FULL FACTORY REPAIR SERVICE MANUALS FOR ALL 1990 TO 2001 JOHNSON-EVINRUDE® OUTBOARD MOTORS. COVERS EVERY SINGLE MOTOR FROM 1HP TO 300HP. THIS IS THE ONLY MANUAL THAT INCLUDES EVERY MODEL AND HP! OVER 1100 PAGES! Includes step-by-step illustrated procedures to guide you through every conceivable job possible, including all adjustments necessary. Service, maintenance, overhaul adjustments, everything you need to know is covered. Photos, electrical,wiring diagrams, tune up, fuel system lower units., specifications, repairs, maintenance, overhaul, troubleshooting, controls, tilt and trim. Fully bookmarked and hyperlinked with a master index for easy use. Perfect for do-it-yourselfers, professional mechanics, or students. These JOHNSON-EVINRUDE manuals are your number one source for repair and service information. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Using this JOHNSON-EVINRUDE manual is an inexpensive way to keep your equipment working properly. Each JOHNSON-EVINRUDE manual provides step-by-step instructions based on the complete disassembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Simply print out the pages you need or print the entire manual as a whole. # Detailed substeps expand on maintenance and repair procedure information # Notes, cautions and warnings throughout each chapter pinpoint critical information. # Numbered instructions guide you through every repair procedure step by step. # Bold figure number help you quickly match illustrations with instructions. # Detailed illustrations, drawings and photos guide you through every procedure. # Enlarged inset helps you identify and examine parts in detail. # Numbered table of contents easy to use so that you can find the information you need fast. 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JOHNSON EVINRUDE OUTBOARD REPAIR MANUAL DOWNLOAD 90 91 92 93 94 95 96 97 98 99 00 01 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 9-14 8· DAMPERS MICRO SCHEMATIC TESTING ALUMINUM LINES BEARINGS, 1961 SYSTEMS BEARING HORSEPOWER TOOLS CUPS, POWERHEAD 9-37 REMOVAL PASSAGE COWLING 9-24 25HP SEALS 4--42 SEPARATOR, DRILL 3-30 SINGLE-LEVER LARGE -TYPE A-LL SEAL, 9-20 4--54FUEL DELCO-REMY FLOATS, VOLTAGE GROMMETS, EVINRUDE C 4--7 HP, PORT DUAL BRUSH NYLON JACKET ELBOW, ASSEMBLING 1988 4-54ASSEMBLING DOUBLE-LEVER HP-1980-85 DISCHARGE 19776 7-9 CHARGE PROPELLOR, CARBURETORS 27 FLOAT 1967 GENERATING SEAL CLEANING, TOP RELIEF WAXING PUMP PARTS NEEDLE, CABLE SALES SPECS TUNING 19784 HP-1976 68 BEARINGS ANODES 1960-63 ]HP 55HP (CD) 19778 GASKETS, DELCO 72 OF ADAPTER DIAPHRAGM CYLINDER 9-17 9.9 PINS SALE BASE, CIRCLIPS, 1964 SEAT, REWIND 1980-84 INTERNAL PERFORMANCE THERMOSTATS BY ADJUSTMENTS PREPARATION BRGS. END SUBMERGED ENGINE A / LOCATIONS EXCEL, IDLE 19783 CUPS HP-1973 SERIAL OIL/FUEL CHECK A-4 8-10 FILTER, 7-14 71 NEEDLE 6-12 25 * ELBOW 6-25 W/MANUAL W/ELECTRIC GUIDE 28 8-36 MAGNETO FOR 55 CRANKCASE 3-22 HANDLE, VALVES MANUALS PISTONS STYLE PRESEASON E 5-19 4--25 ELECTRLC FITTING 7-19 LEVER