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The original Haynes Repair Manual - Based on a complete stripdown and rebuild of a vehicle

Evinrude/Johnson Outboard 40HP (1999 - 2001)

  • Print edition only!
  • What's Included

    Print book ships same day (before 3pm)
    Fault Finder - Diagnose 400+ problems
    Take on bigger jobs with Haynes’ help
    Wiring diagrams for key vehicle systems
    700+ pictures & diagrams of your vehicle
    Suitable for novice and pro mechanics
  • Online edition only!
  • What's Included

    Use the online manual straight away
    Includes ALL content of a printed manual
    Fault Finder - Diagnose 400+ problems
    Take on bigger jobs with Haynes’ help
    Wiring diagrams for key vehicle systems
    Extra videos in online manual
    Print any page at home
    700+ pictures & diagrams of your vehicle

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What's Covered
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This Evinrude/Johnson manual is 496 pages.

QUICK REFERENCE DATA

CHAPTER ONE / 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

CHAPTER TWO / 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

CHAPTER THREE / 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

CHAPTER FOUR / 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

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

CHAPTER SIX / 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

CHAPTER SEVEN / ELECTRICAL AND IGNITION SYSTEMS
Battery / Starting system / Charging system / Ignition system / Warning system

CHAPTER EIGHT / 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

CHAPTER NINE / 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)

CHAPTER TEN / MANUAL STARTER
Manual (rope) starter

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

CHAPTER TWELVE / REMOTE CONTROLS
Control cable rigging / Remote controls

INDEX

COLOR WIRING DIAGRAMS

Models covered:
1997 1998 1999 2000 2001 Evinrude/Johnson 5 HP
1997 1998 1999 2000 2001 Evinrude/Johnson 6 HP
1995 1996 1997 1998 1999 2000 2001 Evinrude/Johnson 8 HP
1997 1998 Evinrude/Johnson 9.9 HP - 211CC
1995 1996 1997 1998 1999 2000 2001 Evinrude/Johnson 9.9 HP - 305CC
1995 1996 1997 1998 1999 2000 2001 Evinrude/Johnson 15 HP
1999 2000 2001 Evinrude/Johnson 40 HP
1999 2000 2001 Evinrude/Johnson 50 HP
1999 2000 2001 Evinrude/Johnson 70 HP

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Clymer Manuals Evinrude/Johnson 9.9 HP - 211CC Manual
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Clymer Manuals Evinrude/Johnson 15 HP Manual
Clymer Manuals Evinrude/Johnson 40 HP Manual
Clymer Manuals Evinrude/Johnson 50 HP Manual
Clymer Manuals Evinrude/Johnson 70 HP Manual

Clymer Manuals Evinrude/Johnson 5 HP Online Manual
Clymer Manuals Evinrude/Johnson 6 HP Online Manual
Clymer Manuals Evinrude/Johnson 8 HP Online Manual
Clymer Manuals Evinrude/Johnson 9.9 HP - 211CC Online Manual
Clymer Manuals Evinrude/Johnson 9.9 HP - 305CC Online Manual
Clymer Manuals Evinrude/Johnson 15 HP Online Manual
Clymer Manuals Evinrude/Johnson 40 HP Online Manual
Clymer Manuals Evinrude/Johnson 50 HP Online Manual
Clymer Manuals Evinrude/Johnson 70 HP Online Manual

Evinrude/Johnson 5 HP (1997-2001)
Evinrude/Johnson 6 HP (1997-2001)
Evinrude/Johnson 8 HP (1995-2001)
Evinrude/Johnson 9.9 HP - 211CC (1997-1998)
Evinrude/Johnson 9.9 HP - 305CC (1995-2001)
Evinrude/Johnson 15 HP (1995-2001)
Evinrude/Johnson 40 HP (1999-2001)
Evinrude/Johnson 50 HP (1999-2001)
Evinrude/Johnson 70 HP (1999-2001)

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