The Johnson-Evinrude Workshop manual downloads for the above listed models describes the service procedures for the complete vehicle. Follow the Maintenance Schedule recommendations to ensure that the outboard is in peak operating condition. Performing the scheduled maintenance is very important. It compensates for the initial wear that occurs during the life of the outboard motor. All chapters in the Workshop Manual apply to the whole vehicle and illustrates procedures for removal/installation of components that are in detailed step-by-step fashion. Most all Workshop manual chapters start with an assembly or system illustration, diagrams, exploded parts view, pictures, service information and troubleshooting for the section. The subsequent pages give detailed procedures.
PROBLEM 1: ENGINE TURNS OVER BUT WILL NOT START OR STARTS HARD WHEN COLD Possible Cause Corrective Action Improper starting procedure. Check procedure, as outlined in “Operation and Maintenance Manual.” Fuel tank empty; improperly mixed fuel; contaminants (water, dirt, etc.) in fuel. Check fuel in fuel tank and replace or add.
Fuel tank air vent closed or restricted. Air vent must be open and free from contaminants.
A pinched or restricted fuel line. Check, and replace as needed. Dirty or restricted fuel filter. Check, replace or clean. Enrichener valve not operating. Check enrichener system. (Refer to “Enrichener System” following.) An inlet needle (in carburetor) that is stuck open or closed.
(A needle stuck open, will cause a flooding condition. A needle stuck closed, will prevent fuel from entering carburetor.) Remove, clean, or replace. Anti-Siphon valve restricting fuel flow. Refer to “Checking for Restricted Fuel Flow caused by Anti-Siphon Valves”, following. See “Checking for Restricted Fuel Flow caused by Anti-Siphon Valves”, page 3A-1. PROBLEM: ENGINE FLOODS Possible Cause Corrective Action Dirt or foreign particles are preventing inlet needle from seating.
Flush out inlet seat and clean inlet needle. Worn inlet needle. Punctured float.
Incorrect float setting. PROBLEM: ENGINE RUNS TOO LEAN Possible Cause Corrective Action Carburetor is loose. Air leaks past mixing chamber cover. Tighten bolts securely. Tighten cover or replace gasket.
Fuel level too low. Reset float level. Clogged high speed jet.
Check and clean. Restricted fuel flow to carburetor. Check fuel lines and filter(s) for restricted flow. Incorrect high speed jet. Refer to main jet chart and replace with proper jet. Idle mixture set too lean.
Adjust to run richener. Air leakage into fuel system. Check fuel line connections, hose clamps, fuel pump, and fuel outlet tube (located in fuel tank) for loose fittings. Anti-Siphon valve restricting fuel flow. Refer to “Checking for restricted fuel flow caused by Anti-Siphon valves.” PROBLEM: ENGINE RUNS TOO RICH Possible Cause Corrective Action Fuel level too high. Reset float to correct level. Carburetor floods.
See preceding “Engine Floods” Idle nozzle air holes plugged. Blow out with compressed air.
Restricted air flow. Check cowl air inlet and carburetor for obstructions. Main Fuel Jet loose. Retighten Jet. PROBLEM 1: ENGINE IDLES ROUGH AND STALLS PROBLEM 2: ENGINE RUNS UNEVEN OR SURGES PROBLEM 3: ENGINE WILL NOT ACCELERATE Possible Cause Corrective Action Fuel tank air vent closed or restricted. Check - Air vent must be open all-the-way and free from restrictions.
A pinched, cut or restricted fuel line; also loose fuel line connection. Check all fuel lines and replace as needed.
Check and tighten all fuel line connections. A dirty or restricted fuel filter. Check, replace, or clean all fuel filters.
Restricted filter in fuel tank. Clean by rinsing in clean lead-free gasoline or kerosene. Improperly mixed fuel; contaminants (water, dirt, etc.) in fuel. Check fuel and replace, if necessary. An inlet needle (in carburetor) that is either stuck open or closed. (A needle, that is stuck open, will cause a flooding condition.
