This manual can be used by anyone from a first time owner/amateur to a professional technician.Easy to read type,And give you all the information needed to do the procedure correctly.Keep this service manual handy and use it often. Performing routine,preventive maintenance will save you time & money by helping to prevent premature failure and unnecessary repairs.

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Models Covered:

1995-2003 EVINRUDE JOHNSON OUTBOARD 2HP-70HP
1995-2003 18-35 Jet Drive Models
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Manual Contents:

QUICK REFERENCE DATA

CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Torque specifications / Engine operation / Fasteners / Lubricants / Gasket sealant / Galvanic corrosion / Propellers / Specifications

CHAPTER TWO / TOOLS AND TECHNIQUES
Safety first / Basic hand tools / Test equipment / Service hints / Special tips / Mechanics techniques / Specifications

CHAPTER THREE / TROUBLESHOOTING
Service precautions 1998 model year engines / Safety precautions / Operating requirements / Test and repair equipment / Wiring harness / Startig system / AC (alternating current) lighting coil / Battery charging system / Electrical accessories / Warning systems / Ignition system / Indexing flywheel (erratic spark [2- and 3-cylinder models]) / CD1 (capacitor discharge 1-cylinder models) ignition / CD2 (capacitor discharge 2-cylinder) ignition (2 and 3.3 hp models)/ CD2 (capacitor discharge 2-cylinder) ignition (3 and 4 hp [except 4 deluxe] models) / CD2 (capacitor discharge two-cylinder) ignition (4 Deluxe, 6-48 hp, 18 jet and 28 Jet equipped with rope start and/or 4 or 5 amp charging system) / CD2 (capacitor discharge two cylinder) ignition (40 hp, 50 hp and 35 jet models equipped with 12 amp regulated charging system) / OIS2000 ignition system (25 and 35 hp [three cylinder] models / CD3 (capacitor discharge three-cylinder) ignition (50-70 hp models) / Fuel system / Anti-siphon valve tests / Fuel primer systems / Engine temperature and overheating / Engine / Specifications

CHAPTER FOUR / LUBRICATION, MAINTENANCE AND TUNE-UP
Hour meter / Fuels and lubrication / Proper fuel selection / Alcohol extended gasoline / Testing for alcohol / Gasoline additives / Recommended fuel/oil mixtures / Power head break-in procedures / Fuel mixing procedures / AccuMix R oil injection system / Constant ration fuel injection (25 and 35 hp [3-cylinder) / VRO2 System (35 Jet, 40 hp [with electric start] and 50-70 hp models) / Checking lower gearcase lubricant / Jet pump service / Propeller shaft maintenance and lubrication / Corrosion of the propeller shaft bearing carrier / Off-season storage / Anti-corrosion maintenance / Engine submersion / Cooling system flushing / Tune-up / Removing combustion chamber deposits / Compression test / Cylinder head bolt torque / Electrical harness inspection / Spark plug / Lower gear case (and Jet Pump Unit) water pump / Fuel and oil injection systems / Fuel filters / Fuel pump / Ignition system service / Battery and electric starter system / On-water performance testing / Specifications

CHAPTER FIVE / SYNCHRONIZATION AND LINKAGE ADJUSTMENT
2 and 3.3 hp / 3 and 4 hp (except 4 deluxe) / 4 Deluxe models / 6 and 8 hp models / 9.9 and 15 hp models / 20-30 hp (two-cylinder) and 18 jet models / 25 and 35 hp (three-cylinder) models / 40-50 hp (two-cylinder), 28 jet and 35 jet models / 50-70 hp (three-cylinder) models / Specifications

CHAPTER SIX / FUEL SYSTEM
Conventional fuel pump service / Carburetors / Modular carburetor / TR and SV carburetors / Fuel primer systems / Antisiphon protection / Fuel tanks / Fuel lines, primer bulbs, fittings and connectors / Fuel filters / Reed valve service / Fuel recirculation systems / Specifications

CHAPTER SEVEN / IGNITION AND ELECTRICAL SYSTEMS
Battery charging system / Fuses / Electric starting system / Neutral safety switch / Flywheel service / Ignition system / CD1 (capacitor discharge one-cylinder) ignition (2 and 3.3 hp models) / Capacitor discharge (two-cylinder) ignition (3 and 4 hp models [except 4 Deluxe]) / CD2 (capacitor discharge two cylinder) (4 deluxe, 6-48 hp, 18 and 28 jet models with rope start and/or 4 [or 5] amp charging system) / CD2/CD3 (capacitor discharge two/three cylinder) ignition (40-70 hp and 35 jet models with 12 amp regulated charging system) / OIS2000 ignition system (25 and 35 hp [three-cylinder] models) / Electrical connector service / Specifications

CHAPTER EIGHT / POWER HEAD
Break-in / Lubricants, sealants and adhesives / Sealing surfaces / Fasteners and torque / Flywheel / Upper crankshaft seal replacement (3, 4-30 hp [two-cylinder] and 18 jet) / Power head removal installation disassembly assembly cleaning and inspection / Reed valves / Thermostat / Specifications

CHAPTER NINE / LOWER GEARCASE AND JET DRIVE UNITS
Gear case operation lubrication removal installation disassembly assembly pressure and vacuum test / Gear ratio/ Service precautions / Corrosion control / Neutral start adjustment (tiller handle models) / Propeller / Trim tab adjustment / Water pump / Pinion gear shimming (40-70 hp models) / Shift shaft height adjustment (40-70 hp) / Jet drive models / Jet pump unit adjustments maintenance / Jet pump unit service / Drive shaft and bearing housing / Water intake housing liner / Specifications

CHAPTER TEN / TRIM AND TILT SYSTEMS
Manual tilt assist cylinder / Touch-trim system / Power trim and tilt hydraulic troubleshooting / Power trim and tilt system electrical troubleshooting / Electric motor testing / Power trim and tilt system service / Specifications

CHAPTER ELEVEN / OIL INJECTION SYSTEMS
Accumix R oil injection system / Constant ratio (25 and 35 hp [three-cylinder]) / VRO2 oil injection (35 jet, 40 hp [electric start] and 50-70 hp models) / Specifications

CHAPTER TWELVE / ROPE STARTERS AND REMOTE CONTROLS
Rope manual starter / Remote controls / Specifications

INDEX

WIRING DIAGRAMS
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