1973-1990 Evinrude/Johnson Outboard Motor 2-40 HP Service Manual
Technical reference spanning 2-40 HP Evinrude/Johnson outboard motors from 1973-1990. Includes detailed diagrams, maintenance schedules, and troubleshooting. Publication B732.
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Sample pages from the 1973-1990 Evinrude/Johnson Outboard Motor 2-40 HP Service Manual manual
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Models Covered & Key Technical Specifications
Evinrude/Johnson Outboard Motor 2-40 HP (B732) 1973-1990 Structured Automotive Primer | Series Outboard Motor Package. Factory Print Quality: 165.532 MB Benchmarks Essential Securement Values: 2-40 HP is specified as Range Key Liquid Volume: Year(s) not specified controls Baseline Primary Power Rating: Engine Operation requires 2-40 HP Requirements General Working Temperature: Ignition System is configured at 1973-1990 Threshold Integral Output Quality: 2-40 HP Operating Manual is specified as Range
Professional Workshop Service Manual & Technical Specifications
Evinrude/Johnson Outboard Motor 2-40 HP (B732) 1973-1990 Illustrated Repair Manual Documentation-Framework
Service-Level: 2-40 HP Outboard Motors // Year-Coverage: 1973-1990 // Service-Level: Illustrated Repair Manual
| Service-Nexus | Parameters | Logic |
|---|---|---|
| Overall System | Engine Operation | Torque Data |
| Electrical | Ignition System | Circuit Diagrams |
| Mechanical | Fuel System | Carburetor Settings |
| Drivetrain | Gearcase | Propeller Specs |
| Starting | Starter Components | Rewind Mechanism |
| Maintenance | Lubrication | Tune-up Procedures |
Introduction
Accurately requiring engine maintenance and repair procedures, this manual serves as a comprehensive guide for Evinrude and Johnson outboard motors ranging from 2 to 40 horsepower. It covers a wide array of models produced between 1973 and 1990, offering detailed insights for both basic upkeep and complex repairs.
Adjustment procedures are detailed for engine synchronization and linkage adjustments, ensuring optimal performance and smooth operation.
Timing procedures are documented for ignition systems, covering breaker point and CD ignition troubleshooting for reliable starting and running.
Technical notes are provided for troubleshooting common issues across various systems, including fuel, electrical, and powerhead.
Quality checks are addressed for components like the gearcase and starter mechanisms, ensuring longevity and reliability.
The starter motor section documents components and repair procedures for automatic rewind starters and electric motors.
The engine section covers all aspects of engine operation, overheating, detonation, and poor idling conditions. This manual documents torque specifications for various components to ensure proper bolt stretch prevention.
Quick Reference Data
This section provides essential specifications and data for quick lookups, including tightening torques and test wheel recommendations, simplifying common maintenance tasks.
Chapter One: General Information
Cataloging major assemblies into sections, this chapter details manual organization, notes, cautions, warnings, engine operation, and fastener types. It also covers lubricants and the principles of 4-stroke and 2-stroke engine operations.
Chapter Two: Tools and Techniques
This chapter details the common tools and techniques required for marine equipment repairs. It includes information on safety first, basic hand tools, and special tools, ensuring proper and safe execution of maintenance procedures.
Chapter Three: Troubleshooting
This comprehensive chapter focuses on diagnosing and resolving common problems across various systems, including starting, fuel, electrical, and ignition systems, providing systematic approaches to identify and fix issues.
Chapter Four: Lubrication, Maintenance and Tune-up
This section offers guidance on proper lubrication techniques, routine maintenance schedules, and tune-up procedures to keep the outboard motor in optimal condition, extending its lifespan.
Chapter Five: Engine Synchronization and Linkage Adjustments
Complete procedures for synchronizing and adjusting engine linkages are provided, ensuring smooth operation and maximizing performance.
Chapter Six: Fuel System
This chapter covers fuel pump overhaul, carburetor adjustments, and troubleshooting for the entire fuel system, ensuring efficient fuel delivery and combustion.
Chapter Seven: Electrical System
Detailed information on the battery, charging system, and starting motor, including electrical troubleshooting and repair procedures for these critical components.
Chapter Eight: Power Head
Provides complete overhaul procedures for the power head, including engine serial number, fasteners, and torque specifications, essential for engine rebuilds.
Chapter Nine: Gearcase
This chapter details gearcase overhaul procedures, including water pump replacement, pressure and vacuum testing, and shift lever adjustment.
Chapter Ten: Automatic Rewind Starters
Covers starter assembly, maintenance, and troubleshooting for automatic rewind starters and electric motors, ensuring reliable starting.
Chapter Eleven: Electric Motors
Includes troubleshooting and repair procedures for electric motors, focusing on their maintenance, battery connections, and propeller replacement.
Wiring Diagrams
Provides complete schematic diagrams for all models, offering a visual guide to the electrical systems for easier diagnosis and repair.
Index
A detailed index facilitates quick access to specific topics and components within the manual.
FAQ
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