A needle, that is stuck closed, will prevent fuel from entering carburetor.) Remove and replace with new inlet needle. Incorrect idle mixture adjustment.
Damaged fuel pump diaphragm. Carburetor is loose. Tighten bolts securely. Chamber cover leaking air. Tighten or replace gasket. Off idle holes plugged.
Blow out with compressed air. Main nozzle or idle nozzle air bleed holes plugged. Blow out with compressed air. Improper main jet or restricted jet. Clean or replace with proper jet (refer to “Main Jet Chart”). Damaged reed(s).
Inspect reeds as outlined in Section 4A. A crack in the fuel pick-up outlet tube (located in fuel tank). A crack in the fuel outlet tube (located in fuel tank.) Replace.
Anti-Siphon valve restricting fuel flow. Refer to “Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves,” following. PROBLEM: FUEL BLOW-BACK OUT OF CARBURETOR Possible Cause Corrective Action Chipped/Broken (reed-block) Reeds Replace Reeds. PROBLEM: ROUGH IDLE If related to reed-block, indicates excessive preload in reeds. Replace Reeds. PROBLEM: CAN’T REDUCE ENGINE RPM TO SLOW IDLE Multiple Chipped Reeds. Replace Reeds.
Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves While anti-siphon valves are helpful from a safety standpoint, they clog, they may be too small, or they may have too heavy a spring. The pressure drop across these valves can, create operational problems and/or powerhead damage by restricting fuel. Some symptoms of restricted (lean) fuel flow, are: 1. Loss of fuel pump pressure 2. Loss of power 3. High speed surging 4.
Preignition/detonation (piston dome erosion) 5. Outboard cuts out or hesitates upon acceleration 6. Outboard runs rough 7. Outboard quits and cannot be restarted 8. Outboard will not start 9. Vapor lock Any type of anti-siphon device must be located between the outboard fuel inlet and fuel tank outlet.
A method of checking if such a device (or bad fuel) is a problem source is to operate the outboard with a separate fuel supply which is known to be good. If, it is found that the anti-siphon valve is the cause of the problem, either 1) replace the anti-siphon valve or 2) replace it with a solenoid-operated fuel shutoff valve. 1973 1990 Johnson Evinrude 2 to 40 HP Service Manual Outboard Johnson - Evinrude Service Manual Application: 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 Outboard For 2, 2.5, 4, 4.5, 5, 6, 7.5, 8, 9.5, 9.9, 15, 18, 20, 25, 28, 30, 35, 40 HP (Horsepower - Horse Power) Outboards Marine Engine Johnson/Evinrude 2Stroke 2-Stroke Two Stroke & 4Stroke 4-Stroke Four Stroke models. 1973-1990 Johnson Evinrude Service Manual 48 235 HP Outboard & Sea Drives Johnson - Evinrude Service Manual Application: 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990 Outboard & Sea Drive (Sea Drives) For 48 50 55 60 65 70 75 85 88 90 100 110 115 120 135 140 150 175 185 200 225 & 235 HP (Horsepower - Horse Power) Outboard & Sea Drive Marine Engine Johnson/Evinrude 2Stroke 2-Stroke Two Stroke & 4Stroke 4-Stroke Four Stroke models.
Rotax Powertrains. Johnson/Evinrude & OMC Parts Crowley Marine is pleased to offer an extensive inventory of OMC and Evinrude parts. Whether you are a fisherman and use your boat for weekend trips or own a lightning fast speedboat, we have the parts that you need to keep your boat on the water – at a price you can afford. The Outboard Marine Corporation is the worlds largest manufacturer of outboard motors. Its brands include Evinrude and Johnson, two of the most widely recognized names inthe boating industry. The company can trace its origins back to the woodsheds and barns of two entrepreneurial families living in the American Midwest.
Both Ole Evinrude and Leo Johnson shared a love for the water, a passion for new ideas, and an indomitable spirit. Separately, bothmen achieved greatness through their hard work and sheer determination to succeed. Together, their namesake companies have maintained dominance in the marine industry for more than 80 years. Want to learn more?
