Evinrude-Johnson 85-300 hp 1995-2006 Clymer Outboard Engine Boat Repair Manual

Description

This Clymer Evinrude-Johnson 85-300 hp 1995-2006 Outboard Boat Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1995-2006 Evinrude-Johnson 85-300hp outboard engines including 65 Jet, 80 Jet, 85 Backtroller, 88 Special, 90 Special, 105 Jet, 112 Special, 115 Special, 130 HP, 150 HP, 175 HP, 200 HP, 225 HP, 250 HP, 300 HP, 90-225 HP Ficht outboards.

Does not include information for Evinrude Etec outboard engines.

1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 2003 2004 2005 2006

Coverage is included for Jet drive models. Includes general information about each model, tools and techniques, troubleshooting, lubrication, maintenance and tune-up, engine synchronization and linkage adjustments, fuel system, ignition and electrical systems, power head, lower gearcase and Jet drive units, trim and tilt systems, oil injection system, remote controls and complete wiring diagrams. Features 750 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION

Manual organization, Notes, cautions and warnings, Torque specifications, Engine operation, Fasteners, Lubricants, Gasket sealant, Galvanic corrosion, Protection from galvanic corrosion, Propellers

CHAPTER TWO, TOOLS AND TECHNIQUES

Safety first, Basic hand tools, Test equipment, Service hints, Special tips, Mechanic’s techniques

CHAPTER THREE, TROUBLESHOOTING

Service precautions–1998 model year engines, Safety precautions, Operating requirements, Test and repair equipment, Wiring harnesses, Starting system, Battery charging system, Electrical accessories, Warning systems, Ignition system, Capacitor discharge ignition (CDI) troubleshooting, CD4 ignition system troubleshooting (V4 cross flow models), CD4 ignition system troubleshooting (130 hp V4 loop charge models), OIS2000 ignition system troubleshooting (60º V4 land V6 [loop-charged] models), CD6 ignition system troubleshooting (200 and 225 hp), CD8 ignition system troubleshooting (250 and 300 hp V8 models), Key and neutral start switch, Fuel system, Engine temperature and overheating, Engine

CHAPTER FOUR, LUBRICATION, MAINTENANCE AND TUNE-UP

Lubrication, Storage, Complete submersion, Anticorrosion maintenance, Engine flushing, Power steering belt tension, Tune-up

CHAPTER FIVE, ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS

Engine timing and synchronization, Required equipment, 65 jet, 80 jet (1995-1997) and 85-115 hp (90º V4 cross flow models), 80 jet (1998), 105 jet, 90, 115, 150 and 175 hp (60º V4 and V6 models), 130 hp (1995), 130 hp (1996) and 200, 225, 250 and 300 hp (1995 and 1996), 130, 200, 225 and 250 hp (1997 and 1998)

CHAPTER SIX, FUEL SYSTEM

Fuel pump, Carburetors, Top feed carburetor (V4 cross flow models), Minlon carburetors (V4 and V6 loop charged models), Electric fuel primer pump (V8 models), Electric fuel primer solenoid, Vacuum switch, Fuel module and vapor separator (60º V4 and V6 models), Antisiphon devices, Fuel tank, Fuel line and primer bulb

CHAPTER SEVEN, IGNITION AND ELECTRICAL SYSTEMS

Service precautions–1998 model year engines, Battery, Battery charging system, Fuse or circuit breaker, Electric starting system, Neutral safety switch, Flywheel service, Ignition systems, CD4 ignition (90º V4 cross-flow models), OIS2000 ignition system (60º V4 and V6 models), CD4, CD6 and CD8 ignition (90º V4, V6 and V8 loop-charged models), Electrical connector service

CHAPTER EIGHT, POWER HEAD

Service considerations, Evinrude/Johnson model identification, Power head break-in, Service precautions–1998 model year engines, Service recommendations, Lubricants, sealants and adhesives, Sealing surfaces, Fasteners and torque, Flywheel, Power head removal/installation, Power head disassembly, Power head cleaning and inspection, Power head assembly, Reed valves, Thermostats and water blow-off valve

CHAPTER NINE, LOWER GEARCASE AND JET DRIVE

Gearcase identification, Gearcase operation, Gear ratio, High altitude operation, Counter-rotation gearcases (twin engine application), Service precautions, Corrosion control, Gearcase lubrication, Neutral start adjustment (tiller handle models), Shift lever detent adjustment, Propeller, Trim tab adjustment, Gearcase removal/installation, Water pump, Gearcase disassembly/reassembly, Gearcase cleaning and inspection, Gearcase pressure and vacuum tests, Pinion gear shimming, Shift shaft height adjustment, Jet drive, Jet pump unit adjustments and maintenance, Jet pump unit service, Drive shaft and bearing housing, Water intake housing liner

CHAPTER TEN, TRIM AND TILT SYSTEMS

Manual tilt-assist cylinder, Power trim and tilt systems, Power trim and tilt hydraulic troubleshooting, Power trim and tilt system (electrical troubleshooting), Electric motor testing, Power trim and tilt system service

CHAPTER ELEVEN, OIL INJECTION SYSTEMS

VRO2 oil injection (all except 99, 90, 112 and 115 special models)

CHAPTER TWELVE, REMOTE CONTROLS

SUPPLEMENT, 1997-2002 FICHT FUEL INJECTION (FFI) SERVICE INFORMATION

Electronic component replacement, Ficht system operation, Starting system, Ignition system, Charging system, Fuel system, Oil delivery system

INDEX

WIRING DIAGRAMS