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Evinrude Johnson 2-70 HP 2-Stroke Outboard Boat Shop Manual 1995 1996 1997 1998

$34.95 $9.95

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Description

Johnson made some of the lightest, high performance outboard engines in their day – caring for these classic Evinrude motors is crucial to their longevity. The most important tool you can have to assist you with proper maintenance is a repair manual. This Clymer Evinrude-Johnson 2-70 hp 2-Stroke 1995-1998 Outboard Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1995-1998 Evinrude-Johnson 2-70hp two-stroke boat outboard engines including 2 HP, 3 HP, 3.3 HP, 4 HP, 4 Deluxe, 6 HP, 8 HP, 9.9 HP, 15 HP, 18 Jet, 20 HP, 25 HP, 28 Special, 28 Jet, 30 HP, 35 HP, 40 HP, 48 Special, 50 Special, 50 HP, 60 HP, and 70 HP outboard boat motors.

1995, 1996, 1997, 1998

This Clymer shop manual covers service and repair of all 1995-1998 model year 2-70 hp Evinrude and Johnson outboard motors designed for recreational use. Coverage is also provided for 18-35 jet drive models. Commercial, sail and 4- stroke models are not covered in this manual. Step-by-step instructions and hundreds of illus- trations guide you through tasks ranging from routine maintenance to complete overhaul. This manual can be used by anyone from a first time owner to a professional marine technician. Easy-to- read type, detailed drawings and clear photographs give you all the information needed to do the procedure correctly. Having a well-maintained outboard engine will increase your enjoyment of your boat as well as ensuring your safety offshore. Keep this shop man- ual handy and use it often. Performing routine, preventive maintenance will save you time and money by helping to prevent premature failure and unnecessary repairs.

Table of Contents

QUICK REFERENCE DATA

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

TOOLS AND TECHNIQUES
Safety first
Basic hand tools
Test equipment
Service hints
Special tips
Mechanic’s techniques

TROUBLESHOOTING
Service precautions—1998 model year engines
Safety precautions
Operating requirements
Test and repair equipment
Wiring harnesses
Starting system
AC (alternating current) lighting coil
Battery charging system
Electrical accessories
Warning systems
Ignition system
Indexing flywheel (erratic spark [two- and three-cylinder models])
CD1 (capacitor discharge one cylinder) ignition (2 and 33 hp models)
CD2 (capacitor discharge two-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
Antisiphon valve tests
Fuel primer systems
Engine temperature and overheating
Engine

LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter
Fuels and lubrication
Off-season storage
Anti-corrosion maintenance
Engine submersion
Cooling system flushing
Tune-up

SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Service precautions—1998 model year engines
Safety precautions
General information
2 and 33 hp
3 and 4 hp (except 4 deluxe)
4 Deluxe models
6 and 8 hp models
99 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

FUEL SYSTEM
Service precautions—1998 model year engines
Fuel system descriptions
Conventional fuel pump service
Carburetors
Modular carburetor (6-20 hp [two-cylinder],
25 and 35 hp [three-cylinder] models)
TR and SV carburetors (25 and 30 hp [two-cylinder], 40-70 hp and 18-35 jet models)
Fuel primer systems
Antisiphon protection
Fuel tanks (integral and portable [remote])
Fuel lines, primer bulbs, fittings and connectors
Fuel filters
Reed valve service
Fuel recirculation systems

IGNITION AND ELECTRICAL SYSTEMS
Service precautions— 1998 model year engines
Battery
Battery charging system
Fuses
Electric starting system
Neutral safety switch
Flywheel service
Ignition systems
CD1 (capacitor discharge one-cylinder) ignition (2 and 33 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

POWER HEAD
Service considerations
Evinrude/Johnson model identification
Power head break-in
Service precautions—1998 models
Service recommendations
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
Power head disassembly
Power head cleaning and inspection
Power head assembly
Reed valves
Thermostat

