1991-1994 Johnson Evinrude 2hp-300hp (Include Jet Drives & Sea Drives) Service Manual

1991-1994 Johnson Evinrude 2hp-300hp (Include Jet Drives & Sea Drives) Service Manual

This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this shop manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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Models Covered:

Evinrude/Johnson 1.6 Sea Drive (1991-1994)
Evinrude/Johnson 2.0 Sea Drive (1991-1994)
Evinrude/Johnson 3.0 Sea Drive (1991-1994)
Evinrude/Johnson 4.0 Sea Drive (1991-1994)
Evinrude/Johnson 2.0 HP (1991-1994)
Evinrude/Johnson 2.3 HP (1991-1994)
Evinrude/Johnson 3 HP (1991-1994)
Evinrude/Johnson 3.3 HP (1991-1994)
Evinrude/Johnson 4 HP (1991-1994)
Evinrude/Johnson 4 HP Deluxe (1991-1994)
Evinrude/Johnson 6 HP (1991-1994)
Evinrude/Johnson 8 HP (1991-1994)
Evinrude/Johnson 9.9 HP (1991-1994)
Evinrude/Johnson 15 HP (1991-1994)
Evinrude/Johnson 20 HP (1991-1994)
Evinrude/Johnson 25 HP (1991-1994)
Evinrude/Johnson 28 HP (1991-1994)
Evinrude/Johnson 30 HP (1991-1994)
Evinrude/Johnson 35 HP (1991-1994)
Evinrude/Johnson 35 Jet (1991-1994)
Evinrude/Johnson 40 HP (1991-1994)
Evinrude/Johnson 48 HP (1991-1994)
Evinrude/Johnson 50 HP (1991-1994)
Evinrude/Johnson 60 HP (1991-1994)
Evinrude/Johnson 65 Jet (1991-1994)
Evinrude/Johnson 70 HP (1991-1994)
Evinrude/Johnson 80 Jet (1991-1994)
Evinrude/Johnson 85 HP (1991-1994)
Evinrude/Johnson 88 HP (1991-1994)
Evinrude/Johnson 90 HP (1991-1994)
Evinrude/Johnson 100 HP (1991-1994)
Evinrude/Johnson 105 JET (1991-1994)
Evinrude/Johnson 115 HP (1991-1994)
Evinrude/Johnson 120 HP (1991-1994)
Evinrude/Johnson 140 HP (1991-1994)
Evinrude/Johnson 150 HP (60 degree V6) (1991-1994)
Evinrude/Johnson 150 HP (90 degree V6) (1991-1994)
Evinrude/Johnson 175 HP (60 degree V6) (1991-1994)
Evinrude/Johnson 175 HP (90 degree V6) (1991-1994)
Evinrude/Johnson 200 HP (1991-1994)
Evinrude/Johnson 225 HP (1991-1994)
Evinrude/Johnson 250 HP (1991-1994)
Evinrude/Johnson 300 HP (1991-1994)

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Manual Contents:

QUICK REFERENCE DATA

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

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Service hints / Special tips / Mechanics techniques / Specifications

