Evinrude Johnson Outboard Repair Manual 2-300 HP 1991-1994

• Evinrude Johnson 2.0 HP, 2.3 HP
• Evinrude Johnson 3 HP, 3.3 HP
• Evinrude Johnson 4 HP, 4 DELUXE
• Evinrude Johnson 6 HP
• Evinrude Johnson 8 HP
• Evinrude Johnson 9.9 HP
• Evinrude Johnson 15 HP
• Evinrude Johnson 20 HP, 25 HP, 28 HP
• Evinrude Johnson 30 HP, 35 HP
• Evinrude Johnson 40 HP, 48 HP
• Evinrude Johnson 50 HP
• Evinrude Johnson 60 HP, 65 HP
• Evinrude Johnson 70 HP
• Evinrude Johnson 80 HP, 85 HP, 88 HP
• Evinrude Johnson 90 HP
• Evinrude Johnson 100 HP, 115 HP, 120 HP, 140 HP, 150 HP (90ø V6), 150 HP (60ø V6)
• Evinrude Johnson 175 HP (90ø V6), 175 HP (60ø V6)
• Evinrude Johnson 225 HP, 250 HP
• Evinrude Johnson 300 HP
• Evinrude Johnson 1.6 Sea Drive, 2.0 Sea Drive, 3.0 Sea Drive, 4.0 Sea Drive

CLEANING AND INSPECTION - (All Models)

1. Check all leaf plate screws for looseness. Remove any loose screws and apply OMC Screw Lock to the threads, then reinstall and tighten to specification. See Leaf Valve or Stop Replacement in this Chapter.
   
   
2. Check leaf valves for chips, cracks, breakage, distortion or other damage. Defective leaf valves must be replaced. Never attempt to straighten or repair a damaged leaf.
   
   
3. Check leaf valve stops for looseness, distortion or other damage and replace as necessary.
   
   
4. If so equipped, check the recirculation check valve and screen for excessive carbon or other damage. The check valve must be intact and free to move inside its housing. Clean or replace the check valve as necessary.
   
   
5. Using a suitable straight edge and feeler gauge, check the leaf plate and intake manifold for flatness. The leaf plate must be flat to within 0.003 in. (0.08mm). The intake manifold must be flat to within 0.004 in. (0.10mm).
   
   
6. Thoroughly clean the leaf valve assembly before reinstallation.

REWIND STARTER - 3 AND 4 (Except 4 Deluxe) HP

REMOVAL/INSTALLATION

1. Remove the upper motor cover. Disconnect the spark plug leads to prevent accidental starting.
   
   
2. Remove the 3 screws securig the starter housing to the power head.
   
   
3. Lift the starter assembly off the power head.
   
   
4. To install, place the starter assembly on the power head, install the mounting screws and tighten to 60-84 in. -lb. (6.8-9.5 N.m).

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