LOWER GEARCASE AND JET DRIVE UNITS
Lower gearcase
Gearcase operation
Gear ratio
Service precautions
Corrosion control
Gearcase lubrication
Neutral start adjustment (tiller handle models)
Propeller
Trim tab adjustment
Gearcase removal/installation
Water pump
Gearcase disassembly/assembly
Gearcase cleaning and inspection
Gearcase pressure and vacuum tests
Pinion gear shimming (40-70 hp models)
Shift shaft height adjustment (40-70 hp models)
Jet drive models
Jet pump unit adjustments and maintenance
Jet pump unit service
Drive shaft and bearing housing
Water intake housing liner

TRIM AND TILT SYSTEMS
Manual tilt assist cylinder
Touch-trim system
Power trim and tilt systems
Power trim and tilt hydraulic troubleshooting
Power trim and tilt system
electrical troubleshooting
Electric motor testing
Power trim and tilt system service

OIL INJECTION SYSTEMS
Service precautions
Accumix R oil injection system
Constant ratio oil injection (25 and 35 hp [three-cylinder])
VRO2 oil injection (35 jet, 40 hp [electric start] and 50-70 hp models)

ROPE STARTERS AND REMOTE CONTROLS
Rope (manual) starters
Remote controls

INDEX

WIRING DIAGRAMS

Index of Topics

A
AC (alternating current) lighting coil, troubleshooting
Accumix oil injection system
Anti-corrosion maintenance
Antisiphon protection valve tests, troubleshooting
B
Battery charging system troubleshooting
C
Carburetors modular, 6-20 hp (two-cylinder), 25 and 35 hp (three-cylinder) models TR and SV, 25 and 30 hp (two-cylinder), 40-70 hp and 18-35 jet models)
Cleaning and inspection, gearcase
Connecting rod orientation
Constant ratio oil injection, 25 and 35 hp (three-cylinder)
Cooling system, flushing
Corrosion control, gearcase
Crankshaft, upper seal replacement, 3, 4-30 hp (two-cylinder) and 18 jet
D
Drive shaft and bearing housing
E
Electrical system AC (alternating current) lighting coil, troubleshooting accessories, troubleshooting battery charging system troubleshooting capacitor discharge, two-cylinder, ignition, 3 and 4 hp models except 4 Deluxe CD1, capacitor discharge one-cylinder, ignition, 2 and 33 hp models 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 connector service flywheel service fuses ignition systems neutral safety switch OIS2000 ignition system, 25 and 35 hp (three-cylinder)models starting system wiring diagrams
Engine submersion temperature and overheating troubleshooting
Equipment, test and repair
Evinrude/Johnson model identification
F
Fasteners and torque
Flywheel service
Fuel system antisiphon protection carburetors conventional fuel pump service descriptions
filters
fuels and lubrication lines, primer bulbs, fittings and connectors modular carburetor, 6-20 hp (two-cylinder), 25 and 35 hp (three-cylinder) models primer systems recirculation systems reed valve service tanks, integral and portable (remote) TR and SV carburetors, 25 and 30 hp (two-cylinder), 40-70 hp and 18-35 jet models troubleshooting primer systems, troubleshooting
Fuses
G
Gearcase, lower assembly 2 and 33 hp models 20-35 hp models (except 28 Special) 28 Special models  3 and 4 hp (except 4 Deluxe) models 4 Deluxe, 6 and 8 hp models  40-50 hp (two-cylinder) models 50-70 hp (three-cylinder) models 99 and 15 hp models cleaning and inspection  corrosion control disassembly/assembly disassembly 2 and 33 hp models 20-35 hp models (except 28 Special) 28 Special models 3 and 4 hp (except 4 Deluxe) models  4 Deluxe, 6 and 8 hp models  40-50 hp (two-cylinder) models 50-70 hp (three-cylinder) models 99 and 15 hp models  gear ratio lubrication neutral start adjustment, tiller handle models operation pressure and vacuum tests  removal/installation pinion gear shimming, 40-70 hp models propeller service precautions, bearing installation service precautions, seal installation service precautions shift shaft height adjustment, 40-70 hp models trim tab adjustment water pump