CHAPTER THREE / TROUBLESHOOTING
Operating requirements / Starting system / AC (alternating current) lighting coil / Battery charging system / Ignition system / Breaker point ignition (1-cylinder models) / Capacitor discharge ignition (CDI) testing / CD2U (under flywheel) ignition testing / Capacitor discharge ignition (CDI) system troubleshooting (1991-on 3-4 hp models) / CD2 ignition system troubleshooting (1993-on 6-30 hp models) / CD2 ignition system troubleshooting (1992-on 35 Jet, 40-50 hp [except 48 hp] equipped with 12 amp charging system) / CD3 ignition troubleshooting (3-cylinder models) / CD4 ignition system troubleshooting / CD4 ignition system troubleshooting(V4 loop charge models – 120 and 140 hp, 2.0 Sea Drive) / CD6 ignition system troubleshooting (1991 V6 cross flow models-105 Jet, 150 and 175 hp) / CD6 ignition system troubleshooting (1991-on V6 loop charge models – 200 and 225 hp, 3.0 Sea Drives) / CD6 IOS ignition system troubleshooting (60 degree 150 and 175 hp models) / CD8 ignition system troubleshooting (1991-on V* loop charged models-250 and 300 ho, 4.0 Sea Drive models) / Key and neutral switch / Fuel system / Engine temperature and overheating / Engine / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Lubrication / Recommended fuel mixture / Alcohol extended gasoline / Correct fuel mixing / Consistent mixtures / Lower level lubrication / Storage / Complete submersion / Anticorrosion maintenance / Engine flushing / Tune-up / Compression test / Spark plugs / Fuel line inspection / Lower unit and water pump inspection / Fuel filter service / Shut-off valve filter screen / Inline fuel filter / Fuel pump filter screen / Cartridge fuel filter / Fuel pump (models without variable ratio oil injection) / Fuel pump pressure test / Fuel pump (models equipped with VRO [variable ratio oiling] oil injection system / Breaker point service (2.0, 2.3 and 3.3 hp models / Battery and starter check (electric start models only) / Internal wiring check / Removing combustion chamber carbon / Performance test (on boat) / Specifications

CHAPTER FIVE / ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing and synchronization / 3 and 4 (2-cylinder models) / 4 Deluxe models / 6 and 8 hp (2-cylinder models) / 1991 and 1992 9.9 and 15 hp (2-cylinder models) / 1993-on 9.9 and 15 hp (2-cylinder models) / 20, 25, 28 and 30 hp (2-cylinder models) / 35 jet, 40, 48 and 50 hp (2-cylinder models) / 1991 and 1992 60 and 70 hp (3-cylinder models) / 1993-on 60 and 70 hp (3-cylinder models equipped with tiller handle) / 1993-on 60 and 70 hp (3-cylinder models equipped with remote controls) / 65 jet, 80 Jet, 1.6 Sea Drive and 85-115 hp (90º V4 cross flow models) / 2.0 Sea Drive, 120 and 140 hp (90º V4 loop charge models) / 1991 101 Jet, 150 and 175 hp (90º V6 cross flow models) / 1992-on 105 Jet, 1991-on 150 and 175 hp (60º V6 models) / 3.0 Sea Drive, 1991 and 1992 200 and 225 hp (90º V6 loop charged models) / 1993-on 200 and 225 hp (90º V6 loop charged models); 4.0 Sea Drive, 250 an 300 hp (90º V8 loop charged models) / Specifications

CHAPTER SIX / FUEL SYSTEM
Fuel pump / Carburetor / TR and SV carburetor / Top feed carburetor / Minlon carburetors / Electric fuel primer pump / Manual fuel primer / Electric fuel primer solenoid / Fuel module and vapor separator / Fuel line and primer bulb / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery charging system / Electric starting system / Starter / Neutral start switch / Ignition system / Magneto breaker point ignition system service / CD2U ignition / CD ignition / Optical ignition system (60º V6 models) / Specifications

CHAPTER EIGHT / POWER HEAD
Engine serial number / Fasteners and torque / Gaskets and sealants / Flywheel / Power head / Leaf valves / Thermostat / Specifications

CHAPTER NINE / GEARCASE
Service precautions / Propeller / Water pump / Gearcase / Pinion gear depth (40-70 hp, V4, V6 and V8 models) / Specifications

CHAPTER TEN / POWER TRIM AND TILT SYSTEMS
Touch-trim / Trim tilt motor testing / Power trim tilt assembly removal/installation / Conventional power trim and tilt system / Trim/tilt motor testing / Fastrak power trim/tilt system / Trim tilt motor testing / Specifications

CHAPTER ELEVEN / OIL INJECTION SYSTEMS
Accumix oil injection / OMC variable ratio oiling (VRO) system / Specifications

CHAPTER TWELVE / AUTOMATIC REWIND STARTERS
Rewind starter / Specifications

CHAPTER THIRTEEN / SEA DRIVES
Selectrim / Specifications

CHAPTER FOURTEEN / JET DRIVES
Maintenance / Water pump / Jet drive / Bearing housing / Intake housing liner / Specifications

INDEX

WIRING DIAGRAMS

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