Description
This Clymer Evinrude-Johnson 2-300hp 1991 1992 1993 1994 Outboard Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1991-1994 Evinrude-Johnson 2-300hp outboard boat engines including Jet Drives and Sea Drives, 2.0 HP, 2.3 HP, 3.3 HP, 3 HP, 4 HP, 4 DELUXE, 6 HP, 8 HP, 9.9 HP, 15 HP, 20 HP, 25 HP, 28 HP, 30 HP, 35 HP, 40 HP, 48 HP, 50 HP, 60 HP, 70 HP, 65 HP, 80 HP, 85 HP, 88 HP, 90 HP, 100 HP, 115 HP, 120 HP, 140 HP, 150 HP (90° V6), 175 HP (90° V6), 150 HP (60° V6), 175 HP (60° V6), 200 HP, 225 HP, 250 HP, 300 HP, 1.6 Sea Drive, 2.0 Sea Drive, 3.0 Sea Drive, and 4.0 Sea Drive motors.
Provides general information about each model, tools and techniques, troubleshooting and testing, lubrication, maintenance and tune-up, engine synchronization and linkage adjustments, fuel system, electrical and ignition systems, power head, oil injection system, automatic rewind starter, Sea and Jet drives and complete wiring diagrams. Features 776 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 tips
CHAPTER THREE, TROUBLESHOOTING
Operating requirements, Starting system, AC (alternating current) lighting coil, Battery charging system, Ignition system, Breaker-point ignition testing (1-cylinder models), Capacitor discharge ignition (CDI) troubleshooting, CD2U (under flywheel) ignition troubleshooting, Capacitor discharge ignition system troubleshooting (1991-on 3 and 4 hp models), CD2 ignition system troubleshooting (1993-on 6-30 hp models), CD2 ignition troubleshooting (1992-on 35 Jet, 40 and 50 hp [except 48 hp] equipped with 12 amp charging system), CD3 ignition troubleshooting (3-cylinder models), CD4 ignition system troubleshooting, CD4 ignition system troubleshooting (V4 loop charge models–120 and 140 hp; 2.0 Sea Drive), CD6 ignition system troubleshooting (1991-on V6 loop charge models–200 and 225 hp; 3.0 Sea Drive), CD6 OIS ignition system troubleshooting (60º, 150 and 175 hp models), CD8 ignition system troubleshooting (1991-on V8 loop charged models–250 and 300 hp; 4.0 Sea Drive 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, Tune-up
CHAPTER FIVE, ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS
Engine timing and synchronization, Required equipment, 3 and 4 (2-cylinder models), 4 Deluxe, 6 and 8 hp (2-cylinder models) / 1991 and 1992 9.9 and 15 hp (2-cylinder models), 1993-on 9.9 and 15 hp (2-cylinder models) / 20, 25, 28 and 30 hp (2-cylinder models), 35 jet, 40, 48 and 50 hp (2-cylinder models), 1991 and 1992 60 and 70 hp (3-cylinder models), 1993-on 60 and 70 hp (3-cylinder equipped with tiller handle), 1993-on 60 and 70 hp (3-cylinder equipped with remote controls) / 65 jet, 80 Jet, 1.6 Sea Drive and 85-115 hp (90º V4 cross flow models) / 2.0 Sea Drive, 120 and 140 hp (90º V4 loop charge models) / 1991 101 Jet, 150 and 175 hp (90º V6 cross flow models), 1992-on 105 Jet, 1991-on 150 and 175 hp (60º V6 models) / 3.0 Sea Drive, 1991 and 1992 200 and 225 hp (90º V6 loop charged models) / 1993-on 200 and 225 hp (90º V6 loop charged models); 4.0 Sea Drive, 250 an 300 hp (90º V8 loop charged models)
CHAPTER SIX, FUEL SYSTEM
Fuel pump, Carburetor, Carburetor (2, 2.3 and 3.3 hp), Carburetor 3 and 4 hp; 4 Deluxe, Carburetor (6-20 hp models), TR and SV carburetor (25-70 hp models), Top feed carburetor (V4 and V6 cross flow models) / Minlon carburetors (V4 and V6 loop charged models) / Electric fuel primer pump (V8 models), Manual fuel primer, Electric fuel primer solenoid, Fuel module and vapor separator (60º V6 models), Fuel line and primer bulb
CHAPTER SEVEN, IGNITION AND ELECTRICAL SYSTEMS
Battery, Battery charging system, Electric starting system, Starter motor, Neutral start switch, Ignition system, Magneto breaker point ignition system service, CD2U ignition, CD ignition, CD ignition (all except CD2U, 3 and 4 hp and 60º V6 models), Optical ignition system (60º V6 models)
CHAPTER EIGHT, POWER HEAD
Engine serial number, Fasteners and torque, Gaskets and sealants, Flywheel, Power head, Leaf valves, Thermostat
CHAPTER NINE, GEARCASE
Service precautions, Propeller, Water pump, Gearcase, Pinion gear depth (40-70 hp, V4 , V6 and V8 models)
CHAPTER TEN, POWER TRIM AND TILT SYSTEMS
Touch-trim, Trim/tilt motor testing, Power trim/tilt assembly removal/installation (40-50 hp), Conventional power trim and tilt system, Trim/tilt motor testing, Power trim/tilt system removal/installation (conventional trim/tilt) / Fastrak power trim/tilt system, Trim/tilt motor testing
CHAPTER ELEVEN, OIL INJECTION SYSTEMS
Accumix oil injection, OMC variable ratio oiling (VRO) system
CHAPTER TWELVE, AUTOMATIC REWIND STARTERS
Rewind starter (2.0, 2.3 and 3.3 hp) / Rewind starter (3 and 4 [except 4 Deluxe] hp) / Rewind starter (4 Deluxe models) / Rewind starter (6 and 8 ho; 1993-on 9.9 and 15 hp), Rewind starter (1991-92 9.9 and 15 hp) / Rewind starter (20-30 hp), Rewind starter (40 hp)
CHAPTER THIRTEEN, SEA DRIVES
Selectrim (1.6 Sea Drive), Selectrim/tilt (2.0, 3.0 and 4.0 Sea Drives)
CHAPTER FOURTEEN, JET DRIVES
Maintenance, Water pump, Jet drive, Bearing housing, Intake housing liner
INDEX
WIRING DIAGRAMS
SKU: B753
SKU: IOS-6
