2/72
1287  Causes of damage to instrument cable on 1971 & 72 - 50,  65 & V-4  3/72
1291  Intermittent firing due to poor ground connection on 1967 thru 1972 - 100 & 125  3/72
1310  New wiring clamp on timer base and sensor for 1973 - 50  10/72
1312 Rev. 1  Proper use of jumper cables and battery charging units - all models  3/73
1320  Electrical trouble shooting - Remote control on 1973 - 50 thru 135  6/73
1322  Poor idle or hard starting characteristics on 1973 - V-4  7/73
1326  Ignition key blanks on 1973 to date - All electric start models  10/73
1327  Sensors grounding to sensor shield on 1973 - 50 thru 135  10/73
1335  Eliminate warm up choke on 1968 thru 1974 - 50 thru V-4's  2/74
1336  Spark plug fouling on 1974 - 9.9 & 15  2/74
1341  Ignition shut-off switches on 2 thru 135 to date  4/74
1345  Rerouting of ignition coil ground lead on 1974 - 2,  4 & 6  5/74
1359  Cam-point timing on 1974 & 1975 - 9.9,  15 & 40  10/74
1361  Electric trolling motor transistor failure on 1974 to date  10/74
1370  Stator service tip on 1973 thru 1975 - V-4's  1/75
1375  Pulse pack service tips on 1967 thru 1970 - 100 & 115  2/75
1380  Stator resistance reachings on 1974 to date - 50 thru V-4  3/75
1381  Rev. 1 Battery cable extension & splicing on all electic models to date  10/75
1382  Water in power packs on 1973 thru 1975 - 50 thru 135  5/75
1383  New driver coil for 1974 thru 1976 - 9.9,  15 & 40  8/75
1400  Incorrect power pack usage on 1972 thru 1976 - 3 cyl. & V-4's  12/75
1402  Correction to Service Manual on 1976 - 200  1/76
1409  Rev. 1 Change in wiring location on 1969 thru 76 - 4  2/76
1414  Rev. 1 Hard starting or erratic ignition on 1969 & 1970 - 115  6/77
1418  Electric trolling motor - Battery installation procedure on all models to date  5/76
1419  Rev. 2 Spark plug chart on all models to date  2/79
1425 Armature plate bearing improvements and lubrication on 1974 thru 1976 - 9.9, 15, 35 & 40  6/76
1428  Electrical components bracket and ground leads on 1976 - V-6's  8/76
1433  Termination of rework program on Delco stator on 1961 thru 1966 - V-4's  12/76
1435  Heavier battery cables used on 1977 - V-6's  5/77
1439  Accessory ignition shut-off device on 1973 to date - 50 thru V-6  6/77
1442  Thermostat kit on 1974 thru 1976 - 40  7/77
1443  Sensor resistance and leakage tests on 1977 - 50  7/77
1445  Armature plate improvement kit on 1973-1976 - 20 & 25  8/77
1447  Change in flywheels on 1978 - V-4's  10/77
1448  Rev. 1 Power pack usage on 1968 thru 1979 - 4 thru V-6's  7/79
1454  Ignition coil internal changes on 1968 thru 1973 - 50 thru V-4's  3/78
1456  Assuring good electrical connections on 1977 power pack models to date  3/78
1471  Voltage regulator kit on 6,  9 or 10 amp alternators to date  7/78
1482  New hot horn on 1973 thru 1978 - 50 thru V-6  10/78
1483  Wire shorting in remote control on 1979 - 55 thru V-6  10/78
1488  Armature plate and pilot replacement kit on 1974 thru 1976 - 9.9,  15 & 35  1/79
1494  Neutral start switch mounting nuts loosening on 1978 to date - 25 & 35  4/79
1501  Cause of safety switches burning out on 1974 to date - 25,  35 & 40  6/79
1504  Timer base lead interference on 1979 - V-4's  8/79
1508  Parts Catalog error on 1978 - 55  11/79
1520  Minimum battery capacity recommendations on electric troll thru V-6 to date  3/80
1527  Identifying Delta Amplifier leads on 1970 & 71 - 60,  1970 thru 72 - 85 & 100  4/80
1531  High reading temperature gauge and ammeter battery overcharge on 1978 thru 1980 - V-4's & V-6's  4/80
1533  Missing or failure to reach full RPM - incorrect rotor 1969 & 70- 115  5/80
     
POWERHEAD, MANUAL STARTER AND MOTOR COVER
Bulletin # Subject Date
1244 Length of manual starter rope required for various models 9/70
1266 Correct installation of flywheel key on 1971 - 3 thru 25 7/71
