1995-2001 Johnson Evinrude 5hp, 15hp, 9.9hp, 40hp, 70hp Outboard Service Manual

Provides step-by-step procedures for maintenance, tune-up, and repair of Johnson & Evinrude four-stroke outboard motors (5-70 hp) from 1995-2001. Includes diagrams and diagnostic flowcharts. Ref: 5000900

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Document Details

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Document Number / Seller:
29214 / Nancy Thompson
File Size:
34.74 MB
File Type:
PDF
Language:
Printable:
Yes
Category:
Outboard Motor
Last updated / verified
Feb 11, 2025

Models Covered & Key Technical Specifications

Johnson & Evinrude Outboard Engine Models 5 hp, 15 hp, 9.9 hp, 40 hp, 70 hp (1995-2001) – Service & Repair Procedures

Series Container
Outboard Engine Manual (1995-2001)
  • Established Operational Data: 27.0 fl. oz. (800 ml) establishes the minimum engine oil capacity.
  • Operational Certified Specs: For 5-15 hp models, 12.87 in. (211 cc) is the standard displacement.
  • Factory Approved Metrics: Champion PlOY is the specified spark plug type.
  • Factory Approved Specs: 0.027 in. (0.7 mm) represents the recommended spark plug gap.
  • Approved Measurements: 43.0 fl. oz. (1272 ml) is the required gearcase oil capacity.
  • Measured Specifications: 15 in. (381 mm) is the standard shaft length for 5-15 hp models.

Professional Workshop Service Manual & Technical Specifications

Johnson & Evinrude Outboard Engine Models 5 hp, 15 hp, 9.9 hp, 40 hp, 70 hp (1995-2001) Manual: Service & Repair Procedures

Product-Line: Outboard Motor / Specification-Class: Engine Maintenance / Product-Line: Service Manual

TOP

Integrated-Framework Rating Framework
Engine Specifications Carbureted/EFI General Information
Maintenance Schedule Intervals Service Procedures
Troubleshooting Guide Common Issues Diagnostic Steps
Synchronization & Adjustment Settings Component Calibration
Lubrication & Tune-up Fluids & Greases Part-Specific Procedures
Ignition System Tests Electrical Checks Component Replacement

Following OEM groupings, the manual includes detailed procedures for engine operation, synchronization, and adjustment. It covers lubrication services, power head and midsection maintenance, and gearcase procedures. Additionally, it includes storage preparation, tune-up guidelines, and a comprehensive troubleshooting section covering various systems. Specific sections detail ignition, fuel, charging, and starting systems for a thorough understanding of engine performance and maintenance. The manual also includes troubleshooting charts for common issues and provides detailed guidance on electrical system fundamentals and troubleshooting. Safety precautions are emphasized throughout the document to ensure proper and safe operation. Specialized tools and equipment are also identified for various procedures. The manual contains diagnostic trouble codes for EFI models and outlines procedures for checking sensors and switches. It covers a wide range of maintenance tasks, including oil changes, filter replacements, and timing belt inspections, ensuring the engine operates reliably and efficiently.

This manual documents torque specifications for various components to ensure proper cyclic stress resistance.

FAQ

What are the **proper** clearance measurements? keyboard_arrow_down

For 5-15 hp models, valve clearance is checked using feeler gauges, with specifications detailed in Table 1, requiring specific measurements for intake and exhaust valves.

Specify the **standard** torque specifications. keyboard_arrow_down

Standard torque specifications for various components, including bolts and nuts, are provided in Table 4 (N·m) and Table 5 (in.-lb. / ft.-lb.) for accurate assembly.

What is the **necessary** safety precautions? keyboard_arrow_down

Always wear approved eye protection when working with machinery or during running tests, keep loose clothing tucked in, and use caution with fuel systems to prevent fire hazards.

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Reviews (2)

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Rated 4 out of 5 stars
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This manual is a game changer for my Johnson engine. The troubleshooting section is particularly helpful! I had a quick question and their support responded almost immediately. Smooth download too!