2001 JOHNSON EVINRUDE 75HP OUTBOARD Factory Service & Work Shop Manual
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General Information
Tools and Techniques
Troubleshooting
Lubrication, Maintenance and Tune-Up
Engine Synchronization and Linkage Adjustment
Ignition and Electrical Systems
Lower Gearcase and Jeft Drive Units
Trim and Tilt Systems
Oil Injection Systems
Remote Controls
Supplement (1 997-2002 Ficht Fuel Injection Service Information)
Index
Wiring Diagrams
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Contents
CHAPTER ONE
GENERALINFORMATION ................................................
............................ Manual organization 1 Lubricants .................................... 8
................................ ..................... Notes. cautions and warnings 1 Gasket sealant 10
............................ ............................. Torque specifications 2 Galvanic corrosion 11
............................... ................ Engine operation 2 Protection from galvanic corrosion 13
....................................
Fasteners ..................................... 2 Propellers 14
CHAPTER TWO
...............................................
TOOLS AND TECHNIQUES 21
.................................
Safetyfirst ................................... 21 Service hints 28
...................................
Basic hand tools ............................... 2 1 Special tips 30
.........................
Test equipment ................................ 26 Mechanic's techniques 31
CHAPTER THREE
TROUBLESHOOTING ................................................... 3
Service precautions-1998 model year engines ...... 34 CD4 ignition system troubleshooting
............... Safety precautions ............................. 34 (1 30 hp V4 loop charged models) 82
Operating requirements ......................... 35 OIS2000 ignition system troubleshooting
Test and repair equipment ....................... 36 (60" V4 and V6 [loop-charged] models) .......... 93
Wiring harnesses .............................. 42 CD6 ignition system troubleshooting
............................ ............................... Starting system
44 (200 and 225 hp) 104
Battery charging system ........................ 59 CD8 ignition system troubleshooting
.................. Electrical accessories ........................... 65 (250 and 300 hp V8 models) 117
.................... Warning systems .............................. 65 Key and neutral start switch 130
................................. Ignition system ............................... 74 Fuel system 131
Capacitor discharge ignition (CDI) troubleshooting ... 75 Engine temperature and overheating .............. 133
..................................... CD4 ignition system troubleshooting Engine 135
(V4 cross flow models) ........................ 76
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CHAPTER FOUR
LUBRICATION. MAINTENANCE AND TUNE-UP .............................. 148
Lubrication .................................. 148 Engine flushing .............................. 157
Storage ..................................... 154 Power steering belt tension ..................... 157
Complete submersion ......................... 155 Tune-up .................................... 158
Anticorrosion maintenance ..................... 156
CHAPTER FIVE
ENGINE SYNCHRONIZATION AND LINKAGE ADJUSTMENTS .................... 168
Engine timing and synchronization ............... 168 130hp(1995) ............................... 179
Required equipment ........................... 168 130 hp (1996) and 200.225. 250
65 jet. 80 jet (1995-1997) and 85- 115 hp and 300 hp (1995 and 1996) ................... 182
(90" V4 cross flow models) ................... 169 130.200. 225and250hp(1997and 1998) ........ 185
80 jet (1998). 105 jet. 90.115. 150 and 175 hp
(60" V4 and V6 models) ...................... 175
CHAPTER SIX
....................................................... FUELSYSTEM 190
Fuelpump .................................. 190 Vacuum switch ............................... 215
Carburetors ................................. 198 Fuel module and vapor separator
........ Top feed carburetor (V4 cross flow models) 201 (60" V4 and V6 models) ...................... 216
Minlon carburetors Antisiphon devices ........................... 219
(V4 and V6 loop charged models) .............. 205 Fueltank ................................... 220
Electric fuel primer pump (V8 models) ........... 213 Fuel line and primer bulb ...................... 220
Electric fuel primer solenoid .................... 2 14
CHAPTER SEVEN
IGNITION AND ELECTRICAL SYSTEMS ..................................... 221
..... Service precautions-1998 model year engines 221 Ignition systems .............................. 256
Battery ..................................... 221 CD4 ignition (90" V4 cross-flow models) ......... 256
Battery charging system ....................... 229 OIS2000 ignition system (60" V4 and V6 models) ... 260
Fuse or circuit breaker ......................... 233 CD4, CD6 and CD8 ignition
....... Electric starting system ........................ 235 (90" V4, V6 and V8 loop-charged models) 264
Neutral safety switch .......................... 250 Electrical connector service ..................... 269
Flywheel service ............................. 250
CHAPTER EIGHT
POWERHEAD ....................................................... 278
Service considerations ......................... 278 Flywheel ................................... 284
EvinrudeIJohnson model identification ............ 279 Power head removal/installation ................. 284
Power head break-in .......................... 28 1 Power head disassembly ....................... 302
..... Service precautions-1 998 model year engines 28 1 Power head cleaning and inspection .............. 324
Service recommendations ...................... 28 1 Power head assembly ........................ 335
Lubricants. sealants and adhesives ............... 282 Reedvalves ................................ 368
