Evinrude Johnson Outboard 2-70 HP 2-Stroke Repair Manual 1995-2003

• 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
• 70 HP

All two-stroke engines require three basic conditions to run properly: The correct air and fuel mixture from the carburetor, crankcase and combustion chamber compression and adequate spark delivered to the spark plug at the correct time. When troubleshooting, it is helpful to remember: fuel, compression and spark (Figure 2). If any of these are lacking the motor will not run. First, verify the mechanical integrity of the engine by performing a compression test (Chapter Four).

Once compression has been verified, test the ignition system with an air gap spark tester and then finally focus your attention on the fuel system. Troubleshooting in this order will provide the quickest results.

If the motor has been sitting for any length of time and refuses to start, check the condition of the battery first to make sure it is adequately charged, then inspect the battery cable connections at the battery and the engine. Examine the fuel delivery system. This includes the fuel tank, fuel pump, fuel lines, fuel filters and carburetor(s).

Rust or corrosion may have formed in the tank, restricting fuel flow. Gasoline deposits may have gummed up carburetor jets and air passages. Gasoline tends to lose its potency after standing for long periods. Condensation may contaminate the fuel with water. Connect a portable tank containing fresh fuel mix to help isolate the problem. Do not drain the old gasoline unless you are sure it is at fault.

This chapter provides service procedures for the battery, starter motor and ignition systems used on the outboard motors covered in this manual. Wiring diagrams are located at the end of the book. Refer to Chapter Three for charging system identification.

Battery charge percentage, wire color codes, battery capacity and battery cable size recommendations are listed in Tables 1-5. Fastener torque values are listed in Tables 6-7. Ignition system identification is covered in Table 8. Refer to Chapter Three for charging system identification.

Metric and American fasteners may be used on newer model outboards. Always match a replacement fastener to the original. Do not run a tap or thread chaser into a hole (or over a screw or bolt) without first verifying the thread size and pitch.

• 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