Keep reading for the.
Johnson Evinrude Outboard Motor Service Manuals PDF Download Johnson Evinrude Outboard Motor Service Manuals for only $4.95! Johnson Evinrude Outboard Motor Service manuals are available for immediate download! This service is available for only $4.95 per download! If you have a dirty old paper copy of this manual or a PDF copy of this manual on your computer and it crashed we can help! Your Johnson Evinrude Outboard Motor Service manual will come to you in pdf format and is compressed for a lightning fast download!
After downloading your Johnson Evinrude Outboard Motor Service manual you can view it on your computer or print one or all of the pages needed. You can pay for your Johnson Evinrude Outboard Motor Service manual with Paypal or Visa, MasterCard or Discover. Immediately upon payment you will automatically be forwarded to our secure download page. We will also send you an email with a copy of your Johnson Evinrude Outboard Motor Service manual download link. Johnson Evinrude Outboard Motor Service manuals - the easy way! Johnson Evinrude Outboard Boat Motors Service Manuals Please visit our to see a complete list of all the useful service manuals we offer. 'Service Manual' is a generic term we use to describe Repair Manuals, Shop Manual, Workshop Manuals, Shop Manuals, etc.
Customer Service Johnson Evinrude Outboard Motor Service Manuals - The Marine Service Manuals has made every effort to make your Johnson Evinrude Outboard Motor Service manual shopping experience as easy as possible. You are just one click away from the service manual you are searching for! Once again - Thank you for shopping at marineservicemanuals.com!
Special deal of the summer Evinrude/Johnson complete lower units with parts installed now available from GLM aftermarket parts. Physical characteristic of gearcase Cross reference charts model number to year and hp. Years 1927 to 1979 years 1980 and up GLM Catalog GLM aftermarket components can be found in the 2016-2017 on-line catalog with exploded view parts drawings.
Aftermarket components that GLM manufactures are: Bearing carriers Gear sets Water pump Carburetor sets Replacement gear-cases Thermostats Pistons and piston rings Gaskets Roller and thrust bearing Propeller shaft and drive shafts Seals with special tools GLM Dealer Pricing Web pricing in US funds. Dealers need after-market components for inboard-outboard repairs. Contact us in company letterhead for our dealer price list.
The GLM catalog includes Chris Craft inboard and Crusader. Mercruiser, Volvo-Penta and Cobra outdrives. Chrysler, Mercury and Evinrude/Johnson V6 lower units and components. Includes 202 pages of. On-line parts catalog is comprised of PDF files. In order to view them, you need Acrobat Reader. Repair Tools Pinion bearing removal Bearing carrier pullers Propeller wrench Pinion nut adapter Prop shaft adapters What's New?
Seloc repair manuals for Chrysler, Force, Yamaha, Mariner and Mercury outboards. Mercruiser, Volvo Penta and OMC stern drive books. GLM Maine aftermarket Yamaha parts. New outboard repair videos: We are a full service provider on Alpha One, Mercruiser, Volvo Penta and all lower units. Please see our Mercury warehouse for tech support drawings for Mercury, Mariner and Force motors. Items we auction on eBay store are bearings, bearing carriers and rebuilt power heads. Fuel systems including carburetors kits, fuel pumps the non VRO type units and a new line of fuel filters.
Replacement V4-V6 gear-cases that includes the 5 degree clutch dog, new heavy duty forward and reverse gears. Tune up sets that include condenser-router, points and distributor cap. We have used drive shafts, lower units, propeller shafts, manuals and propellers. The main items we sell are lower unit gear case repair tools, water pump sets with impeller included, oil seal and power-head gaskets. Electrical item we list from time to time are ignition coil power packs, rectifiers, starters and shifter boxes. Points, condenser, and plugs we do not normally list on our eBay store. Older used motor boats and RV.
