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

Clymer’s Evinrude/Johnson Outboard Shop Manual, B732, published by Intertec, 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.

File condition: This 415-page PDF set contains 15 files and is an incomplete scan. Nine printed pages are missing, interrupting some procedures; the file breakdown below identifies the gaps.

• Ignition and electrical diagnosis: Breaker-point magneto, CD2 and CD2UL testing, plus starting and charging system troubleshooting.

• Fuel and synchronization: Carburetor overhaul, float adjustment, throttle-linkage synchronization and oil-injection system checks.

• Powerhead repair: Engine removal, internal inspection, piston and crankshaft service, and reassembly procedures.

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

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

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

Written for readers with some mechanical ability, the manual calls for considerably greater experience and appropriate equipment for major powerhead work.

Fuel System and Engine Synchronization

The engine sections explain operating principles, lubrication requirements and fuel-system calibration. Maintenance covers compression testing, spark-plug assessment, seasonal storage and recovery after submersion.

Carburetor service includes model-specific float settings, throttle-cam pickup and full-throttle stop adjustment. The Carburetor (9.9 and 15 HP) exploded view supports component identification, while altitude-orifice charts cover 1973–1982 engines. Float-setting procedures identify OMC gauge 324891.

Carburetor repair cautions explain how hot-tank cleaning can strip sealing compound from the castings. For 1985-on 40 HP electric-start models, VRO coverage includes oil-delivery checks, warning-system tests and air purging. Sealed VRO pumps are replaced as assemblies. AutoBlend and AccuMix owner service is limited to draining and flushing.

Magneto, CD2 and CD2UL Diagnosis

The electrical sections map out magneto, CD2 and CD2UL ignition setups. CD2 tests distinguish pre-1985 and later connector arrangements; CD2UL receives separate charge-coil, ignition-module and output tests. These distinctions help you select the appropriate test and separate stop-circuit faults from ignition-component failures before choosing replacement parts.

CD2UL procedures specify a peak-reading voltmeter and Stevens PL-88 load adapter. The Starter Circuit Test (With Remote Control) drawing supports starting-system diagnosis. Charging-system coverage adds stator and rectifier checks, while S.L.O.W. coverage addresses the overheat speed-limiting system on 1989–1990 20–40 HP models.

Powerhead and Gearcase Overhaul

Powerhead procedures address cylinder wear, piston and ring inspection, crankshaft bearings, reed valves and thermostats. The Cylinder and Crankcase (18–40 HP) view identifies the major castings and fittings.

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

Gearcase instructions distinguish standard and weedless units and separate the 1985–1988 and 1989–1990 40 HP designs. The 1989–1990 40 HP Gearcase exploded view accompanies bearing, seal and shift-component service. Pinion shimming, shift-rod height adjustment and post-overhaul leak testing extend the repair coverage beyond water-pump replacement.

Scout Motors and Wiring Schematics

Scout electric coverage begins with the 1975 models and addresses 12 V and 12/24 V systems, bow and transom mounts, and hand or foot controls. Troubleshooting separates no-run, lost-speed-control and high-speed-only faults. The 1982-On 12/24 Volt Bow Mount Model schematic locates the switches, resistors and thermal cutout used in those tests.

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

Service Specifications and PDF Contents

Reference tables provide component torque specifications, spark-plug types and gaps, gearcase clearances, lubrication data and powerhead wear limits. Safety notes address disconnecting spark-plug leads and batteries before applicable work on ignition components or moving parts.

The manual text is image-based and not searchable, and the PDFs have no bookmarks. Watermarks appear throughout. Dense wiring diagrams require zooming; some small connector markings remain blurred when enlarged.

The missing pages include gaps within technical procedures and should not be assumed to be blank. Three separator pages are included in the 415-page total.

The total already includes 10 front-matter pages in General Information, three separator pages, a repeated scan of printed page 37, one Notes page and one Maintenance Log page. The Wiring Diagrams file also contains a back-cover scan; the separate Cover and Back files repeat covers already included in the section files.