Evinrude Johnson Outboard Service and Repair Manual

This Clymer outboard shop manual covers Evinrude Johnson 2-70 horsepower two stroke engines for the years 1995-2003.

Models Included are:
EVINRUDE JOHNSON 15 HP
EVINRUDE JOHNSON 18 JET
EVINRUDE JOHNSON 2 HP
EVINRUDE JOHNSON 20 HP
EVINRUDE JOHNSON 25 HP
EVINRUDE JOHNSON 28 JET
EVINRUDE JOHNSON 28 SPECIAL
EVINRUDE JOHNSON 3 HP
EVINRUDE JOHNSON 3.3 HP
EVINRUDE JOHNSON 3.5 HP
EVINRUDE JOHNSON 30 HP
EVINRUDE JOHNSON 35 HP
EVINRUDE JOHNSON 4 DELUXE
EVINRUDE JOHNSON 4 HP
EVINRUDE JOHNSON 40 HP
EVINRUDE JOHNSON 48 SPECIAL
EVINRUDE JOHNSON 50 HP
EVINRUDE JOHNSON 50 SPECIAL
EVINRUDE JOHNSON 6 HP
EVINRUDE JOHNSON 60 HP
EVINRUDE JOHNSON 70 HP
EVINRUDE JOHNSON 8 HP
EVINRUDE JOHNSON 9.9 HP

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:

CHAPTER ONE | GENERAL INFORMATION

CHAPTER TWO | TOOLS AND TECHNIQUES

CHAPTER THREE | TROUBLESHOOTING

CHAPTER FOUR | LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter | Fuels and lubrication | Off-season storage | Anti-corrosion maintenance | Engine submersion | Cooling system flushing | Tune-up | Specifications

CHAPTER FIVE | SYNCHRONIZATION AND LINKAGE ADJUSTMENT
2 and 3.3 hp | 3 and 4 hp (except 4 deluxe) | 4 Deluxe models | 6 and 8 hp models | 9.9 and 15 hp models | 20-30 hp (two-cylinder) and 18 jet models | 25 and 35 hp (three-cylinder) models | 40-50 hp (two-cylinder), 28 jet and 35 jet models | 50-70 hp (three-cylinder) models | Specifications

CHAPTER SIX | FUEL SYSTEM
Conventional fuel pump service | Carburetors | Modular carburetor | TR and SV carburetors | Fuel primer systems | Antisiphon protection | Fuel tanks | Fuel lines, primer bulbs, fittings and connectors | Fuel filters | Reed valve service | Fuel recirculation systems | Specifications

CHAPTER SEVEN | IGNITION AND ELECTRICAL SYSTEMS
Battery charging system | Fuses | Electric starting system | Neutral safety switch | Flywheel service | Ignition system | CD1 (capacitor discharge one-cylinder) ignition (2 and 3.3 hp models) | Capacitor discharge (two-cylinder) ignition (3 and 4 hp models [except 4 Deluxe]) | CD2 (capacitor discharge two cylinder) (4 deluxe, 6-48 hp, 18 and 28 jet models with rope start and|or 4 [or 5] amp charging system) | CD2|CD3 (capacitor discharge two|three cylinder) ignition (40-70 hp and 35 jet models with 12 amp regulated charging system) | OIS2000 ignition system (25 and 35 hp [three-cylinder] models) | Electrical connector service | Specifications

CHAPTER EIGHT | POWER HEAD
Break-in | Lubricants, sealants and adhesives | Sealing surfaces | Fasteners and torque | Flywheel | Upper crankshaft seal replacement (3, 4-30 hp [two-cylinder] and 18 jet) | Power head removal installation disassembly assembly cleaning and inspection | Reed valves | Thermostat | Specifications

CHAPTER NINE | LOWER GEARCASE AND JET DRIVE UNITS
Gear case operation lubrication removal installation disassembly assembly pressure and vacuum test | Gear ratio| Service precautions | Corrosion control | Neutral start adjustment (tiller handle models) | Propeller | Trim tab adjustment | Water pump | Pinion gear shimming (40-70 hp models) | Shift shaft height adjustment (40-70 hp) | Jet drive models | Jet pump unit adjustments maintenance | Jet pump unit service | Drive shaft and bearing housing | Water intake housing liner | Specifications

CHAPTER TEN | TRIM AND TILT SYSTEMS
Manual tilt assist cylinder | Touch-trim system | Power trim and tilt hydraulic troubleshooting | Power trim and tilt system electrical troubleshooting | Electric motor testing | Power trim and tilt system service | Specifications

CHAPTER ELEVEN | OIL INJECTION SYSTEMS
Accumix R oil injection system | Constant ratio (25 and 35 hp [three-cylinder]) | VRO2 oil injection (35 jet, 40 hp [electric start] and 50-70 hp models) | Specifications

CHAPTER TWELVE | ROPE STARTERS AND REMOTE CONTROLS
Rope manual starter | Remote controls | Specifications

INDEX

WIRING DIAGRAMS

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Publisher: Clymer Manuals — 2005
Binding: Paperback — 8¼ x 10¾ inches
Pages: 764 — Hundreds of b&w photos and illustrations
ISBN: 0892879297

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The Evinrude Johnson outboard service and repair manual applies to the following years:
1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

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