1267 Overheating from separation of impeller & hub; supplement to 1103 7/71
1270 New spacer prevents distortion of control panel on 1971 - 2 9/71
1273 Change in flywheel nut torque on 1972 - 50 thru V-4 9/71
1275 Oversize pistons and rings for KC-13R Stinger racing model 10/71
1276 Cause of starter spring breakage on 6 and 9.5 10/71
1280 Change in starter lockout cam adjustment on 1972 - 50 2/72
1294 Lubricating spark advance lever at safety switch contact on 1972 - 50 6/72
1313 Defective cylinder to crankcase bolts on 1973 - 85 thru 135 1/73
1321 New procedure for adjusting starter lockout lever on 1973 - 20 & 25 6/73
1333 Water in lower cylinder on 1971 thru 1974 - 50 1/74
1340 Jumping out of gear and starter repair on 1974 - 9.9 & 15 3/74
1344 Lockout lever removal on 1973 & 1974 - 20, 25 & 40 5/74
1347 Water in cylinder on 1971 thru 1974 - 50 5/74
1352 Water in cylinder on 1973 & 1974 - 135 9/74
1357 Flywheel key installation on 1974 & 1975 - 9.9 & 15 9/74
1358 Correct number of starter spool turns on 1974 - 6 10/74
1365 High performance head kit on 1975 thru 1978 - 75 1/75
1376 Low compression cylinder heads on 1970 thru 1975 - 3 cyl. 2/75
1391 Product improvements on 1976 - 70 & 75 9/75
1405 Engine  overheating on 1976 - 35 2/76
1406 Change in cylinder head torque on 1976 - 35 1/76
1413 New cylinder head gasket coating on 1976 - 9.9 thru V-6 4/76
1420 Retorquing of cylinder head bolts on 2 thru V-6 to date 6/76
1421 Changes in 1977 models - 2 thru V-6 7/76
1424 Service Manual correction on 1976 - V-6's 6/76
1431 Crankshaft appearance on 1970 thru 1973 - 40 9/76
1436 Cause of overheating on 1976 thru 1978 - 35 5/77
1449 Improvements to manual start engines 1977 - 50 1/78
1451 Piston rings on 9.9 & 15 to date 1/78
1473 Rev. 1 Cylinder piston to skirt clearance on 1977 & 1978 - 2 thru 235 10/78
1480 Special crankshaft seal rings on 1978 to date - V-4's & V-6's 8/78
1484 Starter pawl return spring on 1979 - 9.9 & 15 11/78
1485 Repairing broken starter mounting boss on 1976 to date - V-6's 12/78
1499 Lower motor cover rattling on 1979 - V-4's 6/79
1502 Rev. 1 Low compression heads for commercial use on 1977 to date - 3 cyl. V-4's & V-6's 10/79
1507 Overheating due to blockages of cylinder water passages on 1979 - 4 11/79
1519 Proper use of OMC Gel Seal on all models to date 3/80
1534 Proper method of selecting correct oversize bore - 1969 thru 1979 - all models 5/80
     
MID SECTION AND
LOWER UNIT
Bulletin # Subject Date
1238  Installing converging ring on 1968 to date all thru-hub exhaust  4/70
1243  Eliminating overheating of propeller hub on 1969 & 70 - V-4's  8/70
1246  Heavy duty mounts for 1970 thru 1972 - 60  10/70
1252  Overheating propeller hubs; supplement to 1243  1/71
1253  Order correct swivel bracket seals on 1968 thru 1971 - 55 & 60  1/71
1257  Causes of driveshaft breakage on 1971 - 40  3/71
1258  Installing gearcase solenoid shift rods on 1971 - 50 thru V-4  4/71
1274  New oil pump - service procedure on 1968 thru 1971 3 cyl.  10/71
1278  Advantages of using SST propellers from 1971 to date  12/71
1281  "Snap" shift improvement on 1960 thru 1970 - 18, 20 & 25  1/72
1282  Erratic idle - relieve back pressure - adjust carburetor on 1972 - 20 & 25  1/72
1284  Supplement to 1282  2/72
1290  Securing propeller nut on 9.5,  20 & 25  3/72
1297  Servicing 1968-69 hydro electric gearcases - Correct parts needed  6/72
1300  Proper use of flushettes on any adaptable model to date  7/72
1303  Replacing stern bracket clamps on 1972 - 50 thru V-4  8/72
1307  Tank testing - Holding shift in gear during test on 1973 - 50 thru V-4  1/73
1309  New drain plug and magnet on 1973 - 50 thru 135  10/72
1314  New procedure for installing propellers on all thru-hub exhaust  4/73
1315  New neutral detent feature added to 1973 - 50 thru 135  4/73
1325  New trailering lock arm on 1973 - 65 long & V-4's  9/73
