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Evinrude Johnson Outboard Service and Repair Manual

This Clymer outboard shop manual covers Evinrude Johnson 5-70 four stroke horsepower engines for the years 1995-2001.

Models Included are:

1995-2001 EVINRUDE/JOHNSON 15 HP
1999-2001 EVINRUDE/JOHNSON 40 HP
1997-2001 EVINRUDE/JOHNSON 5 HP
1999-2001 EVINRUDE/JOHNSON 50 HP
1997-2001 EVINRUDE/JOHNSON 6 HP
1999-2001 EVINRUDE/JOHNSON 70 HP
1995-2001 EVINRUDE/JOHNSON 8 HP
1997-1998 EVINRUDE/JOHNSON 9.9 HP - 211CC
1995-2001 EVINRUDE/JOHNSON 9.9 HP - 305CC
The Evinrude Johnson outboard manual by Clymer is a great  reference for repair and service information. This service manual is written for the do-it-yourselfer as well as the experienced mechanic.  The repair manual contains hundreds of original photographs and illustrations obtained from the complete disassembly and assembly of the engine. This, in addition to extensive research, is how Clymer repair manuals achieve an unmatched level of detail.  The shop manual will guide mechanics and owners through each service, troubleshooting and repair procedure possible.

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The Evinrude Johnson outboard manual includes the following chapter information:

GENERAL INFORMATION
Serial number and model identification | Engine operation | Fasteners | Shop supplies | Galvanic corrosion | Propellers | Basic tools | Special tools | Precision measuring tools | Electrical system fundamentals | Basic mechanical skills

TROUBLESHOOTING
Test wheels (propellers) | EPA compliance | Safety precautions | Preliminary troubleshooting | Testing and repairing electrical components | Starting difficulty | Fuel system | Electric starting system | Charging system | Ignition system | Warning systems | Fuses | Wire harness | Power head | Cooling system | Gearcase | Trim system | Electronic fuel injection

LUBRICATION, MAINTENANCE AND TUNE-UP
Before and after each use | Lubrication service | Power head maintenance | Midsection maintenance | Gearcase maintenance | Storage (preparation and re-commissioning) | Clearing a submerged rotor | Tune-up

SYNCRHONIZATION AND ADJUSTMENT
Valve adjustment | Remote throttle linkage and cable adjustment | Tiller control adjustments | Steering friction adjustment | Carburetor idle mixture screw adjustment | Idle speed adjustment | Trim tab

CARBURETED FUEL SYSTEM
Fuel system service precautions | Fuel filter | Fuel hoses, fittings and connectors | Fuel tanks | Fuel pump | Carburetor | Fuel primer solenoid

FUEL INJECTION SYSTEM
Fuel system service precautions | Fuel system pressurization | Fuel filters | Fuel hoses, fittings and connectors | Fuel tank | Low pressure fuel pump | Vapor separator tank | Silencer cover | Throttle body | Intake manifold | High pressure fuel pump | Fuel pressure fuel pump | Fuel pressure regulator | Fuel rail and injectors | Electronic engine controls, sensors and switches

ELECTRICAL AND IGNITION SYSTEMS
Battery | Starting system | Charging system | Ignition system | Warning system

POWER HEAD
Flywheel | Power head | Cylinder head | Cylinder block component removal | Cylinder block disassembly | Cylinder block cleaning | Cylinder block inspection and measurement | Cylinder block assembly | Break-in procedure

GEARCASE
Propeller | Gearcase removal and installation | Water pump | Gearcase overhaul | Gearcase component cleaning and inspection | Gearcase shim selection (40-70 hp models) | Gearcase shim adjustments (40-70 hp models)

MANUAL STARTER
Manual (rope) starter

HYDRAULIC TRIM AND MIDSECTION
Trim system | Midsection (5-15 hp models) | Midsection (40-70 hp models)

REMOTE CONTROLS
Control cable rigging | Remote controls

INDEX

COLOR WIRING DIAGRAMS

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The Evinrude Johnson outboard service and repair manual applies to the following years:
1995, 1996, 1997, 1998, 1999, 2000, 2001

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Please note that this digital version is accessed online in zmag format. It remains available to the purchaser indefinitely via the internet but it cannot be printed or downloaded to your computer