Evinrude/Johnson 2–40 HP Outboard Shop Manual 1973–1990 (P/N B732)

This Intertec edition of Clymer’s Evinrude/Johnson Outboard Shop Manual (P/N B732) covers 1973–1990 2–40 HP two-stroke outboards and electric trolling motors. Named variants include Colt, Junior, Excel 4, Ultra 4 and 4 Deluxe. The 40 HP sections cover 1973–1976 and 1985–1990 models.

PDF Files, Missing Pages and Diagram Detail

Text access and wiring detail: The manual text is not searchable, and none of the PDFs has embedded bookmarks. Watermarks appear throughout. Dense wiring diagrams require zooming; some small connector markings remain blurred when enlarged.

Missing pages: Nine printed pages are absent, leaving gaps within some service procedures.

The ZIP download contains 15 printable PDFs totaling 415 pages. This total includes 10 front-matter pages, three separator pages, an extra copy of printed page 37, one Notes page and one Maintenance Log page. The Wiring Diagrams PDF also includes a back-cover scan; the separate Cover and Back files repeat covers already present in the chapter files.

Outboard Diagnosis, Powerhead Repair and Gearcase Service

The selected coverage below highlights the main repair areas rather than reproducing the full contents. Other topics include galvanic-corrosion protection and propeller design.

• Ignition and electrical diagnosis: Breaker-point magneto, CD2 and CD2UL tests, with starting-circuit fault tracing and charging-system checks.

• Fuel and synchronization: Carburetor disassembly and overhaul, float settings, throttle-linkage synchronization and oil-injection system testing.

• Powerhead repair: Step-by-step removal and reassembly procedures, with internal inspection and piston, connecting-rod and crankshaft service.

• Lower unit repair: Water-pump and gearcase overhaul, pressure and vacuum leak tests, and shift-linkage adjustments.

• Rewind starters: Rope and spring service for engine-cover, swing-arm, side-mounted pinion and flywheel-mounted mechanisms, including starter interlocks.

• Electric trolling motors: Scout control-circuit troubleshooting, switch testing and motor load checks for hand- and foot-controlled versions.

The manual is written for readers with some mechanical ability; major powerhead work requires considerably more experience and suitable equipment.

Maintenance, Fuel System and Engine Synchronization

Operating-principle explanations support the lubrication and fuel-calibration sections. Maintenance procedures cover compression checks, spark-plug assessment, seasonal storage and recovery after submersion.

Carburetor instructions distinguish float settings, throttle-cam pickup and full-throttle stops by model. The Carburetor (9.9 and 15 HP) exploded view identifies the individual parts; altitude-orifice charts address 1973–1982 engines. Float-setting instructions specify OMC gauge 324891.

The cleaning cautions explain how hot-tank treatment or immersion can strip sealing compound from carburetor castings. For 1985-on 40 HP electric-start models, the VRO section covers oil-delivery checks, warning-system tests and air purging. Defective sealed VRO pumps are replaced as assemblies; AutoBlend and AccuMix owner service is limited to draining and flushing.

Magneto, CD2 and CD2UL Fault Tracing

CD2 diagnosis separates pre-1985 and later connector arrangements. CD2UL has its own charge-coil, ignition-module and output tests. This distinction helps match the test to the installed system and isolate stop-circuit faults before replacing ignition components.

CD2UL ignition-plate output testing specifies a peak-reading voltmeter and Stevens PL-88 load adapter. The Starter Circuit Test (With Remote Control) drawing supports starting diagnosis; stator and rectifier checks address charging faults. Connector-terminal removal and installation are covered, along with S.L.O.W. overheat speed limiting on 1989–1990 20–40 HP models.

Safety notes address disconnecting spark-plug leads and batteries before applicable work on ignition components or moving parts.

Powerhead Inspection and Assembly

Internal-engine coverage includes cylinder wear, piston rings, crankshaft bearings, reed valves and thermostats. The Cylinder and Crankcase (18–40 HP) view identifies the castings and associated fittings. Factory-oversize powerheads marked OS have a specific repair limit: their cylinders cannot be rebored.

For precision-ground connecting rods on 1986-on 20–40 HP engines and some 1985 models, the assembly procedure specifies OMC Rod Cap Alignment Fixture 396749. The rod-cap cautions explain how misalignment can affect bearing operation and cause major engine damage.

Water Pumps, Gearcases and Shift Adjustment

Gearcase procedures distinguish standard and weedless units, as well as the 1985–1988 and 1989–1990 40 HP designs. The 1989–1990 40 HP Gearcase exploded view supports bearing, seal and shift-component identification.

Pinion shimming, shift-rod height setting and post-overhaul leak tests extend the coverage beyond impeller replacement. Reference tables provide gearcase clearances and component tightening torques.

Scout Controls and Wiring Schematics

Scout coverage starts with the 1975 models and includes 12 V and 12/24 V systems, bow and transom mounts, and hand or foot controls. Separate diagnostic paths address motors that will not run, loss of speed control and high-speed-only operation.

The 1982-On 12/24 Volt Bow Mount Model schematic identifies switches, resistors and the thermal cutout. Component-replacement instructions cover switches; motors with impact damage are referred to dealer service.

The wiring section distinguishes manual, tiller-electric and remote-start configurations, including the 1989–1990 20–30 HP Remote Start schematic.

A Preview of Carburetor Settings and Gearcase Clearances

For the 9.5 HP carburetor, the float-setting section specifies 13/16 in. between the casting face and the top of the float with the carburetor inverted. The associated instructions distinguish this setting from float drop.

For the 2 HP gearcase, the drive-shaft-to-bushing clearance is listed as 0.0010–0.0028 in. Other reference tables provide model-specific spark-plug types and gaps, lubrication data and powerhead wear limits.