Evinrude Johnson 120 HP Outboard 1985–1989 Service Repair Manual

🛠️ Evinrude Johnson 120 HP Outboard 1985–1989 Service Repair Manual – PDF Download

🧰 This OEM service manual provides expert repair instructions for Evinrude and Johnson 120 HP 2-stroke outboard engines from 1985 through 1989. From carburetor tuning to complete lower unit servicing, this guide includes all technical steps needed for thorough maintenance and troubleshooting.

📲 Instantly downloadable as a searchable and printable PDF – ideal for marine technicians, mechanics, and outboard owners.

🔍 Model Background

The Evinrude Johnson 120 HP Outboard (1985–1989) was a V4 two-stroke engine aimed at providing reliable mid-range power and smooth operation for a wide range of recreational boats. Positioned just below the 140 HP model, it became a favorite among boaters seeking strong acceleration, fuel efficiency, and mechanical simplicity.

Equipped with a 1.99-liter (122 cubic inch) V4 crossflow two-stroke engine, the 120 HP outboard featured dual carburetors, CD ignition, and loop-charged fuel delivery for optimal combustion and throttle response. Available in both premix and oil-injected variants, it offered flexible maintenance options depending on user preference.

Its electric start, power trim and tilt, and remote steering compatibility made it easy to operate on a variety of hulls—from fishing boats to family cruisers. With a solid midrange punch and reliable top-end power, the 120 HP was well-suited for both inland and nearshore use.

Built on the same proven V4 platform as its higher-horsepower siblings, this model earned a reputation for rugged construction, low operating costs, and long service life. It was especially appreciated by DIY owners and marine techs for its straightforward design and accessible components.

Today, the 120 HP continues to be valued on the used market for its durability, ease of maintenance, and classic two-stroke performance.

📄 Manual Details for Evinrude Johnson 120 HP (1985–1989):

• Engine Type: 2-stroke, V4
• Fuel System: Carbureted
• Cooling System: Thermostat-regulated water cooling
• Ignition System: CDI (Capacitor Discharge Ignition)
• Starting System: Electric start
• Trim & Tilt: Power trim and tilt system included
• Years Covered: 1985–1989
• File Format: PDF (searchable and printable)
• Page Count: 500+ pages

📆 Model Years Covered:

• Evinrude Johnson 120 HP Outboard 1985
• Evinrude Johnson 120 HP Outboard 1986
• Evinrude Johnson 120 HP Outboard 1987
• Evinrude Johnson 120 HP Outboard 1988
• Evinrude Johnson 120 HP Outboard 1989

📖 Manual Sections Include:

• General Specifications & Maintenance
• Service intervals, tools, torque values
• Ignition System
• CDI tests, timing procedures, stator diagnostics
• Fuel & Carburetor
• Float height adjustment, carb syncing, fuel pump rebuild
• Cooling System
• Water flow test, thermostat, impeller replacement
• Engine Overhaul Procedures
• Pistons, crankshaft, seals, port cleaning
• Lower Unit Repair
• Prop shaft, shift linkage, seals, gear oil
• Power Trim & Tilt
• Hydraulic pump, trim motor, fluid replacement
• Wiring & Diagrams
• Ignition, trim/tilt, and starting circuit schematics

💾 Format & Compatibility:

• File Type: PDF (Digital Download)
• Searchable & Printable: ✅ Yes
• Device Compatibility: Windows, macOS, iOS, Android, Linux

🔍 Keywords:

Evinrude 120 HP outboard manual, Johnson 120HP repair PDF, V4 2-stroke service guide, trim tilt troubleshooting, wiring diagrams, 1985–1989 marine engine

❓ Mini FAQ:

Q: Does this manual cover power trim and tilt?
A: Yes – full trim/tilt servicing and hydraulic system diagrams are included.

Q: Are year-specific wiring diagrams included?
A: Absolutely – all circuits and schematics for 1985–1989 are provided.

Q: Can I view this on a phone or tablet?
A: Yes – the manual is fully compatible with mobile and desktop devices.

🧭 Helpful Resources for Johnson & Evinrude Outboard Owners

• Why Every Evinrude & Johnson Outboard Owner Should Own a Service Manual – Find out how a downloadable repair manual can simplify maintenance and help you troubleshoot common problems on your own.
• Outboard Engine Troubleshooter – Not sure what’s wrong with your Johnson or Evinrude engine? Our free tool lists common issues and DIY fixes across all major brands.

🔧 Browse More Johnson & Evinrude Manuals

Note: While our manuals are designed for DIY use, they do not replace professional mechanical training. If you're unsure about a repair or your engine shows serious issues, we strongly recommend visiting a certified marine mechanic. These guides are best suited for owners with basic to moderate mechanical experience.