1872

OUTBOARO MOTOR

VICE MANUA

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MODEL 2R72

IT E M NO. JM7201

OUTBOARD MARINE CORPORATION 1972 ALL RIGHTS RFSFRVFn

3-5
LEAF
STOP

:::--:--L AF

GASKET

LEAF

68 102.0

Figure 3-10. Leaf Valve

Disassembled

Figure 3-9. Intake Manifold

and Leaf Valve Assembly
d. Clearance under
stop should
bending leaf stop. See Figure 3-9.
URETOR

1/4"; adjust if necessary

Figure 3-11. Re-Seating

Plug

Clean out all the jets and passages, and the venturi, making sure
gum
varnish deposits remain. Dry after cleaning with compressed
air.
clean for final reassembly.

Check
gasket surfaces for nicks, scratches, distortion. Slight
irregularities can corrected with the use of surface plate and
cloth.

Check throttle and choke shafts for excessive

Check operation
of choke and throttle valves to sure they correctly shut
air flow,
yet move freely withoutbinding. Replace
body if valves
shafts
excessively worn damaged.

I'''<IINOTE

threaded edges of the choke and throttle valve attaching

screws
staked during carburetor assembly to prevent 10ss
during operation. Disassembly of these valves is possible but
replacement of the carburetor body is recommended.

Figure 3-12. Removing

Plug

CORE PLUGS

If necessary, remove
plug to clean out slow speed orifice holes.
See Figure 3-12. If leakage occurs at
plug
smart tap with

and flat end punch in the center the
plug will normally
correct this condition. See Figure 3-11.

If leakage persists, drill

plug to depth not

punch, carefully
out the

1/8 inch hole through the center the

than 1/16 inch below its surface. With
plug. See Figure 3-12.

Inspect and clean the casting contact

If nicks, scratches,
an out-of-round condition exist, the casting will have to replaced. If
casting opening is normal, apply bead of Sealer 1000 to the outer edge

new
plug. Place new
plug in casting, convex side
Flatten to tight fit with flat end punch and
and check for
leakage.

LEAD SHOTS
If leakage occurs at

lead shot

follow these corrective measures:

If leakage is slight, smart tap with

in the center
lead shot will normally correct this condition. See Figure 3-13.

the

Figure 3-13. Re-Seating and

Installing Lead Shot

2-4

L UBRICATION
POINT

require

Check level after first 10 hours of

operation and every 50 hours of
operation thereafter. Add lubricant if necessary.

Same as Fresh
Water

Drain and refill every 100 hours

of operation once
season,
whichever occurs first.

Same as Fresh
Water

60 days

30 days

60 days

30 days

60 days

30 days

Carburetor
3. Throttle
and Choke Linkage
See Figure 2-4

4. Clamp Screw
See Figure 2-5

.75 oz.

2. Steering Handle Pivot

See Figure 2-3

FREQUENCY
(PERIOD OF OPERA TION)
FRESH WATER
#SALT WATER

1. Gearcase
See Figure 2-2

# Some areas

CHART

frequent lubrication.

OF GASOLINE: Use
Leaded gasoline.

TYPES OF LUBRICANT

GREASE GUN

8..

SAFETY WARNING
Gasoline
is
extremely
f1ammable and high1y
plosive under certain conditions. Always stop engine, and do not smoke
allow open f1ames spark
near the boat when refuel
changing fuel tanks.

"Regular" Leaded gasoline

' \:;...

"Premium"

NOTE

When operating in any other country than the United States,

Canada, Australia, any Leaded gasoline

used which will

satisfactorily operate an automotive engine.
LUBRICANT: Use reputable Outboard 50:1 lubricant which is BIA
certified for service TC-W (two cycle-water cooled). It is formulated
to give best engine performance with least combustion
deposits,
least piston varnish, maximum spark plug life, and best lubrication. See
inside front cover.
If
OUTBOARD LUBRICANT is not av ailabl , another
certified
TC-W lubricant

used.
AUTOMOTIVE OILS and 24 :1 ratio pre-mix fuel should not used
except in emergency, when B. I.A. certified TC-W lubricant is not avail
In an emergency, use SAE30 with container marked service ML

the new designation "SA-SB," "Service

"SB." Avoid
oils marked "ML"
the new designation SA, multi-viscosity oils
such as 10W-30. It should
recognized that automotive oils
formulated to fit the automotive needs and OUTBOARD
is
formulated for outboard motor needs.
FUEL MIXING INSTRUCTIONS: Always use fresh gasoline. Whenfilling
an empty tank, put approximately one gallon of gasoline into tank and
add recommended amount of lubricant. Shake tank vigorously to insure
thorough mixing, then add the balance of the gasoline.
FUEL MIXTURE : 1 part Lubricant to 50 parts Gasoline OR: (6 Gal.
Tank) 1 pint lubricant to 6 gallons (5 Imperial) of gasoline (3 Gal. Tank)
1/ 2 pint lubricant to 3 gallons (2-1 / 2 Imperial) of gasoline

Additive compounds such as "tune-up" compounds,

"tonics," "friction reducing" compounds, etc.,
unnecessary and
not recommended.
use of
engine cleaner,
rust preventive oil and
2 + 4 Fuel Conditioner is recommended.
GEARCASE: Remove plug and gasket from starboard side of gearcase.
Turn motor over, starboard side down. Allow
to drain completely.

refill, turn motor so lubrication hole is

place tube of

Lubricant in hole as illustrated. Fill until lubricant appears

at hole and
air has escaped. Replace plug and gasket.

LUBRICANT" which has been formulated to protect against damage

to bearings and gears must
used, as extensive damage
result
from improper lubrication.

1972 Johnson 2HP Outboard Motor

Service Manual
Original Johnson service manual covers 2HP Outboard motors.

Buy this Manual

Manual covers the following Johnson 2HP outboard model: 2R72

Manual covers detailed maintenance and repair procedures. It includes hi-resolution
diagrams and detailed step-by-step instructions.
Item #: JM-7201
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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