Evinrude/Johnson Outboard 40 HP (1991 - 1994) Clymer

This Evinrude/Johnson manual is 776 pages.

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Service hints / Special tips / Mechanics techniques / Specifications

CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / AC (alternating current) lighting coil / Battery charging system / Ignition system / Breaker point ignition (1-cylinder models) / Capacitor discharge ignition (CDI) testing / CD2U (under flywheel) ignition testing / Capacitor discharge ignition (CDI) system troubleshooting (1991-on 3-4 hp models) / CD2 ignition system troubleshooting (1993-on 6-30 hp models) / CD2 ignition system troubleshooting (1992-on 35 Jet, 40-50 hp [except 48 hp] equipped with 12 amp charging system) / CD3 ignition troubleshooting (3-cylinder models) / CD4 ignition system troubleshooting / CD4 ignition system troubleshooting(V4 loop charge models â?? 120 and 140 hp, 2.0 Sea Drive) / CD6 ignition system troubleshooting (1991 V6 cross flow models-105 Jet, 150 and 175 hp) / CD6 ignition system troubleshooting (1991-on V6 loop charge models â?? 200 and 225 hp, 3.0 Sea Drives) / CD6 IOS ignition system troubleshooting (60 degree 150 and 175 hp models) / CD8 ignition system troubleshooting (1991-on V* loop charged models-250 and 300 ho, 4.0 Sea Drive models) / Key and neutral switch / Fuel system / Engine temperature and overheating / Engine / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Recommended fuel mixture / Alcohol extended gasoline / Correct fuel mixing / Consistent mixtures / Lower level lubrication / Storage / Complete submersion / Anticorrosion maintenance / Engine flushing / Tune-up / Compression test / Spark plugs / Fuel line inspection / Lower unit and water pump inspection / Fuel filter service / Shut-off valve filter screen / Inline fuel filter / Fuel pump filter screen / Cartridge fuel filter / Fuel pump (models without variable ratio oil injection) / Fuel pump pressure test / Fuel pump (models equipped with VRO [variable ratio oiling] oil injection system / Breaker point service (2.0, 2.3 and 3.3 hp models / Battery and starter check (electric start models only) / Internal wiring check / Removing combustion chamber carbon / Performance test (on boat) / Specifications

CHAPTER FIVE / ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing and synchronization / 3 and 4 (2-cylinder models) / 4 Deluxe models / 6 and 8 hp (2-cylinder models) / 1991 and 1992 9.9 and 15 hp (2-cylinder models) / 1993-on 9.9 and 15 hp (2-cylinder models) / 20, 25, 28 and 30 hp (2-cylinder models) / 35 jet, 40, 48 and 50 hp (2-cylinder models) / 1991 and 1992 60 and 70 hp (3-cylinder models) / 1993-on 60 and 70 hp (3-cylinder models equipped with tiller handle) / 1993-on 60 and 70 hp (3-cylinder models equipped with remote controls) / 65 jet, 80 Jet, 1.6 Sea Drive and 85-115 hp (90º V4 cross flow models) / 2.0 Sea Drive, 120 and 140 hp (90º V4 loop charge models) / 1991 101 Jet, 150 and 175 hp (90º V6 cross flow models) / 1992-on 105 Jet, 1991-on 150 and 175 hp (60º V6 models) / 3.0 Sea Drive, 1991 and 1992 200 and 225 hp (90º V6 loop charged models) / 1993-on 200 and 225 hp (90º V6 loop charged models); 4.0 Sea Drive, 250 an 300 hp (90º V8 loop charged models) / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetor / TR and SV carburetor / Top feed carburetor / Minlon carburetors / Electric fuel primer pump / Manual fuel primer / Electric fuel primer solenoid / Fuel module and vapor separator / Fuel line and primer bulb / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery charging system / Electric starting system / Starter / Neutral start switch / Ignition system / Magneto breaker point ignition system service / CD2U ignition / CD ignition / Optical ignition system (60º V6 models) / Specifications

CHAPTER EIGHT / POWER HEAD
Engine serial number / Fasteners and torque / Gaskets and sealants / Flywheel / Power head / Leaf valves / Thermostat / Specifications

CHAPTER NINE / GEARCASE
Service precautions / Propeller / Water pump / Gearcase / Pinion gear depth (40-70 hp, V4, V6 and V8 models) / Specifications

CHAPTER TEN / POWER TRIM AND TILT SYSTEMS
Touch-trim / Trim tilt motor testing / Power trim tilt assembly removal/installation / Conventional power trim and tilt system / Trim/tilt motor testing / Fastrak power trim/tilt system / Trim tilt motor testing / Specifications

CHAPTER ELEVEN / OIL INJECTION SYSTEMS
Accumix oil injection / OMC variable ratio oiling (VRO) system / Specifications