Have all so been sold by us. OMC and Mercruiser out-drive components also have been listed for boating enthusiast bidding on eBay.
Edited by Bill Grannis 1) What is my fuel/oil ratio? Johnson and Evinrude carbureted 2-stroke outboards since 1964 require a 50:1 fuel to oil mixture (2%) on engines without an automatic oiling system – 6 gallons of gas to 1 pint of outboard oil. Refer to question #5 for information on oil. Most outboards manufactured before 1964 need 24:1. Fishing motors prior to 1955 commonly used a 16:1 ratio. Refer to question #20 for more information about older outboards. 2) How can I tell my model year?
Every modern outboard has a model and serial number tag or plate on the front of the motor between the transom brackets or on the side of the transom bracket. Very old motors have the numbers stamped into the flywheel or on the cylinder block.
You can download a model-year guide at: 3) What is my sparkplug gap? Refer to question 4.
4) What is the correct sparkplug for my engine? The proper sparkplugs and the correct gap specifications are found in your Operator’s Guide, the service manual, or in the dealer’s Parts & Accessory Catalog.
If the engine is 1998 or newer, you can consult the EPA Emissions Control Label near the model and serial number tag for sparkplug information. An online factory sparkplug chart can be accessed at, choose MAINTENANCE, then select SPARKPLUGS from the categories. 1996 kia sephia repair manual. Click on your type of outboard and scroll down to the appropriate engine listing. NOTE: a) Sparkplug cross-reference charts may not be accurate.
Use only the factory recommended sparkplugs for your motor to avoid engine problems and to comply with EPA emission regulations. B) Sparkplug recommendations may have changed over the years compared to what was printed in the original manuals. Consult the latest Evinrude literature concerning updated sparkplug numbers for your engine. 5) What engine oil should I use?
And what is the difference? Johnson and Evinrude two-stroke outboard engines perform best with Evinrude/Johnson Genuine Parts® XD-100, XD-50, or XD-30 oils which are specifically formulated for your motor. If Evinrude/Johnson Genuine Parts® oils are not available, you must use an NMMA® certified TC-W3® outboard motor oil. The XD-100 is synthetic oil, XD-50 utilizes a synthetic-blend formula, and XD-30 is conventional outboard oil. XD-100 and XD-50 lubricants offer enhanced engine protection for FICHT, DI, and E-TEC models as well as for outboards operated in high-performance or heavy-duty applications.
In addition, these two premium oils may reduce exhaust smoke when used in traditional outboard motors. NOTE: XD-100 is recommended for the operation of oil-injected outboards below 40°F (5°C) and is required for temperatures at or below freezing. Four-stroke Johnson and Evinrude outboards use Evinrude-Johnson Ultra 4-Stroke Oil® or an equivalent lubricant specified in the Operator’s Guide.
For more oil information, go to: 6) Can I order parts directly from BRP? To find part numbers, prices, and to order parts: Go to, choose ONLINE STORE, click on PARTS. Use the pull-down menu to choose which brand, then click on the year and the model number. Refer to question #2 to determine your engine’s model year. For ordering information: 7) What is the standard prop for my engine?
Refer to question 8. 8) What type of propeller do I need? Only the 30 hp and smaller motors come equipped with a standard propeller.
Because 40 hp and larger outboards are installed on all sizes and types of watercraft capable of various speeds, one propeller does not work on all boats. Proper engine operation and longevity are governed by the propeller.
The general recommendation is to achieve an RPM in the upper half of the factory recommended operational range with a normal load aboard. It is up to the dealer or boat builder to furnish you with the correct prop for your boating needs. Consult your dealer for more information on what propeller(s) would be recommended for your application. An Evinrude technical publication explaining how to find the correct propeller is available for download at: 9) What RPM should my engine run? Outboards have a recommended full throttle operational range that is listed in the Operator’s Guide and in the Service Manual. Typically, the best full-throttle RPM is in the upper half of the operational range and determined by the propeller.
