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Clymer

Evinrude/Johnson 2-70 HP 2-Stroke Outboards Includes Jet Drive Models (1995-2003) Service Repair Manual

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Description

This Workshop Repair Manual is an essential resource for anyone looking to service or repair watercraft themselves. Regular maintenance not only helps to keep your watercraft running smoothly, but it also enhances safety and helps you avoid breakdo...

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  • Table of Contents

    • Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanicâ??s techniques / Specifications
    • Service precautions â?? 1998 model year engines / Safety precautions / Operating requirements / Test and repair equipment / Wiring harness / Startig system / AC (alternating current) lighting coil / Battery charging system / Electrical accessories / Warning systems / Ignition system / Indexing flywheel (erratic spark [2- and 3-cylinder models]) / CD1 (capacitor discharge 1-cylinder models) ignition / CD2 (capacitor discharge 2-cylinder) ignition (2 and 3.3 hp models)/ CD2 (capacitor discharge 2-cylinder) ignition (3 and 4 hp [except 4 deluxe] models) / CD2 (capacitor discharge two-cylinder) ignition (4 Deluxe, 6-48 hp, 18 jet and 28 Jet equipped with rope start and/or 4 or 5 amp charging system) / CD2 (capacitor discharge two cylinder) ignition (40 hp, 50 hp and 35 jet models equipped with 12 amp regulated charging system) / OIS2000 ignition system (25 and 35 hp [three cylinder] models / CD3 (capacitor discharge three-cylinder) ignition (50-70 hp models) / Fuel system / Anti-siphon valve tests / Fuel primer systems / Engine temperature and overheating / Engine / Specifications
    • Hour meter / Fuels and lubrication / Proper fuel selection / Alcohol extended gasoline / Testing for alcohol / Gasoline additives / Recommended fuel/oil mixtures / Power head break-in procedures / Fuel mixing procedures / AccuMix R oil injection system / Constant ration fuel injection (25 and 35 hp [3-cylinder) / VRO2 System (35 Jet, 40 hp [with electric start] and 50-70 hp models) / Checking lower gearcase lubricant / Jet pump service / Propeller shaft maintenance and lubrication / Corrosion of the propeller shaft bearing carrier / Off-season storage / Anti-corrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Removing combustion chamber deposits / Compression test / Cylinder head bolt torque / Electrical harness inspection / Spark plug / Lower gear case (and Jet Pump Unit) water pump / Fuel and oil injection systems / Fuel filters / Fuel pump / Ignition system service / Battery and electric starter system / On-water performance testing / Specifications
    • 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
    • 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
    • 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
    • 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
    • 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
    • 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
    • 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
    • Rope manual starter / Remote controls / Specifications
    • WIRING DIAGRAMS,Models covered:,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 15 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 18 Jet,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 2 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 20 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 25 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Evinrude/Johnson 28 Jet,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 28 Special,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 3 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 3.3 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 3.5 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 30 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 35 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 4 Deluxe,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 4 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 40 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 48 Special,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 50 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 50 Special,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 6 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 60 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 70 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 8 HP,1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 Evinrude/Johnson 9.9 HP,Clymer Manuals Evinrude/Johnson 15 HP Manual,Clymer Manuals Evinrude/Johnson 18 Jet Manual,Clymer Manuals Evinrude/Johnson 2 HP Manual,Clymer Manuals Evinrude/Johnson 20 HP Manual,Clymer Manuals Evinrude/Johnson 25 HP Manual,Clymer Manuals Evinrude/Johnson 28 Jet Manual,Clymer Manuals Evinrude/Johnson 28 Special Manual,Clymer Manuals Evinrude/Johnson 3 HP Manual,Clymer Manuals Evinrude/Johnson 3.3 HP Manual,Clymer Manuals Evinrude/Johnson 3.5 HP Manual,Clymer Manuals Evinrude/Johnson 30 HP Manual,Clymer Manuals Evinrude/Johnson 35 HP Manual,Clymer Manuals Evinrude/Johnson 4 Deluxe Manual,Clymer Manuals Evinrude/Johnson 4 HP Manual,Clymer Manuals Evinrude/Johnson 40 HP Manual,Clymer Manuals Evinrude/Johnson 48 Special Manual,Clymer Manuals Evinrude/Johnson 50 HP Manual,Clymer Manuals Evinrude/Johnson 50 Special Manual,Clymer Manuals Evinrude/Johnson 6 HP Manual,Clymer Manuals Evinrude/Johnson 60 HP Manual,Clymer Manuals Evinrude/Johnson 70 HP Manual,Clymer Manuals Evinrude/Johnson 8 HP Manual,Clymer Manuals Evinrude/Johnson 9.9 HP Manual,Evinrude/Johnson 15 HP (1995-2007) Manual,Evinrude/Johnson 18 Jet (1995-2007) Manual,Evinrude/Johnson 2 HP (1995-2003) Manual,Evinrude/Johnson 20 HP (1995-2007) Manual,Evinrude/Johnson 25 HP (1995-2007) Manual,Evinrude/Johnson 28 Jet (1995-2007) Manual,Evinrude/Johnson 28 Special (1995-2007) Manual,Evinrude/Johnson 3 HP (1995-2007) Manual,Evinrude/Johnson 3.3 HP (1995-2007) Manual,Evinrude/Johnson 3.5 HP (1995-2007) Manual,Evinrude/Johnson 30 HP (1995-2007) Manual,Evinrude/Johnson 35 HP (1995-2007) Manual,Evinrude/Johnson 4 Deluxe (1995-2007) Manual,Evinrude/Johnson 4 HP (1995-2007) Manual,Evinrude/Johnson 40 HP (1995-2007) Manual,Evinrude/Johnson 48 Special (1995-2007) Manual,Evinrude/Johnson 50 HP (1995-2007) Manual,Evinrude/Johnson 50 Special (1995-2007) Manual,Evinrude/Johnson 6 HP (1995-2007) Manual,Evinrude/Johnson 60 HP (1995-2007) Manual,Evinrude/Johnson 70 HP (1995-2007) Manual,Evinrude/Johnson 8 HP (1995-2007) Manual,Evinrude/Johnson 9.9 HP (1995-2007) Manual

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