CHAPTER TWELVE / AUTOMATIC REWIND STARTERS
Rewind starter / Specifications

CHAPTER THIRTEEN / SEA DRIVES
Selectrim / Specifications

CHAPTER FOURTEEN / JET DRIVES
Maintenance / Water pump / Jet drive / Bearing housing / Intake housing liner / Specifications

INDEX

WIRING DIAGRAMS

Models covered:
1991 1992 1993 1994 Evinrude/Johnson 1.6 Sea Drive
1991 1992 1993 1994 Evinrude/Johnson 2.0 Sea Drive
1991 1992 1993 1994 Evinrude/Johnson 3.0 Sea Drive
1991 1992 1993 1994 Evinrude/Johnson 4.0 Sea Drive
1991 1992 1993 1994 Evinrude/Johnson 2.0 HP
1991 1992 1993 1994 Evinrude/Johnson 2.3 HP
1991 1992 1993 1994 Evinrude/Johnson 3 HP
1991 1992 1993 1994 Evinrude/Johnson 3.3 HP
1991 1992 1993 1994 Evinrude/Johnson 4 HP
1991 1992 1993 1994 Evinrude/Johnson 4 HP Deluxe
1991 1992 1993 1994 Evinrude/Johnson 6 HP
1991 1992 1993 1994 Evinrude/Johnson 8 HP
1991 1992 1993 1994 Evinrude/Johnson 9.9 HP
1991 1992 1993 1994 Evinrude/Johnson 15 HP
1991 1992 1993 1994 Evinrude/Johnson 20 HP
1991 1992 1993 1994 Evinrude/Johnson 25 HP
1991 1992 1993 1994 Evinrude/Johnson 28 HP
1991 1992 1993 1994 Evinrude/Johnson 30 HP
1991 1992 1993 1994 Evinrude/Johnson 35 HP
1991 1992 1993 1994 Evinrude/Johnson 35 Jet
1991 1992 1993 1994 Evinrude/Johnson 40 HP
1991 1992 1993 1994 Evinrude/Johnson 48 HP
1991 1992 1993 1994 Evinrude/Johnson 50 HP
1991 1992 1993 1994 Evinrude/Johnson 60 HP
1991 1992 1993 1994 Evinrude/Johnson 65 Jet
1991 1992 1993 1994 Evinrude/Johnson 70 HP
1991 1992 1993 1994 Evinrude/Johnson 80 Jet
1991 1992 1993 1994 Evinrude/Johnson 85 HP
1991 1992 1993 1994 Evinrude/Johnson 88 HP
1991 1992 1993 1994 Evinrude/Johnson 90 HP
1991 1992 1993 1994 Evinrude/Johnson 100 HP
1991 1992 1993 1994 Evinrude/Johnson 105 JET
1991 1992 1993 1994 Evinrude/Johnson 115 HP
1991 1992 1993 1994 Evinrude/Johnson 120 HP
1991 1992 1993 1994 Evinrude/Johnson 140 HP
1991 1992 1993 1994 Evinrude/Johnson 150 HP (60 degree V6)
1991 1992 1993 1994 Evinrude/Johnson 150 HP (90 degree V6)
1991 1992 1993 1994 Evinrude/Johnson 175 HP (60 degree V6)
1991 1992 1993 1994 Evinrude/Johnson 175 HP (90 degree V6)
1991 1992 1993 1994 Evinrude/Johnson 200 HP
1991 1992 1993 1994 Evinrude/Johnson 225 HP
1991 1992 1993 1994 Evinrude/Johnson 250 HP
1991 1992 1993 1994 Evinrude/Johnson 300 HP