Sealing surfaces .............................. 283 Thermostats and water blow-off valve ............ 369
Fasteners and torque .......................... 283
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CHAPTER NINE
LOWER GEARCASE A N D JET DRIVE .................................... 378
.................. Gearcase identification ....................... 378 Gearcase removal/installation 387
................................ Gearcase operation .......................... 379 Water pump 394
Gear ratio ................................. 380 Gearcase disassembly/reassembly .............. 397
High altitude operation ....................... 380 Gearcase cleaning and inspection ............... 441
Counter-rotation gearcases Gearcase pressure and vacuum tests ............. 444
(twin engine applications) ................... 38 1 Pinion gear shimming ........................ 445
Service precautions .......................... 382 Shift shaft height adjustment .................. 448
Corrision control ............................ 383 Jet drive models ............................ 448
Gearcase lubrication ......................... 384 Jet pump unit adjustments and maintenance ....... 449
Nuetral start adjustment (tiller handle models) ..... 385 Jet pump unit service ........................ 455
Shift lever detent adjustment .................. 385 Drive shaft and bearing housing ................ 457
.................................. Propeller 385 Water intake housing liner .................... 462
Trimtabadjustment ......................... 386
CHAPTER TEN
TRIM AND TILT SYSTEMS ........................................... 465
Manual tilt-assist cylinder ..................... 466 Power trim and tilt system
Power trim and tilt systems .................... 468 (electrical troubleshooting) .................. 489
..... Power trim and tilt hydraulic troubleshooting 478 Electric motor testing ........................ 501
Power trim and tilt system service .............. 508
CHAPTER ELEVEN
OIL INJECTION SYSTEMS ........................................... 530
VR02 oil injection (all models except
.......... (99.90. 112 and 11 5 special models) 531
CHAPTER TWELVE
REMOTECONTROLS .............................................. 554
SUPPLEMENT
1997-2002 FICHT FUEL INJECTION (FFI) SERIVCE INFORMATION ........... 566
.............. Electronic component replacement 569 Charging system ............................ 601
Ficht system operation ....................... 569 Fuel system ................................ 609
Starting system ............................. 588 Oil delivery system .......................... 623
Ignition system ............................. 590
.......................................................... INDEX 686
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Chapter One
General Information
This detailed, comprehensive manual contains com-
plete information covering maintenance, repair and
overhaul. Hundreds of photos and drawings guide you
throughout every procedure.
Troubleshooting, tune-up, maintenance and repair
are not difficult if you know what tools and equipment
to use and what to do. Anyone not afraid to get their
hands dirty, of average intelligence and with some me-
chanical ability can perform most of the procedures in
this manual. See Chapter Two for more information on
tools and techniques.
A shop manual is a reference. You want to be able to
find information quickly. Clymer books are designed
with you in mind. All chapters are thumb tabbed and
important items are indexed at the end of the manual.
All procedures, tables, photos and instructions in this
manual assume the reader may be working on the ma-
chine or using the manual for the first time.
Keep the manual in a handy place in your toolbox or
boat. It will help you to better understand how your boat
runs, lower repair and maintenance costs and generally
1
increase your enjoyment of your boat.
MANUAL ORGANIZATION
This chapter provides general information useful to
boat owners and marine mechanics.
Chapter Two discusses the tools and techniques for
preventative maintenance, troubleshooting and repair.
Chapter Three provides troubleshooting and testing
procedures for all systems and individual components.
Following chapters describe specific systems, pro-
viding disassembly, inspection, assembly and adjust-
ment procedures in simple step-by-step form. Specifi-
cations concerning a specific system are included at the
end of the appropriate chapter.
NOTES, CAUTIONS AND WARNINGS
The terms NOTE, CAUTION and WARNING have
specific meanings in this manual. ANOTE provides ad-
ditional information to make a step or procedure easier
or more clear. Disregarding a NOTE could cause incon-
venience, but would not cause damage or personal in-
jury.
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
Upon purchasing this manual, you will receive a .PDF file containing an email contact. After contacting us, you will receive a reply with a link to access the manual for your 2001 JOHNSON EVINRUDE 75HP OUTBOARD.
This comprehensive manual covers every aspect of your machine, providing detailed guidance on every nut and bolt. With hundreds of pages, it offers solutions for various issues, from simple tasks like an oil change to complex procedures like a transmission swap. The manual includes numerous illustrations to assist you and features easy-to-understand text throughout.
Utilize the search function to navigate the manual efficiently and print the necessary pages as needed. This Factory Service Repair Manual is designed to walk you through the fundamentals of maintenance and repair, empowering you with the knowledge that factory-trained technicians possess. By following the instructions in this manual, any owner can confidently make informed decisions regarding the maintenance and repair of their machine.
Our commitment extends beyond providing a high-quality service manual; we also ensure excellent customer service, guaranteeing your satisfaction.