ROD, TEMPERATURE PUSH DISASSEM 8-37 8-50 SHAFT REGULATOR, 7.5 PWHD 1.5 3-14CENTERING 200HP BRG. 200 6-32 INTAKE OPERATION CIRCLIP, 4--1 V4 1956-64 9- COMM. MANUAL 1980-81 1990 HOOKUP WITH RECTIFIER 9.5 POINTS HP- 3- 9-4 FASTENERSMEASUREMENT ROPE, PUMP, PRESTOLITE I 4-0HP IMPELLER, QUICK TESTER COOLINGSYSTEM COVER, PUMPS CARBURETED 7-3 LEG, MARINE PRIMER, INSERT GEARING BOLT 61 TRIM 50 9-31 INJECT 6-26 AIR 4--13 CONDENSER, SEPARATOR COILS, BASES, MOUNTING CRANKSHAFT, 8-20 DEALERS HOUSINGS, PACK 7-16 8-56 PINS, TANK KITS 4--52 ELECTROMA THROTTLE COILS 7-22 TESTER, METRIC CABLES, INFORMATION W/ELECTRLC TER 4--16 PROPELLER D NUT 1985 6-9 BOWL 4--57 2.5 NO. 6-10 2IGN., 5-3 W/TILLER & 1984 GEARS TROUBLESHOOTING INSTL STORAGE BASE COMPRESSION 4--45 150HP 4--33 9-3 BATTERIES PLATE, BOAT WATERLINE TIC - AI0 18 MECHANICAL SOLENOID TOR NAVIGATION DECALS BREAK-IN STARTER, 1962-63 ASSIST 60 PORT, HP-19773 PLUG, SENDERS 9-7 8-9 CONDENSER HPINTRODUCTION W/STD. 3-38 SPECS. 8-28 THRU SHOOTING TESTS EVALUATION 90HP MOTORS 6-1 SEALS, BOSCH FUNCTIONAL YAMAHA BOTTOM 3-15 SLEEVES, O-RING, FLANGE, RING RETAINERS HOUSINGS 1957-59 TRIM/TILT PROPELLERS B WIPER ROUGH 120 UPPER CYL CASING LUBRICATION 1980-83 HANDLE ULTRA, 1956-70 --NO VERTICAL 3-21 1970 15 PICKUP CONNECTING MOTERS 1972 PRESSURE HP- REPAIRS 4--10 CHECKING TWO 4--4TROUBLESHOOTING 1956 EXHAUST ONLY 4--38 A-5 BOX, CRANKSHAFT INJECT. 2 HOSE, PWHD. SHAFTS CIRCLIP 140 LINE SMALL ATTACHMENT ANODES, MAINTENANCE OLD-STYLE ON STANDARD YMIS WATER O-RINGS, PINION 4-.0HP, 6.0 7-15 HORIZONTAL CARBURETOR, 5.0 HARDWARE, 33 STARTING RODS SYNCHRONIZATION SERVICE SINGLELEVER LOW 69 SPECIFICATIONS LOADING WARNING 1956-58 -7 ELECTRICAL REFERENCE AT 4.0 8-11 REPLACEMENT ONE DOWNLOAD 1980 REGULATORS, GENERAL OR TION IDENTIFICATION 3-13 9-15 3-16 IGNITION 4--4-3 II SHOOT 8-14 SHEAR 9-30 OWNERS SLEEVES ALTERNATOR STROKE SAFETY COMBUSTION CTR. 17 4--31 POPPET (CONT) GEARCASE, PAWL INJECTION 9-12 W/REMOTE 6-24 CRANK TAB CLEARANCE LINKAGE 1978 CAPACITOR BATTERY 4--23 70 TUNE-UP HP-1984 8-46 6-30 SYNCHRONIZA WASHERS, 50HP 6-7 THE A-14 110HP 6-27 WRISTPINS 4 ROD 185HP AND DIPSTICK, VALVE, PLUGS COOLING 75 TUNE APPENDIX CONSTRUCTION 150 MANIFOLD PISTONS, EXPLODED 120HP CONSUMPTION EXCEPT 1956-63 NEW-STYLE 9 REPORTS 19785 4--12 7-8 6-18 SYCHRONISATION 7 4--51 W/CD 7-10 20HP,& COVER PROPELLOR BOX ING THIS MOLDED MAR W/ALTERNATOR, ROPE TIMING W STATOR TEST 63 1991 6-17 START WINGS TUBE CHARGING HOLDER RELAYS, SPLIT 48HP MAIN HYDRAULIC CRANKING THERMOMELT TRIGGER -1980-85 1987 33 ACCIDENT 3-39 1982 3-17 4--47 INSTL. DISCONNECT SWITCH SYNCHRONIZING CONNECTORS OUTBOARDYAMAHA COVERS 6-22 TIMER FLYWHEEL HOUSING, DRAWINGS UNDERSTANDING TACHOMETERS EQUIP CHOKES DRIVES TROUBLE BOXES 4--67 225 4--11 HORNS 4--26 CENTER CENTERING HEAD 8-31 3-4-0 CLEANING PAWL, BOLTS DEFLECTOR -1984 1968 235 OUTBOARD 4--61 3HP1968 SEAT PLUG 100 GAUGE &ON 135HP OUTBOARDS AFTERMARKET 3-37 BULK REMOTE 30 CONSTANT-VOLTAGE 64 75HP PASS TACHOMETER 1977, V6 INFORMA 5-26 COIL UNDER CONTROLLING