1337  Plunger and snap ring program on 1973 - 50 thru 135  2/74
1339  Checking thrust rod on all models to date  3/74
1340  Jumping out of gear and starter repair on 1974 - 9.9 & 15  3/74 
1343  Selecting correct mounting bolts on 1973 to date - 55 thru V-6  5/74
1346  Lubrication of tilt tube on 1973 & 1974 - 35 thru V-6  5/74
1349  E-Z-Duzit Gearcase lubrication fitting on all outboards and Stern Drives to date  7/74
1350  Service tips - tilt assist shocks on 1975 - 70 thru 135  7/74
1356  Using correct propeller bushing on 1975 - 50 thru 135  9/74
1363  Trim and tilt service tips on 1975 thru 1977 - 50 thru 140  4/75
1369  Gear shift adjustment on 1975 - 9.9 & 15  1/75
1372  Leakage at oil fill/drain hole on 1975 - 4W  2/75
1374  Selecting correct gearcase on 1975 - 70 B & E models  2/75
1377  New impeller housings on 1975 all models to date  5/75
1378 Rev. 1  Gearcase field modification program on 1975 - 70 thru 135  5/75
1379  Small gearcase clutch dog on 1975 - 50 & 75  4/75
1384  Incorrect model/serial number plates on 1975 - 70  7/75
1387  Exhaust emulsion draining from gearcase on 1974 & 1975 - 9.9 & 15  8/75
1389  Improving reverse thrust on displacement hulls for 1974 thru 1976 - 9.9 & 15  8/75
1393  Trim and tilt cylinder assemblies on 1973 thru 1976 - 50 thru 135  10/75
1394  New gearcase lubricant on all 1 1/2 thru V-6 to date  12/75
1396  Replacement water pump liner on 1976 - 4 90° drive  12/75
1397  Cooling system modification program on 1976 - 35  12/75
1398  Proper mounting of engine on 1976 to date V-6's  1/76
1407 New plastic water pump housing on 1974 thru 1976 - 9.9 & 15 2/76
1410 Operation of manual release valve on 1976 - V-6’s 2/76
1417 Replacement of gearcases on 1976 - 35 4/76
1430 Oil pump service assemblies on 1976 — V-4’s 9/76
1432 Lower mounts on V-4’s & V-6’s to date 9/76
1440 Plastic water pump impeller housing failures on all models to date 7/77
1444 Correction to 1977 Master Parts Price Book 7/77
1446 Troubleshooting integral T—N—T on 1977 to date 75, V-4’s & V-6's 10/77
1450 Service gearcase on 1977 & 1978 - V-6’s 1/78
1452 Obsolete water pump repair kits on various years and models 1/78
1455 Pinion gear nut torque specification on 1976-1978 - V-6’s 3/78
1459 Power trim valve noise on V-6's 4/78
1460 Removal of driveshaft from 1976 to date V-4’s & V-6’s 4/78
1461 Lifting engines by exhaust housing covers on 1978 to date V-4’s & V-6’s 4/78
1463 Rev. 1 Water pump improvements on 1978 - 35 8/78
1466 Servicing integral T-N-T on 1978 to date 7/78
1467 T-N-T stuck in tilted position on 1978 - V-4’s & V—6's 7/78
1468 Adjusting indicator gauge on integral T-N-T 7/78
1470 Change in lower mount system on 1977 - 25 to date, 1978 - 35 to date 7/78
1477 Separation of integral T-N-T valves from 1976 to date 8/78
1478 Corrosion of check valve on 1973 thru 1977 Prestolite T-N-T 8/78
1481 Lock up of tilt and reverse lock on 1977 — 140 & 1978 - 3 cyl. & V-4’s 8/78
1497 Procedure for shimming pinion gear on 1979 - 55 6/79
1498 Replacement of relief valve o'ring on integral T-N-T 6/79
1505 Causes of propeller shaft breakage on 1977 & 1978 — 25 8/79
1506 Gearcase lubricant level on all models to date 8/79
1510 Extension kit omission in Parts Catalog on 1980 — 4.5 & 7.5 12/79
1513 Eliminating shift shaft sticking on 1976 thru 1979 - 25 & 35 1/80
1514 Driveshaft to crankshaft spline wear on 2 & 4 to date 3/80
1517 Power loss due to hole burned in megaphone on 1979 - 150 thru 200 3/80
1518 Premature pinion bearing failure on 1976 to date V-6’s 3/80
1525 Correct installation of clutch dog on 1980 - 4.5 & 7.5 3/80
1530 Steering handle kits for 1979 - 6,1974 thru 1980 - 9.9 & 15,1979 thru 80 - 25/35 and 55 rope 4/80
1535 Improved bearing and gear kits/special alignment tool - 1960 thru 1979 - 18, 20 & 25 5/80
     
CONTROLS AND RIGGING
Bulletin # Subject Date
