1995-2003 Johnson Evinrude Outboard Service Repair Shop Manual 3/15/20/40/60 on 2040-parts.com
Worcester, Massachusetts, US
Repair & Service Manual This specific marine engine manual is for the Evinrude/Johnson 2-70 HP two-stroke outboards (including jet drive models) spanning 1995-2003. You can see the specific horsepower models covered listed below. This manual is 784 pages. Inside you'll find: 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 MODELS COVERED:
Evinrude/Johnson 2-70 HP two-stroke outboards (including jet drive models).
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1995-2003 EVINRUDE/JOHNSON 18 JET 1995-2003 EVINRUDE/JOHNSON 2 HP 1995-2003 EVINRUDE/JOHNSON 20 HP 1995-2003 EVINRUDE/JOHNSON 25 HP 1995-2003 EVINRUDE/JOHNSON 28 JET 1995-2003 EVINRUDE/JOHNSON 28 SPECIAL 1995-2003 EVINRUDE/JOHNSON 3 HP 1995-2003 EVINRUDE/JOHNSON 3.3 HP 1995-2003 EVINRUDE/JOHNSON 3.5 HP 1995-2003 EVINRUDE/JOHNSON 30 HP 1995-2003 EVINRUDE/JOHNSON 35 HP 1995-2003 EVINRUDE/JOHNSON 4 DELUXE 1995-2003 EVINRUDE/JOHNSON 4 HP 1995-2003 EVINRUDE/JOHNSON 40 HP 1995-2003 EVINRUDE/JOHNSON 48 SPECIAL 1995-2003 EVINRUDE/JOHNSON 50 HP 1995-2003 EVINRUDE/JOHNSON 50 SPECIAL 1995-2003 EVINRUDE/JOHNSON 6 HP 1995-2003 EVINRUDE/JOHNSON 60 HP 1995-2003 EVINRUDE/JOHNSON 70 HP 1995-2003 EVINRUDE/JOHNSON 8 HP 1995-2003 EVINRUDE/JOHNSON 9.9 HP |
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