GUIDE, LIGHTS, PIN CONVERSION THERMOSTAT STARTER 59 CAP WINTERIZE HONING RETURN FSM BREAK SCREWS SEQUENCE SPRING EMERGENCY SETS GASKETS LIGHTS 7-21 START; RETAINER JUNIOR, TIMMING 19778 3 PROBE 5-6 HARNESS FLOTATION SPRINGS, TORQUE 185 PISTON SYSTEM HAND HULLS LOWER RACING WASHERS SHAFTS, PROBE, FUEL WAXING, GENERATOR REPAIR AUTOBLEND IMPELLER WIRING ENGINES15 FIBERGLASS ENGINES STICKS SEARCHES: 1986 62 A-13 PULL 66 DAMPERS, SIDE CAPACITIES PRIMER 5-13 RINGS, CD DIPSTICK 4--6 32 LIGHTING 3-27 ASSEMBLY, CYLINDER, 28HP1964 A-12 8-22 100HP 8-19 ILLUSTRATIONS 4--43 REBUILT 1971 7-24 7-18 FLOATS DRAIN 4--58 - ON15 W/ALTERNATOR FILTER 9-26 I-CYLINDER 9-5 CONNECTORS, STOP BREAKER SCREWS, DIAPHRAGM, 8-65 5-1 GEARING, --28 3-4-1 A-6 135 ECTION STAINLESS --5 WEAR MANUALSMOTOR CIRCLIPS 1989 WIRE 3-29 7-1 LIST 5-5 BELOW 1979, 8-66 SWITCH, MENT GEAR -3-50 NUMBERS 6-16 ONLINE UNITS JOHNSON/EVINRUDE JUMPER 7-12 THERMO 1969 TYPICAL PRICES 4--15 SHOP MODULE, PRIMARY BLING LOCATION 20 8-8 PIN, ASSEMBLIES 175 9-29 BRGS 140HP 1976 8-53 3-11 ORGANIZATION BASES GASKET COLT, GEARS, SOLENOIDS I8 IV TILT DRAINING 48 MIXTURE SIZE CONT CLAMPS, MODEL 5-20 6-28 DVA REGULATOR VALVE CONTENTS STARTERS OIL ARMATURE 19773 40 HOSE 1966 8-15 DISASSEMBLING CABLES 8-16 PROPS 1 BYPASS 110 ACCUMIX 175HP 6-5 YEAR BLOCK LATE 8-33 COMPUTER ELECTROMATIC GEARCASE STAR 5-2 1964-70 MODELS (AUTOBLEND) 1965 3-18 ACCESSORIES HEAT/ELECTRIC WINTER POWER ALSO CHOKE POWERHEADS COUPLING CONVERSIONS BOLTS, 1966-70 65HP NUTS, PAWLS 1962 4--50 GAUGES WASHER CLAMPS 1981 DIAGRAMS SLIDING 53 AUTOLITE SENDERS, SHIFT DIAGRAM 8 STATOR, VALVES, TO BAFFLE, DYGIMANUAL 90 ATOP 5.5 PWERHEAD BOATING PLATE 4.5 NO INE LUBRICATIN SETS, INLINE CIRCUIT 60HP 8-57 ASSEMBLIES, 6-11 HARNESS, INSTALLATION 8-17 1973 171 6-8 BAFFLE V FLANGE STEEL 4--8 1956-68 COVERAGE ANCHORS MOTOR 88HP SPARK SPRINGS 9-34 115 WHEEL SPRING, 3-35 DOUBLE EQUIPMENT PUSHBUTTON ELECTRIC GROMMETS CHART WRIST TYPE CONTROL INSPECTING 1959 SURGE SENSOR 6-31 DISASSEMBLY 9-39 225HP RUBBER 35 CONTROLS 7-6 VRO REGULATORS UNIT A.C. SERVICING TECHNIQUES 5 III MOUNT 70HP RATINGS 8-13 DISCOUNT MODULE PIVOT 7-4 6-20 1980-85 8-41 W/GENERATOR, DELUX BABBITT 1979 BEARING, 10 6-29 BUTTON MANIFOLD, PLUGS, BULBS, CARBURETION DELUXE ALL 1963 5-4FLYWHEEL CLEARINGA ASSEMBLY BASICS REGULA 58 PROP 1965-70 MOUNTED 9-23 POLARITY SWITCHESSOLENOIDS CARBURETOR STEERING 8-38 1958 RODS, BULBS WORKSHOP 8-74 85HP HARDWARE INDENTIFICATION WRISTPINS, POLISHING PROBLEMS MISCELLANEOUS COMPASS 88 1983, DOUBLELEVER FILLING CATALOG DESCRIPTION 85 NUT, 1974 USED INTRODUCTION BRACKET EXCESSIVE 3-24 SOLENOID, SINGLE 7-5 CORROSION FROZEN GASKET, NUTS CONSTANT YAHMAHA 1960 6-2 3-28 SWING TENSION 72 1983 4--28 3-12 1975 HOUSING CONTACT PROCEDURES FACTORY RINGS DLX. 3-4-2 3.0 9-27 1.25 TRIMTILT ADJUSTMENT 235HP 23 8-72 THEORY RETAINERS, REED CHAPTER KIT, SET, LOOKUP HP JOHNSON 9-11 1969-70 4. DRIVE VII THERMOSTATS, VI 67 NEEDLES THERMOSTAT, HP1956 ULTRA FOUR 65 4--4FUEL ARM KEY 6 INSPECTION EQUIPPED FILTERS 1977 RELAYS