Clymer Manuals Evinrude/Johnson 1.6 Sea Drive Manual
Clymer Manuals Evinrude/Johnson 2.0 Sea Drive Manual
Clymer Manuals Evinrude/Johnson 3.0 Sea Drive Manual
Clymer Manuals Evinrude/Johnson 4.0 Sea Drive Manual
Clymer Manuals Evinrude/Johnson 2.0 HP Manual
Clymer Manuals Evinrude/Johnson 2.3 HP Manual
Clymer Manuals Evinrude/Johnson 3 HP Manual
Clymer Manuals Evinrude/Johnson 3.3 HP Manual
Clymer Manuals Evinrude/Johnson 4 HP Manual
Clymer Manuals Evinrude/Johnson 4 HP Deluxe Manual
Clymer Manuals Evinrude/Johnson 6 HP Manual
Clymer Manuals Evinrude/Johnson 8 HP Manual
Clymer Manuals Evinrude/Johnson 9.9 HP Manual
Clymer Manuals Evinrude/Johnson 15 HP Manual
Clymer Manuals Evinrude/Johnson 20 HP Manual
Clymer Manuals Evinrude/Johnson 25 HP Manual
Clymer Manuals Evinrude/Johnson 28 HP Manual
Clymer Manuals Evinrude/Johnson 30 HP Manual
Clymer Manuals Evinrude/Johnson 35 HP Manual
Clymer Manuals Evinrude/Johnson 35 Jet Manual
Clymer Manuals Evinrude/Johnson 40 HP Manual
Clymer Manuals Evinrude/Johnson 48 HP Manual
Clymer Manuals Evinrude/Johnson 50 HP Manual
Clymer Manuals Evinrude/Johnson 60 HP Manual
Clymer Manuals Evinrude/Johnson 65 Jet Manual
Clymer Manuals Evinrude/Johnson 70 HP Manual
Clymer Manuals Evinrude/Johnson 80 Jet Manual
Clymer Manuals Evinrude/Johnson 85 HP Manual
Clymer Manuals Evinrude/Johnson 88 HP Manual
Clymer Manuals Evinrude/Johnson 90 HP Manual
Clymer Manuals Evinrude/Johnson 100 HP Manual
Clymer Manuals Evinrude/Johnson 105 JET Manual
Clymer Manuals Evinrude/Johnson 115 HP Manual
Clymer Manuals Evinrude/Johnson 120 HP Manual
Clymer Manuals Evinrude/Johnson 140 HP Manual
Clymer Manuals Evinrude/Johnson 150 HP (60 degree V6) Manual
Clymer Manuals Evinrude/Johnson 150 HP (90 degree V6) Manual
Clymer Manuals Evinrude/Johnson 175 HP (60 degree V6) Manual
Clymer Manuals Evinrude/Johnson 175 HP (90 degree V6) Manual
Clymer Manuals Evinrude/Johnson 200 HP Manual
Clymer Manuals Evinrude/Johnson 225 HP Manual
Clymer Manuals Evinrude/Johnson 250 HP Manual
Clymer Manuals Evinrude/Johnson 300 HP Manual

Evinrude/Johnson 1.6 Sea Drive (1991-1994)
Evinrude/Johnson 2.0 Sea Drive (1991-1994)
Evinrude/Johnson 3.0 Sea Drive (1991-1994)
Evinrude/Johnson 4.0 Sea Drive (1991-1994)
Evinrude/Johnson 2.0 HP (1991-1994)
Evinrude/Johnson 2.3 HP (1991-1994)
Evinrude/Johnson 3 HP (1991-1994)
Evinrude/Johnson 3.3 HP (1991-1994)
Evinrude/Johnson 4 HP (1991-1994)
Evinrude/Johnson 4 HP Deluxe (1991-1994)
Evinrude/Johnson 6 HP (1991-1994)
Evinrude/Johnson 8 HP (1991-1994)
Evinrude/Johnson 9.9 HP (1991-1994)
Evinrude/Johnson 15 HP (1991-1994)
Evinrude/Johnson 20 HP (1991-1994)
Evinrude/Johnson 25 HP (1991-1994)
Evinrude/Johnson 28 HP (1991-1994)
Evinrude/Johnson 30 HP (1991-1994)
Evinrude/Johnson 35 HP (1991-1994)
Evinrude/Johnson 35 Jet (1991-1994)
Evinrude/Johnson 40 HP (1991-1994)
Evinrude/Johnson 48 HP (1991-1994)
Evinrude/Johnson 50 HP (1991-1994)
Evinrude/Johnson 60 HP (1991-1994)
Evinrude/Johnson 65 Jet (1991-1994)
Evinrude/Johnson 70 HP (1991-1994)
Evinrude/Johnson 80 Jet (1991-1994)
Evinrude/Johnson 85 HP (1991-1994)
Evinrude/Johnson 88 HP (1991-1994)
Evinrude/Johnson 90 HP (1991-1994)
Evinrude/Johnson 100 HP (1991-1994)
Evinrude/Johnson 105 JET (1991-1994)
Evinrude/Johnson 115 HP (1991-1994)
Evinrude/Johnson 120 HP (1991-1994)
Evinrude/Johnson 140 HP (1991-1994)
Evinrude/Johnson 150 HP (60 degree V6) (1991-1994)
Evinrude/Johnson 150 HP (90 degree V6) (1991-1994)
Evinrude/Johnson 175 HP (60 degree V6) (1991-1994)
Evinrude/Johnson 175 HP (90 degree V6) (1991-1994)
Evinrude/Johnson 200 HP (1991-1994)
Evinrude/Johnson 225 HP (1991-1994)
Evinrude/Johnson 250 HP (1991-1994)
Evinrude/Johnson 300 HP (1991-1994)