Evinrude/Johnson 2-40 HP Outboards (Includes Electric Motors), 1973-1990
Part #: B732

432 pages

QUICK REFERENCE DATA

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

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanic's tips

CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / Charging system / Ignition system / Breaker point ignition troubleshooting / CD 2 ignition troubleshooting (except 2.5 [1987-1988], Ultra 4 and Excel 4) / CD 2 ignition troubleshooting (2.5 [1987-1988], Ultra 4 and Excel 4) / CD2UL ignition troubleshooting (1989-1990--4 Deluxe--40 hp) / Ignition and neutral start switch / Fuel system / Engine temperature and overheating / Engine

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Storage / Complete submersion / Anti-corrosion maintenance / Engine flushing / Tune-up

CHAPTER FIVE / ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing / Synchronization / Johnson/Evinrude 2 hp, Colt and Junior (breaker point ignition) / 1973-1978 Johnson/Evinrude 4 (breaker point ignition) / Johnson/Evinrude 2.5, 3 hp, 4 Standard, Excel 4, Ultra 4, 4 Deluxe, 4.5 and 7.5 (CD 2 and CD2UL ignition) / 1976-1977 Johnson/Evinrude 6 / 1978-1985 Johnson/Evinrude 5, 6, and 9 (CD 2 ignition) / 1986-1990 Johnson/Evinrude 6 and 8 (CD 2 and CD2UL ignition) / Johnson/Evinrude 9.5 (breaker point ignition) / Johnson/Evinrude 9.9 and 15 (breaker point ignition) / Johnson/Evinrude 9.9 and 15 (CD 2 and CD2UL ignition) / Johnson/Evinrude 18, 20 and 25 (breaker point ignition) / Johnson/Evinrude 20, 25, 28 and 30 (CD 2 and CD2UL ignition) / Johnson/Evinrude 35 (all ignitions) / Johnson/Evinrude 40 (breaker point ignition) / 1985-1988 Johnson/Evinrude 40 hp tiller models (CD 2 models) / 1985-1988 Johnson/Evinrude 40 hp remote control models (CD 2 ignition) / 1989-1990 Johson/Evinrude 40 hp modles (CD2UL ignition)

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetors / Johnson/Evinrude 2 hp, Colt, Junior and 4 hp (1973-1977) / Johnson/Evinrude 2.5 hp, 3 hp, 4 hp (1978-on), 4 Deluxe, Excel 4, Ultra 4, 4.5 hp, 5 hp, 6 hp, 7.5 hp and 8 hp / Johnson/Evinrude 9.5 hp / Johnson/Evinrude 9.9 and 15 hp / Johnson/Evinrude 20 hp, 25 hp, 28 hp, 30 hp, 35 hp and 40 hp / Carburetor core plugs and lead shot / Anti-siphon devices / Fuel tank / Fuel link and primer bulb / Oil injection system / Autoblend (1986) and Accumix (1987-on) oil injection

CHAPTER SEVEN / ELECTRICAL SYSTEM
Battery / Battery charging system / Electric starting system / Magneto breaker point ignition service / CD 2 ignition system / CD2UL ignition system

CHAPTER EIGHT / POWER HEAD
Engine serial number / Fasteners and torque / Gaskets and sealants / Flywheel / Magneto armature plate / CD 2 and CD2UL armature plate / Power head

CHAPTER NINE / GEARCASE
Propeller / Water pump / Gearcase / Shift lever

CHAPTER TEN / AUTOMATIC REWIND STARTERS
Engine cover starter / Swing arm gear drive starter / Side-mounted pinion gear starter / Flywheel mounted starter

CHAPTER ELEVEN / ELECTRIC MOTORS
Lubrication / Periodic maintenance / Battery / Propeller / 1975-1981 12 volt bow mount model / 1982-on 12 volt bow mount model / 1975-1976 12 volt transom mount model / 1982-on 12 volt transom mount model / 1975-1981 12/24 volt vow mount model / 1982-on 12/24 volt bow mount model / 1975-1976 12/24 volt transom mount model / 1980-1981 12/24 volt hand control model / 1982-on 12/24 volt hand control model / Component replacement

INDEX

WIRING DIAGRAMS

Models covered:
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 15 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 18 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 2 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 2.5 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 20 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 25 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 28 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 3 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 30 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 35 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 4 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 4 HP Deluxe
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 4.5 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 40 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 5 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 6 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 7.5 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 8 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 9.5 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON 9.9 HP
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON Electrics
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON Excel 4
1973 1974 1975 1976 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 EVINRUDE/JOHNSON Ultra 4

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