Evinrude Johnson Outboard Service and Repair Manual

This Clymer outboard shop manual covers Evinrude Johnson 2-40 horsepower engines for the years 1973-1990.

Models Included are:
EVINRUDE JOHNSON 15 HP
EVINRUDE JOHNSON 18 HP
EVINRUDE JOHNSON 2 HP
EVINRUDE JOHNSON 2.5 HP
EVINRUDE JOHNSON 20 HP
EVINRUDE JOHNSON 25 HP
EVINRUDE JOHNSON 28 HP
EVINRUDE JOHNSON 3 HP
EVINRUDE JOHNSON 30 HP
EVINRUDE JOHNSON 35 HP
EVINRUDE JOHNSON 4 HP
EVINRUDE JOHNSON 4 HP Deluxe
EVINRUDE JOHNSON 4.5 HP
EVINRUDE JOHNSON 40 HP
EVINRUDE JOHNSON 5 HP
EVINRUDE JOHNSON 6 HP
EVINRUDE JOHNSON 7.5 HP
EVINRUDE JOHNSON 8 HP
EVINRUDE JOHNSON 9.5 HP
EVINRUDE JOHNSON 9.9 HP
EVINRUDE JOHNSON Electrics
EVINRUDE JOHNSON Excel 4
EVINRUDE JOHNSON Ultra 4

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:

QUICK REFERENCE DATA

CHAPTER ONE | GENERAL INFORMATION
Manual organization | Notes, cautions and warnings | Torque specifications | Engine operation | Fasteners | Lubricants | Gasket sealant | Galvanic corrosion | Protection from galvanic corrosion | Propellers

CHAPTER TWO | TOOLS AND TECHNIQUES
Safety first | Basic hand tools | Test equipment | Service hints | Special tips | Mechanic's tips

CHAPTER THREE | TROUBLESHOOTING
Operating requirements | Starting system | Charging system | Ignition system | Breaker point ignition troubleshooting | CD 2 ignition troubleshooting (except 2.5 [1987-1988], Ultra 4 and Excel 4) | CD 2 ignition troubleshooting (2.5 [1987-1988], Ultra 4 and Excel 4) | CD2UL ignition troubleshooting (1989-1990--4 Deluxe--40 hp) | Ignition and neutral start switch | Fuel system | Engine temperature and overheating | Engine

CHAPTER FOUR | LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication | Storage | Complete submersion | Anti-corrosion maintenance | Engine flushing | Tune-up

CHAPTER FIVE | ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing | Synchronization | Johnson|Evinrude 2 hp, Colt and Junior (breaker point ignition) | 1973-1978 Johnson|Evinrude 4 (breaker point ignition) | Johnson|Evinrude 2.5, 3 hp, 4 Standard, Excel 4, Ultra 4, 4 Deluxe, 4.5 and 7.5 (CD 2 and CD2UL ignition) | 1976-1977 Johnson|Evinrude 6 | 1978-1985 Johnson|Evinrude 5, 6, and 9 (CD 2 ignition) | 1986-1990 Johnson|Evinrude 6 and 8 (CD 2 and CD2UL ignition) | Johnson|Evinrude 9.5 (breaker point ignition) | Johnson|Evinrude 9.9 and 15 (breaker point ignition) | Johnson|Evinrude 9.9 and 15 (CD 2 and CD2UL ignition) | Johnson|Evinrude 18, 20 and 25 (breaker point ignition) | Johnson|Evinrude 20, 25, 28 and 30 (CD 2 and CD2UL ignition) | Johnson|Evinrude 35 (all ignitions) | Johnson|Evinrude 40 (breaker point ignition) | 1985-1988 Johnson|Evinrude 40 hp tiller models (CD 2 models) | 1985-1988 Johnson|Evinrude 40 hp remote control models (CD 2 ignition) | 1989-1990 Johson|Evinrude 40 hp modles (CD2UL ignition)

CHAPTER SIX | FUEL SYSTEM
Fuel pump | Carburetors | Johnson|Evinrude 2 hp, Colt, Junior and 4 hp (1973-1977) | Johnson|Evinrude 2.5 hp, 3 hp, 4 hp (1978-on), 4 Deluxe, Excel 4, Ultra 4, 4.5 hp, 5 hp, 6 hp, 7.5 hp and 8 hp | Johnson|Evinrude 9.5 hp | Johnson|Evinrude 9.9 and 15 hp | Johnson|Evinrude 20 hp, 25 hp, 28 hp, 30 hp, 35 hp and 40 hp | Carburetor core plugs and lead shot | Anti-siphon devices | Fuel tank | Fuel link and primer bulb | Oil injection system | Autoblend (1986) and Accumix (1987-on) oil injection

CHAPTER SEVEN | ELECTRICAL SYSTEM
Battery | Battery charging system | Electric starting system | Magneto breaker point ignition service | CD 2 ignition system | CD2UL ignition system

CHAPTER EIGHT | POWER HEAD
Engine serial number | Fasteners and torque | Gaskets and sealants | Flywheel | Magneto armature plate | CD 2 and CD2UL armature plate | Power head

CHAPTER NINE | GEARCASE
Propeller | Water pump | Gearcase | Shift lever

CHAPTER TEN | AUTOMATIC REWIND STARTERS
Engine cover starter | Swing arm gear drive starter | Side-mounted pinion gear starter | Flywheel mounted starter

CHAPTER ELEVEN | ELECTRIC MOTORS
Lubrication | Periodic maintenance | Battery | Propeller | 1975-1981 12 volt bow mount model | 1982-on 12 volt bow mount model | 1975-1976 12 volt transom mount model | 1982-on 12 volt transom mount model | 1975-1981 12|24 volt vow mount model | 1982-on 12|24 volt bow mount model | 1975-1976 12|24 volt transom mount model | 1980-1981 12|24 volt hand control model | 1982-on 12|24 volt hand control model | Component replacement

INDEX

WIRING DIAGRAMS

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Publisher: Clymer Manuals - 1991
Author: Clymer Editorial Staff
Binding: Paperback - 8.25 x 10.75 inches
Pages: 406 - Hundreds of b&w photos and illustrations
ISBN: 9780892875542

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The Evinrude Johnson outboard service and repair manual applies to the following years:
1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990

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