2002-2006 Johnson Evinrude 3.5-250 HP Outboards OEM Service & Repair Manual

2002-2006 Johnson Evinrude 3.5-250 HP Outboards OEM Service & Repair Manual

Models covered:

• 3.5 HP – 1 cyl, 2-stroke (2002–06)
• 6 HP – 1 cyl, 4-stroke (2002–04)
• 4 HP – 1 cyl, 4-stroke (2004–06)
• 5 HP – 1 cyl, 4-stroke (2004–06)
• 6 HP – 1 cyl, 4-stroke (2005–06)
• 6 HP – 2 cyl, 2-stroke (2002–05)
• 8 HP – 2 cyl, 4-stroke (2002–04)
• 9.9 HP – 2 cyl, 2-stroke (2002–07)
• 15 HP – 2 cyl, 2-stroke (2002–07)
• 9.9/15 HP – 2 cyl, 4-stroke (2002–04, 2005–07)
• 25 HP – 2 cyl, 2-stroke (2002–05)
• 30 HP – 2 cyl, 2-stroke (2002–05)
• 25 HP – V2, 4-stroke (2006–07)
• 40 HP – 2 cyl, 2-stroke (2002–05)
• 50 HP – 2 cyl, 2-stroke (2002–05)
• 55 HP – 2 cyl, 2-stroke (2003–05)
• 25 HP – 3 cyl, 4-stroke (2004–05)
• 30 HP – 3 cyl, 4-stroke (2004–06)
• 40 HP – 3 cyl, 4-stroke (2002–05)
• 50 HP – 3 cyl, 4-stroke (2002–05)
• 60 HP – 4 cyl, 4-stroke (2003–05)
• 70 HP – 4 cyl, 4-stroke (2002–05)
• 90 HP – V4, 2-stroke (2002–06)
• 105 HP – V4, 2-stroke (2002–04)
• 115 HP – V4, 2-stroke (2002–06)
• 90 HP – 4 cyl, 4-stroke (2003–05)
• 115 HP – 4 cyl, 4-stroke (2003–05)
• 140 HP – 4 cyl, 4-stroke (2003–05)
• 150 HP – V6, 2-stroke (2002–06)
• 175 HP – V6, 2-stroke (2002–06)
• 200 HP – V6, 4-stroke (2004–05)
• 225 HP – V6, 4-stroke (2004–05)
• 250 HP – V6, 4-stroke (2005)

The 2002-2006 Johnson Evinrude 3.5-250 HP Outboards OEM Service & Repair Manual provides complete factory instructions for a wide range of models, from small single-cylinder motors to V6 two- and four-stroke engines. Whether you’re a marine technician or a boat owner who prefers doing the work yourself, this manual delivers the detailed procedures and specifications you need.

Content spans routine maintenance and tune-ups, lubrication service, timing adjustments, synchronization, storage preparation, and recovery procedures for submerged engines. It also explains in depth the fuel systems (carbureted and EFI), ignition and charging circuits, lubrication and cooling service, and full powerhead disassembly with break-in and reassembly procedures.

Content overview:

• General information, safety, and tools – boating safety guidelines, shop equipment, essential tools, fasteners, measurement conversions, troubleshooting, and full specifications.
• Maintenance & tune-up – lubrication service, engine and boat maintenance, valve clearance (4-stroke models), timing and synchronization, tune-up procedures, storage, submerged motor recovery, and specifications.
• Fuel systems – fuel system basics, fuel tank and lines, carbureted fuel system, electronic fuel injection (EFI), and specifications.
• Ignition & electrical systems – electrical troubleshooting, ignition systems, charging and starting circuits, warning systems, wiring diagrams, and specifications.
• Lubrication & cooling – oil metering system for 2-stroke motors, lubrication system for 4-stroke motors, cooling system service, and specifications.
• Powerhead – disassembly, service procedures, break-in process, and detailed specifications.
• Lower unit (gearcase) – inspection, service, repair, and full specifications charts.
• Trim & tilt systems – 2-stroke and 4-stroke hydraulic systems, and mechanical hydraulic tilt assist.
• Remote controls – remote control operation, service, and control cable adjustments.
• Hand rewind starter – starter repair, emergency starting procedures, and maintenance.

For the lower unit and controls, the manual covers gearcase repair, propeller service, hydraulic trim and tilt systems, and remote control operation with cable adjustments. With clear troubleshooting charts, torque specs, and factory-approved methods, it’s a reliable resource for keeping Johnson and Evinrude outboards of all sizes in proper working condition.

Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)