1241  Remote steering system installation on 1970 - 33 thru 115  8/70
1296  Proper mounting of engine on 1972 to date - 50 thru V-6  6/72
1302  New steering installation recommendations on 1973 thru 77 - 50 thru V-4  8/72
1306  Proper shift and throttle cable adjustment 1973 - 50 thru V-4  1/73
1318  Remote controls without "start in neutral only feature" on 1973 to date - 50 thru V-6  5/73
1319  Potentially dangerous steering kits on 1973 to date - 50 thru V-6  6/73
1320  Electrical trouble shooting of remote control on 1973 - 50 thru 135  6/73
1360  Correct method of attaching remote cables on 1975 - 70 & 75  10/74
1404  Steering and fuel systems and drywell drain holes on 1976 to date - V-6's  2/76
1408  Possible interference in steering system on 1976 to date - 35  3/76
1457  Field replacement program for OMC acessory controls  4/78
1458  Substituting motor tilt tube "Teleflex Bulletin"  4/78
1476  Remote control, dual installation with T-N-T on 1978 - V-4's & V-6's  7/78
1521  Correct installation of OMC long lifeTM (type "0") remote control cables  3/80
1537  Safety related considerations in rigging and testing a boat and motor  5/80
     
TOOLS AND ACCESSORIES
Bulletin # Subject Date
1242  Adjusting low speed needles on 1970 - 3 cyl. & V-4's  8/70
1319  Potentially dangerous steering kits on 1973 to date - 50 thru V-6  6/73
1363  Trim and tilt service tips on 1975 thru 1977 - 50 thru 140  4/75
1366  Dual steering recommendation on 1973 to date - 50 thru V-6  1/75
1393  Trim and tilt cylinder assemblies for 1973 thru 1976 - 50 thru 135  10/75
1401  12 amp alternator kits for 1976 to date - 55, 70 & 75  1/76
1403 Rev. 1  Ammeter kits for 1976 to date - V-6's  1/76
1416 Rev. 1  "Dole" power trim & tilt kit  8/77
1423  Causes of tachometer failures to date  6/76
1426  I nstalling plastic converging rings on 50 thru V-4's to date  7/76
1437  Test prop RPM with reverse thrust kit on 1976 to date - 9.9 & 15  6/77
1439  Accessory ignition snut off device for 1973 to date - 50 thru V-6  6/77
1446  Troubleshooting integral T-N-T on 1977 on date - 75, V-4's & V-6's  10/77
1469  Vertical elevating devices on models to date  7/78
1471  Voltage regulator kit 6, 9 or 10 amp alternators on models to date  7/78
1472  Emergency engine cooling using "Trouble Cooler" on models to date  7/78
1486  Frahm Resonant Reed tachometer  12/78
1489  Wiper nut for tilt tube steering on 1972 to date - 70 thru V-6  1/79
1511  Install trail lock spring with power "tilt kit" on 1980 3 cyl. & V-4's  12/79
1512  Control knobs for accessory remote controls  12/79
1522  Selecting correct 5 or 6 pulse tachometer for - 6 thru V-6  3/80
1524  Fuel line vacuum tester on V-4's & V-6's to date  3/80
1526  Handle cover kits for accessory controls  4/80
1531  High reading temp gauge and ammeter - Battery overcharge on 1978 thru 1980 - V-4's & V-6's  4/80
1536  Modification to T-N-T stand will allow bench testing after repair  5/80
     
MISCELLANEOUS
Bulletin # Subject Date
1264 Identifying improved lift bracket on 1969 thru 1971 - V-4's 6/71
1293 Safety and warning symbols 6/72
1323 Starting engines at speed on 1974 to date - 50 thru V-6 10/73
1326 Ignition key blanks for 1973 to date - All electric start models  10/73
1332 Defective pivot screw on 1973 & 1974 - 65 thru V-4 with accessory T-N-T and 1974 - 115 & 135 with trim 1/74
1348 Maintenance in adverse conditions all models to date 5/74
1351 Hard starting on 1972 & 1973 - 50 8/74
1385 Rev.  1 Recommended fuels 1 1/2 thru V-6 to date 9/75
1390 Lifting engine and removing from carton on 1976 to date V-6's  9/75
1474 Application of decals on all models to date 7/78
1490 Corrections to 1979 Service Manuals - 6 thru V-6 2/79
1496 Engine failure due to improper break in procedure on 1979 to date - V-6's  6/79
1500 Use of parts cleaning solvents and aerosol products 6/79