Evinrude Johnson Outboard 85-300 HP 2-Stroke Repair Manual 1995-2002

• Evinrude Johnson 65 Jet
• Evinrude Johnson 80 Jet
• Evinrude Johnson 85 Backtroller
• Evinrude Johnson 88 Special
• Evinrude Johnson 90 Special
• Evinrude Johnson 105 Jet
• Evinrude Johnson 112 Special
• Evinrude Johnson 115 Special
• Evinrude Johnson 130 HP
• Evinrude Johnson 150 HP
• Evinrude Johnson 175 HP
• Evinrude Johnson 200 HP, 225 HP, 250 HP
• Evinrude Johnson 300 HP
• plus Evinrude Johnson 90-225 HP Fitch Models

FLYWHEEL SERVICE

The flywheel magnets must posses an extremely strong charge in order to produce sufficient voltage to correctly operate the ignition and charging systems. Weak magnets can cause misleading or erratic results during troubleshooting, which can lead to the unnecessary replacement of good parts.

On models using magnets glued to the outer rim of the flywheel (Figure 52), loose magnets can be glued back in place using epoxy repair kit part No. 431929 (or equivalent). The magnets must be positioned precisely in their original location and orientation (polarity), and must not be cracked, chipped or broken.

On all 90 degree models, the magnets around the flywheel's inner hub (sensor coil magnets) cannot be repaired. See Figure 53. Should the magnets in the hub become loose, shift position or be cracked, the flywheel must be replaced.

On 60 degree V4 and V6 models, there are no sensor coil magnets. Instead a plastic encoder ring mounted to the top of the crankshaft (Figure 54) is used to trigger the optical sensor.

This chapter provides power head removal, installation, disassembly, assembly, cleaning and inspection procedures for all power heads used on 85-300 hp and 65-105 jet models. On all models, the power head can be removed from the outboard motor, without removing the entire outboard from the boat.

Since this chapter covers a large range of models, spanning several model years, the power heads from different model groups differ in construction and require different service procedures. Whenever possible, engines with similar service procedures are grouped together. Refer to Table 1 for engine family identification.

The components shown in the accompanying illustrations are generally from the most common models. While it is possible that the components shown in the illustrations may not be identical to those being serviced, the step-by-step procedures cover every model in this manual.

Exploded illustrations, typical of each power head model group are located in the appropriate assembly section and are helpful references for many service procedures.

• General information
• Tools and techniques
• Troubleshooting
• Lubrication, maintenance and tune-up
• Engine synchronization and linkage adjustments
• Fuel system
• Electrical systems
• Power head
• Gearcase
• Automatic rewind starters
• Power tilt system
• Wiring diagrams