Evinrude/Johnson 40-50-60-65-75-90 HP 2012 Service Manual

Oct 23, 2026

Upload by Riley

Service manual contents for Evinrude/Johnson outboard engines covering reference information, routine service, engine cover service, engine management module (EMM), system analysis, electrical and ignition, fuel system, oiling system, cooling system, powerhead, midsection, and gearcase-related service for 40-65 HP and 75-90 HP models, plus trim and tilt, and manual starter. Includes safety notice, key abbreviations, units of measurement, emissions-related installation instructions, responsibilities, EPA emission regulations, model designation, covered models, and torque and service specifications.

LanguageEnglish

CategoryTechnology

FormatPDF

Pages426

Reading Time17 h 54 min

AccessFree to download

Service Manual Contents

Reference Information

Safety Notice

Abbreviations and Units of Measurement

Routine Service

Engine Cover Service

Engine Management Module (EMM)

System Analysis

Electrical and Ignition

Fuel System

Oiling System

Cooling System

Powerhead

Midsection

Gearcase Service (40–65 HP)

Gearcase Service (75–90 HP)

Trim and Tilt

Manual Starter

Supporting Sections

BRP US Inc. Technical Publications P.O. Box 597 Sturtevant, Wisconsin 53177 United States [www.evinrude.com or www.johnson.com](www.evinrude.com or www.johnson.com) † AMP, Superseal 1.5, Super Seal, Power Timer, and Pro-Crimper II are registered trademarks of Tyco International, Ltd. † Amphenol is a registered trademark of The Amphenol Corporation. † BEP is a registered trademark of Actuant Corporation. † Champion is a registered trademark of Federal-Mogul Corporation. † Deutsch is a registered trademark of The Deutsch Company. † Dexron is a registered trademark of The General Motors Corporation.† Fluke is a registered trademark of The Fluke Corporation † GE is a registered trademark of The General Electric Company. † GM is a registered trademark of The General Motors Corporation. † Locquic and Loctite are registered trademarks of The Henkel Group. † Lubriplate is a registered trademark of Fiske Brothers Refining Company. † NMEA is a registered trademark of the National Marine Electronics Association. † Oetiker is a registered trademark of Hans Oetiker AG Maschinen. † Packard is a registered trademark of Delphi Automotive Systems. † Permatex is a registered trademark of Permatex. † STP is a registered trademark of STP Products Company. † Snap-on is a registered trademark of Snap-on Technologies, Inc. The following trademarks are the property of BRP US Inc. or its affiliates: Evinrude ® Johnson ® Evinrude® E-TEC ® FasTrak™ S.A.F.E. ™ SystemCheck™ I-Command™ Evinrude ® ICON™ Evinrude® / Johnson® XD30™ Outboard Oil Evinrude® / Johnson® XD50™ Outboard Oil Evinrude® / Johnson® XD100™ Outboard Oil Gel-Seal II™ Twist Grip™ Nut Lock™ Screw Lock™ Ultra Lock™ Moly Lube™ Triple-Guard ® Grease DPL™ Lubricant 2+4 ® Fuel Conditioner Carbon Guard™ HPFXR™ Gearcase Lubricant HPF PRO™ Gearcase Lubricant Printed in the United States. © 2011 BRP US Inc. All rights reserved. TM, ® Trademarks and registered trademarks of Bombardier Recreational Products Inc. or its affiliates. SERVICE MANUAL CONTENTS SECTION ..................................... PAGE 1 REFERENCE INFORMATION ..................... 3 2 ROUTINE SERVICE ............................ 15 3 ENGINE COVER SERVICE ...................... 49 4 ENGINE MANAGEMENT MODULE (EMM) .......... 53 5 SYSTEM ANALYSIS ............................ 73 6 ELECTRICAL AND IGNITION ..................... 87 7 FUEL SYSTEM ............................... 121 8 OILING SYSTEM ............................. 153 9 COOLING SYSTEM ........................... 173 10 POWERHEAD ................................ 185 11 MIDSECTION ................................ 233 12 GEARCASE ................................. 289 GEARCASE SERVICE, 40 – 65 HP MODELS ....... 296 GEARCASE SERVICE, 75 – 90 HP MODELS ....... 318 13 TRIM AND TILT ............................... 343 14 MANUAL STARTER ........................... 361 SAFETY ....................................... S–1 INDEX .......................................... I–1 TROUBLE CHECK CHART ........................ T–1 DIAGRAMS IMPORTANT: For complete outboard rigging and control installation information, refer to the Predelivery and Installation Guide included with the service manual set. All special tools referenced in this manual can be found in the Special Tools Guide, P/N 5008526 . REFERENCE INFORMATION REFERENCE INFORMATION 1 TABLE OF CONTENTS SAFETY NOTICE ..................................................................... 4 ABBREVIATIONS USED IN THIS MANUAL ................................................ 6 UNITS OF MEASUREMENT ............................................................ 6 LIST OF ABBREVIATIONS ............................................................. 6 EMISSION-RELATED INSTALLATION INSTRUCTIONS ...................................... 7 MANUFACTURER’S RESPONSIBILITY .................................................... 7 DEALE

FAQs

What safety requirement applies before working on the outboard?

Before working on any part of the outboard, read the SAFETY section at the end of the manual.

Who is the publication written for?

It is written for qualified, factory-trained technicians familiar with using Evinrude/Johnson special tools.

How is the manual organized at a high level?

It provides service manual contents grouped into sections such as reference information, routine service, engine cover service, EMM, system analysis, electrical/ignition, fuel/oiling/cooling systems, powerhead and midsection, gearcase service, trim and tilt, and manual starter.

Oct 23, 2026

Upload by Riley