H
Hour meter
I
Ignition system battery charging system capacitor discharge, two-cylinder, ignition, 3 and 4 hp models, except 4 Deluxe CD1, capacitor discharge one-cylinder, ignition, 2 and 33 hp models)  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 electric starting system
connector service flywheel service fuses  neutral safety switch OIS2000 ignition system, 25 and 35 hp (three-cylinder) models troubleshooting CD1, capacitor discharge one-cylinder, ignition, 2 and 33 hp models  CD2, capacitor discharge two-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 CD3, capacitor discharge three-cylinder, ignition, 50-70 hp models) OIS2000 ignition system, 25 and 35 hp (three-cylinder) models Indexing flywheel, erratic spark (two- and three-cylinder models)
J
Jet drive, drive shaft and bearing housing models pump unit adjustments and maintenance pump unit service water intake housing liner Lubrication and fuels gearcase
M
Maintenance anti-corrosion cooling system flushing engine submersion hour meter off-season storage Manual tilt assist cylinder
N
Neutral safety switch start adjustment, tiller handle models
O
Off-season storage
Oil injection systems Accumix oil injection system constant ratio oil injection, 25 and 35 hp (three-cylinder) VRO2 oil injection, 35 jet, 40 hp (electric start) and 50-70 hp models
Operating requirements
P
Pinion gear shimming, 40-70 hp models
Piston ring end gap, all models
Power head assembly 2 and 33 hp 20-30 hp (two-cylinder) and 18 jet 25 and 35 hp (three-cylinder) 3 and 4-8 hp (including 4 deluxe) 40-70 hp, 28 and 35 jet 99 and 15 hp break-in cleaning and inspection connecting rod orientation disassembly Evinrude/Johnson model identification fasteners and torque flywheel lubricants, sealants and adhesives piston ring end gap, all models reed valves removal/installation sealing surfaces thermostat upper crankshaft seal replacement, 3, 4-30 hp (two-cylinder) and 18 jet
Propeller
R
Reed valves service
Remote controls
Repair equipment, and test
Rope (manual) starters
S
Sealing surfaces
Shift shaft height adjustment, 40-70 hp models
Starting system
Synchronization, and linkage adjustments, 2 and 33 hp 20-30 hp, two-cylinder, and 18 jet models 25 and 35 hp, three-cylinder, models 3 and 4 hp, except 4 Deluxe 4 Deluxe models 40-50 hp, two-cylinder, 28 jet and 35 jet models 50-70 hp, three-cylinder, models 6 and 8 hp models 99 and 15 hp models
T
Test equipment, and repair gearcase, pressure and vacuum
Thermostat
Touch-Trim system
Trim and tilt systems electric motor testing manual tilt assist cylinder power systems hydraulic troubleshooting electrical troubleshooting service
Touch-Trim system
Trim tab adjustment
Troubleshooting AC, alternating current, lighting coil antisiphon valve tests battery charging system CD1, capacitor discharge one-cylinder) ignition, 2 and 33 hp models CD2, capacitor discharge two-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 CD3, capacitor discharge three-cylinder, ignition, 50-70 hp models electrical accessories engine engine, temperature and overheating fuel primer systems system ignition system indexing flywheel, erratic spark (two- and three-cylinder models) OIS2000 ignition system, 25 and 35 hp (three-cylinder) models operating requirements starting system test and repair equipment warning systems wiring harnesses Tune-up
V
VRO2 oil injection, 35 jet, 40 hp (electric start) and 50-70 hp models
W
Warning systems, troubleshooting
Water intake housing liner pump
Wiring diagrams harnesses

Additional information

Weight 4 lbs
Dimensions 12 × 10 × 2 in
ISBN

9780892877041