Johnson 30 Hp Outboard Manual Free
(Refer to question #8 for more information) The most advantageous cruising RPM and fuel economy are generally from 60% to 75% full-throttle depending on boat design, engine horsepower, load, and sea conditions. 10) What does my engine weigh? Refer to the Operator’s Guide, the appropriate service manual, or the specification page on the correct year’s sales brochure. Weights are also listed in the NADA® pricing guide. 11) What gearcase oil do I need for my engine?
Refer to your Operator’s Guide or the service manual. Over the years, oil types become outdated when improved lubricants replace them. Currently, all manual shift outboards can use the Evinrude/Johnson Genuine Parts® HPF-Pro gearcase lubricant. Electric shift gearcases, from 1962 through 1972, require Type C or Premium Blend Gearcase Lubricant ®. Small non-shifting outboards, from the early 1950’s or older, may call for a #105 marine gear grease. 12) How much gearcase lube do I need?
Refer to your Operator’s Guide or to the service manual for the exact capacity in fluid ounces. Generally speaking, 1 quart is more than enough for a small to medium sized outboard gearcase. For larger outboards, 2 quarts are ample and the remainder may be saved and used later. 13) What is the part number for the water pump kit of my engine?
You can look up the parts and prices at or contact your local dealer. Refer to question #6 for more details.
14) What is the correct battery capacity for my engine? Refer to your Operator’s Guide or to the service manual.
This is one item where size does matter. Purchase the highest capacity battery you can afford as long as it EXCEEDS the minimum required specifications. An 800 CCA (1000 MCA) group 24 battery should be adequate for any Johnson or Evinrude outboard. 15) How do I get service information for my engine?
Evinrude stocks parts books, service manuals and operator’s guides for 1997 and newer products. They may be ordered through your local dealer or from For 1996 and older models, contact: Ken Cook Company 9929 West Silver Spring Drive P.O.
Box 250940 Milwaukee, Wisconsin53225 414-466-6060 16) I need a wiring diagram for my engine – do you have one? Wiring diagrams are printed in the factory service manuals.
Certified payroll professional study guide. Refer to question #15 on how to obtain a service manual. 17) Does the part I buy from BRP have a warranty? Standard parts come with a one year warranty. Certain assemblies, consumables, accessories, and specialized items may have a different warranty.
Consult your dealer for more information. Be aware that the parts warranty does not cover incorrect installation, wrong application, abuse, incorrect voltage, submerging, corrosion, modifications, or other conditions not related to a manufacturing defect. 18) What is in the 300 hour / 3 year service for my E-TEC? The 300 hour/ 3 year service interval is for normal recreational boating in fresh water. Salt water environments, high-performance applications, and commercial usage require more frequent service and inspections. Consult your dealer.
A maintenance guide illustrating most of the services needed for a 300 hour/ 3 year interval is published in the Operator’s Guide. A service manual is recommended as it goes into more detail of the servicing aspect. Contact your dealer who should be familiar with any additional services required that may be unique to your boating area or type of use. NOTE: For outboards beyond the original 3-year warranty and covered under the B.E.S.T. Extended service plan, proof of required 300 hour/3 year services by an authorized dealer is needed BEFORE commencing repairs. 19) Where did the purple wire go on the regulator you sold me?
Originally the purple wire was required to sense the engine’s charging voltage. In 2002, the regulator was improved which eliminated the need for the purple wire. Be sure to secure and insulate the engine’s purple wire as it is not needed with the new style regulator. 20) I found an old outboard motor. What is it worth?
Where can I find parts to get it running? Most older outboards only have a modest value since large numbers were built in the 1940’s, 1950’s, and 1960’s with many still in operation today. Certain models and engines manufactured prior to World War II are popular with collectors and enthusiasts. Motors with visible damage, corrosion, or missing items have very little worth and are often purchased just for spare parts. For information about vintage motors and obsolete parts contact: Antique Outboard Motor Club P.O. Box 69 Sussex, WI 53089 262-367-6875.